Sportage 2.7L 2008

Page 1 of 28
SPORTAGE(KM) > 2008 > G 2.7 DOHC > General Information
General Information > General Information > General Information

IDENTIFICATION NUMBER LOCATIONS
IDENTIFICATION NUMBER DESCRIPTION

VEHICLE IDENTIFICATION NUMBER
Page 2 of 28
1 - 3 : Make / Vehicle type

- KND = Kia MPV
4 - 5 : Vehicle Line /Series
- JE = SPORTAGE 4x4
- JF = SPORTAGE 4x2
6 - 7: Body type
- 72 = 4Door Sport Utility Vehicle & GVW 1821 ~ 2270kg
8 : Engine type
- 2 = 2.0 Gasoline (G4GC) (Federal)
- 3 = 2.7 Gasoline (G6BA)
- 4 = 2.0 Gasoline (G4GC) (California)
9 : Transmission type
- Check digit
10 : Model year
- 4 = 2004, 5 = 2005
11 : Plant location
- K = Kwang-ju plant
12 - 17 : Sequential number
- 000001 ~ 999999
PAINT CODE
CODE COLOR
UD Clear White
S4 Grayish Silver
S6 Satin Silver
Y3 Greenish Gold
9L Natural Oliv
1L Vert Jade Pearl
K6 Smart Blue
3P Volcanic Red
6D Smokey Brown
9D Black Cherry
ENGINE IDENTIFICATION NUMBER

Page 3 of 28
1. Engine fuel
- G : Gasoline
2. Engine range
- 4 : 4 cycle 4 cylinder
- 6 : 4 cycle 6 cylinder
3. Engine development order
- B : DELTA Engine
- G : BETA Engine
4. Engine capacity
- A : 2656cc (Gosoline)
- C : 1975 cc (Gasoline)
5. Production year
- 4 : 2004, 5 : 2005, 6 : 2006
6. Engine production sequence number
- 000001 ~ 999999
TRANSMISSION IDENTIFICATION NUMBER
MANUAL
1. Model
- L : M5GF1
2. Production year
- 4 : 2004, 5 : 2005, 6 : 2006, 7 : 2007
3. Gear ratio
- H : 4.063
- J : 4.533
4. Transaxle production sequence number
- 000001 ~ 999999
AUTOMATIC
1. Modle
- N : F4A42-2
2. Production year
- 4 : 2004, 5 : 2005, 6 : 2006, 7 : 2007
3. Gear ratio
- N : 4.042
- O : 4.407
- R : 4.626
Page 4 of 28
4. Detailed chassification
- AD : 2.0 2WD
- BD : 2.0 4WD
- FD : 2.7 4WD
- HD : 2.7 2WD
- ID : 2.0 DSL 2WD + LSD
- JD : 2.0 DSL 4WD
- KD : 2.0 DSL 2WD
5. Spare
6. Transaxle production sequence number
- 000001 ~ 999999
WARNING / CAUTION LABEL LOCATIONS
Page 5 of 28
AIR BAG WARNING / CAUTION LABEL

Page 6 of 28
AIR BAG WARING / CAUTION LABEL (CONT'D)

Page 7 of 28
WARNING / CAUTION LABEL (cont'd)

A : 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 near the side airbag.
• Do not use excessive force on the side of the seat.
• For further information, see the owner's manual.
Page 8 of 28
B : CAUTION
AIRBAG ESPE UNIT
Detach connector before unmounting. Assemble strictly according to manual instructions.
C : 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.
D : 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 does 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 in injury to you or other occupants in the vehicle
• See the "SRS" section in Owner's Manual for more information about airbags.
BATTERY CAUTION LABEL DESCRIBTION

Page 9 of 28
LIFT AND SUPPORT POINTS
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.
Page 10 of 28
• Since each tire/wheel assembly weights approximately 30lbs (14kg), placing the front wheels in the luggage
area can assist with the weight distribution.
• Use the same support points to support the vehicle on safety stands.
1. Place the lift blocks under the support points as shown in the illustration.
2. Raise the hoist a few inches (centimeters) 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.
Page 11 of 28
1.
Fuel tank cauld be damaged or broken when using the lift in the illustration above. So, install the rubber or
wooden block on the position supporting the lift and then lift up the vehicle.
Minimum height of the block is 8cm.
TOWING
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.
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.
Page 12 of 28
• Turn off the engine.
• Improper towing preparation will damage the transmission. Follow the above procedure exactly. If you
cannot shift the transmission or start the engine(automatic transmission), your vehicle must be
transported on a flatbed.
• It is the 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

Page 13 of 28
Bolt nominal diameter Torque Nm (kg.cm, lb.ft)

Pitch (mm)
(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 ~ 50, 3.6 ~ 4.3) 9 ~ 11 (90 ~ 110, 6.5 ~ 8.0)
20 ~ 25 (200 ~ 250, 14.5 ~
M8 1.25 12 ~ 15 (120 ~ 150, 9 ~ 11)
18.0 )
25 ~ 30 (250 ~ 300, 18 ~ 30 ~ 50 (300 ~ 500, 22 ~
M10 1.25
22) 36)
35 ~ 45 (350 ~ 450, 25 ~ 60 ~ 80 (600 ~ 800, 43 ~
M12 1.25
33) 58)
75 ~ 85 (750 ~ 850, 54 ~ 120 ~ 140 (1,200 ~ 1,400,
M14 1.5
61) 85 ~ 100)
110 ~ 130 (1,100 ~ 1,300, 180 ~ 210 (1,800 ~ 2,100,
M16 1.5
80 ~ 94) 130 ~ 150)
160 ~ 180 (1,600 ~ 1,800, 260 ~ 300 (2,600 ~ 3,000,
M18 1.5
116 ~ 130) 190 ~ 215)
220 ~ 250 (2,200 ~ 2,500, 360 ~ 420 (3,600 ~ 4,200,
M20 1.5
160 ~ 180) 260 ~ 300)
290 ~ 330 (2,900 ~ 3,300, 480 ~ 550 (4,800 ~ 5,500,
M22 1.5
210 ~ 240) 350 ~ 400)
360 ~ 420 (3,600 ~ 4,200, 610 ~ 700 (6,100 ~ 7,000,
M24 1.5
260 ~ 300) 440 ~ 505)
Page 14 of 28
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 indicated below, under the following conditions, if will
be the standard value.
• If spring washers are used : 85%
• If threads and bearing sufaces are stained with oil : 85%
LUBRICANTS
RECOMMENDED LUBRICANTS
Parts OIL & GREASE STANDARD
Engine Oil Gasoline API SL(SJ) or ABOVE,
ILSAS GF-3 and ABOVE
Disesl API CF -4 or ABOVE,
ACEA B4 OR ABOVE
Transaxle Manual GENUINE PART MTF 75W/90 (API GL - 4)
Auto DIAMOND ATF SP-III, SK ATF SP-III
Power Steering PSF -3
Brake Steering DOT 3, DOT 4 or equivalent
Coolant Ethlyene glycol base for aluminum radiator
Transaxle linkage, parking breake cable mechanism,
hood, door latch, seat adjuster, tailgate latch, door Multipurpose grease NIGL grade #2
hinges, tailgate hinge
Always use Genuine Kia motors parts and recommedended fluid.

Using any other type of parts and fluid can cause serious damage to vehicle.
LUBRICANTS CAPACITIES
Page 15 of 28
Description 2.7 2.0
Engine oil 4.2 (4.44, 3.7 (3.90,
Oil pan
3.70) 3.26)
0.3 (0.32, 0.3 (0.32,
Oil filter
0.26) 0.26)
4.5 (4.75, 4.0 (4.23,
Total
3.96) 3.52)
Cooling system 7.8 (8.2, 6.8) 6.0 (6.4, 5.31)
2.15 (2.3, 2.15 (2.3,
Manual transaxle
1.86) 1.86)
Automatic transaxle 7.8 (8.2, 6.8) 7.8 (8.2, 6.8)
0.9 (0.95, 0.9 (0.95,
Power steering
0.79) 0.79)
Capacities : [liter (U.S.qts, Imp.qts)]

SELECTION OF ENGINE OIL (Gasoline)
RECOMMENDED ILSAC classification : GF-3 OR ABOVE
RECOMMENDED API classification : SL(SJ) OR ABOVE
RECOMMENDED SAE viscosity grades :
Page 16 of 28
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.
3. Lubricants that do not have both an SAE grade number and API service classification on the container should
not be used.
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 causing possible 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 MESURING EQUIPMENT
Be sure that all necessary tools and measuring equipment are available starting work.
SPECIAL TOOLS
Use special tools when they are required.
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 aggect their performance or external appearance.
Page 17 of 28
1. Inspection of parts
Each part, when removed, should be carefulley on spected 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 repllaced from those that will be used again.
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 KIA MOTORS genuine parts.
Page 18 of 28
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. Selalant should be applied to gaskets.
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.
Page 19 of 28
ADJUSTMENT
Use gauges and testers to adjust correclty the parts to standard values correctly.
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 DIMENSIONGS

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 actual - measurement dimensions are used in this
manual.
DIMENSIONS PROJECTED
1. These are the dimensions measured when the measurement points are projected from the vehicle's surface, and
are the reference dimensions used for used for body alterations.
Page 20 of 28
2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as
the different value in height of the two surface.
MEASURING ACTUAL DIMENSIONS

1. These dimensions indicate the actual linear distance between mesaurement 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 fo 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 corcuits.
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).
Page 21 of 28
6. Check grounded parts to verify that there is complete continuity between thier attaching bolt(s) and the vehicle's
body.
7. Check for incorrect wiring.
8. Check that the wiring is so clamped to the prevent contact with sharp corners of the vehicle body, etc. or hot
parts (exhaust manifold, etc.)
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 taps provided to allow checking the fuse itself without removing if from the fuse box. The fuse
is good if the test lamp lights up when one lead is connected to the test taps (one at a time) and the other lead is
grounded. (Turn the ignition switch so that the fuse circuit becomes operative)
SERIVICING THE ELECTRICAL SYSTEM

Page 22 of 28
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. There fore, if necessary, read the diagnostic before
removing the battery cable.
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 surronding 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 if from damage.
Page 23 of 28
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.
6. The electronlic 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 before hand.
Page 24 of 28
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 the illustration.
10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.
Page 25 of 28
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 appropartate wire size.
Permissible current
Noeminal size SAE gauge No.
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 gasolined gasoline flow 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 and extended time. Engine compression tests must be made as rapidly as
possible.
5. Avoid coasting with the ignition turned and during prolonged braking.
6. Do not dispose of used catalytic converter together with parts contaminated with gasoline or oil.
BODY - DIMENSION
Page 26 of 28
MAINTENANCE SCHEDULE
SCHEDULE 1 - NORMAL MAINTENANCE
Page 27 of 28
SCHEDULE 2 - SEVERE MAINTENANCE

Page 28 of 28
Page 1 of 289
SPORTAGE(KM) > 2008 > G 2.7 DOHC > Automatic Transaxle System
Automatic Transaxle System > General Information > Special Service Tools (F4A42-2)
SPECIAL TOOLS
TOOL
Illustration Use
(Number and name)
09200 - 38001 Removal and installation of transaxle.
Engine support fixture
09431-39000 Installation of differential oil seal.

Oil seal installer
09433-21000 1. Removal of transafer driven gear taper

Removing plate bearing (Use with 09432-33800).
2. Removal of differential ball bearing.
09500-11000 Installation of differential bearing outer race.

Bar (Use with 09532-11500)
09455-33200 Installation of differential ball bearing and

Bearing installer output shaft taper roller bearing.
09453-21100 Removal and installation of the low and

Spring compressor reverse brake snap ring (Use with 9453-
21000).
09532-11500
Bearing installer
Page 2 of 289
09532-11500 Installation of differential bearing outer race
Bearing installer (Use with 09500-11000).
09453-21000 1. Removal and installation of low and reverse

Snap ring / spring brake snap ring.
compressor 2. Removal and installation of overdrive clutch
snap ring (Use with 09456-39000).
09452-33100 Removal of the oil pump.

Oil pump remover
09452-21200 Installation of the oil pump oil seal.

Oil pump oil seal installer
09456-39100 Measurement of low and reverse brake and

A/B Clearance dummy plate second brake end plays.
09456-39000 Removal and installation of low and reverse

Spring compressor brake or overdrive clutch snap ring.
Automatic Transaxle System > General Information > Specifications (F4A42-2)

SPECIFICATION
Page 3 of 289
Item F4A42
Torque converter type 3-element, 1-stage, 2-phase type
Transaxle type 4-speed forward, 1-speed reverse
Engine displacement 2.0 GSL 2.7 GSL
1st 2.842 2.842
2nd 1.529 1.529
Gear ratio 3rd 1.000 1.000
4th 0.712 0.712
Reverse 2.480 2.480
2WD 4.626 4.042
Final gear ratio
4WD 4.626 4.407
Shift pattern Variable
Shift range 4range ( P-R-N-D) + Sports mode
Shift range valve PWM ; 5EA(Duty control)
2.0(GSL) : 2400~3000rpm, 2.7(GSL) :
Stall speed
2100~2700rpm
Planetary gear 2EA(Output planetary/Overdrive planetary)
Clutch 3EA
Brake 2EA
OWC 1EA
SERVICE SPECIFICATIONS
Items Standard value
Output shaft preload 0.01-0.09 mm (0.0004-0.0035 in)
Brake reaction plate end play 0-0.16 mm (0-0.0063 in)
Low and reverse brake end play 1.65-2.11mm (0.065-0.083 in)
Second brake end play 0.79-1.25 mm (0.0311-0.0492 in)
Underdrive sun gear end play 0.25-0.45 mm (0.0098-0.0177 in)
Input shaft end play 0.70-1.20 mm (0.0276-0.0472 in)
Differential case preload 0.045-0.105 mm (0.0018-0.0041 in)
Underdrive clutch end play(wave disk) 1.25-1.45 mm (0.0492-0.057 in)
Overdrive clutch return spring retainer end 0-0.09 mm (0-0.0035 in)
play
Overdrive clutch end play(wave disk) 1.6-1.8 mm (0.0630-0.0709 in)
Reverse clutch end play 1.5-1.7 mm (0.0590-0.0609 in)
Backlash between differential side gear and 0.025-0.150 mm (0.001-0.006 in)
pinion
Page 4 of 289
TIGHTENING TORQUE
ITEM Nm kgf.cm lb-ft
Wiring harness bracket 20 ~ 26 200 ~ 260 14 ~ 18
Control cable bracket bolt 20 ~ 26 200 ~ 260 14 ~ 18
Eye bolt 30 ~ 45 300 ~ 450 22 ~ 33
Oil cooler feed tube 10 ~ 12 100 ~120 7~8
Input shaft speed sensor 10 ~ 12 100 ~ 120 7~8
Output shaft speed sensor 10 ~ 12 100 ~ 120 7~8
Manual control lever 18 ~ 25 180 ~ 250 13 ~ 18
Transaxle range switch 10 ~ 12 100 ~ 120 7~8
Speedometer gear 4~6 40 ~ 60 3~4
Valve body cover 8 ~ 10 80 ~ 100 6~7
Valve body mounting bolt 10 ~ 12 100 ~ 120 7~8
Oil temperature sensor 10 ~ 12 100 ~ 120 7~8
Manual control shaft detent 5~7 50 ~ 70 4~5
Rear cover 20 ~ 26 200 ~ 260 14 ~ 18
Torque converter housing 42 ~ 54 420 ~ 540 29 ~ 38
Oil pump 20 ~ 26 200 ~ 260 14 ~ 18
Transfer drive gear 16 ~ 22 160 ~ 220 11 ~ 15
Output shaft lock nut 160 ~ 180 1600 ~ 1800 110 ~ 126
Output shaft bearing retainer 20 ~ 26 200 ~ 260 14 ~ 18
Oil filler plug 29 ~ 34 290 ~ 340 21.4 ~ 25.1
Oil drain plug 40 ~ 50 400 ~ 500 29 ~ 36
Transfer drive gear lock nut 180 ~ 210 1800 ~ 2100 126 ~ 147
Differential drive gear to
130 ~ 140 1300 ~ 1400 91 ~ 98
subframe bolts
Valve body 10 ~ 12 100 ~ 120 7~8
Solenoid valve support 5~7 50 ~ 70 4~5
Plate 5~7 50 ~ 70 4~5
Pressure check plug 8 ~ 10 80 ~ 100 6~7
Front roll stopper bracket to
40 ~ 55 400 ~ 550 29 ~ 40
subframe bolts
Front roll stopper insulator bolt
50 ~ 65 500 ~ 650 36 ~ 47
and nut
Front roll stopper bracket to
60 ~ 80 600 ~ 800 43 ~ 58
transaxle bolts
Rear roll stopper bracket 40 ~ 55 400 ~ 550 29 ~ 40
Page 5 of 289
Rear roll stopper insulator bolt
50 ~ 65 500 ~ 650 36 ~ 47
and nut
Rear roll stopper bracket to
60 ~ 80 600 ~ 800 43 ~ 58
transaxle bolts
Transaxle mounting sub bracket
60 ~ 80 600 ~ 800 43 ~ 58
nut
Transaxle mounting bracket
40 ~ 55 400 ~ 550 29 ~ 40
bolts
Transaxle mounting insulator bolt 90 ~ 110 900 ~ 1100 65 ~ 80
LUBRICANT
Item Specified lubricant Quantity
Transmission oil Diamond ATF SP-III 7.8ℓ(8.2 Us qt, 6.9Imp.qt)
SEALANT
Item Specified Sealant
Rear cover
Torque converter housing Three Bond - TB 1281B or LOCTITE - FMD - 546
Valve body cover
Transmission case side cover Three Bond - TB 1389 or LOCTITE - 518
Side cover Three Bond - TB 1389 or LOCTITE - 518/587
Automatic Transaxle System > Automatic Transaxle System > Description and Operation (F4A42-2)
Description
The automatic transmission is a combination of 3-element 2-phase 1-stage torque converter and double shaft
electrocally-controlled unit which provides 4 speeds forward and 1 reverse. The entire unit is in line with the engine.
Characteristics
HIVEC: Hyundai Intelligent Vehicle Electronic Control
It differs significantly compared to previous T/M such as alpha, Bcta or KM series automatic transaxles.
Hyundai vehicles adopted with an engine volume of 2.0 liters or more has the HIVEC automatic transaxle developed
and produced by Hyundai.
Some of the characteristics include:
Different power transfer
Different component layout
New shift logic(HIVEC) to improve shift feeling
Position of Valve Body
Variable shift pattern
Communication protocol and method
Page 6 of 289
Item Details
1. Aluminum oil pump
- 2.3kg Approx
Weight Reduction 2. Pressed parts
- Retainer and hub of brakes and clutches
- Carrier of planetary gear set
1. Independent control of clutches and brakes enabled better control of hydraulic
pressure and skip shift possible (4 to 2, 3 to 1)
2. During N to D or N to R shift, feedback control adopted.
3. When starting from Creep condition, reduction of shock.(Creep condition is controlled
Better shift quality with 1st gear)
4. Solenoid valve frequency is increased for more accurate control. 35Hz to 61.3Hz
except DCCSV that is 35Hz.
5. HIVEC adoption for better shift feeling.
6. Variable shift pattern.
1. Variable oil level
Increase in Power train
- An oil dam is incorporated in the case to temporarily contain ATF, so the damage of
efficiency
power train is decreased at low temperatures
- Manual shifting possible
Dynamic drive by
sports mode
Page 7 of 289
MECHANICAL SYSTEM
OPERATION COMPONENTS AND FUNCTION
Page 8 of 289
Operating Element Symbol Function
Under drive clutch UD Connect input shaft and under drive sun gear
Reverse clutch REV Connect input shaft and reverse sun gear
Overdrive clutch OD Connect input shaft and over drive carrier
Low&Reverse brake LR Hold LR annulus gear and OD carrier
Second brake 2ND Hold reverse sun gear
One way clutch OWC Restrict the rotating direction of low &amp; reverse annulus gear
Operating elements
UD/C OD/C REV/C 2ND/B LR/B OWC
P ●
R ● ●
N ●
D1 ● ● ○
D2 ● ●
D3 ● ●
D4 ● ●
1) O : OWC is operated when shifts from 1st gear to 2nd gear.

2) L&R brake is released in 1st gear when the vehicle speed is more than 5KPH approximately.
Torque converter and shaft
The torque converter consists of a impeller(pump), turbine and stator assembly in a single unit. The pump is
connected to the engine crankshaft and turns as the engine turns. This drawing force is transmitted to the turbine
through the oil which is recycled by the stator.
The transmission has two parallel shafts ; the input shaft and the output shaft. Both shafts are in line with the engine
crankshaft. The input shaft includes the overdrive clutch, reverse clutch, underdrive clutch, one way clutch, 2ND
brake, low&reverse brake, overdrive planetary carrier, output planetary carrier and transfer drive gear. The output
shaft includes the transfer driven gear.
CLUTCHES
Page 9 of 289
The gear changing mechanism utilizes three multi-disc clutches. The retainers of these clutches are fabricated from
high-precision sheet metal for lightness and ease of production. Also, more responsive gearshifts at high engine
speeds are achieved by a pressure-balanced piston mechanism that cancels out centrifugal hydraulic pressure. This
mechanism replaces the conventional ball check valve.
UNDERDRIVE CLUTCH
The underdrive clutch operates in 1st, 2nd, and 3rd gears and transmits driving force from the input shaft to the
underdrive sun gear(A).
The components comprising the under clutch are as illustrated below.
Hydraulic pressure acts in the piston pressure chamber(B) (between the piston(c) and retainer) and thus pushes the
piston(C). In turn, the piston depresses the clutch discs and thereby transmits driving force from the retainer(D) to
the hub(E) side.
At high speed, fluid remaining in the piston pressure chamber is subjected to centrifugal force and attempts to push
the piston.
However, fluid in the balance fluid chamber(A) (the space between the piston and return spring retainer(B)) is also
subjected to centrifugal force.
Thus, the hydraulic pressure on one side of the piston cancels out the hydraulic pressure on the other side, and the
piston does not move.
REVERSE CLUTCH AND OVERDRIVE CLUTCH

The reverse clutch(C) operates when the reverse gear is selected and transmits driving force from the input shaft to
the reverse sun gear.
The overdrive clutch(D) operates in 3rd and 4th gears and transmits driving force from the input shaft to the
Page 10 of 289
overdrive planetary carrier and low-reverse annulus gear.
BRAKES
The gear changing mechanism utilizes two multi-disc brakes.
LOW&REVERSE BRAKE AND SECOND BRAKE
The low&reverse brake(A) operates in 1st and reverse gears, when the vehicle is parked, and during manual
operation. It locks the low&reverse annulus gear and overdrive planetary carrier to the case.
The second(C) brake(B) operates in 2nd and 4th gears and locks the reverse sun gear(D) to the case.
The components comprising the low&reverse brake and second brake are as illustrated below.
As shown, the discs and plates of the two brakes are arranged on either side of the rear cushion plate(E), which is
itself secured to the case(F) by a snap ring.
OWC
To improve the shift feeling from 1st. to 2nd gear, OWC was adopted on the Low&reverse brake annulus gear.
Instead of hydraulic fixing by Low&reverse brake at the 1st gear, this mechanical fixing device was used. This
structure is not new concept, because this OWC already has been installed on the:
ACCUMULATORS
Number Function Name Color
1 Low&Reverse Brake None
2 Underdrive Clutch Yellow
3 Second Brake Blue
4 Overdrive Clutch None
Page 11 of 289
Objective
* Energy (hydraulic pressure) storage
* Impact and pulsation damping when solenoid valves operating
* Operation as spring element
* Smooth shifting by preventing sudden operation of clutches and brakes
TRANSFER DRIVE GEAR
With the transfer drive gear, increased tooth height and a higher contact ratio have reduced gear noise.
Also, the bearing that supports the drive gear is a preloaded type that eliminates rattle, and the rigidity of the gear
mounting has been increased by bolting the bearing directly onto the case.
OUTPUT SHAFT/TRANSFER DRIVEN GEAR

As shown in the illustration below, the transfer driven gear is press-fitted onto the output shaft, and the output shaft is
secured by a locking nut and supported by bearings.
The locking nut has a left-handed thread, and a hexagonal hole in the other end of the shaft enables the shaft to be
held in position for locking nut removal.
Page 12 of 289
MANUAL CONTROL SYSTEM

MANUAL CONTROL LEVER
The manual control lever is fitted to the top of the valve body and is linked to the parking roller rod and manual
control valve pin.
A detent mechanism is provided to improve the gear shift feeling during manual selection.
PARKING MECHANISM
When the manual control lever is moved to the parking position, the parking roller rod moves along the parking
roller support and pushes up the parking sprag.
As a result, the parking sprag meshes with the transfer driven gear (parking gear), thereby locking the output shaft.
To minimize the operating force required, a roller is fitted to the end of the rod.
POWER TRAIN
P POSITION
Hydraulic pressure is applied to the LR brake and the RED brake, so power is not transmitted from the input shaft
to the UD clutch or OD clutch, and the output shaft is locked by the park brake pawl interlocking the park gear.
N POSITION
Hydraulic pressure is applied to the LR brake(A) and the RED brake, so power is not transmitted from the input
shaft to the UD clutch or OD clutch.
Page 13 of 289
1st GEAR POWER FLOW

Hydraulic pressure is applied to the UD clutch(B) the LR brake(A) and the one way clutch(OWC), then the UD
clutch transmits driving force from the input shaft to the UD sun gear, and the LR brake locks the LR annulus gear to
the case.The UD sun gear of the planetary gear drives the output pinion gear, and the LR brake locks the annulus
gear, and the output pinion drives the output carriers, and the output carrier drives the transfer drive gear, and the
transfer drive gear drives the transfer driven gear of the output shaft, and power is transmitted to the differential gear
through the differential drive gear.
2nd GEAR POWER FLOW

Hydraulic pressure is applied to the UD clutch(A) the 2nd brake(B) and the one way clutch(OWC), then the UD
clutch transmits driving force from the input shaft to the UD sun gear, and the 2nd brake locks the reverse sun gear
to the case.The UD sun gear of the planetary gear drives the output pinion gear and the LR annulus gear, and the LR
annulus gear drives the OD planetary carriers, and OD planetary carriers drives OD pinion gear, and the OD pinion
gear drives the output carriers, and the output carrier drives the transfer drive gear, and the transfer drive gear drives
the transfer driven gear of the output shaft, and power is transmitted to the differential gear through the differential
drive gear.
Page 14 of 289
3rd GEAR POWER FLOW

Hydraulic pressure is applied to the UD clutch(A) and the OD clutch(B), then the UD clutch transmits driving force
from the input shaft to the UD sun gear, and the OD clutch transmits driving force from the input shaft to the
overdrive planetary carrier and low&reverse annulus gear.The UD sun gear of the planetary gear drives the output
pinion gear and the LR annulus gear, and the LR annulus gear drives the OD pinion gear through the OD planetary
carrier, and the OD pinion gear drives the reverse sun gear and the output carrier.The OD clutch drives the OD
carrier, and the OD carrier drives the OD pinion gear, and the OD pinion gear drives the reverse sun gear and the
output carrier, and the output carrier drives the transfer drive gear, and the transfer drive gear drives the transfer
driven gear of the output shaft, and power is transmitted to the differential gear through the differential drive gear.
4th GEAR POWER FLOW

Hydraulic pressure is applied to the OD clutch(A) and the 2nd brake(B), then the OD clutch transmits driving force
from the input shaft to the OD planetary carrier and LR annulus gear, and the 2nd brake locks the reverse sun gear
to the case.The OD clutch drives the OD carrier, and the OD carrier drives the OD pinion gear and the LR annulus
gear, and the OD pinion gear drives the output carrier, and the output carrier drives the transfer drive gear, and the
transfer drive gear drives the transfer driven gear of the output shaft, and power is transmitted to the differential gear
through the differential drive gear.
Page 15 of 289
Rev GEAR POWER FLOW

Hydraulic pressure is applied to the reverse clutch(A) and the LR brake(B), then the reverse clutch transmits driving
force from the input shaft to the reverse sun gear, and the LR brake locks the LR annulus gear and OD planetary
carrier to the case.The reverse clutch drives the reverse sun gear, and the reverse sun gear drives the output carrier
through the OD pinion gear, and the output carrier drives the transfer drive gear, and the transfer drive gear drives
the transfer driven gear of the output shaft, and power is transmitted to the differential gear through the differential
drive gear.
Hydraulic Control System

DESCRIPTION
• Better and smoother shift quality.

• In order to prevent ATF leakage from the valve body or each elements, the exhaust ports have been grouped
into only one with an addition of a check ball.
Page 16 of 289
• If a failure occurs in its electric control, the switch valve and fail safe valve is able to move to enable 3rd speed
drive or reverse.
• The hydraulic system consists of oil pump, regulator valve, solenoid valves, pressure control valve and valve
body.
OPERATION COMPONENTS AND FUNCTIONS
Oil Pump
The oil pump is made of aluminum to reduce its weight. The oil pump is not a serviceable part; it must be replaced as
a pump assembly.
Do not disassemble the pump as improper alignment during assembly will cause pump failure and could cause
damage to the transaxle.
When removing the oil pump from the T/M case, the S.S.T. (09452-33100) must be used.
OPERATION OF EACH VALVE
Torque converter pressure control valve : The function of this valve is to maintain a constant pressure within the
torque converter.
Damper clutch control valve : Its function is to control the hydraulic pressure that acts on the Damper Clutch.
Manual valve :The position of the manual valve is determined by the selector lever and applies or cuts line pressure
to different valves.
Pressure control valve&Solenoid valve : The pressure control valve prevents a rapid decrease in hydraulic pressure
when the clutch becomes disengaged. It also reduces the sharp increase in input shaft speed during clutch to clutch
control.
Switch valve : When the OD clutch is applied, the hydraulic pressure is applied to the regulator valve via the switch
valve. Hence, the line pressure is reduced at 3rd and 4th gear.
Fail Safe Valve-A : During fail safe mode, this valve releases the pressure in the LR Brake.
Fail Safe Valve-B : During fail safe mode, this valve cuts the pressure from the 2nd pressure control valve to 2nd
brake.
Hydraulic flow
P and N position
The TCM(PCM) controls the solenoid valves. The conditions of the solenoid valve and positions of the solenoid
valve are as follows :
• The LR solenoid valve is turned off, and the LR pressure solenoid valve is moved to the left side.
• The 2nd solenoid valve is turned on, and the 2nd pressure solenoid valve remains in the right side.
• The UD solenoid valve is turned on, and the UD pressure solenoid valve remains in the right side.
• The OD solenoid valve is turned on, and the OD pressure solenoid valve remains in the right side.
• The line pressure is supplied to the regulator valve and the fail-safe valve A.
• The line pressure is supplied to each element (fail-safe valve B, switch valve, DCCV, LR solenoid valve, LR
pressure control valve).
• The fail-safe valve B moves to the left side by the line pressure through the manual valve.
• The switch valve moves to the left side by the line pressure.
• The line pressure is supplied to the DCCV, and DCCV moves to the right side.
• The line pressure is supplied to the LR pressure control valve and the LR solenoid valve, and TCM(PCM) turns
off the LR solenoid valve, so the line pressure is supplied to the LR brake through the switch valve and the fail-
safe valve A.
• The regulator valve moves to the left side by the line pressure through the manual valve, and the line pressure is
supplied to the torque converter pressure control valve and the oil pump.
Page 17 of 289
D position : 1st gear

• The UD solenoid valve is turned off, and the UD pressure solenoid valve is moved to the left side.
• The line pressure is supplied to each element (fail-safe valve B, switch valve, damper clutch control valve, LR
solenoid valve, LR pressure control valve).
Page 18 of 289
• The line pressure through the manual valve is supplied to each element (DCCV, 2nd solenoid valve, 2nd pressure
control valve, OD solenoid valve, OD pressure control valve, UD solenoid valve, UD pressure control valve).
• The fail-safe valve B moves to the left side by the line pressure.
• The line pressure is supplied to the DCCV, and TCM(PCM) turns off the DCCSV, so the DCCV remains in the
right side
off the LR solenoid valve, so the line pressure is supplied to the LR brake through the switch valve and the fail-
safe valve A.
• The line pressure is supplied to the UD pressure control valve and the UD solenoid valve, and TCM(PCM) turns
off the UD solenoid valve, so the line pressure is supplied to the UD clutch and the fail-safe valve B.
Page 19 of 289
D position : 2nd gear

• The LR solenoid valve is turned on, and the LR pressure solenoid valve remains in the right side.
• The 2nd solenoid valve is turned off, and the 2nd pressure solenoid valve is moved to the left side.
• The line pressure is supplied to each element (fail-safe valve B, switch valve, damper clutch control valve, LR
solenoid valve, LR pressure control valve).
Page 20 of 289
• The line pressure through the manual valve is supplied to each element (DCCV, 2nd solenoid valve, 2nd pressure
control valve, OD solenoid valve, OD pressure control valve, UD solenoid valve, UD pressure control valve).
• The fail-safe valve B moves to the right side by the line pressure through 2nd pressure control valve and the line
pressure through the UD pressure control valve.
• The pressure through the manual valve is supplied to the fail-safe valve A, and the fail-safe valve A moves to the
left side
• The line pressure is supplied to the DCCV and the DCCSV, and TCM(PCM) turns off the DCCSV, so the
DCCV remains in the right side
• The line pressure is supplied to the 2nd pressure control valve and the 2nd solenoid valve, and TCM(PCM)
turns off the 2nd solenoid valve, so the line pressure is supplied to the 2nd brake and the fail-safe valve A
through the fail-safe valve B.
Page 21 of 289
D position : 3rd gear

• The OD solenoid valve is turned off, and the OD pressure solenoid valve is moved to the left side.
Page 22 of 289
• The line pressure through the manual valve is supplied to each element (DCCSV, 2nd solenoid valve, 2nd
pressure control valve, OD solenoid valve, OD pressure control valve, UD solenoid valve, UD pressure control
valve).
• The fail-safe valve B moves to the right side by the line pressure through the UD pressure control valve and the
line pressure through the OD pressure control valve.
• The pressure is supplied to the fail-safe valve A through the OD pressure control valve, but the fail-safe valve A
does not move to the right side
• The line pressure is supplied to the DCCV and the DCCSV, and TCM(PCM) turns on the DCCSV, and the
DCCV moves to the left side, and the damper clutch is operated.
• The line pressure is supplied to the OD pressure control valve and the OD solenoid valve, and TCM(PCM)
turns off the OD solenoid valve, so the line pressure is supplied to the OD clutch and the fail-safe valve A/B and
the switch valve.
• The switch valve moves to the right side by the line pressure through the OD pressure control valve.
• The regulator valve moves to the left side by the pressure through the manual valve and the pressure through the
switch valve.
Page 23 of 289
D position : 4th gear

• The 2nd solenoid valve is turned off, and the 2nd pressure solenoid valve is moved to the left side.
• The OD solenoid valve is turned off, and the OD pressure solenoid valve is moved to the left side.
• The line pressure through the manual valve is supplied to the regulator valve and the fail-safe valve A.
Page 24 of 289
• The line pressure through the manual valve is supplied to each element (DCCSV, 2nd solenoid valve, 2nd
pressure control valve, OD solenoid valve, OD pressure control valve, UD solenoid valve, UD pressure control
valve).
• The fail-safe valve B moves to the right side by the line pressure through the 2nd pressure control valve and the
line pressure through the OD pressure control valve.
• The line pressure through the OD pressure control valve is supplied to the fail-safe valve A, and the fail-safe
valve A moves to the right side by the line pressure through the fail-safe valve B and the line pressure through the
OD pressure control valve.
• The line pressure is supplied to the DCCV and the DCCSV, and TCM(PCM) turns on the DCCSV, so DCCV
moves to the right side, and the damper clutch is operated.
• The line pressure is supplied to the OD pressure control valve and the OD solenoid valve, and TCM(PCM)
turns off the OD solenoid valve, so the line pressure is supplied to the OD clutch and the fail-safe valve A/B and
the switch valve.
• The line pressure is supplied to the 2nd pressure control valve and the 2nd solenoid valve, and TCM(PCM)
turns off the 2nd solenoid valve, so the line pressure through the 2nd pressure control valve is supplied to the 2nd
brake through the fail-safe valve B.
• The regulator valve moves to the left side by the line pressure through the manual valve and the line pressure
through the switch valve.
Page 25 of 289
Reverse position
• The line pressure through the manual valve is supplied to the reverse clutch and the fail-safe valve B.
Page 26 of 289
• The fail-safe valve B moves to the left side by the line pressure.
• The switch valve moves to left side by the line pressure, and the line pressure through the LR pressure control
valve is supplied to the LR brake through the fail-safe valve A.
• The line pressure is supplied to the DCCV, so the DCCV remains in the right side.
• The fail-safe valve A moves to the right side by the line pressure through the switch valve.
off the LR solenoid valve, and the line pressure is supplied to the LR brake through the LR pressure control valve
and the switch valve and the fail-safe valve A.
• The regulator valve moves to the right side due to the lock of line pressure through the manual valve, and the line
pressure is higher than in the other gear ranges.
Page 27 of 289
Electronic Control System
DESCRIPTION
The electronic control system used in the new generation auto transaxle is far superior to the previous systems. This
system is able to adopt a variable shift pattern for smooth and problem free shifting.
A solenoid valve is applied to each of the clutches and brakes and is independently controlled. Feedback control
and correction control is performed in all gears as well as utilization of mutual control system to increase shift feeling.
The torque converter damper clutch uses a partial lock up and full lock-up system. An additional control method
called the HIVEC system (neural network) is adopted to increase shift feeling.
Block Diagram (CAN)
ELECTRIC CONTROL LOCATION

The TCM(PCM) is located below the dashboard. However, in the ß-engine vehicles, there is not TCM(PCM).
Page 28 of 289
OPERATING COMPONENTS AND FUNCTIONS

Page 29 of 289
Sensor Function
Input shaft speed sensor Detect turbine speed at UD retainer
Output shaft speed sensor Detect T/F drive gear speed at T/F driven gear (4A/T)
Crank angle sensor Detect engine speed
TPS(Gasoline) Throttle opening ratio by potentiometer
Air conditioner switch A/C load by thermister
Inhibitor switch Select lever position by contact switch
Brake switch Brake pedal position
Vehicle speed sensor Detect vehicle speed by speedometer driven gear
Sport mode switch Sport mode On/Off signal
Kick down servo switch Kick down piston position
Vehicle speed sensor Vehicle speed
Sport mode up-shift switch Sport mode up-shift signal
Sport mode downshift switch Sport mode downshift signal
Request of torque reduction Send the request of torque reduction to ECM
ABS-ECM, Engine ECM CAN communication
HIVEC
HIVEC uses information from various inputs and feedback adaptation and selects the best appropriate gear position
and shift timing under all possible driving conditions.
CONTROL FOR ALL DRIVING CONDITION
This function makes TCM(PCM) decide optimal gear range under all driving condition. The optimal operation of the
manual shift lever by several drivers’ and various driving condition is pre-set in the TCM(PCM). On the basis of
mapping data, TCM(PCM) decides the driving condition from throttle opening, vehicle speed and brake signal. And
then TCM(PCM) controls the gear position optimally. Optimal gear position is achieved under various driving
condition by HIVEC logic.
Optimal control for all driving condition
HIVEC INHIBIT CONDITIONS

Page 30 of 289
- ATF temperature below 40°C(104°F).
- When standard pattern is not used.
• Inhibitor switch: P, R, N, L
• Extremely low temperature mode
• Lower emission shift pattern
• ATF control variable shift pattern
- During fail safe mode (3rd gear hold)
- In case of prohibition of Intelligent shift
• TPS faulty (Short: P1702, Open: 1701)
• ATF Temperature sensor faulty (P1712)
• Stop lamp s/w faulty (P0703)
- TCM faulty (Check engine lamp ON)
- After IG ON until first time stop lamp S/W comes ON→OFF.
Sports Mode
Sports Mode Switch
Sports mode allows the manual up-shift and downshift with the accelerator pedal depressed. The prompt response
and shift would be obtained due to the continuous shifting without cutting of driving power. The shifting time is also
decreased about 0.1sec during up-shift, 0.2sec during downshift. As the selector lever is pushed upward or
downward one time, the gear is up shifted or downshifted by one gear.
Signals of sports mode switch
Page 31 of 289
DOWN
Items Mode S/W UP S/W
S/W
D range selection OFF OFF OFF
Sports mode selection ON OFF OFF
Sports mode up-shift
ON ON OFF
selection
Sports mode downshift
ON OFF ON
selection
Controller Area Network (CAN)

Previously, for different computers in the vehicle to share the same information, each signal required a different pin
and wiring. However, with the introduction of a CAN system, only two lines are required to achieve the same
function. The information is in digital format.
Input signals to TCM(PCM) through 'CAN communication'

- Engine rpm, TPS signal
- A/CON signal, Engine coolant temperature
- Quantity of intake airflow, Vehicle speed
- Shift holding signal (FTCS ON)
Output signals from TCM(PCM) through 'CAN communication'
- Request signal for torque reduction
- ATF temperature, TCM(PCM) type, TCM(PCM) error or not
- Damper clutch ON, OFF / Gear position
TCM(PCM) PIN DESCRIPITION
Terminal
Description
Number
1 SOLENOID VALVE(UD)
2 POWER 1(SOLENOID VALVE)
3 POWER 2(SOLENOID VALVE)
4 -
Page 32 of 289
5 -
6 -
7 -
8 AUTO CRUISE
9 -
10 -
11 POWER(IG.1)
12 GROUND POWER
13 GROUND POWER
C89-1
14 SOLENOID VALVE(OD)
15 SOLENOID VALVE(DCC)
16 SOLENOID VALVE(2ND)
17 -
18 -
19 POWER FOR FLASH ROM
20 -
21 SHIFT POSITION SIGNAL
22 -
23 -
24 POWER(IG.1)
25 GROUND FOR POWER
26 GROUND FOR POWER
1 SENSOR-INPUT SPEED
2 SENSOR-OUTPUT SPEED
3 -
4 -
5 -
6 -
7 -
8 POWER FOR S-RAM
C89-2
9 -
10 -
11 -
12 -
13 GROUND FOR SENSOR
14 OIL TEMPERATURE SENSOR
Page 33 of 289
15 -
16 -
1 -
2 -
3 CAN-'HIGH'
4 CAN-'LOW'
5 INHIBITOR SW.(P)
6 INHIBITOR SW.(N)
7 SPT SELECT SW.
8 SPT DOWN SW.
9 STOP LAMP SW.
10 -
11 -
C89-1
12 SOLENOID VALVE(LR/DIR)
13 K-LINE
14 -
15 -
16 INHIBITOR SW.(R)
17 INHIBITOR SW.(D)
18 SPT UP SW.
19 -
20 -
21 A/T CONTROL RELAY
22 GROUND FOR SIGNAL
Terminal
PIN Description
NO.
1 -
Page 34 of 289
2 -
3 -
4 -
5 Sports down switch
6 Inhibiter switch(N)
7 -
8 -
9 -
10 -
11 Auto cruise
12 -
13 Sports up switch
14 Inhibiter switch(R)
C18-2
15 -
16 -
17 -
18 Sensor ground
19 Stop switch
20 Output speed sensor
21 Sports select switch
22 Inhibiter switch(P)
23 -
24 Shift signal(PWM)
25 -
26 Oil temperature sensor
27 -
28 Input speed sensor
29 Inhibiter switch(D)
30 -
31 -
32 A/T relay
33 Solenoid valve(OD)
34 -
C18-2
35 Solenoid valve(DCC)
36 Power source(SOL.)
37 Ground1
Page 35 of 289
38 Solenoid valve(LR)
39 Solenoid valve(2ND)
40 Solenoid valve(UD)
TCM INPUT/OUTPUT SIGNAL VOLTAGE CHECK SHEET

Gasoline 2.7 Engine (C89-1,2,3)
INPUT/OUTPUT
SIGNAL SIGNAL TEST
No. CONDITION REMARK
NAME RESULT
TYPE Level
HI : V_BAT
14.5V
1 UD Solenoid Shifting Pulse LO : Max .
0.31V
1.0V
2 A/T PWR IG Off Max. 1.0V 0.0mV
DC "L"
3 Source IG On V_BAT 12.7V
1st Speed V_BAT 13.8V
4 1ST Lamp DC
Otherwise Max. 1.0V 8mV
3rd Speed V_BAT 13.8V
5 3rd Lamp DC
6 N.A - - - -
7 N.A - - - -
Non-operating V_BAT
8 ACC Cancel SIG DC
Operating Max. 0.5V
C89-
1 9 N.A - - - -
10 N.A - - - -
11 IG Off Max. 0.5 V 0.0mV
V_IG DC TCM(PCM)
24 IG On V_BAT 12.4V
12 GND_PWR1 Idle DC Max. 50 mV 0.0mV
13 GND_PWR2 Idle DC Max. 50 mV -2.0mV
14 OD Solenoid Shifting Pulse
Damper Clutch Lock_Up HI : V_BAT 14.5V
15 Pulse
Solenoid On LO : Max. 1.0V 0.31V
HI : V_BAT 14.4V
16 2ND Solenoid Shifting Pulse
LO : Max. 1.0V 0.27V
2nd Speed V_BAT 13.8V
17 2nd Lamp DC
4th Speed V_BAT 13.8V
18 4th Lamp DC
Flash PWR IG On 4.0~5.0V 4.5V
19 DC Flash ROM
Source IG Off Max. 0.5 V 0.0mV
20 N.A - - - -
C89-
1 21 N.A - - - -
Page 36 of 289
22 N.A - - - -
23 N.A - - - -
Speed Sensor- HI : Min. 4.0V 4.96V
1 Idle Pulse
Input LO : Max. 1.0V 354mV
Speed Sensor- HI : Min. 4.0V 4.95V
2 30kph Pulse
Output LO : Max. 1.0V 359mV
3 N.A - - - -
4 N.A - - - -
5 N.A - - - -
6 N.A - - - -
7 N.A - - - -
DC
C89- 8 Key removal Below 1.0 mA 0.41mA
V_BAT vol. TCM(PCM)
2 Always V_BAT 12.6V
Current
9 N.A - - - -
10 N.A - - - -
11 N.A - - - -
12 N.A - - - -
13 GND_Sensor Idle DC Max. 50 mV 22mV OTS/PG-B
Oil Temp.
14 Idle Analog 0.5V ~ 4.5V 2.5V at 60.0°C
Sensor_ATM
15 N.A - - - -
16 N.A - - - -
1 N.A - - - -
2 N.A - - - -
2.0 ~ 3.0V 2.51V (Commnicatio speed
3 CAN_HI - Pulse
2.75~4.5V 3.52V : 500kbps)
2.0 ~ 3.0V 2.48V (Commnicatio speed
4 CAN_LO - Pulse
0.5~2.25V 1.49V : 500kbps)
P Range P Position V_BAT 13.8V
5 DC
Selection Otherwise Max. 1.0V 21mV
C89- N Range N Position V_BAT 13.8V
6 DC
3 Selection Otherwise Max. 1.0V 21mV
SPT Select Select Position V_BAT 14.1V
7 DC
SPT Down Down Position V_BAT 13.9V
8 DC
Page 37 of 289
Release Max. 0.5V 13.4V
9 Brake SW(N.O) DC
Push V_BAT 0.0mV
10 N.A - - - -
11 N.A - - - -
HI : V_BAT
14.4V
12 LR Solenoid Shifting Pulse LO : Max .
0.27V
1.0V
HI : Min V_BAT
Scan tool 70% 11.3V (Commnicatio speed:
13 Diagnosis "K" Pulse
communication LO : Max. 0.21V >10.4kbps)
V_BAT 30%
14 N.A - - - -
15 N.A - - - -
C89- 16 R Range R Position V_BAT 13.4V

DC
3 Selection Otherwise Max. 1.0V 0mV
D Range D Position V_BAT 13.8V
17 DC
SPT Up Up Position V_BAT 13.9V
18 DC
19 N.A - - - -
20 N.A - - - -
RLY Off Max. 1.0V 0.0mV
21 RLY A/T Control DC "S2"
RLY On V_BAT 12.8V
22 GND_Sensor Idle DC Max. 50 mV 8mV TCM(PCM) Signal
GASOLINE 2.0 ENGINE (C18-2)

PIN INPUT. OUTPUT VALUE
SIGNAL CONDITION TEST RESULT REMARK
No. TYPE LEVEL
Vlow < 1.8V 12.37V
Sport down DOWN ON Static Vhigh > 4.2V Sport mode down
5 (Vbatt Level)
SW signal SW
Others Active : high 0.2V
Vlow < 1.8V 12.37V
N ON Static Vhigh > 4.2V
6 N-SW (Vbatt Level) Inhibitor SW (N)
signal
12.4V
ON Batt. Voltage after
9 V_ATREL Power (Vbatt Level)
A/T RELAY
OFF 0.2V
Page 38 of 289
Auto cruise 12.37V
ON PULL (Vbatt Level) Auto cruise input
Vlow < 1.8V
11 Auto cruise UP from Cruise
Auto cruise Vhigh > 4.2V
INPUT 0.2V controller
OFF
Vlow < 1.8V 12.37V
UP ON Static Vhigh > 4.2V
13 Sport up SW (Vbatt Level) Sport mode up SW
signal
Vlow < 1.8V 12.37V
R ON Static Vhigh > 4.2V
14 R-SW (Vbatt Level) Inhibitor SW (R)
signal
18 Sensor GND Always Power GND level (0V)
12.37V Detect BW input
Brake ON Vlow < 1.0V
19 BRAKE SW Sens (Vbatt Level) with open status
Vhigh > 6V
Brake OFF 0.2V detection function
No signal: Vlow < 1.8V Duty 50±20%,

20 Output speed Pulse
1009 RPM Vhigh > 4.2V 1.116kHz
Vlow < 1.8V 12.37V

Sport SEL. SEL. ON Static Vhigh > 4.2V Sport mode Select
21 (Vbatt Level)
SW signal SW
Vlow < 1.8V 12.37V
P ON Static Vhigh > 4.2V
22 P-SW (Vbatt Level) Inhibitor SW (P)
signal
Sports Mode
P,R,N,D range :
100%
24 Trip computer PWM 3.0 < I < 5.0 A 50Hz 1st gear : 12.5%
2nd gear : 27.5%
3rd gear : 42.5 %
4th gear : 57.5 %
Oil
26 Temperature Analog V = -0.3~VB 85°C → 0.8V
sensor
Vlow < 1.8V
Ne signal: Vhigh > 4.2V Duty 50±20%,
28 Input speed Pulse
2068 RPM 2.049kHz
Active : high
Vlow < 1.8V 12.37V
D ON Static Vhigh > 4.2V
29 D-SW (Vbatt Level) Inhibitor SW (D)
signal
Page 39 of 289
11.44V
A/T ON Static Norminal load
32 A/T Relay (Vbatt Level)
signal current 1.1A
A/T OFF 0.2V
1st,2nd : 2kHz, 30%
Signal: 3.0 < Isol <
Positive duty
Solenoid 5.0A
33 → PWM (VB:12V)
valve(OD) Supply :
3rd,4th: 100%
V_ATREL.
Positive duty
1st,2nd : 100%
Solenoid 5.0A
35 → PWM Positive duty
valve(DCC) Supply :
3rd,4th: unknown
V_ATREL.
37 Power GND Always Power GND level
1st: 100% Positive
Signal: 3.0 < Isol < duty
Solenoid 5.0A 2nd,3rd,4th:2kHz,
38 → PWM
valve(LR) Supply : 30%
V_ATREL. Positive duty
(VB:12V)
1st,3rd:2kHz, 30%
Positive duty
Solenoid 5.0A
39 → PWM (VB:12V)
valve(2ND) Supply :
2nd,4th : 100%
V_ATREL.
Positive duty
1st,2nd,3rd :
100% Positive duty
Solenoid 5.0A
40 → PWM 4th: 2kHz, 30%
valve(UD) Supply :
Positive duty
V_ATREL.
(VB:12V)
Sensors
Input shaft & Output shaft speed sensor
- Type: Hall sensor
- Current consumption: 22mA (MAX.)
- Sensor body and sensor connector have been unified as one.
Page 40 of 289
Hall type sensor: specification

Input shaft speed sensor 1.3
Air gap (mm)
Output shaft speed sensor 0.85
Input shaft speed sensor over 1MΩ
Coil Resistance
Output shaft speed sensor over 1MΩ
High 4.8~5.2V
Peak-Peak Voltage
Low 0.8V
Wave Form With High-scan
Hall Type Sensor: Structure & Interface

Page 41 of 289
Oil Temperature Sensor

The oil temperature sensor is of the thermistor type, and senses the automatic transaxle fluid temperature. Using the
signal from this sensor, TCM(PCM) controls the shift pattern optimally during shift. In order to operate the damper
clutch, this signal is also referred.
- Range of temperature : -40°C~145°C(-40°F~293°F)
- Type: Separated type (High / Low temperature)
- Standard value of internal resistance
Temp.[°C(°F)] Resistance(kΩ) Temp.[°C(°F)] Resistance(kΩ)
-40(-40) 139.5 80(176) 1.08
-20(-4) 47.7 100(212) 0.63
0(32) 18.6 120(248) 0.38
20(68) 8.1 140(284) 0.25
40(104) 3.8 160(320) 0.16
60(140) 1.98
Page 42 of 289
Inhibitor Switch
- Type: Rotary contact type
- Range of temperature : -40°C~145°C(-40°F~293°F)
Inhibitor Switch - Continuity check
Actuators
Solenoid Valve for Pressure Control
- Sensor type: Normal open 3-way
- Operating temperature : -30°C~130°C(-22°F~266°F)
- Frequency:
LR, 2ND, UD, OD, RED: 61.27Hz [at the ATF temp. -20°C above(-4°F above)]
DCC: 30.64Hz
- Internal resistance: 2.6Ω or more
Page 43 of 289
- Surge voltage: 56 V
Location
Identification Color of Each Solenoid Valves

Solenoid
Wire color Housing Frequency
valve
UD sol.
White, Red, Red Black 61.27 Hz
valve
OD sol.
Orange, Red Black 61.27 Hz
valve
L/R sol.
Brown, Yellow Milky white 61.27 Hz
valve
2nd sol.
Green, Red, Red Milky white 61.27 Hz
valve
DCC sol.
Blue, Yellow, Yellow Black 34.64 Hz
valve
ATF temp.
Black, Red Black
Sensor
- L/R solenoid valve controls the direct clutch in 5A/T as well as low-reverse brake
Page 44 of 289
Wave Form with High-scan

Solenoid valve ON: Hydraulic pressure is released from corresponding clutch or brake.
Solenoid valve OFF: Hydraulic pressure is supplied to corresponding clutch or brake.
Except) DCCSV: When the DCCSV is ON, the damper clutch is operated.
Controlled Pressure
Solenoid
Duty 0% Duty 50% Duty 75% Duty 100%
valve
UD, OD,
10.5±0.1 6.4±0.25 3.6±0.25 0.1 or less
LR, 2ND
DCC 10.5±0.1 5.9±0.3 3.2±0.3 0.1 or less
Solenoid Valves Schedule

Position Solenoid valves
Operation LR 2ND UD OD * DCC
1st gear OFF ON OFF ON OFF
2nd gear ON OFF OFF ON OFF
3rd gear ON ON OFF OFF ON
4th gear ON OFF ON OFF ON
Reverse OFF ON ON ON OFF
N, P (STD. mode) OFF ON ON ON OFF
N, P (Hold mode) ON OFF ON ON OFF
*: Reference value.
Page 45 of 289
(DCC solenoid valve will be ON when the operating condition is satisfied)
A/T Control Relay
The control relay supplies power to the solenoid valves.
As soon as the A/T control relay is ON, the battery voltage is directly supplied to solenoid valves and each solenoid
valve is operated when the TCM grounds the opposite terminal. → (-) Control At fail safe condition, the power is
cut causing 3 gear hold.
Automatic Transaxle System > Automatic Transaxle System > Troubleshooting (F4A42-2)
TROUBLESHOOTING
DIAGNOSIS FLOW
Page 46 of 289
INSPECTION CHART FOR TROUBLE SYMPTOMS

Trouble symptom Probable cause
Communication with HI-SCAN is not possible - Malfunction diagnosis line
If communication with the HI-SCAN is not possible, the cause is - Malfunction of connector
probably a defective diagnosis line or the TCM(PCM) is not - Malfunction of the TCM(PCM)
functioning.
Driving impossible Starting impossible - Malfunction of the engine system
Starting is not possible when the selector - Malfunction of the torque converter
lever is in P or N range. In such cases, the - Malfunction of the oil pump
cause is probably a defective engine system,
Page 47 of 289
torque converter or oil pump.
Does not move forward - Abnormal line pressure
If the vehicle does not move forward when - Malfunction of the underdrive solenoid
the selector lever is shifted from N to D, 3, 2 valve
or L range while the engine is idling, the - Malfunction of the underdrive clutch
cause is probably abnormal line pressure or - Malfunction of the valve body
a malfunction of the underdrive clutch or
valve body.
Does not reverse - Abnormal reverse clutch pressure
If the vehicle does not reverse when the - Abnormal low and reverse brake
selector lever is shifted from N to R range pressure
while the engine is idling, the cause is - Malfunction of the low and reverse brake
probably abnormal pressure in the reverse solenoid valve
clutch or low and reverse brake or a - Malfunction of the reverse clutch
malfunction of the reverse clutch, low and
- Malfunction of the low and reverse brake
reverse brake or valve body.
- Malfunction of the valve body
Does not move (forward or reverse) - Abnormal line pressure
If the vehicle does not move forward or - Malfunction of power train
reverse when the selector lever is shifted to - Malfunction of the oil pump
any position while the engine is idling, the - Malfunction of the valve body
cause is probably abnormal line pressure or
a malfunction of the power train, oil pump or
valve body.
Malfunction when Engine stalling when shifting - Malfunction of the engine system
starting If the engine stalls when the selector lever is - Malfunction of the damper clutch control
shifted from N to D or R range while the solenoid valve
engine is idling, the cause is probably a - Malfunction of the valve body
malfunction of the engine system, damper - Malfunction of the torque converter
clutch solenoid valve, valve body or torque (Malfunction of the damper clutch)
converter (damper clutch malfunction).
Shocks when changing from N to D and - Abnormal underdrive clutch pressure
large time lag - Abnormal low and reverse brake
If abnormal shocks or a time lag of 2 pressure
seconds or more occur when the selector - Malfunction of the underdrive solenoid
lever is shifted from N to D range while the valve
engine is idling, the cause is probably - Malfunction of the valve body
abnormal underdrive clutch pressure or a
- Malfunction of the idle position switch
malfunction of the underdrive clutch, valve
body or idle position switch.
Malfunction when Shocks when changing from N to R and - Abnormal reverse clutch pressure
starting large time lag - Abnormal low and reverse brake
If abnormal shocks or a time lag of 2 pressure
seconds or more occur when the selector - Malfunction of the low and reverse
lever is shifted from N to R range while the solenoid valve
engine is idling, the cause is probably - Malfunction of the reverse clutch
abnormal reverse clutch pressure or low and
- Malfunction of the low and reverse brake
reverse brake pressure, or a malfunction of
the reverse clutch, low and reverse brake,
Page 48 of 289
the reverse clutch, low and reverse brake,
valve body or idle position switch. - Malfunction of the idle position switch
Shocks when changing from N to D, N to - Abnormal line pressure

R and large time lag - Malfunction of the oil pump
If abnormal shocks or a time lag of 2 - Malfunction of the valve body
seconds or more occur when the selector
lever is shifted from N to D range and from
N to R range while the engine is idling, the
cause is probably abnormal line pressure or
a malfunction of the oil pump or valve body.
Malfunction when Shocks and running up - Abnormal line pressure
shifting If shocks occur when driving due to up - Malfunction of each solenoid valve
shifting or down shifting and the transmission - Malfunction of the oil pump
speed becomes higher than the engine - Malfunction of the valve body
speed, the cause is probably abnormal line
- Malfunction of each brake or each clutch
pressure or a malfunction of a solenoid
valve, oil pump, valve body or of a brake or
clutch.
Displaced shifting All points - Malfunction of the output shaft speed
points If all shift points are displaced while driving, sensor
the cause is probably a malfunction of the - Malfunction of the throttle position sensor
output shaft speed sensor, TPS or of a - Malfunction of each solenoid valve
solenoid valve. - Abnormal line pressure
- Malfunction of the TCM(PCM)
Some points - Malfunction of the valve body
If some of the shift points are displaced while
driving, the cause is probably a malfunction
of the valve body, or it is related to control
and is not an abnormality.
Does not shift No diagnosis codes - Malfunction of the transaxle range
If shifting does not occur while driving and - Malfunction of the TCM(PCM)
no diagnosis codes are output, the cause is
probably a malfunction of the transaxle range
switch, or TCM(PCM)
Malfunction while Poor acceleration - Malfunction of the engine system
driving If acceleration is poor even if down shifting - Malfunction of the brake or clutch
occurs while driving, the cause is probably a
malfunction of the engine system or of a
brake or clutch.
Malfunction while Vibration - Abnormal damper clutch pressure
driving If vibration occurs when driving at constant - Malfunction of the engine system
speed or when accelerating and deceleration - Malfunction of the damper clutch control
in top range, the cause is probably abnormal solenoid valve
damper clutch pressure or a malfunction of - Malfunction of the torque converter
the engine system, damper clutch control
solenoid valve, torque converter or valve
body.
Page 49 of 289
Transaxle range switch system - Malfunction of the transaxle range switch
The cause is probably a malfunction of the inhibitor switch circuit, - Malfunction of the ignition switch
ignition switch circuit or a defective TCM(PCM). - Malfunction of connector
Idle position switch system - Malfunction of the triple pressure switch
The cause is probably a defective idle position switch circuit, or a - Malfunction of connector
defective TCM(PCM). - Malfunction of the TCM(PCM)
Triple pressure switch system - Malfunction of the triple pressure switch
The cause is probably a defective dual pressure switch circuit or a - Malfunction of connector
defective TCM(PCM). - Malfunction of A/C system
Vehicle speed sensor system - Malfunction of the vehicle speed sensor
The cause is probably a defective vehicle speed sensor circuit or a - Malfunction of connector
defective TCM(PCM). - Malfunction of the TCM(PCM)
HOW TO USE SCAN TOOL

INSTRUCTION
With the advent of electronic control vehicles, the system efficiency increases with the complexities, as you would
realize.
As medical diagnostic devices do, the advanced testers can help identify and fix the problems.
The scan tool can provide you with the versatile and user friendly monitoring capabilities.
SCAN TOOL FUNCTION
Scan tool offers the following functionality:
Diagonstic trouble codes
Freeze frame data
Current data
Actuation test
HOW TO CONNECT
For vehicles with 16 pin Data Link Connector(DLC), power is supplied from the DLC terminal through the DLC
CABLE without the need for an additional power supply.
For connections between the Hi-scan and these vehicle data link terminals the DLC CABLE 16 is all that is
required.
HOW TO SELECT VEHICLE AND SYSTEM

OPERATION FLOW
1. Select "KIA VEHICLE DIAGNOSIS"
Page 50 of 289
2. Select "VEHICLE NAME"
3. Select "AUTOMATIC TRANSAXLE SYSTEM"
4. Select the engine model.
BASIC APPLICATION
Having connected and turned on scan tool, the vehicle and system selection must be made from the 1.0 KIA
VEHICLE DIAGNOSIS SCREEN.
The support functions vary according to vehicles. Therefore, the correct selection must be made.
Selection may be made by scrolling up or down the screen and pressing ENTER, or by using the numeric keypad to
select the appropriate option number and pressing ENTER.
HOW TO READ DTC
OPERATION FLOW
1. Select vehicle and system
(Refer to How to select vehicle and system)
2. Select 1.1 DIAGNOSTIC TROUBLE CODES
MODE APPLICATION
At this level, Diagnostic trouble codes(DTC) are displayed for the selected TCM.
HOW TO ERASE DTC
OPERATION FLOW
1. Select "1.1 DIAGNOSTIC TROUBLE CODES"
(Refer to How to read DTC)
Page 51 of 289
2. Select "ERAS" key on the Diagnostic Trouble codes mode.
3. Select "1.2.2. ERASE FAULT CODE"
MODE APPLICATION
"ERAS"
This soft function key will clear the DTC currently held in the memory of the selected TCM.
If this option is selected, a message requesting confirmation of the ERAS request will be displayed.
The YES or NO key should be used to confirm or cancel the request to clear the current DTC.
DTC TROBLESHOOTING INDEX
TCM(PCM) DTCs (GSL 2.7)
DTC No. DESCRIPTION SEE PAGE
P0560 Back-Up BATTERY LINE OPEN TR-
P0605 EEPROM Abnormal TR-
P0703 BRAKE SWITCH CIRCUIT TR-
P0707 TRANS.RANGE SENSOR-LOW TR-
P0708 TRANS.RANGE SENSOR-HIGH TR-
P0711 FLUID TEMPERATURE.SENSOR RATIONALITY TR-
P0712 FLUID TEMPERATURE.SENSOR CIRCUIT-LOW TR-
P0713 FLUID TEMPERATURE.SENSOR CIRCUIT-HIGH TR-
P0715 INPUT SPEED SENSOR CIRCUIT TR-
P0720 OUTPUT SPEED SENSOR CIRCUIT TR-
P0731 Gear 1 Incorrect Ratio TR-
P0736 REVERSE INCORRECT RATIO TR-
P0741 Torque Converter Clutch Circuit Stuck off TR-
P0742 Torque Converter Clutch Circuit Stuck on TR-
DCC(TCC) Solenoid - Open or ground short(Torque Converter Clutch TR-
P0743
Circuit Electrical)
P0750 LR Solenoid - Open or ground short(SCSV "A" CIRCUIT MAL.) TR-
P0755 UD Solenoid - Open or ground short(SCSV "B" CIRCUIT MAL.) TR-
P0760 2ND Solenoid - Open or ground short(SCSV "C" CIRCUIT MAL.) TR-
P0765 OD Solenoid - Open or ground short(SCSV "D" CIRCUIT MAL.) TR-
P0885 A/T RELAY CIRCUIT MAL TR-
P1500 VEHICLE SPEED SENSOR CIRCUIT TR-
U0001 CAN COMMUNICATION BUS OFF TR-
U0100 NO ID From ECU TR-
TCM(PCM) DTCs (GSL 2.0)

Page 52 of 289
DTC No. DESCRIPTION SEE PAGE
P0703 BRAKE SWITCH CIRCUIT TR-
P0707 TRANS.RANGE SENSOR-LOW TR-
P0708 TRANS.RANGE SENSOR-HIGH TR-
P0711 FLUID TEMPERATURE.SENSOR RATIONALITY TR-
P0712 FLUID TEMPERATURE.SENSOR CIRCUIT-LOW TR-
P0713 FLUID TEMPERATURE.SENSOR CIRCUIT-HIGH TR-
P0717 INPUT SPEED SENSOR CIRCUIT TR-
P0721 OUTPUT SPEED SENSOR TR-
P0722 OUTPUT SPEED SENSOR CIRCUIT TR-
P0736 REVERSE INCORRECT RATIO TR-
P0741 Torque Converter Clutch Circuit Stuck off TR-
DCC(TCC) Solenoid - Open or ground short(Torque Converter Clutch
P0743 TR-
Circuit Electrical)
P0750 LR Solenoid - Open or ground short(SCSV "A" CIRCUIT MAL.) TR-
P0755 UD Solenoid - Open or ground short(SCSV "B" CIRCUIT MAL.) TR-
P0760 2ND Solenoid - Open or ground short(SCSV "C" CIRCUIT MAL.) TR-
P0765 OD Solenoid - Open or ground short(SCSV "D" CIRCUIT MAL.) TR-
P0885 A/T RELAY CIRCUIT MAL TR-
U0001 CAN COMMUNICATION BUS OFF TR-
U0100 NO ID From ECU TR-
SERVICE DATA LIST(WITH SCAN TOOL)

No. ITEM NAME UNIT DATA Data Description Failure
700
1 ENGINE RPM rpm Current Engine rpm 0 rpm
rpm
2 VEHICLE SPEED km/h 0km/h Current Vehicle speed 0km/h
3 THROTTLE P.SENSOR % 12.5% Current TPS open angle 0%
700 Input speed rpm. Always output
4 INPUT SPEED(PG-A) rpm 0 rpm
rpm rpm when turning start ON
OUTPUT SPEED(PG- Output speed rpm. Always output
5 rpm 0 rpm 0 rpm
B) rpm when driving
DCC(TCC) Control 0% → 100% when
6 % 0%
SOLENOID DUTY operating Damper Clutch
Page 53 of 289
DAMPER CLUTCH 260
7 rpm Current Damper clutch slip ratio 0 rpm
SLIP rpm
Control 100% → 0% when
8 LR SOLENOID DUTY % 100% 0%
operating brake
9 UD SOLENOID DUTY % 100% 0%
operating clutch
2ND SOLENOID Control 100% → 0% when
10 % 100% 0%
DUTY operating clutch
11 OD SOLENOID DUTY % 100% 0%
operating clutch
80°C
12 OIL TEMPERATURE °C 40°C Current Oil temperature
(176°F)
N,P,REV/1st
13 SHIFT POSITION D Current shift position P, N
G/…/5th G
TRANSAXLE RANGE
14 P,N/R/D/SPORTS D Current shift lever position P, N
SW
OFF/ON/-/NOT
15 A/CON SWITCH OFF -
SUPP
OFF/ON/-/NOT
16 IDLE STATUS ON When idling, ON
SUPP
OFF/ON/-/NOT
17 BRAKE SWITCH ON When braking, ON
SUPP
OFF/ON/-/NOT
18 CRUISE SWITCH
SUPP
SPORT MODE OFF/ON/-/NOT
19 ON When selecting sport mode, ON
SELECT SW SUPP
OFF/ON/-/NOT When Selecting Sport mode up,
20 SPORT MODE UP SW ON
SUPP ON
SPORT MODE DOWN OFF/ON/-/NOT When selecting sport mode down,
21 ON
SW SUPP ON
A/T CONTROL
22 V 12.9V 0V
RELAY VOLT
23 ENGINE TORQUE % 20%
A/B/C/D is control mode, F is
24 HIVEC MODE A/B/C/D/-/F F F
release mode
HIVEC -SAT(SIEMENS ADAPTIVE TRANSMISSION CONTROL) Mode (Shift Patten)

Page 54 of 289
Shift patten Description(Help) SCAN DISPLAY
ECONOMY Economy Driver shift patten for flat road A
MEDIUM Shift patten for medium road B
SPORTS Shift patten for sport road C
LOAD 1 Shift patten for low land, slow grade and slope D
LOAD 3 Shift patten for downhill road F
Actuator inspection
NO ITEM NAME Actuator Driving Condition
1 LR SOLENOID(SCSV A) 1. IG Key ON
2 UD SOLENOID(SCSV B) 2. Inhibitor SW normal
3. P range
3 2ND SOLENOID(SCSV C)
Solenoid valve driven for 5 sec. 4. Vehicle speed 0km/h
4 OD SOLENOID(SCSV D) 5. Engine stop
TORQUE CONVERTER SOLENOID 6. No failure
5 7. TPS < 1V
VALVE
6 A/T CONTROL RELAY OFF for 3 sec. -
7 INTELLIGENT SHIFT PROHIBIT Prohibit until IG off -
8 CLEAR LEARNING VALUE - -
ROAD TEST
No. Condition Operation Judgment value Check item
Ignition switch : OFF Ignition switch Battery voltage (mV) Control relay
1
(1) ON
• Ignition switch : Selector lever position (1) P, (2) R, (3) N, (4) Transaxle range switch
ON (1) P, (2) R, (3) N, (4) D D
• Engine : Stopped Accelerator pedal (1) 400~1,000 mV Throttle position sensor
• Selector lever (1) Released (2)Gradually rises from
2 position : P (2) Half depressed (1)
(3) Depressed (3) 4,500~5,000 mV
Brake pedal (1) ON Brake switch
(1) Depressed (2) OFF
(2) Released
• Ignition switch : Starting test with lever P or Starting should be Starting possible or
3 ST N range possible impossible
• Engine : Stopped
Warming up Drive for 15 minutes or Gradually rises to Oil temperature sensor
more so that the automatic 70~90°C(158~194°F)
4
fluid temperature becomes
70~90°C(158~194°F)
• Engine : Idling A/C switch (1) ON Triple pressure switch
Page 55 of 289
• Selector lever (1) ON (2) OFF
position : N (2) OFF
Accelerator pedal (1) ON Idle position switch
(1) Released (2) OFF
(2) Half depressed
(1) 600~900 rpm
(2) Gradually rises
5
from (1)
Communication with
(1) Data changes
engine-ECU
Selector lever position Should be no abnormal Malfunction when starting
(1) N→D shifting shocks
(2) N→R Time lag should be
within 2 seconds
Selector lever Selector lever position and (2) 1st, (4) 3rd, (3) Shift condition
position : N (Carry vehicle speed 2nd, (5) 4th
out on a flat and 1. Idling in 1st gear
straight road) (Vehicle stopped) (2) 0%, (4) 100%, (3) Low and reverse solenoid
2. Driving at constant 100%, (5) 100% valve
speed of 20
(2) 0%, (4) 0%, (3) Underdrive solenoid valve
km/h(12mph) in 1st
0%
gear
3. Driving at constant (1) 100%, (2) 0%, (3) Second solenoid valve
speed of 30 100%
6
km/h(19mph) in 2nd
gear (2) 100%, (3) 100%, Overdrive solenoid valve
4. Driving at 50 (4) 0%
km/h(31mph) in 3rd
gear with accelerator (1) 0km/h Vehicle speed sensor
fully closed (4) 50km/h
5. Driving at constant
speed of 50 (4) 1,800 ~ 2,100rpm Input shaft speed sensor
km/h(31mph) in 4th
(4) 1,800 ~ 2,100rpm Output shaft speed sensor
gear
Selector lever • Accelerate to 4th gear For (1), (2) and (3), Malfunction when shifting
position : D (Carry at a throttle position the reading should be
out on a flat and sensor output of 1.5V the same as the
straight road) (accelerator opening specified output shaft
torque, and no Displaced shift points
angle of 30 %).
• Gently decelerate to a abnormal shocks
standstill. should occur.
• Accelerate to 4th gear For (4), (5) and (6), Does not shift
at a throttle position downshifting should
sensor output of 2.5 V occur immediately after
(accelerator opening the shifting operation is
angle of 50%). made.
7
Page 56 of 289
(accelerator opening the shifting operation is
angle of 50%). made. Does not shift from 1 to 2
7 or 2 to 1
• While driving at 60
km/h(37mph) in 4th
gear, shift down to 3rd
gear. Does not shift from 2 to 3
• While driving at 40 or 3 to 2
km/h(25mph) in 3rd
gear, shift down to 2nd
gear.
• While driving at 20 Does not shift from 3 to 4
km/h(12mph) in 2nd or 4 to 3
gear, shift down to 1st
gear.
Selector lever Move selector lever to R The ratio between Does not shift
position : N (Carry range drive at constant input and output shaft
out on a flat and speed of 10km/h(6mph) speed sensor data
8
straight road) should be the same as
the gear ratio when
reversing.
TORQUE CONVERTER STALL TEST

This test measures the maximum engine speed when the selector lever is in the D or R position. The torque converter
stalls to test the operation of the torque converter, starter motor, one-way clutch operation, the holding performance
of the clutches, and brakes in the transaxle.
Do not let anybody stand in front of or behind the vehicle while this test is being carried out
1. Check the automatic transmission fluid level and temperature, and the engine coolant temperature.
A. Fluid level : At the HOT mark on the oil level gauge
B. Fluid temperature : 80~100°C (176~212°F)
C. Engine coolant temperature : 80~100°C (176~212°F)
2. Prevent all wheels from moving during the test.
3. Pull the parking brake lever up, with the brake pedal fully depressed.
4. Start the engine.
5. Move the selector lever to the "D" position, fully depress the accelerator pedal and take a reading of the
maximum engine speed at this time.
Stall speed :
2.0(GSL) : 2400~3000 rpm
2.7(GSL) : 2100~2700 rpm
• The throttle should not be left fully open for any more than five seconds.
• If carrying out the stall test two or more times, move the selector lever to the "N" position and run the
engine at 1,000 r/min to let the automatic transaxle fluid cool down before carrying out subsequent
tests.
6. Move the selector lever to the "R" position and carry out the same test again.
Page 57 of 289
TORQUE CONVERTER STALL TEST CONCLUSION
1. Stall speed is too high in both "D" and "R" ranges
A. Low line pressure
B. Low & reverse brake(B) slippage
2. Stall speed is to high in "D" range only
A. Underdrive clutch(C) slippage
3. Stall speed is too high in "R" range only
A. Reverse clutch(A) slippage
4. Stall speed too low in both "D" and "R" ranges
A. Malfunction of torque converter(D)
B. Insufficient engine output
HYDRAULIC PRESSURE TEST

1. Warm up the engine until the automatic transaxle fluid temperature is 80-100°C(176~212°F).
2. Jack up the vehicle so that the wheels are free to turn.
3. Connect the special tool (oil pressure gauge) to each pressure discharge port.
4. Measure the hydraulic pressure at each port under the conditions given in the standard hydraulic pressure table,
and check that the measured values are within the standard value ranges.
5. If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test
diagnosis table.
Page 58 of 289
STANDARD HYDRAULIC PRESSURE TEST

Measurement condition Standard hydraulic pressure kPa (psi)
Low and
Selector Engine Under drive Reverse Overdrive Second Torque
Shift reverse
lever speed clutch clutch clutch brake converter
position brake
position (rpm) pressure pressure pressure pressure pressure
pressure
310-390 250-350
P - 2,500 - - - -
(45-56) (36-56)
1,270-
1,270-1,770 500-700
R Reverse 2,500 - 1,770 - -
(185-256) (185-256)
(185-256)
310-390 250-390
N 2,500 - - - - -
(45-56) (36-56)
1,010-
1,010-1,050 500-700
1st gear 2,500 1,050 - - -
(146-152) (73-101)
(146-152)
1,010- 1,010-
500-700
2nd gear 2,500 1,050 - - - 1,050
D (73-101)
(146-152) (146-152)
590-690 590-690 450-650
3rd gear 2,500 - - -
(85-100) (85-100) (65-94)
590-690 590-690 450-650
4th gear 2,500 - - -
(85-100) (85-100) (65-94)
The values are subject to change according to vehicle model or condition

OIL SEAL LOCATION
Page 59 of 289
HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE

Trouble symptom Probable cause
All hydraulic pressures are high Incorrect transmission control cable adjustment
Malfunction of the regulator valve
All hydraulic pressures are low Incorrect transmission control cable adjustment
Malfunction of the oil pump
Page 60 of 289
Clogged oil filter
Clogged oil cooler
Malfunction of the relief valve
Incorrect valve body installation
Hydraulic pressure is abnormal in "R" range Malfunction of the regulator valve
only Clogged orifice
Hydraulic pressure is abnormal in "3" or "4" Malfunction of the regulator valve
range only
Clogged orifice
Malfunction of the overdrive solenoid valve
Malfunction of the overdrive pressure control valve
Malfunction of the switch valve
Clogged orifice
Only underdrive hydraulic pressure is Malfunction of the oil seal K
abnormal Malfunction of the oil seal L
Malfunction of the oil seal M
Malfunction of the underdrive solenoid valve
Malfunction of the underdrive pressure control valve
Malfunction of check ball
Clogged orifice
Only reverse clutch hydraulic pressure is Malfunction of the oil seal A
abnormal
Malfunction of the oil seal B
Malfunction of the oil seal C
Clogged orifice
Only overdrive hydraulic pressure is Malfunction of the oil seal D
abnormal
Malfunction of the oil seal E
Malfunction of the oil seal F
Malfunction of the overdrive solenoid valve
Malfunction of the overdrive pressure control valve
Malfunction check ball
Page 61 of 289
Clogged orifice
Only low and reverse hydraulic pressure is Malfunction of the oil seal I
abnormal Malfunction of the oil seal J
Malfunction of the low and reverse solenoid valve
Malfunction of the low and reverse pressure control valve
Malfunction of the switch valve
Malfunction of the fail safe valve A
Clogged orifice
Only second hydraulic pressure is abnormal Malfunction of the oil seal G
Malfunction of the oil seal H
Malfunction of the oil seal O
Malfunction of the second solenoid valve
Malfunction of the second pressure control valve
Malfunction of the fail safe valve B
Clogged orifice
Only reverse clutch hydraulic pressure is Malfunction of the oil cooler
abnormal Malfunction of the oil seal N
Malfunction of the damper clutch control solenoid valve
Malfunction of the damper clutch control valve
Malfunction of the torque converter pressure control valve
Clogged orifice
Pressure applied to non operating element Incorrect valve body installation
Incorrect transmission control cable adjustment
Malfunction of the manual valve
Automatic Transaxle System > Automatic Transaxle System > Repair procedures (F4A42-2)
SERVICE ADJUSTMENT PROCEDURE
Automatic transaxle fluid
INSPECTION
1. Drive the vehicle until the fluid reaches normal operating temperature 70~80°C (158~176°F).
2. Place the vehicle on a level surface.
Page 62 of 289
3. Move the selector lever through all gear position. This will fill the torque converter and the hudraulic system with
fluid and move the selector lever to the "N" (Neutral) or "P" (Park) position.
4. Before removing the oil level gauge, wipe all contaminants from around the oil level gauge. Then take out the oil
level gauge and check the condition of the fluid.
If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from the
bushes and friction materials, a transaxle overhaul may be necessary.
5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is low, add automatic
transaxle fluid until the level reaches the "HOT" mark.
Auto transaxle fluid:

DIAMOND ATF SP-III, SK ATF SP-III
Quantity : 7.8ℓ (8.2 US qt, 6.9 lmp.qt)
Low fluid level can cause a variety of a 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 ,slipping 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 acuse 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 brake operation. Foaming can also result in fluid escaping from the transaxle
vent where it may be mistaken for a leak.
6. Insert the oil level gauge securely.
When new, automatic transmission fluid should be red. The red dye is added so the assembly plant can
identify it as transmission fluid and distinguish it from engine oil or antifreeze. The red dye, which is not an
indicator of fluid quality, is not permanent. As the vehicle is driven the transmission fluid will begin to look
darker. The color may eventually appear light brown.
REPLACEMENT
If you have a fluid changer, use this changer to replace the fluid. If you do not, replace it using the following
procedure.
1. Disconnect the hose, which connects the transmission and the oil cooler which is within the radiator only in 2.0L
engine(2.7L-the oil cooler is separated).
Page 63 of 289
2. Start the engine and let the fluid drain out.
Running conditions : "N" range with engine idling.
The engine should be stopped within one minute after it is started. If the fluid has all drained out before
then, the engine should be stopped at that point.
3. Romove the drain plug from the bottom of the transmission case to drain the fluid.
4. Install the drain plug with a new gasket, and tighten it to the specified torque.
TORQUE :
40 ~ 50Nm (400 ~ 500 kgf.cm, 29 ~ 36 lb-ft)
5. Pour the new fluid in through the oil filler tube.
Stop pouring if the full volume of fluid cannot be poured

in.
6. Repeat the procedure in step (2).
Check the old fluid for contamination. If it has been contaminated, repeat the steps (5) and
(6).
7. Pour the new fluid in through the oil filler tube.

8. Reconnect the hose, which was disconnected in step (1) above, and firmly replace the oil level gauge.(In case of
this "replace", this means after wiping off any dirt around the oil level gauge, insert it into the filler tube.)
9. Start the engine and run it at idle for 1~2 minutes.
10. Move the select lever through all positions, and then move it to the "N" position.
11. Drive the vehile until the fluid temperature rises to the normal temperature [70~80°C (158~176°F)], and then
check the fluid level again. The fluid level must be at the HOT mark.
12. Firmly insert the oil level gauge into the oil filler tube.
Page 64 of 289
TRANSAXLE RANGE SWITCH (INHIBITOR SWITCH)

REPLACEMENT
1. Pull up the parking brake.
2. Position the shift lever in 'N' range.
3. Remove the air cleaner assembly.
4. Remove the battery.
5. Remove the battery tray(A).
6. Remove the inhibiter switch connector.

7. Remove the shift cable mounting nut(A).
8. Remove the inhibiter switch loosening the mounting bolts.

Page 65 of 289
9. Refering to 'INSPECTION', check for continuity. If there is an error, replace the inhibiter switch.
10. After tightening the shift cable mounting nut, connect the inhibiter switch.
11. Install the battery, battery tray and the air cleaner assembly.
INSPECTION
1. Check for the starter motor when the ignition switch is at 'START' position and the shift lever at 'P' or 'N' range.
2. Check for the rear lamp when the ignition switch if it does not work properly.
3. Check for the inhibiter switch if it does not work properly.
4. If the inhibiter switch is not fixed in a proper position, reassemble it in the right position.
5. Re-check 1 and 2.
6. Using a scan tool, confirm the DTCs.
7. Disconnect the battery (-) terminal and the inhibiter switch.
8. Check for continuity between terminals at the switch connector.
9. If there are not continuity between the terminals in the table above for each switch position, replace the inhibiter
switch.
ADJUSTMENT
1. Set the select lever to the "N" position.
2. Loosen the control cable to manual control lever coupling nut to free the cable and lever.
Page 66 of 289
3. Set the manual control lever to the neutral position.
4. Loosen the transaxle range switch body mounting bolts and then turn the transaxle range switch body so the hole
in the end of the manual control lever and the hole (cross section A-A in the figure) in the flange of the transaxle
range switch body flange are aligned.
5. Tighten the transaxle range switch body mounting bolts to the specified torque. Make sure at this time that the
position of the switch body did not move.
TORQUE :
10~12Nm (100~120kgf.cm, 7~8lb-ft)
6. Gently pull the transmission control cable in the direction of the arrow, and then tighten the adjusting nut.
7. Check that the select lever is in the "N" position.
OIL TEMPERATURE SENSOR
REPLACEMENT
1. Remove the automatic transaxle assembly.
2. Remove the valve body cover(refer to the overhaul manual).
3. Disconnect the oil temperature sensor connector.
Page 67 of 289
4. Remove the oil temperature sensor(B), loosening the mounting bolt(A).
5. Replace the sensor with the new one and reassemble the rest of the parts.
INSPECTION
1. Remove the oil temperature sensor(A).
2. Measure the resistance between the terminal 1 and 2 of the sensor connector.
Temp.[°C(°F)] Resistance(KΩ)
0(32) 18.6
100(212) 0.63
3. If the value is out of the specfication, replace the oil temperature sensor.
INPUT SHAFT SPEED SENSOR
REPLACEMENT
1. Remove the battery and air cleaner (see "Transaxle range switch replacement").
2. Remove the transaxle range switch connector.
3. Remove the control cable to transaxle range switch mounting nut.
Page 68 of 289
4. Remove the clip(A) of the control cable(B).
5. Remove the control cable mounting bracket.

6. Remove the input shaft speed sensor(A).
(1) Disconnect the input shaft speed sensor connector.
(2) Remove the bolt(B).
(3) Inspect the input shaft speed sensor bore.

7. Apply a light coat of automatic transaxle fluid to the O-ring seal before installation.
8. Install the input shaft speed sensor.
9. Install the control cable mounting bracket.
10. Connect the input shaft speed sensor connector.
11. Install the holder of the control cable.
12. Adjust the control cable to transaxle range switch and tighten the transaxle manual lever to the control cable
mounting nut. (see "Automatic transaxle shift control installation")
13. Installation is the reverse of removal.
OUTPUT SHAFT SPEED SENSOR
REPLACEMENT
1. Remove the battery and air cleaner. (see "Transaxle range switch replacement")
Page 69 of 289
2. Remove the output shaft speed sensor(A).
(1) Disconnect the output shaft speed sensor connector(B).

(2) Remove the bolt(C).
(3) Inspect the output shaft speed sensor bore.
VEHICLE SPEED SENSOR
REPLACEMENT
1. Lift up the vehicle.
2. Remove the vehicle speed sensor(A).
(1) Disconnect the vehicle speed sensor connector(B).

(2) Remove the bolt (10 mm(0.4 in)).
(3) Inspect the vehicle speed sensor bore.
3. Inspect the O-ring for nicks or cut. Install a new O-ring as necessary.
5. Install the vehicle speed sensor.
6. Connect the vehicle speed sensor connector.
SOLENOID VALVE CHECK
1. Remove the valve body cover.
Page 70 of 289
2. Disconnect the connectors of each solenoid valve.
3. Measure the resistance between terminals 1 and 2 of each solenoid valve.

Standard value :
Name Resistance
Damper clutch solenoid valve
Low and reverse solenoid valve
2.7 ~ 3.4Ω
Second solenoid valve
(at 20°C(68°F))
Underdrive solenoid valve
Overdrive solenoid valve
Page 71 of 289
4. If the resistance is outside the standard value, replace the solenoid valve.
Resistance of the solenoid valve connector.
Terminal No. Name Resistance

Damper clutch solenoid
7 & 10
valve
Low & reverse solenoid
10 & 6 2.7 ~ 3.4Ω
valve
(at 20°C(68°F))
9&4 Second solenoid valve
9&3 Underdrive solenoid valve
9&5 Overdrive solenoid valve
Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Components and
Components Location (F4A42-2)
COMPONENTS (1)
Page 72 of 289
Page 73 of 289
COMPONENTS (2)
Page 74 of 289
COMPONENTS (3)
Page 75 of 289
COMPONENTS (4)
Page 76 of 289
COMPONENTS (5)
Page 77 of 289
Page 78 of 289
Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Repair
procedures (F4A42-2)
REMOVAL
Page 79 of 289
1. Remove the air duct(A).
2. Remove the battery.
3. Remove the battery tray.

4. Remove the air cleaner assembly.
5. Remove the intercooler inlet pipe.

Page 80 of 289
6. Disconnect the connectors relevant to the transaxle.
7. Disconnect the ground earth wire.

8. Remove the bolt(B) which mounts the clutch release cylinder(A) to the inhibiter switch.
9. Detach the clutch release cylinder(B) clip(A).

Page 81 of 289
10. Detach the hoses(A), loosening the oil cooler hose clamps.
11. Using SST(09200-38001), support the engine.
12. Remove the trasaxle mounting bracket(A) bolts.

Page 82 of 289
13. Remove the transaxle upper mounting bolts(A).
14. Remove the bolts which mount the transaxle to the front sub frame.
16. After removing the oil drain plug(A), Drain the fluid.
17. Support the transaxle with a jack.

18. Remove the steering column bolt(See 'ST' group).
19. Remove the driveshafts (See 'DS' group-'DRIVESHAFT').
20. Remove the bolt(A) which mounts the transaxle to the rear sub-frame.
Page 83 of 289
21. Remove the sub-frame. If it is a 4 wheel drive vehicle(4WD), remove the propeller shaft first(See 'DS' group-
'PROPELLER SHAFT').
22. Remove the transaxle lower mounting bolts.

23. Remove the transaxle assembly.
INSTALLATION
1. Attach the torque converter on the transaxle side and mount the transaxle assembly onto the engine.
If the torque converter is mounted first on the engine, the oil seal on the transaxle may be damaged.
Therefore, be sure to first assemble the torque converter to the transaxle.
Page 84 of 289
2. Install the transaxle control cable and adjust as follows.
(1) Move the shift lever and the transaxle range switch to the "N" position, and install the control cable.
(2) When connecting the control cable to the transaxle mounting bracket, install the clip until it contacts the
control cable.
(3) Remove any free-play in the control cable by adjusting nut and then check to see that the selector lever
moves smoothly.
(4) Check to see that the control cable has been adjusted correctly.
DISASSEMBLY
• Because the automatic transmission is manufactured from high-precision parts, sufficient care must be taken not
to scratch or damage these parts during disassembly and reassembly.
• The working area should be convered with a rubber mat to keep it clean at all times.
• Do not wear any cloth gloves and do not use any rags during disassembly. Use nylon cloth or paper towels if
you need to use something.
• Parts which have been disassembled should all be cleaned. Metal parts can be cleaned with normal detergent
but they should be dried completely using compressed air.
• Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF) so
that they do not become dirty.
• If the transmission body has been damaged, disassemble and clean the cooler system also.
1. Remove the torque converter and set aside.
2. Measure the input shaft(A) end play.
3. Remove the left and right roll stopper brackets.

4. Remove the wiring harness bracket.
5. Remove the control cable support bracket.
6. Remove the dipstick.
Page 85 of 289
7. Remove the oil cooler feed tube, gasket, and eye bolt.
8. Remove the input shaft speed sensor and the output shaft speed sensor.
9. Remove the manual control lever, then remove the transaxle range switch.
10. Remove the vehicle speed sensor.
11. Remove the valve body cover.

Page 86 of 289
12. Remove the manual control shaft detent.
13. Disconnect the harness connectors of the valve body.
To prevent damage to transaxle components make sure that the manual control lever and the park/neutral
switch have been removed before attempting to remove the valve body.
The valve body mounting bolts are different lengths. Note the locations of the bolts to aid in assembly.
14. Remove 28 of the valve body mounting bolts. Do not remove the bolts shown in the illustration at this time.
Page 87 of 289
15. Remove the oil temperature sensor.
16. Remove the valve body, gasket, and the 2 steel balls.
Make sure not to lose the 2 steel balls.
17. Remove the solenoid valve wiring harness snap ring.
18. Remove the solenoid valve harness.

19. Remove the strainer.
Page 88 of 289
20. Remove the second brake retainer oil seal.
The second brake retainer oil seal must be removed before removing the transaxle powertrain
components from the case or damage to the seal will occur.
21. Remove the 4 accumulator pistons, the 4 large springs, and the 3 small springs.
Number Functional Name
1 Low&Reverse Brake
2 Underdrive Clutch
3 Second Brake
4 Overdrive Clutch
22. Remove the manual control lever shaft pin (roller).

23. Remove the manual control lever shaft.
24. Remove the parking pawl rod.
Page 89 of 289
25. Remove the torque converter housing and 18 mounting bolts. Tap the housing off with a non-metallic hammer.
26. Remove the 2 O-rings from the case.
27. Remove the differential.
28. Remove the main oil filter.

Page 90 of 289
29. Remove oil pump mounting bolts.
The oil pump is not serviceable, it must be replaced as a pump assembly. Do not disassemble the pump
as improper alignment during assembly will cause pump failure and could cause damage to the transaxle.
30. Install the special tool (09452-33100), as shown in the illustration.
31. Remove the oil pump by turning special tool screws clockwise.
32. Remove the oil pump gasket.
33. Remove thrust bearing #1.
Page 91 of 289
34. Grasp the input shaft, then pull out the underdrive clutch and input shaft as an assembly.
36. Remove the underdrive clutch hub.
37. Remove the rear cover and mounting bolts.
38. Remove the thrust race #8.

Page 92 of 289
39. Remove the 4 seal rings.
Do not remove the input shaft rear bearing unless directed to do so by the
instructor.
Once this bearing has been removed, it MUST be replaced.
40. Remove the 3 O-rings.
42. Remove the reverse and overdrive clutch.

44. Remove the overdrive clutch hub.

Page 93 of 289
46. Remove the planetary reverse sun gear.
47. Remove the second brake piston snap ring.
48. Remove the second brake piston and return spring.

Page 94 of 289
49. Remove the second brake pressure plate, 3 brake discs, and 2 brake plates.
50. Remove the overdrive planetary carrier.
52. Remove the output planetary carrier.

53. Remove the underdrive sun gear.
Page 95 of 289
55. Remove the low and reverse reaction plate snap ring.
56. Remove the low and reverse reaction plate and brake disc.
57. Remove the low and reverse brake snap ring.
58. Remove the low and reverse 6 brake discs, 5 brake plates, and brake pressure plate.
Page 96 of 289
59. Remove the wave spring.
60. Remove the parking pawl shaft.

61. Remove the spacer.
62. Remove the parking pawl spring. Note the orientation of the spring to aid in reassembly.
63. Remove the 2 parking roller support shafts.
64. Remove the parking pawl case.

65. Remove the parking roller support.
66. Remove the snap ring.
67. Remove the spring retainer.

Page 97 of 289
68. Remove the return spring.
69. Remove the low and reverse brake piston. Use compressed air directed into the valve body passage.
70. Remove the 7 transfer gear mounting bolts.
71. Remove the transfer drive gear.
72. Remove the plastic cap, if present.
73. Straighten the locking tab of the output shaft locking nut, if bent.
The output shaft locking nut is left-hand thread.

Page 98 of 289
74. Remove the output shaft locking nut.
75. Remove the output shaft bearing retainer mounting bolts.
76. Tap out the output shaft, tapered roller bearing, and the collar from the back side.
77. Tap out the bearing outer race and spacer using a suitable driver.
78. Remove the snap ring.

79. Remove the differential bearing outer race and spacer from the torque converter housing.
80. Remove the differential bearing outer race from the transaxle case.
REASSEMBLY
Page 99 of 289
• Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling.
• Never use grease other than blue petrolatum jelly and white Vaseline.
• Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch
disc or brake disc in ATF for at least two hours before assembling them.
• Never apply sealant or adhesive to gaskets.
• When replacing a bushing, replace the assembly which it belongs to.
• Never use any cloth gloves or any rags during reassembly.
Use nylon cloth or paper towels if you need to use something. Change the oil in the cooler system.
1. Tap the differential bearing outer race into the transaxle case using special tools tools (09500-11000 and 09532-
11500).
2. Tap the output shaft bearing outer race into the transaxle case using special tool (09500-11000).
3. Install the spacer and the snap ring.

4. Install the low and reverse brake piston, return spring, and spring retainer.
5. Install the snap ring using special tools (09453-21000). To be sure that you have the correct snap ring, measure
the thickness and compare it to the chart in the general parts of the service manual.
Page 100 of 289
6. Install the wave spring.
In steps 7 through 9, you will determine the actual clearance between the low and reverse brake discs and
plates when the clutch is released.
7. Replace the pressure plate of the low and reverse brake, then install the brake discs, 5 brake plates and the snap
ring.
8. Install the low and reverse reaction plate and the old snap ring.
9. With a dial indicator installed, move the special tool up and down to measure the end play.
Standard value :
0-0.16 mm (0-0.0063 in)
If the end play is incorrect, measure the old snap rig, then select the proper snap rig from the chart shown in the
service manual and recheck the clearance.
Page 101 of 289
10. Remove the special tool.
In steps 11 through 16, you will determine the actual clearance between the second brake discs and
11. Install the 3 second brake discs and 2 plates.
12. Install the second brake return spring, second brake piston, and snap ring.
13. Install a dial indicator as shown in the illustration.
14. Move up and down, while observing the end play.

15. To determine the proper thickness of the second brake pressure plate.
Standard value :
0.79-1.25 mm (0.0311-0.0492 in)
16. If the standard value is incorrect, select a pressure plate of the proper thickness from the chart in the general
parts of the service manual and recheck the clearance.
In steps 18 through 21, you will determine the actual clearance between the low-reverse brake discs and
17. Install the special tool in place of the low/reverse brake pressure plate.
18. Install the 6 brake discs, 5 brake plates and snap ring.
19. Turn the transaxle upside down, install a dial indicator, as shown in the illustration.
20. Move the special tool up and down while observing the end play.
Page 102 of 289
21. To determine the proper thickness of the low/reverse brake pressure plate.
Standard value :
1.65-2.11 mm (0.0650-0.0830 in)
22. If the standard value is incorrect, select a pressure plate of the proper thickness from the chart in the service
manual and recheck the clearance.
23. Remove the special tool.
24. Install the output shaft.
25. Install the output bearing retainer mounting bolts. Tighten the bolts to 23 Nm (230 kg·cm, 17 lb·ft) of torque.
26. Install the output shaft collar and tapered roller bearing using special tool (09455-33200).
The output shaft locking nut is left-hand thread.
27. Apply ATF and install the locking nut and tighten to 123 lb ft. Loosen the nut one full turn, then retighten the nut
to 123 lb ft and stake the nut.
Page 103 of 289
28. Install a dial indicator as shown in the illustration.
29. Move the output shaft in and out to measure the end lay.
Standard value :
0.01-0.09 mm (0.0004-0.0035 in)
30. If the standard value is incorrect, use this formula to select the correct spacer from the chart in the general parts
of the service manual.
31. Install the output shaft protective cap.
32. Install the transfer drive gear using special tool (09500-11000).
Page 104 of 289
33. Install the 7 transfer gear mounting bolts. Tighten the bolts to 19 Nm (190 kgf.cm, 14 lbf.ft).
34. Install the parking pawl, spacer and spring, then install the parking pawl shaft.
35. Install the parking roller support, then the two parking roller support shafts.
Be sure to install the thrust bearing in the proper direction.

Page 105 of 289
36. Install the underdrive sun gear and thrust bearing #3 to the output planetary carrier.
37. Install the output planetary carrier and thrust bearing #4.
38. Install the overdrive planetary carrier.
Rotating the output shaft will help align the clutch teeth and help the carrier
seat.
Page 106 of 289
39. Install the reverse planetary sun gear.
40. Install the wave spring.
41. Install the low/reverse pressure plate, 6 brake discs, and 5 brake plates.
42. Install the snap ring.

Page 107 of 289
43. Install the reaction plate.
45. Install the second brake pressure plate, 3 brake discs, and 2 brake plates.
46. Install the return spring and second brake piston.

Page 108 of 289
Be sure to install the thrust bearing in the proper

direction.
48. Install thrust bearing #5.

direction.
49. Install the overdrive clutch hub and thrust bearing #6 to the reverse and overdrive clutch.

Page 109 of 289
50. Install the reverse and overdrive clutch and thrust bearing #7.
51. Install the three O-rings.
52. Install the 3 seal rings into the rear cover.
The cover should be clean and dry for step 56. It is only being installed to measure the underdrive sun
gear end play.
53. Install the used thrust race #8 and rear cover.

Page 110 of 289
54. Using a dial indicator, measure the end play of the underdrive sun gear.
Standard value :
0.25-0.45 mm (0.0098-0.0177 in)
55. If the end play exceeds the standard value, measure the used race with a micrometer and select the proper size
from the chart in the service manual.
56. Reinstall the rear cover and mounting bolts. Tighten the mounting bolts to 23 Nm (230 kgf.cm, 17 lbf.ft).
57. Install the underdrive clutch hub.

direction.
Page 111 of 289
58. Install thrust bearing #2.
59. Grasp the input shaft and lower the underdrive clutch into position.
Looking into the hole where the input speed sensor mounts to the case will help you ensure that the
underdrive clutch is fully seated.
60. Install the used thrust bearing #1.
Be sure to use a new oil pump gasket.

Page 112 of 289
61. Install the oil pump, a new gasket, and the oil pump mounting bolts.
62. Using a dial indicator, measure the end play of the input shaft.
Standard value :
0.70-1.20 mm (0.0276-0.0472 in)
63. If the end play exceeds the standard value, measure the used race with a micrometer and select the proper size
from the chart in the service manual.
64. Reinstall the oil pump and mounting bolts. Tighten the mounting bolts to 23 Nm (230 kgf.cm, 17 lbf.ft).
Page 113 of 289
65. Install the oil internal filter.
66. Install the differential.
67. Place two strips of solder, approximately 10 mm (0.39 in) long and 3 mm (0.12 in) thick, on the torque
converter housing.
68. Install the torque converter housing and mounting bolts. Tighten the bolts to 47 Nm (470 kgf.cm, 35 lbf.ft) of
torque.
69. Remove the torque converter housing, the bolts and the solder.
70. Using a micrometer, measure the thickness of the pressed solder.
Page 114 of 289
71. Select a spacer that will give the following clearance.
Standard value :
0.045 mm (0.0018 in)-0.105 mm (0.0041 in)
72. Install the differential spacer selected in the previous step in the torque converter housing.
73. Use special tools 09532-11500 and 09500-11000 to press in the differential bearing outer race.
74. Install the two O-rings.

Page 115 of 289
75. Install the torque converter housing and mounting bolts. Tighten the bolts to 47 Nm (470 kgf.cm, 35 lbf.ft) of
torque.
76. Install the manual control lever shaft and parking pawl.
77. Install the manual control shaft roller.

78. Install the three small springs and three larger springs into the accumulator pistons. The accumulator springs are
identified in the illustration and in the chart below.
Number Function Name
1 Low&Reverse Brake
2 Underdrive Clutch
3 Second Brake
4 Overdrive Clutch
Page 116 of 289
79. Install the accumulators with the springs according to the illustration and the chart below. The accumulators
should be flush with the transaxle case.
Number Function Name Color
1 Low&Reverse Brake None
2 Underdrive Clutch Yellow
3 Second Brake Blue
4 Overdrive Clutch None
80. Install the strainer and the second brake retainer oil seal.
The oil seal orientation in the illustration.
81. Install the solenoid wiring harness, then install the snap ring in its groove.
Page 117 of 289
82. Install the valve body, gasket, and two steel balls.
83. Install the oil temperature sensor. Tighten the mounting bolt to 11 Nm (110 kgf.cm, 8 lbf.ft).
84. Install 28 valve body mounting bolts. Tighten all valve body mounting bolts to 11 Nm (110 kgf.cm, 8 lbf.ft).
85. Connect the solenoid wiring and temperature sensor connectors according to the illustration and the chart
below.
Connector housing
No. Part to be connected Wire color
color
1 Underdrive solenoid valve White, Red, Red Black
2 Overdrive solenoid valve Orange, Red Black
3 Low&Reverse solenoid valve Brown, Yellow Milky White
4 Second solenoid valve Green, Red, Red Milky White
5 Damper clutch control solenoid valve Blue, Yellow, Yellow Black
6 Oil temp. sensor Black, Red Black
86. Install the manual control shaft detent. Tighten the nut to 6 Nm (60 kgf.cm, 4.4 lbf.ft) of torque.
Page 118 of 289
87. Install the valve body cover and mounting bolts. Tighten the mounting bolts to 9 Nm (90 kgf.cm, 7 lbf.ft) of
torque.
88. Install the vehicle speed sensor and mounting bolt. Tighten the mounting bolt to 5 Nm (50 kgf.cm, 4 lbf.ft) of
torque.
89. Install the park/neutral position switch. Tighten the mounting bolt to 11 Nm (110 kgf.cm, 8 lbf.ft) of torque.
90. Install the manual control lever. Tighten the mounting nut to 22 Nm (220 kgf.cm, 16 lbf.ft) of torque.
Page 119 of 289
91. Install the input and output shaft speed sensors. Tighten the mounting bolts to 11 Nm (110 kgf.cm, 8 lbf.ft) of
torque.
Make sure that you are installing the correct oil filter. While the engine oil filter and the transaxle oil filter
locksimilar, their filtering action is different. Installing the wrong oil filter could cause damage to the
transaxle. Transaxle oil filters are identified as A/T ONLY.
92. Install the cooler feed tube with a new gasket and the eye bolt. Tighten the eye bolt to 30 Nm (300 kgf.cm, 22
lbf.ft) of torque.
93. Install the dipstick.

94. Install the control cable bracket. Tighten the mounting bolt to 23 Nm (230 kgf.cm, 17 lbf.ft).
95. Install the wiring harness bracket. Tighten the mounting bolt to 23 Nm (230 kgf.cm, 17 lbf.ft).
96. Install the two roll stopper brackets. Tighten the mounting bolts to 69 Nm (690 kgf.cm, 51 lbf.ft).
97. Install the torque convertor and secure it so that dimension A.
Meets the reference value.
Reference value :
approx. 12.2 mm (0.480 in)
Apply ATF to the oil pump drive hub before installing the torque converter. Be careful not to damage the
oil pump seal.
Automatic Transaxle System > Hydraulic System > Oil Pump > Components and Components Location
(F4A42-2)
COMPONENTS
Page 120 of 289
Automatic Transaxle System > Hydraulic System > Oil Pump > Repair procedures (F4A42-2)
REASSEMBLY
Oil seal replacement
1. Using the special tool (09452-21200), install the oil seal to the pump housing.
2. Apply a thin coat of automatic transaxle fluid to the lip of the oil seal before installation.
Automatic Transaxle System > Valve Body System > Valve Body > Components and Components
Location (F4A42-2)
COMPONENTS
Page 121 of 289
INSIDE VALVE BODY

Page 122 of 289
OUTSIDE VALVE BODY

Page 123 of 289
Automatic Transaxle System > Clutch & Brake > Underdrive Clutch > Components and Components
Location (F4A42-2)
COMPONENTS
Page 124 of 289
Automatic Transaxle System > Clutch & Brake > Underdrive Clutch > Repair procedures (F4A42-2)
DISASSEMBLY
1. Remove the input shaft snap ring.
2. Remove the input shaft.
3. Remove the 2 seal rings.
4. Remove the clutch reaction plate snap ring.
5. Remove the clutch reaction plate.
Page 125 of 289
6. Remove the 4 clutch discs and 4 clutch plates.
7. Compress the clutch return springs using special tools, 09453-24000 and 09453-21000 then remove the clutch
spring retainer snap ring.
8. Remove the clutch spring retainer.

9. Remove the D-ring seal.
10. Remove the clutch return spring.
11. Remove the underdrive clutch piston using compressed air.
12. Remove the 2 D-ring seals.
REASSEMBLY
1. Install the 2 D-ring seals.
2. Install the underdrive clutch piston.
3. Install the clutch return spring.
4. Install the D-ring seal.
5. Install the clutch spring retainer.
Page 126 of 289
6. Compress the clutch return springs using special tools, 09453-21100 and 09453-21000, then install the clutch
spring retainer snap ring.
Dip each clutch disc in ATF before assembling.
7. Align the spaces between the teeth (A) on the clutch plates, clutch discs, and reaction plate to the outer
circumference hole (B) in the underdrive clutch retainer.
8. Install the 4 clutch discs and the 4 clutch plates.

9. Install the clutch reaction plate with the shear droop toward the clutch disc.
10. Install the clutch reaction plate snap ring.
Page 127 of 289
11. Install special tools, MD998924 and MB991628, as shown, then check the clearance between the snap ring
and the reaction plate using a feeler gauge.
Standard value :
1.6-1.8 mm (0.0630-0.0709 in)
12. If the clearance is correct, measure the old snap ring, then select the correct size from the chart in the service
manual.
13. Install the seal rings.
14. Install the input shaft.
15. Install the input shaft snap ring.
Automatic Transaxle System > Clutch & Brake > Reverse and Overdrive Clutch > Components and
COMPONENTS
Page 128 of 289
Automatic Transaxle System > Clutch & Brake > Reverse and Overdrive Clutch > Repair procedures
(F4A42-2)
DISASSEMBLY
Page 129 of 289
1. Remove the overdrive clutch reaction plate snap ring.
2. Remove the overdrive clutch reaction plate.

3. Remove the 2 overdrive clutch discs and 2 plates.
4. Remove the reverse clutch reaction plate snap ring.
5. Remove the reverse clutch reaction plate.
6. Remove the 4 reverse clutch discs and 4 plates.
7. Compress the clutch return springs using special tools, 09453-21000 then remove the clutch spring retainer snap
ring.
8. Remove the clutch spring retainer.

10. Remove the clutch return spring.
11. Remove the overdrive clutch piston using compressed air.
13. Remove the Reverse clutch piston.
14. Remove the 3 D-ring seals.
REASSEMBLY
1. Install the 3 D-ring seals.
Page 130 of 289
2. Align the outer circumference holes (A and B) on the reverse piston and the reverse piston retainer before
assembly.
3. Install the Reverse clutch piston.

5. Install the overdrive clutch piston.
6. Install the clutch return spring.
8. Install the clutch spring retainer.
9. Compress the clutch return springs using special tools, 09453-21000 then install the clutch spring retainer snap
ring.
10. Check the clearance between the snap ring and the return spring retainer
Standard value :
0.01-0.09 mm (0.0004-0.0035 in)
Page 131 of 289
11. If the clearance is incorrect, measure the old snap ring, then select the correct size from the chart in the service
manual.

circumference hole (B) in the reverse clutch retainer.
13. Install the 4 reverse clutch discs and 4 plates.

14. Install the reverse clutch reaction plate.
15. Install the reverse clutch reaction plate snap ring.
16. Install special tools, 09453-21000 as shown, then check the clearance between the snap ring and the reaction
plate using a feeler gauge.
Standard value :
1.6-1.8 mm (0.0630-0.0709 in)
manual.

Page 132 of 289
circumference hole (B) in the overdrive clutch retainer.
19. Install the 2 overdrive clutch discs and 2 plates.

20. Install the overdrive clutch reaction plate.
21. Install the overdrive clutch reaction plate snap ring.
22. Check the clearance between the snap ring and the clutch reaction plate.
Standard value :
1.5-1.7 mm (0.0590-0.0670 in)
manual.
Automatic Transaxle System > Clutch & Brake > Second Brake > Components and Components
Location (F4A42-2)
COMPONENTS
Page 133 of 289
Automatic Transaxle System > Clutch & Brake > Low and Reverse Brake > Components and
COMPONENTS
Page 134 of 289
Automatic Transaxle System > Clutch & Brake > Low and Reverse Brake > Repair procedures
(F4A42-2)
REASSEMBLY
Apply ATF or white Vaseline on the O-ring and install it caring not to damage it.
Automatic Transaxle System > Gear System > Differential > Components and Components Location
(F4A42-2)
COMPONENTS
Page 135 of 289
Automatic Transaxle System > Gear System > Differential > Repair procedures (F4A42-2)
DISASSEMBLY
1. Clamp the differential case in a vise.
2. Remove the differential drive retaining bolts and remove the differential drive gea from the case.
Page 136 of 289
3. Remove the taper bearing using the special tool (09433-21000).
Do not reuse the bearing removed from the shaft.
4. Drive out the lock pin from the hole A using a punch.
5. Drive out the pinion shaft.
REASSEMBLY
1. Install the spacer on the back of the side gear and then install the gear in the differential case.
• When installing a new side gear, use a spacer of medium thickness [0.83-0.92 mm (0.33-0.036
in)].
• Do not reuse the lock pin.
• The lock pin head must be sunk below the flange surface of the differential case.
2. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them
with the side gears by turning them.
Page 137 of 289
3. Insert the pinion shaft.
4. Measure the backlash between the side gears and pinions.
Standard value :
0.025-0.150 mm (0.001-0.006 in)
0.025-0.0150 mm (0.001-0.006 in)
5. If the backlash is out of specification, disassemble and install the correct spacer, reassemble and remeasure.
Adjust the backlash of both side gears to the same specification.

6. Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.
• Do not reuse the lock pin.

• The lock pin head must not protrude more than 3 mm (0.0118 in) gear in the differential
case.
Page 138 of 289
7. Install the tapered roller bearing on both sides of the differential case using the special tool (09455-21100).
When press-fitting the bearing, press on the inner race only.
8. Apply specified sealant to the entire threads of the bolts. Tighten to specifications using the sequence shown in the
illustration.
If a bolt is reused, remove the old sealant from the threads.
Automatic Transaxle System > Gear System > Speedometer Driven Gear Assembly > Components and
COMPONENTS
Page 139 of 289
Automatic Transaxle System > Gear System > Transfer Drive Gear > Components and Components
Location (F4A42-2)
COMPONENTS
Page 140 of 289
Automatic Transaxle System > Gear System > Transfer Drive Gear > Repair procedures (F4A42-2)
DISASSEMBLY
1. Loosen the locking nut caulking.
Page 141 of 289
2. Remove the lock by using socket.
REASSEMBLY
1. Apply ATF to the new locking nut and tighten to the specified torque. And loosen 1 turn and tighten to the
specified torque again.
2. Caulk the locking nut by using punch.
Automatic Transaxle System > Gear System > Output Shaft > Components and Components Location
(F4A42-2)
COMPONENTS
Page 142 of 289
Automatic Transaxle System > Gear System > Output Shaft > Repair procedures (F4A42-2)
REASSEMBLY
1. Remove the transfer driven gear by press.
Page 143 of 289
2. Remove the taper roller bearing.
Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Components and
COMPONENTS
Page 144 of 289
Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Repair
procedures (F4A42-2)
REMOVAL
Page 145 of 289
1. Remove the shift lever knob(A).
2. Disconnect the three connectors.

3. Remove the console cover. (Screw:10EA, Fastener:4EA)
4. Remove the sports mode connector(A) from the shift lever(B).
5. Remove the control cable(A) and shift lock cable(B).
6. Remove the shift lever assembly. (Bolt:4EA)
INSTALLATION
Page 146 of 289
1. Install the shift lever assembly. (Bolt:4EA)
TORQUE :
18-25Nm (180-250kgf.cm, 13.3-18.4lb-ft)
2. Install the cable.

3. Connect the sports mode connector.
4. Inspect the shift lock. (Refer to shift lock inspection)

5. Connect the three connectors.
6. Install the console cover. (Screw:10EA, Fastener:4EA)
7. Install the shift lever knob.
INSPECTION
1. Adjusting method for T/M control cable
(1) Set room side lever and T/M side lever to "N" position.
(2) Connect gear selector lever and shift cable.
(3) Connect T/M side lever to cable in a following orders.
A. Push cable lightly to "F" direction shown to eliminate FREE PLAY of cable.
B. Tighten adjusting nut.
(4) After adjustment, ensure that the transaxle gear selector lever operates properly by moving the lever to each
gear position.
Page 147 of 289
2. Shift lock
(1) With shift lever at "P" position and brake pedal not depressed. Push button cannot be operated.
(2) With IG key at the position other than "LOCK"(may be at "ACC") and brake pedal stroke 15-25mm (0.59-
0.98 in) (with shift lever at "P" position). Push button can be operated and shift lever can be shifted smoothly
to out of "P" range.
(3) With brake pedal not depressed. Shift lever can be shifted smoothly to "P" position from other positions.
(4) Brake pedal should operate smoothly without catching at all positions.
Adjusting procedure for "P" shift lock cable
1. Check that each lock cam(A) is shown below.
2. Loosen nut "A" securing shift lock cable to shift lever assembly.
3. Adjust cable by sliding the cable housing. The shift lock cam must remain stationary during this step.
4. Tighten shift lock cable mounting nut "A".
5. Verify correct operation.
Automatic Transaxle System > Troubleshooting > P0707

COMPONENT LOCATION
Page 148 of 289
GENERAL DESCRIPTION
The Transaxle Range Switch sends the shift lever position information to the TCM(PCM) using a 12V (battery
voltage) signal. When the shift lever is in the D (Drive) position the output signal of Transaxle Range Switch is 12V
and in all other positions the voltage is 0V. The TCM(PCM) judges the shift lever position by reading all signals, for
the Transaxle Range Switch, simultaneously.
DTC DESCRIPTION
The TCM(PCM) sets this code when the Transaxle Range Switch has no output signal for more than 30 seconds.
DTC DETECTING CONDITION

[2.7 GSL]
Item Detecting Condition & Fail Safe Possible cause
DTC Strategy • Check for No signal • Open or short in circuit
• Faulty TRANSAXLE
Enable Conditions • Continuous
RANGE SWITCH
Threshold value • No signal detected • Faulty TCM(PCM)
Diagnostic Time • More than 30sec
• Recognition as previous signal
- When P-D or R-D or D-R SHIFT is detected,
it is regarded as N-D or N-R though "N" signal
Fail Safe is not detected.
- When sports mode S/W is ON without P,R,N,
D-RANGE signals, it is regarded sports
mode.(DTC is not set)
[2.0 GSL]
Page 149 of 289
DTC Strategy • Check for No signal • Open or short in circuit
• Faulty TRANSAXLE
Enable Conditions • Engine speed ≥ 400rpm and TPS ≥ 10%
RANGE SWITCH
Threshold value • No signal detected • Faulty TCM(PCM)
- When P-D or R-D or D-R SHIFT is detected,
it is regarded as N-D or N-R though "N" signal
Fail Safe is not detected.
- When sports mode S/W is ON without P,R,N,
D-RANGE signals, it is regarded as sports
mode.(DTC is not set)
SPECIFICATION
Inspection condition Reference value
Shift lever : P P,N
Shift lever : R R
* IG KEY : ON or Engine stall
Shift lever : N P,N
Shift lever : D D
SCHEMATIC DIAGRAM
Page 150 of 289
MONITOR SCANTOOL DATA

1. Connect scantool to data link connector(DLC).
2. Ignition "ON" & Engine "OFF".
3. Monitor the "TRANSAXLE RANGE SWITCH" parameter on the scantool.
Page 151 of 289
4. Move selector lever from "P" range to other range.
5. Does "TRANSAXLE RANGE SWITCH" follow the reference data?
Fault is intermittent caused by poor contact in the sensor's and/or TCM(PCM)'s connector or was repaired
and TCM(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.
Go to "TERMINAL & CONNECTOR 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 vehicle Repair" procedure.
Go to "Power Supply circuit inspection" procedure.

POWER SUPPLY CIRCUIT INSPECTION
1. CHECK POWER TO RANGE SWITCH
(1) Disconnect "TRANSAXLE RANGE SWITCH" connector.
(2) Ignition "ON" & Engine "OFF".
(3) Measure voltage between teminal "8" of the sensor harness connector and chassis ground.
Specification : approx. B+
Page 152 of 289
(4) Is voltage within specifications?
Go to "Signal circuit inspection" procedure.
Check that Fuse 24-10A is installed or not blown.

Check for open in harness. Repair as necessary and Go to "Verification Vehicle Repair" procedure.
SIGNAL CIRCUIT INSPECTION
1. Ignition "OFF".
2. Disconnect "TRANSAXLE RANGE SWITCH" and "TCM(PCM)" connector.
3. Measure resistance between each teminal of the sensor harness connector and TCM(PCM)harness connector as
below.
Specification : Shown below
[2.7 GSL]
Pin No of "TRANSAXLE
C70 No.1 C70 No.3 C70 No.4 C70 No.7
RANGE SWITCH"
Pin No of "TCM(PCM)"
C89-3 No.17 C89-3 No.5 C89-3 No.6 C89-3 No.16
harness
Specification 0Ω 0Ω 0Ω 0Ω
[2.0 GSL]
Pin No of "TRANSAXLE
C21 No.1 C21 No.3 C21 No.4 C21 No.7
RANGE SWITCH"
Pin No of "TCM(PCM)"
C18-2 No.29 C18-2 No.22 C18-2 No.6 C18-2 No.14
harness
Specification 0Ω 0Ω 0Ω 0Ω
Page 153 of 289
4. Is resistance within specifications?
Go to "Component inspection" procedure.
Check for Open in harness. Repair as necessary and Go to "Verification Vehicle Repair" procedure.
COMPONENT INSPECTION
1. Ignition "OFF".
2. Remove "TRANSAXLE RANGE SWITCH".
3. Measure the resistance between each terminal of the sensor.
Specification : approx. 0 Ω
Page 154 of 289
Substitute with a known-good TCM(PCM) and check for proper operation. If the problem is corrected,
replace PCM/TCM as necessary and then go to "Verification of Vehicle Repair" procedure.
Replace "TRANSAXLE RANGE SWITCH" as necessary and Go to "Verification Vehicle Repair"

procedure.
VERIFICATION OF VEHICLE REPAIR

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode.
2. Using a scantool, Clear DTC.
3. Operate the vehicle within DTC Enable conditions in General information.
4. Are any DTCs present?
Go to the applicable troubleshooting procedure.
System performing to specification at this time.

COMPONENT LOCATION
GENERAL DESCRIPTION
The Transaxle Range Switch sends the shift lever position information to the TCM(PCM) using a 12V (battery
voltage) signal. When the shift lever is in the D (Drive) position the output signal of Tansaxle Range Switch is 12V
and in all other positions the voltage is 0V. The TCM(PCM) judges the shift lever position by reading all signals, for
the Transaxle Range Switch, simultaneously.
DTC DESCRIPTION
The TCM sets this code when the Transaxle Range Switch outputs multiple signals for more than 30 seconds.

[2.7 GSL]
Page 155 of 289
DTC Strategy • Check for multiple signals • Open or short in
TRANSAXLE RANGE
SWITCH
Threshold value • Multiple signal • Faulty TRANSAXLE
RANGE SWITCH
• Faulty TCM(PCM)
- When signal is input "D" and "N" at the same
time, TCM(PCM) regards it as "N" RANGE.
Fail Safe
- After TCM(PCM) Reset, if the TCM(PCM)
detects multiple signals or no signal, then it holds
the 3rd gear position.
[2.0 GSL]
DTC Strategy • Check for multiple signals • Open or short in
TRANSAXLE RANGE
Enable Conditions • Always
SWITCH
Threshold value • Multiple signal • Faulty TRANSAXLE
RANGE SWITCH
• Faulty TCM(PCM)
- When signal is input "D" and "N" at the same
time, TCM(PCM) regards it as "N" RANGE.
Fail Safe
- After TCM(PCM) Reset,If the if the
TCM(PCM) detects multiple signal or no signal,
then it holds the 3rd gear position.
SPECIFICATION
Inspection condition Reference value
Shift lever : P P,N
Shift lever : R R
* IG KEY : ON or Engine stall
Shift lever : N P,N
Shift lever : D D
SCHEMATIC DIAGRAM
Page 156 of 289

2. Ignition "ON".
3. Monitor the "TRANSAXLE RANGE SWITCH" parameter on the scantool.
Page 157 of 289
4. Move selector lever from "P" range to "L" range.
5. Does "TRANSAXLE RANGE SWITCH" follow the referance data?
and TCM(PCM) memory was not cleared. Throughly check connectors for looseness, poor connection,
Go to "TERMINAL & CONNECTOR INSPECTION" procedure.

or damage.

1. Disconnect "TRANSAXLE RANGE SWITCH" connector.
3. Measure voltage between terminal "8" of the sensor harness connector and chassis ground.
Specification : Approx. B+
Page 158 of 289
4. Is voltage within specifications?
Check for Short in harness. Repair as necessary and Go to "Verification Vehicle Repair" procedure.
1. Ignition "OFF".
2. Disconnect "TRANSAXLE RANGE SWITCH" and "TCM(PCM)" connector.
3. Measure resistance between each terminals of the sensor harness to check for Short.
Specification : Infinite
1. Ignition "OFF".
2. Remove "TRANSAXLE RANGE SWITCH".
Specification : Approx. 0 Ω
Page 159 of 289
replace PCM/TCM as necessary and then go to "Verification of Vehicle Repair" procedure.
Replace "TRANSAXLE RANGE SWITCH" as necessary and Go to "Verification Vehicle Repair"

procedure.


COMPONENT LOCATION
GENERAL 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(PCM) supplies a 5V
reference voltage to the sensor, and the output voltage.
Page 160 of 289
DTC DESCRIPTION
This DTC code is set when the ATF temperature output voltage is lower than a value generated by thermistor
resistance, in a normal operating range, for approximately 1 second or longer. The TCM(PCM) regards the ATF
temperature as fixed at a value of 80°C(176°F).

[2.7 GSL]
DTC Strategy • Check for ground short • Sensor signal circuit is short
to ground
• -4°F(-20°C) ≤ OIL TEMP ≤ 248°F(120°C), In
Enable Conditions 1) • Faulty sensor
condition that Oil TEMP is changed over 10
JUMP • Faulty TCM(PCM)
degrees during 10 sec
Enable Conditions 2)
• OIL TEMP ≥ 86°F(30°C) and In case of OIL
STUCK ON HIGH
TEMP is higher 15 degrees than WATER TEMP
TEMP
• OIL TEMP ≤ 86°F(30°C)
Enable Conditions 3) • Engine speed ≥ 1000rpm
STUCK ON LOW • Maintenance time : 10minutes
TEMP In condition that OIL TEMP is changed less than 5
degrees
Threshold value
Diagnostic Time
• Learning control and Intelligent shift are inhibited
Fail Safe
• Fluid temperature is regarded as 80°C(176°F)
[2.0 GSL]
DTC Strategy • Check rationality • Sensor signal circuit is short
to ground
• Engine speed≥1000rpm and Output
speed≥1000rpm for 5min cumulative and • Faulty sensor
Engine coolant temperature has changed • Faulty TCM(PCM)
Case 1 by more than 40°C(104°F) since start up
and other OTS related error is not
detected. In condition that Oil TEMP is
not changed more than 2°C(36°F)
• OTS output at IG-OFF≥50°C(122°F)
and the engine coolant temperature at
IG-OFF≥73.5°C(164°F) and the engine
Enable Conditions coolant temperature have decreased over
Case 2
34°C(93°F) from IG-OFF of the
previous trip. In condition that OTS
TEMP is not changed morethan
2°C(36°F)
Page 161 of 289
• Output speed ≥ 1000rpm, Engine speed
≥ 1000rpm for 5min cumulative and the
engine coolant
Case 3
temperature≥73.5°C(164°F). In
condition that OTS output ≤ -23.5°C(-
10.3°F)
Threshold value •-
Diagnostic Time •-
• Learning control and Intelligent shift are
inhibited
Fail Safe
• Fluid temperature is regarded as
80°C(176°F)
SPECIFICATION
-40(-40) 139.5 80(176) 1.08
-20(-4) 47.7 100(212) 0.63
0(32) 18.6 120(248) 0.38
20(68) 8.1 140(284) 0.25
40(104) 3.8 160(320) 0.16
60(140) 1.98
SCHEMATIC DIAGRAM
Page 162 of 289

2. Engine "ON".
3. Monitor the "TRANSAXLE FLUID TEMPERATURE SENSOR" parameter on the scantool.
Specification : Increasing Gradually

Page 163 of 289
4. Does "TRANSAXLE FLUID TEMPERATURE SENSOR " follow the reference data?
Go to "W/Harness Inspection" procedure.

or damage.
Page 164 of 289
1. CHECK "TRANSAXLE FLUID TEMPERATURE SENSOR"
(1) Ignition "OFF".
(2) Disconnect the "TRANSAXLE FLUID TEMPERATURE SENSOR" connector.
(3) Measure the resistance between terminals "1" and "2" of the "TRANSMISSION FLUID TEMPERATURE
SENSOR".
Specification : Refer to " Reference data"
[REFERENCE DATA]
-40(-40) 139.5 80(176) 1.08
-20(-4) 47.7 100(212) 0.63
0(32) 18.6 120(248) 0.38
20(68) 8.1 140(284) 0.25
40(104) 3.8 160(320) 0.16
60(140) 1.98
(4) Is resistance within specifications?
Go to "CHECK TCM(PCM)" as below.
Replace "TRANSAXLE FLUID TEMPERATURE SENSOR" as necessary and Go to "Verification

Vehicle Repair" procedure.
Page 165 of 289
2. CHECK TCM
(2) Connect "TRANSAXLE FLUID TEMPERATURE SENSOR" connector.
(3) Install scantool and select a SIMU-SCAN.
(4) Simulate voltage (0→5V) to "TRANSMISSION FLUID TEMPERATURE SENSOR" signal circuit.
(5) Is FLUID TEMP. SENSOR signal value changed according to simulation voltage?
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.
Substitute with a known-good TCM(PCM) and check for proper operation. If the problem is corrected, replace
TCM(PCM) as necessary and then go to "Verification of Vehicle Repair" procedure.


COMPONENT LOCATION
Page 166 of 289
GENERAL DESCRIPTION
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(PCM)'s control of the
Torque Converter Clutch, and is also used for many other purposes.
DTC DESCRIPTION

[2.7 GSL]
DTC Strategy • Check for ground short • Sensor signal circuit is short
to ground
• Faulty sensor
Threshold value • Voltage < 0.49V • Faulty TCM(PCM)
Fail Safe
[2.0 GSL]
DTC Strategy • Check for Voltage range • Sensor signal circuit is short
to ground
• Faulty sensor
Threshold value • Voltage < 0.05V • Faulty TCM(PCM)
Fail Safe
Page 167 of 289
SPECIFICATION
-40(-40) 139.5 80(176) 1.08
-20(-4) 47.7 100(212) 0.63
0(32) 18.6 120(248) 0.38
20(68) 8.1 140(284) 0.25
40(104) 3.8 160(320) 0.16
60(140) 1.98
SCHEMATIC DIAGRAM

2. Engine "ON".
Page 168 of 289
bending, corrosion, contamination, deterioration or damage.Repair or replace as necessary and go to

or damage.

Page 169 of 289
2. Disconnect the "TRANSAXLE FLUID TEMPERATURE SENSOR" connector.
3. Measure the voltage between terminal "1" of the "TRANSMISSION FLUID TEMPERATURE SENSOR"
harness connector and chassis ground.
Specification : Approx. 5V
Go to "Component Inspection" procedure.
Check for short to ground in harness. Repair as necessary and Go to "Verification Vehicle Repair" procedure .
(1) Ignition "OFF".
SENSOR".
[REFERENCE DATA]
-40(-40) 139.5 80(176) 1.08
-20(-4) 47.7 100(212) 0.63
0(32) 18.6 120(248) 0.38
20(68) 8.1 140(284) 0.25
40(104) 3.8 160(320) 0.16
60(140) 1.98
Page 170 of 289
Replace "TRANSAXLE FLUID TEMPERATURE SENSOR" as necessary and Go to "Verification

2. CHECK TCM(PCM)
(4) Simulate voltage (0→5V) to "TRANSMISSION FLUID TEMPERATURE SENSOR" signal circuit.


Page 171 of 289
COMPONENT LOCATION
GENERAL DESCRIPTION
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(PCM)'s control of the
Torque Converter Clutch, and is also used for many other purposes.
DTC DESCRIPTION

[2.7 GSL]
DTC Strategy • Check voltage range • Open in circuit
• Faulty sensor
• Engine speed > 2000rpm
• Faulty TCM(PCM)
Enable Conditions • Output speed > 1000rpm
(1) • Accumulated time in above condition : 10
min
• Enable Conditions(1) or
Enable Conditions • Engine speed > 700rpm
(2) • Engine Coolant Temperature > 35°C(95°F)
• Accumulated time in above condition : 60 sec
Threshold value • Voltage > 4.5V
• Learning control and Intelligent shift are
inhibited.
Fail Safe
• Fluid temperature is regarded as
80°C(176°F)
Page 172 of 289
[2.0 GSL]
DTC Strategy • Check for Voltage range • Sensor signal circuit is short
to ground
• Faulty sensor
Threshold value • Voltage ≥ 0.49V • Faulty TCM(PCM)
Fail Safe
SPECIFICATION
-40(-40) 139.5 80(176) 1.08
-20(-4) 47.7 100(212) 0.63
0(32) 18.6 120(248) 0.38
20(68) 8.1 140(284) 0.25
40(104) 3.8 160(320) 0.16
60(140) 1.98
SCHEMATIC DIAGRAM
Page 173 of 289

2. Engine "ON".

or damage.
Page 174 of 289

3. Measure the voltage between terminal "1" of the "TRANSMISSION FLUID TEMPERATURE SENSOR"
Go to "Ground circuit inspection" procedure.
Check for short to ground in harness. Repair as necessary and Go to "Verification Vehicle Repair" procedure.
GROUND CIRCUIT INSPECTION
1. Ignition "OFF".
3. Measure the resistance between terminal "2" of the "TRANSMISSION FLUID TEMPERATURE SENSOR"
Page 175 of 289
(1) Ignition "OFF".
SENSOR".
[REFERENCE DATA]
-40(-40) 139.5 80(176) 1.08
-20(-4) 47.7 100(212) 0.63
0(32) 18.6 120(248) 0.38
20(68) 8.1 140(284) 0.25
40(104) 3.8 160(320) 0.16
60(140) 1.98
Replace OIL TEMPERATURE SENSOR as necessary and Go to "Verification Vehicle Repair"

procedure.
2. CHECK TCM(PCM)
(4) Simulate voltage (0→5V) to OIL TEMPERATURE SENSOR signal circuit.
Page 176 of 289


COMPONENT LOCATION
GENERAL DESCRIPTION
The input(turbine) speed sensor outputs pulse-signals according to the revolutions of the input shaft of the
transmission. The TCM(PCM) determines the input shaft speed by counting the frequency of the pulses. This value
is mainly used to control the optimum fluid pressure during shifting.
DTC DESCRIPTION
The TCM(PCM) sets this code if an output pulse-signal is not detected, from the input speed sensor, when the
vehicle is running faster than 30 km/h. The Fail-Safe function will be set by the TCM(PCM) if this code is detected.

[2.7 GSL]
Page 177 of 289
DTC Strategy • Speed rationality check • Signal circuit is open or short
• Sensor power circuit is open
• Vehicle speed is over 30 Km/h(19 mph) in
D,3,2,L(A/T range swhitch) and SP(SPORTS • Sensor ground circuit is open
MODE) • Faulty INPUT SPEED
Enable Conditions SENSOR
• But do not check the DTC in below condition
- A/T oil temp sensor voltage >4.5 V • Faulty TCM(PCM)
- Eng revolution < 2600 rpm
Threshold value • No signal
• Locked into 3rd or 2nd gear
Fail Safe • Manual shifting is possibe
(2 nd → 3 rd, 3 rd → 2 nd)
SIGNAL WAVEFORM
SPECIFICATION
● Type : Hall sensor
● Current consumption : 22mA(MAX)
● sensor body and sensor connector have been unified as one.
SCHEMATIC DIAGRAM
Page 178 of 289

2. Engine "ON" .
3. Monitor the "INPUT SPEED SENSOR" parameter on the scantool
Page 179 of 289
4. Driving at speed of over 30 Km/h(19 mph).
5. Does "input speed sensor " follow the reference data?

1. Many malfunctions in the electrical system may be caused from poor harness and terminals. These faults can be
caused by interference from other electrical systems and mechanical or chemical damage.
or damage.
Go to "Signal Supply circuit inspection" procedure.

2. Disconnect the "INPUT SPEED SENSOR" connector.
3. Measure voltage between terminal "2" of the INPUT SPEED SENSOR harness connector and chassis ground.
Specification : approx. 5V
Page 180 of 289
4. Is voltage within specification?
Go to "Power Supply circuit Inspection" procedure.
Check for open or short in harness. Repair as necessary and Go to "Verification Vehicle Repair" procedure
If signal circuit in harness is OK, Go to "Check TCM(PCM)" of the "Component Inspection" procedure.
4. Is voltage within specification ?
3. Measure resistance between terminal "1" of the INPUT SPEED SENSOR harness connector and chassis
ground.
4. Is resistance within specification ?
If ground circuit in harness is OK, Go to "Check TCM(PCM)" of the "Component Inspection" procedure.
Page 181 of 289
1. Check "INPUT SPEED SENSOR"
(1) Ignition "OFF".
(2) Disconnect the "INPUT SPEED SENSOR" connector.
(3) Measure resistance between terminal "1","2" and "2","3" and "1","3" of the "INPUT SPEED SENSOR"
connector.

[REFERENCE DATA]
Data Reference Data
Current 22 mA
Input sensor 1.3 mm
Air Gap
Output sensor 0.85 mm
1(red) - 2(black) Infinite
1(black) - 2(red) Approx. 3.89 MΩ
1(red) - 3(black) Approx. 6.55 MΩ
Resistance
2(black) - 3(red) Infinite
Replace "INPUT SPEED SENSOR" as necessary and Go to "Verification Vehicle Repair" procedure.
Page 182 of 289
2. CHECK TCM(PCM)
(2) Connect "INPUT SPEED SENSOR" connector.
(4) Simulate frequency to INPUT SPEED SENSOR signal circuit.
(5) Is "INPUT SPEED SENSOR" signal value changed according to simulation frequency?


COMPONENT LOCATION
Page 183 of 289
GENERAL DESCRIPTION
The input(turbine) speed sensor outputs pulse-signals according to the revolutions of the input shaft of the
transmission. The TCM(PCM) determines the input shaft speed by counting the frequency of the pulses. This value
is mainly used to control the optimum fluid pressure during shifting.
DTC DESCRIPTION
The TCM(PCM) sets this code if an output pulse-signal is not detected, from the input speed sensor, when the
vehicle is running faster than 30 km/h. The Fail-Safe function will be set by the TCM(PCM) if this code is detected.

[2.0 GSL]
• Vehicle speed is over 19 Mile/h(30 Km/h) and
Enable Conditions Engine speed≥2000rpm in D,3,2,L(A/T range • Sensor ground circuit is open
swhitch) and SP(SPORTS MODE) • Faulty INPUT SPEED
SENSOR
• Faulty TCM(PCM)
(2 nd → 3 rd, 3 rd → 2 nd)
SIGNAL WAVEFORM
Page 184 of 289
SPECIFICATION
● sensor body and sensor connector have been unified as one.
SCHEMATIC DIAGRAM
Page 185 of 289

2. Engine "ON" .
3. Monitor the "INPUT SPEED SENSOR" parameter on the scantool
5. Does "input speed sensor " follow the reference data?

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

Page 186 of 289
4. Is voltage within specification ?
Page 187 of 289
3. Measure resistance between terminal "1" of the INPUT SPEED SENSOR harness connector and chassis
ground.
1. Check "INPUT SPEED SENSOR"
(1) Ignition "OFF".
(2) Disconnect the "INPUT SPEED SENSOR" connector.
(3) Measure resistance between terminal "1","2" and "2","3" and "1","3" of the "INPUT SPEED SENSOR"
connector.

Page 188 of 289
[REFERENCE DATA]
Data Reference Data
Current 22 mA
Input sensor 1.3 mm
Air Gap
Resistance
Replace "INPUT SPEED SENSOR" as necessary and Go to "Verification Vehicle Repair" procedure.
2. CHECK TCM(PCM)
(2) Connect "INPUT SPEED SENSOR" connector.
(4) Simulate frequency to INPUT SPEED SENSOR signal circuit.
(5) Is "INPUT SPEED SENSOR" signal value changed according to simulation frequency?
Page 189 of 289

COMPONENT LOCATION
GENERAL DESCRIPTION
The Output Speed Sensor outputs pulse-signals according to the revolutions of the output shaft of the transmission.
The Output Speed Sensor is installed in front of the Transfer Drive Gear to determine the Transfer Drive Gear rpms
by counting the frequency of the pulses. This value, together with the throttle position data, is mainly used to decide
the optimum gear position.
DTC DESCRIPTION
The TCM(PCM) sets this code if the calculated value of the pulse-signal is noticeably different from the value
calculated, using the Vehicle Speed Sensor output, when the vehicle is running faster than 30 km/h. The
TCM(PCM) will initiate the fail safe function if this code is detected.

[2.7 GSL]
Page 190 of 289
• Vehicle speed is over 30 Km/h(19 mph) in
D,3,2,L(A/T range swhitch) and SP(SPORTS • Sensor ground circuit is open
MODE) • Faulty OUTPUT SPEED
Enable Conditions SENSOR
• DTC detection inhibited
- A/T oil temp sensor voltage >4.5 V • Faulty TCM(PCM)
- Eng revolution < 2600 rpm
• If the output from the output speed sensor is
Threshold value continuously 50% lower than the value calculated
by vehicle speed sensor
(2 nd → 3 rd, 3 rd → 2 nd)
SIGNAL WAVEFORM
SPECIFICATION
● Sensor body and sensor connector have been unified as one.
SCHEMATIC DIAGRAM
Page 191 of 289

2. Engine "ON".
3. Monitor the "OUTPUT SPEED SENSOR" parameter on the scantool.
Page 192 of 289
5. Does "output speed sensor" follow the reference data?

or damage.

2. Disconnect the "OUTPUT SPEED SENSOR" connector.
Page 193 of 289
3. Measure voltage between terminal "2" of the OUTPUT SPEED SENSOR harness connector and chassis
ground.
ground.
Page 194 of 289
3. Measure resistance between terminal "1" of the OUTPUT SPEED SENSOR harness connector and chassis
ground.
4. Is resistance within specification?
1. Check "OUTPUT SPEED SENSOR"
(1) Ignition "OFF".
(2) Disconnect the "OUTPUT SPEED SENSOR" connector.
(3) Measure resistance between terminal "1","2" and "2","3" and "1","3" of the "OUTPUT SPEED SENSOR"
connector.

Page 195 of 289
[REFERENCE DATA]
Data Reference Data
Current 22 mA
Input sensor 1.3 mm
Air Gap
Resistance
Replace "OUTPUT SPEED SENSOR" as necessary and Go to "Verification Vehicle Repair" procedure.
2. CHECK TCM(PCM)
(2) Connect "OUTPUT SPEED SENSOR" connector.
(4) Simulate frequency to OUTPUT SPEED SENSOR signal circuit.
(5) Is "OUTPUT SPEED SENSOR" signal value changed according to simulation frequency?
Page 196 of 289

COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION

[2.0 GSL]
Page 197 of 289
• Vehicle speed is over 31 Mile/h(50 Km/h) in
Enable Conditions D,3,2,L(A/T range swhitch) and SP(SPORTS • Sensor ground circuit is open
MODE) • Faulty OUTPUT SPEED
SENSOR
• If the output from the output speed sensor is • Faulty TCM(PCM)
Threshold value continuously 50% lower or higrer than the value
calculated by vehicle speed sensor
• Apply an electric current to Solenoide valve
Fail Safe
• Manual shifting is possibe
(2 nd → 3 rd, 3 rd → 2 nd)
SIGNAL WAVEFORM
SPECIFICATION
SCHEMATIC DIAGRAM
Page 198 of 289

2. Engine "ON".
Page 199 of 289

or damage.

Page 200 of 289
ground.
ground.
ground.
Page 201 of 289
(1) Ignition "OFF".
connector.

[REFERENCE DATA]
Data Reference Data
Current 22 mA
Input sensor 1.3 mm
Air Gap
Resistance
Page 202 of 289
2. CHECK TCM(PCM)


COMPONENT LOCATION
Page 203 of 289
GENERAL DESCRIPTION
DTC DESCRIPTION

[2.0 GSL]
• Vehicle speed is over 19 Mile/h(30 Km/h) and
Enable Conditions Engine speed≥2000rpm in D,3,2,L(A/T range • Sensor ground circuit is open
swhitch) and SP(SPORTS MODE) • Faulty OUTPUT SPEED
SENSOR
• Faulty TCM(PCM)
• Apply an electric current to Solenoide valve
Fail Safe
• Manual shifting is possibe
(2 nd → 3 rd, 3 rd → 2 nd)
SIGNAL WAVEFORM
Page 204 of 289
SPECIFICATION
SCHEMATIC DIAGRAM
Page 205 of 289

2. Engine "ON".

or damage.

Page 206 of 289
ground.
ground.
Page 207 of 289
ground.
(1) Ignition "OFF".
connector.

Page 208 of 289
[REFERENCE DATA]
Data Reference Data
Current 22 mA
Input sensor 1.3 mm
Air Gap
Resistance
2. CHECK TCM(PCM)
Page 209 of 289

COMPONENT LOCATION
GENERAL DESCRIPTION
The value of the input shaft speed should be equal to the value of the output shaft speed, when multiplied by the 1st
gear ratio, while the transaxle is engaged in the 1st gear. For example, if the output speed is 1000 rpm and the 1st
gear ratio is 2.842, then the input speed is 2,842 rpm.
DTC DESCRIPTION
This code is set if the value of input shaft speed is not equal to the value of the output shaft, when multiplied by the
1st gear ratio, while the transaxle is engaged in 1st gear. This malfunction is mainly caused by mechanical troubles
such as control valve sticking or solenoid valve malfuctioning rather than an electrical issue.

[2.7 GSL]/ [2.0 GSL]
Page 210 of 289
DTC Strategy • 1st gear incorrect ratio • Faulty Input speed sensor
• Faulty output speed sensor
• Engine speed >450rpm
• Faulty UD clutch or LR brake
• Output speed >350rpm
or Oneway clutch
• Shift stage 1st. gear
Enable Conditions • Input speed >0rpm
• A/T oil temp sensor voltage <4.5V
• Voltage of Battery >10V
• TRANSAXLE RANGE SWITCH is normal
• input speed/1st gear ratio - output
Threshold value
speed|≥200rpm /1st. gear ratio
• Locked into 3rd gear.
Fail Safe (If diagnosis code P0731 is output four times, the
transaxle is locked into 3rd gear)
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
Page 211 of 289

2. Engine "ON".
3. Monitor the "ENGINE SPEED, INPUT SPEED SENSOR, OUTPUT SPEED SENSOR, GEAR POSITION"
parameter on the scantool.
Page 212 of 289
4. Perform the "STALL TEST" with gear position "1"
Specification :
2.0(GSL) : 2400~3000rpm
2.7(GSL) : 2100~2700rpm
OPERATING ELEMENT OF EACH SHIFTING RANGE

P ●
R ● ●
N ●
D1 ● ● ○
D2 ● ●
D3 ● ●
D4 ● ●
Low & Reverse Brake is released When the Vehicle speed over the 5 MPH(7Km/h).
Stall test procedure in D1 and reason
Procedure
A. Warm up the engine
B. After positioning the select lever in "D" , depress the foot brake pedal fully. After that, depress the accelerator
pedal to the maximum
* The slippage of 1st gear operating parts can be detected by stall test in D
Reason for stall test
A. If there is no mechanical defaults in A/T, every slippage occur in torque converter.
B. Therfore, engine revolution is output, but input and output speed revolution must be "zero" due to wheel's
lock.
C. If 1st gear operating part has faults, input speed revolution will be out of specification.
D. If output speed revolution is output. It means that the foot brake force is not applied fully. Remeasuring is
required.
Page 213 of 289
5. Is "STALL TEST " within specification?
Go to "Signal Circuit Inspection" procedure.
● Do not let anybody stand in front of or behind the vehicle while this test is being carried out.
● Check the A/T fluid level and temperature and the engine coolant temperature.
- Fluid level : At the hot mark on the oil level gauge.
- Fluid temperature : 80~100°C (176~212°F).
- Engine coolant temperature : 80~100°C (176~212°F).
● Chock both rear wheel(left and right).
● Pull the parking brake lever on with the brake pedal fully depressed.
● The throttle should not be left fully open for more than eight second.
● If carrying out the stall test two or more time, move the select lever to the "N" position and run the engine
at 1,000 rpm to let the A/T fluid cool down before carrying out subsequent.

1. Connect Scantool.
2. Engine "ON".
3. Monitor the "INPUT & OUTPUT SPEED SENSOR" parameter on the scantool.
4. Accelerate the Engine speed until about 2000 rpm in the 1st gear.
Specification : INPUT SPEED - (OUTPUT SPEED × GEAR RATIO) ≤ 200 RPM
5. Are "INPUT & OUTPUT SPEED SENSOR" within specifications?
Check for electrical niose of circuit in INPUT & OUTPUT SPEED SENSOR or Replace INPUT &
OUTPUT SPEED SENSOR. Repair as necessary and Go to "Verification Vehicle Repair" procedure.
Page 214 of 289
1. Connect Oil pressure gauge to "UD" and "L/R" port.

2. Engine "ON".
3. Drive a car with gear position 1 in "SPORTS MODE".
4. Compare it with referance data as below.
Specification : shown below

Under Low and
Selector Engine Reverse Overdrive Second Torque
Shift drive reverse
lever speed clutch clutch brake converter
position clutch brake
position (rpm) pressure pressure pressure pressure
pressure pressure
310-390 250-350
P - 2,500 - - - -
(45-56) (36-56)
1,270- 1,270-
500-700
R Reverse 2,500 - 1,770 - 1,770 -
(185-256)
(185-256) (185-256)
310-390 250-390
N 2,500 - - - - -
(45-56) (36-56)
1,010- 1,010-
500-700
1st gear 2,500 1,050 - - 1,050 -
(73-101)
(146-152) (146-152)
1,010- 1,010-
500-700
2nd gear 2,500 1,050 - - - 1,050
D (73-101)
(146-152) (146-152)
590-690 590-690 450-650
3rd gear 2,500 - - -
(85-100) (85-100) (65-94)
590-690 590-690 450-650
4th gear 2,500 - - -
(85-100) (85-100) (65-94)

Page 215 of 289
5. Is oil pressure value within specification?
Repair AUTO TRANSAXLE(Clutch or Brake) as necessary and Go to "Verification Vehicle Repair"

procedure.
Replace AUTO TRANSAXLE (BODY CONTROL VALVE faulty) as necessary and Go to "Verification
Vehicle Repair " procedure.

4. Are any DTCs present ?

COMPONENT LOCATION
GENERAL DESCRIPTION
The value of the input shaft speed should be equal to the value of the output shaft speed, when multiplied by the 2nd
gear ratio, while the transaxle is engaged in the 2nd gear. For example, if the output speed is 1000 rpm and the 2nd
DTC DESCRIPTION
2nd gear ratio, while the transaxle is engaged in 2nd gear. This malfunction is mainly caused by mechanical troubles

[2.7 GSL]/ [2.0 GSL]
Page 216 of 289
DTC Strategy • 2nd gear incorrect ratio • Faulty Input speed sensor
• Faulty UD clutch or 2nd
brake
• Shift stage 2nd. gear
• input speed/2nd gear ratio - output
Threshold value
speed|≥200rpm /2nd. gear ratio
• Locked into 3 rd gear.
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
Page 217 of 289

2. Engine "ON".
Page 218 of 289
4. Perform the "STALL TEST" with gear position "2".
Specification :
2.0(GSL) : 2400~3000rpm
2.7(GSL) : 2100~2700rpm

P ●
R ● ●
N ●
D1 ● ● ○
D2 ● ●
D3 ● ●
D4 ● ●
Procedure
B. After positioning the select lever in "D" , depress the foot brake pedal fully after that, depress the accelerator
pedal to the maximum
* The slippage of 1st gear operating parts can be detected by stall test in D2
A. If there is are mechanical defaults in A/T, all slippage occurs in the torque converter.
lock.
C. If 2nd brake system(2nd gear operating part) has faults, input speed revolution will be out of specification.
D. If wheels pin occurs, the applied brake force is not adequate. Retry using more brake force.
Page 219 of 289
● The throttle should not be left fully open for more than eight second.
at 1,000 rpm to let the A/T fluid cool down before carrying out subsequent.

2. Engine "ON".
4. Accelerate the Engine speed until about 2000 rpm in the 2nd gear.
5. Are "INPUT &OUTPUT SPEED SENSOR" within specifications?
Page 220 of 289
1. Connect Oil pressure gauge to "UD" and "2ND" port.

2. Engine "ON".
3. Drive a car with gear position 2 in "SPORTS MODE".

Under Low and
Shift drive reverse
pressure pressure
310-390 250-350
P - 2,500 - - - -
(45-56) (36-56)
1,270- 1,270-
500-700
R Reverse 2,500 - 1,770 - 1,770 -
(185-256)
(185-256) (185-256)
310-390 250-390
N 2,500 - - - - -
(45-56) (36-56)
1,010- 1,010-
500-700
1st gear 2,500 1,050 - - 1,050 -
(73-101)
(146-152) (146-152)
1,010- 1,010-
500-700
2nd gear 2,500 1,050 - - - 1,050
D (73-101)
(146-152) (146-152)
590-690 590-690 450-650
3rd gear 2,500 - - -
(85-100) (85-100) (65-94)
590-690 590-690 450-650
4th gear 2,500 - - -
(85-100) (85-100) (65-94)

Page 221 of 289

procedure.


COMPONENT LOCATION
GENERAL DESCRIPTION
The value of the input shaft speed should be equal to the value of the output shaft speed, when multiplied by the 3rd
gear ratio, while the transaxle is engaged in the 3rd gear. For example, if the output speed is 1,000 rpm and the 3rd
DTC DESCRIPTION
3rd gear ratio, while the transaxle is engaged in 3rd gear. This malfunction is mainly caused by mechanical troubles

[2.7 GSL]/ [2.0 GSL]
Page 222 of 289
DTC Strategy • 3rd gear incorrect ratio • Faulty Input speed sensor
• Faulty UD clutch or OD
clutch
• Shift stage 3rd. gear
• input speed/3rd gear ratio - output
Threshold value
speed|≥200rpm /3rd. gear ratio
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
Page 223 of 289

2. Engine "ON".
Page 224 of 289
4. Disconnect the solenoide valve connector and perform the "STALL TEST".
Specification :
2.0(GSL) : 2400~3000rpm
2.7(GSL) : 2100~2700rpm

P ●
R ● ●
N ●
D1 ● ● ○
D2 ● ●
D3 ● ●
D4 ● ●
Procedure
B. Set 3rd gear hold by disconnecting the solenoid valve connector. Fully depress the brake pedal, then place
the transaxle gear lever into "D" range. Press and hold the accelerator pedal to the floor for no more than eight
seconds while observing the engine, input speed, and output speed RPM values.
* The slippage of 3rd gear operating parts can be detected by stall test in D3
A. If there is no mechanical defaults in A/T, all slippage occurs in torque converter.
lock.
C. If OD clutch system(3rd gear operating part) has faults, input speed revolution will be out of specification.
D. If output speed revolution is output. It means that the foot brake force is not applied fully. Retesting using
greater braking force is required.
Page 225 of 289
● The throttle should not be left fully open for more than eight seconds.
● If carrying out the stall test two or more times, move the select lever to the "N" position and run the
engine at 1,000 rpm to let the A/T fluid cool down before carrying out subsequent tests.

2. Engine "ON".
4. Accelerate the Engine speed until about 2000 rpm in the 3rd gear.
5. Are "INPUT & OUTPUT SPEED SENSOR" within specifications?
Page 226 of 289
1. Connect Oil pressure gauge to "UD" and "OD" port.

2. Engine "ON".
3. Drive a car with gear position 3 in fail mode.

Under Low and
Shift drive reverse
pressure pressure
310-390 250-350
P - 2,500 - - - -
(45-56) (36-56)
1,270- 1,270-
500-700
R Reverse 2,500 - 1,770 - 1,770 -
(185-256)
(185-256) (185-256)
310-390 250-390
N 2,500 - - - - -
(45-56) (36-56)
1,010- 1,010-
500-700
1st gear 2,500 1,050 - - 1,050 -
(73-101)
(146-152) (146-152)
1,010- 1,010-
500-700
2nd gear 2,500 1,050 - - - 1,050
D (73-101)
(146-152) (146-152)
590-690 590-690 450-650
3rd gear 2,500 - - -
(85-100) (85-100) (65-94)
590-690 590-690 450-650
4th gear 2,500 - - -
(85-100) (85-100) (65-94)

Page 227 of 289

procedure.


COMPONENT LOCATION
GENERAL DESCRIPTION
The value of the input shaft speed should be equal to the value of the output shaft speed, when multiplied by the 4th
gear ratio, while the transaxle is engaged in the 4th gear. For example, if the output speed is 1,000 rpm and the 4th
gear ratio is 0.712, then the input speed is 712 rpm.
DTC DESCRIPTION
4th gear ratio, while the transaxle is engaged in 4th gear. This malfunction is mainly caused by mechanical troubles

[2.7 GSL]/ [2.0 GSL]
Page 228 of 289
DTC Strategy • 4th gear incorrect ratio • Faulty Input speed sensor
• Faulty UD clutch or 2nd
brake
• Shift stage 4th. gear
• input speed/4th gear ratio - output
Threshold value
speed|≥200rpm /4th. gear ratio
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
Page 229 of 289

It is difficult to "STALL TEST" in 4th gear, therefore Go to "W/Harness Inspection" procedure.
Page 230 of 289
P ●
R ● ●
N ●
D1 ● ● ○
D2 ● ●
D3 ● ●
D4 ● ●

2. Engine "ON".
4. Accelerate the Engine speed until about 2000 rpm in the 4th gear while driving the vehicle on a level road.
5. Doed "INPUT & OUTPUT SPEED SENSOR" within specifications?
Page 231 of 289
1. Connect Oil pressure gauge to "OD" and "2nd" port.

2. Engine "ON".
3. Drive a car with gear position "4".

Under Low and
Shift drive reverse
pressure pressure
310-390 250-350
P - 2,500 - - - -
(45-56) (36-56)
1,270- 1,270-
500-700
R Reverse 2,500 - 1,770 - 1,770 -
(185-256)
(185-256) (185-256)
310-390 250-390
N 2,500 - - - - -
(45-56) (36-56)
1,010- 1,010-
500-700
1st gear 2,500 1,050 - - 1,050 -
(73-101)
(146-152) (146-152)
1,010- 1,010-
500-700
2nd gear 2,500 1,050 - - - 1,050
D (73-101)
(146-152) (146-152)
590-690 590-690 450-650
3rd gear 2,500 - - -
(85-100) (85-100) (65-94)
590-690 590-690 450-650
4th gear 2,500 - - -
(85-100) (85-100) (65-94)

Page 232 of 289

procedure.


COMPONENT LOCATION
GENERAL DESCRIPTION
The value of the input shaft speed should be equal to the value of the output shaft speed, when multiplied by the
reverse gear ratio, while the transaxle is engaged in the reverse gear. For example, if the output speed is 1,000 rpm
and the reverse gear ratio is 2.480, then the input speed is 2,480 rpm.
DTC DESCRIPTION
reverse gear ratio, while the transaxle is engaged in reverse gear. This malfunction is mainly caused by mechanical
troubles such as control valve sticking or solenoid valve malfuctioning rather than an electrical issue.

[2.7 GSL]/ [2.0 GSL]
Page 233 of 289
DTC Strategy • Reverse gear incorrect ratio • Faulty Input speed sensor
• Faulty RVS clutch or L/R
brak
• Shift stage Rev. gear
• input speed/Rev gear ratio - output
Threshold value
speed|≥200rpm /Rev. gear ratio
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
Page 234 of 289

2. Engine "ON".
Page 235 of 289
4. Perform the "STALL TEST" with gear position "R".
Specification :
2.0(GSL) : 2400~3000rpm
2.7(GSL) : 2100~2700rpm

P ●
R ● ●
N ●
D1 ● ● ○
D2 ● ●
D3 ● ●
D4 ● ●
Stall test procedure in Reverse and reason
Procedure
B. Fully depress the brake pedal, then place the transaxle gear lever into "R" range. Press and hold the
accelerator pedal to the floor for no more than eight seconds while observing the engine, input speed, and
output speed RPM values.
* The slippage of REVERSE clutch and L/R brake can be detected by stall test in R range
A. If there is no mechanical defaults in A/T, all slippage occurs in the torque converter.
lock.
C. If reverse clutch and L/R brake system(reverse gear operating parts) has faults, input speed revolution will be
out of specification.
D. If output speed revolution is output. It means that the foot brake force is not applied fully. Remeasuring is
required.
Page 236 of 289
● The throttle should not be left fully open for more than eight seconds.
at 1,000 rpm to let the A/T fluid cool down before carrying out subsequent tests.

2. Engine "ON".
4. Accelerate the Engine speed until about 2000 rpm in the "R" gear.
5. Are "INPUT && OUTPUT SPEED SENSOR" within specifications?
Page 237 of 289
1. Connect Oil pressure gauge to "RV" and "LR" port.

2. Engine "ON".
3. Drive a car with gear position R.

Under Low and
Shift drive reverse
pressure pressure
310-390 250-350
P - 2,500 - - - -
(45-56) (36-56)
1,270- 1,270-
500-700
R Reverse 2,500 - 1,770 - 1,770 -
(185-256)
(185-256) (185-256)
310-390 250-390
N 2,500 - - - - -
(45-56) (36-56)
1,010- 1,010-
500-700
1st gear 2,500 1,050 - - 1,050 -
(73-101)
(146-152) (146-152)
1,010- 1,010-
500-700
2nd gear 2,500 1,050 - - - 1,050
D (73-101)
(146-152) (146-152)
590-690 590-690 450-650
3rd gear 2,500 - - -
(85-100) (85-100) (65-94)
590-690 590-690 450-650
4th gear 2,500 - - -
(85-100) (85-100) (65-94)

Page 238 of 289

procedure.


GENERAL DESCRIPTION
The TCM(PCM) controls the locking and unlocking of the Torque Converter Clutch (or Damper Clutch), to the
input shaft of the transmission, by appling hydraulic pressure. The main purpose of T/C clutch control is to save fuel
by decreasing the hydraulic load inside the T/C. The TCM(PCM) outputs duty pulses to control the Damper Clutch
Control Solenoid Valve(DCCSV) and hydraulic pressure is applied to the DC according to the DCC duty ratio
value. When the duty ratio is high, high pressure is applied and the Damper Clutch is locked. The normal operating
range of the Damper Clutch Control duty ratio value is from 30%(unlocked) to 85%(locked).
DTC DESCRIPTION
The TCM(PCM) increases the duty ratio to engage the Damper Clutch by monitoring slip rpms (difference vlaue
beteween engine speed and turbine speed). To decrease the slip of the Damper Clutch, the TCM(PCM) increases
the duty ratio by appling more hyraulic pressure. When slip rpm does not drop under specification with 100% duty
ratio, the TCM(PCM) determines that the Torque Converter Clutch is stuck OFF and sets this code.

[2.7 GSL]
Page 239 of 289
DTC Strategy • Stuck "OFF" TORQUE
CONVERTER(DAMPER)
• Throttle position >1.5V
CLUTCH : TCC
• Output speed >1000rpm • Faulty TCC or oil pressure
Enable Conditions • Solenoid status OFF system
• A/T range switch D,SP • Faulty TCC solenoid valve
• Time after TCC release >5secs • Faulty body control valve
• (rationality-low) Calculated slip • Faulty TCM(PCM)
Threshold value (engine speed-input speed)<5rpm
or (rationality-high) Calculated slip >-5rpm
• Damper clutch abnormal system (If diagnosis code
P0741 is output four times, TORQUE
Fail Safe
CONVERTER(DAMPER) CLUTCH is not
controlled by TCM(PCM))
[2.0 GSL]
DTC Strategy • Stuck "OFF" TORQUE
CONVERTER(DAMPER)
Enable Conditions • During the connect control
CLUTCH : TCC
• Detect 2 times the Lock-up clutch control • Faulty TCC or oil pressure
Threshold value
duty=100% for 2sec system
Diagnostic Time • 1 event • Faulty TCC solenoid valve
• Faulty body control valve
• Damper clutch abnormal system (If diagnosis code • Faulty TCM(PCM)
Fail Safe
SCHEMATIC DIAGRAM
Page 240 of 289

2. Engine "ON".
3. Sellect "D RANGE" and drive vehicle.
Page 241 of 289
4. Monitor the "TORQUE CONVERTER(DAMPER) CLUTCH" parameter on the scantool.
Specification : TCC SLIP<160RPM(In condition that TCC SOL. DUTY > 80% )
5. Are "TCC SOLENOID DUTY and TCC SLIP" within specifications?
1. CHECK TORQUE CONVERTER CLUTCH SOLENOID VALVE
(1) Connect scantool to data link connector(DLC).
(3) Select A/T Solenoid valve Actuator test and Operate Actuator test.
(4) Can you hear operating tone for using TCC SOLENOID VALVE Actuator Testing Function?
Go to "CHECK OIL PRESSURE" as below.
Replace "TCC SOLENOID VALVE" as necessary and Go to "Verification Vehicle Repair" procedure.
Page 242 of 289
2. CHECK OIL PRESSURE
(1) Connect Oil pressure gauge to "DA" port.

(3) After connecting Scantool and monitor the "TCC SOLENIOD VALVE DUTY" parameter on the Scantool
data list.
(4) Select 1st gear and accelerate Engine speed to 2500 rpm.
(5) Measure oil pressure.
Specification : approx. 6.1kg/cm²
(6) Is oil pressure value within specification?
Repair TORQUE CONVERTER CLUTCH(REPLACE Torque Converter ) as necessary and Go to

"Verification Vehicle Repair " procedure.
Replace A/T ass'y (possible to BODY CONTROL VALVE faulty) as necessary and Go to "Verification


GENERAL DESCRIPTION
The TCM(PCM) controls the locking and unlocking of the Torque Converter Clutch (or Damper Clutch), to the
Page 243 of 289
DTC DESCRIPTION
The TCM(PCM) increases the duty ratio to engage the Damper Clutch by monitoring the slip rpms (difference vlaue
beteween engine speed and turbine speed ). If a very small amount of slip rpm is maintained though the TCM(PCM)
applies 0% duty ratio value, then the TCM(PCM) determines that the Torque Converter Clutch is stuck ON and
sets this code.

[2.7 GSL]
DTC Strategy • Stuck "ON" TORQUE
CONVERTER(DAMPER)
• Throttle position >1.5V
CLUTCH : TCC
• Faulty TCC or oil pressure
Enable Conditions • Solenoid status OFF system
• A/T range switch D,SP • Faulty TCC solenoid valve
• Time after TCC release >5secs • Faulty body control valve
• (rationality-low) Calculated slip • Faulty TCM(PCM)
Threshold value (engine speed-input speed)<5rpm
or (rationality-high) Calculated slip >-5rpm
• Damper clutch abnormal system (If diagnosis code
Fail Safe
SCHEMATIC DIAGRAM
Page 244 of 289

2. Engine "ON".
3. Sellect "D RANGE" and drive vehicle.
Page 245 of 289
4. Monitor the "TORQUE CONVERTER(DAMPER) CLUTCH" parameter on the scantool.
Specification : TCC SLIP>5RPM
5. Are "TCC SOLENOID DUTY and TCC SLIP" within specifications?
1. CHECK TORQUE CONVERTER CLUTCH SOLENOID VALVE
(4) Can you hear operating tone for using TCC SOLENOID VALVE Actuator Testing Function?
Go to "CHECK OIL PRESSURE" as below.
Replace "TCC SOLENOID VALVE" as necessary and Go to "Verification Vehicle Repair" procedure.
Page 246 of 289
2. CHECK OIL PRESSURE
(1) Connect Oil pressure gauge to "DR" port.

(3) After connecting Scantool and monitor the "TCC SOLENIOD VALVE DUTY" parameter on the Scantool
data list.
(4) Select 1st gear and accelerate Engine speed to 2500 rpm.
(5) Measure oil pressure.
Specification : approx. 6.1kg/cm²
(6) Is oil pressure value within specification?
Repair TORQUE CONVERTER CLUTCH(REPLACE Torque Converter ) as necessary and Go to

"Verification Vehicle Repair " procedure.
Replace A/T ass'y (possible to BODY CONTROL VALVE faulty) as necessary and Go to "Verification


COMPONENT LOCATION
Page 247 of 289
GENERAL DESCRIPTION
The TCM(PCM) controls the locking and unlocking of the Torque Converter Clutch ( or Damper Clutch ), to the
DTC DESCRIPTION
The TCM(PCM) checks the Damper Clutch Control Signal by monitoring the feedback signal from the solenoid
valve drive circuit. If an unexpected signal is monitored (for example, high voltage is detected when low voltage is
expected, or low voltage is detected when high voltage is expected) the TCM(PCM) judges that DCCSV circuit is
malfunctioning and sets this code.

[2.7 GSL]
DTC Strategy • Check voltage range TORQUE
CONVERTER(DAMPER)
• Solenoid status Either solid ON or OFF
Enable Conditions CLUTCH : TCC
• Open or short in circuit
Threshold value • Voltage <3V • Faulty TCC SOLENOID
VALVE
Diagnostic Time • more than 320 ms
• Faulty TCM(PCM)
Fail Safe • Locked in 3 rd gear.(Control relay off)
[2.0 GSL]
Page 248 of 289
DTC Strategy • Check voltage range TORQUE
CONVERTER(DAMPER)
• 16V > Voltage Battery >10V
CLUTCH : TCC
Enable Conditions • In gear state(no gear shifting) 500msec is passed • Open or short in circuit
from turn on the relay
• Faulty TCC SOLENOID
• Feedback voltage from DCC control solenoide > VALVE
Vb-2V and DCC control duty is 100% • Faulty TCM(PCM)
Threshold value
• Feedback voltage from DCC control solenoide ≤
5.5V and DCC control duty is 0%
Diagnostic Time • More than 500 ms
Fail Safe • Locked in 3rd gear.(Control relay off)
SPECIFICATION
• Sensor type : Normal open 3-way
• Operating temperature : -30°C~130°C(-22~266°F)
• Frequency :
- LR, 2ND, UD, OD, RED : 61.27Hz (at the ATF temp. -20°C(-4°F) above)
- DCC : 30.64Hz
• Internal resistance : 2.7~3.4Ω[20°C(68°F)]
• Surge voltage : 56 V
SCHEMATIC DIAGRAM
Page 249 of 289

1. Connect scantool to data link connector(DLC)
2. Engine "ON".
3. Monitor the "TCC SOL. VALVE" parameter on the scantool
4. Sellect "D RANGE" and Operate "TCC SOLENOID DUTY" more than 85%
Page 250 of 289
1. Does "TCC SOLENOID DUTY " follow the reference data?
Go to "Terminal & Connector Inspection " procedure.

or damage.
Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
Go to "Power Supply Circuit Inspection" procedure.

1. Disconnect "A/T SOLENOID VALVE" connector.
2. Measure voltage between teminal "10" of the sensor harness connector and chassis ground.
3. Turn ignition switch OFF → ON
Specification: 12V is measured only for approx. 0.5sec

Page 251 of 289
Check that A/T-30A Fuse in engine room junction is installed or not blown.
1. Check signal circuit open inspection.
(1) Ignition "OFF".
(2) Disconnect "A/T SOLENOID VALVE" connector and "TCM(PCM)" connector.
(3) Measure resistance between terminal "7" of the ATM SOLENOID VALVE harness connector and terminal "15/35"
of the TCM(PCM) harness connector.
Specification: approx. 0 Ω
Go to "Check signal circuit short Inspection" procedure.
Page 252 of 289
2. Check signal circuit short inspection
(1) Ignition "OFF".
(2) Disconnect "A/T SOLENOID VALVE" connector and "TCM(PCM)" connector
(3) Measure resistance between terminal "7" of the ATM SOLENOID VALVE harness and chassis ground.
Specification: Infinite
Check for short to ground in harness. Repair as necessary and Go to "Verification Vehicle Repair"
procedure.
1. CHECK SOLENOID VELVE
(1) Ignition "OFF".
(2) Disconnect "A/T SOLENOID VALVE" connector.
(3) Measure resistance between terminal "7" and terminal "10" of the ATM SOLENOID VALVE harness
connector.
Specification: Approximately 2.7~3.4 Ω [20°C(68°F)]
(4) Is resistance within specification?
Replace TCC SOLENOID VALVE as necessary and go to "Verification Vehicle Repair" procedure.
Page 253 of 289
2. CHECK TCM(PCM)
(4) Can you hear operating sound for TCC SOLENOID VALVE Actuator Testing Function?
Go to "Verification Vehicle Repair" procedure.
Replace TCM(PCM) as necessary and Go to "Verification Vehicle Repair" procedure

ACTUATOR TEST CONDITION
A. IG SWITCH ON
B. TRANSAXLE RANGE SWITCH is normal
C. P RANGE
D. Vehicle Speed 0km/h
E. Throttle position sensor< 1V
F. IDLE SWITCH ON
G. ENGINE RPM 0


COMPONENT LOCATION
GENERAL DESCRIPTION
The Automatic Transmission changes the gear position of the transmission by utilizing a combination of Clutches and
Page 254 of 289
Brakes, which are controlled by solenoid valves. The HIVEC Automatic Transmission consists of a: LR ( Low and
Reverse Brake ), 2ND ( 2nd Brake ), UD ( Under Drive Clutch ), OD ( Over Drive Clutch ), REV ( Reverse
Clutch ), and a RED ( Reduction Brake, only for 5 speed transmissions). The LR Brake is engaged in the 1st gear
and reverse gear positions.
DTC DESCRIPTION
The TCM(PCM) checks the Low and Reverse Control Signal by monitoring the feedback signal from the solenoid
expected, or low voltage is detected when high voltage is expected), the TCM(PCM) judges that the Low and
Reverse control solenoid circuit is malfunctioning and sets this code.

[2.7 GSL]
DTC Strategy • Check voltage range • Open or short in circuit
• Faulty LR SOLENOID
Enable Conditions VALVE
• Faulty TCM(PCM)
Threshold value • Voltage <3V
[2.0 GSL]
• Faulty LR SOLENOID
VALVE
Enable Conditions • In gear state(no gear shifting) 500msec is passed
• Faulty TCM(PCM)
• Feedback voltage from LR control solenoide >
Vb-2V and LR control duty is 0%
Threshold value
• Feedback voltage from LR control solenoide ≤
5.5V and LR control duty is 100%
SPECIFICATION
• Operating temperature : -22~266°F(-30°C~130°C)
• Frequency :
- LR, 2ND, UD, OD, RED : 61.27Hz (at the ATF temp. -20°C above)
- DCC : 30.64Hz
• Internal resistance : 2.7~3.4Ω(68°F or 20°C)
Page 255 of 289
SCHEMATIC DIAGRAM

2. Engine "ON".
3. Monitor the "LR SOL. VALVE" parameter on the scantool.
Page 256 of 289
4. Shift gear position 1st to 2nd.
Specification: 1st → 0%, 2nd → 100%
5. Does "LR SOLENOID DUTY " follow the reference data?

or damage.

2. Measure voltage between terminal"10" of the sensor harness connector and chassis ground.
Page 257 of 289
3. Turn ignition switch OFF → ON.
1. Check signal circuit open inspection
(1) Ignition "OFF".
(2) Disconnect "A/T SOLENOID VALVE" connector and "PCM/TCM" connector.
of the TCM(PCM) harness connector
Page 258 of 289
(1) Ignition "OFF".
(1) Ignition "OFF".
connector.

Page 259 of 289
Replace LR SOLENOID VALVE as necessary and go to "Verification Vehicle Repair" procedure.

2. CHECK TCM(PCM)
(4) Can you hear operating sound for LR SOLENOID VALVE Actuator Testing Function?
Replace TCM(PCM) as necessary and Go to "Verification Vehicle Repair" procedure.

A. IG SWITCH ON
C. P RANGE
E. Throttle position sensor < 1V
F. IDLE SWITCH ON
G. ENGINE RPM 0


COMPONENT LOCATION
Page 260 of 289
GENERAL DESCRIPTION
DTC DESCRIPTION

[2.7 GSL]
• Faulty UD SOLENOID
• Faulty TCM(PCM)
[2.0 GSL]
Page 261 of 289
• Faulty UD SOLENOID
VALVE
from turn on the relay • Faulty TCM(PCM)
• Feedback voltage from UD control solenoide >

Vb-2V and UD control duty is 0%
Threshold value
• Feedback voltage from UD control solenoide ≤
5.5V and UD control duty is 100%
SPECIFICATION
• Frequency :
- DCC : 30.64Hz
SCHEMATIC DIAGRAM
Page 262 of 289

2. Engine "ON".
3. Monitor the "UD SOL. VALVE" parameter on the scantool.
Page 263 of 289
4. Shift gear position "N" to "D".
Specification: P/N → 100%, D → 0.0%
5. Does "UD SOLENOID DUTY " follow the reference data?

or damage.

Page 264 of 289
(1) Ignition "OFF".
Page 265 of 289
(1) Ignition "OFF".
(1) Ignition "OFF".
connector.
Replace UD SOLENOID VALVE as necessary and go to "Verification Vehicle Repair" procedure.

Page 266 of 289
2. CHECK TCM(PCM)
(1) Connect scantool to data link connector(DLC)
(4) Can you hear operating sound for UD SOLENOID VALVE Actuator Testing Function?
Replace TCM(PCM) as necessary and Go to "Verification Vehicle Repair" procedure.

A. IG SWITCH ON
C. P RANGE
F. IDLE SWITCH ON
G. ENGINE RPM 0


COMPONENT LOCATION
GENERAL DESCRIPTION
Page 267 of 289
DTC DESCRIPTION

[2.7 GSL]
• Faulty 2nd SOLENOID
• Faulty TCM(PCM)
[2.0 GSL]
• Faulty 2nd SOLENOID
VALVE
• Faulty TCM(PCM)
• Feedback voltage from 2nd control solenoide >
Vb-2V and 2nd control duty is 0%
Threshold value
• Feedback voltage from 2nd control solenoide ≤
5.5V and 2nd control duty is 100%
SPECIFICATION
• Frequency :
- DCC : 30.64Hz
Page 268 of 289
SCHEMATIC DIAGRAM

2. Engine "ON".
3. Monitor the "2nd SOL. VALVE" parameter on the scantool.
Page 269 of 289
4. Shift gear position 1st to 2nd.
Specification: 1st gear → 100%, 2nd gear → 0.0%
5. Does "2nd SOLENOID DUTY " follow the reference data?

or damage.

Page 270 of 289
Specification : 12V is measured only for approx. 0.5sec
(1) Ignition "OFF".
Page 271 of 289
(1) Ignition "OFF".
(1) Ignition "OFF".
connector.
Replace 2nd SOLENOID VALVE as necessary and go to "Verification Vehicle Repair" procedure.
Page 272 of 289
2. CHECK TCM(PCM)
(1) Connect scantool to data link connector(DLC)
(4) Can you hear operating sound for 2ND SOLENOID VALVE Actuator Testing Function?
Replace TCM(PCM) and Go to "Verification Vehicle Repair" procedure.

A. IG SWITCH ON
C. P RANGE
F. IDLE SWITCH ON
G. ENGINE RPM 0


COMPONENT LOCATION
GENERAL DESCRIPTION
The Automatic Transmission changes the gear position of the transmission utilizing a combination of Clutches and
Page 273 of 289
Clutch ), and RED ( Reduction Brake, only for 5 speed transmissions). The OD Clutch is engaged in the 3rd gear
and 4th gear positions.
DTC DESCRIPTION
The TCM(PCM) checks the Under Drive Clutch Control Signal by monitoring the feedback signal from the solenoid
expected or low voltage is detected when high voltage is expected), the TCM(PCM) judges that the OVER DRIVE
CLUTCH drive control solenoid circuit is malfunctioning and sets this code.

[2.7 GSL]
• Faulty OD SOLENOID
• Faulty TCM(PCM)
[2.0 GSL]
• Faulty OD SOLENOID
Case1 • 16V > Voltage Battery >10V
VALVE
• Voltage Battery >10V • Faulty TCM(PCM)
• OIL TEMP. ≥ -23.5°C(-10.3°F)
• 2nd gear and not downshifting
Enable Conditions • Engine speed ≥ 450rpm
Case2
• Output speed > 100rpm
• Input speed > 0rpm
• Inhibitor switch is normal and after 2sec
is passed from IG ON
• Feedback voltage from 2nd control
solenoide>Vb-2V and 2nd control duty
is 0%
Case1
• Feedback voltage from 2nd control
Threshold value solenoide≤5.5V and 2nd control duty is
100%
• input speed/3rd gear ratio - output
Case2
speed ≤ 50rpm
Fail Safe • Locked in 3 rd gear.(Control relay off)
Page 274 of 289
SPECIFICATION
• Frequency :
- DCC : 30.64Hz
SCHEMATIC DIAGRAM
Page 275 of 289

2. Engine "ON".
3. Monitor the "OD SOL. VALVE" parameter on the scantool.
Page 276 of 289
4. Shift gear position 2nd to 3rd.
Specification: 2nd gear → 100%, 3rd gear → 0.0%
Does "OD SOLENOID DUTY " follow the reference data?
Fault is intermittent caused by poor contact in the sensor's and/or TCM(PCM)'s connector or was repaired and
TCM(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.

or damage.

Page 277 of 289
3. Turn ignition switch OFF → ON.
Specification : 12V is measured only for approx. 0.5sec
Is voltage within specifications?
(1) Ignition "OFF".
Is resistance within specifications?

Page 278 of 289
(1) Ignition "OFF" & Engine "OFF".
(3) Measure resistance between terminal "5" and terminal "9" of the ATM SOLENOID VALVE harness.
Check for short to ground in harness. Repair as necessary and Go to "Verification Vehicle Repair"
procedure.
(1) Ignition "OFF".
(3) Measure resistance between terminal "5" of the ATM SOLENOID VALVE harness connector and chassis
ground.

Page 279 of 289
Replace OD SOLENOID VALVE as necessary and go to "Verification Vehicle Repair" procedure.

2. CHECK TCM(PCM)
(3) Select A/T Solenoide valve Actuator test and Operate Actuator test.
(4) Can you hear operating sound for OD SOLENOID VALVE Actuator Testing Function?
Replace TCM(PCM) and Go to "Verification Vehicle Repair" procedure.

A. IG SWITCH ON
C. P RANGE
F. IDLE SWITCH ON
G. ENGINE RPM 0


COMPONENT LOCATION
Page 280 of 289
GENERAL DESCRIPTION
The HIVEC Automaic Transmission supplies the power to the solenoid valves by way of a control relay. When the
TCM(PCM) sets the relay to ON, the relay operates and the battery power is supplied to all the sonenoid valves.
When the TCM(PCM) sets the relay to OFF, all solenoid valve power is shut off and the transmission is held in the
3rd gear position. (Fail Safe Mode)
DTC DESCRIPTION
The TCM(PCM) checks the A/T control relay signal by monitoring the contol signal. If, after the iginiton key is
turned on, an unexpected voltage value, which is quite a bit lower than battery voltage is detected, the TCM(PCM)
sets this code.

[2.7 GSL]
• Faulty A/T control relay
Enable Conditions • Faulty TCM(PCM)
• Time after TCM(PCM) turns on >0.5sec
Diagnostic Time • 0.1sec
[2.0 GSL]
• Faulty A/T control relay
Enable Conditions • Faulty TCM(PCM)
• Time after TCM(PCM) turns on >0.5sec
Threshold value • Voltage < 7V orVoltage > 24.5V
Diagnostic Time • 0.1sec
Page 281 of 289
SCHEMATIC DIAGRAM

Page 282 of 289
3. Monitor the "A/T CON. RELAY VOLT" parameter on the scantool.
4. Is A/T RELAY VOLT within specifications?
Go to "Terminal & Connector Inspection" procedure.

or damage.

2. Disconnect the "A/T CONTROL RELAY" connector.
Page 283 of 289
3. Measure the voltage between terminal "1" of the "A/T CONTROL RELAY" harness connector and chassis ground.
1. CHECK A/T control relay harness
(1) Ignition "OFF".
(2) Disconnect the "A/T CONTROL RELAY" connector.
(3) Measure the voltage between terminal "4" of the "A/T CONTROL RELAY" harness connector and chassis ground.
(4) Turn ignition switch OFF → ON.

Page 284 of 289
(5) Is voltage within specifications?
Go to "Check Supplying Power to solenoid valve" procedure.
Check for open in harness. Repair as necessary and Go to "Verification Vehicle Repair" procedure
If signal circuit is OK, Substitute with a known-good TCM(PCM) and check for proper operation. If the problem
is corrected, replace TCM(PCM) and then go to "Verification of Vehicle Repair" procedure.
2. CHECK Supplying Power to solenoid valve harness
(1) Ignition "OFF".
(2) Disonnect the "A/T CONTROL RELAY" and TCM(PCM) connector.
(3) Measure the resistance between terminal "3" of the "A/T CONTROL RELAY" harness connector and terminal "2 or
3/ 32 or 36" of the TCM(PCM) harness connector
Check for Open in JC104/ JC04 joint connector.

1. Ignition "OFF".
2. Connect the "A/T CONTROL RELAY" connector.
Page 285 of 289
3. Measure the resistance between terminal "2" of the "A/T CONTROL RELAY" harness connector and chassis
ground.
1. Ignition "OFF".
2. Remove "A/T CONTROL RELAY"
Specification: Shown below
Item Terminal No
1(red) - 3(pink) INFINITE
Resistance
2(black) - 4(pink)
supply(B+) to number 4 and supply (B-) to number
1(red) - 3(pink) 0Ω
2.
4. Is resistance with in specification?
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.
Replace ATM CONTROL RELAY and then go to "Verification of Vehicle Repair" procedure.

Page 286 of 289
Automatic Transaxle System > Troubleshooting > U0100

COMPONENT LOCATION
GENERAL DESCRIPTION
The TCM can either receive data from the Engine Control Module or ABS control module, or it can send data to
the ECM andABSCM by using CAN communication. The CAN communicaton is one of the vehicle
communications method, which is now widely used to transfer the vehicle data.
DTC Description
When the TCM cannot read the data from the ECM through the CAN-BUS line, the TCM sets this code.
CAN-BUS circuit malfunctioning or ECM can be a posssible cause of this DTC.

[2.7 GSL]
Page 287 of 289
DTC Strategy • Check voltage range • Open or Short in CAN
communication harness
• IG switch ON
• Faulty ECM
• No actuator test
• Faulty TCM
• No FAIL SAFE status of 3rd gear holding
Enable Conditions • No FAIL in PG-A,B
• Power voltage ≥ 10V is detected for a series of
0.5 sec
• Engine STOP
Threshold value • In case of no ECU information
Diagnostic Time • 1.5 Sec
• INTELLIGENT SHIFT is inhibited
• Learning for oil pressure control is inhibited
Fail Safe
• Torque Retard requirement is inhibited
• Direct connection control of TCC is inhibited
[2.0 GSL]
DTC Strategy • Check communication • Open or Short in CAN
• Input speed ≥ 1000rpm and 5000msec passed
Enable Conditions • Faulty ECM
from IG "on"
• Faulty TCM
Threshold value • No message from ems
Diagnostic Time • 1.5 sec
Fail Safe
SCHEMATIC DIAGRAM
Page 288 of 289
Monitor Scantool Data

2. Engine "ON".
3. Monitor the "CAN COMMUNICATION SERVICE DATA (ENGINE RPM, VEHICLE SPEED SENSOR,
THROTTLE P. SENSOR)" parameters on the scantool.
Page 289 of 289
5. Does "CAN BUS LINE DATA " follow the reference data?
Fault is intermittent caused by poor contact in the sensor's and/or TCM's connector or was repaired and TCM
memory was not cleared. Go to Verification of Vehicle Repair procedure.
Substitute with a known-good TCM and check for proper operation.

If the problem is corrected, replace TCM as necessary and then go to "Verification of Vehicle Repair"
procedure.
Verification of Vehicle Repair


Page 1 of 99
SPORTAGE(KM) > 2008 > G 2.7 DOHC > Body (Interior and Exterior)
Body (Interior and Exterior) > General Information > Special Service Tools
SPECIAL TOOLS
Tool (Number and name) Illustration Use
09800-21000 Trim removal
Ornament remover
09853-31000 Removal of the headliner clip

Headliner clip remover
09861-31100 Cutting the sealant of the windshield

Sealant cut-out tool (use with 09861-312000)
09861-31200 Cutting the sealant of the windshield

Sealant cutting blade (use with 09861-31100 )
09861-31300 Application of the sealant to the windshield

Sealant gun
09861-31400 Removal and installation of the windshield

Glass hold
09861-31000 Removal of the windshield molding

Windshield molding remover
09880-4F000 Installation of the hogring clip

Hogring clip installer
Body (Interior and Exterior) > General Information > Troubleshooting

Page 2 of 99
TROUBLESHOOTING
Symptom Suspect Remedy
Weatherstrip not folding firmly Adjust hit door
Improperly installed weatherstrip Repair or replace
Improperly closed door Adjust
Wind noise around door Improperly fit door Adjust
Improperly clearance between door glassAnd
Adjust
division channel
Deformed door Repair or replace
Dirt accumulated in drain tube Clear dirt inside of drain
Broken or dislocated drain tube, defectiveor Check tube installation and
cracked clip flange contact
Blow air into drain to remove
Water leaks from sunroof Clogged drain tube
dirt
Deteriorated roof lid weatherstrip Replace
Excessive roof lid-to-body clearance and
Adjust
improperly fitted weatherstrip
Loosen or deformed deflector, gaps in body
Wind noise around sunroof Retighten adjust or replace
work
Door glass fails to operate up Incorrect window glass installation Adjust position
and down Damaged or faulty regulator arm or regulator Correct or replace
Incorrect door installation Adjust position
Door dose not open or close
Defective door check assembly Correct or replace
completely
Door hinge requires grease Apply grease
Striker and latch not properly aligned Adjust
Hood does not open or close
Incorrectly installed hood Adjust
completely
Incorrect hood bumper height Adjust
Water leak through windshield Defective seal Fill with sealant
and rearwindow Defective flange Correct
Body (Interior and Exterior) > General Information > Specifications

SPECIFICATIONS
Page 3 of 99
HOOD
Type Rear hinged, rod type
FRONT DOOR
Construction Front hinged, frame door construction
Regulator system X-ARM type
Locking system Pin-fork system
REAR DOOR
Construction Front hinged, frame door construction
Regulator system X-ARM type
Locking system Pin-fork system
TAILGATE
Type Inner hinged, gas lifter type
GLASS THICKNESS Laminated clear, tinted
Windshield glass 5mm
Front door glass 3.5mm
Rear door glass 3.2mm
Rear window glass
SEAT BELTS
3 point type with Emergency Locking
Front
Retractor(E.L.R)
Rear 3 point type with Emergency Locking
Retractor(E.L.R)
2 point type
TIGHTENING TORQUE
Items Nm Kgf·m lb·ft
Front and rear doors
Door hinge to body 33.3~41.2 3.4~4.2 24.6~30.4
Door hinge to door 21.6~26.5 2.2~2.7 15.9~19.5
Tailgate
Trunk lid hinge to body 6.9~10.8 0.7~11 5.1~8.0
Trunk lid hinge to trunk lid 6.9~10.8 0.7~11 5.1~8.0
Trunk lid latch to trunk lid 6.9~10.8 0.7~11 5.1~8.0
Hood
Hood hinge to body 21.6~26.5 2.2~2.7 16~19.5
Hood hinge to hood 21.6~26.5 2.2~2.7 16~19.5
Hood latch to body 6.9~10.8 0.7~1.1 5.1~6.5
Seat
Front seat mounting bolts and nut 43.1~64.7 4.4~6.6 31.8~47.7
Rear seat mounting bolts 43.1~64.7 4.4~6.6 31.8~47.7
Seat belt
Front seat belt height adjuster 39.2~53.9 4.0~5.5 28.9~39.8
Front seat belt buckle mounting bolt 39.2~53.9 4.0~5.5 28.9~39.8
Front seat belt anchor mounting bolt 39.2~53.9 4.0~5.5 28.9~39.8
Page 4 of 99
Front seat belt low anchor 39.2~53.9 4.0~5.5 28.9~39.8
Front seat belt upper anchor 39.2~53.9 4.0~5.5 28.9~39.8
Rear seat belt anchor attaching bolt 39.2~53.9 4.0~5.5 28.9~39.8
Rear seat belt retractor mounting bolt 39.2~53.9 4.0~5.5 28.9~39.8
Body (Interior and Exterior) > Exterior > Hood > Repair procedures
REPLACEMENT
HOOD REPLACEMENT
- When removing and installing the hood, an assistant is necessary.

- Take care not to damage the hood and body.
1. Remove the hood insulator.
2. Disconnect the windshield washer nozzle connecting tube(A).
3. After loosening the hood hinge (B) mounting bolts, remove the hood(C).
- Make sure the hood open properly and locks securely.

- Adjust the hood alignment.
Page 5 of 99
HOOD INSULATOR REPLACEMENT

Page 6 of 99
1. Using a clip remover, detach the clips, and remove the hood insulator(A).
Take care not to scratch the hood panel.
- Replace any damaged clips.
HOOD SEAL WEATHERSTRIP REPLACEMENT

1. Detach the clips, then remove the hood weathersrip(A).
HOOD LATCH REPLACEMENT

Page 7 of 99
1. Remove the undercover(A).
2. Remove the latch cover(A).
3. Remove the hood latch(A)mounting bolts and disconnect hood latch cable (B) and release cable(C).
Page 8 of 99
- Make sure the hood latch cable is connected

properly.
- Make sure the hood lock securely.
HOOD LATCH RELEASE HANDLE REPLACEMENT

1. Remove the screws, then remove the hood release handle(A).
2. Disconnect the hood latch cable(B).
- Make sure the hood ; latch cable is connected

properly.
- Make sure the opens properly.
HOOD LATCH RELEASE CABLE REPLACEMENT

1. Remove the following items:
A. Hood latch.
B. Hood latch release handle.
Page 9 of 99
2. Using a clip remover, detach the clips from the body, then disconnect the hood latch cable(A) and release
cable(B).
- Take care not to bend the cable.
- Make sure the hood latch cable is connected properly.

ADJUST HOOD
1. After loosening the hood hinge (A)mounting bolts.
2. Adjust the hood (B) by moving it up or down, or right or left.
3. Adjust the hood height by turning the hood overslam bumpers(C).
4. After loosening the hood latch (D) mounting bolts, ad-just the hood latch by moving it up or down, or right or left.
Page 10 of 99
Body (Interior and Exterior) > Exterior > Tailgate > Repair procedures
REPLACEMENT
TAILGATE TRIM REPLACEMENT
Page 11 of 99
- When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the
related parts, to prevent damage.
- Wear gloves to protect hands from injury.
- Open the tailgate glass.
- After loosening the screws the remove the tailgate trim(A).
- Remove the upper trim(B).
- Replace and damaged clips.
TAILGATE GLASS REPLACMENT

Page 12 of 99
related parts, to prevent damage.
- Take care not to scratch the surface the tailgate glass.
- Wear gloves to protect hands from injury.
1. Remove the rear wiper arm.
(Refer to the BE group - "Rear Wiper/Washer")
2. Remove the rear wiper motor.
(Refer to the BE group - "Rear Wiper/Washer")
3. Remove the rear glass defogger.
(Refer to the BE group - "Rear Glass Defogger")
4. Remove the tailgate lifter.
(Refer to the BD group - "Tailgate")
5. Using a star wrench and then loosen the mounting bolts (B).
6. Remove the tailgate glass (A).
Tightening torque:
3.9~5.9 N.m (0.4~0.6 kgf.m, 2.9~4.3 lb-ft)
• Make sure the connector is plugged in

properly.
TAILGATE LATCH REPLACMENT

1. Remove the tailgate trim.
Page 13 of 99
2. Disconnect the outside handle rod (A) and actuator rod(B).
3. Loosen the latch mounting bolts and disconnect the connector(A),remove Tailgate latch(B).
4. Installation is the reverse of removal .
- Make sure the tailgate open properly and locks

securely.
ACTUATOR ASSEMBLY REPLACMENT

2. Disconnect the outside handle rod(A), actuator rod(B),glass latch rod(C), key cylinder(D) and connector.
Page 14 of 99
3. After loose the mounting bolt and nuts, then remove the actuator assembly.

securely.
TAILGATE GLASS LATCH REPLACEMENT

2. Disconnect the tailgate glass latch rod(A).
3. After loosening the mounting bolts, disconnect the connector(B) and remove the tailgate glass latch(C).

securely.
KEY HOLDER REPLACEMENT

2. Remove the tailgate garnish.
Page 15 of 99
3. Disconnect the key rod (A) and connector.
4. Remove the key holder(B).


securely.
GLASS WEATHERSTRIP REPLACEMENT

1. After disconnecting the tailgate lifter, remove the glass weathersrip (A).

TAILGATE WEATHERSTRIP REPLACMENT
Page 16 of 99
1. Remove the tailgate weatherstrip (A).

TAILGATE OUTSIDE HANDLE REPLACEMENT
2. Disconnect the outside handle rod(A) and latch rod(B).
3. Loosen the inside handle (C) mounting bolts.

Page 17 of 99
Make sure the tailgate open properly and locks

securely.
LIFTER REPLACMENT
1. Using a screwdriver (A), lift up slightly the socket clips (B) of both ends on the lifter (C), and then remove the
lifter from the bracket (D).
2. Push the socket of the lifter into the bracket for installation.
ADJUSTMENT
1. Adjust the tailgate alignment.
A. After loosening the tailgate hinge(A) mounting bolt, adjust the tailgate by moving it up or down, or right or left.
B. Adjust the tailgate fit by turning the tailgate side bumpers(B).
C. Adjust the striker(C) by moving it up or down, or right or left.
2. Make sure the trunk lid opers and locks securely.
Page 18 of 99
FUEL FILL DOOR REPLACEMENT

Page 19 of 99
1. Loosen the bolts, then remove the fuel filler door (A).
- Make sure the fuel fill door opens properly and locks
securely.
RELEASE HANDLE REPLACEMENT

1. Remove the front door scuff trim and center pillar lower trim.
2. Loosen the release handle (A), mounting bolt.
Disconnect the release cable (B). then remove the release handle.
Page 20 of 99
- Make sure the fuel fill door opens properly and locks
securely.
FUEL FILLER DOOR RELEASE CABLE REPLACEMENT

A. Front seat.
B. Rear seat.
C. Front/rear door scuff trim LH.
D. Center pillar lower trim.
E. Luggage side trim.
F. Fuel fill door release handle.
2. Disconnect the fuel filler door release cable from the release handle.
3. Remove the release cable (A) from the clip, and disconnect the fuel filler door catch (B), then remove the fuel
filler door cable from the vehicle.
Make sure the fuel fill door opens properly and locks.
Page 21 of 99
Body (Interior and Exterior) > Exterior > Front Door > Components and Components Location
COMPONENTS
Page 22 of 99
Page 23 of 99
Body (Interior and Exterior) > Exterior > Front Door > Repair procedures
REPLACEMENT
DOOR TRIM REPLACEMENT
- Take care not to scratch the door trim and other parts.
- Put on glove to protect your hands.
Page 24 of 99
1. Remove the quadrant inner cover.
2. Remove the inside handle cover(A).
3. Loosen the door trim(A) mounting screws. Disconnect the power window switch connector(B), power mirror
connector(C), and door courtesy lamp connector(D).
4. Remove the door trim seal.

- Roll the glass and down to see if it moves freely without

binding.
- Make sure the door locks and opens properly.
GLASS REPLACEMENT
1. Remove the front door trim.
Page 25 of 99
2. Carefully move the glass(A) until you can see the bolts, then loosen them. Separate the glass from the glass run
and carefully pull the glass out through the window slot(B).
- Take care not to drop the glass or scratch the glass surface.
- Make sure the door locks and opens

properly.
- Adjust the position of the glass as necessary.
REAR CHANNEL REPLACEMENT

2. Remove the glass.
3. After disconnecting the glass molding, remove the rear channel (A).

OUTSIDE HANDLE REPLACEMENT
1. Remove the following items;
A. Door trim.
B. Glass.
C. Rear channel.
Page 26 of 99
2. Disconnect the outside handle rod (A) and lock rod (B).
3. After removing the outside handle mounting bolt, remove the outside handle base (C) and key cylinder.
4. After removing key cylinder (A) and outside handle base (B), remove the outside handle lever(C).

binding.
POWER WINDOW MOTOR REPLACEMENT

Page 27 of 99
2. After disconnecting the connector (A), remove the power window motor(B).

binding.
LATCH ASSEMBLE REPLACEMENT

3. Remove the door module.
4. Lock cable(B), inside handle cable(C) then remove the latch assemble(D).

binding.
DOOR MODULE REPLACEMENT

Page 28 of 99
3. Disconnect the wiring harness (A).
4. Disconnect the lock rod(A) and outside handle rod(B).
- Roll the glass up and down to see if it moves freely without

binding.
SPEAKER REPLACMENT
2. Disconnect the speaker connector (A), and remove the speaker (B).
Page 29 of 99
INSIDE HANDLE REPLACMENT

2. Lossen the inside handle (A) mounting screw.
Push the inside handle forward to disconnect from the door module.
3. Disconnect the lock cable (A) and inside handle connect cable (B).
4. Remove the inside handle(C).

Page 30 of 99

properly.
DOOR BELT WEATHERSTRIP REPLACMENT

2. Release the hooks (A), and then remove the door belt weatherstrip (B).

GLASS RUN REPLACMENT
3. Remove the glass run(A) from the lower part.

DOOR WEATHEESTRIP REPLACMENT
Page 31 of 99
1. Release the clips then remove the door weatherstrip(A).
ADJUSTMENT
GLASS ADJUSTMENT
- Check the glass run channel for damage or deterioration, and replace them if necessary.
1. Remove the following parts;
A. Quadrant cover.
B. Door trim.
2. Chack that the glass moves smoothly.

DOOR STRIKER ADJUSTMENT
Page 32 of 99
DOOR POSITION ADJUSTMENT
After installing the door, check for a flush fit with the body, then check for equal gaps between the front, rear, and
bottom, door edges and the body. Check that the door and body edges are parallel. Before adjusting, replace the
mounting bolts.
1. Place the vehicle on a firm, level surface when adjusting the doors.
2. Adjust at the hinges(A):
A. Loosen the door mounting bolts(B) slightly, and move the door IN or OUT until it aligns flush with the body.
B. Loosen the hinge mounting bolts (C) slightly, and move the door BACKWARD or FORWARD, UP or
DOWN as necessary to equalize the gaps.
C. Place a shop towel(D) on the jack(E) to prevent damage to the door when adjusting the door.
Page 33 of 99
3. Check that the door and body edges are parallel.
4. Grease the pivot portions of the hinges indicated by the arrows.
5. Check for water leaks.
Body (Interior and Exterior) > Exterior > Rear Door > Components and Components Location
COMPONENTS
Page 34 of 99
Page 35 of 99
Body (Interior and Exterior) > Exterior > Rear Door > Repair procedures
REPLACMENT
REMOVE REAR DOOR TRIM
- Take care not to scratch the door trim and other parts.
- Put on gloves to protect your hands.
Page 36 of 99
1. Remove the inside handle cover (A).
2. loosen the door trim (A) mounting screws. Release the clips that hold the door trim, then remove the door trim by
pulling it upward. Disconnect the power window switch connector.
3. Remove the door trim seal.


binding.
GLASS REPLACMENT
1. Remove the rear door trim.
Page 37 of 99
2. After disconnecting the glass run (A) and weatherstrip (B), then remove the delta molding(C).
3. After loosening the mounting bolt, remove the glass(D).
- Take care not to drop the glass and scratch the glass
surface.
- Roll the glass up down to see if move freely without

binding.
REAR CHANNEL REPLACMENT

3. Remove the rear channel mounting bolt and remove the chanel from the door assembly.
Page 38 of 99

binding.
DOOR MODULE REPLACMENT

3. Remove the rear channel.
4. Disconnect the power window motor connector(A),speaker connector(B), and actuator connector(C).
5. Remove the door module assembly(A).
- Make sure the door locks and open

properly.
SPEAKER REPLACMENT
2. After disconnecting the speaker connector (A), remove the speaker (B).
Page 39 of 99
REAR DOOR LATCH REPLACEMENT

3. Remove the rear door module.
4. Remove the latch cover, then disconnect the lock cable (A) and inside handle cable (B).
Remove the rear door latch(C).

POWER WINDOW MOTOR REPLACMENT
2. Disconnect the power window motor connector (A).
Page 40 of 99
3. After loosening the mounting nut, remove the power window motor (B).

binding.
OUTSIDE HANDLE REPLACEMENT

3. Remove the rear channel.
4. Remove the outside handle base (A).
Page 41 of 99
5. Remove the outside hand lever (A) and cover (B).

properly.
DOOR BELT WEATHERSTRIP REPLACEMENT

1. Release the hooks (A) and then remove the door belt weatherstrip(B).

INSIDE HANDLE REPLACEMENT
Page 42 of 99
2. Loosen the inside handle(A) forward to disconnect from the door module.
3. Disconnect the lock cable (A) and inside handle connect cable (B).
4. Remove the inside handle(C).


properly.
DOOR WEATHERSTRIP REPLACEMENT

Page 43 of 99
1. Release the clips then remove the door weatherstrip(A).
ADJUSTMENT
GLASS ADJUSTMENT
- Check the weatherstrip and glass run channel for dabage or deterioration, and replace them if necessary.
2. Carefully move the glass(A) until you can see the glass mounting bolts(B), then loosen them.
3. Push the glass against the center channel, the tighten the glass mounting bolts.
4. Check that the glass moves smoothly.
DOOR STRIKER ADJUSTMENT
Page 44 of 99
1. Make sure the door latch securely without slamming it. If necessary, adjust the striker(A): The striker nuts are
fixed. The striker can be fine adjusted up or down and, in or out .
2. Make sure the door locks and opens properly.

DOOR POSITION ADJUSTMENT
After installing the door, check for a flush fit with the body, then check for equal gaps between the front, rear, and
bottom, door edges and the body. Check that the door and body edges are parallel. Before adjusting, replace the
mounting bolts.
1. Place the vehicle on a firm, level surface when adjusting the doors.
Page 45 of 99
2. Adjust at the hinge(A):
Loosen the hinge mounting bolts(C) slightly, and move the door BACKWARD or FORWARD, UP or DOWN
ad necessary to equalize the gaps.
3. Check that the door edges are parallel.
Body (Interior and Exterior) > Exterior > Body Side Moldings > Repair procedures
REPLACEMENT
ROOF RACK REPLACEMENT
- When prying with a flat-tip screwdriver, wrap it with protective tape around the related parts, to prevent
damage.
- Take care not to scratch the body surface.
1. Remove the rack cover (A).
Page 46 of 99
2. Remove the roof rack(A).

TAILGATE GARNISH REPLACEMENT
damage.
2. Remove the key cylinder.
3. Move the tailgate garnish(A).
Body (Interior and Exterior) > Exterior > Mirror > Components and Components Location
COMPMNEMTS
Page 47 of 99
Body (Interior and Exterior) > Exterior > Mirror > Repair procedures
REPLACEMENTC
OUTSIDE REAR VIEW MIRROR REPLACEMENT
damage.
Page 48 of 99
1. Remove the quadrant inner cover(A).
2. Remove the door trim(See Page BD-23).

3. After disconnecting the connector (A), remove the outside rear view mirror(B).

INSIDE REAR VIEW MIRROR REPLACEMENT
MANUAL MIRROR
1. Push the inside rear view mirror base(A) down to remove the inside rear view mirror assembly(B).
ECM MIRROR REPLACEMENT

1. Remove the cover and connector (A).
2. Push the ECM mirror base down to remove the ECM mirror assembly (B).
Page 49 of 99
Body (Interior and Exterior) > Interior > Console > Components and Components Location
COMPONENTS
Page 50 of 99
Body (Interior and Exterior) > Interior > Console > Repair procedures
REPLACEMENT
FLOOR CONSOLE REPLACEMENT
damage.
1. Remove the storage box.
2. Remove the armrest assembly.
Page 51 of 99
3. Remove the rear end cover.
4. After disconnecting the seat heater connector (A), remove the console assembly(B).

FLOOR CONSOLE ARMREST REPLACEMENT
1. Remove the storage box ped.
2. After loosening the storage box mounting bolt, then remove the storage box(A).
3. After loosening the armrest mounting bolt, then remove the armrest(A).
Page 52 of 99
POP-UP UNIT REPLACEMENT

1. Loosen the armrest cover(A) mounting screws.
2. Remove the pop-up unit(A).
Body (Interior and Exterior) > Interior > Crash Pad > Components and Components Location
COMPMNENTS
Page 53 of 99
Body (Interior and Exterior) > Interior > Crash Pad > Repair procedures
REPLACEMENT
CLUSTER FACIA PANEL REPLACEMENT
Page 54 of 99
damage.
1. Tilt the steering column down.
2. After disconnecting the trip sensor connector (A), remove the cluster facia panel(B).
- Make sure the connector is plugged

properly.
- Replace any damage clips.
CENTER FACIA PANEL REPLACEMENT

1. Disconnect the following items to remove the center facia panel(A).
- When prying with a flat-tip screwdriver, wrap it with protective tape around the related parts, to
prevent damage.
Take care not to scratch the body surface.
Page 55 of 99

properly.
LOWER CRASH PAD PANEL REPLACEMENT

1. Disconnect the hood release cable from the hood release handle.
2. Remove the lower crash pad panel(A).

HEATER CONTROL UNIT REPLACEMENT
1. Remove the center facia panel.
2. Loosen the screws. Remove the heater control unit(A).

properly.
CLUSTER REPLACEMENT
1. Remove the cluster facia panel.
Page 56 of 99
2. Loosen the screws.
3. Disconnect the cluster connector (A), then remove the cluster(B).
- Make sure the connector is plugged properly.

AUDIO ASSEMBLY REPLACEMENT
1. Remove the center facia panel.
2. Loosen the screws.
3. Disconnect the audio connector(B) and antenna cable(C), then remove the audio assembly (A).
Page 57 of 99

properly.
COVER REPLACEMENT
damage.
1. Remove the crash pad side cover(A), crash pad center under cover(B).
CRASH PAD SIDE COVER
Drive’s center lower side cover

Page 58 of 99
Passenger’s center lower side cover
AIR VENT REPLACEMENT
damage.
1. Remove the air vent (A) by detaching the clips.
GLOVE BOX REPLACEMENT

Page 59 of 99
1. Disconnect the air damper(A) and guide(B) from the glove box(C).
2. Disconnect the pin(A), then remove the glove box(B).

MAIN CRASH PAD REPLACEMENT
damage.
- Take care not to scratch the crash pad, body and other related parts.
Page 60 of 99
A. Front seat.
B. Cluster facia panel, cluster.
C. Audio assembly.
D. Glove box.
E. Side cover, crash pad center under cover.
F. Front pillar trim.
G. Steering wheel.
2. Disconnect the passenger’s air bag connector(A).
3. Loosen the bolts and nut, then remove the crash pad(B).
Body (Interior and Exterior) > Interior > Interior Trim > Repair procedures
REPLACEMENT
FLOOR AND SIDE AREA
Page 61 of 99
1. Remove the trims.
- When prying with a flat-tip screwdriver, wrap it with protective tape around the related parts, to
prevent damage.
- Take care not to bend or scratch the trim and panels.
TRUNK AREA
Page 62 of 99
ROOF AREA
Page 63 of 99
Body (Interior and Exterior) > Interior > Windshield Glass > Components and Components Location
COMPONENTS
Page 64 of 99
Body (Interior and Exterior) > Interior > Windshield Glass > Repair procedures
REPLACEMENT
REMOVAL

- Use seat covers to avoid damaging any surfaces.
Page 65 of 99
A. Outside rear view mirror.
B. Sunvisors and holders, both sides, overhead console, Grab handles, both sides.
C. Front pillar trim, both sides.
D. Windshield wiper arms and cowl cover.
2. Remove the molding (A) from the edge of the windshield (B). If necessary, cut the molding with a utility knife.
3. Remove the spacer (C).
4. Pull down the front portion of the headliner. Take care not to bend the headliner excessively, or you may crease
or break it.
5. Cut out the sealant using the sealant cutting tool [A(09861-31100)].
Page 66 of 99
6. Remove the winshield (A) carefully using the glass holder [B(09861-31100)].
INSTALLTION
1. With a knife, scrape the old adhesive smooth to a thickness of about 2mm (0.08 in.) on the bonding surface
around the entire windshield opening flange:
A. Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
B. Remove the rubber dam and fasteners from the body.
C. Mask off surrounding surfaces before painting.
2. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water
from getting on the clean surface.
3. Apply the glass primer (A) to the side of the windshield glass edge and stick the both-sided adhesive tape (B) on
the inside of molding (C).
4. When attaching the molding, make it in line (D) with the windshield glass and attach the windshield glass pad
(E)to the designated place.
5. Install the spacer (A) install the windshield glass (B) temperarily with making sure to position them on the center,
and then place the alignment mark (C).
Page 67 of 99
6. Remove the windshield.
7. Apply a light coat of glass primer to the outside of the fasteners.
- Never touch the primed surface with your hand. If you do, the adhesive may not bond to the glass
properly, causing a leak after the windshield glass is installed.
- Do not apply body primer to the glass.
- Keep water, dust, and abrasive materials away from the primer.
Page 68 of 99
8. With a sponge, apply a light coat of body primer to the original adhesive remaining around the windshield opening
flange. Let the body primer dry for at least 10 minutes:
A. Do not apply glass primer to the body, and be careful not to mixup glass and body primer sponges.
B. Never touch the primed surfaces with your hands.
C. Mask off the dashboard before painting the flange.
9. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking
gun, and run a bead of sealant (A) around the edge of the windshield (B) between the fastener and molding as
shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each
corner.
Page 69 of 99
10. Use glass holder (A) to hold the windshield over the opening, align it with the alignment marks (B) made in step
15, and set it down on the adhesive. Lightly push on the windshield until its edges are fully seated on the
adhesive all the way around. Do not open or close the doors until the adhesive is dry.
11. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface
or the windshield, wipe with a soft shop towel dampened with alcohol.
12. Let the adhesive dry for at least one hour, then spray water over the windshield and check for leaks. Make
leaking areas, and let the windshield dry, then seal with sealant:
A. Let the vehicle stand for at least four hours after windshield installation. If the vehicle has to be used within
the first four, it must be driven slowly.
B. Keep the windshield dry for the first hour after installation.
13. Reinstall all remaining removed parts. Install the rearview mirror after the adhesive has dried thoroughly. Advise
the customer not to do the following things for two the three days:
A. Slam the door with all the windows rolled up.
B. Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough,
uneven roads).
Body (Interior and Exterior) > Interior > Quarter Fixed Glass > Repair procedures
REPLACEMENT
REMOVAL

- Take care not to damage body surface and other parts.
1. Remove the following parts:
A. Rear seat assembly.
B. Rear door scuff trim.
C. Self covering trim.
D. Luggage side trim.
E. Rear seat belt upper anchor bolt.
F. Rear pillar trim.
Page 70 of 99
2. Loosen the quarter fixed glass (A) mounting nut.
3. Cut out the sealant using the sealant cutting tool [A(09801-311000)].
4. Remove the quarter fixed glass.

INSTALLATION
1. With a putt knife, scrape the old adhesive smooth to a thickness of about 2mm (0.08 in.) on the bonding surface
around the entire quarter fixed glass flange.
A. Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
B. Mask off surrounding surfaces before painting.
C. Remove the fasteners from the body.
2. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water
from getting on the surface.
Page 71 of 99
3. With a sponge, apply a light coat of glass primer along the edge of the quarter fixed glass as shown, then lightly
wipe it off with gauze or cheesecloth:
A. Do not apply body primer to the quarter fixed glass, and do not get body and glass primer sponges mixed up.
B. Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the quarter fixed
glass properly, causing a leak after the quarter fixed glass in installed.
C. Keep water, dust, and abrasive materials away from the primed surface.
4. With a sponge, apply a light coat of body primer to the original adhesive remaining around the flange. Let the
body primer dry for at least 10 minutes.
A. Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges.
B. Never touch the primed surfaces with your hands.
Page 72 of 99
5. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking
gun, and run a bead of sealant (A) around the edge of the quarter fixed glass (B) as shown. Apply the adhesive
within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
6. Install the quarter fixed glass.
7. Let the adhesive dry for at least one hour, then spray water over the rear window and check for leaks. Mark the
leaking areas, let the rear window dry, then seal with sealant. Let the vehicle stand for at least four hours after
rear window installation. If the vehicle has to be used within the first four hours, it must be driven slowly.
8. Reinstall all remaining removed parts.
Body (Interior and Exterior) > Bumper > Front Bumper > Repair procedures
FRONT BUMPER
REPLACEMENT
related parts to prevent damage.
- Remove the under cover.
- Take care not to bend or scratch the cover and other parts.
Page 73 of 99
Page 74 of 99
Body (Interior and Exterior) > Bumper > Rear Bumper > Repair procedures
REPLACEMENT
Page 75 of 99
- Remove the rear combination lamps first.

related parts to prevent damage.
- Take care not to bend or scratch the cover and other parts.
Body (Interior and Exterior) > Seat & Power Seat > Front Seat > Components and Components
Location
Page 76 of 99
COMPONENTS
Body (Interior and Exterior) > Seat & Power Seat > Front Seat > Repair procedures
REPLACEMENT
SEAT ASSEMBLY REPLACEMENT
Page 77 of 99
1. Remove the seat assembly mounting cover.
After loosening the seat assembly mounting bolts, remove the seat assembly(A).
2. Open the connector box(A).

Disconnect the connector (B), and remove the seat assembly.
SEAT MOUNTING BOLT INSTALLATION PROCEDURE

- Set the seat into the full rearward position
Check that each slide is locked, and then tighten the front mounting bolt temporarily.
- Set the seat into the full forward position
Check that each slide is locked, and then tighten the rear mounting bolt completely.
- Set the seat into the full rearward position.
Check the front mounting bolt completely.
- Check that the seat operates to and fro smoothly And the locking portion locks
properly.
RECLINER COVER, KNOB AND HEIGHT KNOB REPLACEMENT

1. Remove the height adjuster knob(A) and recliner knob(B).
Page 78 of 99
2. Loosen the recliner mounting screw and clip, then remove the recliner cover(C).

SEAT BACK COVER REPLACEMEN
1. After disconnecting the scuff band(A), remove the seat back panel(B).
2. Disconnect the protector (A) from the back frame, then open the zipper(B).
Page 79 of 99
3. Remove the headrest and headrest guide(A).
4. After removing the hogring clips (A) on the front of seat back and remove the seat back cover(B).
- To prevent wrinkles, make sure the material is stretched evenly over the cover(B) before securing the
hogring clips(A).
- Replace the hogring clips with new ones using special tool(C).
SEAT CUSHION COVER REPLACEMENT

1. Remove the seat assembly.
2. Disconnect the scuff band.
Page 80 of 99
3. Remove the connector box(A).
4. Remove the connectors (A). After loosening the mounting bolts, remove the cushion(B).
5. Disconnect the protector (A) from the cushion frame (B).

Page 81 of 99
6. After removing the hogring clips (A) on the front of seat cushion and remove the seat cushion cover(B).
- To prevent wrinkles, make sure the material is stretched evenly over the cover (B) before securing the
hogring clips(A).
SEAT BACK FRAME REPLACEMENT

1. Remove the seat back panel.
2. Remove the headrest guide.
3. Remove the seat back cover and pad from the frame.
4. Loosen the mounting bolts, then remove the seat back frame(A).
- Remove the side air bag for replacing side air bag installation seat.
- Before service, be fully aware of precautions and service procedure relevant to air bag(Seepage RT-
“Airbag”)
Page 82 of 99

SEAT TRACK REPLACEMENT
1. After removing the seat back panel, disconnect the protector and open the zipper.
2. Remove the seat back assembly(A).
3. Remove the seat cushion.

4. Remove the recliner cover, recliner knob and height adjuster knob(Seepage BD-75).
5. Remove the seat track(A).

SEAT BACK HEATER REPLACEMENT
1. Remove the seat back cover.
2. Cut the heater(A) attached to the pad (B), as shown in the picture.
Page 83 of 99
3. Take off the paper from the backside of the heater assembly.
- Ensure the replacement heater is fitted properly

during.
SEAT CUSHION HEATER REPLACEMENT

1. Remove the seat cushion cover.
2. Cut the heater(A) attached to the pad(B), as shown in the picture.
3. Take off the paper from to the backside of the heater assembly.
4. Attach the heater to the main part of pad.
- Ensure the replacement heater is fitted properly

during.
Body (Interior and Exterior) > Seat & Power Seat > Rear Seat > Components and Components
Location
COMPONENTS
Page 84 of 99
Body (Interior and Exterior) > Seat & Power Seat > Rear Seat > Repair procedures
REPLACEMENT
SEAT ASSEMBLY REPLACEMENT
1. After disconnect the cushion frame hinge(A) cover, loosen the mounting bolts. Fold the cushion(B).
2. Loosen the recliner hinge (C)mounting nut and bolts, then rear seat assembly(D).
Page 85 of 99
SEAT MOUNTING BOLT AND NUT INSTALLATION PROCEDURE.

- Tighten temporarily in the order of nut and bolt on the front of recliner hinge installation part.
- After completely tightening the bolt on the back of the recliner hinge installation part, tighten the bolt on
the front of it completely.
- Setting down the seat cushion, tighten the mounting bolt of the cushion frame hinge.
- Check if reclining the seat and folding seat back operate smoothly.
SEAT CUSHION COVER REPLACEMENT

1. After loosening cushion frame hinge mounting bolts, fold the cushion.
Page 86 of 99
2. Remove the protector (A) and hogring clip (B), then remove the cushion(C).
3. Pull out the hogring clips (A) on the front of seat cushion, remove the seat cushion cover(B).
- To prevent wrinkles, make sure the material is stretched evenly over the cover(B) before securing the
hogring clips(A).
SEATBACK COVER REPLACEMENT

Page 87 of 99
A. Headrest.
B. Armrest.
2. Remove the back folding hinge cover(A).
After loosening the mounting bolts, remove the cushion(B).
3. After folding the seat back, remove the shopping hook (A) from the back panel.
4. Remove the back panel (A).

Page 88 of 99
5. Remove the recliner lever cover (A).
6. Remove the hogring clip (A) and headrest guide (B), then remove the seat back assembly(C).
7. Remove the hogring clip (A) of the pad.
8. Disconnect the aplix (A) on the front of seat back, remove the back cover (B).

SEAT BACK FRAME AND RECLINER REPLACEMENT
Page 89 of 99
1. Remove the seat back cover.
2. Remove the recliner (A).
3. Loosen the recliner (A) mounting bolt.

After disconnecting the recliner cable (B),remove the seat back frame(C).

SEAT CUSHION FRAME REPLACEMENT
1. Remove the seat cushion.
Page 90 of 99
2. Disconnect the protector and remove the hogring clip. Remove the cushion assembly (A).
3. Loosen the back folding cover (A). After loosening the mounting, remove the cushion frame (B).

ARMREST REPLACEMENT
1. Squeeze out the gap between the seat back (A) and the armrest(B) to open using a screwdriver(C) and remove
the bushing(D).
Page 91 of 99
2. Pushing the armrest to the left, remove the arm rest.
3. Remove the armrest cover(A).

RECLINER LEVER REPLACEMENT
1. Remove the seat back frame.
2. After removing the “E” ring (A) from the recliner mounting pin, remove the recliner mounting pin (B).
3. Disconnect the recliner cable wire (C), then remove the recliner lever (D).
Page 92 of 99
Body (Interior and Exterior) > Seat Belt > Front Seat Belt > Components and Components Location
COMPONENTS
Page 93 of 99
Body (Interior and Exterior) > Seat Belt > Front Seat Belt > Repair procedures
REPLACEMENT
FRONT SEAT BELT
When installing the seat belt, make sure not to damage the pretensioner.
Page 94 of 99
A. Front seat assembly.
B. Front and rear door scarf trim.
2. After raise the lower anchor cover(A), loosen the lower anchor mounting bolt(B).
3. Remove the center pillar lower trim.

4. Remove the upper anchor cover (A), then loosen the upper anchor(B).
5. After disconnecting the pretensioner connector lock pin, remove the connector(C).
loosen the mounting bolt, then remove the pretensioner(D).
Page 95 of 99
REAR SEAT BELT REPLACEMENT
When installing the seat belt, make sure not to damage the retractor.
A. Rear seat assembly.
B. Front and rear door scarf trim.
C. Self covering trim.
D. Trunk trim.
2. Remove the lower anchor (A).
Page 96 of 99
3. Remove the luggage side trim.
4. Remove the upper anchor cover (A), then loosen the mounting bolt. Remove the upper anchor (B).
5. After loosening the retractor (C) mounting bolt, remove the rear seat belt (D).
Page 97 of 99

FRONT SEAT BELT BUCKLE REPLACEMENT
B. Front seat recliner cover.
2. Remove the seat belt buckle (A).
Page 98 of 99
REAR SEAT BELT BUCKLE REPLACEMENT

1. After cushion frame hinge mounting bolts, fold the cushion.
2. Remove the seat belt buckle (A).
HEIGHT ADJUSTER REPLACEMENT

B. Front and rear door scuff trim.
C. Front seat belt lower ,upper trim.
D. Center pillar lower and upper trim.
Page 99 of 99
2. Loosen the mounting bolt, then remove the height adjuster (A).
Page 1 of 222
SPORTAGE(KM) > 2008 > G 2.7 DOHC > 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.
Page 2 of 222
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 (A) is
contaminated, replace it.
11. Insert the connector all the way and make sure it is securely locked.
Page 3 of 222
12. Position wires so that the open end of the cover faces down.
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, and 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.
Page 4 of 222
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).
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.
Page 5 of 222
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 > Troubleshooting

TROUBLESHOOTING
INSTRUMENTS AND WARNING SYSTEM
Symptom Possible cause Remedy
Speedometer does not operate Cluster fuse (10A) blown Check for short and replace fuse
Speedometer faulty Check speedometer
Vehicle speed sensor faulty Check vehicle speed sensor
Wiring or ground faulty Repair if necessary
Tachometer does not operate Cluster fuse (10A) blown Check for short and replace fuse
Tachometer faulty Check tachometer
Fuel gauge does not operate Cluster fuse (10A) blown Check for short and replace fuse
Fuel gauge faulty Check gauge
Fuel sender faulty Check fuel sender
Low fuel warning lamp does not light Cluster fuse (10A) blown Check for short and replace fuse
up Bulb burned out Replace bulb
Fuel sender faulty Check fuel sender
Water temperature gauge does not Cluster fuse (10A) blown Check for short and replace fuse
operate Water temperature gauge faulty Check gauge
Water temperature sender faulty Check sender
Oil pressure warning lamp does not Cluster fuse (10A) blown Check for short and replace fuse
light up
Bulb burned out Replace bulb
Oil pressure switch faulty Check switch
Parking brake warning lamp does Cluster fuse (10A) blown Check for short and replace fuse
not light up
Page 6 of 222
Brake fluid level warning switch
Check switch
faulty
Parking brake switch faulty Check switch
Open door warning lamp and trunk Room lamp fuse (10A) blown Check for short and replace fuse
lid warning lamp do not light up
Door switch faulty Check switch
Seat belt warning lamp does not light Cluster fuse (10A) blown Check for short and replace fuse
up Bulb burned out Replace bulb
Seat belt switch faulty Check switch
LIGHTING SYSTEM
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
Ignition fuse (LOW:10A,
Check for short and replace fuse
HIGH:20A) blown
Head lamp fuse (15A) blown Check for short and replace fuse
Head lamp relay faulty Check relay
Lighting switch faulty Check switch
Tail lamps and license plate lamps do Bulb burned out Replace bulb
not light
Position lamp fuse (10A) blown Check for short and replace fuse
Tail lamp relay faulty Check relay
Lighting switch faulty Check switch
Stop lamps do not light Bulb burned out Replace bulb
Stop lamp fuse (15A) blown Check for short and replace fuse
Stop lamp switch faulty Adjust or replace switch
Stop lamps do not turn off Stop lamp switch faulty Repair or replace switch
Instrument lamps do not light Rheostat faulty Check rheostat

(Tail lamps light) Wiring or ground faulty Repair if necessary
Page 7 of 222
Turn signal lamp does not flash on
Turn signal switch faulty Check switch
one side
Turn signal lamps do not light Bulb burned out Replace bulb
Turn signal lamp fuse (10A) blown Check for short and replace fuse
ETACS faulty Check ETACS
Turn signal switch faulty Check switch
Hazard warning lamps do not light Bulb burned out Replace bulb
Hazard warning lamp fuse (10A)
Check for short and replace fuse
blown
Hazard switch faulty Check switch
Flasher rate too slow or too fast Lamps' wattages are smaller or
Replace lamps
larger than specified
Back up lamps do not light Bulb burned out Replace bulb
Turn signal lamp fuse (10A) blown Check for short and replace fuse
Back up lamp switch (M/T) faulty Check switch
Transaxle range switch (A/T) faulty Check switch
Room lamp does not light Bulb burned out Replace bulb
Room lamp fuse (15A) blown Check for short and replace fuse
Room lamp switch faulty Check switch
Front fog lamps do not light Bulb burned out Replace bulb
Front fog lamp fuse (15A) blown Check for short and replace fuse
Front fog lamp relay faulty Check relay
Front fog lamp switch faulty Check switch
Map lamp does not light Bulb burned out Replace bulb
Map lamp switch faulty Check switch
Tailgate room lamp does not light Bulb burned out Replace bulb
Page 8 of 222
Tailgate switch faulty Check switch
AUDIO SYSTEM
There are six areas where a problem can occur: wiring harness, the radio, the cassette tape deck, the CD player,
and speaker. Troubleshooting enables you to confine the problem to a particular area.
Chart 1
Page 9 of 222
Page 10 of 222
Chart 2
Chart 3
Page 11 of 222
Chart 4
Page 12 of 222
Page 13 of 222
Chart 5
Page 14 of 222
Page 15 of 222
Chart 6
Page 16 of 222
Chart 7
Chart 8
Page 17 of 222
Chart 9
WINDSHIELD WIPER
Page 18 of 222
1. Wiper low and wiper high do not work.
2. When washer switch is on, wiper does not work.
POWER WINDOW
Page 19 of 222
1. No windows operate from the main switch on the driver's door.
2. Driver's side window does not operate.

Page 20 of 222
3. Passenger's side window does not operate.
POWER DOOR LOCK

1. Lock function works but unlock function does not work. → Since door unlock relay is malfunctioning, replace
the door unlock relay.
2. Unlock function works but lock function does not work. → Since door lock relay is malfunctioning, replace the
door lock relay.
3. When passenger side knob is controlled, all doors locks, but when driver side knob is controlled, all doors do not
lock.
Page 21 of 222
4. When driver side knob is controlled. All doors lock. But when the passenger side knob is controlled, all doors do
not lock.
Page 22 of 222
5. Both sides do not lock either.

Page 23 of 222
KEYLESS ENTRY & BURGLAR ALARM SYSTEM

1. Alarm does not work. (Hazard lamp works)
Page 24 of 222
2. When hood is opened inside the car, burglar horn does not work.
3. When door is opened inside the car, burglar horn does not work (If tailgate and hood is opened, alarm works)
Page 25 of 222
4. When tailgate is opened inside the car, siren does not work.
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, even when the alarm is disarmed.

Page 26 of 222
7. Central door lock function works, but keyless entry system does not work.
Body Electrical System > Audio > Components and Components Location
COMPONENTS
Page 27 of 222
Body Electrical System > Audio > Specifications

SPECIFICATION
Page 28 of 222
Item Specification
AM/FM/CD AM/FM/Cassette AM/FM/Cassette
Model
(M445) /MP3 (M455) /6CDC (M465)
Power supply DC 14.4V
Rated output Max 43W x 4 Maw 50W x 4
Speaker impedance 4Ω x 4 2Ω x 4
Antenna 80PF 75Ω
Tuning type PLL synthesized type
External amp,
The others -
Sub woofer
Frequency range / FM 87.5~107.9 MHz/ 200KHz
Channel space AM 530~1710 KHz/ 10KHz
Body Electrical System > Audio > Audio Unit > Components and Components Location
COMPONENT
Page 29 of 222
Page 30 of 222
Page 31 of 222
Body Electrical System > Audio > Audio Unit > Repair procedures
REPLACEMENT
1. Disconnect the negative (-) battery terminal.
Page 32 of 222
2. Remove the center facia panel (C) after pulling it by using regular screwdriver(-) at part (A).Take care of fixing
clips (B).
3. Remove the connectors.

4. Remove the mounting screws then remove the audio unit assembly (A).
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 an alcohol. Wipe the head and
capstan.
Body Electrical System > Audio > Speakers > Repair procedures
REPLACEMENT
FRONT SPEAKER
1. Remove the front door trim panel (Refer to the BD group - front door).
Page 33 of 222
2. Remove the front speaker (A) after removing 3 screws.

REAR SPEAKER
1. Remove the rear door trim panel (Refer to the BD group - rear door).
2. Remove the rear speaker(A) after removing 3 screws.

TWEETER SPEAKER
1. Remove the front door trim panel (Refer to the BD group - front door).
2. Remove the tweeter speaker (A) after removing 2 screws.

WOOFER SPEAKER
1. Remove the assist side seat.(Refer to the BD group - front seats)
Page 34 of 222
2. Remove the woofer speaker(A) from the assist side floor after removing 2 bolts and 2 nuts.
EXTERNAL AMP
1. Remove the driver seat.(Refer to the BD group - front seats)
2. Remove the external amp (A) from the floor beyond the driver seat after removing 3 bolts and 1nut.
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
REPLACEMENT
1. Remove the rear roof trim (Refer to BD group-roof trim).
2. Disconnect the 1P connector (A) and antenna jack (B) from the roof antenna.
Page 35 of 222
3. Remove the roof antenna after removing a nut.
Body Electrical System > Multifunction switch > Components and Components Location
COMPONENTS
Page 36 of 222
Body Electrical System > Multifunction switch > Repair procedures

REPLACEMENT
Page 37 of 222
1. Remove the steering column upper and lower shrouds (A) after removing 3 screws.
2. Remove the light switch (B) after loosening its 2 screws and connector (A).
3. Remove the wiper switch (B) after loosening its 2 screws and connector (A).
INSPECTION
LIGHTING SWITCH INSPECTION
With the multi function switch in each position, make sure that continuity exists between the terminals below. If
continuity is not as specified, replace the multi-function switch.
Page 38 of 222
LIGHTING SWITCH (AUTO LIGHT)
LIGHTING SWITCH
DIMMER AND PASSING SWITCH
TURN SIGNAL SWITCH
FRONT FOG LAMP SWITCH

Page 39 of 222
WIPER AND WASHER SWITCH INSPECTION

With the multi function switch in each position, make sure that continuity exists between the terminals below. If
continuity is not as specified, replace the multi-function switch.
WIPER SWITCH
WASHER SWITCH
REAR WIPER & WASHER SWITCH

Page 40 of 222
Body Electrical System > Multifunction switch > Specifications
SPECIFICATIONS
Items Specifications
Rated voltage DC 12 V
Operating temperature range -30°C ~ +80°C (-22 ~ +176°F)
Rated load
Dimmer & passing switch High : 15A (Relay load)
Low : 10A (Relay load)
Passing : 15A (Relay load)
Lighting switch Lighting : 1A (Relay load)
Turn signal & lane change switch 6.6±0.5A (Lamp load)
Front fog lamp switch 1A (Relay 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)
Rear wiper & washer switch Max. 25mA
Rear wiper : 200mA (Relay load)
Rear washer : 4A (Motor load)
Body Electrical System > Horn > Components and Components Location
COMPONENTS
Page 41 of 222
Body Electrical System > Horn > Repair procedures

REPLACEMENT
1. Remove the front bumper. (Refer to the BD group - front bumper).
Page 42 of 222
2. Remove the bolt (C) and disconnect the horn connector, then remove the high pitch horn (A) and low pitch horn
(B).
INSPECTION
Test the horn by connecting battery voltage to the 1 terminal and ground the 2 terminal.
The horn should make a sound. If the horn fails to make a sound, replace it.
ADJUSTMENT
Operate the horn, and adjust the tone to a suitable level by turning the adjusting screw.
After adjustment, apply a small amount of paint around the screw head to keep it from loosening.
HORN RELAY INSPECTION

1. Remove the horn relay (A) from the engine room relay box.
2. There should be continuity between the No.87 and No.30 terminals when power and ground are connected to
the No.86 and No.85 terminals.
Page 43 of 222
3. There should be no continuity between the No.87 and No.30 terminals when power is disconnected.
Body Electrical System > Keyless Entry And Burglar Alarm > Description and Operation
DESCRIPTION
BURGLAR ALARM SYSTEM
The burglar alarm system is armed automatically after the doors, hood, and tailgate are closed and locked.
The system is set off when any of these things occur :
• A door is forced open.
• A door is unlocked without using the transmitter.
• The tailgate is opened without using the key.
• The hood is opened.
• The engine starter circuit and battery circuit are bypassed by breaking the ignition switch.
When the system is set off, the alarm (horn) sounds and the hazard lamp flash for about two minutes or until the
system is disarmed by unlocking the transmitter.
For the system to arm, the ignition switch must be off and the key removed. Then, the ETACS module must receive
signals that the doors, hood, and tailgate are closed and locked. When everything is closed and locked, none of the
control unit inputs are grounded.
If anything is opened or improperly unlocked after the system is armed, the ETACS module gets a ground signal
from that switch, and the system is set off.
If one of the switches is misadjusted or there is a short in the system, the system will not arm. As long as the ETACS
module continues to get a ground signal, it thinks the vehicle is not closed and locked and will not arm.
The receiver is integrated in the ETACS.
KEYLESS ENTRY SYSTEM
The burglar alarm system is integrated with the keyless entry system. The keyless entry system allows you to lock
and unlock the vehicle with the remote transmitter. When you push the LOCK button, all doors lock. When you
push the UNLOCK button all doors unlock.
The room lamp, if its switch is in the center position, will come on when you press the UNLOCK button. If you do
not open a door, the light will go off in about 30 seconds, the doors will automatically relock, and the burglar alarm
system will rearm. If you relock the doors with the remote transmitter within 30 seconds, the light will go off
immediately.
You cannot lock or unlock the doors with the remote transmitter if the key is in the ignition switch.
Page 44 of 222
The system will signal you when the doors lock and unlock by flashing the hazard lamp once when they lock, and
twice when they unlock.
PANIC MODE
The panic mode rigs the ETACS to sound the alarm with the remote transmitter in order to attract attention. When
the PANIC button is pressed and held for 0.5 seconds, the alarm will sound and exterior lights will flash for about
30 seconds.
The panic mode can be canceled at any time by pressing any button on the remote transmitter or by turning the
ignition switch ON. The panic mode will not function if the ignition switch is ON.
FUNCTION
ANTI-THEFT FUNCTION
1. ARM function
(1) When using LOCK on the RKE (Remote Keyless Entry) the doors will lock, the hazard lamp will blink once
within .06 seconds (max 0.06seconds) and the anti-theft system will ARM, if the following conditions have
been met.
A. The ignition key is removed from the ignition switch.
B. All entry points are closed (doors, trunk and hood)
(2) If either the door or trunk or hood is open when activating LOCK using the RKE, the doors will lock,
however the hazard lamp will not flash and the anti-theft system will not arm.
(3) In step 2) if the opened entry points are subsequently closed, the door will lock, the hazard lamp will blink
once and the anti-theft system will ARM.
(4) If LOCK is activated on the RKE while the anti-theft system is already in the ARM mode, the hazard lamp
will blink once. (If, however, any of the vehicle entry points is unlocked the anti-theft system will lock the
door, the hazard lamp will blink once, and the system will re-ARM itself.
(5) The ARM mode of the anti-theft system can only be set using the LOCK feature of the RKE. The door key
will not arm the anti-theft system.
(6) Once the ignition key is IN (inserted into the ignition switch) and the ignition is turned to the ON position the
anti-theft system will immediately DISARM.
(7) If the UNLOCK signal is sent by the RKE, and either the ignition key is not inserted or entry (door, trunk,
hood) to the vehicle is not made within 30 seconds, the LOCK mode will be automatically reset, the hazard
lamps will blink, and the anti-theft system will rearm. (Key IN = Key Insertion)
(Provided that there is no automatic lock function at a period of 30 seconds, when the UNLOCK is done by
the RKE with an entry being open).
(8) In steps 7), when UNLOCK is activated within the initial 30 seconds, another period of 30 seconds occurs.
(9) Automatic lock will not function if an entry point is opened within 30 seconds of activating UNLOCK.
Page 45 of 222
(10) Once the 30 seconds have passed, after the initial UNLOCK, the anti-theft system will lock the doors, blink
the hazard lamps and then ARM.
T1 : 0.5 sec,
T2 : 1.0 ± 0.1 sec.
2. DISARM function
(1) When UNLOCK is pressed on the RKE (Remote Keyless Entry control) the anti-theft system will
DISARM, the hazard lamps blink 2 times and the doors unlock.
(Whether entry points are open or closed is irrelevant)
(2) In DISARM mode, the alarm and start inhibitor do not function.
(3) When repeating UNLOCK on the RKE, the hazard lamps blink 2 times and the doors unlock.
T1 : 0.5 sec,
T2 : 1.0 ± 0.1 sec,
T3 : 30 sec.
Page 46 of 222
3. ALARM Function
(1) When a point of entry is opened while the Anti-Theft System is in the ARM mode, the hazard lamp and horn
alarm will activate (ON/OFF 3 times each) for a period of 27 seconds.
(2) Output intervals for the horn alarm and hazard lamps are identical.
(3) The alarm sequence, when activated will continue for the duration of the alarm period even when the entry
point is closed. (The alarm will reactivate if entry port is reopened after the initial alarm sequence completes.)
T1 : 27 ± 2 sec,
T2 : 10 ± 1 sec,
T3 : 0.5 ± 0.1 sec.
4. New alarm condition during active alarm activation.
(1) If a new alarm condition occurs during the initial alarm sequence, the start inhibitor will remain on and only the
horn alarm will continue. (The alarm will continue even if the point of entry is closed.)
5. Activating RKE UNLOCK during an alarm sequence

(1) If the RKE UNLOCK is activated during an alarm sequence, UNLOCK will output and hazard lamps blink
2 times the anti-theft system will DISARM.
The horn, hazard lamps and start inhibitor will be off.
T1 : 0.5 sec.
Page 47 of 222
6. RKE controlled LOCK during an alarm sequence
(1) When a RKE (Remote Keyless Entry) controlled LOCK occurs during an alarm sequence, but after the
door, that had been broken-in, has been closed the following occurs:
A. All entry points are checked and then LOCK occurs.
B. Horn alarm and start inhibitor are set to off.
C. Hazard lamp blinks once.
D. Anti-Theft system is set to ARM.
(2) When a RKE controlled LOCK occurs during an alarm sequence, but the broken-in door remains opened
the following occurs:
A. All entry points are checked and then LOCK occurs.
B. Horn alarm and start inhibitor are set to off.
(If the door is then closed the hazard lamp will blink once and the Anti-Theft system will ARM)
T1 : 0.5 sec,
T2 : 1.0 ± 0.1 sec.
7. New condition occurs after an alarm.
(1) When all the doors are opened after the doors were closed and locked after an alarm is ON 3 times, the
horn alarm, hazard lamps and start inhibitor will engage again.
T1 : 27 ± 2 sec,
T2 : 10 ± 1 sec,
T3 : 0.5 ± 0.1 sec.
Page 48 of 222
(2) If an alarm occurs due to an open point of entry, and then an unaffected door is opened, the start inhibitor will
remain ON, but the horn alarm will not restart.
T1 : 27 ± 2 sec,
T2 : 10 ± 1 sec,
T3 : 0.5 ± 0.1 sec.
8. Alarm clearance
(1) When choosing LOCK on the RKE (Remote Keyless Entry) either during or after alarm activation, the alarm
is cleared.
(2) When choosing UNLOCK on the RKE either during or after alarm activation, the alarm is cleared.
(3) If the ignition key is turned to ON for 30 seconds either during or after alarm activation the alarm will be
cleared and the start inhibitor reset.
(4) If during an alarm sequence the ignition key is turned ON and then OFF within 30 seconds, the alarm will
continue.
T1 : 30 sec.
Page 49 of 222
9. Battery separation
(1) When the battery is reconnected after having been disconnected/removed while in ARM mode. ARM mode
continues.
(2) When the battery is reconnected after having been disconnected/removed, and after the alarm completes, the
alarm will restart.
(3) When battery is reconnected after having been disconnected/ removed during an active alarm, the alarm
sequence will restart from the beginning.
10. Panic
(1) If panic on the RKE (Remote Keyless Entry) is activated while in ARM mode, alarm activation will be set
to hold for 30 seconds. If during the 30 seconds someone breaks in, panic mode is cleared and the alarm
activates.
(2) When panic on the RKE is activated while in DISARM mode, the horn alarm and hazard lamps will activate
for 30seconds.
(3) If LOCK, UNLOCK, or panic is activated on the RKE control during Steps 1) or 2), panic mode will be
cleared.
(4) When a panic signal is received during or after an alarm, the alarm turns OFF, the start inhibitor is set to
OFF, and panic mode is set to ON.
(5) Panic mode will not start if the ignition key is IN or ON even if a panic signal is received.
(6) Panic mode operates independently from entry points (door, hood, trunk) being opened or closed.
T1 : 27 ± 2 sec,
T2 : 30 ± 1 sec,
T3 : 0.5 ± 0.1 sec(Duty 50%)
Body Electrical System > Keyless Entry And Burglar Alarm > Components and Components Location
COMPONENTS
Page 50 of 222
Body Electrical System > Keyless Entry And Burglar Alarm > Repair procedures
INSPECTION
FRONT DOOR LOCK ACTUATOR INSPECTION
1. Remove the front door trim panel. (Refer to the BD group - front door)
Page 51 of 222
2. Disconnect the 6P 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. (Refer to the BD group - rear door)
TAILGATE LOCK ACTUATOR INSPECTION

1. Remove the tailgate trim panel.(Refer to the BD group - tailgate)
Page 52 of 222
FRONT DOOR LOCK SWITCH INSPECTION

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

Page 53 of 222
TAILGATE LOCK SWITCH INSPECTION

Remove the tailgate trim panel.
1. Remove the tailgate trim panel. (Refer to the BD group - tailgate)
DOOR SWITCH INSPECTION

Remove the door switch and check for continuity between the terminals.
Page 54 of 222
TAILGATE OPEN SWITCH INSPECTION

1. Remove the tailgate trim panel.
2. Remove the tailgate latch after removing 3 bolts and disconnect the 1P connector from the tailgate switch.
3. Check for continuity between the terminals according to the table.
HOOD SWITCH INSPECTION

Page 55 of 222
1. Disconnect the 1P connector from the hood switch.
2. Check for continuity between the terminals and ground according to the table.
KEY WARNING SWITCH INSPECTION

1. Remove the driver's crash pad lower panel. (see BD group-crash pad)
2. Disconnect the 6P connector from the key warning switch.
3. Check for continuity between the terminals in each position according to the table.
BURGLAR HORN INSPECTION

1. Remove the burglar horn after removing 2 bolts and disconnect the 2P connector from the burglar horn.
Page 56 of 222
2. Test the burglar horn by connecting battery power to the terminal 1 and ground the terminal 2.
3. The burglar horn should make a sound. If the burglar horn fails to make a sound replace it.
Body Electrical System > Keyless Entry And Burglar Alarm > Transmitter > Repair procedures
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.
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

Page 57 of 222
1. Connect the DLC cable of hi-scan to the data link connector (16 pins) in driver side crash pad lower panel, turn
the power on hi-scan.
2. Select the vehicle model and then do "CODE SAVING".
3. After selecting "CODE SAVING" menu, button "ENTER" key, then the screen will be shown as below.
4. After removing the ignition key from key cylinder, push "ENTER" key to proceed to the next mode for code
saving. Follow steps 1 to 3 and then code saving is completed.
Body Electrical System > Keyless Entry And Burglar Alarm > Transmitter > Specifications
Page 58 of 222
SPECIFICATIONS
Keyless entry transmitter
Lithium 3V battery (1EA)
Power source
Transmissible distance 10m or more
2 years or more (at 20 times
Life of battery
per day)
Door lock
Button Door unlock
Tailgate open (option) panic
Transmission frequency 315.00 MHz
Body Electrical System > BCM (Body Control Module) > Description and Operation
DESCRIPTION
ETACS module (A) receives various input switch signals
controlling time and alarm functions for the intermittent
wiper timer, washer timer, rear defogger timer, seat belts
warning, delayed out room lamp, central door lock,
ignition key reminder, power window timer, door
warning, tail lamp auto cut, crash door unlock, ignition
key hole illumination, rear fog lamp control and keyless
entry & burglar alarm.
Body Electrical System > BCM (Body Control Module) > Specifications
SPECIFICATIONS
Page 59 of 222
Rated voltage DC 12V
Operating voltage DC 9 ~ 16V
Operating temperature -22°F~176°F(-30°C~ 80°C)
Insulation resistance 100MΩ or more
Less than 6mA (12.8 V) - ETACS
Dark current & Receiver
Less than 4mA (12.8V) - ETACS
Rated load
DC 12V, 3.5A (Inductance load)
Burglar alarm horn
DC 12V, 200mA (Inductance load)
Burglar alarm relay
Horn relay
Tail lamp relay
Front fog lamp relay
Rear defogger relay
Tail gate safety relay
Power window timer relay
DC 12V, 1.4W (Lamp load)
Seat belt warning indicator
DC 12V, 2W (Lamp load)
Key hole illumination lamp
DC 12V, 10W (Lamp load)
Room lamp
Intermittent wiper relay
DC 12V, 25A (Actuator load) :
Central door actuator
5EA
Rear wiper relay
Windshield deicer relay
Door lock relay
Door unlock relay
Hazard lamp relay
Driver door unlock relay
Body Electrical System > BCM (Body Control Module) > ETACS Module > Schematic Diagrams
CIRCUIT DIAGRAM
Page 60 of 222
ETACS CONNECTOR TERMINALS

Page 61 of 222
Terminal
Connector A Connector B Connector C
No.
1 Room lamp Windshield deicer relay Ground
2 IGN 2 - Cluster
Windshield deicer & Rear
3 Wiper relay Key hole illumination
defogger switch
4 Rear wiper relay - Intermittent wiper switch
5 Start inhibit relay Alternator (L) Washer switch
6 Rear defogger relay Speed sensor Intermittent rear wiper switch
7 D.R.L Crash sensor Rear washer switch
8 Tail lamp relay Code saving Tail lamp switch
9 Seat belt indicator - Seat belt switch
10 Hazard lamp relay - Key warning switch
11 Burglar horn relay - Driver door open switch
12 IGN1 - Assist door open switch
13 B+ [For ETACS] - 4 door open switch
14 Driver door unlock switch Intermittent wiper volume Tailgate open switch
15 Assist door unlock switch - Hood switch
16 Rear & Tailgate unlock switch Diagnosis Tailgate door key unlock switch
17 - Parking brake switch
18 Driver door key unlock switch Head lamp switch
19 Door lock switch Front fog lamp switch
20 Assist door key unlock switch -
21 Door unlock switch ACC
22 Power window relay -
23 Door lock relay
24 Door unlock relay
25 -
26 Ground
ETACS MODULE INPUT SIGNAL TEST

Page 62 of 222
Pin
Input signal name Test condition Measured value Ordinary
No.
10V or
A1 Room lamp Door open 1V or less
more
A2 IGN 2 Ignition switch ON Battery voltage 1V or less
Intermittent wiper, washer switch 10V or
A3 Wiper relay 1V or less
ON more
Rear intermittent wiper, washer
A4 Rear wiper relay Battery voltage 1V or less
switch ON
10V or
A5 Start inhibit relay Engine start condition 1V or less
more
Windshield deicer switch & Rear 10V or
A6 Rear defogger relay 1V or less
defogger switch ON more
10V or
A7 D.R.L Tail lamp switch ON 1V or less
more
10V or
A8 Tail lamp relay Tail lamp switch ON 1V or less
more
1V or less / 10V or more
A9 Seat belt indicator Seat belt is unbuckled 1V or less
(1sec period)
1V or less / 10V or more 10V or
A10 Hazard lamp relay Remote control LOCK/UNKOCK
(1sec period) more
A11 Burglar horn relay Remote control LOCK/UNKOCK
(1sec period) more
A12 IGN1 Ignition switch ON Battery voltage 1V or less
A13 B+ [For ETACS] Constant Battery voltage 1V or less
A14 Driver door unlock switch Driver door UNLOCK 5~12V 1V or less
A15 Assist door unlock switch Assist door UNLOCK 5~12V 1V or less
Rear & Tailgate unlock
A16 Rear & Tail gate UNLOCK 5~12V 1V or less
switch
A17 - - - -
Driver door key unlock Driver door key UNLOCK switch
A18 5~12V 1V or less
switch ON
A19 Door lock switch Door LOCK ON 5~12V 1V or less
Assist door key unlock
A20 Assist door key unlock switch ON 5~12V 1V or less
switch
A21 Door unlock switch Door unlock switch ON 5~12V 1V or less
10V or
A22 Power window relay Ignition switch ON 1V or less
more
Remote control & Central door 10V or
A23 Door lock relay 1V or less
LOCK more
Page 63 of 222
Remote control & Central door 10V or
A24 Door unlock relay 1V or less
UNLOCK more
A25 - - - -
A26 Ground Constant 1V or less 1V or less
Windshield deicer & Rear defogger 10V or
B1 Windshield deicer relay 1V or less
switch ON more
B2 - - - -
10V or
B3 Key hole illumination Key hole illumination ON 1V or less
more
B5 Alternator (L) Engine start condition Battery voltage 1V or less
B6 Speed sensor Speed sensor input
(1sec period) more
10V or
B7 Crash sensor Crash sensor signal input 1V or less
more
10V or
B8 Code saving Code saving 1V or less
more
10V or
B14 Intermittent wiper volume Intermittent wiper volume ON 12V→0V
more
10V or
B16 Diagnosis Diagnostic tool signal 1V or less
more
10V or
C1 Ground Constant 1V or less
more
10V or
C2 Cluster Cluster signal input 1V or less
more
Windshield deicer & Rear Windshield deicer & Rear defogger 10V or
C3 1V or less
defogger switch switch ON more
C4 Intermittent wiper switch Intermittent wiper switch ON 10V or more 1V or less
C5 Washer switch Washer switch ON 10V or more 1V or less
Intermittent rear wiper
C6 Intermittent rear wiper switch ON 10V or more 1V or less
switch
C7 Rear washer switch Rear washer switch ON 10V or more 1V or less
C8 Tail lamp switch Tail lamp switch ON 5~12V 1V or less
10V or
C9 Seat belt switch Seat belt is unbuckled 1V or less
more
C10 Key warning switch Key is inserted into the ignition switch 10V or more 1V or less
10V or
C11 Driver door open switch Driver door open 1V or less
more
10V or
C12 Assist door open switch Assist door open 1V or less
more
10V or
C13 4 door open switch 4 door open 1V or less
more
Page 64 of 222
10V or
C14 Tailgate open switch Tailgate open 1V or less
more
10V or
C15 Hood switch Hood open 1V or less
more
Tailgate door key unlock 10V or
C16 Tailgate door key unlock 1V or less
switch more
10V or
C17 Parking brake switch Parking brake switch ON 1V or less
more
10V or
C18 Head lamp switch Head lamp switch ON 1V or less
more
10V or
C19 Front fog lamp switch Front fog lamp switch ON 1V or less
more
C20 - - - -
C21 ACC ACC 10V or more 1V or less
Body Electrical System > BCM (Body Control Module) > ETACS Module > Repair procedures
REPLACEMENT
2. Remove the center facia panel (C) after pulling it by using regular screw driver (-) at part (A). Take care of fixing
clips (B).
3. Remove the connectors.

4. Remove the mounting screws then remove the audio unit (A) assembly.
Page 65 of 222
5. Remove the antenna cable and ETACS module (A) after removing 2 nuts.
INSPECTION
Verify each components operation using related timing charts.
1. TAIL LAMP AUTO CUT
(1) With the tail lamp switched ON, if the ignition.
Is switched OFF and the driver's door opened, the tail lamp should be automatically turned OFF.
(2) With the ignition switch ON, if the driver's door is opened and the ignition is switched to OFF, the tail lamp
should be automatically turned OFF.
(3) When the tail lamp is cut automatically and the tail lamp switch is turned OFF and ON, the tail lamp
illuminates and auto cut function is cancelled.
(4) When the tail lamp is cut automatically and the ignition key is inserted, the tail lamp illuminates and auto cut
function is canceled.
(5) In case of battery disconnection-connection in auto cut mode, preserve auto cut mode.
Page 66 of 222
2. IGNITION KEYHOLE ILLUMINATION
(1) Ignition keyhole illumination is turned ON when the driver or passenger door is opened.
(2) The "ON" state for ignition keyhole illumination is delayed 10 seconds when the door is closed as in step 1).
(3) Ignition keyhole illumination is turned off if the ignition switch is turned ON as in Step 1) & 2).
(4) Ignition keyhole illumination is turned off if ARM state is entered. See steps 1) & 2).
T1 : 10 ± 1 sec,
T2 : 0 ~ 10 sec.
3. DELAYED ROOM LAMP
(1) When the first door (driver, or assist or 4doors) is opened, Room lamp is turned on.
(2) When the door is closed, the room lamp is fade out for 2 seconds after there is on for 30 seconds.
(3) Regardless of IG ON/OFF in door open state, room lamp output is ON.
(4) When remote control UNLOCK is received, room lamp is turned on for 30 seconds.
(5) While room lamp is on due to Remote control unlock, if another Remote control unlock is received, then
room lamp is again on for 30 sec.
(6) During on for 30 seconds, when Remote control LOCK receive (ARM condition) or IG2 is ON,put out
lights after sensitize for 2 seconds.
(7) During ON for 30 seconds, when produce all doors LOCK in driver/Assist/4door close state (But, hood &
tail gate door exception), put out lights after sensitize for 2 seconds.
(8) 30 seconds delay function is suspended when it is door open during 30 seconds delay action regard to
remote control UNLOCK.(Function achievement by sensitization room lamp)
T1 : 5.5 ±1 sec.,
T2 : 30 ±5 sec.,
T3 : 20 ±1 min.
Page 67 of 222
4. CENTRAL DOOR LOCK/UNLOCK
(1) Central door lock/unlock
(2) Installation of the battery should not change the state of the locks. (Knob is LOCK state, do not produce
LOCK output even if connect battery despite UNLOCK state,)
(3) Signals of duration less than 60 milliseconds will be ignored.
(4) When UNLOCK is input during LOCK output, the LOCK output stops immediately and the UNLOCK
output continues. (Vice versa)
(5) When the LOCK/UNLOCK signal is received by the remote control, the LOCK/UNLOCK output
continues for 0.5 seconds.
(6) When the hazard lamp is on during the LOCK/UNLOCK by the remote control, the LOCK/UNLOCK
signal by the remote control shall be ignored.
T1,2 : 0.5 ±0.1 sec.

Page 68 of 222
5. CRASH DOOR UNLOCK
(1) If IG1 is on and a crash signal is received, send an unlock pulse to the door locks.
(2) This function is prior in all door lock functions.
(3) If door lock switch is locked in door lock switch is unlocked state, after the first crash unlock output, issue
unlock pulse for again 5 sec.
(4) Only one crash unlock can occur during one ignition on cycle.
T1 : 0.2 ± 0.02 sec.,

T2 : 0.04 sec.,
T3 : 5 ± 0.5sec.
6. IGNITION KEY REMINDER
(1) If the key is in the ignition and the driver's door or assist door is open and the vehicle is locked using driver's
knob or assist knob, then the central locking system will issue an unlock pulse of duration 1 second to the all
doors, thus preventing locking of the vehicle.
(2) If a Knob remains locked, then the central locking shall issue a maximum of 3 pulses of 0.5 second duration
to unlock the vehicle. If during these pulses, the door lock knob becomes unlocked, stop the next pulse.
(3) If during the 3 pulses door is closed or the key is removed, stop the next pulse.
(4) If after the 3 unlock pulses the knob remains in the locked state, the condition is remembered. 1sec unlock
(reset) pulse is issued if there is a change in any of the following inputs: Door warning switch, driver door
switch, assist door switch, driver door lock switch, assist door lock switch.
(5) If a door is open and locked and a key is inserted, issue one unlock pulse of duration 1 sec. (At KEY is
inserted after driver seat unlock in 2 turn UNLOCK vehicle, no issue one unlock pulse)
(6) When Door is closed in 0.5 seconds after LOCK, an unlock pulse of duration 1sec shall be issued.
(7) When is Power window main switch LOCK, issue one unlock pulse immediately after 0.5 second LOCK. (
Key warning switch = Keyless switch)
(8) To further prevent locking of keys in ignition, a guard time of 0.5 seconds is introduced after a door is closed.
When key is in ignition and the door changes from open to close and a lock occurs within 0.5 sec, an unlock
pulse of duration 1 sec shall be issued.
Page 69 of 222
(9) If door warning switch is off and ignition input is on then ignition key reminder function is disabled. (If vehicle
speed is greater than 3 km/h, ignition key reminder function is disabled.)
T1 : MAX 0.1 sec.,

T2 : 1.0 sec.,
T3 : 0 sec. < T3 < 0.5 sec.
T4 : 0.5 sec.
7. SEAT BELT WARNING TIMER
(1) When the ignition is switched ON, the seat belt warning indicator will illuminate (period: 1.0 sec., duty rate:
50%) and the chime bell will sound (period: 1.0 sec., duty rate: 50%) for total of 6 seconds.
(2) If the ignition is switched off while the seat belt warning indicator and chime bell are active (Step 1) the
indicator and chime bell will be switched OFF. If the seat belt is sensed as fastened during indicator and
chime bell output, the chime bell will switch OFF however the seat belt warning indicator will stay illuminated
for the remaining seconds.
(3) If the seat belt is removed, with the ignition switched ON, the seat belt warning indicator and chime bell will
activate for 6 seconds.
T1 : 6 ± 1 sec.,
T2 : 0.5 ± 0.1 sec (ON TIME).,
T3 : 0.3 ± 0.1 sec. (ON,OFF TIME)
Page 70 of 222
8. KEY OPERATED WARNING
(1) If the key is in the ignition and the driver's door is opened, the buzzer is sounded (period: 1.0 sec., duty rate:
50%).
(2) If the ignition key is removed, or the door is closed, the buzzer is switched OFF immediately.
T1,T2 : 0.5±0.1sec.
9. WINDSHIELD DEICER & REAR DEFOGGER TIMER
(1) Once ALT "L" is ON, if the defogger is switched ON, the defogger will stay ON for 20 minutes duration.
(2) If defogger switch is pressed again (See step 1), or if ignition is switched OFF, the defogger will shut OFF.
T1 : 0.06 ± 0.01 sec.,

T2 : 20 ± 1 min.
10. POWER WINDOW TIMER
(1) When the ignition is switched OFF, power window output remains ON for 30 seconds and then turns OFF.
(2) Related to step 1), if the driver's door or assist door is opened, window power output is turned OFF
immediately.
(3) When the driver's door or assist door is opened, the power window relay output is turned OFF
immediately.
T1 : 30 ± 3 sec.
Page 71 of 222
11. REAR WIPER AND WASHER
(1) If rear washer switch is turned on while the ignition switch is ON, rear wiper output will turn ON after 0.3
sec.
(2) If rear washer switch is turned OFF, rear wiper output remains ON for up to 3.8 sec.(T2).
T1 : 0.3
T2 : 2.5 ~ 3.8 sec.
(3) When the ignition switch is ON, if the intermittent rear wiper switch is turned ON, rear wiper output will
remain ON for up to 0.7 sec. (T3).
T3 : 0.7 ± 0.1sec.,
T4 : 5 ± 0.5sec.
12. WIPER RELATED TO WASHER
(1) When the ignition switch is turned ON:
A. If washer switch is turned on, wiper output is ON after 0.3 sec. (T5)
B. If washer switch is turned OFF, wiper output is OFF after 3.8 sec. (T6)
Page 72 of 222
(2) If the washer switch is turned OFF within 0.6 sec.(T2) of the ignition switch the wiper will remain ON for
up to 0.7 sec.(T3) from the moment that washer switch is turned OFF.
T1 : Less than 0.2 sec.

T2 : 0.2 ~0.6 sec. (MIST Function)
T3 : 0.7 ± 0.1sec.
T4 : More than 0.6 sec.
T5 : 0.3sec.
T6 : 2.5 ~3.8 sec.
13. VARIABLE INTERMITTENT WIPER (WINDSHIELD WIPER)
(1) With the ignition switch ON, if the intermittent wiper switch is turned on, wiper output is ON according to
the setting.
(2) When the intermittent wiper switch is ON, if the ignition switch is turned ON , wiper output is ON.
T1 : MAX 0.5 sec.,

T2 : 0.7 ± 0.1sec.,
T3 : 2.6 ± 0.7 sec. (FAST),
T3 : 18.0 ± 1.0sec. (SLOW) Car speed 0 Km
14. KEY REMOVE DOOR UNLOCK
Issue on door unlock pulse in case is locked state between all door at KEY separation after IGN SW OFF.
T1: 0.5 ± 0.5sec.

Page 73 of 222
15. PARKING START WARNING
(1) When Ignition 2 is on and the park brake switch is on, if the vehicle speed is greater than 10km/h, then the
chime buzzer is activated within 2 - 3 sec at a period of 1sec.
(2) While execute 2) clause in following case, output does OFF immediately.
A. If the vehicle speed falls below 10km/h the chime buzzer is deactivated.
B. If the park brake switch is off, the chime buzzer is deactivated.
T1 : 2.5 ± 0.5 sec.

T2 : 1.0 ± 0.1 sec.
16. 2-TURN UNLOCK
(1) When driver / assist key unlock signal is recived, only driver door/assist door unlock pulse are issued, if
remote control unlock signal is received, only driver door pulse is issued.
(2) After 2) clauses action, when re-input by driver or assist key unlock or remote control unlock signal within
T2 all door unlock pulse is issued.
(3) When unlock signal re-inputs ater T2 after 2) clauses acton, do only driver door unlock pulse are
issued.(When door is inputed unlock signal in unlock state, no again unlock pulse is issued.
(4) When remote control signal is again received in driver unlock & harzard pulse is issuing by remote control
unlock, all door unlock pulse issued and hazard pulse is issued 2 th.
(5) When input again remote unlock signal in 4 sec after driver unlock output & hazard output by unlock, all
door unlock & hazard pulse is issued 2 th.
T1 : 0.5±0.1S
T2 : Less than 4 sec
T3 : More than 4 sec
Page 74 of 222
17. HORN ANSWER BACK
(1) In the lock (arm state) state by transmitter lock, when received again transmitter lock signal within 4 sec
after receive finally transmitter lock signal, horn pulse (30ms) is issued.
T1 : 0.5 ± 0.1 sec

T2 : 1.0 ± 0.1 sec
T3 : 30ms sec ± 5 ms
T4 : Less than 4 sec
T5 : More than 4 sec
Body Electrical System > Seat Electrical > Components and Components Location
COMPONENTS
Body Electrical System > Seat Electrical > Seat Heater Switch > Repair procedures
INSPECTION
Page 75 of 222
2. Remove the seat warmer switch from the floor console upper cover with scraper (A).
SEAT WARMER INSPECTION

1. Check for continuity and measure the resistance between No.1 and NO.3 terminals.
Standard value: 2.34Ω ± 10%

(Cushion: 1.19Ω ± 10%, Back: 1.15Ω ± 10%)
Page 76 of 222
2. Operate the seat warmer after connecting the 2P connector, and then check for the thermostat by measuring the
temperature of seat surface.
3. Check for continuity between the terminals after disconnecting the 3P connector.
Standard value :
28 ±3.5°C(Continuity), 37 ±3.0°C(Short)
Body Electrical System > Fuses And Relays > Components and Components Location
COMPONENTS
Page 77 of 222
Page 78 of 222
Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Components and
Components Location
COMPONENT
Page 79 of 222
Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Repair procedures
INSPECTION
POWER RELAY TEST (TYPE A)
Check for continuity between the terminals.
Page 80 of 222
POWER RELAY TEST (TYPE B)

2. There should be no continuity between the No.30 and No.87A terminals when power is disconnected.
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?
Page 81 of 222
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
first and completely eliminate the problem before installing a new fuse.
Body Electrical System > Fuses And Relays > Relay Box (Passenger Compartment) > Components
and Components Location
COMPONENTS
Page 82 of 222
Body Electrical System > Fuses And Relays > Relay Box (Passenger Compartment) > Repair
procedures
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?
Page 83 of 222
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
first and completely eliminate the problem before installing a new fuse.
ICM (Integrated circuit module) RELAY
The ICM is united with many kinds of relay and installed at the below the relay box(passenger compartment).
ICM (Integrated circuit module) RELAY TEST

DOOR LOCK RELAY
the No.17 and No.20 in the M37-1 terminals.
DOOR UNLOCK RELAY
1. There should be continuity between the No.17 and No18 terminals when power and ground are connected to the
No.17 and No.5 in the M37-1 terminal.
BURGLAR ALARM
1. There should be continuity between the No.7 and No.9 terminals when power and ground are connected to the
No.7 and No.8 in the M37-2 terminals.
BURGLAR ALARM HORN
No.6 and No.1 in the M37-2 terminals.
Body Electrical System > Indicators And Gauges > Components and Components Location
COMPONENTS
Page 84 of 222
Body Electrical System > Indicators And Gauges > Instrument Cluster > Schematic Diagrams
CIRCUIT DIAGRAM
[email protected]
Page 85 of 222
Body Electrical System > Indicators And Gauges > Instrument Cluster > Components and Components
Location
COMPONENTS
Page 86 of 222
Body Electrical System > Indicators And Gauges > Instrument Cluster > Repair procedures
REPLACEMENT
2. Remove the cluster facia panel (A) after removing 2 screws.
[email protected]
Page 87 of 222
3. Remove the trip switch connector.
4. Remove the cluster (A) from the housing after removing 4 screws.
5. Remove the cluster connecter (A) and the cluster (B).
INSPECTION
SPEEDOMETER
1. Adjust the pressure of the tires to the specified level.
Page 88 of 222
2. 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.
Velocity
20 40 60 80 100
(km/h)
Tolerance +4.0 +4.0 +4.6 +5.2 +6.2
(km/h) +0.0 +0.0 +0.6 +1.2 +2.2
Velocity
120 140 160 180 200
(km/h)
Tolerance +7.0 +8.0 +9.0 +10.0 +11.0
(km/h) +2.4 +3.4 +4.4 +5.0 +6.0
Velocity
10 20 40 60
(MPH)
Tolerance +3.0 +3.0 +3.0 +3.8
(MPH) +0.0 +0.0 +0.0 +0.8
Velocity
80 100 120
(MPH)
Tolerance +4.8 +5.6 +6.6
(MPH) +1.2 +2.0 +3.0
VEHICLE SPEED SENSOR

1. Connect the positive (+) lead from battery to terminal 3 and negative (-) lead to terminal 1.
2. Connect the positive (+) lead from tester to terminal 2 and the negative (-) lead to terminal 1.
3. Rotate the shaft.
4. Check that there is voltage change from approx. 0V to 11V or more between terminals 1 and 2.
5. The voltage change should be 4 times for every revolution of the speed sensor shaft.
If operation is not as specified, replace the sensor.
TACHOMETER
1. Connect the scan tool to the diagnostic link connector or install a tachometer.
[email protected]
Page 89 of 222
2. With the engine started, compare the readings of the tester with that of the tachometer. Replace the tachometer if
the tolerance is exceeded.
• Reversing the connections of the tachometer will damage the transistor and diodes inside.
• When removing or installing the tachometer, be careful not to drop it or subject it to severe shock.
Revolution(rpm) 1,000 2,000 3,000 4,000

Tolerance(rpm) ±100 ±125 ±150 ±150
Revolution(rpm) 5,000 6,000 7,000
Tolerance(rpm) ±150 ±180 ±210
FUEL GAUGE
1. Disconnect the fuel sender connector from the fuel sender.
2. Connect a 3.4 wattages, 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
1. Using an ohmmeter, measure the resistance between terminals 5 and 6 at each float level.
2. Also check that the resistance changes smoothly when the float is moved from "E" to "F".
Position Resistance(Ω)
Sender (E) 104.8 ± 1
Warning lamp 89.9 ± 1
1/2 13.7 ± 1
Sender (F) 4.2 ± 1
Page 90 of 222
3. If the height 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.
SUCTION FUEL GAUGE SENDER
1. Using an ohmmeter, measure the resistance between terminals 1 and 2 of SUB sender connector (A) at each
float level.
2. Also check that the resistance changes smoothly when the float is moved from "E" to "F".
Position Resistance(Ω)
Sender (E) 95.2 ± 1
1/2 90.2 ± 1
Sender (F) 3.8 ± 1
3. If the height resistance is unsatisfied, replace the fuel sender as an assembly.

ENGINE COOLANT TEMPERATURE GAUGE
1. Disconnect the wiring connector (A) 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 wattages 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 specified, replace the
engine coolant temperature gauge. Then recheck the system.
ENGINE COOLANT TEMPERATURE SENDER

1. Using an ohmmeter, measure the resistance between the terminal 2 of sender connector and ground.
[email protected]
Page 91 of 222
2. If the resistance value is not as shown in the table, replace the temperature sender.
Temperature (°C) 49 71 Engine
Gauge angle (° ) -23 -1 ± 2 -
Resistance (Ω) 128 53.8 Gasoline
Temperature (°C) 110 127.4 Engine
Gauge angle (° ) 1±2 23 ± 5 -
Resistance (Ω) 16.1 14.1 Gasoline
OIL PRESSURE SWITCH

1. Check that there is continuity between the oil press switch terminal (A) 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.
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.
Page 92 of 222
5. Verify that the warning lamp lights.
PARKING BRAKE SWITCH

The parking brake switch (A) is a pulling type. It is 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 body with 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.
SEAT BELT SWITCH

1. Remove the connector from the switch.
[email protected]
Page 93 of 222
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 94 of 222
Body Electrical System > Power Door Locks > Power Door Lock Actuators > Repair procedures
INSPECTION
FRONT DOOR LOCK ACTUATOR INSPECTION
1. Remove the front door trim panel. (Refer to the BD group-front door)
[email protected]
Page 95 of 222
REAR DOOR LOCK ACTUATOR INSPECTION

1. Remove the rear door trim panel. (see BD group-rear door)
TAILGATE LOCK ACTUATOR INSPECTION

1. Remove the tailgate trim panel. (see BD group-tailgate)
Page 96 of 222
FRONT DOOR LOCK SWITCH INSPECTION

REAR DOOR LOCK SWITCH INSPECTION

[email protected]
Page 97 of 222
TAILGATE LOCK SWITCH INSPECTION

1. Remove the tailgate trim panel. (see BD group - tailgate)
Body Electrical System > Power Door Locks > Power Door Lock Relay > Repair procedures
INSPECTION
1. Remove the negative (-) battery terminal.
2. Remove the driver side crash pad lower panel.
Page 98 of 222
3. Remove the ICM relay box (A) after loosening 2 mounting nuts and removing 3 connectors under the junction
box(Passenger compartment).
4. Check for continuity between the terminals.

DOOR LOCK
DOOR UNLOCK
Body Electrical System > Power Door Locks > Power Door Lock Switch > Repair procedures
INSPECTION
DRIVER'S DOOR LOCK SWITCH INSPECTION
2. Remove the power window switch module by pressing fixing clip part (B) with scraper (A).
[email protected]
Page 99 of 222
ASSIST DOOR LOCK SWITCH INSPECTION

Page 100 of 222
Body Electrical System > Power Door Mirrors > Components and Components Location
COMPONENTS
Body Electrical System > Power Door Mirrors > Power Out Side Mirror Switch > Schematic Diagrams
CIRCUIT DIAGRAM
[email protected]
Page 101 of 222
Body Electrical System > Power Door Mirrors > Power Out Side Mirror Switch > Repair procedures
INSPECTION
Page 102 of 222
Body Electrical System > Power Door Mirrors > Power Door Mirror Actuator > Repair procedures
INSPECTION
1. Disconnect the power door mirror connector from the harness.
[email protected]
Page 103 of 222
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
Page 104 of 222
Body Electrical System > Power Windows > Power Window Motor > Repair procedures
INSPECTION
FRONT POWER WINDOW MOTOR INSPECTION
1. Remove the front door trim panel. (Refer to the BD group-front door)
[email protected]
Page 105 of 222
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

1. Remove the rear door trim panel. (Refer to the BD group-rear door)
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.
Page 106 of 222
Body Electrical System > Power Windows > Power Window Switch > Schematic Diagrams
CIRCUIT DIAGRAM
[email protected]
Page 107 of 222
Body Electrical System > Power Windows > Power Window Switch > Repair procedures
INSPECTION
POWER WINDOW MAIN SWITCH INSPECTION
Page 108 of 222
3. Check for continuity between the terminals. If the continuity condition is not normal, replace the switch.
POWER WINDOW LOCK SWITCH
ASSIST POWER WINDOW SWITCH

[email protected]
Page 109 of 222
3. Check for continuity between the terminals. If the continuity condition is not normal, replace the switch.
[WITHOUT DOOR LOCK SWITCH]
[WITH DOOR LOCK SWITCH]
REAR POWER WINDOW SWITCH INSPECTION

Page 110 of 222
Body Electrical System > Power Windows > Power Window Relay > Repair procedures
INSPECTION
2. Remove the junction box.
4. There should be continuity between the No.1 in the I/P-J terminal and No.12 or 13 in the I/P-F terminal when
power and ground are connected to the No.1 in the I/P-J terminal and No.12 in the I/P-C terminal.
[email protected]
Page 111 of 222
5. There should be no continuity between the No.1 in the I/P-J terminal and No.12 or 13 in the I/P-F terminal when
power is disconnected.
Body Electrical System > Windshield Deicer > Components and Components Location
COMPONENTS
Windshield glass deicer system prevent windshield wiper from freezing in the winter season. It consists of deicer in
the lower part of windshield glass, switch and relay. ETACS module receives an input signal from the deicer switch,
then controls relay. Operating condition is the same that of rear window defogger system.
Since the alternator "L" is switched ON, if the deicer switch is ON, then deicer output is ON for 20 minutes.
Page 112 of 222
Body Electrical System > Windshield Deicer > Windshield Deicer > Repair procedures
INSPECTION
1. Remove the cowl top cover.(Refer to wiper)
[email protected]
Page 113 of 222
2. Disconnect the windshield glass deicer connector (A) from the wiper motor linkage.
3. Check for continuity between the terminals of deicer lines.
4. Turn the ignition switch ON and the windshield deicer switch ON, then measure the voltage between the
terminals of harness side deicer connector.
O K : approx. Battery voltage
Body Electrical System > Windshield Deicer > Windshield Deicer Switch > Repair procedures
INSPECTION
Page 114 of 222
2. Remove the center facia panel (C) by pressing hole of part (A) with driver. Take care of fixing clip (B).
3. Disconnect the connectors.

4. Using an ohmmeter, inspection the continuity between the terminals after removing to the switch connector.
Body Electrical System > Windshield Deicer > Windshield Deicer Timer > Repair procedures
INSPECTION
1. Once ALT "L" is ON, if the defogger is switched ON, the defogger will stay ON for 20 minutes duration.
2. If defogger switch is pressed again (See step 1), or if ignition is switched OFF, the defogger will shut OFF.
T1 : 0.06 ± 0.01 sec.,

T2 : 20 ± 1 min.
[email protected]
Page 115 of 222
Body Electrical System > Windshield Deicer > Windshield Deicer Relay > Repair procedures
INSPECTION
2. Remove the windshield deicer relay (A) from the engine room relay box.
INSPECTION
2. If defogger switch is pressed again (see Step 1), or if ignition is switched OFF, the defogger will shut OFF.
T1 : 0.06 ± 0.01 sec.,

T2 : 20 ± 1 min.
Body Electrical System > Rear Glass Defogger > Components and Components Location
COMPONENTS
Page 116 of 222
Body Electrical System > Rear Glass Defogger > Rear Glass Defogger Printed Heater > Repair
procedures
INSPECTION
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.
[email protected]
Page 117 of 222
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.
Page 118 of 222
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).
[email protected]
Page 119 of 222
Body Electrical System > Rear Glass Defogger > Rear Glass Defogger Switch > Repair procedures
INSPECTION
2. Remove the center facia panel (C) after pulling it by using regular screw driver(-) at part (A). Take care of fixing
clips (B).
3. Disconnect the connectors.

4. Using an ohmmeter, inspection the continuity between the terminals after removing to the switch connector.
Body Electrical System > Rear Glass Defogger > Rear Glass Defogger Relay > Repair procedures
INSPECTION
4. There should be continuity between the No.1 in the I/P-J terminal and No.7 in the I/P-F terminal when power
and ground are connected to the No.14 in the I/P-D terminal and No.7 in the I/P-C terminal.
Page 120 of 222
5. There should be no continuity between the No.1 in the I/P-J terminal and No.7 in the I/P-F terminal when power
is disconnected.
Body Electrical System > Rear Glass Defogger > Rear Glass Defogger Timer > Repair procedures
INSPECTION
2. If defogger switch is pressed again (See step 1), or if ignition is switched OFF, the defogger will shut OFF.
T1 : 0.06 ± 0.01 sec.,

T2 : 20 ± 1 min.
Body Electrical System > Windshield Wiper/Washer > Components and Components Location
COMPONENT
[email protected]
Page 121 of 222
Body Electrical System > Windshield Wiper/Washer > Windshield Wiper-Washer Switch > Repair
procedures
REPLACEMENT
Page 122 of 222
1. Remove the steering column upper and lower shrouds (A) after removing 3 screws.
2. Remove the wiper switch (B) after loosening its 2 screws and connector (A).
INSPECTION
Check for continuity between the terminals while operating the wiper and washer switch. If it is not normal condition,
replace wiper and wiper switch.
WIPER SWITCH
[email protected]
Page 123 of 222
WASHER SWITCH
Body Electrical System > Windshield Wiper/Washer > Front Wiper Motor > Components and
Components Location
COMPONENTS
Page 124 of 222
Body Electrical System > Windshield Wiper/Washer > Front Wiper Motor > Repair procedures
REMOVAL
[email protected]
Page 125 of 222
1. Remove the windshield wiper arm and blade after removing a nut (A).
TORQUE :
28~33 Nm (2.8~3.3 kgf.m,20~23.8 lbf.ft)
2. Remove the weather strip then remove the cowl top cover (A) after removing 3 clips (B).
3. Remove the windshield wiper motor and linkage assembly after removing 2 bolts and a nut. Disconnect the wiper
motor connector (A) and windshield deicer connector (B) from the wiper motor & linkage assembly.
TORQUE :
7~11Nm (0.7~1.1kgf.m, 5.1~8.1 lbf.ft)
INSTALLATION
Page 126 of 222
1. Install the wiper arm and blade to the specified position.
Specified
A B
position
Distance 1.26 ± 0.2 1.26 ± 0.2
[in (mm)] (32 ± 5) (32 ± 5)
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 4 and the negative (-) lead to terminal 1.
3. Check that the motor operates at low speed.
4. Connect the positive (+) lead from the battery to terminal 5 and the negative (-) lead to terminal 1.
5. Check that the motor operates at high speed.
[email protected]
Page 127 of 222
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 4
3. Connect terminals 4 and 2.
5. Check that the motor stops running at the off position.
Body Electrical System > Windshield Wiper/Washer > Front Washer Motor > Repair procedures
REPLACEMENT
2. Remove the front bumper cover. (Refer to BD group - Front bumper)
3. Remove the washer hose and the washer motor connector (A).
4. Remove the washer reservoir after removing 2 bolts.
INSPECTION
1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water.
2. Connect positive (+) battery cables to terminal 2 and negative (-) battery cables to terminal 1 respectively.
3. Check that the motor operates normally and the washer motor runs and water sprays from the front nozzles.
Page 128 of 222
4. If they are abnormal, replace the washer motor.
Body Electrical System > Rear Wiper/Washer > Components and Components Location
COMPONENT
[email protected]
Page 129 of 222
Body Electrical System > Rear Wiper/Washer > Rear Wiper Motor > Repair procedures
REMOVAL
Page 130 of 222
1. Detach the wiper cap (A), then remove the rear wiper arm after removing a nut (B).
Tightening torque Nut(B) :

14~17 Nm (1.4~1.7 kgf.m, 10.1~12.3 lbf.ft)
2. Remove the handle (B) after removing a nut (A).
Tightening torque Nut (A) :

10~13 Nm (1.0~1.3 kgf.m, 7.2~9.4 lbf.ft)
3. Open the tailgate glass then remove the rear wiper motor cover (A).
4. Disconnect the rear wiper motor connector then remove the rear wiper motor (B) after removing 3 nuts.
Tightening torque Nut :

14~17 Nm (1.4~1.7 kgf.m, 10.1~12.3 lbf.ft)
INSTALLATION [email protected]
Page 131 of 222
1. Install the rear wiper arm and blade to the specified position.
Specified position A
Distance 19 ± 5 mm
Specified position : The first deicer line from bottom of the rear window.
2. Set the rear washer nozzle on the specified spray position.
INSPECTION
1. Remove the 4P connector from the rear wiper motor.
2. Connect battery positive (+) and negative (-) cables to terminals 3 and 4 respectively.
3. Check that the motor operates normally. Replace the motor if it operates abnormally.
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 3.
3. Connect terminals 2 and 3.
Page 132 of 222
5. Check that the motor stops running at the off position.
Body Electrical System > Rear Wiper/Washer > Rear Washer Switch > Repair procedures
INSPECTION
With the rear wiper & washer switch in each position, make sure that continuity exists between the terminals below.
If continuity is not as specified, replace the multifunction switch.
REAR WIPER & WASHER SWITCH
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. Remove the front bumper cover. (Refer to the BD group- Front bumper cover)
3. Connect positive (+) and negative (-) battery cables to terminals 3 and 1 respectively to see that the washer
motor runs and water is pumped. [email protected]
Page 133 of 222
4. Check that the motor operates normally.
Replace the motor if it operates abnormally.
Body Electrical System > Electro chromic Inside Rear View Mirror > Description and Operation
DESCRIPTION
The ECM (Electro Chromic inside rear view Mirror) is for dimming the reflecting light from a vehicle behind at night.
The front looking sensor detects brightness of the surroundings, while the rearward looking sensor the strength of the
reflecting light so that adjusts the reflexibility of the mirror in the range of 10~70%. But, when the reverse gear is
engaged, it stops functioning.
Page 134 of 222
1. The front looking sensor sees if the brightness of the surroundings is low enough for the mirror to operate its
function.
2. The rearward looking sensor detects glaring of the reflecting light from a vehicle behind.
3. The ECM is darkened to the level as determined by the rearward looking sensor. When the glaring is no longer
detected, the mirror stops functioning.
COMPASS MIRROR
FUNCTION OF THE COMPASS MIRROR
1. Push the 'COMP' button lower of the rear view mirror to turn on the function of the compass mirror so that
displays a sign of a direction on the small board in the upper-right side of the mirror.
2. Push the 'COMP' button again to turn off its function.
Calibration procedure
If the compass has been calibrated or set to variance zone number incorrectly, or you are driving in specific places
(tunnel, parking lot in building, underground parking lot, near transformer substation, etc.), some phenomenon is
occur as follows:
• The display read "C".
• The compass headings become inaccurate.
• The compass heading is not changed.
• Some compass headings are not displayed.
• The compass headings are inaccurate in long distance driving.
This compass automatically calibrates itself while the vehicle is driven as your route takes you in complete circles..
If the vehicle's compass headings become inaccurate continuously, the compass should be manually calibrated as
[email protected]
Page 135 of 222
follows:
1. Move the vehicle from the large steel structure or electric power supply cable.
2. Turn on the compass by pressing the COMP button.
3. Check the zone number by pressing the COMP button for more than 4 seconds until the current zone number
appears in the display.
To re-calibrate, hold the COMP button for 3 seconds until C is displayed. If the zone number is different for your
country, set the correct zone number referring to "Setting the compass zone" and do the "Calibration procedure"
again.
4. Drive your vehicle in at least 2 circles at less than 5 miles per hour (8 km/h) until the compass heading appears.
Driving in a circle in right-handed direction and opposite direction are possible and if possible, stop the wiper
operation.
5. If the vehicle's compass headings become inaccurate as before, do the following procedure again.
If new vehicle is first driven or if the battery has been disconnected, do the calibration procedure as
above.
Setting the compass zone
This compass must be set to compensate for the variation between true north and magnetic north. To set variation:
1. Find your current location and variance zone number on the zone map.
2. Press the COMP button for more than 4 seconds. The current zone number will appear in the display.
3. Release and press the COMP button until the new zone number appears in the display. After you stop pressing the
button in, the display will show a compass direction within a few seconds.
Page 136 of 222
1. Do not install the ski rack, antenna, etc. which are attached to the vehicle by means of a magnet. They
affect the operation of the compass
2. If the compass deviates from the correct indication soon after repeated adjustment, have the compass
checked at an authorized dealer.
3. The compass may not indicate the correct compass point in tunnels or while driving up or down a steep hill.
(The compass returns to the correct compass point when the vehicle moves to an area where the
geomagnetism is stabilized.)
Body Electrical System > Electro chromic Inside Rear View Mirror > Repair procedures
INSPECTION
Check it by the procedure below to see if the function of the ECM is normal.
1. Turn the ignition key to the "ON" position.
2. Cover the front looking sensor to stop functioning.
[email protected]
Page 137 of 222
3. Head a light to the rearward looking sensor.
4. The ECM should be darkened as soon as the rearward looking sensor detects the light.
If this test is performed in daytime, the ECM may be darkened as soon as the front looking sensor is
covered.
5. When the reverse gear is engaged, the ECM should not be darkened
6. When heading lights to both the front looking and rearward looking sensors, the ECM should not be darkened.
Body Electrical System > Sun Roof > Schematic Diagrams

CIRCUIT DIAGRAM
Body Electrical System > Sun Roof > Components and Components Location
COMPONENTS
Page 138 of 222
Body Electrical System > Sun Roof > Sunroof Assembly > Components and Components Location
COMPONENTS
[email protected]
Page 139 of 222
Body Electrical System > Sun Roof > Sunroof Assembly > Repair procedures
REPLACEMENT
Put on gloves to protect your hands.

GLASS REPLACEMENT
1. Close the glass fully and slide the sunshade all the way back.
Page 140 of 222
2. Remove both decoration covers (A).
3. Remove the glass (A) by lifting it up.
Do not damage the roof panel.
4. Installation is the reverse of removal, and adjust the glass height alignment. Check for water leaks.
Do not use high-pressure water.
MOTOR AND CONTROLLER REPLACEMENT
1. Remove the over head console.
2. Disconnect the motor connector (A), remove the screws and then remove the motor (B).
[email protected]
Page 141 of 222
DEFLECTOR REPLACEMENT
1. Open the glass fully.
2. Disconnect the deflector link (A) from the frame (B), and then remove the deflector (C).
SUNROOF ASSEMBLY REPLACEMENT

1. Remove the follows parts;
A. Front and rear door scuff trim.
B. Front, center and rear pillar trim.
C. Headlining.
D. Assist handle bracket.
E. Sunroof glass.
2. Disconnect the drain tubes (A).
Page 142 of 222
3. After loosening the mounting bolts and nuts, remove the sunroof assembly (B).
Take care not to scratch the interior trims and other parts.
4. Installation is the revers of removal.
SUNSHADE AND DRIP RAIL REPLACEMENT

1. Remove the sunroof assembly.
2. Remove the drip link (A) and sunshade stopper (B).
3. Remove the sunshade (C) and drip rail (D).
[email protected]
Page 143 of 222
GUIDE ASSEMBLY REPLACEMENT

1. Remove the sunroof assembly.
2. Remove a guide assembly (A) after lowering a guide thoroughly by pushing a slide (B) to rear.
Page 144 of 222
3. Remove the guide (A) and slide (B).
- Make sure to align the slide with the center of "A" and
"B".
- Make sure to mitialize the motor.
Adjustment
How to initialize motor
1. Completely close the sunroof press and hold the CLOSE button for more 5 seconds.
[email protected]
Page 145 of 222
2. Release the CLOSE button press the TILT UP button until the sunroof has tilted up completely. Release the
TILT UP button.
3. Press and hold the TILT UP button. The sunroof should briefly raise above, then return to, the maximum TILT
UP position.
4. Release the TILT UP button.
MOTOR INITIALIZATION IS REQUIRED WHEN
1. First operation the vehicle after maunfacture it.
2. Initial value is erased or damaged because of electrical circuit malfuntion, battery disconnect, or battry discharge.
3. After opening the sunroof manually.
OPERATING THE SUNROOF EMERGENCY HANDLE
1. Use the sunroof emergency handle to close and open the sunroof manually for the following case only:
A. To close the sunroof before driving a vehicle in a rainy day or on the highway if the sunroof cannot be closed
due to failure of the sunroof motor or controller.
Page 146 of 222
2. Operating method
A. Remove the overhead console.
B. Push the emergency handle up into the hexagonal drive (A) of the sunroof motor. You must push hard enough
to disengage the motor clutch; otherwise the emergency handle will slip due to uncompletely fit in the motor.
C. Carefully turn the emergency handle clockwise to close the sunroof.
D. After closing the sunroof, wiggle the handle back and forth as you remove the tool from the motor, to ensure
the motor clutch reengages.
E. A 5mm hex socket may be used in place of the emergency handle, with a "Speeder" type handle.
Do not use power tools to operate the sunroof.

Damage to the components may occur.
Body Electrical System > Sun Roof > Sunroof Switch > Repair procedures
INSPECTION
2. Remove the lens from the overhead console then loose the 2 screws holding the overhead console.
[email protected]
Page 147 of 222
3. Disconnect the connector (6P) of sunroof switch and the connector (2P) of map lamp then remove the overhead
console lamp assembly from the headliner. Check for continuity between the terminals. If the continuity is not as
specified, replace the sunroof switch.
Body Electrical System > Sun Roof > Sunroof Motor > Repair procedures
REPLACEMENT
console lamp assembly from the headliner.
Page 148 of 222
4. Remove the sunroof motor (A) after removing 3 screws and disconnect.
INSPECTION
2. Apply the battery voltage to terminal 3, 6 and ground the terminal 1.
3. Ground the terminals as below table, and check that the sunroof unit operates as below table.
RESETTING THE SUNROOF

Whenever the vehicle battery is disconnected or discharged, or you use the emergency handle to operate the
sunroof, you have to reset your sunroof system as follows:.
1. Turn the ignition key to the ON position.
2. According to the position of the sunroof, do as follows.
(1) In case that the sunroof has closed completely or been tilted :
Press the TILT UP button until the sunroof has tilted upward completely.
(2) In case that the sunroof has slide-opened:
Press and hold the CLOSE button for more than 5 seconds until the sunroof has closed completely.
Press and hold the CLOSE button for more than 5 seconds after the sunroof has closed completely. Press
the TILT UP button until the sunroof has tilted upward completely.
3. Release the TILT UP button.
[email protected]
Page 149 of 222
4. Press and hold the TILT UP button once again until the sunroof has returned to the original position of TILT UP
after it is raised a little higher than the maximum TILT UP position.
When this is complete, the sunroof system is reset.
Body Electrical System > Lighting System > Components and Components Location
COMPONENTS
Page 150 of 222
Body Electrical System > Lighting System > Specifications
SPECIFICATION
Items Bulb Wattage(W)
Head lamp
(High/Low)
60/55
Front turn signal lamp
27
Front position lamp
5
Front fog lamp
35
Rear tail/stop lamp
8/28
Rear tail lamp
8/28
Back up lamp
17
Rear turn signal lamp
27
License plate lamp
5
Side repeater
5
Room lamp
10
Overhead console
10 x 2
lamp
LED
High mounted stop
5
lamp
5
Glove box lamp
5
Trunk room lamp
Door courtesy lamp
Body Electrical System > Lighting System > Head Lamps > Repair procedures
REPLACEMENT
2. Loose the fastener of radiator grill cover (A) and the mounting bolts.
[email protected]
Page 151 of 222
3. Remove the mounting bar (B) by pulling up after raising the radiator grill cover (A).
4. Remove the head lamp assembly after disconnecting the lamp connector.
Take care that holding clip (A) is not to be damaged.
HEAD LAMP AIMING INSTRUCTIONS

The head lamps should be aimed with the proper beam-setting equipment, and in accordance with the equipment
manufacturer's instructions.
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.
Alternately turn the adjusting gear to adjust the head lamp aiming. If beam-setting equipment is not available,
proceed as follows :
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.
Page 152 of 222
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.
HEAD LAMP AND FOG LAMP AIMING POINT
1. Turn the low beam on without driver aboard.

The cut-off line should be projected in the allowable range (shaded region).
[email protected]
Page 153 of 222
2. Turn the front fog lamp on without the driver aboard.
The cut-off line should be projected in the allowable range (shaded region)
HEAD LAMP RELAY INSPECTION

1. Pull out the head lamp relay (Low) (A) and head lamp relay (High) (B) from the engine compartment relay box.
2. Check for continuity between terminals. There should be continuity between the No.30 and No.87 terminals
when power and ground are connected to the No.85 and No.86 terminals
Body Electrical System > Lighting System > Turn Signal Lamp > Repair procedures
REPLACEMENT
Page 154 of 222
2. Loose the screws holding the rear combination lamp then disconnect the 6P connector.
3. Remove the rear combination lamp and replace the bulbs; stop & tail lamp, turn signal lamp, back up lamp.
Body Electrical System > Lighting System > Room Lamp > Schematic Diagrams
CIRCUIT DIAGRAM
Body Electrical System > Lighting System > Room Lamp > Repair procedures
INSPECTION
1. Remove the room lamp assembly then check for continuity between terminals.
REMOVAL
2. Detach the lamp lens (A) from the room lamp with a flat-tip screwdriver then remove the bulb (B).
3. Loosen the fixing screw (2EA) and disconnect the 3P connector. And then remove the room lamp assembly.
INSTALLATION
1. Install the room lamp assembly after connecting the lamp connector.
2. Install the lamp lens after assembling the bulb.
INSPECTION
1. Remove the room lamp assembly then check for continuity between terminals.
[email protected]
Page 155 of 222
Body Electrical System > Lighting System > Overhead Console Lamp > Repair procedures
REPLACEMENT
console lamp assembly from the headliner.
INSPECTION
Remove the overhead console lamp assembly then check for continuity between terminals.
Body Electrical System > Lighting System > Hazard Lamp Switch > Repair procedures
INSPECTION
HAZARD LAMP SWITCH
Page 156 of 222
2. Remove the hazard lamp switch from the center facia panel and disconnect the 10P connector.
3. Operate the switch and check for continuity between terminals with an ohmmeter.
HAZARD LAMP RELAY INSPECTION

4. There should be continuity between the No.1 in the I/P-J terminal and No.11/No.10 in the I/P-G terminal when
power and ground are connected to the No.1 in the I/P-J terminal and No.4 in the I/P-C terminal.
5. There should be no continuity between the No.1 in the I/P-J terminal and No.11/No.10 in the I/P-G terminal
when power is disconnected.
Body Electrical System > Lighting System > Flasher Unit > Repair procedures
INSPECTION
2. Disconnect the hood release cable from the hood release handle
[email protected]
Page 157 of 222
3. Remove the lower crash pad panel (A).
4. Remove the flasher unit (A) after loosening the nut and disconnecting the connector.
6. Connect the two turn signal lamps in parallel to terminals 1 and 3. 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 > Front Fog Lamps > Repair procedures
REPLACEMENT
2. Remove the front bumper.
(Refer to the BD group - front bumper).
Page 158 of 222
3. Remove the front fog lamp (A) after loosening the screws and disconnecting the fog lamp connector.
FRONT FOG LAMP RELAY INSPECTION

1. Pull out the front fog lamp (A) relay from the engine compartment relay box.
2. Check for continuity between terminals. There should be continuity between the No.30 and No.87 terminals
when power and ground are connected to the No.85 and No.86 terminals.
Body Electrical System > Lighting System > License Lamps > Repair procedures
REPLACEMENT
[email protected]
Page 159 of 222
2. Remove the license plate lamp after removing 2 screws and lens (A).
3. Replace the bulb.

Body Electrical System > Lighting System > High Mounted stop lamp > Repair procedures
HIGH MOUNTED STOP LAMP REPLACEMENT
2. Open the tail gate and then loose the mounting nuts.
3. Remove the high mounted stop lamp after disconnecting the connector of high mounted stop lamp.
Body Electrical System > Lighting System > Trunk Lamps > Repair procedures
REPLACEMENT
2. Detach the lamp lens from the trunk room lamp with a flat-tip screwdriver then replace the bulb.
Page 160 of 222
3. Remove the trunk room lamp assembly after removing 2 screws and disconnecting the 3P connector.
Body Electrical System > Auto Lighting Control System > Schematic Diagrams
CIRCUIT DIAGRAM
[email protected]
Page 161 of 222
Body Electrical System > Auto Lighting Control System > Description and Operation
DESCRIPTION
The auto light control system operates by using the auto light switch.
If you set the multi-function switch to "AUTO" position, the tail lamp and head lamp will be turned automatically on
or off according to external illumination.
Body Electrical System > Auto Lighting Control System > Components and Components Location
COMPONENTS
Page 162 of 222
Body Electrical System > Auto Lighting Control System > Specifications
SPECIFICATIONS
Rated voltage 12V
Max. 200mA (Relay
Load
load)
Detection illuminations
Tail lamp / Head lamp ON : 24 ± 5.2 (Lux),
0.81 ±0.05 (V)
OFF : 48 ± 10.5 (Lux),
1.41 ±0.05 (V)
Body Electrical System > Auto Lighting Control System > Auto Light Contorl unit > Repair procedures
AUTO LIGHT SENSOR INSPECTION
[email protected]
Page 163 of 222
1. Remove the photo & auto light sensor (A) after removing the defroster center cover.
2. Disconnect the 8P connector from the auto light sensor then inspect the connector on the wire harness side, as
shown in the chart.
Tester connection Condition Specified condition
1-Ground Auto light switch ON Continuity
2-Ground Constant Continuity
3-Ground Ignition switch ON 12V
Constant 5V
4-Ground
Tail lamp switch ON 0V
Ignition switch ON 12V
6-Ground
Head lamp switch ON 0V
3. If the circuit is not as specified, inspect the circuits connected to other parts.
Body Electrical System > Auto Lighting Control System > Auto Light Switch > Repair procedures
INSPECTION
Operate the auto light switch, and then check for continuity between terminals of 18P multi-function switch
connector.
Page 164 of 222
Body Electrical System > Daytime Running Lights > Schematic Diagrams
CIRCUIT DIAGRAM
[email protected]
Page 165 of 222
Body Electrical System > Daytime Running Lights > Repair procedures
INSPECTION
1. Daytime running unit & resister assembly (A) is installed at the right side strut housing.
2. Check that the light operate according to the following timing chart.
3. Inspect the connector and terminals to be sure they are all making good contact. If the terminals are bent, loose
or corroded, repair them as necessary, and recheck the system. If the terminals look OK, go to step 4.
4. Make these input tests at the connector If any test indicates a problem, find and correct the cause, then recheck
the system. If all the input tests prove OK, the control unit must be faulty; replace it.
Page 166 of 222
Terminal Test condition Test: Desired result
1 Under all conditions Check for voltage to ground : There should be continuity.
3 Engine running Check for voltage to ground : There should be battery voltage.
4 P/brake switch ON Check for voltage to ground : There should be continuity.
5 IG1 Check for voltage to ground : There should be battery voltage.
7 Under all conditions Check for voltage to ground : There should be battery voltage.
10 - -
11 - -
12 - -
5. Check for resistance between the terminals of the resistor in each position according to the table.
Terminal Specified value (Ω)

1-2 1.6 ± 5%
1-3 1.6 ± 5%
[email protected]
Page 167 of 222
Body Electrical System > Immobilizer System > Schematic Diagrams
CIRCUIT DIAGRAM (1)
CIRCUIT DIAGRAM (2)

Page 168 of 222
SCHEMATIC DIAGRAM
[email protected]
Page 169 of 222
Body Electrical System > Immobilizer System > Description and Operation
DESCRIPTION
The immobilizer system will disable the vehicle unless the proper ignition key is used, in addition to the currently
available anti-theft systems such as car alarms, the immobilizer system aims to drastically reduce the rate of auto
theft. There are two types of immobilizer. One is a "SMARTRA (SMART TRansponder Antenna)" type and
another is a "shinchang" type.
1. SMARTRA type immobilizer
A. The "SMARTRA" type immobilizer system is applied to the 2.0β engine.
B. The SMARTRA system consists of a transponder located in left side cowl cross bar, a coil antenna, a
SMARTRA unit, an indicator light and the ECM.
C. The SMARTRA communicates to the ECM (Engine Control Module) via a dedicated communications line.
Since the vehicle engine management system is able to control engine immobilization, it is the most suitable unit
to control the SMARTRA.
D. When the key is inserted in the ignition and turned to the ON position, the coil antenna sends power to the
transponder in the ignition key. The transponder then sends a coded signal back through the SMARTRA unit
to the ECM.
E. If the proper key has been used, the ECM will energize the fuel supply system. The immobilizer indicator light
in the cluster will simultaneously come on for more than five seconds, indicating that the ECM has recognized
the code sent by the transponder.
F. If the wrong key has been used and the code was not received or recognized by the ECM the indicator light
will continue blinking for about five seconds until the ignition switch is turned OFF.
G. If it is necessary to rewrite the ECM to learn a new key, the dealer needs the customer's vehicle, all its keys
and the Hi-scan (pro) equipped with an immobilizer program card. Any key that is not learned during
rewriting will no longer start the engine.
H. The immobilizer system can store up to four key codes.
I. If the customer has lost his key, and cannot start the engine, contact HMC motor service station.
2. Shinchang type immobilizer
A. The " Shinchang " type immobilizer system is applied to the 2.7δ engine.
B. The shinchang system consists of a transponder located in left side cowl cross bar, a coil antenna, an ICM
(Immobilizer control module) , an indicator light and the ECM.
C. When the key is inserted in the ignition and turned to the ON position, the coil antenna sends power to the
transponder in the ignition key. The transponder then sends a coded signal back through the coil antenna to
the ICM.
D. If the ID code transmitted from the key does not match the pre-registered code in the ICM, injection is not
performed by the engine ECM. Hence, each vehicle has a set of keys containing a unique ID code which are
registered on the ICM. This signal is captured by the coil antenna located in the front section of the steering
handle lock and transmitted to the ICM. The ICM analyses and verifies the signal to determine if the signal
matches the pre-registered code.If the signal is verified, the ICM transmits a message to the engine ECM to
allow injection. The immobilizer indicator light in the cluster will simultaneously come on for more than five
seconds, indicating that the ICM has recognized the code sent by the transponder.If the signal is not verified
by the ICM, fuel injection is not performed by the engine ECM. The indicator light will continue blinking for
five seconds until the ignition switch is turned OFF.Communication between ICM and ECM communicates
through the K-line of ECM. K-line is also used for the communication between ECM and scan tool. there is a
regal inside of ICM to switch the communication.
Page 170 of 222
E. If it is necessary to rewrite the ICM to learn a new key, the dealer needs the customer's vehicle, all its keys
and the Hi-scan (pro) equipped with an immobilizer program card. Any key that is not learned during
rewriting will no longer start the engine.
F. The immobilizer system can store up to four key codes.
G. If the customer has lost his key, and cannot start the engine, contact HMC motor service station.
OPERATION
ECM (Engine Control Module)
1. SMARTRA type immobilizer
The ECM carries out a check of the ignition key using a special encryption algorithm, which is programmed into
the transponder as well as the ECM simultaneously. Only if the results are equal, the engine can be started. The
data of all transponders, which are valid for the vehicle, are stored in the ECM.
2. Shinchang type immobilizer
In the Ignition ON position, the engine ECM receives information from the ICM and permits injection to take
place.
ICM (Immobilizer Control Module)

The ICM carries out communication with the built-in transponder in the ignition key. This wireless communication
runs on RF (Radio frequency of 125 kHz). The ICM is mounted at the behind of the crush pad under panel close to
the antenna coil for RF transmission and receiving.
The ICM carries out a check of the ignition key using a special encryption algorithm, which is programmed into the
transponder as well as the ICM simultaneously. Only if the results are equal, transmits the signal to the ECM to
permits injection. The data of all transponders, which are valid for the vehicle, are stored in the ICM.
[Shinchang Type]
SMARTRA unit
The SMARTRA carries out communication with the built-in transponder in the ignition key. This wireless
communication runs on RF (Radio frequency of 125 kHz). The SMARTRA is mounted at the behind of the crush
pad under panel close to the antenna coil for RF transmission and receiving. The RF signal from the transponder,
received by the antenna coil, is converted into messages for serial communication by the SMARTRA device. And,
the received messages from the ECM are converted into an RF signal, which is transmitted to the transponder by the
antenna.
The SMARTRA does not carry out the validity check of the transponder or the calculation of encryption algorithm.
This device is only an advanced interface, which converts the RF data flow of the transponder into serial
communication to the ECM and vice versa.
[SMARTRA Type]
TRANSPONDER (Built-in keys)

The transponder has an advanced encryption algorithm. During the key teaching procedure, the transponder will be
programmed with vehicle specific data. The vehicle specific data are written into the transponder memory. The write
procedure is once only; therefore, the contents of the transponder can never be modified or changed.
Body Electrical System > Immobilizer System > Troubleshooting

[email protected]
Page 171 of 222
DIAGNOSIS OF IMMOBILIZER FAULTS
- Communication between the ECM and the SMARTRA/ICM.
- Function of the SMARTRA/ICM and the transponder.
- Data (stored in the ECM/ICM related to the immobilizer function.
The following table shows the assignment of immobilizer related faults to each type :
[2.7 - SHINCHANG TYPE]
Immobilizer Related
Fault types Diagnostic codes
Faults
Transponder fault 1. Corrupted data from transponder P1693
2. More than one transponder in the magnetic field - Transponder no
(Antenna coil) response
3. No transponder (Key without transponder) in the error/transponder
magnetic field (Antenna coil) invalid response,
4. Transponder not in the password mode Transponder status
5. Transponder transport data has been changed6. error, Transponder
Transponder programming error programming error
SMARTRA/ECM fault P1691(δ2.7)
1. Antenna coil error
- Antenna coil error
P1678 (δ2.7)
1. Communication line error (Open/Short etc.)
- ECM no response
2. Invalid message from SMARTRA/ICM to ECM
message error
1. ECM internal permanent memory (EEPROM) fault
ECM internal permanent P1677 (δ2.7)
2. Invalid write operation to permanent memory
memory(EEPROM) fault - ECM has different VIN
(EEPROM)
ECM fault 1. Request from ECM is invalid (Protocol layer P1679 (δ2.7)
violation- Invalid request, check sum error etc.) - ECM message error
Invalid TP TP has different PIN P1698 (δ2.7)
[2.0 - SMARTRA TYPE]

Immobilizer Related
Fault types Diagnostic codes
Faults
PCM(ECM) fault 1. Non-Immobilizer-EMS connected to an Immobilizer P1610
1. Transponder not in password mode P1674
Transponder key fault
2. Transponder transport data has been changed. (Transponder status error)
P1675
Transponder key fault 1. Transponder programming error (Transponder programming
error)
P1676
SMARTRA fault 1. Invalid message from SMARTRA to PCM(ECM) (SMARTRA message
error)
1. Virgin SMARTRA at learnt EMS
P169A
2. Neutral SMARTRA at learnt EMS
SMARTRA fault (SMARTRA
3. Incorect the Authentication of EMS and SMARTRA
Authentication fail)
4. Locking of SMARTRA
Page 172 of 222
1. No response from SMARTRA
2. Antenna coil error P1690
SMARTRA fault
3. Communication line error (Open/Short etc.) (SMARTRA no response)
4. Invalid message from SMARTRA to PCM(ECM)
P1691
Antenna coil fault 1. Antenna coil open/short circuit
(Antenna coil error)
Immobilizer indicator lamp P1692
1. Immobilizer indicator lamp error (Cluster)
fault (Immobilizer lamp error)
1. Corrupted data from transponder
2. More than one transponder in the magnetic field P1693
Transponder key fault (Antenna coil) (Transponder no response
3. No transponder (Key without transponder) in the error/invalid response)
magnetic field (Antenna coil)
1. Request from PCM(ECM) is invalid P1694
PCM(ECM) fault (Protocol layer violation- Invalid request, check sum (PCM(ECM) message
error etc.) error)
1. PCM(ECM) internal permanent memory
PCM(ECM) internal P1695
(EEPROM) fault
permanent memory (PCM(ECM) memory
2. Invalid write operation to permanent memory
(EEPROM) fault error)
(EEPROM)
1. Virgin transponder at PCM(ECM) status
P1696
Invalid key fault "Learnt"Learnt (Invalid) Transponder at PCM(ECM)
(Authentication fail)
status "Learnt"(Authentication fail)
1. Exceeding the maximum limit of Twice IGN ON ( P1699
Locked by timer
32 times) (Twice IG ON over trial)
Body Electrical System > Immobilizer System > Repair procedures

TEACHING PROCEDURES
1. Key Teaching Procedure
Key teaching must be done after replacing a defective ECM (ICU) or when providing additional keys to the
vehicle owner.
The procedure starts with an ECM (ICU) request for vehicle specific data (PIN code: 6digits) from the tester.
The "virgin" ECM (ICU) stores the vehicle specific data and the key teaching can be started. The "learnt" ECM
(ICU) compares the vehicle specific data from the tester with the stored data. If the data are correct, the teaching
can proceed.
If incorrect vehicle specific data have been sent to the ECM (ICU) three times, the ECM (ICU) will reject the
request of key teaching for one hour. This time cannot be reduced by disconnecting the battery or any other
manipulation. After reconnecting the battery, the timer starts again for one hour.
The key teaching is done by ignition on with the key and additional tester commands. The ECM (ICU) stores the
relevant data in the EEPROM and in the transponder. Then the ECM (ICU) runs the authentication required for
confirmation of the teaching process. The successful programming is then confirmed by a message to the tester.
If the key is already known to the ECM (ICU) from a previous teaching, the authentication will be accepted and
the EEPROM data are updated. There is no changed transponder content (this is impossible for a learnt
transponder).
The attempt to repeatedly teach a key, which has been taught already during the same teaching cycle, is
[email protected]
Page 173 of 222
recognized by the ECM (ICU). This rejects the key and a message is sent to the tester.
The ECM (ICU) rejects invalid keys, which are presented for teaching. A message is sent to the tester. The key
can be invalid due to faults in the transponder or other reasons, which result from unsuccessful programming of
data. If the ECM (ICU) detects different authenticators of a transponder and an ECM (ICU), the key is
considered to be invalid.
The maximum number of taught keys is 8
If an error occurs during the Immobilizer Service Menu, the ECM (ICU) status remains unchanged and a specific
fault code is stored.
If the ECM (ICU) status and the key status do not match for teaching of keys, the tester procedure will be
stopped and a specific fault code will be stored at ECM (ICU).
(1) ECM learnt status.

Page 174 of 222
(2) ECM virgin status.

After replacing new "ECM" scantool displays that ECM is virgin status in Key Teaching mode.
"VIRGIN" status means that ECM has not matched any PIN code before.
[email protected]
Page 175 of 222
Page 176 of 222
2. User Password Teaching Procedure
The user password for limp home is taught at the service station. The owner of the vehicle can select a number
with four digits.
The user password teaching is only accepted by a "learnt" PCM(ECM). Before first teaching of user password to
an PCM(ECM), the status of the password is "virgin" No limp home function is possible.
The teaching is started by ignition on, with a valid key(learnt key) and sending the user password by tester. After
successful teaching, the status of the user password changes from "virgin" to "learnt"
The learnt user password can also be changed. This can be done if the user password status is "learnt" and the
tester sends authorization of access, either the old user password or the vehicle specific data. After correct
authorization, the PCM(ECM) requests the new user password. The status remains "learnt" and the new user
password will be valid for the next limp home mode.
If wrong user passwords or wrong vehicle specific data have been sent to the PCM(ECM) three times
continuously or intermittently, the PCM(ECM) will reject the request to change the password for one hour. This
time cannot be reduced by disconnecting the battery or any other actions. After reconnecting the battery, the
timer starts again for one hour.
(1) User password teaching
[email protected]
Page 177 of 222
In case of putting wrong password, retry from first step after 10 seconds.
(2) User password changing
Page 178 of 222
LIMP HOME FUNCTION

1. LIMP HOME BY TESTER
If the ECM (ICU) detects the fault of the SMARTRA or transponder, the ECM (ICU) will allow limp home
function of the immobilizer. Limp home is only possible if the user password (4 digits) has been given to the ECM
(ICU) before. This password can be selected by the vehicle owner and is programmed at the service station.
The user password can be sent to the ECM (ICU) via the special tester menu.
Only if the ECM (ICU) is in status "learnt" and the user password status is "learnt" and the user password is
correct, the ECM (ICU) will be unlocked for a period of time (30 sec.). The engine can only be started during
this time. After the time has elapsed, engine start is not possible.
If the wrong user password is sent, the ECM (ICU) will reject the request of limp home for one hour.
[email protected]
Page 179 of 222
Disconnecting the battery or any other action cannot reduce this time. After connecting the battery to the ECM
(ICU), the timer starts again for one hour.
Page 180 of 222
2. LIMP HOME BY IGNITION KEY
The limp home can be activated also by the ignition key. The user password can be input to the ECM (ICU) by a
special sequence of ignition on/off.
Only if the ECM (ICU) is in status "learnt" and the user password status is "learnt" and the user password is
correct, the ECM (ICU) will be unlocked for a period of time (30 sec.). The engine can be started during this
time. After the time has elapsed, engine start is not possible. After a new password has been input, the timer (30
sec.) will start again.
After ignition off, the ECM (ICU) is locked if the timer has elapsed 8 seconds. For the next start, the input of the
user password is requested again.
PROBLEMS AND REPLACEMENT PARTS:
[email protected]
Page 181 of 222
Scan tool
Problem Part set
required?
All keys have been lost Blank key (4) YES
Antenna coil unit does not work Antenna coil unit NO
ECM/ICU does not work ECM/ICU YES
Ignition switch does not work Ignition switch with Antenna coil unit YES
Unidentified vehicle specific data
Key, ECM/ICU YES
occurs
SMARTRA unit does not work SMARTRA unit NO
REPLACEMENT OF ECM/ICU AND SMARTRA

In case of a defective ECM/ICU, the unit has to be replaced with a "virgin" or "neutral" ECM/ICU. All keys have to
be taught to the new ECM/ICU. Keys, which are not taught to the ECM/ICU, are invalid for the new ECM/ICU
(Refer to key teaching procedure). The vehicle specific data have to be left unchanged due to the unique
programming of transponder.
In case of a defective SMARTRA, there is no special procedure required. A new SMARTRA device simply
replaces the old one. There are no transponder-related data stored in this device.
1. Things to remember before a replacement (ECM/ICU)
Page 182 of 222
2. Things to remember before a replacement (Keys & Additional registration)
1. When there is only one key registered and you wish to register another key, you need to re-register the
key which was already registered.
2. When the key #1 is registered and master key #2 is not registered, Put the key #1 in the IG/ON or the
start position and remove it. The engine can be started with the unregistered key #2.
(Note that key #2 must be used within 10 seconds of removing key #1)
3. When the key #1 is registered and key #2 is not registered, put the unregistered master key #2 in the
IG/ON or the start position.
The engine cannot be started even with the registered key #1.
4. When you inspect the immobilizer system, refer to the above paragraphs 1, 2 and 3.
Always remember the 10 seconds zone.
5. If the pin code & password are entered incorrectly on three consecutive inputs, the system will be
locked for one hour.
6. Be cautious not to overlap the transponder areas.
7. Problems can occur at key registration or vehicle starting if the transponders should overlap.
NEUTRALISING OF ECM/ICU
The ECM/ICU can be set to the "neutral" status by a tester.
A valid ignition key is inserted and after ignition on is recorded, the ECM/ICU requests the vehicle specific data
from the tester. The communication messages are described at "Neutral Mode" After successfully receiving the data,
the ECM/ICU is neutralized.
The ECM/ICU remains locked. Neither the limp home mode nor the "twice ignition on" function, is accepted by the
ECM/ICU.
The teaching of keys follows the procedure described for the virgin ECM/ICU. The vehicle specific data have to be
unchanged due to the unique programming of the transponder. If data should be changed, new keys with a virgin
transponder are requested.
[β2.0 engine]
This function is for neutralizing the ECM and Key. Ex) when lost key, Neutralize the ECM then teach keys.
(Refer to the Things to do when Key & PIN Code the ECM can be set to the "neutral" status by a scanner. A valid
ignition key is inserted and after ignition on is recorded, the ECM requests the vehicle specific data from the scanner.
The communication messages are described at" Neutral Mode". After successfully receiving the data, the ECM is
neutralized.
The ECM remains locked. Neither the limp home mode nor the "twice ignition on" function is accepted by ECM.
[email protected]
Page 183 of 222
The teaching of keys follows the procedure described for virgin ECM. The vehicle specific data have to be
unchanged due to the unique programming of transponder. If data should be changed, new keys with virgin
transponder are requested.
[δ2.7 engine]
This function is for neutralizing the ICU and ECU.
When replacing the ICU and ECM, The ICU and ECM need neutralization by scanner.
When neutralized, EEPROM data (VIN code, Password, Pin code, Key data) in the immobilizer are erased.
After doing neutralization of ICU by scanner, it is necessary to turn the key "OFF → ON" Because ECM is
neutralized by ICU.
• Neutralizing setting condition

- Input correct PIN code by scanner.
- Neutralizing meaning .
: PIN code (6) & user password (4) deletion.
: Locking of ECM (except key teaching permission)
Page 184 of 222
Body Electrical System > Immobilizer System > Immobilizer Control Unit > Repair procedures
REPLACEMENT
2. Remove the crash pad. (Refer to the Body group - "Crash pad").
3. Disconnect the 5P connector of the SMARTRA unit and then remove the SMARTRA unit (A) with bracket (B)
located on the cowl cross bar after loosening the bolt and nut.
- Punch the shear bolt using a centering punch.

- And drill its head off with a drill bit.
- Becarefull not to damage the SMARTRA unit.
[SMARTRA Type]
[Shinchang Type]
[email protected]
Page 185 of 222
4. Installation is the reverse of removal procedure.
- Tighten the shear bolt until the bolt head break

off.
Body Electrical System > Ignition Switch Assembly > Ignition Switch > Repair procedures
REPLACEMENT
2. Disconnect the hood release cable from the hood release handle.
3. Remove the lower crash pad panel (A).
4. Remove the ignition switch (A) after loosening the screw and disconnecting the 6P connector.
5. Remove the steering column shaft (Refer to the ST group).

6. Remove the key warning switch (A) and key illumination lamp (B) after loosening the screws and disconnecting
the 6P connector.
Page 186 of 222
7. If it is necessary to remove the key lock cylinder (A), remove the key lock cylinder (A after pushing lock pin (B)
with key ACC.
8. Installation is the reverse of removal procedure.
INSPECTION
1. Disconnect the ignition switch connector and key warning switch connector from under the steering column.
3. If continuity is not specified, replace the switch.
Body Electrical System > Troubleshooting > P1674

Component Location [email protected]
Page 187 of 222
General Description
The vehicle immobilizer system consists of the ECM, the SMARTRA3 and ignition keys with built-in transponder.
The ECM carries out the check of ignition key by special encryption algorithm with SMARTRA3 and Transponder.
The encryption algorithm (between ECM ans SMARTRA3) is used one offered from BOSCH.
The encryption algorithm (between ECM and Transponder) is Hitag2 type which is the high level. When IGN On,
the ECM executes the key Authentication after SMARTRA3 authentication. The Engine can be started in case of
the success in SMARTRA3 and key authentication.
The Key teaching procedure starts with ECM request of PIN from Scanner. The "virgin"ECM stores the PIN and
the key Learning can be started. The "learnt"ECM compares the PIN from tester with the vehicle password in
Transponder. If the data are correct, the key Learning can be started.
Scanner requests the Learning of the first key, the SMARTRA3 is registered at first and then the first key is
registered by ECM. If the SMARTRA3 status is learnt and PIN number is different, the SMARTRA3 will return the
incorrect PIN data to the ECM. In this case, The ECM can't excute the key learning process.
DTC Description
The ECM sets DTC P1674 if transponder key that can't be register(TP not in the password mode or whose
transport data has been changed) is inserted for registration procedure.
DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy
Enable Conditions ● IG ON (On Registering TP Procedure) ● Invalid transponder
Threshold value Key not in 'VIRGIN' Status or with
Detecting time invalid ID code
FAIL SAFE

1. Check status
(1) IGN "ON" & Engine "OFF"
(2) Monitor the "ECM KEY and Smartra Status" Parameter on the Scantool.
Specification : 'LEARNT'
Fig.1) This data show that 3 keys have been taught, ECU has been learnt, Key in key cylinder has been
learnt and SMARTRA3 has been learnt
(3) Have both the ECM and KEY status been learnt ?
Substitute with known good "virgin" transponder and go to "Component Inspection" Procedure.
Go to "Component Inspection" Procedure.

Page 188 of 222
Component Inspection
1. Check transponder
(2) Neutralize ECM and Register transponder key by scantool.
Pin code is requied to Neutralize ECM and to Register transponder key
(3) Are Neutralizing and Registering completed normally ?
Check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or
Substitute with a known-good transponder and perform key teaching procedure with scanner.
If the problem is corrected, replace transponder and then go to "Verification of Vehicle Repair" procedure.

1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
System is performing to specification at this time.
Diagnostic Circuit Diagram

Component Location
General Description
the key Learning can be started. The "learnt" ECM compares the PIN from tester with the vehicle password in
[email protected]
Page 189 of 222
DTC Description
The ECM sets DTC P1675 if characteristic data of transponder doesn't coincide with that of ECM owing to
transponder programming error.

DTC Strategy
Enable Conditions ● IG ON ● Invalid transponder
Invalid characteristic data
Threshold value
No transponder or more than two
Detecting time transponder is detected by coil antenna
FAIL SAFE

1. Check status
(2) Monitor the "ECM, KEY and Smartra Status" Parameter on the Scantool.
learnt and SMARTRA3 has been learnt.
(3) Has the KEY status been learnt?
Check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
damage on the ECM or SMARTRA. And This DTC has not erased in previous repair. Repair or replace as
necessary and then go to "Verification of Vehicle Repair" procedure.
Page 190 of 222
1. Check transponder and ECU status
(1) IGN "ON" & Engine "OFF" with key intended to register
(2) Monitor the "ECM,KEY and Smartra STATUS" Parameter on the Scantool.
(3) Are "KEY STATUS", "SMARTRA STATUS" and "ECU STATUS" Parameter within specifications?
Go to "Check Transponder" procedure

Pin code is required to Neutralize ECM and to Register transponder key
Substitute with a known-good transponder and perform key teaching procedure with scanner.


Component Location
[email protected]
Page 191 of 222
General Description
1. The sequences of the PIN code storage are as follows.
(1) Input the PIN code into the scanner when key teaching process.
The scanner transmits the Encrypted Code to the ECM after converting the PIN code into Encrypted Code.
(2) When the ECM gets the firtst key learning command , it transmits the SMARTRA3 learnt command and
Encrypted Code to the SMARTRA3
(3) If the SMARTRA3 statue is virgin/neutral, the SMARTRA3 stores Encrypted Code in EEPROM and
transmits the success message of the Encrypted Code storage.
(If the SMARTRA3 is learnt, the SMARTRA3 compares Encrypted Code transmitted by the ECM with
Encrypted Code stored in EEPROM and transmits the (in)correct Encrypted Code message to ECM)
(4) If the SMARTRA3 is learnted normally or the Encrypted Code of the registered SMARTRA3 is same as the
ECM, the ECM begins operation the Transponder Learning.
(5) If the learning of the first transponder, the ECM stores the Encrypted Code in its EEPROM and converts
state into learnt state.
2. The SMARTRA3 learning :
(1) starts with EMS request of PIN from scanner through the key teaching procedure.
(2) is possible in case that the status of SMARTAR is "virgin" or "neutral ".
(3) In case that the SMARTRA3 is "learnt", the SMARTRA3 will transmits the information if PIN inputted from
scanner is same as the PIN in SMARTRA3.
(4) is possible regardless of key status.
3. The sequence of the SMARTRA3 confirms are as follows.
(1) After communication with the SMARTRA3, the ECM transmits the random number with requirement of the
TP ID information.
(2) The SMARTRA3 encryptes the random number and transmits the result(Encrypted Random Number) to the
ECM with TP ID information.
(3) The ECM compares the result transmitted from the SMARTRA3 with the result calculated by ECM.
And If result are coincided with each other; the ECS concludes the valid confirmation of the SMARTRA3.
DTC Description
The ECM sets DTC P1676 if there's any fault in message from SMARTRA to ECU.

DTC Strategy
Enable
● IG ON
Conditions
● Faulty
Threshold
SMARTRA
value
Detecting time
FAIL SAFE
Page 192 of 222

(1) IGN "ON" & Engine "OFF" with key intended to register
(2) Monitor the "ECU, KEY, Smartra STATUS" Parameter on the Scantool.
Fig.1) his data show that 3 keys have been taught, ECU has been learnt, Key in key cylinder has been learnt
and SMARTRA3 has been learnt.
(3) Has the "SMARTRA" status been learnt?
damage on the ECM or SMARTRA. And this DTC has not erased in previous repair. Repair or replace as
necessary and then go to "Verification of Vehicle Repair" procedure.
Go to "Check SMARTRA" procedure.

2. Check SMARTRA
(2) Neutralize SMARTRA with scantool.
Pin code is required to Neutralize SMARTRA & ECM and to Register transponder key
(4) Are Neutralizing and Registering Key completed normally ?
damage on the ECM or SMARTRA. Or It has not been erased this DTC in previous repair. Repair or
replace as necessary and then go to "Verification of Vehicle Repair" procedure.
Substitute with a known-good SMARTRA and perform the Key teaching.

If the problem is corrected, replace SMARTRA and then go to "Verification of Vehicle Repair" procedure.
If the SMARTRA3 is only replaced using an existing key and ECM, after replacing the "virgin" or
"neutral" SMARTRA3, reteaching is possible by key Learning mode of scanner. In this case, all
existing key must be retaught.
If SMATRA3 is replaced to another one (used at other vehicle), it can only recycle its neutralized first
before replacing.

[email protected]
Page 193 of 222

Component Location
General Description
Immobilizer Control Unit (ICU) supplies power to the coil antenna, receives and analyses signal from the
transponder, transmits signal to engine ECM and stores VIN(Not the number on the bulkhead of vehicle but Vehicle
Identification Number for Immobilizer ) data which composes of ID code and password.
DTC Description
ICU stores VIN which composes of ID code and password. This DTC is defined that VIN of EMS is inconsistent
data of ICU.

Item Detecting Condition Possible cause
Enable Condition ● IG ON
Detecting factors ● EMS VIN DATA error
● Faulty EMS
● Inconsistent data
Detecting Criteria
between EMS and ICU
Signal Waveform and Data

Current Data
Fig.1) Current data display

Current Data from Immobilizer will show the numbers of Key learnt, ECM status, ICU status, and Key status as Fig
1.
Thanks to this current data, the symptom of unable starting is probably assumed what problem it is.
Page 194 of 222
1. ECU : VIN - It is Vehicle ID number which consists of ID code and password,not the vehicle body number,
(1) Virgin (This is status that ECM does not memorize VIN)
(2) Neutral (This is a status that VIN is erased on the ECM by special command from scantool)
(3) Learnt (This is a status that VIN is learnt on the ECM by special command from scantool )
(4) Not yet checked (The status is stored in permanent memory (EEPROM or Flash etc.).
In case of not plausible data from this circuit the EMS cannot check the status.
2. KEY :
(1) Virgin (It means the key in the key cylinder has not matched with ICU yet)
(2) Learnt (It means the key in the key cylinder has matched with ICU)
(3) Invalid (mismatched)
- Key with NO Transponder
- More than 1(One) Transponder in the magnetic field
- No Transponder in the magnetic field.
- TP data blocked
- TP data does not exist
- TP data changed
- TP Teaching error
- Multiple TP data input
(4) Not yet checked [The status is stored in permanent memory (EEPROM or Flash etc)].
In case of not plausible data from this circuit the ICU cannot check the status.
[ Immobilizer Functions Table depending on ECM status ]

1. Ignition "ON" & Engine "OFF"
2. After connecting Scantool, Monitor the DTCs and CURRENT DATA to check key status.
Fig. 1 Normal Data

3. Are both Key and ECU status learnt?
Fault is intermittent caused by poor contact in the ICU and/or the engine ECU connector or was repaired and
ICU memory was not cleared.
deterioration, or damage.
Repair or replace as necessary and then go to "Verification of Vehicle Repair" procedure.
If ECU status is not yet checked" is displayed, check engine ECU and then go to "Verification of Vehicle
Repair" procedure.
Be sure that P1677 can be displayed, when engine ECU has a different VIN DATA(Engine ECU is
replaced by another vehicle’s ECU) with ICU.

1. Connect scan tool and monitor "CURRENT DATA". [email protected]
Page 195 of 222
2. Select "Diagnostic Trouble Codes(DTCs)" mode and Clear the DTCs.
Go to the applicable troubleshoooting procedure.
System is performing to specification at this time

Component Location
General Description
In the Ignition ON position, the engine ECM receives information from the ICM and permits injection to take place
If the CODE memorized in ECM is concided with ICM.
When the ID code from the tranponder is verified by the ICM then the registering sequence is complete and a
answer signal is sent to the ECM.
The ICM sends a START or NO START signal to the ECM.
DTC Description
This DTC is defined as that there is no request code from EMS for 5 sec after ignition ON.

● Open in harness between
Detecting factors ● EMS no request
EMS and ICU
● No request from EMS for 5 ● Faulty EMS
Detecting Criteria
sec

Current Data

Current Data from Immobilizer will show the numbers of Key learnt, ECM status, ICU status, and Key status as Fig
1.
Page 196 of 222
2. KEY :
- TP data blocked
- TP data changed
- TP Teaching error

Fig. 1 Normal Data

3. Are DTSs and CURRENT DATA displayed as same as before when using another virgin or learnt key ?
If ECU status is not yet checked" is displayed, check engine ECU and then go to "Verification of Vehicle
Repair" procedure.
Be sure that P1678 can be displayed, when engine ECU is replaced by "Non-immobilizer" enging ECU.
Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness(es) and terminals. Faults can also be
or damage.
[email protected]
Page 197 of 222
Repair as necessary and then go to "Verification of Vehicle Repair" procedure
Go to "Signal Circuit Inspection" procedure

Signal Circuit Inspection
1. Ignition "OFF"
2. Disconnect ICU and engine ECU connector.
3. Measure resistance between ECM terminal of the ICU harness connector and ECM terminal of the engine ECU
harness connecotor.
The ICU communicate with the engine ECU by dedicated communication line.
4. Is measured resistances within specification?
Go to "Verification of Vehicle Repair " procedure.
Check for open or short in signal harness. Repair as necessary and then go to "Verification of Vehicle Repair"
procedure.

1. Connect scan tool and monitor "CURRENT DATA".

Component Location
General Description
When the ID code from the transponder is verified by the ICU then the registering sequence is complete and a
answer signal is sent to the EMS.
The ICU sends a START or NO START signal to the EMS.
Page 198 of 222
DTC Description
This DTC is defined as Invalid request from EMS or corrupted data.

Detecting
Item Possible cause
Condition
Detecting factors ● EMS Data fail
● Data frame ● Faulty EMS
error ● Faulty ICU
Detecting
● Check sum
Criteria
error
● Message error

Current Data

Current Data from Immobilizer will show the number of learnt Key, ECU status, Key status, and ICU status as Fig
1.
[email protected]
Page 199 of 222
2. KEY :
- TP data blocked
- TP data changed
- TP Teaching error

2. Connect Scan tool and clear the DTCs.
Fig. 1 Normal Data

3. Is DTC P1679 displayed again ?
Go to "Component Inspection" procedure
Fault is intermittent caused by poor contact in the ICU and/or the antenna coil connector or was repaired and
ICU memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage.
Check ECU
2. Netralize ICU and engine ECU with scanner.
1.Be sure that PIN code is prepared before performing neutralization and key teaching.
2.After doing neutralization of ICU by scanner, It is neccessary to turn the key "OFF → ON" . Because
ECM is neutralized by ICU.
3. Substitute with a known-good neutral ECU, and perform key teaching.

4. Monitor CURRENT DATA and DTCs.
Page 200 of 222
Go to "Check ICU" procedure as below.
Replace the engine ECU and Perform key, password teaching.
Before replace the engine ECU, perform neutralization of the ICU.

Check for proper operation and the go to "Verification of Vehicle Repair" procedure.
Check ICU
2. Netralize ICU and engine ECU with scanner.
1.Be sure that PIN code is prepared before performing neutralization and key teaching.
2.After doing neutralization of ICU by scanner, It is neccessary to turn the key "OFF → ON" . Because
ECM is neutralized by ICU.
3. Substitute with a known-good neutral ECU, and perform key teaching.
4. Monitor CURRENT DATA and DTCs.
Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination,deterioration,
or damage.
Replace the ICU and Perform key, password teaching.
Before replace the ICU, perform neutralization of the engine ECU.
Check for proper operation and the go to "Verification of Vehicle Repair" procedure.


[email protected]
Page 201 of 222
Component Location
General Description
TP ID information.
DTC Description
The ECM sets DTC P1690 if there's No Response from SMARTRA.

DTC Strategy
Enable ● Open Circuit in signal
● IG ON
Conditions harness
● Short Circuit in signal
Threshold value
harness
Detecting time ● Faulty SMARTRA
FAIL SAFE
Page 202 of 222

1. Connect scantool to Data Link Connector(DLC).
2. IGN "ON" & Engine "OFF"
3. Monitor the "ECU, KEY and Smartra STATUS" Parameter on the Scantool.
Fig. 1) This data show that 3 keys have been taught, ECU has been learnt, Key in key cylinder has been learnt
4. Has the "Smartra STATUS" been learnt ?
Check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, damage
on the ECM or SMARTRA.
And this DTC has not been erased in previous repair. Repair or replace as necessary and then go to "Verification
of Vehicle Repair" procedure.
Go to "Inspection & Repair" procedure.

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 aor chemical damage.
or damage.
Repair as necessary and go to "Verification Vehicle Repair" procedure.

Power Circuit Inspection
1. Check for open in harness
(1) Ignition "OFF"
(2) Disconnect SMARTRA Connector.
(3) Ignition "ON" & Engine "OFF"
(4) Measure voltage between Engine Control Relay Power of SMARTRA harness connector and chassis
ground.
Specification : 9~16V
(5) Is the measured voltage within specifications?
Go to "Signal circuit Inspection" procedure.
Check for open or short in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.
[email protected]
Page 203 of 222
1. Check for open in harness
(1) Ignition "OFF"
(2) Disconnect SMARTRA connector.
(3) Measure resistance between signal terminal of smartra harness connector and ECM/PCM harenss connector.
Specification : 1 Ω or less
(4) Is the measured resistance within specifications?
Go to "Check for short in harness" procedure.
Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure.
2. Check for short in harness
(1) Ignition "OFF"
(4) Measure voltage between signal terminal of SMARTRA harness connector and chassis ground.
Specification :Approx. 5.48V
Go to "Signal circuit Inspection" procedure.
Check for short in harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure.
Ground Circuit Inspection
1. Check for open in ground harness
(1) Ignition "OFF"
(2) Disconnect SMARTRA Connector.
(3) Measure resistance between ground terminal of SMARTRA harness and chassis ground.
Specification : 1 Ω or less
Page 204 of 222
1. Check SMARTRA
(2) Neutralize Both "SMARTRA" and "ECM" and Register transponder key by scantool.
Pin code is required to Neutralize SMARTRA and to Register transponder key
Perform all the key teaching procedure with scantool. (All the keys must be retaught) and then, go to
"Verification of Vehicle Repair" Procedure.
Substitute with a known-good SMARTRA and Perform Key teaching procedure.

If the problem is corrected, replace SMARTRA and then go to "Verification of Vehicle Repair" procedure.


Component Location
General Description
[2.0]
This wireless communication runs on RF (Radio frequency of 125 kHz). The antenna coil is mounted on the top of
ignition lock for RF transmission and receiving. The RF signal from the transponder received by the antenna coil is
converted into messages for serial communication by the SMARTRA device. And the received messages from the
ECM are converted into an RF signal, which is transmitted, to the transponder by the antenna.
[2.7]
The coil antenna has the following functions.
1. The coil antenna supplies energy to the transponder.
2. The coil antenna receives signal from the transponder.
3. The coil antenna sends transponder signal to the ICU.
It is located directly in front of the steering handle lock.
[email protected]
Page 205 of 222
DTC Description
The ECM sets DTC P1691 if there's any fault in immobilizer antenna coil.

[2.0]
DTC Strategy
Enable ● Open Circuit in
● IG ON antenna coil
Conditions
● Short Circuit in
Threshold value
antenna coil
Detecting time ● Faulty antenna coil
FAIL SAFE
[2.7]
Detecting factors ● Antenna signal error
● Open or short in coil circuit
● Before transponder ● Faulty Antenna Coil
Detecting Window
communications
Detecting Criteria ● Antenna open / short circuit

[2.0]
3. Monitor the "ECU, KEY and Smartra STATU" Parameter on the Scantool.
Fig. 1) This data show that 3 keys have been taught, ECU has been learnt, Key in key cylinder has been learnt
4. Have the both "ECM, KEY and Smartra STATUS" been learnt ?
Check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, damage
on the ECM or SMARTRA.
And This DTC has not been erased in previous repair. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

[2.7]
Page 206 of 222
Fig.1) Normal Data
When DTC P1691 occurs, DTC P1693 can be displayed simultaneously and
If key status changed from "invalid" to "virgin or learnt", This is not antenna coil (antenna harness) problem.
Subsititute with a known-good Transponder and check for proper operation. If the problem is correted, replace
a virgin Transponder and then go to "Verification of Vehicle Repair" procedure.
[2.0]
1. Check coil antenna
(1) Ignition "OFF"
(3) Measure resistance between antenna coil(+) and (-) terminal of SMARTRA harness connector.
Specification : Approx 8.5 Ω
Go to "Check SMARTRA" procedure.
Check for open or short in antenna coil. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.
2. Check SMARTRA
(2) Neutralize Both "SMARTRA" and "ECM" and Register transponder key with scantool.
(3) Are Neutralizing and Registering completed normally?
Substitute with a known-good transponder and perform the key teaching procedure.
[2.7]
[email protected]
Page 207 of 222
1. Check antenna coil
(1) Ignition "OFF"
(2) Disconnect Antenna coil connector.
(3) Measure resistance between antenna (+) terminal and (-) terminal of the Antenna coil connector (Component
Side)
Specification : Approx. 7.5 Ω
(4) Is measured resistance within specification ?
Substitute with a known-good Antenna Coil and check for proper operation.
If the problem is corrected, replace Antenna Coil and then go to "Verification of Vehicle Repair" procedure.


[2.0]
[2.7]

Component Location
General Description
When driver inserts key and IGN "ON", Immobilizer informs status of system and result of Authentication by
blinking of immobilizer lamp on instrument cluster. through Authentication procedure immobilizer lamp keep lighting
up till engine starts. In normal status. Immobilizer lamp lights up for 30sec Right after ignition "ON". If there's any
fault in immobilizer system or in Authentication, lamp blinks 5 times after ignition "ON" .
Page 208 of 222
DTC Description
The ECM sets DTC P1692 if there's short circuit in immobilizer lamp circuit.

DTC Strategy
● Short Circuit in immobilizer
Enable Conditions ● IG ON
lamp circuit
Threshold value ● Short to GND, Wiring open ● Open/Short in control
harness
Detecting time
● Faulty PCM/ECM
FAIL SAFE

Faults can also be caused by interference from other electrical systems, and mechanical aor chemical damage.
or damage.
Repair as necessary and go to "Verification Vehicle Repair" procedure.

Contol Circuit Inspection
Check for open in harness
1. IG KEY OFF
2. Connect SMARTRA connector and disconnect PCM connector
3. IG KEY ON & Engine "OFF"
4. Measure voltage between indicator terminal of PCM harness connector and chassis ground.
Specification : Batt.
5. Is the measured voltage within specifications
Check for open or short in harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure.
Visual / Physical Inspection
[email protected]
Page 209 of 222
1. Check immobilizer lamp circuit
(2) Check if immobilizer lamp operates properly.
Right after ignition "ON", Immobilizer lamp lights up for 30sec.

If lamp blinks 5 times after ignition "ON", there’s any fault in immobilizer system.
(3) Is immobilizer lamp operates properly?
Check immobilizer lamp
1. IG KEY OFF
2. Connect SMARTRA connector and disconnect PCM connector
3. Ground indicator terminal of PCM harness connector with wire.
4. IG KEY ON & Engine "OFF"
Specification : Immobilizer lamp "ON"
5. Is the Immobilizer lamp "ON"?
Substitute with a known-good ECM and check for proper operation.

If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure.
ECM substitued for old one must be in "Virgin" or "Neutral" status and Pin code is requied to Neutralize
ECM and to Register transponder key
Check that fuse has blown off and harness between ECM connector and Battery is in normal condition. And.
check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage.


Page 210 of 222

Component Location
General Description
[2.0]
[2.7]
A transponder is incorporated in the head section of the key. The antenna coil supplies energy to the transponder.
The transponder accumulates energy in the condenser. Once the energy supply from the coil has stopped, using the
stored energy in the condenser, the transponder transmits the ID CODE (stored within the ASIC).
When Ignition is set 'ON' the ICM receives a request signal from the ECM and starts ID Code registering sequence.
If the ID code format from the transponder is not correct, the ICM repeatedly performs the registering sequence.
When the correct ID code format is registered, the code is verified by the ICM.
If the code is not verified, the registering sequence is repeated a maximum of 5 times which is equivalent to 1 second
duration.
Once the correct ID code is registered and verified after Ignition is turned ON, the registering sequence is not
reperformed until Ignition is turned OFF.
DTC Description
[2.0]
The ECM sets DTC P1693 if there's abnormal response from transponder.
[2.7]
This DTC is defined as Invalid(More than one TP or No TP in the magnetic field) Transponder Data.

[2.0]
[email protected]
Page 211 of 222
DTC Strategy ● Corrupted data from
Enable Conditions ● IG ON Transponder
● More than one TP in the
Threshold value
magnetic field
Detecting time ● No TP(Key without TP) in
FAIL SAFE the magnetic field
[2.7]
Detecting factors ● Transponder error
● During Transponder IDE
● During Transponder Authentication
requests
Detecting Window ● During Transponder Write EEPROM page ● Faulty Transponder
requests
● During Transponder Read EEPROM page
requests
● Corrupted data form Transponder (Tp), or
Detecting Criteria more than one TP in the field, or no TP in
the magnetic field.

[2.0]
(2) Monitor the "ECU, KEY and Smartra STATUS" Parameter on the Scantool..
Fig.1) his data show that 3 keys have been taught, ECU has been learnt, Key in key cylinder has been learnt

[2.7]
Page 212 of 222
Fig.1) Normal Data
When DTC P1691 occurs, DTC P1693 can be displayed simultaneously and current Data will show you
that Key status is invalid
If key status not changed from "invalid" to "virgin or learnt", This is not transponder(key) problem.
Check for "antenna coil(harness) refer to P1691 antenna error" and then go to "Verification of Vehicle repair"
procedure.
If key status changed from "invalid" to "virgin or learnt", Subsititute with a known-good Transponder and
check for proper operation.
If the problem is correted, replace a virgin Transponder and then go to "Verification of Vehicle Repair"
procedure.
1. when replacing the key, it is neccessary to teach the key.

2. Be sure that PIN code is prepared before performing key teaching.
Substitute with a known-good transponder and perform the key teaching precedure.


[email protected]
Page 213 of 222

[2.0]
[2.7]

Component Location
General Description
The relevant data for the immobilizer function are stored at permanent memory (EEPROM or Flash etc.)..
The immobilizer data are stored by three independent entries.
The data from EEPROM are evaluated by 2 of 3 decision". That means all three entries are read and the content is
compared before authentication process.
If the contents of all entries are equal, the authentication will run without additional measures.
If only the contents of two entries are equal, the authentication will run and fault code "EEPROM defective" is stored
at ECM.
If the contents of all three entries are different from each other, no authentication will be possible and the fault code
"EEPROM defective" will be stored. The limp home function cannot be activated. The ECM shall be replaced if the
EEPROM related fault occurs again after new teaching of all keys.
DTC Description
The ECM sets DTC P1694 if there's any fault in EMS internal permanent memory(EEPROM or Flash etc.).

DTC
Strategy
Enable
● IG ON
Conditions
Threshold ● Faulty EMS
value
Detecting
time
FAIL SAFE

Page 214 of 222
1. Check status
(2) Monitor the "KEY STATUS", "SMARTRA STATUS" and "ECU STATUS" Parameter on the Scantool.
damage on the ECM or SMARTRA.
And this DTC has not been erased in previous repair. Repair or replace as necessary and then go to
1. Check ECM
Pin code is requried to Neutralize ECM and to Register transponder key
Substitute with a known-good ECM and perform the key teaching procedure.
ECM substitued for old one must be in "Virgin" or "Neutral" status and Pin code is requied to
Neutralize ECM and to Register transponder key


[email protected]
Page 215 of 222

Component Location
General Description
DTC Description
The ECM sets DTC P1696 if invaild key is inserted into key hole for Authentication.

DTC Strategy
● Virgin TP at PCM/ECM status
"Learnt"
Threshold value ● Invalid transponder
● Learnt(Invalid) TP at PCM/ECM
status "Learnt"
Detecting time ● Immediately
FAIL SAFE

Page 216 of 222
1. Check status
(2) Monitor the "ECM, Key and Smartra Status" Parameter on the Scantool.
Pin code is requied to Neutralize ECM and to Register transponder key
Substitute with a known-good transponder and perform the key teaching procedure.


[email protected]
Page 217 of 222
Component Location
General Description
A transponder is incorporated in the head section of the key. The antenna coil supplies energy to the transponder.
The transponder accumulates energy in the condenser. Once the energy supply from the coil has stopped, using the
stored energy in the condenser, the transponder transmits the ID CODE (stored within the ASIC).
When Ignition is set 'ON' the ICM receives a request signal from the ECM and starts ID Code registering sequence.
If the ID code format from the transponder is not correct, the ICM repeatedly performs the registering sequence.
When the correct ID code format is registered, the code is verified by the ICM.
If the code is not verified, the registering sequence is repeated a maximum of 5 times which is equivalent to 1 second
duration.
Once the correct ID code is registered and verified after Ignition is turned ON, the registering sequence is not
reperformed until Ignition is turned OFF.
DTC Description
This DTC is defined as Invalid(virgin or invalid) Transponder Data.

Detecting factors ● Invalid TP
● Virgin TP at EMS STATUS ● Faulty TP(Virgin or Invalid)
"Learnt"
Detecting Criteria
● Learnt(Invalid) TP at EMS status
"Learnt"(Authentication fail)

■ Current Data

Current Data from Immobilizer will show the number of learnt Key, ECU status, Key status, and ICU status as Fig
1.
Page 218 of 222
2. KEY :
- TP data blocked
- TP data changed
- TP Teaching error

Fig. 1 Normal Data

3. Are DTSs P1698 displayed again and CURRENT DATA displayed as same as before ?
If key status is "invalid" is displayed, check transponder(key) and then go to "Verification of Vehicle Repair"
procedure.
1.Be sure that P1698 is displayed, when transponder(key) is unintentionally exchanged with another key.
2.Be sure that P 1698 is displayed, when using virgin transponder(key) with lernt ICU.
3.Be sure thatP1698 is displayed by arbnormal stop when key theaching is performed by learnt key(with
same PIN code)
Fault is intermittent caused by poor contact in the ICU and/or the antenna coil connector or was repaired and
ICU memory was not cleared.

[email protected]
Page 219 of 222

Component Location
General Description
This is a special function for engine start by vehicle manufacturer. The engine can be started for moving from the
production line to an area where the key teaching is proceeded.
DTC Description
The ECM sets DTC P1697 if the maximum limit of Twice IGN is Exceeded.

DTC Strategy
Enable
● IG ON
Conditions
● Twice IGN ≥ 32
Threshold
times
value
Detecting time
FAIL SAFE

Page 220 of 222
1. Check status
(2) Monitor the "ECM, Key and Smartra Status" Parameter on the Scantool.
(3) Is the "ECU STATUS" Parameter "Locked"?
Keep "KEY ON" status for 1 hours to withdraw "Locked by Timer" status. Then register transponder and
go to "Verification of Vehicle Repair" procedure.
damage on the ECM or SMARTRA.
And this DTC has not erased in previous repair. Repair or replace as necessary and then go to "Verification
of Vehicle Repair" procedure..

Body Electrical System > Troubleshooting > P169A

Component Location
General Description
[email protected]
Page 221 of 222
TP ID information.
DTC Description
The PCM/ECM sets DTC P169A if authentication between PCM/ECM and SMARTRA has been failed.

DTC Strategy
● Virgin SMARTRA at Learnt EMS
● Neutral SMARTRA at Learnt EMS
Threshold value ● Incorect the Authetication of EMS ● Locking of SMARTRA
and SMARTRA
● Locking of SMARTRA
Detecting time
FAIL SAFE

Page 222 of 222
3. Monitor the "KEY STATUS", "SMARTRA STATUS" and "ECU STATUS" Parameter on the Scantool.
Fig.1) This data show that 3 keys have been taught, ECU has been learnt, Key in key cylinder has been learnt
4. Has the "SMARTRA STATUS" been learnt ?
Keep "KEY ON" status for 1 hours to withdraw "Locked by Timer" status. Then register transponder and go
to "Verification of Vehicle Repair" procedure.
1. Check SMARTRA
(2) Neutralize Both "SMARTRA" and "ECM" and Register transponder key with scantool.
Substitute with a known-good SMARTRA and Perform Key teaching procedure. If the problem is
corrected, replace SMARTRA and then go to "Verification of Vehicle Repair" procedure.

[email protected]
Page 1 of 235
SPORTAGE(KM) > 2008 > G 2.7 DOHC > Brake System
Brake System > General Information > Special Service Tools

SPECIAL TOOL
TOOL(Number and Name) ILLUSTRATION USE
09581-11000 Spreading the front disc brake piston
Piston expander
Brake System > General Information > Troubleshooting

TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Symptom Suspect Area Reference
Lower pedal or 1. Brake system (Fluid leaks) repair
spongy pedal 2. Brake system (Air in) air·bleed
3. Piston seals (Worn or damaged) replace
4. Rear brake shoe clearance(Out of adjustment) adjust
5. Master cylinder (Faulty) replace
Brake drag 1. Brake pedal freeplay (Minimum)

adjust
2. Parking brake lever travel (Out of adjustment) adjust
3. Parking brake wire (Sticking) repair
5. Pad or lining (Cracked or distorted) replace
6. Piston (Stuck) replace
7. Piston (Frozen) replace
8. Anchor or Return spring (Faulty) replace
9. Booster system (Vacuum leaks) repair
replace
10. Master cylinder (Faulty)
Brake pull 1. Piston (Sticking) replace
2. Pad or lining (Oily) replace
3. Piston (Frozen) replace
4. Disc (Scored) replace
Hard pedal but brake 1. Brake system (Fluid leaks)

repair
inefficient 2. Brake system (Air in) air·bleed
3. Pad or lining (Worn) replace
6. Pad or lining (Oily) adjust
7. Pad or lining (Glazed) replace
Page 2 of 235
8. Disc (Scored)
9. Booster system (Vacuum leaks) repair
Noise from brake 1. Pad or lining (Cracked or distorted)

replace
2. Installation bolt (Loosen) adjust
4. Sliding pin (Worn) replace
5. Pad or lining (Dirty) clean
6. Pad or lining (Glazed) replace
7. Anchor or Return spring (Faulty) replace
8. Brake pad shim (Damage) replace
9. Shoe hold-down spring (Damage) replace
Brake fades replace

1. master cylinder
1. brake booster replace

2. pedal free play adjust
Brake vibration, replace
3. master cylinder
pulsation replace
4. caliper
replace
5. master cylinder cap seal replace
6. damaged brake lines
Brake chatter is usually caused by loose or worn components, or
glazed or burnt linings. Rotors with hard spots can also contribute to
Brake Chatter brake chatter. Additional causes of chatter are out-of-tolerance
rotors, brake lining not securely attached to the shoes, loose wheel
bearings and contaminated brake lining.
Brake System > General Information > Specifications

SPECIFICATIONS
Item Specification
Master cylinder
· Type Tandem type
· I.D. mm(in.)(CBS/ABS) 23.8 / 25.4(0.937 / 1.0)
· Piston stroke mm(in) 30 ~ 32(1.18 ~ 1.26)
· Output port(CBS/ABS) 4port / 4port
· Fluid level warning sensor Provided
Proportioning valve
· Cut-in pressure(Split point) 15 Kgf /cm²
· Decompression ratio 0.27 : 1 (2WD)
0.32 : 1(4WD)
Brake booster
· Type Vacuum
· Effective dia. mm(in.) 8+9 in
· Boosting ratio 9:1
Front brake(Disc)
[email protected]
Page 3 of 235
· Type Floating type with ventilated disc
· Disc O.D. 280 mm(11.02 in)
· Disc I.D. 172 mm (6.77 in.)
· Disc thickness 26 mm(1.02 in)
· Pad thickness 11 mm(0.43 in)
· Cylinder type single piston
· Cylinder I.D. 60 mm (2.36 in.)
Rear brake(Disc)
· Type Floating type with solid disc
· Disc O.D. (2WD/4WD) 262 / 284 mm (10.31 / 11.18 in.)
· Parking Brake Drum I.D 190 mm(7.48 in.)
· Disc thickness 10 mm (0.39 in.)
· Pad thickness 10 mm (0.39 in.)
· Cylinder type single piston
· Cylinder I.D 34 mm (1.34 in.)
Parking brake
· Type V type
· Actuation Mechanical brake acting on rear wheels
· Cable arrangement Lever
O.D=Outer Diameter
I.D=Inner Diameter
CBS : Conventional Brake System

SPECIFICATION(ESC)
Part Item Standard value Remark
4 Channel 4 Sensor
System
(MGH-40)
Motor, valve relay
Type
intergrated type Total control
HECU
Operating Voltage 10 ~ 16 V (ABS, EBD, ESC)
-40 ~ 110 °C (-40 ~ 230
Operating Temperature
°F)
Motor power 240 W
Min. Operating Voltage 12 V
Warning lamp
Max. Current consumption 80 mA
Supply voltage DC 6 ~ 16 V
Output current low 5.9 ~ 8.4 mA Typ. 7 mA
Active Wheel speed sensor
Output current high 11.8 ~ 16.8 mA Typ. 14 mA
(ABS)
Output range 1 ~ 2000 Hz
Tone wheel 48 teeth
Operating Voltage 9 ~ 16 V
Operating Angular velocity Max. 1500 °/sec
Page 4 of 235
-30 ~ 75 °C (-22 ~ 167
Operating temperature
Steering Wheel Angle °F)
Sensor Max Consumption Current 100 mA
Max Output Current 10 mA
Max Output Absorption
50 mA
Current
Operating Voltage 8 V ~ 17 V
Current Consumption Max. 140 mA
-40 ~ 85 °C (-40 ~ 185
Yaw rate & Operating Temperature
°F)
Lateral G sensor
(CAN TYPE) Yaw rate sensor
± 75 °/sec
measurement range
Lateral G sensor
± 1.5 g
measurement range
SERVICE STANDARD
Standard value Service limit
Brake pedal height 163mm( 6.42 in.)
Brake pedal full stroke 128 mm (5.04 in.)
Brake pedal free play 3~8mm(0.11~0.31in.)
Brake pedal to floorboard clearance 82mm( 3.23 in.)
Stop lamp switch outer case to pedal stopper
1.2 ~ 1.7mm(0.047 ~ 0.067in.)
clearance
Booster push rod to master cylinder piston
0 (at 500 mmHg vacuum)
clearance
Parking brake lever stroke when lever assembly is
7~8 clicks
pulled with 196N (20Kgf, 44lb force)
Front disc brake pad thickness 11 mm (0.43 in.) 2 mm (0.079 in.)
Front disc thickness (minimum) 26 mm (1.02 in.) 24.4 mm ( 0.961in.)
Front disc runout Max.0.03 mm ( 0.001in.)
Front disc thickness variation Max.0.005 mm (0.0002in.)
Rear drum brake lining thickness 4.5 mm (0.177 in.) 1.0 mm (0.039 in.)
Rear drum brake drum I.D. 228.6 mm (9 in.) Max.230.6mm (9.079 in.)
Rear disc brake pad thickness 10 mm (0.394 in.) 2 mm (0.079 in.)
Rear disc brake disc thickness 10 mm (0.394 in.) 8 mm (0.315 in.)
Rear disc runout Max.0.03mm ( 0.001in.)
Max.0.005 mm (
Rear disc thickness variation
0.0002in.)
TIGHTENING TORQUE [email protected]

Page 5 of 235
Item Nm Kgf·cm lb-ft
Proportioning valve to master cylinder 34.30~53.90 350~550 25.45~39.99
Master cylinder to booster mounting nut 7.84~11.76 80~120 5.82~8.72
Brake booster mounting nut 12.74~15.68 130~160 9.45~11.63
Brake booster vacuum hose fitting to surge tank 14.70~17.64 150~180 10.91~13.09
Bleeder screw 6.86~12.74 70~130 5.09~9.45
Brake tube nut, brake hose 12.74~16.66 130~170 9.45~12.36
Caliper assembly to knuckle 78.40~98.00 800~1000 58.2~72.7
Brake hose to front caliper 24.50~29.40 250~300 18.18~21.81
Brake hub flange nut 196.00~254.80 2000~2600 145.4~189
Push rod locking nut 15.68~21.56 160~220 11.63~15.99
Caliper guide rod bolt 21.56~31.36 220~320 15.99~23.26
TIGHTENING TORQUE (ESC)

Item Nm kgf·cm Ib-ft
Active wheel speed sensor mounting
bolt on the brake plate
·Front 7.84~8.82 80~90 5.82~6.54
·Rear 7.84~8.82 80~90 5.82~6.54
Hydraulic & electronic control unit
7.84~8.82 80~100 5.82~7.27
mounting bolt
Hydraulic & electronic control unit
16.66~25.48 170~260 12.36~18.9
mounting bracket bolt
Brake tubes nut 11.74~16.66 130~170 9.45~12.36
Air bleeder screw 6.86~12.74 70~130 5.09~9.45
Yaw rate & lateral acceleration sensor
7.84~10.78 80~110 5.82~8.0
Nut
Steering wheel nut 39.2~49 400~500 29.1~36.4
Master cylinder pressure sensor 22.09~26.13 224~265 16.29~19.27
Brake System > Brake System > Repair procedures

Operation and Leakage Check
Check all of the following items:
Page 6 of 235
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 • Check brake operation by applying the brakes. Look for damage or signs of fluid
cup inspection (B) 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 is damaged or leaking.
Caliper piston seal and Check brake operation by applying the brakes.
piston 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 Check brake operation by applying the brakes.
and 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.
BRAKE BOOSTER OPERATING TEST

For simple checking of the brake booster operation, carry out the following tests.
[email protected]
Page 7 of 235
1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains
unchanged, the booster is defective.
2. With the engine stopped, step on the brake pedal several times.
Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good
condition. If there is no change, the booster is defective.
3. With the engine running, step on the brake pedal and then stop the engine.
Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if
the pedal rises, the booster is defective.
If the above three tests are okay, the booster performance can be determined as good.
Even if one of the above three tests is not okay, check the check valve, vacuum hose and booster for defect.
VACUUM HOSE (CHECK VALVE)

INSPECTION
1. Disconnect the brake booster vacuum hose (check valve built in) (A) at the booster (B).
2. Start the engine and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not
working properly. Replace the brake booster vacuum hose and check valve and retest.
Page 8 of 235
BRAKE PEDAL BRAKE SWITCH ADJUSTMENT

PEDAL HEIGHET
1. Disconnect the brake switch connector, loosen the brake switch locknut (A), and brake off the brake switch (B)
unil 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).
Standard pedal height( with carpet removed): 163mm(6.41 in.)
[email protected]
Page 9 of 235
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

Screw in the brake switch until its plunger is fully depressed (threded end (A) touching the pad (B) on the pedal
arm) then adjust the switch 3/4 turn to until clearance between the brake switch connector. Make sure that the
brake lights go off when the pedal is released.
PEDAL FREE PLAY

Page 10 of 235
1. With the engine off, inspect the pedal free play (A) on the pedal pad (B) by pushing the pedal by hand.
Free play: 3 ~ 8 mm (0.11 ~ 0.31 in.)
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.
INSPECTION OF FRONT DISC BRAKE PAD
1. Check the brake pad thickness through the caliper body inspection hole
Pad thickness
Standard value : 11.0 mm ( 0.43 in.)
Service limit : 2.0 mm (0.0787 in.)
• If the pad lining thickness is out of specilfication, left and right pads must be replaced as a complete set.
• When the thickness difference between the left pad and right pad is large, check the sliding condition of
the piston and the guide rod.
INSPECTION OF REAR DISC BRAKE PAD
[email protected]
Page 11 of 235
1. Check the rear disk brake pad thickness through the caliper body inspection hole.
Pad thickness
Standard value : 10.0 mm (0.39 in.)
• If the pad thickness is out of specification, left and right pads must be replaced as a complete set.
• When the thickness difference between the left pad and right pad is large, check the sliding condition of
the piston and the guide rod.
Brake System > Brake System > Brake Booster > Components and Components Location
COMPONENTS
Page 12 of 235
Brake System > Brake System > Brake Booster > Repair procedures
Removal
1. Remove the master cylinder.
[email protected]
Page 13 of 235
2. Disconnect the vacuum hose (A) from the brake booster (B).
3. Remove the snap pin (A) and pin (B).
4. Remove the four booster mounting nuts (C).

5. Remove the brake booster (A).
INSTALLATION
1. Adjust push rod length of the booster, and then install the seal on the booster assembly.
Standard length (A): 106 ± 0.5 mm ( 4.173 ± 0.019 in.)

Page 14 of 235
1. Insert the booster and tighten the nuts (C).
2. Connect the booster push rod and brake pedal with a pin (B) and install a snap pin (A) to the pin (B).
Grease the pin before installing the snap pin.

Always use a new snap pin.
3. Install the master cylinder.
4. Connect the vacuum hose to the brake booster.
5. After filling the brake reservoir with brake fluid, bleed the system.
6. Check for fluid leakage.
7. Check and adjust the brake pedal for proper operation.
Brake System > Brake System > Master Cylinder > Components and Components Location
COMPONENTS
[email protected]
Page 15 of 235
Brake System > Brake System > Master Cylinder > Repair procedures
REMOVAL
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.
Page 16 of 235
1. Remove air cleaner mounting bolts (B) from the air cleaner mounting bracket and air cleaner body (A).
2. Disconnect the brake fluid level switch connectors (A), and remove the reservoir cap (B).
3. Remove the brake fluid from the master cylinder reservoir (C) with a syringe.
4. Disconnect the brake lines (A) from the master cylinder. To prevent spills, cover the hose joints with rags or shop
towels.
5. Remove the master cylinder mounting nuts (B) and washers.

6. Remove the master cylinder(C) from the brake booster (D). Be careful not to bend or damage the brake lines
when removing the master cylinder.
INSTALLATION
1. Install the master cylinder on the brake booster with 2 nuts.
[email protected]
Page 17 of 235
2. Connect 2 brake tubes(A) and the brake fluid level sensor connector.
3. Fill the brake reservoir with the brake fluid and bleed the brake system.
DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.
2. Remove the fluid level sensor.
3. Remove the reservoir from the master cylinder, after remove mounting screw (A).
4. Remove the proportioning valves (A) - CBS only.

Page 18 of 235
5. Remove the retainer ring by using the snap ring pliers then remove the primary piston assembly.
6. Remove the pin with the secondary piston pushed completely using a screwdriver. Remove the secondary piston
assembly.
Do not disassemble the primary and secondary piston assembly.
INSPECTION
1. Check the master cylinder bore for rust or scratch.
2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.
• If the cylinder bore is damaged, replace the master cylinder assembly.

• Wash the contaminated parts in alcohol.
REASSEMBLY
1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
[email protected]
Page 19 of 235
2. Carefully insert the springs and pistons in the proper direction.
3. Press the piston with a screwdriver and install the cylinder pin.
4. Press the piston with a screwdriver and install the retainer ring.
5. Mount two grommets.

6. Install the reservoir on the cylinder.
Brake System > Brake System > Proportioning Valve > Description and Operation
DESCRIPTION
Do not disassemble the proportioning valve. The proportioning valve makes the ideal distribution of fluid pressure to
the front and rear brakes to prevent the brakes from skidding in the event of rear wheel lock up and to obtain a
higher brake efficiency within the range of service brake application.
Brake System > Brake System > Proportioning Valve > Repair procedures
Page 20 of 235
INSPECTION
1. Remove the front brake tube (B) and rear brake tube (C) from the master cylinder (A).
2. Connect two pressure gauges (D); one to the output valve of the front (B) and rear (C) brake.
Be sure to bleed the system after connecting the pressure gauges.

3. With the brake applied, measure the front pressure and the rear pressure.
If the measured pressures are within the specified range as illustrated, the proportioning valve is good.
[email protected]
Page 21 of 235
4. Reconnect the brake lines in their original positions and bleed the system.
This table shows characteristics of the proportioning valve as the pressure

increases.
2WD
Front Rear
A : 15 kg/cm² A' : 15 kg/cm²
(1.47 MPa, 213 psi) (1.47 MPa, 213 psi)
B : 80 kg/cm² B' : 35.8 ± 3 kg/cm²
(7.84 MPa, 1137 psi) (3.51 ± 0.3 MPa, 509 ± 42 psi)
4WD
Front Rear
A : 15 kg/cm² A' : 15 kg/cm²
(1.47 MPa, 213 psi) (1.47 MPa, 213 psi)
B : 80 kg/cm² B' : 32.5 ± 3 kg/cm²
(7.84 MPa, 1137 psi) (3.19 ± 0.3 MPa, 462 ± 42 psi)
Brake System > Brake System > Brake Line > Components and Components Location
COMPONENT
Page 22 of 235
Brake System > Brake System > Brake Line > Repair procedures
REMOVAL
[email protected]
Page 23 of 235
1. Disconnect the brake hose(C) from the brake line(A) using a 10mm flare-nut wrench(B).
2. Remove the brake hose clip(A) from the brake hose(B).
3. Remove the connector bolt from the caliper(C), and disconnect the brake hose from the caliper.
INSTALLATION
1. 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).
2. Install the brake hose (A) on the upper brake hose bracket (B) with a new brake hose clip (C).
3. Connect the brake hose (D) to the brake line.

Page 24 of 235
4. After installing the brake hose, bleed the brake system.
INSPECTION
• Check the brake tubes for cracks, crimps and corrosion.
• Check the brake hoses for cracks, damaged and oil leakage.
• Check the brake tube flare nuts for damage and oil leakage.
INSPECTION
• Check the brake tubes for cracks, crimps and corrosion.
• Check the brake hoses for cracks, damaged and oil leakage.
• Check the brake tube flare nuts for damage and oil leakage.
Brake System > Brake System > Brake Pedal > Components and Components Location
COMPONENTS
[email protected]
Page 25 of 235
Brake System > Brake System > Brake Pedal > Repair procedures
INSPECTION
1. Check the bushing for wear.
2. Check the brake pedal for bending or twisting.
3. Check the brake pedal return spring for damage.
Page 26 of 235
4. Check the stop lamp switch
(1) Connect a circuit tester to the connector (1-2terminals) of stop lamp switch, and check whether or not there
is continuity when the plunger of the stop lamp switch is pushed in and when it is released.
(2) The stop lamp switch is in good condition if there is no continuity when plunger is pushed.
REMOVAL
1. Remove the lower crash pad.(reference to BD-"crash pad")
2. Pull down steering column shaft after removing 4 bolts.
3. Remove the stop lamp switch connector (A).
4. Remove the shift lock cable (A/T).
5. Remove the pin and snap pin.

6. Loosen the brake pedal member assembly mounting nuts and then remove the brake pedal assembly.
INSTALLATION
Coat the inner surface of the bushings with the specified grease.
Specified grease:Chassis grease MS 511-3

[email protected]
Page 27 of 235
2. Before inserting the pin, apply the specified grease to the joint pin.
3. Install the nuts with specified torque, when installing the brake pedal.
TORQUE : Nm(Kgf·cm,lb-ft); 12.74 ~ 15.68(130 ~ 160, 9.45 ~ 11.63)
4. Adjust the brake pedal height and free play.

5. Install the stop lamp switch.
Brake System > Brake System > Front Disc Brake > Components and Components Location
COMPONENTS
Page 28 of 235
[email protected]
Page 29 of 235
Brake System > Brake System > Front Disc Brake > Repair procedures
REMOVAL
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
• Avoid breathing dust particles.
• Never use on air hose or brush to clean brake assemblies.
Page 30 of 235
1. Lossen the front wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported.
Remove the front wheels.
2. Remove the guide rod bolt(B), After raise the caliper assembly(A), support it with a wire.
3. Remove pad shim(A), pad retainer(B) and pad assembly(C) in the caliper bracket.
INSTALLATION
1. Install the pad retainers (A) on the caliper bracket.
[email protected]
Page 31 of 235
2. Check the foreign material at the pad shims (A) and the back of the pads (B).
Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
3. Install the brake pads (B) and pad shims (A) correctly. Install the pad with the wear indicator (C) on the inside.
If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss
of braking efficiency.
4. Push in the piston (A) so that the caliper will fit over the pads. Make sure that the piston boot is in position to
prevent damaging it when pivoting the caliper down.
5. Pivot the caliper down into position. Being careful not to damage the pin boot, install the guide rod bolt (B) and
torque it to proper specification.
Insert the piston in the cylinder using the special tool (09581-11000).
Page 32 of 235
6. Depress the brake pedal several times to make sure the brakes work, then test-drive.
Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been
replaced as a set.Several applications of the brake will restore the normal pedal stroke.
Be sure to do this before driving the vehicle.
7. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
INSPECTION
FRONT BRAKE DISC THICKNESS CHECK
1. Remove all rust and contramination from the surface, and measure the disc thickness at 8 points, at least, of same
distance (5 mm) front the brake disc outer circle.
Front brake disc thickness

Standard value : 26.0 mm(1.024 in.)
Limit : 24.4 mm(0.961 in.)
2. Thickness variation should not exceed 0.005 mm (0.0004 in.) (circumference) and 0.01 mm ( in.)(radius) at any
directions.
3. If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
FRONT BRAKE PAD CHECK
[email protected]
Page 33 of 235
1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Pad thickness
Standard value : 11 mm (0.43 in.)
2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
FRONT BRAKE DISC RUN OUT CHECK
1. Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the run out
of the disc.
Brake disc run out

Limit : 0.1 mm (0.004 in.) or less
Extremly tight specification : 0.04 mm (0.0016 in.)
2. If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out
again.
3. If the run out does not exceed the limit specification, install the brake disc after turning it 180° and then check the
run out of the brake disc again.
4. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc.
Seize of Front brake disc

Page 34 of 235
1. Remove the brake disc from hub using M8 screw(A) if the brake disc has been seized with the hub due to
corrosion or overheat.
Be careful not to use the hammer. The disc can be damaged if you remove the disc from the hub by
hammer.
Brake System > Brake System > Rear Disc Brake > Components and Components Location
COMPONENTS
[email protected]
Page 35 of 235
Brake System > Brake System > Rear Disc Brake > Repair procedures
REMOVAL
1. Raise the rear of the vehicle and make sure it is securely supported. Remove the rear wheel.
Page 36 of 235
2. Remove the guide rod bolt(B), After raise the caliper assembly(A), support it with a wire.
3. Remove pad shim(A), pad retainer(B) and pad assembly(C) in the caliper bracket.
INSTALLATION
1. Install the pad retainers(A) on the caliper bracket.
2. Check the foreign material at the pad shim (A) and the back of the pads (B).
3. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
[email protected]
Page 37 of 235
4. Install the brake pads (B) and pad shims (A) correctly. Install the pad with the wear indicator (C) on the inside.
If you are reusing the pads, always reinstall the brake pads in their original position to prevent a momentary loss
of braking efficiency.
5. Push in the piston (A) so that the caliper will fit over the pads. Make sure that the piston boot is in position to
prevent damaging it when pivoting the caliper down.
6. Pivot caliper down into position. Being careful not to damage the pin boot, install the guide rod bolt (B) and
torque it to proper specification
Insert the piston in the cylinder using the special tool(09581-11000).
7. Depress the brake pedal several time to make sure the brakes work, then test-drive.
Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been
replaced as a set. Several applications of the brake will restore the normal pedal stroke.
8. After installaion, check for leaks at hose and line joints or connections, and retighten if necessary.
INSPECTION
REAR BRAKE DISC THICKNESS CHECK
Page 38 of 235
1. Remove all rust and contamination from the disc surface, and then measure the disc thickness at 8 points, al least,
of the same distance (5 mm) from the brake disk outer circle.
Rear brake disc thickness

Standard value : 10.0 mm (0.39 in.)
Limit : 8.0 mm (0.315 in.)
2. Thickness variation should not exceed 0.005 mm(0.0002 in.) (circumference) and 0.01 mm(0.0004 in.) (radius)
at any directions.
3. If wear exceeds the limit, replace the discs and pad assembly for left and right of the vehicle.
REAR BRAKE PAD CHECK

1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Pad thickness
Standard value : 10.0 mm ( 0.39 in.)
2. Check that grease is applied, and the pad and backing metal for damage.
REAR BRAKE DISC RUN OUT CHECK
[email protected]
Page 39 of 235
1. Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the run out
of the disc.
Brake disc run out

Limit : 0.1 mm (0.004 in.) or less
2. If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out
again.
3. If the run out does not exceed the limit specification, install the brake disc after turning it 180° and then check the
run out of the brake disc again.
4. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc.
Seize of Rear brake disc
1. Remove the brake disc from hub using M8 screw(A) if the brake disc has been seized with the hub due to
corrosion or overheat.
Be careful not to use the hammer. The disc can be damaged if you remove the disc from the hub by
hammer.
Page 40 of 235
Brake System > Parking Brake System > Components and Components Location
COMPONENTS
Brake System > Parking Brake System > Repair procedures

Parking brake check and adjustment
INSPECTION
[email protected]
Page 41 of 235
1. Pull the parking brake lever (A) with 196 N (20 kg, 44lbf) force to fully apply the parking brake. The parking
brake lever should be locked within the specified number of clicks.
Lever locked clicks:7~8
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 floor console.

Page 42 of 235
4. Tighten the adjusting nut (A) until the parking brakes are dragged slightly when the rear wheels are turned.
5. Release the parking brake lever completely, and check if parking brakes are not dragged 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 completly.
7. Reinstall the floor console.
Brake System > Parking Brake System > Parking Brake Switch > Repair procedures
INSPECTION
1. Remove the floor console and the switch (B) from the connector (A).
2. Inspect the continuity between (-) terminal and the ground.

A. When the brake lever is pulled, there should be the continuity between them.
B. When the brake lever is released, there should be no continuity between them.
Brake System > Parking Brake System > Parking Brake Assembly > Repair procedures
Adjustment
Parking Brake Shoe Clearance Adjustment
Disc Brake Type
1. Lift the vehicle, and make sure it is securely supported.
2. Remove the rear tire and wheel.
3. Remove the plug from the disc.
[email protected]
Page 43 of 235
4. Turn the adjusting wheel in arrow direction as shown until the disc won’t be rotated by tangential force of
29.4N(3kgf, 6.6Ib) using the (-)screw driver (A). Then turn back the adjusting wheel by 5 notches.
5. Install the rear tire and wheel after installing the plug.
Parking Brake Lever Stroke Adjustment
1. Lift the vehicle, and make sure it is securely supported.
2. Remove the floor console. (Refer to BD Gr. - "Floor console")
3. After the full stroke operation of the brake lever over 3 times for setting the cable, the travel must be between 8
notches when applying a force of 196N(20kgf, 44Ib) at 40mm from the end of lever assembly (excluding button)
by adjusting nut (A).
4. Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are
turned. Readjust if necessary.
5. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully.
6. Parking indicator lamp must be “OFF”when the lever assembly is released. It must be “ON” when the lever
assembly is operated by 1 notch.
7. Install the floor console. (Refer to BD Gr. - "Floor console")
After repairing the parking brake shoe, adjust the brake shoe clearance, and then adjust the parking brake
lever stroke.
Page 44 of 235
REMOVAL
The parking brake cables must not be bent or distorted.

This will lead to stiff operation and premature failure.
1. Remove the floor console.
2. Loosen the adjusting nut (A) and remove the parking brake cables.
3. Disconnect the connector(A) of the parking brake switch connector.
4. Remove the bolts and parking brake lever assembly(A).

5. Remove the wheel and tire.
6. Remove the brake drum and the brake shoe (Refer to the rear drum brake).
[email protected]
Page 45 of 235
7. Remove the parking brake cable(A) from the brake shoe.
8. Remove the parking brake cable retaining ring (B), from the parking brake cable (A).
9. Remove the parking brake cable assembly.
INSTALLATION
1. Install the removed parts in the reverse order of removal.
2. Apply the specified grease to each sliding parts of the ratchet plate or the ratchet pawl.
Specified grease :
Multi purpose grease SAE J310, NLGI No.2
3. After installing the parking brake cable adjuster, adjust the parking brake lever stroke (Refer to the parking brake
check and adjustment).
Brake System > ESC(Electronic Stability Control) System > Components and Components Location
COMPONENTS
Page 46 of 235
[email protected]
Page 47 of 235
Brake System > ESC(Electronic Stability Control) System > Description and Operation
description of ESC
Optimum driving safety now has a name : ESC, the Electronic Stability Control.
ESC is based on the MGH 40 ABS Hydraulic System. ESC recognizes critical driving conditions, such as panic
reactions in dangerous situations, and stabilizes the vehicle by wheel-individual braking and engine control
intervention with no need for actuating the brake or the gas pedal.
ESC adds a further function known as Active Yaw Control (AYC) to the ABS, TCS, EBD and EDC functions.
Whereas the ABS/TCS function controls wheel slip during braking and acceleration and, thus, mainly intervenes in
the longitudinal dynamics of the vehicle, active yaw control stabilizes the vehicle about its vertical axis.
Page 48 of 235
This is achieved by wheel individual brake intervention and adaptation of the momentary engine torque with no need
for any action to be taken by the driver.
ESC essentially consists of three assemblies : the sensors, the electronic control unit and the actuators.
The electronic control unit incorporates the technological experience accumulated in connection with the MGH 40
system, but has been substantially expanded in terms of capacity and monitoring concept in order to permit the
additional sensor signals and arithmetic operations to be processed and converted into corresponding valve, pump
and engine control commands. Two 16-bit processors and one 8-bit processor, which monitor each other,
cooperate to handle these requirements.
Of course, the stability control feature works under all driving and operating conditions. Under certain driving
conditions, the ABS/TCS function can be activated simultaneously with the ESC function in response to a command
by the driver.
In the event of a failure of the stability control function, the basic safety function, ABS, is still maintained.
DESCRIPTION OF ESC CONTROL

ESC system includes ABS/EBD, TCS and AYC function.
ABS/EBD function : The ECU changes the active sensor signal (current shift) coming from the four wheel sensors to
the square wave.By using the input of above signals, the ECU calculates the vehicle speed and the acceleration &
deceleration of the four wheels.And, the ECU judges whether the ABS/EBD should be actuated or not.
TCS function prevents the wheel slip of drive direction by adding the brake pressure and engine torque reduction via
CAN communication.TCS function uses the wheel speed sensor signal to determine the wheel slip as far as ABS
function.
AYC function prevents unstable maneuver of the vehicle. To determine the vehicle maneuver, AYC function uses the
maneuver sensor signals(Yaw Rate Sensor, Lateral Acceleration Sensor, Steering Wheel Angle Sensor).If vehicle
maneuver is unstable (Over Steer or Under Steer), AYC function applies the brake pressure on certain wheel, and
send engine torque reduction signal by CAN.
After the key-on, the ECU continually diagnoses the system failure. (self-diagnosis)If the system failure is detected,
the ECU informs driver of the system failure through the BRAKE/ABS/ESC warning lamp. (fail-safe warning)
[email protected]
Page 49 of 235
INPUT AND OUTPUT DIAGRAM

Page 50 of 235
ESC OPERATION MODE

ESC HYDRAULIC SYSTEM DIAGRAM
[email protected]
Page 51 of 235
1. ESC Non-operation : Normal braking.

Solenoid Motor
Continuity Valve TC Valve
valve pump
IN (NO) OFF OPEN
OFF OFF
OUT (NC) OFF CLOSE
Page 52 of 235
2. ESC operation
Solenoid valve Continuity Valve Motor pump TC Valve
Understeering IN(NO) OFF OPEN
(Only inside of
rear wheel) OUT(NC) OFF CLOSE
ON ON
Oversteering IN(NO) OFF OPEN
(Only outside
of front wheel) OUT(NC) OFF CLOSE
ESC HECU EXTERNAL DIAGRAM
ABS Warning Lamp module

The active ABS warning lamp module indicates the self-test and failure status of the ABS .The ABS warning lamp
shall be on:
- During the initialization phase after IGN ON. (continuously 3 seconds).
- In the event of inhibition of ABS functions by failure.
- During diagnostic mode.
- When the ECU Connector is seperated from ECU.
EBD/PARKING BRAKE WARNING LAMP MODULE
The active EBD warning lamp module indicates the self-test and failure status of the EBD. However, in case the
[email protected]
Page 53 of 235
Parking Brake Switch is turned on, the EBD warning lamp is always turned on regardless of EBD functions. The
EBD warning lamp shallbe on:
- When the Parking Brake Switch is ON or brake fluid level is low.
- When the EBD function is out of order .
- When the ECU Connector is seperated from ECU.
ESC Warning Lamp (ESC system)
The ESC warning lamp indicates the self-test and failure status of the ESC.
The ESC warning lamp is turned on under the following conditions :
- In the event of inhibition of ESC functions by failure.
- When driver trun off the ESC function by on/off switch.
ESC Function Lamp (ESC system)
The ESC function lamp indicates the self-test and operating status of the ESC.
The ESC Function lamp operates under the following conditions :
- When the ESC control is operating. (Blinking - 2Hz)
ESC On/Off Switch (ESC system)
The ESC On/Off Switch shall be used to toggle the ESC function between On/Off states based upon driver input.
The On/Off switch shall be a normally open, momentary contact switch.Closed contacts switch the circuit to ignition.
Initial status of the ESC function is on and switch toggle the state.
Brake System > ESC(Electronic Stability Control) System > Schematic Diagrams
CIRCUIT DIAGRAM - ESC(1)
Page 54 of 235
[email protected]
Page 55 of 235

Page 56 of 235
ESC connector input/output

Connector Terminal
Specification Remark
No Description
Over voltage range : 17 ± 0.5V
Operating voltage range :
9.5 ± 0.5V < V < 17 ± 0.5V
31 IGNITION1(+)
Low voltage range :
7.0 ± 0.5V < V < 9.5 ± 0.5V
Max. current : I < 500mA
Max leakage current : I < 0.8mA
Operating voltage range :
1 POS.BATTERY.(SOLENOID)
9.5 ± 0.5V < V < 17 ± 0.5V
Max. current : I < 40A
Operating voltage range:
9.5 ± 0.5V < V < 16.5 ± 0.5V
2 POS.BATTERY.(MOTOR) Rush current : I < 100A
[email protected]
Page 57 of 235
Max current : I < 40A
Max leakage current : I < 0.2mA
Rated current : I <500mA
46 GROUND
Max. current: I < 40A
Rush current : I < 100A
45 PUMP MOTOR GROUND
Max current : I < 40A
YAW & LATERAL G
16 Rated current : I <150mA
SENSOR GROUND
STEERING ANGLE SENSOR
30 Rated current : I <100mA
GROUND
Max Output current : I < 150mA
17 YAW SENSOR POWER
Max Output voltage : V(IGN) ± 1V
STEERING ANGLE SENSOR Max Output current : I < 100mA
3
POWER Max Output voltage : V(IGN) ± 1V
34 BRAKE LIGHT SWITCH Input voltage (Low) : 0V ≤ V ≤ 3.0V
32 BRAKE SWITCH Input voltage (High) : 7.0V ≤ V ≤ 16.0V
Input voltage (Low) : 0V ≤ V_Low ≤ 3.0V
Input voltage (High) : 7.0V ≤ V_High ≤
8 PARKING BRAKE SWITCH
16.0V
Max input current : I < 10mA
Max current : I < 16mA
SENSOR FRONT RIGHT
27 External pull up resistance :1 KΩ < R
OUTPUT
Output duty :50 ± 20%
Input voltage (Low) :0V ≤ V ≤ 3.0V
18 ESC ON/OFF SWITCH Input voltage (High) : 7.0V ≤ V ≤ 16.0V
Max input current:I <10mA
15 CAN BUS LINE(LOW)
Max. current : I < 10mA
14 CAN BUS LINE(HIGH)
SENSOR FRONT LEFT
4
POWER
SENSOR FRONT RIGHT
5
POWER Output voltage : IGN (V) ± 1V
SENSOR REAR LEFT Output current : Max 30mA
7
POWER
SENSOR REAR RIGHT
6
POWER
SENSOR FRONT LEFT
9
SIGNAL
SENSOR FRONT RIGHT Input current LOW : 5.9 ~ 8.4mA
10
SIGNAL Input current HIGH :11.8 ~ 16.8mA Typ. 7mA
SENSOR REAR LEFT Frequency range :1 ~ 2500Hz Typ. 14mA
12 Input duty : 50 ± 20%
SIGNAL
Page 58 of 235
SENSOR REAR RIGHT
11
SIGNAL
24
PHASE 1
Input duty (ST1, ST2): 50 ± 10%
Typ. 20deg
STEERING ANGLE SENSOR Phase difference (ST1, ST2): 2 ± 0.6deg
25 Typ. 3.5V
PHASE 2 High voltage: 3.0 V < V < 4.1V
Typ. 1.5V
Low voltage: 1.3 V < V < 2.0V
26
PHASE N
Input voltage
IL(V) < 0.3 IGN (V)
DIAGNOSIS IH(V) > 0.7 IGN (V)
13
INPUT/OUTPUT Output voltage
OL(V) < 0.2 IGN (V)
OH(V) > 0.8 IGN (V)
37 ESC W/LAMP DRIVE
Current : I < 300mA (12V)
38 ABS/EBD W/LMAP DRIVE Voltage range : 0 ~ 18V
40 ESC F/LAMP DRIVE Min. shunt resistance : 500KΩ
Brake System > ESC(Electronic Stability Control) System > Troubleshooting

FAILURE DIAGNOSIS
1. In principle, ESC and TCS controls are prohibited in case of ABS failure.
2. When ESC or TCS fails, only the failed system control is prohibited.
3. However, when the solenoid valve relay should be turned off in case of ESC failure, refer to the ABS fail-safe.
4. Information on ABS fail-safe is identical to the fail-safe in systems where ESC is not installed.
MEMORY OF FAIL CODE
1. It keeps the code as far as the backup lamp power is connected. (O)
2. It keeps the code as far as the HCU power is on. (X)
FAILURE CHECKUP
1. Initial checkup is performed immediately after the HECU power on.
2. Valve relay checkup is performed immediately after the IG2 ON.
3. It executes the checkup all the time while the IG2 power is on.
4. Initial checkup is made in the following cases.
(1) When the failure is not detected now
(2) When ABS and ESC are not in control.
(3) Initial checkup is not made after ECU power on.
(4) If the vehicle speed is over 5 mph(8 km/h) when the brake lamp switch is off.
(5) When the vehicle speed is over 24.8 mph(40 km/h).
5. Though, it keeps on checkup even if the brake lamp switch is on.
6. When performing ABS or ESC control before the initial checkup, stop the initial checkup and wait for the HECU
power input again.
7. Judge failure in the following cases.
(1) When the power is normal.
(2) From the point in which the vehicle speed reaches 4.9 mph(8 km/h) after HECU power on.
COUNTERMEASURES IN FAIL [email protected]
Page 59 of 235
1. Turn the system down and perform the following actions and wait for HECU power OFF.
2. Turn the valve relay off.
3. Stop the control during the operation and do not execute any until the normal condition recovers.
WARNING LAMP ON
1. ABS warning lamp turns on when ABS is fail.
2. ESC operation lamp turns on and ESC OFF warning lamp blinks when ESC is fail.
When power voltage and valve relay voltage are abnormal, input/output related failure judgment is not made.
scan tool CHECK
1. Turn the ignition switch OFF.
2. Connector the scan tool to the 16P data link connector located the driver'd side kick panel.
3. Turn the ignition switch ON.

4. Check for diagnostic trouble using the scan tool
5. After completion trouble of the repair or correction of the problem, erase the stored fault codes the clear key on
the scan tool.
6. Disconnect the scan tool from the 16P data link connector.
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Page 60 of 235
NOTES WITH REGARD TO DIAGNOSIS

The phenomena listed in the following table are not abnormal.
Phenomenon Explanation
System check sound When starting the engine, a thudding sound can sometimes be heard coming
from inside the engine compartment. This is because the system operation
check is being performed.
ABS operation sound 1. Sound of the motor inside the ABS hydraulic unit operation (whine).
2. Sound is generated along with vibration of the brake pedal (scraping).
3. When ABS operates, sound is generated from the vehicle chassis due to
repeated brake application and release
(Thump : suspension; squeak: tires)
ABS operation (Long braking For road surfaces such as snow-covered and gravel roads, the braking distance
distance) for vehicles with ABS can sometimes be longer than that for other vehicles.
Accordingly, advise the customer to drive safely on such roads by lowering the
vehicle speed.
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
[email protected]
Page 61 of 235

If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem
symptom in the order given in the table below and proceed to the relevant troubleshooting page.
Page 62 of 235
Symptom Suspect Area
ABS does not operate. Only when 1. -4. are all normal and the problem is still
occurring, replace the HECU.
1. Check the DTC reconfirming that the normal code is
output.
2. Power source circuit.
3. Speed sensor circuit.
4. Check the hydraulic circuit for leakage.
ABS does not operate intermittently. Only when 1. -4. are all normal and the problem is still
occurring, replace the ABS actuator assembly.
1. Check the DTC reconfirming that the normal code is
output.
2. Wheel speed sensor circuit.
3. Stop lamp switch circuit.
4. Check the hydraulic circuit for leakage.
Communication with Scan tool is not possible. 1. Power source circuit
(Communication with any system is not possible) 2. Diagnosis line
Communication with Scan tool is not possible. 1. Power source circuit
(Communication with ABS only is not possible) 2. Diagnosis line
3. HECU
When ignition key is turned ON (engine OFF), the ABS 1. ABS warning lamp circuit
warning lamp does not light up. 2. HECU
Even after the engine is started, the ABS warning lamp 1. ABS warning lamp circuit
remains ON. 2. HECU
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.
DETECTING CONDITION
Trouble Symptoms Possible Cause
Brake operation varies depending on driving conditions and road - Faulty power source circuit
surface conditions, so diagnosis can be difficult.However if a normal - Faulty wheel speed sensor circuit
DTC is displayed, check the following probable cause. When the - Faulty hydraulic circuit for leakage
problem is still occurring, replace the ABS control module. - Faulty HECU
INSPECTION PROCEDURES
DTC INSPECTION
1. Connect the scan tool with the data link connector and turn the ignition switch ON.
[email protected]
Page 63 of 235
2. Verify that the normal code is output.
Is the normal code output?
Check the power source circuit.
Erase the DTC and recheck using scan tool.

CHECK THE POWER SOURCE CIRCUIT.
1. Disconnect the connector from the ABS(ESC) control module.
2. Turn the ignition switch ON, measure the voltage between terminal 3(31) of the ABS(ESC) control module
harness side connector and body ground.
Specification : approximately B+
Is the voltage within specification?
Check the ground circuit.
Check the harness or connector between the fuse (10A) in the engine compartment junction block and the
ABS(ESC) control module. Repair if necessary.
CHECK THE GROUND CIRCUIT.

Page 64 of 235
2. Check for continuity between terminals 25(45), 26(46) of the ABS(ESC) control module harness side connector
and ground point.
Is there continuity?
Check the wheel speed sensor circuit.
Repair an open in the wire and ground point.
CHECK THE WHEEL SPEED SENSOR CIRCUIT.

Refer to the DTC troubleshooting procedures.
Is it normal?
Check the hydraulic circuit for leakage.
Repair or replace the wheel speed sensor.

CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE.
Refer to the hydraulic lines.
Inspect leakage of the hydraulic lines.
Is it normal?
The problem is still occurring, replace the ABS(ESC) control module.
Repair the hydraulic lines for leakage.
DETECTING CONDITION
[email protected]
Page 65 of 235
Brake operation varies depending on driving conditions and road - Faulty power source circuit
surface conditions, so diagnosis can be difficult. However if a - Faulty wheel speed sensor circuit
normal DTC is displayed, check the following probable cause. - Faulty hydraulic circuit for leakage
When the problem is still occurring, replace the ABS control - Faulty HECU
module.
DTC INSPECTION
1. Connect the scan tool with the data link connector and turn the ignition switch ON.
2. Verify that the normal code is output.
Is the normal code output?
Check the wheel speed sensor circuit.
Erase the DTC and recheck using scan tool.

CHECK THE WHEEL SPEED SENSOR CIRCUIT.
Refer to the DTC troubleshooting procedures.
Is it normal?
Check the stop lamp switch circuit.
Repair or replace the wheel speed sensor.

CHECK THE STOP LAMP SWITCH CIRCUIT.
1. Check that stop lamp lights up when brake pedal is depressed and turns off when brake pedal is released.
2. Measure the voltage between terminal 14(34) of the ABS(ESC) control module harness side connector and
body ground when brake pedal is depressed.
Is the voltage within specification?
Check the hydraulic circuit for leakage.
Repair the stop lamp switch. Repair an open in the wire between the ABS(ESC) control module and the stop
lamp switch.
Page 66 of 235
CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE.

Refer to the hydraulic lines.
Inspect leakage of the hydraulic lines.
Is it normal?
The problem is still occurring, replace the ABS control module.
Repair the hydraulic lines for leakage.
DETECTING CONDITION
Possible defect in the power supply system (including ground) for - An open in the wire
the diagnosis line. - Poor ground
- Faulty power source circuit
CHECK THE POWER SUPPLY CIRCUIT FOR THE DIAGNOSIS
Measure the voltage between terminal 9 of the data link connector and body ground.
Is voltage within specification?
Check the ground circuit for the diagnosis.
Repair an open in the wire. Check and replace fuse (15A) from the engine compartment junction block.
[email protected]
Page 67 of 235
CHECK THE GROUND CIRCUIT FOR THE DIAGNOSIS

Check for continuity between terminal 5 of the data link connector and body ground.
Repair an open in the wire between terminal 5 of the data link connector and ground point.
DETECTING CONDITION
When communication with scan tool is not possible, the cause may - An open in the wire
be probably an open in the HECU power circuit or an open in the - Faulty HECU
diagnosis output circuit. - Faulty power source circuit
CHECK FOR CONTINUITY IN THE DIAGNOSIS LINE
1. Disconnect the connector from the ABS control module.
2. Check for continuity between terminals 11(13) of the ABS(ESC) control module connector and 1 of the data link
connector.
Check the power source of ABS(ESC) control module.
Repair an open in the wire.

CHECK THE POWER SOURCE OF ABS(ESC) CONTROL MODULE
Page 68 of 235
2. Turn the ignition switch ON, measure the voltage between terminal 3(31) of the ABS(ESC) control module
harness side connector and body ground.
Check for poor ground.
Check the harness or connector between the fuse (10A) in the engine compartment junction block and the
ABS(ESC) control module.Repair if necessary.
CHECK FOR POOR GROUND

Check for continuity between terminal 5 of the data link connector and ground point.
Replace the ABS(ESC) control module and recheck.
Repair an open in the wire or poor ground.
DETECTING CONDITION
[email protected]
Page 69 of 235
When current flows in the HECU the ABS warning lamp turns from - Faulty ABS warning lamp bulb
ON to OFF as the initial check.Therefore if the lamp does not light - Blown fuse is related to ABS in the
up, the cause may be an open in the lamp power supply circuit, a engine compartment junction block
blown bulb, an open in the both circuits between the ABS warning - Faulty ABS warning lamp module
lamp and the HECU, and the faulty HECU. - Faulty HECU
PROBLEM VERIFICATION
Disconnect the connector the ABS(ESC) HECU and turn the ignition switch ON.
Does the ABS waring lamp light up?
Check the power source for the ABS warning lamp.
Inspect again after replacing the ABS(ESC) HECU.

CHECK THE POWER SOURCE FOR THE ABS WARNING LAMP
1. Disconnect the instrument cluster connector (M06-2) and turn the ignition switch ON.
2. Measure the voltage between terminal (M01-C) 16 of the cluster harness side connector and body ground.
Check for blown fuse.
Check the CAN circuit resistance for ABS warning lamp.

CHECK FOR BLOWN FUSE
Check continuity of fuse (10A) from the engine compartment junction block.
Repair an open in the wire between ABS fuse and 1 of cluster connector.
Replace the blown fuse.

Page 70 of 235
DETECTING CONDITION
If the HECU detects trouble, it lights the ABS warning lamp while at - An open in the wire
the same time prohibiting ABS control. At this time, the HECU - Inoperative instrument cluster assembly
records a DTC in memory.Even though the normal code is output, - Inoperative ABS warning lamp module
the ABS warning lamp remains ON, then the cause may be - Inoperative HECU
probably an open or short in the ABS warning lamp circuit.
CHECK DTC OUTPUT.
1. Connect the Scan Tool to the 16P data link connector located behind the driver's side kick panel.
2. Check the DTC output using Scan Tool.
Is DTC output?
Repair circuit indicated by code output.
Check instrument cluster.

CHECK INSTRUMENT CLUSTER
Disconnect the cluster connector and turn the ignition switch ON.
Does the ABS warning lamp remains ON?
Replace the instrument cluster.
Check for open the wire.

CHECK FOR OPEN IN THE WIRE
Check for continuity in the wire between cluster and ABS control module.
Replace the ABS control module and recheck.
Repair an open in the wire between cluster and ABS control module.
BLEEDING OF BRAKE SYSTEM
This procedure should be followed to ensure adequate bleeding of air and filling of the ABS unit, brake lines and
master cylinder with brake fluid.
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
[email protected]
Page 71 of 235
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.
3. Connect the scan tool to the data link connector located underneath the dash panel.
4. Select and operate according to the instructions on the scan tool screen.
You must obey the maximum operating time of the ABS motor with the scan tool to prevent the motor
pump from burning.
(1) Select vehicle name.
(2) Select Anti-Lock Brake system.
(3) Select air bleeding mode.
(4) Press "YES" to operate motor pump and solenoid valve.
(5) Wait 120 sec. before operating the air bleeding.

(If not, you may damage the motor.)
Page 72 of 235
(6) Perform the air bleeding.
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.
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 (0.7 ~ 1.3 kgf.m, 5.4 ~ 9.5 lb-ft)
DIAGNOSTIC TROUBLE CODE CHART(DTC)

Warning lamp
DTC condition
Trouble description Remark
CODE
EBD ABS ESP
1 C1101 Battery Voltage High ● ● ● ABS/ESC
2 C1102 Battery Voltage Low ○/● ● ● ABS/ESC
3 C1112 Sensor Power Voltage ○ ● ● ABS/ESC
4 C1200 Wheel Speed Sensor Front-LH Open/Short
[email protected]
○/● ● ● ABS/ESC
Page 73 of 235
Wheel Speed Sensor Front-LH Range / Performance /
5 C1201 ○/● ● ● ABS/ESC
Intermittent
6 C1202 Wheel Speed Sensor Front-LH Invalid/no Signal ○/● ● ● ABS/ESC
7 C1203 Wheel Speed Sensor Front-RH Open/Short ○/● ● ● ABS/ESC
Wheel Speed Sensor Front-RH Range / Performance /
8 C1204 ○/● ● ● ABS/ESC
Intermittent
9 C1205 Wheel Speed Sensor Front-RH Invalid/no Signal ○/● ● ● ABS/ESC
10
C1206 Wheel Speed Sensor Rear-LH Open/Short ○/● ● ● ABS/ESC
Wheel Speed Sensor Rear-LH Range / Performance /

11 C1207 ○/● ● ● ABS/ESC
Intermittent
12 C1208 Wheel Speed Sensor Rear-LH Invalid/no Signal ○/● ● ● ABS/ESC
13 C1209 Wheel Speed Sensor Rear-RH Open/Short ○/● ● ● ABS/ESC
Wheel Speed Sensor Rear-RH Range / Performance /
14 C1210 ○/● ● ● ABS/ESC
Intermittent
15 C1211 Wheel Speed Sensor Rear-RH Invalid/no Signal ○/● ● ● ABS/ESC
16 C1235 Primary Pressure Sensor-Electrical ○ ○ ● ESC only
17
C1237 Primary Pressure Sensor-Signal ○ ○ ● ESC only
18 C1259 Steering Angle Sensor - Electrical ○ ○ ● ESC only

19 C1260 Steering Angle Sensor-Signal ○ ○ ● ESC only
20 C1274 Longitudinal G Sensor Open/Short ○ ● ● 4WD only
21
C1275 Longitudinal G Sensor Range/Performance error ○ ● ● 4WD only
22
C1282 Yaw Rate & Lateral G Sensor-Electrical ○ ○ ● ESC only
23
C1283 Yaw Rate & Lateral G Sensor-Signal ○ ○ ● ESC only
24
C1503 ESC Switch Error ○ ○ ● ESC only
25
C1513 Brake Switch Error ○ ○ ● ESC only
26
C1604 ECU Hardware Error ○ ○ ● ABS/ESC
27
C1605 CAN Hardware Error ○ ○ ● ABS/ESC
28
C1611 CAN Time-out ECM ○ ○ ● ABS/ESC
29
C1612 CAN Time-out TCM ○ ○ ● ABS/ESC
Page 74 of 235
30
C1613 CAN Wrong Message ○ ○ ● ABS/ESC
31
C1616 CAN Bus off ○ ○ ● ABS/ESC
32
C1647 Sensor CAN Hardware Error ● ● ● ESC only
33
C2112 Valve Relay Error ○ ○ ● ABS/ESC
34
C2227 Excessive Temperature Of Brake Disc ● ● ● ESC only
35
C2380 ABS / ESC Valve Malfunction ○ ● ● ABS/ESC
36
C2402 Motor Electrical ○ ● ● ABS/ESC
Brake System > ESC(Electronic Stability Control) System > EBD (Electronic Brake-force Distribution)
> Description and Operation
EBD (ELECTRONIC BRAKE-FORCE DISTRIBUTION) OPERATION
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
tothe 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
[email protected]
Page 75 of 235
Brake System > ESC(Electronic Stability Control) System > ESC Control Module > Components and
Components Location
COMPONENTS
Page 76 of 235
Brake System > ESC(Electronic Stability Control) System > ESC Control Module > Repair procedures
REMOVAL
1. Turn the ignition switch OFF.
2. Pull up the lock (A) of the ABS control unit 26P connector , then disconnect the connector.
3. Disconnect the brake tubes from the HECU by unlocking the nuts counterclockwise with a spanner.
[email protected]
Page 77 of 235
4. Loosen the 3 ABS HECU bracket bolts, then remove HECU and bracket.
1. Never attempt to disassemble the HECU.

2. The HECU must be transported and stored in.
3. Never shock to the HECU.
5. Remove the 3 bolts, then remove the bracket from HECU.
INSTALLATION
2. Tighten the HECU mounting bolts and nuts to the specified torque.
Tightening torque
HECU bracket nuts :
11 ~ 14 Nm (1.1 ~ 1.4 kgf.m, 8.1 ~ 10.3 Ib-ft)
HECU bracket mounting bolt :
16.7 ~ 25.5 Nm (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 Ib-ft)
Brake System > ESC(Electronic Stability Control) System > Front Wheel Speed Sensor > Description
and Operation
DESCRIPTION
A toothed rotor is fixed to the rotating member of the wheel, and the sensor is fixed to the static member of the
suspension. As the wheel rotates the toothed rotor causes magnetic flux changes in the magnetic field of the
permanent magnet. The sensor element senses these changes. Depending on the flux changes the sensor sends a
signal out to the ECU. The change in magnet flux thus the sensor signal is directly related to the wheel speed.
The controller monitors the sensor signal, compares the four wheel-speed signals and initiates action as required.
Page 78 of 235
SPECIFICATIONS
Item Standard Value Remark
Supply voltage DC 12 V
Operating temperature -40 ~1 20 °C R = 100 Ω
7 mA(5.9 ~
Low
8.4 mA)
Output current range
14 mA(11.8
High
~ 16.8 mA)
Frequency range 1 ~ 2000 Hz
0.5 ~ 1.5 mm(0.0197 ~
Airgap
0.0591 in.)
Tone wheel Number 48
Brake System > ESC(Electronic Stability Control) System > Front Wheel Speed Sensor > Components
COMPONENTS
[email protected]
Page 79 of 235
Brake System > ESC(Electronic Stability Control) System > Front Wheel Speed Sensor > Repair
procedures
REMOVAL
FRONT WHEEL SPEED SENSOR
Page 80 of 235
1. Remove the front wheel speed sensor mounting bolt (A).
2. Remove the front wheel guard (B), after removing the mud guard (A).
3. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector (A).
REAR WHEEL SPEED SENSOR
[email protected]
Page 81 of 235
1. Remove the rear wheel speed sensor mounting bolt (A).
2. Remove the rear seat side pad then disconnect the rear wheel speed sensor connector (A).
INSPECTION
1. Measure the output voltage between the teminal of the wheel speed sensor and the body ground.
In order to protect the wheel speed sensor, when measuring output voltage, a 100Ω resister must be used
as shown.
Page 82 of 235
1. Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage
as shown below.
• V_low : 590 mV ~ 840 mV

• V_high : 1.18 V ~ 1.68 V
• Frequency range : 1 ~ 2,000 Hz
Brake System > ESC(Electronic Stability Control) System > Yaw-rate and Lateral G Sensor >
Description and Operation
DESCRIPTION
When the vehicle is turning with respect to a vertical axis the yaw rate sensor detects the yaw rate electroniclly by
the vibration change of plate fork inside the yaw rate sensor.
If yaw velocity reaches the specific velocity after it detects the vehicle'yawing, the ESC control is reactivated.
The later G sensor senses vehicle's lateral G. A small element inside the sensor is attached to a deflectable leverarm
by later G.
Direction and magnitude of lateral G loaded to vehicle can be known with electrostatic capacity changing according
to lateral G.
The sensor is located in the front passenger seat lower floor on vehicle.
[email protected]
Page 83 of 235
specifications
Description Specification Remarks
Operating voltage 8 ~ 17V
Current consumption Max. 140mA
Operating temperature -40 ~ 85°C
Measurement
-75 ~ 75°/sec
range
Yaw-rate sensor
Frequency
18 ~ 22Hz
response
Measurement -14.715 ~
range +14.715m/s²
Lateral G sensor
Frequency 50Hz ± 60% (-
response 3dB)
EXTERNAL DIAGRAM
output characteristic
Page 84 of 235
Brake System > ESC(Electronic Stability Control) System > Yaw-rate and Lateral G Sensor >
Components and Components Location
COMPONENTS
[email protected]
Page 85 of 235
Brake System > ESC(Electronic Stability Control) System > Yaw-rate and Lateral G Sensor > Repair
procedures
INSPECTION
1. Connect a tester to both 2 and 3 terminals of the G sensor.
2. Measure the output voltage when IGN is on.
Specification : 2.5V
Page 86 of 235
3. Measure the output voltage between 2 and 3 terminals, posing the arrow mark on the G sensor downward.
4. Replace the G sensor if the output voltage is not on the specification.
Brake System > ESC(Electronic Stability Control) System > ESC OFF Switch > Description and
Operation
DESCRIPTION
1. The ESC OFF switch is for the user to turn off the ESC system.
2. The ESC OFF lamp is on when ESC OFF switch is engaged.
Brake System > ESC(Electronic Stability Control) System > ESC OFF Switch > Repair procedures
INSPECTION
1. Remove the ESC OFF switch from the switch panel on the crushpad of the driver's side.
[email protected]
Page 87 of 235
2. Check the continuity between the switch terminals as the ESC OFF switch is engaged.
Brake System > ESC(Electronic Stability Control) System > G Sensor > Components and Components
Location
COMPONENTS
Brake System > ESC(Electronic Stability Control) System > G Sensor > Repair procedures
INSPECTION
1. Connect a tester to both 2 and 3 terminals of the G sensor.
Page 88 of 235
2. Measure the output voltage when IGN is on.
3. Measure the output voltage between 2 and 3 terminals, posing the arrow mark on the G sensor downward.
4. Replace the G sensor if the output voltage is not on the specification.
Brake System > ESC(Electronic Stability Control) System > Steering Angle Sensor > Description and
Operation
DESCRIPTION
The steering angle speed sensor detects the angle of the steering wheel in order to which direction a user
chooses.The sensor is detached on the MPS(Mutil-Function Switch) under the steering wheel.
MEASUREING PRINCIPLE
The split of the steering angle sensor detects a steering angle of the steering wheel by a ON/OFF pulse caused by
whether or not the LED lights go through the hole of the split, rotating as the steering wheel revolves. There are three
LEDs, two(ST1, ST2) for detecting a steering direction, and the other for the neutral position.The HECU calculates
the steering angle by the pulse from the steering angle sensor.
[email protected]
Page 89 of 235
SPECIFICATION
Description Specification
Operating voltage 9 ~ 16V
Operating
-30 ~ 75°C
temperature
Current
Max.100mA
consumption
Steering angle
Max. ± 1500°/sec
velocity
Voltage(high) 3.0V ~ 4.1V
Voltage(low) 1.3V ~ 2.0V
Pulse duty 40 ~ 60%
CIRCUIT DIAGRAM( STEERING WHEEL SPEED ANGLE SENSOR)
OUTPUT CHARACTERISTIC
Page 90 of 235
Steering
No. INPUT OUTPUT Remark
direction
ST1 L L
Right
ST2 L H
1
ST1 L H
Left
ST2 L L
ST1 L L
Left
ST1 H L
2
ST1 L H
Right
ST2 H H
ST1 H H
Left
ST2 L H
3
ST1 H L
Right
ST2 L L
ST1 H H
Right
ST2 H L
4
ST1 H L
Left
ST2 H H
Brake System > Troubleshooting > C1101

GENERAL DESCRIPTION
The ABS ECU(Electronic Control Unit) checks the battery voltage and alternator output voltage to determine, as a
safety issue, whether the ABS system can operate normally or not.
The normal battery voltage range is essential for controlling the ABS system as intended.
DTC DESCRIPTION
[email protected]
Page 91 of 235
The ABS ECU monitors battery voltage and alternator output voltage.
When the voltage is higher than the expected normal value, this code is set, and the ABS/EBD/ESC functions are
prohibited.
If the voltage recovers, to within normal operating ranges, then the controller returns to normal operation as well.

DTC Strategy ● Battery Voltage Monitoring
● When Vign >17V±0.5V is continued for 500msec. ● Poor connection in power
Enable Conditions - If the voltage recovers to normal operating range, the supply circuit (IGN+)
controller returns to normal state. ● Faulty Alterator
● The ABS/EBD/ESC functions are inhibited. ● Faulty HECU
Fail Safe
● The ABS/EBD/ESC warning lamps are activated.
SPECIFICATION
Normal Voltage ENG "ON"
Range 10V ~ 16V

1. Connect scantool to Data Link Connector(DLC)
2. Ignition "ON" & Engine "ON".
Page 92 of 235
3. Monitor the "BATTERY VOLTAGE" parameter on the scantool.
Specification : Below. 16.7V
Fig 1) Test Condition : Ignition "ON" & Engine "ON".

Normal Data
4. Is parameter displayed within specifications?
Fault is intermittent caused by poor connection in power harness (IGN+) and/or HECU’s connector or was
repaired and HECU memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
Go to "Terminal and Connector Inspection" procedure.
TERMINAL AND CONNECTOR INSPECTION

caused by interference from other electrical systems, and mechanical or chemical damage.
or damage.
Verify presence of battery voltage codes in other ECUs (SRS, etc).

If battery voltage codes are not present in other ECUs, go to "Power Circuit Inspection" procedure.
If battery voltage codes are present in other ECUs, go to "Alternator Output Voltage Inspection" procedure.
Alternator Output Voltage Inspection
■ Charging System Check
2. Maintain ENG RPM 2,500RPM over 2 minutes.
[email protected]
Page 93 of 235
3. Measure voltage between the battery terminal(+) and the battery terminal(-).
Specification : Below. 17±0.5V
4. Is the measured value within specifications?
Go to "Power Circuit Inspection" procedure.
Check that the tension of drive belt, ENG RPM, fuse, terminal of battery, all terminals of alternator are in good
condition and Check for damaged harness and poor connection between alternator and battery.
If OK repair or replace alternator and then go to "Verification of vehicle Repair" procedure.
POWER CIRCUIT INSPECTION
■ Open or Short Check
2. Measure voltage between the battery terminal(+) and power terminal of the HECU harness connector.
Specification : Approx. below 0.2V
4. Go to "Ground Circuit Inspection" procedure.
Check for open or blown 10A ABS fuse referring to "Circuit Diagram".
Repair open or short in power circuit between battery and HECU harness connector and then go to
"Verification of vehicle Repair" procedure.
1. Ignition "OFF" & Engine "OFF".
2. Disconnect HECU connector.
3. Measure resistance between ground terminal of the HECU harness connector and chassis ground.
Specification : Approx. below 1Ω
Substitute with a known-good HECU and check for proper operation.

If problem is corrected, replace HECU and then go to "Verification of Vehicle Repair" procedure.
Repair open or short in ground circuit between HECU harness connector and chassis ground and then go to

1. Connect scantool and select "Diagnostic Trouble Codes(DTCs)" mode.
3. Operate the vehicle within DTC Detecting Condition in General Information.
4. Using a scantool, Check DTC present.
Page 94 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
The ABS ECU(Electronic Control Unit) checks the battery voltage and alternator output voltage to determine, as a
safety issue, whether the ABS system can operate normally or not.
The normal battery voltage range is essential for controlling the ABS system as intended.
DTC DESCRIPTION
The ABS ECU monitors the battery voltage and alternator output voltage by reading the value of voltage.
When the voltage is lower than the expected normal value, this code is set.
The ABS/ESC functions are prohibited and the EBD function is allowed on LOW VOLTAGE CONDITION, the
ABS/EBD/ESC functions are prohibited on UNDER VOLTAGE CONDITION.
If the voltage recovers, to within normal operating ranges, then the controller returns to normal operations as well.
[email protected]
Page 95 of 235

● When Vign<9.5V±0.5V is continued for 500msec
during Vref >= 7Km/h.
Enable ● When Vign<8.5V±0.5V is continued for 500msec
Conditions during Vref < 7Km/h or ABS/ESC control.
- If IGN voltage is recovered to normal operating
voltage, the system recovers to normal state.
Case1 ● Outside the ABS control cycle : Inhibit the ABS/ESC
(Low control, allow the EBD control , The ABS/ESC warning
voltage) ● Poor connection in power
lamps are activated, When the voltage recovers the
supply circuit (IGN+)
normal operating range, erase the error code.
● Faulty HECU
Fail Safe ● Inside the ABS control cycle : Inhibit the ABS/ESC
● Discharge of electricity
control. The ABS/ESC warning lamps are activated.
Althought the voltage recovers the normal operating
range, warning lamps are illuminated and the error code
is always stored.
● When Vign<7.2V±0.5V is continued for 56msec.
Enable
Case2 - If IGN voltage is recovered to normal operating
Conditions
(Under voltage, the system recovers to normal state.
voltage) ● The ABS/EBD/ESC functions are inhibited.
Fail Safe
SPECIFICATION
Normal Voltage ENG "ON"
Range 10V ~ 16V

Page 96 of 235
Specification : Above. 9±0.5V

Normal Data
Fault is intermittent caused by poor connection in power harness (IGN+) and/or HECU’s connector or was
or damage.

or damage.
Go to "Alternator Output Voltage Inspection" procedure.

Alternator Output Voltage Inspection
■ Charging System Check
2. Maintain ENG RPM 2,500RPM over 2 minutes.
Specification : Above. 9±0.5V
[email protected]
Page 97 of 235
Check that the tension of drive belt, ENG RPM, fuse, terminal of battery, all terminals of alternator are in good
condition and Check for damaged harness and poor connection between alternator and battery.
If OK repair or replace alternator and then go to "Verification of vehicle Repair" procedure.
2. Measure voltage between the battery terminal(+) and power terminal of the HECU harness connector.
Specification : Approx. below 0.2V
Go to "Ground Circuit Inspection" procedure.
Check for open or blown 10A ABS fuse referring to "Circuit Diagram".
"Verification of vehicle Repair" procedure..
CONTROL CIRCUIT INSPECTION

Repair open or short in ground circuit between HECU harness connector and chassis ground and then go to


Page 98 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
The HECU supplies operating voltage with Steering angle senor (12V), Yaw rate & lateral G sensor (12V), G
sensor (5V).
The HECU monitors supply voltage of each sensor for normal ESC control.
If supply voltage is out of specified range ABS/ESC warning lamps are turned on and ABS/ESC controls are
inhibited.
DTC DESCRIPTION
A failure is detected if the external sensor supply voltage is out of the specified range for more than the specified min.
fault duration.
[email protected]
Page 99 of 235
● During sensor power ON, If the voltage of sensor
power is out of the specified range for 500ms. ● Faulty HECU
Enable Conditions
● During sensor power OFF, If the voltage of sensor ● Poor connection in power
power is out of the specified range for 500ms. supply circuit to sensor
● ABS/ESP functions are inhibited, EBD function is
Fail Safe
allowed and the ABS/ESC warning lamps are activated.

1. ConneESCct scantool to Data Link Connector(DLC)
3. Monitor the "BATTERY VOLTAGE, 5 VOLT REFERENCE" parameter on the scantool.
Specification : BATTERY VOLTAGE (Approx. 10V ~ 16V)

5 VOLT REFERENCE (Approx. 5V)

Normal Data
Fault is intermittent caused by poor connection in HECU’s connector or was repaired and HECU memory
was not cleared.
or damage.

Page 100 of 235
or damage.

2. Measure voltage between power terminal of the steering angle sensor, Yaw rate & lateral G sensor, G sensor
Specification : Specification : Approx. 12V (steering angle sensor, Yaw rate & lateral G sensor),
Approx. 5V (G sensor)

Repair open or short in power circuit between HECU harness connector and steering angle sensor, Yaw rate
& lateral G sensor, G sensor harness connector and then go to "Verification of vehicle Repair" procedure.
If there is no problem in power circuit, Substitute with a known-good HECU and check for proper operation.

SCHEMATIC DIAGRAM
[email protected]
Page 101 of 235

GENERAL DESCRIPTION
The wheel speed sensor is the essential component the ABS ECU uses to calculate vehicle speed and to determine
whether wheel lock occurs.
For example, rear wheel speed signal is used as a referecnce value, for vehiclespeed, in front wheel drive vehicles,
and if a difference between front andrear wheel speed occurs, then ABS control is performed.
Wheel speed sensor is active hall-sensor type.
DTC DESCRIPTION
The ABS ECU monitors the wheel speed sensor circuit continuously.
If the sensor signal current is continuously out of the specified range for 140msec, then the HECU determines that
the circuit is open/short, and setsthis code.
Warning lamp is turned OFF unless additional faults are detected when the IG KEY is turned ON again, and wheel
speed is more than 10 Km/h (6.2mph).

Page 102 of 235
DTC Strategy ● Current Monitoring
● When the sensor signal current is continuously out of
Enable Conditions the specified range of 4 mA ± 10% ~ 22 mA ± 10% for
140msec.
● Open or short of Wheel speed
1. Only one wheel failure : Inhibit the ABS/ESC control, sensor circuit
allow the EBD control. The ABS/ESC warning lamps ● Faulty Wheel speed sensor
are activated, the EBD warning lamp is not activated.
Fail Safe
2. More than two wheels failure : The ABS/EBD/ESC
functions are inhibited. The ABS/EBD/ESC warning
lamps are activated.
SIGNAL WAVEFORM AND DATA
Fig1) Normal waveform of wheel speed sensor (Active type)

- High : Approx. 1.4V, Low : Approx. 0.7V.
SPECIFICATION
Sensor Output Voltage Tooth
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

3. Start and drive vehicle in gear and maintain vehicle speed at or above 10km/h. (6.2mph)
[email protected]
Page 103 of 235
4. Monitor the "WHEEL SPEED(FL)" parameter on the Scantool.
Specification : Compare with other parameters related to wheel speed sensor.

If it is the same as other parameters, it is in normal condition.
5.
6.
Fig 1) Test Condition : Drive vehicle at a speed of 10km/h or more. (6.2mph or more)
Normal Data
Abnormal Data (Open)
Page 104 of 235
Fault is intermittent caused by poor connection in wheel speed sensor harness (FL) and/or HECU’s connector
or was repaired and HECU memory was not cleared.
or damage.

or damage.

2. Measure voltage between power terminal of the wheel speed sensor harness connector and chassis ground.
4. Go to "Signal Circuit Inspection" procedure.
Repair open or short in power circuit between HECU harness connector and wheel speed sensor harness
connector and then go to "Verification of vehicle Repair" procedure.
If there is no problem in Power circuit, Substitute with a known-good HECU and check for proper operation.
■ Wheel speed sensor circuit check
1. Lift the vehicle.
3. Turn the wheel by hand.
[email protected]
Page 105 of 235
4. Measure waveform between wheel speed sensor signal terminal of the HECU harness connector and chassis ground
with osciloscope.
Specification : High : 1.18~1.68V , Low : 0.59~0.84V
Normal waveform
Fig 1) Normal waveform of wheel speed sensor (Active type)

-High : Approx. 1.4V, Low : Approx. 0.7V
5. Is the measured waveform within specifications?

Repair open or short in signal circuit between HECU harness connector and wheel speed sensor harness
connector, and then go to "Verification of vehicle Repair" procedure.
If there is no problem in signal circuit, go to "Component Inspection" procedure.
Page 106 of 235
4. Measure waveform between signal terminal of the wheel speed sensor harness connector and chassis ground with
osciloscope.
Normal waveform

Fault is intermittent caused by poor connection in wheel speed sensor harness (FL).
Go to "Verification of Vehicle Repair" procedure.
Substitute with a known-good Wheel speed sensor and check for proper operation.
If problem is corrected, replace Wheel speed sensor and then go to "Verification of Vehicle Repair" procedure.

3. Operate the vehicle within DTC Detecting Condition in General Information. (Start and drive vehicle in gear and
maintain vehicle speed at or above 10kmh.(6.2mph))
SCHEMATIC DIAGRAM
[email protected]
Page 107 of 235

GENERAL DESCRIPTION
For example, rear wheel speed signal is used as a referecnce value, for vehicle speed, in front wheel drive vehicles,
and if a difference between front and rear wheel speed occurs, then ABS control is performed.
DTC DESCRIPTION
The ABS ECU monitors the wheel speed sensor signal continuously.
This code is set if an abnormal speed change ratio is detected while the vehicle speed is more than 2Km/h.
speed is more than 10 Km/h.

Page 108 of 235
DTC Strategy ● Signal monitoring
● Max. wheel velocity exceeds 20km/h and the wheel
velocity is 40% of max. wheel velocity. if this condition
is lasted for 2 minutes.
Case1
● Controller counts the number of the wheel
acceleration of 100g[(25km/h) for 7ms]. When the
numbers at one wheel exceed 56 times, or When the
numbers at more two wheels exceed 5 times, controller
recognize the failure.
acceleration of 70g[(17.5km/h) for 7ms]. When the
numbers at more two wheels exceed 20 times,
controller recognize the failure.
Enable ● Controller counts the number of the wheel
Conditions deceleration of -100g[(-25km/h) for 7ms]. When the ● Improper installation of wheel
numbers at each wheel exceed 56 times, controller speed sensor
recognize the failure. ● Abnormal Rotor and wheel
Case2 bearing
● The wheel deceleration of -100g[(-25km/h) for 7ms]
causes the controller to start monitoring this failure and ● Faulty Wheel speed sensor
to compare the wheel velocity with the vehicle velocity
from next cycle. When its difference of -100g is
continued for more than 140msec, controller recognize
the failure.
● In case that any sensor failure at other wheel was
already detected, When the numbers of 100g at each
wheel exceed 5 times, or When the numbers of 70g at
each wheel exceed 20 times, controller recognize the
failure.
- The counter of speed jump is cleared every 30min.
- This monitoring is performed for the period that the
velocity of each wheel exceeds 2km/h.
1. Only one wheel failure : Inhibit the ABS/ESC control,
allow the EBD control. The ABS/ESC warning lamps
Fail Safe
[email protected]
Page 109 of 235

SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type

3. Start and drive vehicle in gear and maintain vehicle speed at or above 40km/h. (24mph)

Page 110 of 235
Fig 1) Test Condition : Drive vehicle at a speed of 40km/h or more. (24mph or more)
Normal Data
Normal Graph
Abnormal Data
Abnormal Data
or damage.
3. Turn the wheel by hand. [email protected]
Page 111 of 235
osciloscope.
Normal waveform

Fault is intermittent caused by faulty HECU, wheel speed sensor or external noise, an interference between
harnesses.
or damage.
If there is no problem in signal circuit, Substitute with a known-good HECU and check for proper operation.
Check for improper installation of wheel speed sensor. If NG, repair as necessary and then go to "Verification
of vehicle Repair" procedure.
Check for damage of rotor teeth or wheel bearing. If NG, repair as necessary and then go to "Verification of
vehicle Repair" procedure.
Substitute with a known-good Wheel speed sensor and check for proper operation. If problem is corrected,
replace Wheel speed sensor and then go to "Verification of Vehicle Repair" procedure.

1. Connect scantool and select "Diagnostic Trouble Codes(DTCs)" mode
maintain vehicle speed at or above 40kmh. (24mph))
Page 112 of 235
Go to the applicable troubleshooting procedure
System performing to specification at this time
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
[email protected]
Page 113 of 235
DTC DESCRIPTION
This code is set when the sensor air gap is out of specified range or when the ABS control cycle is continued
abnormally.
The HECU checks for air gap malfunctioning by monitoring the sensor signal at speeds between 2Km/h to 10 Km/h.
SCHEMATIC DIAGRAM
● When the minimum wheel velocity is 2km/h and the
velocity of other wheels exceed 10km/h (6.2mph) with
the acceleration of < 0.4g, the controller start comparing
the velocity of other wheels except the min. wheel. if
their difference below 4km/h (2.5mph) is continued for
140msec, Otherwise, if their difference beyond 4km/h
(2.5mph) or >0.4g is continued for 2 minutes.
● In < 0.4g, when the velocity of more two wheels is
2km/h (1.2mph) and the max. wheel velocity exceeds
Case1
Enable 10km/h (6.2mph), the condition is continued for 20 sec.
(Large
Conditions Otherwise, In >0.4g, the condition is 2 minutes.
Air-Gap)
● After velocity of 4 wheel exceeds 10km/h (6.2mph),
when velocity of 1 wheel or 2 wheel is 2km/h ● Improper installation of wheel
(1.2mph)and difference of other 2 wheel velocity is less speed sensor
than 4km/h (2.5mph) under that those velocity is more ● Abnormal Rotor and wheel
than 10km/h (6.2mph), if that conditions are continued bearing
for 12 seconds. ● Faulty Wheel speed sensor
minimum velocity rises from 2km/h (1.2mph) to 10km/h
(6.2mph).
Case2 ● During the ABS control cycle, if the wheel velocity of
(Long Enable 2km/h (1.2mph) is lasted for more than 12sec.
term ABS Conditions ● If the ABS control cycle is continued for more than
mode) 36sec.
allow the EBD control. The ABS/ESP warning lamps
Fail Safe
2. Only one wheel failure : Inhibit the ABS/ESP control,

Page 114 of 235

SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


[email protected]
Page 115 of 235
Normal Data
Abnormal Data
or damage.
osciloscope.
Normal waveform

Page 116 of 235

vehicle Repair" procedure..

maintain vehicle speed at or above 10kmh. (6.2mph))
DIAGNOSIC CIRCUIT DIAGRAM
[email protected]
Page 117 of 235

GENERAL DESCRIPTION
DTC DESCRIPTION

Page 118 of 235
140msec.
Fail Safe

SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

[email protected]
Page 119 of 235

5.
6.
Normal Data
Page 120 of 235
or damage.

or damage.

[email protected]
Page 121 of 235
with osciloscope.
Normal waveform


Page 122 of 235
osciloscope.
Normal waveform


SCHEMATIC DIAGRAM
[email protected]
Page 123 of 235

GENERAL DESCRIPTION
DTC DESCRIPTION

Page 124 of 235
Case1
Case2 bearing
the failure.
failure.
Fail Safe
[email protected]
Page 125 of 235

SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


Page 126 of 235
Normal Data
Normal Graph
Abnormal Data
Abnormal Data
or damage.
Page 127 of 235
osciloscope.
Normal waveform

harnesses.
or damage.

Page 128 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
[email protected]
Page 129 of 235
DTC DESCRIPTION
abnormally.
SCHEMATIC DIAGRAM
Case1
(Large
Air-Gap)
(6.2mph).
mode) 36sec.
Fail Safe

Page 130 of 235

SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


[email protected]
Page 131 of 235
Normal Data
Abnormal Data
or damage.
osciloscope.
Normal waveform

Page 132 of 235


[email protected]
Page 133 of 235

GENERAL DESCRIPTION
DTC DESCRIPTION

Page 134 of 235
140msec.
Fail Safe

SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

[email protected]
Page 135 of 235

5.
6.
Normal Data
Page 136 of 235
or damage.

or damage.

[email protected]
Page 137 of 235
with osciloscope.
Normal waveform


Page 138 of 235
osciloscope.
Normal waveform


SCHEMATIC DIAGRAM
[email protected]
Page 139 of 235

GENERAL DESCRIPTION
DTC DESCRIPTION

Page 140 of 235
Case1
Case2 bearing
the failure.
failure.
Fail Safe
[email protected]
Page 141 of 235

SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


Page 142 of 235
Normal Data
Normal Graph
Abnormal Data
Abnormal Data
or damage.
Page 143 of 235
osciloscope.
Normal waveform

harnesses.
or damage.

Page 144 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
[email protected]
Page 145 of 235
DTC DESCRIPTION
abnormally.
SCHEMATIC DIAGRAM
Case1
(Large
Air-Gap)
(6.2mph).
mode) 36sec.
Fail Safe

Page 146 of 235

SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


[email protected]
Page 147 of 235
Normal Data
Abnormal Data
or damage.
osciloscope.
Normal waveform

Page 148 of 235


[email protected]
Page 149 of 235

GENERAL DESCRIPTION
DTC DESCRIPTION

Page 150 of 235
140msec.
Fail Safe

SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

[email protected]
Page 151 of 235

5.
6.
Normal Data
Page 152 of 235
or damage.

or damage.

[email protected]
Page 153 of 235
with osciloscope.
Normal waveform


Page 154 of 235
osciloscope.
Normal waveform


SCHEMATIC DIAGRAM
[email protected]
Page 155 of 235

GENERAL DESCRIPTION
DTC DESCRIPTION

Page 156 of 235
Case1
Case2 bearing
the failure.
failure.
Fail Safe
[email protected]
Page 157 of 235

SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


Page 158 of 235
Normal Data
Normal Graph
Abnormal Data
Abnormal Data
or damage.
Page 159 of 235
osciloscope.
Normal waveform

harnesses.
or damage.

Page 160 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
[email protected]
Page 161 of 235
DTC DESCRIPTION
abnormally.
SCHEMATIC DIAGRAM
Case1
(Large
Air-Gap)
(6.2mph).
mode) 36sec.
Fail Safe

Page 162 of 235

SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


[email protected]
Page 163 of 235
Normal Data
Abnormal Data
or damage.
osciloscope.
Normal waveform

Page 164 of 235



Page 165 of 235

General Description
This transmitter is a transmitter device with tire valve, which is mounted in the valve hole of the wheel rim and
transmits the pressure and temperature inside the tire, the battery voltage of the transmitter, and the tire identification
code (ID) at normal and abnormal condition with the radio wave (RF) that conforms to the used area. Also this
device has a countermeasure function such as the random delay of transmission time so that the RF signal from each
tire will not interfere due to transmission. Wheel sensors shall support usage on steel or aluminum rims.
Sensor transmissions continue when sensor status is 'Normal Fixed State'. Sensor transmissions stop when sensor
Page 166 of 235
status is 'Storage State' or the sensor battery runs out. The transmitter should transmit data at vehicle speeds
between 0 mph (0 kph) and 186 mph (300 kph). Operating Temperature Range is -40 to 248 °F(-40 to 120 °C).
Transmitter shall enter thermal shutdown once the measured temperature is greater than or equal to 257 °F(125 °C).
The accuracy of the sensor is -9/12.6 °F (-5/7 °C) at this temperature, therefore the actual temperature may be
244.4 °F (118 °C). The sensor shall exit thermal shutdown once the temperature is less than or equal to 212 °F(100
°C). The transmitter shall have the capability to measure the internal battery voltage as an indicator of the end of life
of the sensor. Since the unit is sealed, this parameter cannot be verified with a production unit..
Tire Pressure Monitoring
When 4 sensors have been learned as road wheels, it shall not be possible to learn new road wheel sensors on the
same Ignition cycle. In normal mode low line, tire pressure and temperature shall be transmitted every 3 minutes 20 s
nominally independent of vehicle operation. Monitoring shall be every 20 s. If sensor detects rapid deflation, then RF
messages will be transmitted every 4 s for 1 minute duration. Communication from wheel sensors shall be via RF at
a frequency of 315 MHz, 5 kBaud. Tire pressure measurement tolerance shall be ±7 kPa from 32 to 122 °F(0 to
50 °C) and ±17.5 kPa from -40 to 248 °F(-40 to 120°C) with a range of 100 to 450 kPa. Tire temperature
measurement tolerance shall be ±37.4 °F(±3 °C) from -4 to 158 °F(-20 to 70 °C) and ±9 °F(±5 °C) from -40 to
194 °F(40 to 90 °C) and -9/12.6 degree Fahrenheit (-5/7 degree Celsius) from -40 to 248 degree Fahrenheit (-40
to 120 degree Celsius).
DTC Description
This DTC indicates that the Vehicle speed signal is not inputed normally. The most likely cause is speed sensor
failure/ speed signal line's open.

DTC strategy • Check speed signal
Enable
• Vehicle is driving under more than 20 km/h.
conditions
• Open in speed signal line
• Speed Sensor input 2 speed > 20 km/h while Speed
Threshold • Faulty Speed sensor
Sensor input 1 speed < 10 km/h.
value
• Invalid Speed Sensor input 1 is measured.
Diagnosis time • 20 seconds

1. Many malfunctions in the electrical system are caused by poor harness and terminal condition.Faults can also be
2. Thoroughly check all connectors (and connections) for looseness, bending, corrosion, contamination,
deterioration, and/or damage.
Repair if necessary and then go to "Verification of Vehicle Repair" procedure.

Check Open
1. Ignition "OFF"
2. Disconnect Vehicle speed sensor connector and TPMS receiver connector.
Page 167 of 235
3. Measure resistance between terminal "3" of Vehicle speed sensor harness connector and terminal "18" of TPMS
receiver harness connector.
4. Is the measured resistance within specifications?
Faulty Vehicle speed sensor may cause this DTC.

Substitute with a known-good component and check for proper operation. If problem is corrected, it's failure
should cause this DTC. After doing an appropriate repair, Go to "Verification of Vehicle Repair" procedure.
Repair as necessary in speed signal circuit and then go to "Verification of Vehicle Repair" procedure.

1. Connect TPMS exciter or scantool and select "Diagnostic Trouble Codes(DTCs)" mode
2. Using a TPMS exciter or scantool, Clear DTC.

GENERAL DESCRIPTION
The pressure sensor, installed in the HECU, sense the brake oil pressure to judge driver’s brake intention when
ESC is operating.
If pressure of master cyclinder is applied to pressure sensor, the strain of the piezo element is changed and then the
resistance of brige circuit is chanded according to changed strain.
Therefore this changed resistance changes output voltage of brige circuit and output voltage changes linearly.
The sensor output is a analog signal in proportion to supply voltage, and the HECU recognizes a pressure value
according to signal ratio about supply voltage.
DTC DESCRIPTION
A failure is detected if the output signal voltage of the pressure sensor is out of specified range.

Page 168 of 235
DTC Strategy ● Voltage Monitoring
● The output signal voltage of the pressure sensor is out
Enable Conditions of the specified range. ● Open or short of pressure
- The monitoring starts 1sec after power up. sensor circuit
● Faulty pressure sensor
● Inhibit the ESC control and allow the ABS/EBD
Fail Safe control.
● The ESC warning lamp is activated.

3. Press the brake pedal.
4. Monitor the "PRESSURE SENSOR" parameter on the Scantool.
Specification : Approx. 60bar ~150bar (There is difference in displayed parameter according to

braking force)

Normal data
Fig 2) Test Condition : Ignition "ON" & Engine "ON" & Brake "ON".
Normal data (There is difference in displayed parameter according to braking force)
5. Whenever brake pedal is pushed down, is the pressure sensor’s scantool data changed?
Fault is caused by having been repaired and HECU memory was not cleared.
Clear the DTC and then go to "Verification of Vehicle Repair" procedure.
1. Ignition "OFF".
Page 169 of 235
5. Select "Diagnostic Trouble Codes(DTCs)" mode again.

Fault is intermittent caused by faulty HECU.


SCHEMATIC DIAGRAM
Page 170 of 235
GENERAL DESCRIPTION
The pressure sensor, installed in the HECU, sense the brake oil pressure to judge driver’s brake intention when
ESC is operating.
If pressure of master cyclinder is applied to pressure sensor, the strain of the piezo element is changed and then the
resistance of brige circuit is chanded according to changed strain.
Therefore this changed resistance changes output voltage of brige circuit and output voltage changes linearly.
The sensor output is a analog signal in proportion to supply voltage, and the HECU recognizes a pressure value
according to signal ratio about supply voltage.
DTC DESCRIPTION
The failure is detected if the pressure sensor signal noise is out of normal range, or the pressure sensor signal is
changed abnormally.
In spite of no brake switch signal, master cylinder pressure exceeds 20bar when brake switch is normal.

● If input signal is noisy, Which the gradient of the
sensor signal is larger than predefined value for specific
times, ECU detect the failure.
Enable Conditions ● Outside an ABS/ESC control, And after normal
● External noise.
operation of BLS, If the pressure sensor signal is higher
● Faulty pressure sensor
than 20bar and BLS is low for 3sec, ECU detect the
failure.
Fail Safe control. .

Page 171 of 235
4. Monitor the "PRESSURE SENSOR" parameter on the Scantool.
Specification : Approx. 60bar ~150bar (There is difference in displayed parameter according to

braking force)

Normal data
Fig 2) Test Condition : Ignition "ON" & Engine "ON" & Brake "ON".
Normal data (There is difference in displayed parameter according to braking force)
5. Whenever brake pedal is pushed down, is the pressure sensor’s scantool data changed?
Fault is caused by having been repaired and HECU memory was not cleared.
Clear the DTC and then go to "Verification of Vehicle Repair" procedure.
1. Ignition "OFF".

Fault is intermittent caused by faulty HECU.


Page 172 of 235
SCHEMATIC DIAGRAM

General Description
Page 173 of 235
between 0 mph (0 kph) and 186 mph (300 kph). Operating Temperature Range is -40 to 248 °F(-40 to 120 °C).
The accuracy of the sensor is -9/12.6 °F (-5/7 °C) at this temperature, therefore the actual temperature may be
244.4 °F (118 °C). The sensor shall exit thermal shutdown once the temperature is less than or equal to 212 °F(100
°C). The transmitter shall have the capability to measure the internal battery voltage as an indicator of the end of life
of the sensor. Since the unit is sealed, this parameter cannot be verified with a production unit..
measurement tolerance shall be ±37.4 °F(±3 °C) from -4 to 158 °F(-20 to 70 °C) and ±9 °F(±5 °C) from -40 to
194 °F(40 to 90 °C) and -9/12.6 degree Fahrenheit (-5/7 degree Celsius) from -40 to 248 degree Fahrenheit (-40
to 120 degree Celsius).
DTC Description
This DTC indicates that the Vehicle speed signal is not inputed normally. The most likely cause is speed sensor
failure/ speed signal line's open.

DTC strategy • Check speed signal
Enable
• Vehicle is driving under more than 20 km/h.
conditions
• Open in speed signal line
• Speed Sensor input 1 speed >20 km/h while Speed
Threshold • Faulty Speed sensor
Sensor input 2 speed < 10 km/h.
value
• Invalid Speed Sensor input 2 is measured.
Diagnosis time • 20 seconds

1. Many malfunctions in the electrical system are caused by poor harness and terminal condition.Faults can also be

Check Open
Page 174 of 235
1. Ignition "OFF"
2. Disconnect ECM connector and TPMS receiver connector.
3. Measure resistance between terminal "22(39)" of ECM harness connector and terminal "6" of TPMS receiver
harness connector.
Faulty Vehicle speed sensor may cause this DTC.

Substitute with a known-good component and check for proper operation. If problem is corrected, it's failure
should cause this DTC. After doing an appropriate repair, Go to "Verification of Vehicle Repair" procedure.
Repair as necessary in speed signal circuit and then go to "Verification of Vehicle Repair" procedure.


GENERAL DESCRIPTION
The Steering wheel angle sensor uses two sensors ( A-sensor and B-sensor ) to determine the direction of the
rotation.
The main components of each sensor are LED, photo transistor and slit plate.
The slit plate, which has 45 holes, is installed between LED and photo transistor, and generates signals if slit plate
rotates according to the steering wheel rotation.
The sensor signals are generated by photo transistor which is driven whenever the light passes through the holes. The
HECU detects operating speed and direction of the steering wheel by this input signal, and the signal is used to input
signal for anti-roll control.
DTC DESCRIPTION
If some signal voltage stays in abnormal voltage range, the time is counted seperately.
And if the monitored time exceeds the specified min. fault duration, failure is detected.
The monitoring starts 1sec after Power Up.

Page 175 of 235
● When Vsas >4.2±0.1V or Vsas<1.2±0.1V or
2.1±0.1V<Vsas<2.9±0.1V continue 1sec.
Enable Conditions ● Open or short of steering
- The monitoring starts 1sec after Power Up.
wheel sensor circuit
Vsas : Voltage of the steering angle sensor.
● Faulty steering wheel sensor
Fail Safe control.

3. Turn the steering wheel to the left or right.
4. Monitor the "STEERING SNSR" parameters on the Scantool.
Specification : If the parameters are changed according to wheel position during steering the wheel,
it is normal condition.

Normal Data
5. Whenever steering wheel is turned, is the steering sensor’s scantool data changed?
Fault is intermittent caused by poor connection in steering sensor harness and/or HECU’s connector or was
or damage.

Page 176 of 235
or damage.

2. Measure voltage between power terminal of the steering angle sensor harness connector and chassis ground.
Repair open or short in power circuit between steering angle sensor harness connector and HECU harness
3. Disconnect steering angle sensor connector.
4. Measure resistance between ground terminal of the steering angle sensor harness connector and chassis ground.
Repair open or short in ground circuit between steering angle sensor harness connector and HECU harness
connector and then, go to "Verification of vehicle Repair" procedure.
2. Measure voltage between signal terminal of the HECU harness connector and chassis ground.
Specification : HIGH : 2.9±0.1V ~ 4.4±0.1V, LOW : 1.2±0.1V ~ 2.1±0.1V

Page 177 of 235

Repair open or short in signal circuit between the steering angle sensor harness connector and HECU harness
connector and then, go to "Verification of vehicle Repair" procedure.
2. Measure voltage between signal terminal of the steering angle sensor harness connector and chassis ground.
Specification : High : HIGH : 2.9±0.1V ~ 4.4±0.1V, LOW : 1.2±0.1V ~ 2.1±0.1V
Fault is intermittent caused by poor connection in steering sensor harness and/or HECU’s connector.
Substitute with a known-good steering angle sensor and check for proper operation
If problem is corrected, replace steering angle sensor and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 178 of 235

GENERAL DESCRIPTION
The Steering wheel angle sensor uses two sensors ( A-sensor and B-sensor ) to determine the direction of the
rotation.
The main components of each sensor are LED, photo transistor and slit plate.
The slit plate, which has 45 holes, is installed between LED and photo transistor, and generates signals if slit plate
rotates according to the steering wheel rotation.
The sensor signals are generated by photo transistor which is driven whenever the light passes through the holes. The
HECU detects operating speed and direction of the steering wheel by this input signal, and the signal is used to input
signal for anti-roll control.
DTC DESCRIPTION
This monitoring function monitors the changing point of N-signal with measured steering angle from ST1 and ST2.
If N-signal changing point differs more than predefined degree, the failure is detected.
If there is no variation of the steering wheel angle for predefined time ECU detect the failure.

Page 179 of 235
DTC Strategy ● Signal Monitoring
● The STN is low more than ±20 degrees for 70msec.
● When the steering wheel is turned more than 370±5
degrees, if center is not detected, ECU detects the
failure.
● When the steering wheel angle is higher than 700
degrees ECU detects the failure.
● During straight driving, if the steering wheel angle is
larger than 55±5 degree ECU detects the failure.
Enable Conditions ● When the curve is detected after driving straight, if
● External noise
there is no variation of the steering wheel angle for 3sec,
● Faulty steering wheel sensor
ECU detect the failure.
● While the vehicle drive 60±5 degree ↔ -60±5
degree, if STN is not detected low, ECU detect the
failure.
● While steering angle sensor wheel through center, if
steering angle sensor is against specification three times,
ECU detect the failure.
Fail Safe control.
Fig 1) Normal waveform of steering angle sensor with turning left after ENG "ON"
: Output signal change ("LOW" → "HIGH") is detected first in ST1.
Fig 2) Normal waveform of steering angle sensor with turning right after ENG "ON"
Fig 3) Normal waveform of steering angle sensor being center position after ENG "ON"
: Output signal change ("HIGH (approx 3.5V)" → "LOW") is detected when steering wheel is passing by on center
position.
"LOW" : approx 1.5V, "HIGH" : approx 3.5V.

Page 180 of 235
4. Monitor the "STEERING ANGLE SNSR" parameters on the Scantool.
Specification : If the parameters are changed according to wheel position during steering the wheel,
it is normal condition.

Normal Data
Normal Graph
Abnormal Graph
5. Whenever steering wheel is turned, is the steering sensor’s scantool data changed?
Fault is intermittent caused by poor connection in steering sensor harness and/or HECU’s connector or was
or damage.

Page 181 of 235
or damage.

3. Measure waveform between signal terminal of the HECU harness connector and chassis ground with osciloscope.
Specification : Check the voltage range (HIGH : 2.9±0.1V ~ 4.4±0.1V LOW : 1.2±0.1V ~
2.1±0.1V) of the sensor signal in case of turning left, turning right, center position. If normal
waveforms such as fig1, 2, 3 are detected in each condition, It is normal.
Normal waveform
: Output signal change ("HIGH" → "LOW") is detected when steering wheel is passing by on center position.

Repair open or short in signal circuit between steering angle sensor harness connector and HECU harness
connector, and then go to "Verification of vehicle Repair"
If there is no problem in Signal circuit, Substitute with a known-good HECU and check for proper operation.
Page 182 of 235
■ Steering Angel Sensor Check
3. Measure waveform between signal terminal of the steering angle sensor harness connector and chassis ground with
osciloscope.
Specification : Check the voltage range (HIGH : 2.9±0.1V ~ 4.4±0.1V LOW : 1.2±0.1V ~
2.1±0.1V) of the sensor signal in case of turning left, turning right, center position. If normal
waveforms such as fig1, 2, 3 are detected in each condition, It is normal.
Normal waveform
: Output signal change ("HIGH" → "LOW") is detected when steering wheel is passing by on center position.
Fault is intermittent caused by poor connection in steering sensor harness and/or HECU’s connector.
Go to "Verification of vehicle Repair" procedure.
If STN signal is HIGH on center position, Check for improper installation of steering angle sensor.
Repair as necessary and then go to "Verification of vehicle Repair" procedure.
If sensor mounting state is normal, Substitute with a known-good steering angle sensor and check for proper
operation.
If problem is corrected, replace steering angle sensor and then go to "Verification of Vehicle Repair" procedure.

Page 183 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
The 4WD vehicle measures the G-sensor signal to solve for 4WD vehicle unique problems. For example all 4
wheels are locked early on a low-friction road or control response is delayed when road friction coefficients vary.
The HECU uses a filtered signal, as a supplementary value, to determine the road friction coefficient. This value is
used for the accurate calculations of assumed vehicle speed, or precise division of control starting points.
DTC DESCRIPTION
The HECU monitors the G-sensor voltage continuosly,and sets this code if the voltage is either higher than the
permissible normal value ( approx. 4.5 V ) or lower than the value ( approx. 0.6V ) for more than 250ms.

Page 184 of 235
●When the voltage of G sensor signal is >4.5±0.1V or ● Open or short of G-Sensor
Enable Conditions
<0.6±0.1V for 250msec continuously. circuit
● Faulty G-Sensor
● ABS/ESC functions are inhibited, EBD function is
Fail Safe

3. Monitor the "G Sensor" parameter on the Scantool.
Specification : Approx. ±0.01G
Fig 1) Test Condition : Ignition "ON" & Engine "OFF"

Normal Data
G-sensor open circuit Data
Fault is intermittent caused by poor connection in G sensor harness and/or HECU’s connector or was repaired
and HECU memory was not cleared.
or damage.

1. Many malfunctions in the electrical system are caused by poor harness(es) and terminal condition. Faults can also
be caused by interference from other electrical systems, and mechanical or chemical damage.
or damage.
Page 185 of 235

2. Measure voltage between power terminal of the G sensor harness connector and chassis ground.
Repair open or short in power circuit between the G sensor harness connector and HECU harness connector
and then, go to "Verification of vehicle Repair" procedure.
2. Disconnect the G sensor connector.
3. Measure resistance between ground terminal of the G sensor harness connector and chassis ground.
Repair open or short in ground circuit between the G sensor harness connector and HECU harness connector
and then, go to "Verification of vehicle Repair" procedure.
2. Measure voltage between G sensor signal terminal of the HECU harness connector and chassis ground.
Specification : Approx. 2.5V

Repair open or short in signal circuit between the G sensor harness connector and HECU harness connector,
and then go to "Verification of vehicle Repair" procedure.
If there is no problem in Signal circuit, Go to "Component Inspection" procedure.
Page 186 of 235
2. Measure voltage between signal terminal of the G sensor harness connector and chassis ground.
Fault is intermittent caused by poor connection in G sensor harness and/or HECU’s connector.
Substitute with a known-good G sensor and check for proper operation

If problem is corrected, replace G sensor and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 187 of 235

GENERAL DESCRIPTION
The 4WD vehicle measures the G-sensor signal to solve for 4WD vehicle unique problems. For example all 4
wheels are locked early on a low-friction road or control response is delayed when road friction coefficients vary.
The HECU uses a filtered signal, as a supplementary value, to determine the road friction coefficient. This value is
used for the accurate calculations of assumed vehicle speed, or precise division of control starting points.
DTC DESCRIPTION
The HECU monitors the G-sensor voltage continuosly,and sets this code if the G-sensor value is either higher than
0.5G for more than 20 seconds when vehicle speed is above 10 Km/h and brake switch is OFF, or if G-sensor
value is lower than 0.1G for more than 60 seconds when wheel sensor minimum value is above 0.2G.

DTC Strategy ● Signal Monitoring
●When vehicle speed is >10km/h and the brake light ● Improper installation of G-
switch is off, |G>0.5G for 20sec continuously. Sensor
Enable Conditions
● When |min wheel speed| / dt ≥0.2G and |G| ≤0.1G for ● Abnormal Rotor and wheel
60sec continuously. bearing
● Faulty G-Sensor
● ABS/ESC functions are inhibited, EBD function is
Fail Safe
Page 188 of 235

3. Start and drive vehicle in gear and maintain vehicle speed is approx. 10km/h or more (6mph or more) and then
accelerate and decelerate the vehicle several times.
4. Monitor the "G-sensor" parameter on the Scantool.
Specification : Below 0.4G (at a uniform speed)

It is a normal condition if the data is changed while accelerating or decelerating the vehicle
Fig 1) Test Condition : Drive vehicle in 10km/h or more (6mph or more)

Normal Data
Fault is intermittent caused by poor connection in G sensor harness and/or HECU’s connector or was repaired
and HECU memory was not cleared.
or damage.

1. Many malfunctions in the electrical system are caused by poor harness(es) and terminal condition. Faults can also
be caused by interference from other electrical systems, and mechanical or chemical damage.
or damage.

Page 189 of 235
■ G Sensor Check
1. Check installation condition of G-sensor. If NG, repair as necessary and go to "Verification vehicle Repair"
procedure.
2. Check damage of rotor teeth or wheel bearing. If NG, repair as necessary and go to "Verification vehicle Repair"
procedure.
4. Measure waveform between signal terminal of the G sensor harness connector and chassis ground with
osciloscope.

0.3V ~ 4.7V (acceleration or deceleration)
Fault is intermittent caused by poor connection in G sensor harness and/or HECU’s connector.
Substitute with a known-good G sensor and check for proper operation.

If problem is corrected, replace G sensor and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 190 of 235

GENERAL DESCRIPTION
If yaw velocity reaches the specific velocity after it detects the vehicle’ yawing, the ESC control is reactivated.
The later G sensor senses vehicle’s lateral G. A small element inside the sensor is attached to a deflectable leverarm
by later G.
to lateral G.
It interchanges signals with HECU through extra CAN line which only used for communication between HECU and
sensor.
DTC DESCRIPTION
A failure is detected if the Yaw rate & later G sensor message was not received or HECU detects sensor CAN Bus
off state for more than the specified failure detection time.
The Monitoring starts 1sec after Power Up.
Page 191 of 235

DTC
● Yaw rate & later G sensor message monitoring
Strategy
Case1 ● In case that Yaw rate & later G sensor message was
Enable not received for more than 500ms within normal voltage
Conditions condition.
- The Monitoring starts 1s after Power Up. ● Faulty Yaw Rate & Lateral G
sensor
DTC
● Open, short monitoring ● Open or short of Yaw Rate &
Strategy
Case2 Lateral G sensor
Enable ● In case sensor CAN BUS off state continued for
Conditions more than 100ms.
Fail Safe control.

3. Monitor the "Lateral G Sensor, Yaw Rate Sensor" parameter on the Scantool.
Specification : Lateral G Sensor : approx. ± 0.0 G, YAW Rate Sensor :approx. ± 0.0 deg/s
Page 192 of 235
Fig 1) Test Condition : Ignition "ON" & Engine "OFF".

Yaw Rate Sensor Normal Data
Lateral G Sensor Normal Data
Fault is intermittent caused by poor connection in Yaw Rate & Lateral G sensor harness and/or HECU’s
connector or was repaired and HECU memory was not cleared.
or damage.

1. Many malfunctions in the electrical system are caused by poor harness(es) and terminal condition.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
or damage.

2. Measure voltage between power terminal of the Yaw Rate & Lateral G sensor harness connector and chassis
ground.

Page 193 of 235
Go to "Ground Circuit Inspection" procedure
Repair open or short in power circuit between the yaw rate & lateral G sensor harness connector and HECU
harness connector and then, go to "Verification of vehicle Repair"
2. Disconnect yaw rate & lateral G sensor connector.
3. Measure resistance between ground terminal of the yaw rate & lateral G sensor harness connector and chassis
ground.
Repair open or short in ground circuit between the yaw rate & lateral G sensor harness connector and HECU
harness connector and then, go to "Verification of vehicle Repair"
■ Short Check (to ground)
2. Disconnect yaw rate & lateral G sensor, HECU connector.
3. Measure resistance between CAN LOW terminal, CAN HIGH terminal of the yaw rate & lateral G sensor
Specification : ∞ Ω
Go to next procedure.
Repair short to ground in CAN signal circuit in case of abnormal resistance measured and then go to
■ Short Check (to battery)
3. Measure voltage between CAN LOW terminal, CAN HIGH terminal of the HECU harness connector and
chassis ground.
Specification : Approx. 0 V
Page 194 of 235
Repair short to battery in CAN signal circuit in case of abnormal voltage measured and then, go to
■ Internal Resistance Check
3. Measure resistance between CAN LOW terminal and CAN HIGH terminal of the HECU connector.
Go to "Component Circuit Inspection" procedure.

■ Component Resistance Check
3. Measure resistance between CAN LOW terminal and CAN HIGH terminal of the HECU harness connector.
Fault is intermittent caused by poor connection in yaw rate & lateral G sensor harness and/or HECU’s
connector.
In case of the resistance "approx. 1Ω" : Repair mutual short in CAN signal circuit of the yaw rate & lateral G
sensor and then go to "Verification of vehicle Repair" procedure.
In case of the resistance "∞ Ω" : Repair open in CAN signal circuit of the yaw rate & lateral G sensor and then
go to "Verification of vehicle Repair" procedure.
If there is no problem in CAN signal circuit, Substitute with a known-good yaw rate & lateral G sensor and
If problem is corrected, replace the yaw rate & lateral G sensor and then go to "Verification of Vehicle Repair"
procedure.

Page 195 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
by later G.
to lateral G.
sensor.
DTC DESCRIPTION
A lateral acceleration reference signal is calculated from the wheel speeds, the steering angle and the yaw rate signals
to observe the lateral acceleration sensor signal.
Page 196 of 235
The difference between the reference signal and the sensor signal is evaluated for failure detection. A yaw rate
reference signal is calculated from the wheel speeds, the steering angle and the lateral acceleration signals to observe
the yaw rate sensor signal.
The difference between the reference signal and the sensor signal, and the gradient of the measured sensor signal is
evaluated for the failure detection.
If the difference between estimated value and measured value of the sensor is larger than predefined value for
predefined time, the failure is recognized.

● When the difference between estimated value and
Enable
Case1 measured value of the yaw rate sensor is lager than
Conditions
Predefined value for specific time , ECU detects failure.
● When the difference between estimated value and
Enable
Case2 measured value of the lateral G sensor is lager than
Conditions
Predefined value for specific time , ECU detects failure.
● Yaw signal is smaller than predefined value when ● Faulty Yaw Rate & Lateral G
CBIT is transmitted sensor
Enable
Case3 ● Lateral G signal is smaller than defined value when
Conditions
CBIT is transmitted.
CBIT : Commanded Built In Test
Enable ● In case that Yaw&LG Sensor Fail Flag is detected for
Case4
Conditions defined time
Fail Safe control.

Page 197 of 235
3. Monitor the "Lateral G Sensor, Yaw Rate Sensor" parameter on the Scantool.
Specification : Lateral G Sensor : approx. ± 0.0 G, YAW Rate Sensor :approx. ± 0.0 deg/s

Yaw Rate Sensor Normal Data
Lateral G Sensor Normal Data
Fault is intermittent caused by poor connection in Yaw Rate & Lateral G sensor harness and/or HECU’s
connector or was repaired and HECU memory was not cleared.
or damage.

1. Many malfunctions in the electrical system are caused by poor harness(es) and terminal condition.
or damage.
1. Ignition "OFF".
Page 198 of 235
1) Substitute with a known-good Yaw Rate & Lateral G sensor and check for proper operation.
If problem is corrected, replace Yaw Rate & Lateral G sensor and then go to "Verification of Vehicle Repair"
procedure.
2) Substitute with a known-good HECU and check for proper operation.
Fault is intermittent caused by faulty Yaw Rate & Lateral G sensor or poor connection in Yaw Rate & Lateral
G sensor harness and/or HECU’s connector. Go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 199 of 235

GENERAL DESCRIPTION
Driver can inhibit the ESC control by ESC switch.
When switch signal send into HECU, ESC warning lamp go ON and ESC control is stopped and if next switch
signal is inputted again, ESC control is ready. This function is used for sporty driving or vehicle inspection.
DTC DESCRIPTION
Trouble code is set when the condition that the level of ESC switch is high is continued for 60sec.
When the ESC switch failure is set, Warning lamps won't illuminate and HECU allow the ABS/EBD/ESC control.

DTC Strategy ● Circuit Monitoring
Enable Conditions ● When the ESC switch is ON for 1 minute. ● Open or short ESC switch
circuit
Fail Safe control. ● Faulty ESC switch
SPECIFICATION
Page 200 of 235
ESC switch ESC switch
Engine ON HIGH LOW
7.0V ~ 16.0V 0V ~ 3.0V

3. Press the ESC SWITCH.
4. Monitor the "ESC SWITCH" parameter on the scantool.
Specification : It is changed to ON/OFF.

Normal Data
5. Whenever the switch is pushed up/down, is the ESC off switch’s scantool data changed ON/OFF?
Fault is intermittent caused by poor connection in ESC switch line or was repaired and HECU memory was
not cleared.

or damage.
Page 201 of 235

2. Press the ESC SWITCH.
3. Measure voltage between ESC switch signal terminal of the HECU harness connector and chassis ground.
Specification : Approx B+
Check for open or blown 10A fuse referring to "Circuit Diagram".

Repair open or short in power circuit between battery and HECU harness connector and then, go to
If there is no problem in circuit, Go to "Component Inspection" procedure.
■ ESC switch Check
2. Disconnect the ESC switch connector.
3. Measure resistance between power terminal and siganl terminal of the ESC switch connector.
Specification : Approx. below 1Ω (In case of pressing the ESC switch)

Approx. ∞ Ω (In case of not pressing the ESC switch)
Fault is intermittent caused by poor connection in ESC switch harness and/or HECU’s connector.
Substitute with a known-good ESC switch and check for proper operation.
If problem is corrected, replace ESC switch and then go to "Verification of Vehicle Repair" procedure.

Page 202 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
This switch is mounted on the pedal assembly and is used to indicate brake pedal status to the HECU.
The switch is turned on when brake is depressed.
The brake light switch is a normally-open contact which runs to battery voltage when active (brake depressed).
When passive (brake not depressed), the cable is grounded via the brake light bulbs.
DTC DESCRIPTION
The brake light signal is a reference to judge driver's intention for braking.
The HECU checks open or short circuit of brake light switch for normal ESC control.
f an error is present, the warning lamp will illuminate.

Page 203 of 235
DTC Strategy ● Open circuit monitoring
● If both BLS(brake lamp switch) and BS(brake switch) have a same state
and MCP (Master Cylinder Pressure) >15bar for 500ms. ● Open circuit in
● Outside an ABS/ESC control, and after normal operation of MCP, If the brake switch line
Enable
pressure sensor signal is higher than 15bar and BLS is low for 3sec. ● Faulty brake light
Conditions
● If the BLS/BS changed more than 40times and MCP>15bar for 5sec. switch
● While Vehicle speed > 10km/h, MCP<7bar, if BLS is the same with BS ● Faulty input stage
over 1min. in HECU
● Inhibit the ESC control and allow the ABS/EBD control.
Fail Safe
SPECIFICATION
Voltage Range of "High" Voltage Range of "Low"
Brake Light Switch
7.0V ~ 16.0V 0V ~ 3V

4. Monitor the "BRAKE SWITCH" parameter on the scantool.
Specification : It is changed to ON/OFF.

Normal Data
Page 204 of 235
5. Whenever brake pedal is pushed down, is the brake switch’s scantool data changed ON/OFF?
Fault is intermittent caused by poor connection in brake light switch harness and/or HECU’s connector or was
or damage.

or damage.
Go to "Signal Circuit Inspection (brake pedal isn’t depressed)" procedure.

Signal circuit inspection (brake pedal isn’t depressed)
2. Measure voltage between stop lamp switch (brake switch) terminal of the HECU harness connector and hassis
ground.
Specification : Stop lamp switch - 0V

Brake switch B - B+
Go to "Signal Circuit Inspection (brake pedal is depressed)" procedure.
Check for open or blown 15A, 10A fuse referring to "Circuit Diagram".
Signal circuit inspection (brake pedal is depressed)
3. Measure voltage between stop lamp switch (brake switch) terminal of the HECU harness connector and chassis
ground.
Specification : Stop lamp switch - B+

Brake switch B - 0 V
Page 205 of 235
Fault is intermittent caused by poor connection in brake light switch harness and/or HECU’s connector.
Check for open or blown 15A, 10A fuse referring to "Circuit Diagram".
■ Brake light switch Check
2. Disconnect the stop lamp switch connector.
3. Measure resistance between power terminal and siganl terminal of the stop lamp switch connector.
Specification : Resistance between terminals of the stop lamp switch - ∞Ω (when the plunger is
pushed down), 0Ω (when the plunger isn’t pushed down).
Fault is intermittent caused by poor connection in brake light switch harness and/or HECU’s connector.
Substitute with a known-good brake light switch and check for proper operation.
If problem is corrected, replace brake light switch and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 206 of 235

GENERAL DESCRIPTION
The HECU consists of an ECU (Electronic Control Unit ) and a HCU( Hydraulic Control Unit).
The HCU portion of the assembly contains a pump motor, solenoid valves, and accumulator.
Increase and decrease of hydraulic pressure is opreated by electronic motor, according to a measured signal by
wheel speed sensor.
The function of HCU is to increase, decrease or maintain the hydralic pressure supplied to a wheel cylinder by
operating return pump according to HECU control signal while ABS control is active.
The ECU monitors various sensor and switch inputs.
These inputs are used to make decisions regarding HCU component operation.
DTC DESCRIPTION
The HECU monitors the operation of the IC components such as memory, register, A/D converter and so on.
The ECU sets this code when the EEPROM data read by the master processor is different than prior data written,
or when the master/slave processor detects abnormal operation in RAM, Status Register, Interrupt, Timer, A/D
converter or cycle time.

Page 207 of 235
Possible
Item Detecting Condition
cause
DTC Strategy ● Internal monitoring
● When the MCU can't erase or write a data of the EEPROM.
Enable
● When the master/slave processor detects abnormal operation in RAM, status ● Faulty
Conditions
register, interrupt, timer, A/D converter and cycle time. HECU
● The ABS/EBD/ESC functions are inhibited.
Fail Safe

or damage.

Fault is intermittent caused by faulty HECU or was repaired and HECU memory was not cleared.

SCHEMATIC DIAGRAM
Page 208 of 235

GENERAL DESCRIPTION
The HECU sends requirement data, such as Torque reduction, the number of fuel cut cylinders, and ESC control
requests, to the Engine PCM(ECM & TCM) through CAN bus line.
The Engine PCM(ECM) performs fuel cut functions according to requests from the HECU and retards ignition
timing by torque reduction requests.
The PCM(TCM) maintains current gear positions during ESC control time, in order not to increase power which
causes a Kickdown shift.
DTC DESCRIPTION
The HECU checks the CAN RAM for normal TCS control, and sets this code if a CAN RAM malfunction is
detected.

Page 209 of 235
DTC Strategy ● CAN RAM monitoring
Enable Conditions ● CAN Hardware failure.
● Faulty HECU
● Inhibit the ESC control and allow the
Fail Safe ABS/EBD control.

or damage.


SCHEMATIC DIAGRAM
Page 210 of 235

GENERAL DESCRIPTION
DTC DESCRIPTION
The HECU checks the CAN communcation lines for normal ESC control, and sets this code if an ECM message is
not received within 500ms.
The HECU does not detect this code until 2 seconds after the IG KEY is turned to ON.

Page 211 of 235
DTC Strategy ● CAN message monitoring
● In case that EMS1 or EMS2 message was not
received for more than 500ms within normal voltage
Enable Conditions
condition. ● Faulty PCM(ECM)
- The Monitoring starts 2000 ms after Power Up. ● Faulty HECU
Fail Safe control.

or damage.

■ Open Check
2. Disconnect HECU and ECM connector.
3. Measure resistance between CAN HIGH, LOW terminal of the HECU harness connector and CAN HIGH,
LOW terminal terminal of the ECM harness connector.
Specification : Approx. 0Ω
Repair open in CAN BUS line between HECU harness connector and ECM harness connector and then go
1. Ignition "OFF".
Page 212 of 235
Substitute with a known-good PCM and check for proper operation. If problem is corrected, replace PCM
and then go to "Verification of Vehicle Repair" procedure.
If NG, replace HECU and then go to "Verification of Vehicle Repair" procedure.
Fault is intermittent caused by faulty HECU, faulty PCM(ECM) or was repaired and HECU memory was not
cleared.

SCHEMATIC DIAGRAM
Page 213 of 235

GENERAL DESCRIPTION
Page 214 of 235
DTC DESCRIPTION
The HECU checks the CAN communication lines for normal ESC control, and sets this code if a TCM message is
not received within 500ms.
The HECU does not detect this code until 2 seconds after the IG KEY is turned to ON.

● In case that TCU message was not received for more
Enable Conditions than 500ms within normal voltage condition.
● Faulty PCM(TCM)
- The Monitoring starts 2000 ms after Power Up.
● Faulty HECU
Fail Safe control.

or damage.

■ Open Check
2. Disconnect HECU and TCM connector.
LOW terminal terminal of the TCM harness connector.
Repair open in CAN BUS line between HECU harness connector and TCM harness connector and then go
1. Ignition "OFF".
Page 215 of 235
Substitute with a known-good PCM(TCM) and check for proper operation. If problem is corrected, replace
PCM(TCM) and then go to "Verification of Vehicle Repair" procedure..
Fault is intermittent caused by faulty HECU, faulty PCM(TCM) or was repaired and HECU memory was not
cleared.

SCHEMATIC DIAGRAM
Page 216 of 235

GENERAL DESCRIPTION
The HECU send requirement data, such as Torque reduction, the number of fuel cut cylinders, and ESC control
DTC DESCRIPTION
The HECU checks the CAN communcation lines for normal ESC control, and sets this code if the data received
between the EMS2 and TCM is not the same.
The HECU will not detect this code until 2 seconds after the IG KEY is turned ON.

Page 217 of 235
● In case that the information about transmission is
different in the EMS2 message and TCM message
Enable Conditions
within normal voltage condition. ● Faulty PCM(ECM)
- The Monitoring starts 2000 ms after Power Up. ● Faulty HECU
Fail Safe control.

or damage.

■ Open Check
2. Disconnect HECU and ECM connector.
LOW terminal terminal of the ECM harness connector.
Repair open in CAN BUS line between HECU and ECM and then go to "Verification of Vehicle Repair"
procedure.
1. Ignition "OFF".
Page 218 of 235
Substitute with a known-good PCM(ECM) and check for proper operation. If problem is corrected, replace
PCM(ECM) and then go to "Verification of Vehicle Repair" procedure.
Fault is intermittent caused by faulty HECU, faulty PCM(ECM) or was repaired and HECU memory was not
cleared.

SCHEMATIC DIAGRAM
Page 219 of 235

GENERAL DESCRIPTION
Page 220 of 235
DTC DESCRIPTION
The HECU checks the CAN communication lines for normal TCS control, and sets this code if CAN BUS OFF
status is detected for more than 100ms.

DTC Strategy ● Open or short circuit monitoring
● In case CAN BUS off state continued for more than
Enable Conditions ● Open or short circuit in CAN
100ms.
line
● Inhibit the ESC control and allow the ABS/EBD ● Faulty HECU
Fail Safe control.

or damage.
Go to "CAN Signal Circuit Inspection" procedure.

CAN Signal Circuit Inspection
■ Short Check (to ground)
2. Disconnect the HECU connector.
Page 221 of 235
3. Measure resistance between CAN LOW terminal, CAN HIGH terminal of the HECU harness connector and
chassis ground.
Specification : ∞ Ω
If abnormal resistance is detected in CAN HIGH circuit, Repair short to ground in CAN HIGH circuit and
then go to "Verification of vehicle Repair" procedure.
If abnormal resistance is detected in CAN LOW circuit, Repair short to ground in CAN LOW circuit and then
go to "Verification of vehicle Repair" procedure.
■ CAN BUS Resistance Check
3. Measure resistance between CAN LOW terminal and CAN HIGH terminal of the HECU harness connector.
In case of the resistance "approx. 1Ω" : Repair mutual short in CAN signal circuit of the HECU and then go to
In case of the resistance "∞ Ω" : Repair open in CAN signal circuit of the HECU and then go to "Verification of
In case of the resistance "approx. 120 Ω" : Check the resistances(122Ω) in I/P junction box and ECM, repair
as necessary and then go to "Verification of vehicle Repair" procedure.
1. Ignition "OFF".

Fault is intermittent caused by poor connection in CAN signal harness and/or HECU’s connector.

Page 222 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
by later G.
to lateral G.
sensor.
DTC DESCRIPTION
The HECU checks the sensor CAN H/W for normal ESC control, and sets this code if a sensor CAN H/W
Page 223 of 235
malfunction is detected.

DTC Strategy ● Internal Monitoring
Enable Conditions ● Sensor CAN H/W failure ● Faulty HECU
● Faulty Yaw Rate & Lateral G
sensor
Fail Safe control.

or damage.



Page 224 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
The HECU supplies battery power to all soleonid valves with a valve relay which is controlled by the Electronic
Control UNIT(ECU).
The valve relay and all solenoid valves are installed inside the HECU ( Hydraulic and Electronic Control Unit ).
DTC DESCRIPTION
ABS ECU monitors voltage of the valve relay to check if ABS ECU can perform ABS control normally.
When the valve relay is switched to ON, the HECU will set this code if the solenoid drive voltage is below
permissible voltage ranges for a period of time.
When the valve relay is switched to OFF, the HECU sets this code if the solenoid drive voltage is over the
permissible voltage range for a period of time.

Page 225 of 235
● If the valve relay is switched on and the reference
Case1 Enable
voltage of valve relay < 5±0.5V continuously for
(Open) Conditions
56ms, the failure is detected. ● Open or short of power
● If the valve relay is switched off and voltage of valve supply circuit (ABS2)
Case2(Short Enable
relay > 6±0.5V or < 2.5±0.5V continuously for 56ms, ● Faulty HECU
or Leakage) Conditions
the failure is detected.
Fail Safe
MONITOR ACTUATION TEST

3. Select the "Actuation Test" mode on the scantool.
4. Inspect opearating status of all vlaves with Actuation Test.
Specification : It’s normal if operating sound is heard.

Ex) Actuation Test on Front left valve(in)
5. Do all valves operate normally?
Fault is intermittent caused by poor connection in power harness (ABS2) and/or HECU’s connector or was
or damage.

Page 226 of 235
or damage.

2. Measure voltage between power(ABS2) terminal of the HECU harness connector and chassis ground.
Specification : B+
Check for open or blown 40A (ABS2) fuse referring to "Circuit Diagram".

Repair open or short in ground circuit between HECU harness connector and chassis ground, and then go to

Page 227 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
BTCS ( Brake Traction Control System ) is operated when the value ( Wheel acceleration value + speed difference
value ) exceeds the specified value when vehicle speed is lower than the 50 Km/h.
The BTCS intalled HECU calculates the DISC temperature logically, which is an assumed value, by using the value
of Wheel speed, vehicle speed change, CONTROL MODE and BLS SIGNAL.
Assumed DISC Temperature is used to protect DISC overheating, caused by long-time operation, which may cause
a decrease in brake efficiency.
DTC DESCRIPTION
If the HECU decides that the Disc is over-heated ( above 500 °C ), then it turns the ESC lamp ON and inhibits
BTCS operation to protect overheating of the disc.
If the calculated temperature becomes lower than specified value ( arrox. 300 °C ), then the HECU turns the ESC
Page 228 of 235
lamp OFF and operates the BTCS again.

● When the calculated temperature of disc is higher than
predefined value(500°C).
If the calculated temperature drops below 300°C, the
Enable Conditions controller recovers to normal state.
● Faulty HECU
- When IGN switched OFF, HECU calculate
● Brake disk over heat
temperature of disc until calculated temperature drops
below 80°C by BATT1 power.
Fail Safe control.
1. Wait untill the brake disc cool down sufficiently.

Fault is caused by Faulty HECU or was repaired and HECU memory was not cleared.
The DTC code can be set by excessive TCS control in normal system status. Go to "Verification of Vehicle
Repair" procedure.


GENERAL DESCRIPTION
Page 229 of 235
The ABS HECU is composed of a ECU (Electronic Control Unit ) and an HCU( Hydraulic Control Unit), so the
HECU hardware includes all solenoid valves inside the unit as well as the ECU.
Solenoid valves are switched to ON, OFF by HECU when the ABS is activated. Solenoid valves function is to
increase, decrease or maintain the hydralic pressure supplied to a wheel cylinder.
DTC DESCRIPTION
The HECU monitors the operation of the valves by checking the drive circuit of the solenid valves, and then sets this
code when the unexpcted drive voltage is detected.
For example, the HECU sets the DTC if an unexpected high drive voltage is detected when the valve relay is
switched to OFF. (or unexpected low voltage is detected when the solenoid valve drive TR is switched to ON)

● If the valve relay is switched ON and corresponding
solenoid driver OFF and the voltage of solenoid <
3.5±0.5V continuously for 56ms, the failure is detected.
Enable Conditions
● If the valve relay is switched ON and corresponding ● Faulty HECU
solenoid driver ON and the voltage of solenoid >
1.5±0.5V continuously for 56ms, the failure is detected.
Fail Safe


Page 230 of 235
or damage.

or damage.


maintain vehicle speed at or above 40kmh. (24mph)).
SCHEMATIC DIAGRAM
Page 231 of 235

GENERAL DESCRIPTION
The ABS ECU supplies battery power to the electric motor by way of a motor relay which is controlled by the
Electronic Control Unit(ECU).
The electric motor pump supplies hydraulic pressure to all wheel brake calipers by operating the piston inside the
pump.
DTC DESCRIPTION
The ABS ECU monitors the pump motor relay or fuse open, open or short in motor or motor lock and then sets this
code if a malfunction is detected.

Page 232 of 235
Case1
(Motor
Relay ● If the motor relay is switched ON and motor voltage
Enable
Open or < (IGN voltage - 4V±0.5V) continued for 49msec, the
Conditions
Motor failure is detected.
Short to
GND)
● After motor relay is switched OFF, VMR is
measured. If the time which VMR > 1±0.1V is less than
Case2
Enable evaluation time, recheck is performed again for a
(Motor
Conditions maximum of three times.
Lock)
When VMR is not normal even on the third recheck, the ● Open or short of power
controller recognizes it as failure. supply circuit (ABS1)
● Faulty HECU
Case3
(Motor
● After 1.8sec from the time that motor relay is
Open, Enable
switched OFF, VMR > 4±0.5V continued for 1.8sec,
Motor Conditions
the failure is detected.
Short to
BATT)
Case4
● If the motor relay is switched OFF and VMRP
(Motor Enable
(Motor power supply voltage) < 4±0.5V continued for
Fuse Conditions
1sec, the failure is detected.
Open)
●ABS/ESC functions are inhibited, EBD function is
Fail Safe

Page 233 of 235

or damage.

or damage.

2. Measure voltage between power(ABS1) terminal of the HECU harness connector and chassis ground.
Specification : B+
Page 234 of 235
Check for open or blown 40A (ABS1) fuse referring to "Circuit Diagram".

Repair open or short in ground circuit between HECU harness connector and chassis ground, and then go to

SCHEMATIC DIAGRAM
Page 235 of 235
Page 1 of 19
SPORTAGE(KM) > 2008 > G 2.7 DOHC > Clutch System
Clutch System > General Information > Special Service Tools

SPECIAL TOOLS
Tool (Number and name) Illustraion Use
09411-11000 Installation of the clutch
Clutch disc guide disc.
Clutch System > General Information > Troubleshooting

TROUBLESHOOTING
Trouble symptom Suspect area Remedy (See page)
Clutch slipping Insufficient pedal free play Adjust
• Car will not respond to engine Clogged hydraulic system Correct or replace parts
speed during acceleration
• 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 Repair or replace parts
clogging
Unusual wear or corrosion of the clutch disc Replace
spline
Excessive vibration (distortion) of the clutch
Replace
disc
Clutch When the clutch is Insufficient play of the clutch pedal Adjust
noisy not used
Excessive wear of the clutch disc facing Replace
A noise is heard after Unusual wear and/ or damage of the release Replace
the clutch is bearing
disengaged
A noise is heard Insufficient grease on the sliding surface of Repair
when the clutch is the bearing sleeve
disengaged
Improperly installed the clutch assembly or Repair
bearing
A noise is heard Damaged pilot bushing Replace
when the car
suddenly rolled up
with the clutch
partially engaged
Hard pedal effort Insufficient lubrication of the clutch pedal Repair
Insufficient lubrication of the spline part of Repair
clutch disc
Page 2 of 19
Insufficient lubrication of the clutch release Repair
lever shaft
Insufficient lubrication of the front bearing
Repair
retainer
Hard to shift or will not shift Excessive clutch pedal free play Adjust the pedal free play
Faulty of the clutch release cylinder Repair the release cylinder
Clutch disc out of place, runout is excessive Inspect the clutch disc
or lining broken
Spline on the input shaft or clutch disc dirty Repair as necessary
or burred
Faulty of the clutch pressure plate Replace the clutch cover
Clutch slips Insufficient of the clutch pedal free play Adjust the pdal free play
Clogged of the hydraulic system Repair or replace parts
Clutch disc lining oily or worn out Inspect the clutch disc
Faulty of the pressure plate Replace the clutch cover
Binding of the release fork Inspect the release fork
Clutch grabs/chatters Clutch disc lining oily or worn out Inspect the clutch disc
Faulty the pressure plate Replace the clutch cover
Bent the clutch diaphragm spring Replace the clutch cover
Worn or broken torsion spring Replace the clutch disc
Loose the engine mounts Repair as necessary
Clutch noisy Damaged the clutch pedal bushing Replace the clutch pedal bushing
Loose part inside housing Repair as necessary
Worn or dirty release bearing Replace the replease bearing
Sticking release fork or linkage Repair as necessary
Clutch System > General Information > Specifications

SPECIFICATIONS
Clutch operation method Hydraulic type
Clutch disc Type Single dry with diaphragm
Faling diameter(Outter × innter) 235 × 155mm(9.25×6.10 in)
Clutch cover assembly Type Diaphragm spring strap
Clutch release cylinder inner
20.64mm(0.81in)
diameter
Clutch master cylinder inner
15.87mm(0.62 in)
diameter
SERVICE STANDARD
Page 3 of 19
Standard value
Clutch disc thickness [When free]
8.5 ± 0.3 mm (0.326 ~ 0.350 in)
Distance between inner pad and clutch
252 ± 2mm(9.84 ~ 10.00 in)
pedal
6 ~ 13 mm (0.24 ~ 0.51 in)
Clutch pedal free play
150 mm (5.9 in)
Clutch pedal stroke
189.5 mm (7.46 in)
Clutch pedal height
Limit
Clutch disc rivet sink
Diaphragm spring end height difference 0.3 mm (0.011 in)
Clutch replease cylinder clearance to 0.5 mm (0.02 in)
piston 0.15 mm (0.006 in)
Clutch master cylinder clearance to 0.15 mm (0.006 in)
piston
TIGHTENING TORQUE
Item Nm kgf.cm lb-ft
Ignition lock switch 8 ~ 10 80 ~ 100 5.9 ~ 7.4
Clutch pedal mounting 25 ~ 35 250 ~ 350 18.4 ~ 25.8
Clutch tube to clutch oil regulator 13 ~ 17 130 ~ 170 9.6 ~ 12.5
Clutch tube to clutch master cylinder 12 ~ 16 120 ~ 160 8.9 ~ 11.8
Clutch tube to clutch hose 13 ~ 17 130 ~ 170 9.6 ~ 12.5
Clutch release cylinder to clutch hose 25 ~ 35 250 ~ 350 18.4 ~ 25.8
Clutch oil regulator mounting 6~8 60 ~ 80 4.4 ~ 5.9
Clutch release cylinder bledder screw 12 ~ 20 120 ~ 220 8.9 ~ 14.8
Clutch cover 15 ~ 22 150 ~ 220 11.1 ~ 14.8
Clutch mounting 43 ~ 55 430 ~ 550 (3EA)
5.9 ~ 7.4
8 ~ 10 80 ~ 100 (2EA)
Clutch release lever fork nut 27 ~ 40 270 ~ 400 19.5 ~ 28.9
LUBRICANTS
Items Specified lubricants Quantity
Contact surface of release bearing and fulcrum of clutch
CASMOLY L 9508 As required
release fork
Inner surface of clutch release bearing CASMOLY L 9508 As required
Inner surface of clutch release cylinder and outer
Brake fluid DOT 3 or DOT 4 As required
circumference of piston and cup
Inner surface of clutch disc spline CASMOLY L 9508 0.29 g
Inner surface of clutch master cylinder and outer
Brake fluid DOT 3 or DOT 4 As required
circumference of piston assembly
Wheel bearing grease SAE J310,
Clutch master cylinder push rod, clevis pin and washer As required
NLGI No.2
Chassis grease SAE J310a,
Clutch pedal shaft and bushings As required
NLGI No.1
Contact portion of release fork to release cylinder push
CASMOLY L 9508 As required
rod
Page 4 of 19
Input shaft spline CASMOLY L 9508 As required
Clutch System > Clutch System > Components and Components Location
COMPONENTS(1)
COMPONENTS(2)
Page 5 of 19
Clutch System > Clutch System > Repair procedures

SERVICE ADJUSTMENT PROCEDURE
CLUTCH PEDAL INSPECTION AND ADJUSTMENT
Page 6 of 19
1. Measure the clutch pedal height (from the face of the pedal pad to the floorboard) and the distance between inner
pad and clutch pedal.
Standard value:
(A) 252 ± 2 mm (9.84 ~ 10.00 in.)
(B) 189.5 mm (7.46 in.)
2. If the clutch pedal height and distance is not within the standard value range, adjust as follows:
(1) 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 then tighten the lock nut.
(2) Turn the push rod to agree with the standard value and then secure the push rod with the lock nut.
When adjusting the clutch pedal height or the clutch pedal clevis pin play, be careful not to push the
push rod toward the master cylinder.
3. 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: (C) 6 ~ 13 mm (0.24~0.52 in.)

Page 7 of 19
4. If the clutch pedal free play and the distance between the clutch pedal and the floor board when the clutch is
disengaged, do not meet with the standard values, it may be the result of either air in the hydraulic system or a
faulty the clutch master cylinder. Bleed the air or disassemble and inspect the master cylinder or clutch.
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(B) at the clutch release cylinder(A).
2. Pump the clutch pedal 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 disrupt the release cylinder's position.
During the bleeding operation, press the clutch pedal to the floor after it returns to the "A" point.
Clutch System > Clutch System > Clutch Cover And Disc > Components and Components Location
COMPONENETS
Page 8 of 19
Clutch System > Clutch System > Clutch Cover And Disc > Repair procedures
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.
Page 9 of 19
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
REPLACEMENT
1. Remove the transaxle assembly.(See 'TR' group - 'Manual Transaxle')
2. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from falling.
3. Loosen the bolts which attach the clutch cover to the flywheel in a star pattern. 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 the release bearing with cleaning solvent.
4. Remove the release fork shaft and bushing.

Page 10 of 19
5. Apply multipurpose grease to the spline of the disc.
Grease: CASMOLY L 9508 0.2gr
When installing the clutch, apply grease to each part, but be careful not to apply excessive
grease.
It can cause clutch slippage and judder.
6. Install the clutch disc assembly to the flywheel using the special tool (09411-11000).
7. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a
star pattern.
Tightening torque
Clutch cover bolt:
15 ~ 22 Nm (150~220 kgf.cm, 11~16 lb-ft)
8. Align the bearing (A) to the release fork (B) and then install it to the sleeve of the housing.
Apply multipurpose grease (CASMOLY L9508) to the bearing sleeve, contact point of the release fork
(B) and the bushing inner surface (C).
Page 11 of 19
9. Install the release lever to the release fork.
10. Install the transaxle assembly to the engine.
If the transaxle assembly is installed to the engine without performing this step, the release bearing can be
separated, as the release fork rotates freely.
Clutch System > Clutch System > Clutch Master Cylinder > Components and Components Location
COMPONENETS
Page 12 of 19
Clutch System > Clutch System > Clutch Master Cylinder > Repair procedures
REMOVAL
Page 13 of 19
1. Drain the clutch fluid through the bleed plug (A).
2. Remove clutch master cylinder connecting rod (A), split pin (cotter pin) (C) and washer (B).
3. Disconnect the clutch tube (A) (master cylinder side).
4. Remove the master cylinder mounting nuts.

5. Remove the clutch line clips (A).
6. Hold the nut on the clutch hose (B) and loosen the flare nut (C) on the clutch tube.
7. Remove the clutch tube.

Page 14 of 19
8. Disconnect the clutch hose (A) (release cylinder side).
9. Connect the clutch tube (A) (release cylinder side).
10. Temporarily tighten the flare nut by hand, then tighten it to the specified torque, being careful that the clutch hose
does not become twisted.
11. Install the clutch tube and clips (A).
12. Install the master cylinder.

Page 15 of 19
13. Apply the specified grease to the clevis pin and washer.
Wheel bearing grease: SAE J310a, NLGI NO. 2
14. Install the push rod to the clutch pedal.

15. Pour the clutch fluid into the clutch master cylinder.
16. Bleed the clutch system.
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 clogged.
5. Measure the master cylinder inside diameter and the piston outside diameter with a cylinder gauge micrometer.
Measure the inside diameter of the master cylinder at three places (bottom, middle, and top) in a
perpendicular direction.
6. If the master cylinder-to-piston clearance exceeds the limit, replace the master cylinder and/or piston assembly.
Limit: 0.15 mm (0.006 in.)
Clutch System > Clutch System > Clutch Pedal > Components and Components Location
COMPONENTS
Page 16 of 19
Clutch System > Clutch System > Clutch Pedal > Repair procedures
INSPECTION
1. Check the pedal shaft and bushing for wear.
2. Check the clutch pedal for bending or torsion.
3. Check the return spring for damage or deterioration.
4. Check the pedal pad for damage or wear.
Ignition lock switch inspection
Page 17 of 19
RETURING TEST OF CLUTCH PEDAL.

Deformation of pedal pad must be MAX. 5mm after repeating the test 20 times (sudden return from full stroke).
REPLACEMENT
1. Remove the clutch master cylinder connecting rod (A), washer (B), and split pin (C).
2. Remove the clutch pedal mounting bolts.

3. Apply the specified grease to the clutch pedal and bushings.
Chassis grease: SAE J310a, NLGI No.1
4. Install the clutch pedal mounting bolt.
5. Apply the specified grease to the clevis pin and washer.
Wheel bearing grease: SAE J310, NLGI No.2
6. Install the push rod to the clutch pedal.
ADJUSTMENT
• Check for the ignition lock switch.

• Before adjusting, remove the driver's floor seat.
1. After loosening the ignition lock switch nut, move it back until it has no contact with the clutch pedal arm.
Page 18 of 19
2. Check for the specification below.
Clutch pedal stroke : 150 mm (5.9 in)

Clutch pedal free play : 6 ~ 13 mm (0.24 ~ 0.51 in)
Distance between the inner pad and clutch pedal : 250 ~ 254 mm (9.84 ~ 10.00 in)
3. Fix the ignition switch whtn its signal is OFF pressing the pedal slowly 52 ~ 58 mm (2.0 ~ 2.3 in).
Tighten the fixing nut with specification
TORQUE : 8~ 10 Nm (80 ~ 100 kgf·cm, 5.9 ~ 7.4 lbf·ft)
Clutch System > Clutch System > Clutch Release Bearing > Components and Components Location
COMPONENTS
Page 19 of 19
Clutch System > Clutch System > Clutch Release Bearing > Repair procedures
REPLACEMENT
1.
2. Clamp the clutch hose between the clutch release cylinder and the clutch tube.
3. Drain the fluid from the release cylinder by loosening the bleeder screw, then removing the bolt from the clutch
hose.
Use a suitable container to catch the fluid.
4. Remove the clutch release cylinder by loosening the mounting bolt.
5. Install the new clutch release cylinder.
6. Remove the clamp from the clutch hose.
Ensure the brake master cylinder fluid level is correct, then bleed the clutch release cylinder.
Page 1 of 66
SPORTAGE(KM) > 2008 > G 2.7 DOHC > 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 a hub.
09517-43401 Support for the differential carrier

Working base
09517-43500
Adapter
09568-34000 Separation of a lower arm and a tie rod

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

TROUBLESHOOTING
Vehicle pulls to one side Galling of drive shaft ball joint Replace
Wear, rattle or galling of wheel bearing Replace
Defective front suspension and steering Adjust or replace
Vibration Wear, damage or bending of drive shaft Replace
Drive shaft rattle and hub serration Replace
Wear, rattle or scratching of wheel bearing Replace
Shimmy Improper wheel balance Adjust or replace
Excessive noise Wear, damage or bending of drive shaft Replace
Drive shaft rattle and hub serration Replace
Drive shaft rattle and side gear serration Replace
Wear, rattle or galling of wheel bearing Replace
Page 2 of 66
Loose hub nut Adjust or replace
Quire-noise from the rear hub, Cap separation from the hub bearing Remove the rear hub check the
occurs when driving on rugged hub bearing cap.
roads Install a new cap if necessary.
Driveshaft and axle > General Information > Specifications

SPECIFICATION
Joint type Assembly range length
Type
Inner Outer Left Right
FRONT DRIVESHAFT
2.7GSL AT UTJ-II#25 BJ#25 536.5 531.5
2WD
2.0GSL MT/AT UTJ-II#24 BJ#25 536.4 824.2
2.7GSL AT UTJ-II#25 BJ#25 536.5 536.4
4WD AT UTJ-II#24 BJ#25 536.4 536.4
2.0GSL
MT UTJ-II#24 BJ#25 536.4 536.4(Ø24)
Max. permissible angle Inner 46.5° Outer 23°
REAR DRIVESHAFT
4WD ALL TJ#22 BJ#22 670 670
Max. permissible angle Inner 46.5° Outer 23°
REAR DIFFERENTIAL CARRIER
Oil type Hypoid gear oil (GL-5, 80W/SAE90)
Oil capacity Approx. 0.75 ~ 0.80 ℓ (0.79 ~ 0.84 US qt.)
Reduction gear type Hypoid gear
Reduction gear ratio 3.091
Final drive gear backlash mm(in) 0.10 ~ 0.15 (0.0039 ~ 0.0059)
Differential gear backlash mm(in) 0 ~ 0.076 (0 ~ 0.003)
BJ : Birfield Joint
TJ : Tripod Joint
UTJ-II : U-type Tripod Joint
TIGHTENING TORQUE
Page 3 of 66
Items Nm Kgf·m lbf·ft
Front hub Wheel nut 90 ~ 110 9 ~ 11 66.4 ~ 81.2
Driveshaft castle nut 200 ~ 280 20 ~ 28 147.5 ~ 206.6
Break caliper mounting bolt 50 ~ 60 5~6 36.9 ~ 44.3
Lower arm mounting bolt 100 ~ 120 10 ~ 12 73.8 ~ 88.5
Strut lower mounting bolt 140 ~ 160 14 ~ 16 103.3 ~ 118.0
Tie rod end ball joint mounting
45 ~ 60 4.5 ~ 6 33.2 ~ 44.3
nut
Rear Wheel nut 90 ~ 110 9 ~ 11 66.4 ~ 81.2
Break caliper mounting bolt 50 ~ 60 5~6 36.9 ~ 44.3
Break disc(drum) mounting
5~6 0.5 ~ 0.6 3.7 ~ 4.4
screw
Dust cover mounting bolt 50 ~ 60 5~6 36.9 ~ 44.3
Strut lower mounting nut 140 ~ 160 14 ~ 16 103.3 ~ 118.0
Trailing arm mounting bolt 100 ~ 120 10 ~ 12 73.8 ~ 88.5
Hub bearing flange nut[2WD] 200 ~ 260 20 ~ 26 147.5 ~ 191.8
Driveshaft castle nut[4WD] 200 ~ 280 20 ~ 28 147.5 ~ 206.6
Suspension arm mounting
160 ~ 180 16 ~ 18 118.0 ~ 132.8
nut[2WD]
Suspension arm mounting
140 ~ 160 14 ~ 16 103.3 ~ 118.0
nut[4WD]
Propeller shaft Front propeller shaft mounting
50 ~ 60 5~6 36.9 ~ 44.3
bolt
Propeller shaft center bearing
50 ~ 65 5.0 ~ 6.5 36.9 ~ 47.0
bracket mounting bolt
Rear propeller shaft mounting
100 ~ 120 10 ~ 12 73.8 ~ 88.5
bolt
Differential Rear differential mounting bolt 90 ~ 120 9 ~ 12 66.4 ~ 88.5
Differential cover mounting
40 ~ 50 4~5 29.5 ~ 36.9
bolt
Replace self-locking nuts with new ones after removal.
LUBRICANTS
FRONT DRIVESHAFT
[2WD]
Page 4 of 66
Items Recommended Quantity
UTJ-II#24 + BJ#24 type (2.0GSL ALL)
UTJ-II#24 boot grease RTA-R (SK Chemical) 160g +10g
BJ#24 boot grease RBA (SK Chemical) 130g +10g
UTJ-II#25 + BJ#25 type (2.7GSL AT)
[4WD]
UTJ-II#24 + BJ#24 type (2.0GSL ALL)
UTJ-II#25 + BJ#25 type (2.7GSL AT)
REAR DRIVESHAFT (4WD)

TJ#22 - BJ#22 type (ALL)
TJ#22 boot grease RTA-R (SK Chemical) 110g +10g
Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Components and Components
Location
COMPONENTS
Page 5 of 66
COMPONENTS
Page 6 of 66
Page 7 of 66
Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Repair procedures
REMOVAL
1. Loosen the wheel nuts slightly.
Raise the front of the vehicle, and make sure it is securely supported.
Page 8 of 66
2. Remove the front wheel and tire(A) from front hub(B).
Be careful not to damage the hub bolts(C) then remove the front wheel and
tire(A).
3. Remove the split pin(A), then remove castle nut(B) and washer(C) from the front hub under applying the break.
4. Remove the wheel speed sensor(B) from the knuckle(A).

Page 9 of 66
5. Disconnect the tie rod end ball joint(C) from the knuckle(D) using the special tool(09568-34000).
A. Remove the split pin(A).

B. Remove the castle nut(B).
C. Disconnect the ball joint(C) from knuckle(D) using the special tool(09568-34000).
Apply a few drops of oil to the special tool.(Boot contact part)
6. Remove the lower arm ball joint mounting bolts(A).

Page 10 of 66
7. Using a plastic hammer(A), disconnect the driveshaft(C) from the axle hub(C).
8. Push the axle hub(B) outward and separate the driveshaft(C) from the axle hub(B).
9. Insert a pry bar(A) between the transaxle case(B) and joint case(C), and separate the driveshaft(D) from the
transaxle case.
• Use a pry bar(A) being careful not to damage the transaxle and joint.
• Do not insert the pry bar(A) too deep, as this may cause damage to the oil seal.(max. depth :
7mm(0.28in)
• Do not pull the driveshaft by excessive force it may cause components inside the axle shaft joint kit to
dislodge resulting in a torn boot or a damaged bearing.
• Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
• Support the driveshaft properly.
• Replace the retainer ring whenever the driveshaft is removed from the transaxle case.
INSTALLATION
Page 11 of 66
1. Apply gear oil on the driveshaft oil seal case contacting surface(B) and transaxle case splines(A).
[2WD]
[4WD]
2. Before installing the driveshaft(C), set the opening side of the circlip(D) facing downward.
3. After installation, check that the driveshaft cannot be removed by hand.
4. Install the drive shaft into the knuckle.
5. Install the lower arm mounting bolts(A).
Tightening torque :
100 ~ 120 Nm (10 ~ 12 Kgf·m, 73.8 ~ 88.5 lb-ft)
Page 12 of 66
6. After installing the washer(B) with convex surface outward, install the castle nut(A) and the split pin(C).
Tightening torque :
200 ~ 280 Nm (20 ~ 28 Kgf·m, 147.5 ~ 206.6 lb-ft)
7. Install the front wheel and tire(A) on the front hub(B).
Tightening torque :
90 ~ 110 Nm (9 ~ 11 Kgf·m, 66.4 ~ 81.2 lb-ft)
Be careful not to damage the hub bolts(C) then install the front wheel and tire(A).
INSPECTION
1. Check the driveshaft boots for damage and deterioration.
2. Check the ball joint for wear and damage.
3. Check the splines for wear and damage.
Page 13 of 66
4. Check the dynamic damper for cracks, wear and position
5. Check the driveshaft for cracks and wears.
DISASSEMBLY
DRIVESHAFT (2WD)
• Do not disassemble the BJ assembly.

• Special grease must be applied to the driveshaft joint. Do not substitute with another type of grease.
• The boot band should be replaced with a new one.
1. Remove the circlip(B) from driveshaft splines(A) of the transaxle side UTJ case.
2. Remove the both boot clamps from the transaxle side UTJ case.
A. Using a plier or flat-tipped (-) screwdriver, remove the both clamps(UTJ boot band(B), boot band(A)) of the
transaxle side.
3. Pull out the boot from the transaxle side joint(UTJ).

Page 14 of 66
4. While dividing joint(UTJ) boot(A) of the transaxle side, wipe the grease in UTJ case(B) and collect them
respectively.
• Be careful not to damage the boot.

• According to below the illustrated, put marks(D) on roller of trunion assembly(A), UTJ case(B) and
spline part(C), for providing assembly.
5. Using a plier or flat-tipped (-)screwdriver, remove the circlip(A).
6. Remove the trunion assembly(B) from the driveshaft(A) using the special tool(09495-33000).
Page 15 of 66
7. Clean the trunion assembly.
8. Remove the boot(A) of the transaxle side joint(UTJ).
For reusing the boot(A), wrap tape(B) around the driveshaft splines(C) to protect the
boot(A).
9. Using a plier or flat-tipped (-) screwdriver, remove the both side of clamp(B) of the dynamic damper(A).
10. Fix the driveshaft(A) with a vise(B) as illustrated.
11. Apply soap powder on the shaft to prevent being damaged between the shaft spline and the dynamic damper
when the dynamic damper is removed.
Page 16 of 66
12. Saperate the dynamic damper(A) from the shaft(B) carefully.
13. Using a plier or flat-tipped (-) screwdriver, remove the clamp on the side of wheel.
14. Pull out the joint(BJ) on the side of wheel into the transaxle direction.
Be carefull not to damage the boot.
INSPECTION
4. Check the dynamic damper for cracks, wear and position
REASSEMBLY
1. Wrap tape around the driveshaft splines (UTJ side) to prevent damage to the boots.
2. Apply grease to the driveshaft and install the boots. (See page DS - 4)
Page 17 of 66
3. Install the clamps to both boots.
4. To reassemble the dynamic damper(A), keeping the shaft(B) in the straight, tighten the dynamic damper(A) with
dynamic band(C), as the illustration.
5. Install the UTJ boot bands and UTJ boot.

6. Install the trunion assembly(A) and the circlip(E) to the spline(C) on the drivershaft.
At this time align the marks(D) each other.
7. Add the specified grease to the UTJ as mush as wiped away at inspection.
8. Install the boots.
9. Tighten the UTJ boot bands.
Page 18 of 66
10. To control the air in the UTJ boot, keep the specified distance between the boot bands when they are tightened.
Driveshaft and axle > Front Axle Assembly > Front Hub - Axle > Components and Components
Location
COMPONENT LOCATION
COMPONENTS
Page 19 of 66
Driveshaft and axle > Front Axle Assembly > Front Hub - Axle > Repair procedures
REMOVAL
Page 20 of 66
tire(A).
4. Remove the caliper mounting bolts(A), and hang the caliper assembly(B) to one side. To prevent damage to the
caliper assembly or brake hose, use a short piece of wire to hang the caliper from the undercarriage.
Page 21 of 66
5. Remove the wheel speed sensor(B) from the knuckle(A).
6. Disconnect the tie rod end ball joint(C) from the knuckle(D) using the special tool(09568-34000).
A. Remove the split pin(A).

B. Remove the castle nut(B).
C. Disconnect the ball joint(C) from knuckle(D) using the special tool(09568-34000).
Apply a few drops of oil to the special tool. (Boot contact part)
Page 22 of 66
8. Remove the strut lower arm mounting bolts(A).
9. Remove the hub and the knuckle assembly(B).
Be careful not to damage the boot and rotor

teeth.
INSTALLATION
1. Install the hub and the knuckle assembly(B).
2. Install the strut lower mounting bolts(A).
Tightening torque :
140 ~ 160 Nm (14 ~ 16 Kgf·m, 103.3 ~ 118 lb-ft)
Page 23 of 66
3. Install the lower arm ball joint mounting bolts(A).
Tightening torque :
100 ~ 120 Nm (10 ~ 12 Kgf·m, 73.8 ~ 88.5 lb-ft)
4. Install the tie rod end ball joint(C) from the knuckle.
Tightening torque :
45 ~ 60 Nm (4.5 ~ 6 Kgf·m, 33.2 ~ 44.3 lb-ft)
A. Install the castle nut(B).

B. Install the split pin(A).
5. Install the wheel speed sensor(A).
Page 24 of 66
6. Install the brake caliper(B), and then tighten the mounting bolts(A).
Tightening torque :
50 ~ 60 Nm (5 ~ 6 Kgf·m, 36.9 ~ 44.3 lb-ft)
7. Install the washer(C), castle nut(B) and split pin(A) from the front hub.
Tightening torque :
200 ~ 280 Nm (20 ~ 28 Kgf·m, 147.5 ~ 206.6 lb-ft)
Tightening torque :
90 ~ 110 Nm (9 ~ 11 Kgf·m, 66.4 ~ 81.2 lb-ft)
Page 25 of 66
ON-VEHICLE INSPECTION
WHEEL BEARING PLAY INSPECTION
1. Inspection the play of the bearing while the vehicle is jacked up.
2. If there is any play, loosen the wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely
supported.
tire(A).
Page 26 of 66
5. Tighten the hub bearing nut by the following procedures.
A. Hub bearing nut must be fastened with torque 280 Nm (28 kgf·m, 202.5 lb-ft) and rear hub must be rotated
above 3 times enough for secure placement of hub bearing.
B. Unfasten hub bearing nut until its tightening torque is 0 Nm (kgf·m, lb-ft)
C. Hub bearing nut must be fastened again with torque 200 Nm (20 kgf·m, 144.7 lb-ft)
D. Assemble split pin.

E. If the direction of split pin is not in line with the hole of knuckle unfasten hub bearing nut within 30° and
assemble sprit pin.
2. If there is any play, loosen the wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely
supported.
Page 27 of 66
tire(A).


Page 28 of 66
assemble sprit pin.
Driveshaft and axle > Rear Axle Assembly > Rear Hub - Carrier > Components and Components
Location
COMPONENT LOCATION
Page 29 of 66
COMPONENTS
Page 30 of 66
Driveshaft and axle > Rear Axle Assembly > Rear Hub - Carrier > Repair procedures
REMOVAL
Raise the rear of the vehicle, and make sure it is securely supported.
Page 31 of 66
2. Remove the rear wheel and tire(A) from rear hub(B).
Be careful not to damage the hub bolts(C) then remove the rear wheel and
tire(A).
4. Remove the wheel speed sensor(B) from the axle carrier(A).

Page 32 of 66
5. Loosen the brake disc mounting screw(A), and then remove the brake disc(C) from the hub(B).
6. Using a (-)screwdriver, remove the hub cap(A).
7. Remove the hub bearing flange nut(A).

A. Using a flat-tipped (-)screwdriver, spread out the groove(B) on the flange nut(A)
B. Loosen the hub bearing flange nut(A).
Page 33 of 66
8. Remove the rear hub washer(A) and rear hub assembly(B).
• Be careful not disassembly the rear hub assembly.

• For vehicles equipped with ABS.
• Care must be taken not to scratch or damage the teeth of the rotor(A).
• The rotor must never be dropped.
• If the teeth of the rotor are chipped, it results in deformation of the rotor. It will make it impossible to
detect the wheel rotation speed accurately and to operate the system normally.
9. Loosen the rear dust cover mounting bolts(A) and then remove the rear parking brake assembly(B).
Page 34 of 66
10. Remove the rear axle carrier(A).
A. Remove the trailing arm mounting bolt(B).
B. Remove the suspension arm mounting nut(C).
C. Remove the strut mounting nuts(D).
INSTALLATION
1. Install the rear axle carrier(A).
A. Install the strut mounting nuts(D).
Tightening torque :
140 ~ 160 Nm (14 ~ 16 Kgf·m, 103.3 ~ 118.0 lb-ft)
B. Install the suspension arm mounting nut(C).
Tightening torque :
160 ~ 180 Nm (16 ~ 18 Kgf·m, 118.0 ~ 132.8 lb-ft)
C. Install the trailing arm mounting bolt(B).
Tightening torque :
100 ~ 120 Nm (10 ~ 12 Kgf·m, 73.8 ~ 88.5 lb-ft)
Replace the self-locking nut with new ones after removal.

Page 35 of 66
2. Install the rear dust cover(B) and then tighten the mounting bolts(A).
Tightening torque :
50 ~ 60 Nm (5 ~ 6 Kgf·m, 36.9 ~ 44.3 lb-ft)
3. Install the hub assembly(B) and hub washer(A).
4. After tightening the hub bearing flange nut(A), caulk the concave portion(B) of the spindle by crimping the nut.
Tightening torque :
200 ~ 260 Nm (20 ~ 26 Kgf·m, 147.5 ~ 191.8 lb-ft)
Replace the flange nut with new ones after removal.

Page 36 of 66
5. Install the hub cap(A).
Replace the hub cap with new ones after

removal.
6. Installation of the rear speed sensor(A).(For vehicles equipped with ABS):

Insert a feeler gauge(C) into the space between the pole piece of the speed sensor(A) and the rotor teeth(B)
surface, and then tighten the speed sensors(A) at the position where the clearance at all places is within the
standard value.
Standard value :
Clearance : 0.5 ~ 1.5mm (0.02 ~ 0.06 in)
7. Install the brake disc(C) from the hub(B), then tighten the brake disc mounting screw(A).
Tightening torque :
5 ~ 6 Nm (0.5 ~ 0.6 Kgf·m, 3.7 ~ 4.4 lb-ft)
Page 37 of 66
8. Install the brake caliper(B), then tighten the mounting bolt(A).
Tightening torque :
50 ~ 60 Nm (5 ~ 6 Kgf·m, 36.9 ~ 44.3 lb-ft)
9. Install the rear wheel and tire(A) on the rear hub(B).
Tightening torque :
90 ~ 110 Nm (9 ~ 11 kgf·m, 66.4 ~ 81.2 lb-ft)
Be careful not to damage the hub bolts(C) then install the rear wheel and tire(A).
Page 38 of 66
2. If there is any play, loosen the wheel nuts slightly. Raise the rear of the vehicle, and make sure it is securely
supported.
tire(A).
4. Remove the split pin(A), then remove castle nut(B) and washer(C) from the rear hub under applying the break.


Page 39 of 66
assemble split pin
2. If there is any play, loosen the wheel nuts slightly. Raise the rear of the vehicle, and make sure it is securely
supported.
tire(A).
Page 40 of 66


assemble split pin
Driveshaft and axle > Rear Axle Assembly > Rear Hub - Axle > Components and Components
Location
COMPONENT LOCATION
Page 41 of 66
Driveshaft and axle > Rear Axle Assembly > Rear Hub - Axle > Repair procedures
REMOVAL
Page 42 of 66
tire(A).
Page 43 of 66
6. Remove the rear axle assembly(A).

A. Remove the trailing arm mounting bolt(B).
B. Remove the suspension arm mounting nuts(C).
C. Remove the strut mounting nuts(D).
INSTALLATION
1. Install the rear axle assembly(A).
A. Install the strut mounting nuts(D).
Tightening torque :
140 ~ 160 Nm (14 ~ 16 Kgf·m, 103.3 ~ 118 lb-ft)
B. Install the suspension arm mounting nuts(C).
Tightening torque :
140 ~ 160 Nm (14 ~ 16 Kgf·m, 103.3 ~ 118 lb-ft)
Page 44 of 66
C. Install the trailing arm mounting bolt(B).
Tightening torque :
100 ~ 120 Nm (10 ~ 12 Kgf·m, 73.8 ~ 88.5 lb-ft)
2. Install the brake caliper(B), then tighten the mounting bolt(A).
Tightening torque :
50 ~ 60 Nm (5 ~ 6 Kgf·m, 36.9 ~ 44.3 lb-ft)
3. Install the washer(C), castle nut(B) and split pin(A) from the rear hub.
Tightening torque :
200 ~ 280 Nm (20 ~ 28 Kgf·m, 147.5 ~ 206.6 lb-ft)
Page 45 of 66
4. Install the wheel speed sensor(B) from the axle carrier(A).
Tightening torque :
90 ~ 110 Nm (9 ~ 11 Kgf·m, 66.4 ~ 81.2 lb-ft)
INSPECTION
1. Check the hub bearing for wear or damage.
2. Check the carrier for cracks.
Driveshaft and axle > Propeller Shaft Assembly > Propeller Shaft > Components and Components
Location
COMPONENTS
Page 46 of 66
Driveshaft and axle > Propeller Shaft Assembly > Propeller Shaft > Repair procedures
INSPECTION
VL JOINT AND BOOTS
1. Shift the transmission to Neutral.
2. Raise the vehicle off the ground, and support it with safety stands in the proper locations.
Page 47 of 66
3. Check the center support bearing for excessive play or rattle and rubber for rent. If the center support has
excessive play or rattle and rubber has rent, replace the propeller shaft assembly.
4. Check the VL joint boots for damage and deterioration. If the boots are damaged or deteriored. replace the
propeller shaft assembly.
5. Check the VL joints for excessive play or rattle.
If the universal joints have excessive play or rattle, replace the propeller shaft assembly.
PROPELLER SHAFT RUNOUT
1. Install a dial indicator with its needle on the center of front propeller shaft or rear propeller shaft.
2. Turn the other propeller shaft slowly and check the runout. Repear this procedure for the other propeller shaft.
Front Propeller Shaft Runout : 0.3mm (0.012in)
Rear Propeller Shaft Runout : 0.3mm (0.012in)
3. If the runout on either propeller shaft exceeds the service limit, replace the propeller shaft assembly.
REMOVAL
Page 48 of 66
1. After making a match mark(C) on the rubber coupling(A) and rear differential companion(B), remove the
propeler shaft mounting bolts(D).
2. Remove the center bearing bracket mounting bolts(A).
3. After making a match mark(C) on the flange yoke(A) and transaxle companion(B), remove the propeller shaft
mounting bolts(D).
If a grease leak is shown around the nuiversal joint, be sure to put grease in the universal joint through the
nipple enough until grease come out of the universal joint.
INSTALLATION
1. Installation is the reverse of the removal procedures.
2. Install according to match mark of transaxle companion (or rear differential companion) and propeller shaft.
Page 49 of 66
Items Nm Kgf·m lbf·ft
Front propeller shaft
50 ~ 60 5~6 36.9 ~ 44.3
mounting bolt
Center bearing bracket
50 ~ 65 5 ~ 6.5 36.9 ~ 47
mounting bolt
Rear propeller shaft
100 ~ 120 10 ~ 12 73.8 ~ 88.5
mounting bolt
Driveshaft and axle > Rear Driveshaft Assembly > Rear Driveshaft > Components and Components
Location
COMPONENT LOCATION
Page 50 of 66
COMPONENTS
Page 51 of 66
Driveshaft and axle > Rear Driveshaft Assembly > Rear Driveshaft > Repair procedures
REMOVAL
Page 52 of 66
tire(A).
5. Remove the trailing arm mounting bolt(B) from the knuckle(A).

Page 53 of 66
6. Remove the suspension arm mounting nuts(C).
7. Push the axle hub(B) outward and separate the driveshaft(C) from the axle hub(B).
8. Insert a pry bar(A) between the differential case(B) and joint case(C), and separate the driveshaft(D) from the
differential case.
• Use a pry bar(A) being careful not to damage the transaxle and joint.
• Do not insert the pry bar(A) too deep, as this may cause damage to the oil seal.(max. depth :
7mm(0.28in).
• Do not pull the driveshaft by excessive force because it may cause components inside the BJ or TJ joint
kit to dislodge resulting in a torn boot or a damaged bearing.
• Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
• Support the driveshaft properly.
• Replace the retainer ring whenever the driveshaft is removed from the transaxle case.
INSTALLATION
1. Apply gear oil on the driveshaft differential case(B) contacting surface(B) and driveshaft(A) splines.
2. Before installing the driveshaft(A), set the opening side of the circlip facing downward.
Page 54 of 66
3. After installation, check that the driveshaft(A) cannot be removed by hand.
4. Install the BJ into the knuckle.
5. Install the suspension arm mounting nuts(C) and trailing arm mounting bolt(B) from the knuckle(B).
Tightening torque :
Suspension arm mounting nuts(C)
140 ~ 160 Nm (14 ~ 16 Kgf·m, 103.8 ~ 118 lb-ft)
Trailing arm mounting bolt(B)
100 ~ 120 Nm (10 ~ 12 Kgf·m, 73.8 ~ 88.5 lb-ft)
6. Install the washer(C), castle nut(B) and split pin(A) from the rear hub.
Tightening torque :
200 ~ 280 Nm (20 ~ 28 Kgf·m, 147.5 ~ 206.6 lb-ft)
7. Install the wheel speed sensor(B) from the knuckle(A).

Page 55 of 66
Tightening torque :
90 ~ 110 Nm (9 ~ 11 Kgf·m, 66.4 ~ 81.2 lb-ft)
INSPECTION
4. Check the dynamic damper for cracks, wear and position.
DISASSEMBLY
DRIVESHAFT (RH)
• Do not disassemble the BJ assembly.

• Special grease must be applied to the driveshaft joint. Do not substitute with another type of grease.
• The boot band should be replaced with a new one.
Page 56 of 66
1. Remove the TJ boot bands and pull the TJ boot from the TJ outer race.
A. Using a plier or flat-tipped (-) screwdriver, remove the LH boot band and LH TJ boot band from the
driveshaft
B. Remove RH boot band and RH TJ boot band in the same way of LH removal procedure.
Be careful not to damage the boot.
2. Remove the circlip(B) with a flat-tipped (-)screwdriver(A).
3. Pull out the driveshaft from the TJ outer race.

4. Remove the snap ring(A) and take out the inner race(B), cage(C) and balls(D) as an assembly.
5. Clean the inner race, cage and balls without disassembling.

6. Remove the BJ. boot bands and pull out the TJ boot and BJ boot.
If the boot(A) is to be reused, wrap tape(B) around the driveshaft splines(C) to protect the
boot(A).
INSPECTION
Page 57 of 66
4. Check the dynamic damper for cracks, wear and position.
REASSEMBLY
1. Wrap tape around the driveshaft splines (TJ side ) to prevent damage to the boots.
2. Apply grease to the driveshaft and install the boots.
3. Apply the specified grease to the inner race(A) and cage(B). Install the cage(B) so that it is offset on the race as
shown.
Use the grease included in the repair kit.
4. Apply the specified grease to the cage and fit the balls into the cage.
5. Position the chamfered side(A) as shown in the illustration. Install the inner race on the driveshaft(B), and then the
snap ring.
6. Apply the specified grease to the outer race and install the BJ outer race onto the driveshaft. (See page DS - 4)
7. Apply the specified grease into the TJ boot and install the boot with a clip. (See page DS - 4)
Page 58 of 66
8. Tighten the TJ boot bands.
9. Add the specified grease to the BJ as much as wiped away at inspection.
10. Install the boots.
11. Tighten the BJ boot bands.
12. To control the air in the TJ boot, keep the specified distance between the boot bands when they are tightened.
Driveshaft and axle > Differential Carrier Assembly > Rear Differential Carrier > Components and
Components Location
COMPONENTS
Page 59 of 66
Driveshaft and axle > Differential Carrier Assembly > Rear Differential Carrier > Repair procedures
REMOVAL
1. Drain the differential gear oil.
2. Remove the rear drive shaft. (See page DS - 43)
3. Remove the propeller shaft. (See page DS - 39)
4. Support the differential assembly(B) with the jack(A).
5. Disconnect the coupling control connector(A).
6. After loosen the differential mounting bolts(A), and remove the differential(B).
Page 60 of 66
7. After loosen the cover bolts(A), and remove the differential cover(B).
INSTALLATION
1. After apply liquid gasket, install the differential cover(B), and install the mounting bolts(A).
Tightening torque :
40 ~ 50 Nm (4 ~ 5 Kgf·m, 29.5 ~ 36.9 lb-ft)
Page 61 of 66
2. After install the differential(B), and install the mounting bolts(A).
Tightening torque :
90 ~ 120 Nm (9 ~ 12 Kgf·m, 66.4 ~ 88.5 lb-ft)
3. Using the transaxle jack(B), install the differential assembly(A).
4. Connect the coupling control connector(A).
5. Install the propeller shaft. (See page DS - 39)

6. Install the rear drive shaft. (See page DS - 47)
Page 62 of 66
7. Fill the gear oil.
Specified lubricant :
Hypoid gear oil (GL-5, 80W / SAE 90),
Oil quantity : Fill the reservoir to the plug hole
(approx. 0.75 ~ 0.80L)
Be sure to fill the gear oil below the lower end of the filler plug(A).
INSPECTION
Install the differential carrier assembly(A) with the special tools(09517-43401 & 09517-43500).
Then carry out the following inspection.
Page 63 of 66
1. Check the final drive gear backlash by the following procedure.
A. Place the drive pinion and move the drive gear to check backlash is within the standard range.
Measure at 4 points on the gear periphery.
Standard value : 0.10 ~ 0.15mm (0.0039 ~ 0.0059in)
2. Check the drive gear back-face lash by the following procedure.

A. Place a dial gauge on the back-face of the drive gear and measure the runout.
Limit mm(in) : 0.05 (0.002)
B. If the runout is beyond the limit, check that there are no foreign substances between the drive gear and
differential case and, that the bolts fixing the drive gear are not loose.
Page 64 of 66
3. Check the differential carrier backlash by the following procedure.
A. Fix the side gear with a wedge so it cannot move and measure the differential gear backlash with a dial
indicator on the pinion gear.
Standard value : 0 ~ 0.076mm (0 ~ 0.003in)
Take the measurements at two places on the pinion gear.
B. If the backlash exceeds the limit, adjust using side bearing spacers.
If adjustment is impossible, replace the side gear and pinion gear as a set.
4. Check the tooth contact of the final drive gear by the following procedure.
A. Apply the same amount of machine blue slightly to both surfaces of the drive gear teeth.
Page 65 of 66
B. Insert a brass rod between the differential carrier and the differential case, and then rotate the companion
flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to
the drive gear so that some torque (approximately 18.4 ~ 22.1 lbf) is applied to the drive pinion.
If the drive gear is rotated too much, the tooth contact pattern will become unclear and difficult to
check.
C. Check the tooth contact pattern.

Tooth contact Contact state Solution
Standard contact
Heal contact Increase the thickness of

the pinion height adjusting
shim, and position the
drive pinion closer to the
center of the drive gear.
Face contact
Also, for backlash
adjustment, reposition the
drive gear further from the
drive pinion.
Decrease the thickness of
the pinion height adjusting
Toe contact shim, and position the
drive pinion further from
the center of the drive
gear.
Also, for backlash

Flank contact adjustment, reposition the
drive gear closer to the
drive pinion.
Page 66 of 66
• Tooth contact pattern is a method for judging the result of the adjustment of drive pinion height and
final drive gear backlash. The adjustment of drive pinion height and final drive gear backlash should
be repeated until the tooth contact patterns are similar to the standard tooth contact pattern.
• When you cannot obtain a correct pattern, the drive gear and drive pinion have exceeded their
limits. Both gears should be replaced as a set.
5. Check the oil leaks and the lip part for chew or wear.
6. Check the bearings for wear or discoloration..
7. Check the gear carrier for cracks.
8. Check the drive pinion and drive gear for wear or cracks.
9. Check the side gears, pinion gears and pinion shaft for wear or damage.
10. Check the side gear spline for wear or damage.
Page 1 of 84
SPORTAGE(KM) > 2008 > G 2.7 DOHC > Emission Control System
Emission Control System > General Information > Schematic Diagrams

SCHEMATIC DIAGRAM
[2.0 DOHC]
[2.7 V6]
Page 2 of 84
Emission Control System > General Information > Description and Operation
COMPONENTS
Page 3 of 84
Components Function Remarks
Crankcase Emission System
- Positive Crankcase Ventilation (PCV) HC reduction Variable flow rate type
valve
Evaporative Emission System
- Evaporative emission canister HC reduction
- Purge Control Solenoid Valve (PCSV) HC reduction Duty control solenoid valve
Exhaust Emission System

- MFI system (air-fuel mixtrue control CO, HC, NOx reduction Heated oxygen sensor feedback type
device) CO, HC, NOx reduction Monolithic type
- Three-way catalytic converter
Emission Control System > General Information > Components and Components Location
COMPONENTS LOCATION
Page 4 of 84
[2.0 DOHC]
Page 5 of 84
1.Purge Control Solenoid Valve (PCSV) 2. PCV Valve
3. Canister 4. Catalytic Converter
5. Fuel Tank Pressure Sensor (FTPS)

6. Canister Close Valve (CCV)
[2.7 V6]
Page 6 of 84
1. Purge Control Solenoid Valve (PCSV) 2. PCV Valve
3. Canister 4. Catalytic Converter

Emission Control System > General Information > Troubleshooting

TROUBLESHOOTING
Page 7 of 84
Symptom Suspect area Remedy
Vacuum hose disconnected or damaged Repair or replace
Engine will not start or hard to
start Malfunction of the EVAP. Canister Purge
Repair or replace
Solenoid Valve
Vacuum hose disconnected or damaged Repair or replace
Malfunction of the PCV valve Replace
Rough idle or engine stalls Check the system; if there is a
Malfunction of the evaporative emission
problem, check related
canister purge system
components parts
Check positive crankcase
Excessive oil consumption Positive crankcase ventilation line clogged
ventilation system
Emission Control System > General Information > Specifications

SPECIFICATIONS
Item Specification
Purge Control Solenoid Valve Type Duty Control type
(PCSV) Resistance (Ω) 24.5 ~ 27.5 at 20 °C (68 °F)
Fuel Tank Pressure Sensor Type Piezo-Resistivity type

(FTPS) Output Voltage Approx. 2.5V at idle
Type ON/OFF Control type
Canister Close Valve (CCV)
Resistance 23.0 ~ 26.0 Ω at 20°C (68°F)
TIGHTENING TORQUES
Item N·m kgf·cm lbf·ft
Positive Crankcase
7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Ventilation Valve
Emission Control System > Crankcase Emission Control System > Components and Components
Location
COMPONENTS LOCATION
Page 8 of 84
Page 9 of 84
Emission Control System > Crankcase Emission Control System > Positive Crankcase Ventilation
(PCV) Valve > Description and Operation
OPERATION
Page 10 of 84
Engine condition Not running Engine condition Idling or decelerating

PCV valve Not operating PCV valve Fully operating
Vacuum passage Restricted Vacuum passage Small
Accelerating and high

Engine condition Normal operation Engine condition
load
PCV valve Properly operating PCV valve Slightly operating
Vacuum passage Large Vacuum passage Very large
Emission Control System > Crankcase Emission Control System > Positive Crankcase Ventilation
(PCV) Valve > Repair procedures
INSPECTION
1. Remove the PCV valve.
2. Insert a thin stick(A) into the PCV valve(B) from the threaded side to check that the plunger moves.
Page 11 of 84
3. If the plunger does not move, the PCV valve is clogged. Clean it or replace.
REMOVAL
1. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve. Remove the PCV valve from
the rocker cover and reconnect it to the ventilation hose.
2. Run the engine at idle and put a finger on the open end of the PCV valve and make sure that intake manifold
vacuum can be felt.
The plunger inside the PCV valve will move back and forth.
3. If vacuum is not felt, clean the PCV valve and ventilation hose in cleaning solvent, or replace it if necessary.
INSTALLATION
Install the PCV valve and tighten to the specified torque.
PCV valve tightening toraue:

7.8 ~ 11.8N·m (0.8 ~ 1.2kgf·m, 5.8 ~ 8.7lbf·ft)
Page 12 of 84
Emission Control System > Evaporative Emission Control System > Description and Operation
DESCRIPTION
EVAP. SYSTEM MONITORING

Page 13 of 84
DESCRIPTION
This system consists of a fill vent valve, fuel shut-off valve, fuel cut valve (for roll over), two way valve
(pressure/vacuum relief), fuel liquid/vapor separator which is installed beside the filler pipe, charcoal canister which is
mounted under the rear floor LH side member and protector, tubes and miscellaneous connections.
While refueling, ambient air is drawn into the filler pipe so as not to emit fuel vapors in the air. The fuel vapor in the
tank is then forced to flow into the canister via the fill vent valve. The fuel liquid/vapor separator isolates liquid fuel
and passes the pure vapor to the charcoal canister.
While the engine is operating, the trapped vapor in the canister is drawn into the intake manifold and then into the
engine combustion chamber. According to this purge process, the charcoal canister is purged and recovers its
absorbing capability.
COMPONENTS
Page 14 of 84
Emission Control System > Evaporative Emission Control System > Components and Components
Location
SCHEMATIC DIAGRAM
Page 15 of 84
Emission Control System > Evaporative Emission Control System > Repair procedures
INSPECTION
1. Disconnect the vacuum hose from the throttle body, and connect a vacuum pump to the vacuum hose.
2. Check the following points when the engine is cold [engine coolant temperature 60°C(140°F) or below] and
when it is warm [engine coolant temperature 80°C(176°F) or higher].
WHEN ENGINE IS COLD
Page 16 of 84
Engine operating
Applied vacuum Result
condition
Idling 50 kPa
Vacuum is held
3,000 rpm (7.3 psi)
WHEN ENGINE IS WARM

Engine operating condition Applied vacuum Result
50 kPa
Idling Vacuum is held
(7.3 psi)
Within 3 minutes after engine start at 3,000
Try to apply vacuum Vacuum is released
rpm
Vacuum will be held
After 3 minutes have passed after engine 50 kPa
momentarily, after which, it will
start at 3,000 rpm (7.3 psi)
be released
Emission Control System > Evaporative Emission Control System > Canister > Repair procedures
INSPECTION
1. Look for loose connections, sharp bends or damage to the fuel vapor lines.
2. Look for distortion, cracks or fuel leakage.

3. After removing the EVAP. canister, inspect for cracks or damage.
Emission Control System > Evaporative Emission Control System > Purge Control Solenoid Valve
(PCSV) > Repair procedures
INSPECTION
Page 17 of 84
When disconnecting the vacuum hose, make an identification mark on it so that it can be reconnected to its original
position.
1. Disconnect the vacuum hose from the solenoid valve.
2. Detach the harness connector.
3. Connect a vacuum pump to the nipple to which the red-striped vacuum hose was connected.
4. Apply vacuum and check when voltage is applied to the PCSV and when the voltage is discontinued.
Battery voltage Normal condition
When applied Vacuum is released
When discontinued Vacuum is maintained
5. Measure the resistance between the terminals of the solenoid valve.
PCSV coil resistance (Ω):

24.5 ~ 27.5 Ω at 20°C (68°F)
Emission Control System > Evaporative Emission Control System > Fuel Filler Cap > Description and
Operation
DESCRIPTION
Page 18 of 84
Emission Control System > Exhaust Emission Control System > Description and Operation
DESCRIPTION
Modifications to the combustion chamber, intake manifold, camshaft and ignition system form the basic control
system.
These items have been integrated into a highly effective system which controls exhaust emissions while maintaining
good driveability and fuel economy.
AIR/FUEL MIXTURE CONTROL SYSTEM [MULTIPORT FUEL INJECTION (MFI) SYSTEM]
This in turn allows the engine to produce exhaust gases of the proper composition to permit the use of a three way
catalyst. The three way catalyst is designed to convert the three pollutants (1) hydrocarbons (HC), (2) carbon
monoxide (CO), and (3) oxides of nitrogen (NOx) into harmless substances. There are two operating modes in the
MFI system.
1. Open Loop air/fuel ratio is controlled by information programmed into the ECM.
2. Closed Loop air/fuel ratio is adjusted by the ECM based on information supplied by the oxygen sensor.
Emission Control System > Exhaust Emission Control System > CVVT (Continuously Variable Valve
Timing) System > Description and Operation
DESCRIPTION
Page 19 of 84
The CVVT (Continuously Variable Valve Timing) which is installed on the exhaust camshaft controls intake valve
open and close timing in order to improve engine performance.
The intake valve timing is optimized by CVVT system depending on engine rpm.
This CVVT system improves fuel efficiency and reduces NOx emissions at all levels of engine speed, vehicle speed,
and engine load by EGR effect because of valve over-lap optimization.
The CVVT changes the phase of the intake camshaft via oil pressure.
It changes the intake valve timing continuously.
OPERATION [2.0 DOHC]

The CVVT system makes continuous intake valve timing changes based on operating conditions.
Intake valve timing is optimized to allow the engine to produce maximum power.
Cam angle is advanced to obtain the EGR effect and reduce pumping loss. The intake valve is closed quickly to
reduce the entry of the air/fuel mixture into the intake port and improve the changing effect.
Reduces the cam advance at idle, stabilizes combustion, and reduces engine speed.
If a malfunction occurs, the CVVT system control is disabled and the valve timing is fixed at the fully retarded
position.
Page 20 of 84
1. The above figure shows the relative operation structures of the housing vane to the rotor vane.
2. If the CVVT is held a certain control angle, to hold this state, oil is replenished as much as oil leaks from the oil
pump.
The OCV (Oil-flow Control Valve) spool location at this time is as follows.
Oil pump → Advance oil chamber (Little by little open the inflow side to the advance oil chamber) →
Almost close the drain side
Be sure there might be a difference in the position according to the engine running state (rpm, oil temperature, and oil
pressure).
Emission Control System > Exhaust Emission Control System > CVVT (Continuously Variable Valve
Timing) System > Components and Components Location
COMPONENTS LOCATION [2.0 DOHC]
Page 21 of 84
Emission Control System > Troubleshooting > P0420

COMPONENT LOCATION
GENERAL DESCRIPTION
The ECM uses dual oxygen sensors to monitor the efficiency of the manifold catalytic converter (warm-up catalytic
converter). By monitoring the oxygen storage capacity of a catalyst, its efficiency can be indirectly calculated. The
upstream (front) HO2S is used to detect the amount of oxygen in the exhaust gas before it enters the catalytic
converter. A low voltage indicates high oxygen contents (lean air mixture). A high voltage indicates low oxygen
contents (rich air mixture). When the catalyst efficiency drops, no chemical reaction takes place. This means the
concentration of oxygen will be the same at the rear as it is at the front. The output voltage of the rear HO2S copies
the voltage of the front HO2S.To monitor the system, the lean-to-rich switches of the front HO2S to the rear HO2S
is counted. The ratio of rear switches to front switches is used to determine whether the catalyst is operating
properly. An effective catalyst will have fewer rear switches than front switches, that is, a ratio closer to zero.
DTC DESCRIPTION
The ECM calculates oscillation size of rear HO2S signal which represents catalyst conversion properties. This
Page 22 of 84
oscillation size will determine if catalyst conversion is low due to aging or poisoning from leaded fuel or misfiring. The
ECM sets P0420 if the average of calculated oscillation size of rear HO2S signal during predetermined duration is
higher than the predetermined threshold.

ITEM DETECTING CONDITION POSSIBLE CAUSE
• Comparison of the signal ratio of upstream and
DTC Strategy
downstream O2 sensor in a load and speed range
• 400(752°F)< Catalyst model temperature
<600°C(1112°F)
• Coolant temperature >70°C(158)
Enable • Lambda control within limit • Exhaust gas leaks
Conditions • 800rpm< Engine speed < 2500rpm • Rear HO2S malfunction
• Air mass flow <250 mg/stk • Three way catalyst converter
• No misfire is detected malfunction
• Not transient condition
Threshold Value • Averaged malfunction index > 0.7
Diagnostic Time • 120 lambda controller cycles
MIL On Condition • 2 Driving Cycles
MONITOR DTC STATUS
If any codes relating to injectors, HO2S, ECT(Engine Coolant Temperature)Sensor, Throttle Position sensor or
Mass Air Flow Sensor are stored, do ALL REPAIRS associated with those codes before proceeding with this
troubleshooting tree.
2. Press F5(INFO) to select DTC information from the DTCs menu.
3. Confirm that "DTC Readiness Flag" indicates "Complete". If not, drive the vehicle within conditions noted in the
freeze frame data or enable conditions
4. Read "DTC Status" parameter.
Page 23 of 84
5. Is parameter displayed "History(Not Present) fault"?
A. History (Not Present) fault : DTC occurred but has been cleared.
B. Present fault : DTC is occurring at present time.
Fault is intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM
memory was not cleared. Thoroughly check connectors for loose or poor connections, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle
Repair" procedure.
Go to next step as below.
EXHAUST SYSTEM INSPECTION

1. Visually/physically inspect the rear HO2S for the following conditions:
A. Exhaust system between HO2S and Three way catalyst for air leakage
B. Damage, and for loose or missing hardware.
2. Was a problem found in any of the above areas?
Repair as necessary and go to "Verification of Vehicle Repair" procedure.
Go to "Rear HO2S Inspection " procedure.

REAR HO2S INSPECTION
A. Ensure that the HO2S is securely installed.(Pigtail and wiring harness not making contact with the exhaust
pipe)
B. Check for corrosion on terminals.
C. Check for terminal tension. ( at the HO2S and at the ECM)
D. Any road damage.
Repair as necessary and go to "Verification of Vehicle Repair" procedure
Go to "TWC Inspection " procedure

TWC INSPECTION
1. Visually/physically inspect the three-way catalyst(TWC) converter for the following damage:
A. Severe discoloration caused by excessive temperature.
B. Dents and holes.
C. Internal rattle caused by a damaged catalyst.
2. Also, ensure that the TWC is a proper original equipment manufacturer part.
3. Was a problem found?
Replace TWC and go to "Verification of Vehicle Repair" procedure.
Check for poor connection between ECM and component: backed out terminal, improper mating, broken
locks or poor terminal to wire connection. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.

Page 24 of 84
2. Press F5(INFO) and confirm that "DTC Readiness Flag" indicates "Complete". If not, drive the vehicle within
conditions noted in the freeze frame data or enable conditions.
System performing to specification at this time. Clear the DTC

COMPONENT LOCATION
GENERAL DESCRIPTION
The ECM uses dual oxygen sensors to monitor the efficiency of the manifold catalytic converter (warm-up catalytic
converter). By monitoring the oxygen storage capacity of a catalyst, its efficiency can be indirectly calculated. The
upstream (front) HO2S is used to detect the amount of oxygen in the exhaust gas before it enters the catalytic
converter. A low voltage indicates high oxygen contents (lean air mixture). A high voltage indicates low oxygen
contents (rich air mixture). When the catalyst efficiency drops, no chemical reaction takes place. This means the
concentration of oxygen will be the same at the rear as it is at the front. The output voltage of the rear HO2S copies
the voltage of the front HO2S.To monitor the system, the lean-to-rich switches of the front HO2S to the rear HO2S
is counted. The ratio of rear switches to front switches is used to determine whether the catalyst is operating
properly. An effective catalyst will have fewer rear switches than front switches, that is, a ratio closer to zero.
DTC DESCRIPTION
The ECM calculates oscillation size of rear HO2S signal which represents catalyst conversion properties. This
oscillation size will determine if catalyst conversion is low due to aging or poisoning from leaded fuel or misfiring. The
ECM sets P0430 if the average of calculated oscillation size of rear HO2S signal during predetermined duration is
higher than the predetermined threshold.

Page 25 of 84
• Comparison of the signal ratio of upstream and
DTC Strategy
downstream O2 sensor in a load and speed range
• 400(752°F)< Catalyst model temperature
<600°C(1112°F)
• Coolant temperature >70°C(158)
Enable • Lambda control within limit • Exhaust gas leaks
Conditions • 800rpm< Engine speed < 2500rpm • Rear HO2S malfunction
• Air mass flow <250 mg/stk • Three way catalyst converter
• No misfire is detected malfunction
• Not transient condition
Threshold Value • Averaged malfunction index > 0.7
MONITOR DTC STATUS
Page 26 of 84
Repair" procedure.

A. Exhaust system between HO2S and Three way catalyst for air leakage
B. Damage, and for loose or missing hardware.
Go to "Rear HO2S Inspection " procedure.

REAR HO2S INSPECTION
A. Ensure that the HO2S is securely installed.(Pigtail and wiring harness not making contact with the exhaust
pipe)
C. Check for terminal tension. ( at the HO2S and at the ECM)
D. Any road damage.
Go to "TWC Inspection " procedure

TWC INSPECTION
1. Visually/physically inspect the three-way catalyst(TWC) converter for the following damage:
A. Severe discoloration caused by excessive temperature.
B. Dents and holes.
C. Internal rattle caused by a damaged catalyst.
2. Also, ensure that the TWC is a proper original equipment manufacturer part.
3. Was a problem found?
Replace TWC and go to "Verification of Vehicle Repair" procedure.
procedure.

Page 27 of 84

COMPONENT LOCATION
GENERAL DESCRIPTION
The evaporative emission control system prevents hydrocarbon (HC) vapors from the fuel tank from escaping into
the atmosphere where they could form photochemical smog. Gasoline vapors are collected in the charcoal canister.
The ECM controls the Purge Control Solenoid Valve (PCSV) to purge any collected vapors from the canister back
to the engine for combustlon. This valve is actuated by the purge control signal from the ECM and controls fuel
vapor from the canister to the intake manifold.
DTC DESCRIPTION
During "test of vapour generation" a new value from the tank pressure sensor is measured and compared with the
start pressure at beginning of "test of vapour generation".
The ECM sets DTC P0441 if the pressure signal decrease occurs and the difference is below the predetermined
threshold. If same error code is set in the next driving cycle, the ECM illuminates the MIL.

Page 28 of 84
• Monitoring the tank pressure sensor(DTP) signal
DTC Strategy
with underpressure
• Idle state
• Minimum modeled ambient temperature >-
10°C(14°F)
• Coolant temperature >75°C(167°F)
Enable Conditions • Vehicle speed< 5km/h(3mph)
• Estimated altitude< 2.4km(8000ft)
• Leakage on hose to PCSV
• Differential fuel tank pressure: -11 ~ 5.5hPa
• Faulty PCSV
• Limited canister saturation >-10%
• Minimum purge time:100sec.
• Pressure fluctuation in fuel tank < -2hPa during vapor
Threshold Value
generation period
Diagnostic Time • 10 sec. In idle
Fall Safe • EVAP. System monitoring is inhibited
SCHEMATIC DIAGRAM
Page 29 of 84
MONITOR DTC STATUS
If any DTCs (or pending codes) are present, do ALL REPAIRS associated with those codes before proceeding
with this troubleshooting tree.
1. Start engine to normal operating temperature.
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.
2. Install scan tool and clear DTC
3. Perform "EVAP. LEAKAGE TEST" mode referring to enable conditions as below.
EVAP. Leakage Test enable conditions

- Following conditions must be fulfilled to start the test.
1. Engine warm up at Idle Status
2. No relevant DTC
3. Fuel level is below 80%
4. Is DTC P0441 set again?
Go to "PCSV Inspection" procedure
memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion,
Repair" procedure.
PCSV INSPECTION
1. Ignition "OFF"
2. Disconnect the hose leading from the PCSV to the intake manifold at PCSV
3. Using a vacuum pump, apply specified vacuum(Approx. 15 in, Hg) to the manifold side of the valve and verify
PCSV holds vacuum.
5. Install scantool and select "EVAP PURGE VALVE" on the Actuation Test mode
6. Activates "EVAP PURGE VALVE" by pressing "STRT(F1)" key
7. Verify PCSV release vacuum while valve is activating(should hear a faint click from PCSV)
8. Repeat this procedure 4 or 5 times to ensure PCSV reliability.
9. Is PCSV working properly?
Thoroughly check fuel vapor hoses and hose clamp and replace as necessary. Go to "Terminal and connection
inspection" procedure.
Thoroughly check fuel vapor hoses and hose clamps between PCSV and intake manifold. Repair as
necessary.
If OK, test with a new PCSV and check for proper operation. If problem is corrected, replace PCSV and go to
"Verification of Vehicle Repair" procedure
Page 30 of 84
2. Check the following conditions:
(1) Check for damaged harness and terminals: contact resistance, oxidation, bent or broken terminals.
(2) Check for poor connection between ECM and component: backed out terminal, improper mating, broken
locks and poor terminal to wire connection.
Using a suitable male pin to ensure that contact in sockets is good. The pin should remain in position
when pulled gently.
(3) Is a problem found?
procedure.

1. Return vehicle to original condition.
4. Perform "EVAP. LEAKAGE TEST" mode referring to enable conditions as below

2. No relevant DTC
5. Monitoring for (pending) DTC.Is the same DTC set?

COMPONENT LOCATION
Page 31 of 84
GENERAL DESCRIPTION
Due to the increasing ambient temperature of the fuel and the return of unused hot fuel from the engine, fuel vapors
are generated in the tank. In order to control the release of these vapors to the atmosphere, the evaporative
emissions control system is used. The evaporative emission control system reduces hydrocarbon (HC) emissions by
trapping fuel tank vapors until they can be burned in the combustion process. Evaporating fuel is stored in a charcoal
canister until it can be flushed into the intake manifold. The evaporative emission control system is made up of a fuel
tank that can be completely sealed from outside air, a Fuel Tank Pressure Sensor (FTPS), a Canister Close Valve
(CCV) that seals the canister from the outside air, a canister filled with activated charcoal granules, a Purge Control
Solenoid Valve (PCSV). The evaporative emission system can be checked for leaks by sealing the system off from
the outside air, creating a vacuum, and monitoring if the system can hold that vacuum sufficiently for a set amount of
time. If it cannot, a leak exists somewhere in the system.
DTC DESCRIPTION
The ECM closes the Canister Close Valve (CCV) at the charcoal canister to seal off the evaporative emission
system and then opens purge control valve (PCSV) to generate a vacuum in the fuel tank. After vacuum generation,
the ECM measures pressure differential curve in the fuel tank and sets DTC P0442 or P0456 if the vacuum
generated within a monitoring period increases above a defined threshold.
If same error code is set in the next driving cycle, the ECM illuminates the MIL.

Page 32 of 84
• Monitoring the tank pressure sensor(DTP) signal • Fuel filler cap damage or
DTC Strategy
with underpressure missing
• Faulty or damaged fuel filler
• Idle state
pipe
• Leaking, disconnected or
10°C(14°F)
plugged fuel vapor lines.
• Fuel in lines due to faulty
Rollover Valve
• On-Board Refueling Vapor
• Differential fuel tank pressure: -11 ~ 5.5hPa Recovery Valve (ORVR
• Limited canister saturation >-10% valve) or stuck closed CCV.
• Minimum purge time:100sec. • Improperly installed or stuck
• Pressure fluctuation in fuel tank < -2hPa during vapor Purge Control Solenoid Valve
Threshold Value (PCSV).
generation period
• Faulty Fuel Tank Pressure
Diagnostic Time • 26 sec. In idle
Sensor (FTPS).
MIL On Condition • 2 Driving Cycles • Leaking canister
SCHEMATIC DIAGRAM
Page 33 of 84
MONITOR DTC STATUS
If any codes relating to Fuel tank pressure sensor, Canister closing valve or PCSV circuits are present, do ALL
REPAIRS associated with those codes before proceeding with this troubleshooting tree.

2. No relevant DTC
4. Is DTC P0442set again?
Go to "PCSV Line Inspection" procedure
Repair" procedure.
PCSV LINE INSPECTION
1. Ignition "OFF"
PCSV holds vacuum.
Go to "Canister Closing Valve(CCV) Line Inspection" procedure
Verify arrow on PCSV is pointing towards intake manifold. If it is not, reverse installation. Reinstall as
necessary.
If OK, check for cracks or damage in hose connecting PCSV and intake manifold. Repair or replace as
necessary.
If OK, test with a new PCSV and check for proper operation. If problem is corrected, replace PCSV and go
CANISTER CLOSING VLAVE (CCV) LINE INSPECTION
Page 34 of 84
1. Return vehicle to original condition
2. Ignition "OFF"
3. Disconnect the hose connecting Canister Closing Valve(CCV) to canister
4. Blow air to the canister side of the valve and verify air escapes to the air filter side.
5. Turn ignition on and jumper a wire to GND(back probe) at terminal 2 of the ECM connector(CCV valve should
click)
6. Blow air into hose and verify air does not escape.
7. Repeat this procedure 4 or 5 times to ensure CCV reliability.
8. Is CCV working properly?
Go to "Fuel Tank Pressure Sensor Inspection" procedure
A. Check for cracks or damage in hose connecting CCV and canister. Repair or replace as necessary.
B. If OK, replace CCV. If CCV was stuck closed, inspect all lines and canister for liquid fuel. Replace any
contaminated components and blow out lines and go to "Verification of Vehicle Repair" procedure .
FUEL TANK PRESSURE SENSOR INSPECTION
1. Start engine and install scan tool.
2. Monitor "FUEL TANK PRESSURE" parameter on the current data list with depressing increasing engine speed.
Specification : Signal value will vary between -2mmHg to 2 mmHg depending on variation in engine
speed
A. Approx. 0~2 mmHg(2.5V) at Ig. On

B. Approx. 0 mmHg at 1400rpm
C. Approx. -2 mmHg at 4000rpm
3. Is signal value within specification?
Go to "Purge Control Solenoid Valve(PCSV) Inspection" procedure
A. Check for cracks or damage in hose connecting canister and fuel pump. Repair or replace as necessary.
B. Check for open or short in FTPS harness. Repair as necessary.
If OK, test with a new FTPS and check for proper operation. If problem is corrected, replace FTPS and go
PCSV TO CANISTER LINE INSPECTION
1. Check for leakage in hose
(1) Disconnect the hose leading from the canister to the PCSV at canister.
(2) Using a vacuum pump, apply specified vacuum[Approx. 10cmHg(4 inHg)] to the manifold side of the valve
and verify PCSV holds vacuum.
(3) Monitor vacuum pressure for 1 minute. After 1 minute, pressure should not drop more than 2cmHg(0.8 inHg)
(4) Is pressure within specification?
Go to "2. Check for leakage in canister" procedure
Check for cracks or damage in hose connecting PCSV and canister. Repair or replace as necessary and
Page 35 of 84
2. Check for leakage in canister
Thoroughly check all fuel vapor hoses and hose clamps between:
- Canister and fuel tank
- Canister and CCV
- Canister and PCSV
If NG, replace hose or clamps as necessary and go to "Verification of Vehicle Repair" procedure.
If OK, go to next step as below.
(1) Disconnect hose clamps and remove canister assembly
(2) Block the hose of between:
A. Canister and fuel filler neck
B. Canister and CCV
C. Canister and PCSV
(3) Apply maximum of 10cmHg(4 inHg) pressure through fuel tank port from canister.
(4) With system sealed and pressurized, check for leaks.
(5) Were any leak(s) found?
Repair or replace leaking system component(s) and go to "Verification of Vehicle Repair" procedure.
Go to "Fuel Tank Line Inspection" procedure.

FUEL TANK LINE INSPECTION
1. Relieve the fuel system pressure and remove the fuel tank
Before removing the fuel tank, make sure the fuel hoses are not
leaking.
2. Block all of the following outlets:
(1) Fuel lines
(2) Fuel filler neck
3. Apply maximum of 10cmHg(4 inHg) pressure to the EVAP. hose at the fuel tank. Then, pinch the EVAP. hose
to retain the pressure
4. Check the suspect area for leaks with a soap solution.
5. Were any leak(s) found?
Repair or replace leaking system component(s) and go to "Verification of Vehicle Repair" procedure
procedure

Page 36 of 84

2. No relevant DTC

COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION

Page 37 of 84
DTC Strategy • Driver stage check
Enable • Open in PCSV
• 10V< Battery voltage
Conditions harness
Threshold Value • Open circuit • Contact resistance in
connectors
Diagnostic Time • 3 sec.
• Faulty PCSV
MIL On
• 2 Driving Cycles
Condition
SPECIFICATION
Temperature PCSV
Resistance
(°C) (°F) (Ω)
20 68 24.5~27.5
SCHEMATIC DIAGRAM
MONITOR DTC STATUS
Page 38 of 84

Repair" procedure.

or damage.

2. Measure voltage between terminal 1 of the PCSV harness connector and chassis ground.
Page 39 of 84
3. Is voltage within the specification?
Go to "Control Circuit Inspection" procedure.
Check for a open in the power supply circuit. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.
1. Ignition "OFF".
2. Disconnect ECM connector.
3. Measure resistance between terminals 2 of the PCSV harness connector and 42 of the ECM harness
connector(C68-3).
4. Is resistance within the specification?
procedure.
1. Ignition "OFF".
2. Disconnect PCSV connector.
3. Measure resistance between terminals 1 and 2 of the PCSV connector(Component side).
Specification : Approx. 24.5~27.5Ω at 20°C(68°F)

Page 40 of 84
Check PCSV for contamination, deterioration, or damage. 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.


COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION

Page 41 of 84
Enable Conditions • 10V< Battery voltage • Short in PCSV harness
Threshold Value • Short to ground or Short to Battery • Contact Resistance in
connectors
• Faulty PCSV
MIL On
Condition
SPECIFICATION
Temperature PCSV
Resistance
(°C) (°F) (Ω)
20 68 24.5~27.5
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 42 of 84

Repair" procedure.

or damage.

2. Measure voltage between terminal 1 of the PCSV harness connector and chassis ground.
Page 43 of 84
procedure.
1. Check for short to ground in control circuit.
(1) Ignition "OFF".
(2) Disconnect ECM connector.
(3) Measure resistance between terminals 2 of the PCSV harness connector and 42 of the ECM harness
connector(C68-3).
(4) Is resistance within the specification?

2. Check for short to battery in control circuit.
(2) Measure voltage between terminal 2 of the PCSV harness connector and chassis ground.
Page 44 of 84
(3) Is voltage within the specification?
procedure.
1. Ignition "OFF".
2. Disconnect PCSV connector.
3. Measure resistance between terminals 1 and 2 of the PCSV connector(Component side).
Specification : Approx. 24.5~27.5Ω at 20°C(68°F)
Check PCSV for contamination, deterioration, or damage. 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.


COMPONENT LOCATION
Page 45 of 84
GENERAL DESCRIPTION
The evaporative emissions system prevents hydrocarbon (HC) vapors from the fuel tank from escaping into the
atmosphere where they could form photochemical smog. Gasoline vapors are collected in the charcoal canister. The
Canister Closing Valve (CCV) closes off the air inlet into the canister for leak detection of the evaporative emission
system. The CCV also prevents fuel vapors from escaping from the canister. When the engine purges the HC
vapors from the canister, the clean air comes into the canister through the canister air-filter and the CCV.
DTC DESCRIPTION
ECM sets DTC P0447 if the ECM detects that the CCV control line is open.

Enable
• Battery voltage > 10V • Open in CCV harness
Conditions
• Contact resistance in
Threshold Value • Line break
connectors
Diagnostic Time • 3 sec. • Faulty CCV.
MIL On
Condition
SPECIFICATION
Temp.(°F) CCV
(°C) (°F) Resistance(Ω)
20 68 23~26
SCHEMATIC DIAGRAM
Page 46 of 84
MONITOR DTC STATUS

freeze frame data or enable conditions.
- History (Not Present) fault : DTC occurred but has been cleared.
- Present fault : DTC is occurring at present time.
Fault is intermittent, caused by poor contact in the sensor's and/or ECM's connector or was repaired and
ECM 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 of

Page 47 of 84
or damage.

2. Measure voltage between terminal 1 of the CCV harness connector and chassis ground.
procedure.
1. Ignition "OFF".
3. Measure resistance between terminals 2 of the CCV harness connector and 30 of the ECM harness
connector(C68-4).
Page 48 of 84
procedure.
1. Ignition "OFF".
2. Disconnect CCV connector.
3. Measure resistance between terminals 1 and 2 of the CCV connector(Component side).
Specification : Approx. 23~26Ω at 20°C(68°F)
Check CCV for contamination, deterioration, or damage. Substitute with a known-good CCV and check for
proper operation. If the problem is corrected, replace CCV and then go to "Verification of Vehicle Repair"
procedure.

System performing to specification at this time. Clear the DTC.

COMPONENT LOCATION
Page 49 of 84
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0448 if the ECM detects that the CCV control line is short to ground or short to battery line.

Enable Conditions • Battery voltage > 10V • Short in CCV harness
Threshold Value • Short to ground or Short to Battery • Contact resistance in
connectors
• Faulty CCV
MIL On
Condition
SPECIFICATION
Temp.(°F) CCV
20 68 23~26
SCHEMATIC DIAGRAM
Page 50 of 84
MONITOR DTC STATUS


Page 51 of 84
or damage.

2. Measure voltage between terminal 1 of the CCV harness connector and chassis ground.
procedure.
(1) Ignition "OFF".
(3) Measure resistance between terminals 2 of the CCV harness connector and 30 of the ECM harness
connector(C68-4).
Page 52 of 84
Go to "Control Circuit Inspection" procedure

2. Check for short to battery in control circuit
(2) Measure voltage between terminal 2 of the CCV harness connector and chassis ground
procedure
1. Ignition "OFF".
2. Disconnect CCV connector.
3. Measure resistance between terminals 1 and 2 of the CCV connector(Component side).
Check CCV for contamination, deterioration, or damage. Substitute with a known-good CCV and check for
proper operation. If the problem is corrected, replace CCV and then go to "Verification of Vehicle Repair"
procedure.

Page 53 of 84

COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION
The ECM measures pressure in the fuel tank by means of tank pressure sensor during all engine operating states
except engine stop and start. The DTC P0449 is set if pressure is lower than predetermined threshold.

Page 54 of 84
DTC Strategy
with underpressure
• Idle state
10°C(14°F)
• Differential fuel tank pressure: -11 ~ 5.5hPa • Canister Air-Filter
contamination
• Faulty CCV
Threshold Value • Voltage of differential fuel tank pressure <1.5V
• EVAP. emission control function is disabled
Fall Safe • EVAP. System monitoring is inhibited
• Fuel Tank Pressure Sensor monitoring is inhibited
SPECIFICATION
Temp.(°F) CCV
20 68 23~26
SCHEMATIC DIAGRAM
Page 55 of 84
MONITOR DTC STATUS

CANISTER AIR-FILTER INSPECTION
1. Disassemble the Canister Air-Filter and hose from their respective positions.
2. Check the Canister air-filter for contamination.Disconnect CCV connector.
3. Is Canister Air-Filter contaminated with dust?
Replace as necessary and go to "Verification of Vehicle Repair" procedure.
Go to "Canister Closing Valve(CCV) inspection" procedure.

2. Ignition "OFF"
click)
Page 56 of 84
If hose was pinched or restricted:

1. Fueling would be difficult if not impossible.
2. Restriction or blockage could cause pressure to accumulate in tank triggering a P0451.
procedure
Replace CCV. If CCV was stuck closed, inspect all lines and canister for liquid fuel. Replace any
contaminated components and blow out lines.


COMPONENT LOCATION
GENERAL DESCRIPTION
The evaporative emission control system prevents hydrocarbon vapors from escaping from the fuel tank into the
Fuel Tank Pressure Sensor (FTPS) is an integral part of the evaporative monitoring system. The ECM monitors the
FTPS signal to detect vacuum decay and excess vacuum. The FTPS measures the difference between the air
Page 57 of 84
pressure inside the fuel tank and outside air pressure to check the purge control solenoid valve operation and for
leak detection in the evaporative emission control system by monitoring pressure and vacuum levels in the fuel tank
during the purge control solenoid valve operating cycles.
DTC DESCRIPTION
The ECM monitors pressure in the fuel tank by means of Fuel Tank Pressure Sensor (FTPS) during purge control
valve opening or closing phase. This monitoring will determine if pressure sensor signal is stuck. The ECM sets DTC
P0451 if pressure variation is smaller than the predetermined threshold.

DTC Strategy • Check signal oscillations
• Minimum time in part load : 90 sec.
Enable Conditions • Vehicle speed once above threshold :
45km/h(28mph)
Threshold Value • Difference between max./min.voltage < 0.015V • Contact resistance in
connectors
Diagnostic Time • Immediate • Faulty FTPS
• EVAP. System monitoring is inhibited
Fail Safe • Fuel Tank Pressure Sensor monitoring is inhibited
• Canister close valve monitoring is inhibited
SCHEMATIC DIAGRAM
Page 58 of 84
MONITOR DTC STATUS

2. No relevant DTC
Repair" procedure.

or damage.
Go to "Fuel Tank Pressure Sensor(FTPS) inspection" procedure

Page 59 of 84
speed

procedure
to "Verification of Vehicle Repair" procedure


2. No relevant DTC

COMPONENT LOCATION
Page 60 of 84
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0452 if the ECM detects signal voltage lower than the possible range of a properly operating
FTPS.

DTC Strategy • Voltage range check
Enable • Short to ground in
• Battery voltage > 11V FTPS harness
Conditions
• Open in FTPS harness
Threshold Value • Signal voltage <0.35V
Diagnostic Time • 5 sec. connectors
MIL On • Faulty FTPS.
Condition
SCHEMATIC DIAGRAM
Page 61 of 84
MONITOR DTC STATUS

Page 62 of 84

or damage.

1. Ignition "OFF".
2. Disconnect FTPS connector.
3. Ignition "ON" & Fngine "OFF".
4. Measure voltage between terminal 1 of the FTPS harness connector and chassis ground.
procedure.
Page 63 of 84
1. Check for open in signal circuit.
(1) Ignition "OFF".
(3) Measure resistance between terminals 3 of the FTPS harness connector and 34 of the ECM harness
connector(C68-4).

2. Check for short to ground in signal circuit
(1) Measure resistance between terminal 3 of the FTPS harness connector and chassis ground
Specification :Infinite

Page 64 of 84
speed

procedure


COMPONENT LOCATION
GENERAL DESCRIPTION
Page 65 of 84
DTC DESCRIPTION
ECM sets DTC P0453 if the ECM detects signal voltage higher than the possible range of a properly operating
FTPS.

Enable • Short to battery in
• Battery voltage > 11V
Conditions FTPS harness
Threshold Value • Signal voltage < 4.78V • Contact resistance in
connectors
• Faulty FTPS
MIL On
Condition
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 66 of 84

or damage.

1. Ignition "OFF".
2. Disconnect FTPS connector.
Page 67 of 84
procedure.
1. Ignition "OFF".
3. Measure resistance between terminals 2 of the FTPS harness connector and 14 of the ECM harness
connector(C68-4).
Go to "Signal Circuit Inspection" procedure
Check for a open/short circuit. Repair as necessary and go to "Verification of Vehicle Repair" procedure
Page 68 of 84

(1)

speed

procedure


Page 69 of 84

COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION
The ECM monitors pressure stability in the fuel tank by means of Fuel Tank Pressure Sensor (FTPS) for
predetermined duration just before start the leakage monitoring to detect noise signal of pressure sensor. The ECM
sets DTC P0454 if the pressure fluctuation is bigger than predetermined threshold.

Page 70 of 84
DTC Strategy • Sensor signal noise check
• Idle state
10°C(14°F)
• Differential fuel tank pressure: -11 ~ 5.5hPa • Contact resistance in
• Limited canister saturation >-10% connectors
• Minimum purge time:100sec. • Faulty FTPS
Threshold Value • Signal fluctuation > 0.5hPa
Diagnostic Time • Immediate
• EVAP. System monitoring is inhibited
Fail Safe • Fuel Tank Pressure Sensor monitoring is inhibited
• Canister close valve monitoring is inhibited
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 71 of 84

2. No relevant DTC
Repair" procedure.

or damage.
Go to "Fuel Tank Pressure Sensor(FTPS) inspection" procedure

speed

Page 72 of 84
procedure



2. No relevant DTC

COMPONENT LOCATION
Page 73 of 84
GENERAL DESCRIPTION
DTC DESCRIPTION
system and then opens purge control valve (PCSV) to generate a vacuum in the fuel tank. This vacumm generation
phase will determine if there is a large leak like tank cap open or canister shut off valve (CCV) stuck open. The
ECM sets DTC P0455 if the pressure in the fuel tank does not drop as low as predetermined threshold during
predetermined maximum vacuum generation period.
If the same error code is set in the next driving cycle, the ECM illuminates the MIL.

Page 74 of 84
DTC Strategy
with underpressure
• Idle state
10°C(14°F)
• Leakage in EVAP. System
• Differential fuel tank pressure: -11 ~ 5.5hPa
• Pressure fluctuation in fuel tank >-12hPa for 13
Threshold Value
seconds during underpressure period
Diagnostic Time • 24 sec. in idle
SCHEMATIC DIAGRAM
Page 75 of 84
MONITOR DTC STATUS

2. No relevant DTC
Go to "Fuel Filler Cap & Pipe Inspection" procedure
Repair" procedure.
FUEL FILLER CAP & PIPE INSPECTION
1. Check fuel filler cap for being tightly installed, has o-ring seal installed and is in good condition.
2. Verify cap releases pressure / vacuum at specified values
Specification : Approx. 2 psi pressure and approximately 1.5 inches of mercury vacuum)
3. Are cap, o-ring and release pressures okay?
Thoroughly check fuel filler pipe for cracks, damage and o-ring seat for deformation and replace as necessary.
Go to "PCSV to Intake manifold Line Inspection" procedure
Replace fuel filler cap and go to "Verification of Vehicle Repair" procedure

Page 76 of 84
PCSV TO INTAKE MANIFOLD LINE INSPECTION
1. Ignition "OFF"
PCSV holds vacuum.
A. Verify arrow on PCSV is pointing towards intake manifold. If it is not, reverse installation. Reinstall as
necessary.
B. If OK, check for cracks or damage in hose connecting PCSV and intake manifold. Repair or replace as
necessary.
C. If OK, test with a new PCSV and check for proper operation. If problem is corrected, replace PCSV and go
2. Ignition "OFF"
click)
speed

Page 77 of 84
Go to "PCSV to Canister Line Inspection" procedure
- Canister and CCV
- Canister and PCSV
B. Canister and CCV

Page 78 of 84
leaking.
(1) Fuel lines
procedure



2. No relevant DTC

COMPONENT LOCATION
Page 79 of 84
GENERAL DESCRIPTION
DTC DESCRIPTION
system and then opens purge control valve (PCSV) to generate a vacuum in the fuel tank. After vacuum generation,
the ECM measures pressure differential curve in the fuel tank and sets DTC P0442 or P0456 if the vacuum
generated within a monitoring period increases above a defined threshold.

Page 80 of 84
• Monitoring the tank pressure sensor (DTP) signal
DTC Strategy
with underpressure
• Idle state
10°C(14°F)
Enable Conditions • Vehicle speed< 5km/h(3mph) • Leakage in EVAP system line
• Estimated altitude< 2.4km(8000ft) • Defective CCV,PCSV or
• Differential fuel tank pressure: -11 ~ 5.5hPa FTPS
Threshold Value • 0.41mm < leak.diameter <0.8mm
Diagnostic Time • 39 sec. in idle
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 81 of 84

2. No relevant DTC
Go to "Purge Control Solenoid Valve (PCSV) Line Inspection" procedure
Repair" procedure.
PCSV TO INTAKE MANIFOLD LINE INSPECTION
1. Ignition "OFF"
PCSV holds vacuum.
A. Verify arrow on PCSV is pointing towards intake manifold. If it is not, reverse installation. Reinstall as
necessary.
B. If OK, check for cracks or damage in hose connecting PCSV and intake manifold. Repair or replace as
necessary.
C. If OK, test with a new PCSV and check for proper operation. If problem is corrected, replace PCSV and go
Page 82 of 84
2. Ignition "OFF"
click)
speed

Go to "PCSV to Canister Line Inspection" procedure
Page 83 of 84
- Canister and CCV
- Canister and PCSV
B. Canister and CCV

leaking.
(1) Fuel lines
procedure

Page 84 of 84

2. No relevant DTC

Page 1 of 54
SPORTAGE(KM) > 2008 > G 2.7 DOHC > Engine Electrical System
Engine Electrical System > General Information > General Information

THE MICRO 570 ANALYZER
The MICRO 570 Analyzer provides the ability to test the charging and starting systems, including the battery, starter
and alternator.
Because of the possibility of personal injury, always use extreme caution and appropriate eye protection when
working with batteries.
KEYPAD
The MICRO570 button on the key pad provide the following functions :
BATTERY TEST PROCEDURE

Page 2 of 54
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.
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 either CCA or CCP and press the ENTER button.

Page 3 of 54
• 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'sfor cranking batteried 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.
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.
Page 4 of 54
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 andvehicle 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", replacebattery 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.
2. After pressing ENTER key, start the engine.

Page 5 of 54
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

1. Press ENTER to begin charging system test.
Page 6 of 54
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.
Page 7 of 54
5. The MICRO 570 analyzer charging system output at idle for comparision to other readings.
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
Page 8 of 54
IGNITION SYSTEM
Symptom Suspect Area Remedy (See Page)
Engine will not start or is hard to Ignition lock switch Inspect
start (Cranks OK) Ignition coil See page EE-19
Spark plugs See page EE-17
Ignition wiring disconnected or broken Inspect
Spark plug cable See page EE-17
Rough idle or stalls Ignition wiring Inspect
Ignition coil See page EE-19
Spark plug cable See page EE-17
Engine hesitates/poor Spark plugs and spark plug cable See page EE-17
acceleration Ignition wiring Inspect
Poor mileage Spark plugs and spark plugs cable See page EE-17
CHARGING SYSTEM
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-27
Charging warning indicator Drive belt loose or worn See page EE-23, 36
does not go out with engine Battery cables loose, corroded or worn See page EE-39
running (Battery requires Fuse blown Check fuses
frequent recharging) Fusible link blown Replace fusible link
Electronic voltage regulator or generator See page EE-27
Wiring Repair wiring
Engine hesitates/poor Drive belt loose or worn See page EE-23, 36
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-27
Worn battery Replace battery
Electronic voltage regulator See page EE-27
Voltage sensing wire Repair wire
STARTING SYSTEM
Page 9 of 54
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 faulty Replace fusible link
Ignition switch faulty See page EE-44
Inspect
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-44
Starter keeps running Starter motor See page EE-44
Ignition switch Inspect
Starter spins but engine will Short in wiring Repair wiring
not crank Pinion gear teeth broken or starter motor See page EE-44
Ring gear teeth broken See page EM group-fly wheel
CRUISE CONTROL SYSTEM
Before troubleshooting :
- Check the ECM(10A), Horn(10A), ECU #3(10A) and ECU B+(15A) fuse in the under - hood fuse/relay box.
- Check that the horn sounds.
- Check the tachometer to see if it works properly.
Symptom Suspect Area See Page

Cruise control cannot be set Remocon switch See page EE-57
Brake switch See page EE-58
A/T gear position switch See page TR group-automatic
transaxle
Cruise control unit See page EE-8
Cruise control cannot be set but Dimming circuit in gauge See page EE-8
indicator light does not go on Cruise control unit See page EE-8
Cruise speed is noticeably higher or Vehicle speed sensor See page TR group-automatic
lower than what was set Cruise control unit and actuator cable transaxle
deflection See page EE-58
Excessive overshooting or Cruise control unit and actuator cable See page EE-58
undershooting when trying to set speed deflection See page TR group-automatic
Vehicle speed sensor transaxle
Speed fluctuation on a flat road with Vehicle speed sensor See page TR group-automatic
cruise control set Cruise control unit and actuator cable tranxaxle
deflection See page EE-58
Page 10 of 54
Vehicle does not decelerate or Remocon switch See page EE-57
accelerate accordingly when Cruise control unit See page EE-8
SET/RESUME/CANCEL button is
pushed
See page TR group-automatic
Cruise control does not cancel when A/T gear position switch
tranxaxle
shift lever is moved to N position (A/T) Cruise control unit
See page EE-8
Set speed is not cancelled when brake Brake switch See page EE-58
pedal is pushed Cruise control unit See page EE-8
Cruise control will not cancel when Remocon switch See page EE-57
main switch is pushed OFF Cruise control unit See page EE-8
Cruise control will not cancel when Remocon switch See page EE-57
CANCEL button is pushed Cruise control unit See page EE-8
Set speed will not resume when Remocon switch See page EE-57
RESUME button (with main switch on, Cruise control unit See page EE-8
when set speed is temporarily
cancelled)
The transmission shifts down slower Troubleshooting the cruise control See page EE-8
than normal when going up a hill with communication circuit
the cruise control on (A/T)
CRUISE CONTROL COMMUNICATION CIRCUIT TROUBLESHOOTING (A/T)

2. Turn on the cruise control main switch, then drive the vehicle to speeds over 25 mph (40km/h) with the cruise
control.
Does the cruise control operate ?
- Go to step 3.
- Check the cruise control unit or cruise control actuator.
3. Measure the voltage between the O/D control terminal of the cruise control unit connector and ground.
Is there approx. 1V?
- Go to step 4.
- Replace the cruise control unit.
Page 11 of 54
4. Measure the voltage between the cruise control terminal of the TCM(or PCM) connector and ground.
Is there approx. 1V?

- Check for loosen connectors. If necessary replace the TCM and recheck. (See Page TR group-automatic
transaxle)
- Repair short or open in the wire between the TCM (or PCM) terminal and cruise control unit.
Engine Electrical System > General Information > Specifications

SPECIFICATION
IGNITION SYSTEM
Specifications
Item
2.7 2.0
Mold coil Mold coil
Type
type type
0.96 ± 0.58 ±
Ignition coil Primary resistance
10%(Ω) 10%(Ω)
12.5 ± 8.8 ±
Secondary resistance
15%(kΩ) 15%(kΩ)
NGK IFR5G-11 PFR5N-11
Unleaded
Spark plugs CHAMPION - RC10PYPB4
Gap 1.0 mm ~ 1.1 mm
STARTING SYSTEM
Page 12 of 54
Specifications
Item
2.7 2.0
Reduction drive (with planetary
Type
gear)
Rated voltage 12V, 1.2KW 12V, 1.2KW
No. of pinion teeth 8 8
Voltage 11V 11V
No-load Amperage 90A, MAX 90A, MAX
Starter charasteristics
2,800rpm, 3,000rpm,
Speed
MIN MIN
Commutator Standard 29.4 mm (1.157 in.)
diameter Limit 28.4 mm (1.118 in.)
Standard 0.5 mm (0.02 in.)
Undercut depth
Limit 0.2 mm (0.008 in.)
CHARGING SYSTEM
Specifications
Item
2.7 2.0
Type Battery voltage sensing
Rated voltage 12V, 120A 13.5V, 90A
Speed 1,000 ~ 18,000 rpm
Alternator
Voltage regulator Electronic built-in type
Regulator setting voltage 14.55 ± 0.2V 14.4 ± 0.3V
Temperrature compensation -3.5 ± 1mV/°C -10 ± 3mV/°C
Type MF 68 AH MF 60 AH
Cold cranking amperage at-
600A 550A
18°C (0°F)
Battery
Reserve capacity 113min 92min
Specific gravity at 20°C
1.280 ± 0.01 1.280 ± 0.01
(77°F)
- COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a
terminal voltage of 7.2V 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 10.5V at 26.7°C(80°F)
AUTO CRUISE CONTROL SYSTEM
Page 13 of 54
Items Specification
Setting error Within ± 1.5Km/h on level road
Vehicle speed memory variation No variation
Setting time 0.1sec max.
Resuming time 0.1sec max.
Minimum operating speed 40 ± 2Km/h
Cancel speed range 15 ± 2Km/h
Maximum memorized speed 160 ± 2Km/h
Pulling force 127N(13Kgf)
Main switch serial resistance value 3.9kΩ ± 1%
Command switch serial resistance SET switch : 220Ω ± 1%

value RESUME switch : 910Ω ± 1%
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 > Description and Operation
DESCRIPTION
Engine Electrical System > Ignition System > Repair procedures

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.
Page 14 of 54
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
2.0
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.
Page 15 of 54
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).
2.7
1. Remove the engine cover.
2. Disconnect the VIS actuator connectors and injector connectors.
3. Remove the accelerator cable.
4. Remvoe surge tank sub assembly.
5. Remove the spark plug cable.

6. Remvoe the spark plug.
7. Inspect the electrodes and ceramic insulator.
1. INSPECTION OF ELECTRODES
Page 16 of 54
CONDITION DARK DEPOSITS WITHE DEPOSITS
- Fuel mixture too rich - Fuel mixture too lean
DESCRIPTION - Low air intake - Advanced ignition timing
- Insufficient plug tightening
A. Check the electrode gap(A).
Standard (New)
1.0~1.1 mm (0.039~0.043 in.)
B. 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.
C. Connect the ohmmeter probes and measure resistance.
RESISTANCE : 5.6KΩ/m ± 20%

Page 17 of 54
D. Resistance should not be higher than 10KΩ per meter of cable.
If resistance is higher, replace the cable.
INSPECT IGNITION COIL
1. Measure the primary coil resistance between terminals 1-2 and 1-3.
Measure the primary coil resistance between terminals 1-4, 2-4 and 3-4.
Standard value :
0.58Ω ± 10% (2.0)
0.96Ω ± 10% (2.7)
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 :
8.8kΩ ± 15% (2.0)
12.5kΩ ± 15% (2.7)
Be sure, when measuring the resistnace of the secondary coil, to disconnect the connector of the ignition
coil.
Page 18 of 54
Measure the secondary coil resistance between the high-voltage terminals for the No.1 and No.4 cylinders, No.2
and No.5 cylinders and No.3 and No.6 cylinders.
REPLACEMENT
IGNITION COIL
2. Disconnect the spark plug cable and connector.
3. Remove the ignition coil(A).
Page 19 of 54
CRANKSHAFT POSITION SENSOR
1. Disconnect the crankshaft position sensor connector.
2. Remove the crankshaft position sensor(A).
Engine Electrical System > Charging System > Description and Operation
DESCRIPTION
GASOLINE
The charging system included a battery, an generator with a built-in regulator, and the charging indicator light and
wire.
The generator has eight built-in diodes (four positive and four 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

• 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.
Page 20 of 54
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.
2. Using a belt tension gauge(A), measure the drive belt(B) tension.

DRIVE BELT TENSION
New belt 540~640 N (121~143 lb)
Used belt 340~490 N (77~110 lb)
If the belt tension is not as specified, adjust it.

Page 21 of 54
- "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 ALTERNATOR 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 alternator 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 it.
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.
2. Connect a digital voltmeter between the alternator "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 alternator "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.
Page 22 of 54
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
described 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 alternator drive belt.
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the alternator output wire from the alternator "B" terminal.
5. Connect a DC ammeter (0 to 150A) 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 alternator
"B" terminal and (-) lead wire to a good ground.
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 alternator "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 read the maximum current value correctly.
RESULT
Page 23 of 54
1. The ammeter reading must be higher than the limit value. If it is lower but the alternator output wire is in good
condition, remove the alternator from the vehicle and test it.
63A min.
• The nominal output current value is shown on the nameplate affixed to the alternator body.
• The output current value changes with the electrical load and the temperature of the alternator 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 alternator 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 alternator output wire to the alternator "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 alternator drive belt tension.
2. Turn ignition switch to "OFF".
4. Connect a digital voltmeter between the "B" terminal of the alternator and ground. Connect the (+) lead of the
voltmeter to the "B" terminal of the alternator. Connect the (-) lead to good ground or the battery (-) terminal.
5. Disconnect the alternator output wire from the alternator "B" terminal.
6. Connect a DC ammeter (0 to 150A) 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 alternator "B" terminal and the battery and the
battery (-), or the fusible link is blown.
Page 24 of 54
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 alternator 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 alternator is
faulty.
REGULATING VOLTAGE TABLE
GASOLINE
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.
5. Connect the alternator output wire to the alternator "B" terminal.
6. Connect the battery ground cable.
Engine Electrical System > Charging System > Alternator > Components and Components Location
COMPONENTS
GASOLINE (2.0)
Page 25 of 54
GASOLINE (2.7)
Page 26 of 54
Engine Electrical System > Charging System > Alternator > Repair procedures
REPLACEMENT
1. Disconnect the battery negative terminal first, then the positive terminal.
Page 27 of 54
2. Deisconnect the alternator connector(A) and "B" terminal cable(B) from the alternator(C).
3. Remove the adjusting bolt(A) and mounting bolt(B), then remove the alternator belt.
4. Pull out the through bolt(C), then remove the alternator(D).

6. Adjust the alternator belt tension after installation (See page EE-36).
DISASSEMBLY
GASOLINE (2.0)
Page 28 of 54
1. Remove the rear cover(A).
2. Unsolder the 4 stator leads(A) to the main diodes on the rectifier(B).
- When soldering or unsoldering, be careful not to heat the diodes for too
long.
- Be careful that excesive force is not exerted on the leads of the diodes.
3. Remove the rectifier assembly(A).

Page 29 of 54
4. Unsolder between rectifier(A) and brush holder(B).
5. Remove the rear bracket(A).
6. Remove the nut(A), pulley(B) and spacer(C).
7. Disconnect the stator(A), rotor(B) and front bracket(C).

Page 30 of 54
8. Remove the rear bearing(A) and cover(B).
9. Reassembly is the reverse or disassembly.
Before the rotor is attached to the rear bracket, insert a wire through the small hole in the rear bracket to
lock the brush. After the rotor has been installed, the wire can be removed.
GASOLINE (2.7)
1. Remove the alternator cover(A) using a screw driver(B).
2. Loosen the mounting bolts(A) and disconnect the brush holder assembly(B).
Page 31 of 54
3. Remove the slip ring guide(A).
4. Remvoe the nut, pully(A) and spacer.
5. Loosen the 4 through bolts(A).
6. Disconnect the rotor(A) and cover(B).
7. Reassembly is the reverse of disassembly.
INSPECTION
INSPECT ROTOR
Page 32 of 54
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(B) or rotor shaft(C).
3. If the rotor fails either continuity check, replace the alternator.
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 (GASOLINE 2.0)
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 : 5.0 ~ 6.0 mm (0.20 ~ 0.23 in)
New Belt : 4.0 ~ 5.0 mm (0.16 ~ 0.20 in)
If the belt is worn or damaged, replace it.

Page 33 of 54
Belt tension gauge method :

Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions.
Tension
Used Belt : 340~490 N (35~50 kgf, 77~110 lbf)
New Belt : 540~640 N (55~65 kgf, 121~143 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.
Engine Electrical System > Charging System > Battery > Description and Operation
DESCRIPTION
Page 34 of 54
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.
Engine Electrical System > Charging System > Battery > Repair procedures
INSPECTION
BATTERY DIAGNOSTIC TEST (1)
1. CHECKING FLOW
2. CHECKING SHEET
Page 35 of 54
Inspection Items & contents Judgment criteria Remarks
1. Acid Leakage 1. Damage in the case or cover due to
* Type of acid leakage outside impact.
- Leakage on the fusion part for joining the
2. Acid leakage on the molding part of the
case and cover.
case or cover.
- Leakage on the terminal part
(weld line or gate hole)
- Leakage on the other parts
* Clean the wet part or wash it, then dry it 3. Damage on the terminal or cracks in the
before checking with naked eyes. cover.
* Determine a part where leakage might 4. Acid leakage due to the tipped battery or
have occurred slant storage.
; check it by tipping the battery, if the
leakage takes place again. 5. Acid leakage due to poor welding of the
* Conduct a visual inspection for breakage, cover.
deformation, or cracks. (with no damage)
2. Outside damage and breakage 1. Outside damage due to causes without
* Check with naked eyes. damage due to 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 battery 1. 12.0V Refer to load test
; but wait at least one day before measuring
2. 11.0V< battery voltage<12.0V due to
in case of recharging, and recharging should Refer to load test
over-discharge.
be made in accordance with the charging
instructions. 3. Below 11.0V due to charge condition
Refer to load test
failure.
4. Below 11.0V due to discharged for a long
Refer to load test
period.
5. Below 11.0V due to internal short circuit. Refer to load test
4. Load test
; For 15 seconds with a half of the CCA 1. Load test result: below 9.5V
electric current value, but the voltage on the
dischaarging stage should be above 9.6V
(27±5°C)
- Conduct the test with a battery tester. 2. Load test result: above 9.6V Mfg. Defect usable
(Refer to the tester manual)
3. LOAD TEST
1. Perform the following steps to complete the load test procedure for maintenance free batteries.
Page 36 of 54
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.
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.
Page 37 of 54
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.
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 > 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.
Engine Electrical System > Starting System > Repair procedures

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.
Page 38 of 54
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
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. Remove the ECM(B+) fuse from the fuse/relay box.
2. Turn the ignition switch to START (III) with the shift lever in N or P 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.
3. 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.
4. Unplug the connector from the starter.
5. 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.
6. Check the ignition switch.
7. Check the starter relay (see page EE-54).
8. Check the A/T gear position switch (A/T) or the clutch interlock switch (M/T).
9. Check for an open in the wire between the ignition switch and starter.
STARTER SOLENOID TEST
1. Disconnect the wires from the Sterminal and the M terminal.
Page 39 of 54
2. Connect the battery as shown. If the starter pinion pops out, it is working properly. To avoid damaging the
starter, do not leave the battery connected for more than 10 seconds.
3. Disconnect the battery from the M terminal.

If the pinion does not retract, the hold-in coil is working properly. To avoid damaging the starter, do not leave the
battery connected for more than 10 seconds.
4. Disconnect the battery also from the body. If the pinion retracts immediately, it is working properly.
To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.
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 starter motor body.
6. Adjust until battery voltage shown on the voltmeter reads 11 volts.
Page 40 of 54
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and
freely :
2.7
: Max. 90 Amps
: Min. 2,800 rpm
2.0
: Max. 90 Amps
: Min. 3,000 rpm
Engine Electrical System > Starting System > Starter > Components and Components Location
COMPONENTS
GASOLINE
Page 41 of 54
Engine Electrical System > Starting System > Starter > Repair procedures
INSPECTION
ARMATURE INSPECTION AND TEST
1. Remove the starter (see page EE-47).
2. Disassemble the starter as shown at the beginning of this procedure.
Page 42 of 54
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage,
replace the armature.
4. 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.)
5. Check for continuity between the segments of the commutator. If an open circuit exists between any segments,
replace the armature.
Page 43 of 54
6. 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
INSPECT OVERRUNNING CLUTCH

1. Slide the overrunning clutch along the shaft.
Replace it if does not slide smoothly.
Page 44 of 54
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.
DISASSEMBLY
GASOLINE
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).

Page 45 of 54
3. Loosen the brush holder mounting screws(A) and through bolts(B).
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).

Page 46 of 54
7. Disconnect the planet gear(A).
8. Disconnect the planet shaft assembly(A) and lever(B).
9. Press the stop ring(A) using a socket(B).
10. After removing the stopper(A) using stopper pliers(B).

Page 47 of 54
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).
REPLACEMENT
1. Disconnect the battery negative cable.
2. Disconnect the starter cable(A) from the B terminal(B) on the solenoid(C), then disconnect the connector(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.
Engine Electrical System > Starting System > Starter Relay > Repair procedures
INSPECTION
1. Remove the fuse box cover.
Page 48 of 54
2. Remove the starter relay(A).
3. Inspect the relay continuity.

A. Using an ohmmeter, check that there is continuity between terminals 85 and 86.
If there is no continuity, replace the relay.
B. Check that there is no continuity between terminals 30 and 87.
If there is continuity, replace the relay.
4. Inspect the relay operation.
A. Apply battery positive voltage across terminals 85 and 86.
B. Using an ohmmeter, check that there is continuity between terminals 30 and 87.
If there is no continuity, replace the relay.
5. Install the starter relay.

6. Install the fuse box cover.
Engine Electrical System > Cruise Control System > Schematic Diagrams
CIRCUIT DIAGRAM FOR CRUISE CONTROL SYSTEM
Page 49 of 54
Engine Electrical System > Cruise Control System > Components and Components Location
COMPONENTS LOCATION
Page 50 of 54
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 group-air bag module).
Page 51 of 54
3. Disconnect the remocon switch connector(A).
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(A) from the brake switch.
2. Remove the brake switch(B).
Page 52 of 54
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.)
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).
Page 53 of 54
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 cover, actuator cable and connector.
3. Loosen the three mounting bolts(E), and remove the actuator(F) with the bracket.
Page 54 of 54
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 group-air bag module).
3. Disconnect the remocon switch connector(A).
4. Loosen the two mounting screws(B), and remove the cruise remocon switch(C).

6. Connect the battery positive cable and negative cable to the battery.
Page 1 of 142
SPORTAGE(KM) > 2008 > G 2.7 DOHC > Engine Mechanical System
Engine Mechanical System > General Information > General Information

SPECIFICATIONS
Description Specifications Limit
General
Type V-type, DOHC
Number of cylinder 6
Bore 86.7mm (3.4133in.)
Stroke 75mm (2.9528in.)
Total displacement 2,656cc
Compression ratio 10 : 1
Firing order 1-2-3-4-5-6
Valve timing
Intake valve
Opens (BTDC) 6°
Closes (ABDC) 46°
Exhaust valve
Opens (BBDC) 38°
Closes (ATDC) 14°
Camshaft
Drive mechanism Cogged type belt
Cam height
Intake 43.95 ~ 44.15mm (1.7303 ~ 1.7382in.) 43.45mm (1.7106in.)
Exhaust 43.95 ~ 44.15mm (1.7303 ~ 1.7382in.) 43.45mm (1.7106in.)
Journal diameter 25.964 ~ 25.980mm (1.0222 ~ 1.0228in.) 25.914mm (1.0202in.)
Bearing oil clearance 0.02 ~ 0.061mm (0.0007 ~ 0.0024in.) 0.1mm (0.0039in.)
End play 0.1 ~ 0.15mm (0.0039 ~ 0.0059in.)
Cylinder head
Flatness of cylinder head surface Max. 0.03mm (0.0012in.) 0.05mm (0.0020in.)
Flatness of manifold mounting surface
Intake Max. 0.15mm (0.0059in.) 0.15mm (0.0059in.)
Exhaust Max. 0.15mm (0.0059in.) 0.15mm (0.0059in.)
Valve guides hole diameter
0.05 (0.002) O.S. 11.05 ~ 11.068mm (0.435 ~ 0.436in.)
0.25 (0.010) O.S. 11.25 ~ 11.268mm (0.443 ~ 0.444in.)
0.50 (0.020) O.S. 11.50 ~ 11.518mm (0.453 ~ 0.453in.)
Intake valve seat ring hole diameter
0.3 (0.012) O.S. 33.300 ~ 33.325mm (1.311 ~ 1.312in.)
Exhaust valve seat ring hole diameter
0.3 (0.012) O.S. 28.600 ~ 28.621mm (1.126 ~ 1.127in.)
Valve
Overall length
Intake 96.1mm (3.783in.)
Exhaust 97.15mm (3.825in.)
Stem diameter
Intake 5.965 ~ 5.98mm (0.235 ~ 0.2354in.)
Exhaust 5.95 ~ 5.965mm (0.234 ~ 0.235in.)
Page 2 of 142
Face angle 45° ~ 45.5°
Margin
Intake 1.0mm (0.0394in.) 0.5mm (0.0197in.)
Exhaust 1.3mm (0.0512in.) 0.8mm (0.0315in.)
Clearance (Stem-to-guide)
Intake 0.02 ~ 0.05mm (0.008 ~ 0.0020in.) 0.10mm (0.0039in.)
Exhaust 0.030 ~ 0.065mm (0.0012 ~ 0.0026in.) 0.13mm (0.0051in.)
Valve spring
Free length 42.5mm (1.6732in.) 41.5mm (1.6339in.)
Load 21kg/35mm (48.4lb/1.3780in.) 21.9kg/34mm
(48.4lb/1.3386in.)
Out of squareness Max. 1.5° Max. 3°
Piston
Diameter (Standard) 86.68 ~ 86.71mm (3.413 ~ 3.414in.)
Clearance (Piston-to-cylinder) 0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)
Ring groove width
No.1 1.230 ~ 1.250mm (0.0484 ~ 0.0492in.)
No.2 1.220 ~ 1.250mm (0.0480 ~ 0.0488in.)
Oil 2.515 ~ 2.535mm (0.0990 ~ 0.0998in.)
Piston for service 0.25mm (0.010in.), 0.50mm (0.020in.)
Piston ring
Number of rings per piston 3
Compression ring 2
Oil ring 1
Compression ring type
No.1 Inner bevel type
No.2 Under cut type
Oil ring type 3-piece type
Ring end gap
No.1 0.20 ~ 0.35mm (0.0079 ~ 0.0138in.) 0.8mm (0.031in.)
No.2 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.) 0.8mm (0.031in.)
Oil ring side rail 0.2 ~ 0.7mm (0.0079 ~ 0.0276in.) 1.0mm (0.039in.)
Ring side clearance
No.1 0.04 ~ 0.08mm (0.0016 ~ 0.0031in.) 0.1mm (0.004in.)
No.2 0.03 ~ 0.07mm (0.0012 ~ 0.0028in.) 0.1mm (0.004in.)
Rings for service 0.25mm (0.010in.), 0.50mm (0.020in.)
Connecting rod
Piston pin installation force 2,450 ~ 12,225N
(250 ~ 1,250kg, 551 ~ 2,755lb)
Side clearance (big end) 0.10 ~ 0.25mm (0.0039 ~ 0.0098in.) 0.4mm (0.016in.)
Bend 0.05mm or less/100mm
(0.0020in. or less/3.937in.)
Bearing oil clearance 0.018 ~ 0.036mm (0.0007 ~ 0.0014in.) 0.1mm (0.004in.)
Crankshaft
Journal O.D. 61.982 ~ 62.000mm (2.4402 ~ 2.4409in.)
Pin O.D. 47.982 ~ 48.000mm (1.8891 ~ 1.8898in.)
Out-of-round, taper of journal and pin Max. 0.003mm (0.0012in.)
Taper of journal and pin Max. 0.005mm (0.00020in.)
End play 0.070 ~ 0.250mm (0.0028 ~ 0.0098in.) 0.4mm (0.016in.)
Page 3 of 142
Main bearing of clearance 0.004 ~ 0.022mm (0.0002 ~ 0.0009in.) 0.1mm (0.004in.)
Cylinder block
Cylinder bore 86.7mm (3.4134in.)
Flatness of gasket surface Max. 0.03mm (0.0012in.) 0.05mm (0.002in.)
Out-of-round of cylinder bore Max. 0.02mm (0.0008in.)
Oil pump
Body clearance 0.100 ~ 0.181mm (0.0039 ~ 0.0071in.)
Side clearance 0.040 ~ 0.095mm (0.0016 ~ 0.0037in.)
Relief spring
Free height 43.8mm (1.724in.)
Load 4.6kg/39.3mm (10lb/1.548in.)
Oil filter
Type Cartridge, full flow
Engine oil pressure 50kPa (7.3psi) or more
[Conditions : Oil temperature is 75 to 90°C
(167 to 194°F)]
Cooling method Engine coolant cooling, forced circulation
with electric fan
Cooling system quantity 7.0lit (7.4U.S.qts., 6.1lmp.qts)
Theromstat
Type Wax pellet type with jiggle valve
Normal opening temperature 82 ± 2.0°C (179.6 ± 3.6°F)
Opening temperature range 80 ~ 84°C (176 ~ 183.2°F)
Wide open temperature 95°C (203°F)
Radiator cap
Main valve opening pressure 107.9 ± 14.7kPa (1.1 ± 0.15kg/cm², 15.65
± 2.13psi)
Main valve closing pressure 83.4kPa (0.85kg/cm², 12.1psi)
Vacuum valve opening pressure -6.86kPa (-0.07kg/cm², -1.00psi)
Air cleaner
Type Dry
Element Paper type
Exhaust pipe
Muffler Expansion reaonance type
Suspend system Rubber hangers
SERVICE STANDRDS
Standard value
Coolant concentration
Tropical
40%
areas
Other
50%
areas
COOLANT
Page 4 of 142
Ethlylen glycol base for
Engine coolant
aluminum radiator
SEALANT
LOCTITE 262 or equivalent, Three bond
Engine coolant temperature sensor
No.1324 or equivalent.
Oil pressure switch 3M ATD No.8660 or Three bond No.1141E
PCV valve LOCTITE 242 or equivalent
TIGHTENING TORQUE
Item N.m kgf.cm lb-ft
Camshaft sprocket bolt 90 ~ 110 900 ~ 1,100 65 ~ 85
Cylinder head cover bolt 8 ~ 10 80 ~ 100 5.8 ~ 7.2
Main bearing cap bolt 270~300 +

19.5~24 +
M10 27~33 + (90°~94°) (90°~94°)
(90°~94°)
M8 13~19 + (90°~94°) 130~190 +
10~14 + (90°~94°)
(90°~94°)
160~200 +
Connecting rod bolt 16~20 + (90°~94°) 12~15 + (90°~94°)
(90°~94°)
25 + (58°~62°) + 250 + (58°~62°) + 18 + (58°~62°) +
Cylinder head bolt(Cold engine)
(43°~47°) (43°~47°) (43°~47°)
Oil pan drain plug 35 ~ 45 350 ~ 450 25 ~ 33
Lower oil pan bolt 10 ~ 12 100 ~ 120 7~9
Upper oil pan bolt
[10 × 38mm (0.937 × 1.4961in.)] 30 ~ 42 300 ~ 420 22 ~ 30
[8 × 22mm (0.3150 × 0.8661in.)] 19 ~ 28 190 ~ 280 14 ~ 20
[161.5mm (6.3582in.)] 5~7 50 ~ 70 4~5
[152.5mm (6.0039in.)] 5~7 50 ~ 70 4~5
Oil screen bolt 15 ~ 22 150 ~ 220 11 ~ 16
Oil pump case bolt 12 ~ 15 120 ~ 150 9 ~ 11
Oil relief valve plug 40 ~ 50 400 ~ 500 29 ~ 36
Oil pressure switch 15 ~ 22 150 ~ 220 11 ~ 16
Oil pressure cover screw 8 ~ 12 80 ~ 120 6~9
Oil filter 12 ~ 16 120 ~ 160 9 ~ 12
Drive plate and adapte 73 ~ 77 730 ~ 770 53 ~ 56
Air cleaner body installation bolt 8 ~ 12 80 ~ 120 6~9
Surge tank stay 15 ~ 20 150 ~ 200 11 ~ 14
Air intake surge tank to intake manifold(bolt) 15 ~ 20 150 ~ 200 11 ~ 14
Air intake surge tank to intake manifold(nut) 15 ~ 20 150 ~ 200 11 ~ 14
Intake manifold to cylinder head 19 ~ 21 190 ~ 210 14 ~ 15
Page 5 of 142
Heat protector exhaust manifold 12 ~ 15 120 ~ 150 9 ~ 11
Exhaust manifold to cylinder head
30 ~ 35 300 ~ 350 22 ~ 26
(Self-locking nut)
Oil level gauge guide to engine 12 ~ 15 120 ~ 150 9 ~ 11
Water outlet fitting bolt 17 ~ 20 170 ~ 200 12 ~ 14
Power steering oil pump bracket to cylinder
17 ~ 26 170 ~ 260 12 ~ 19
head
Crank position sensor wheel screw 5~6 50 ~ 60 3.6 ~ 4.3
Engine mounting insulator bolt 50 ~ 65 500 ~ 650 36 ~ 47
Engine mounting bracket nut 60 ~ 80 600 ~ 800 43 ~ 58
Engine mounting bracket bolt 60 ~ 80 600 ~ 800 43 ~ 58
Engine support bracket bolt 60 ~ 70 600 ~ 700 43 ~ 51
Front roll stopper bracket sub frame bolt 50 ~ 65 500 ~ 650 36 ~ 47
Front roll stopper insulator bolt and nut 50 ~ 65 500 ~ 650 36 ~ 47
Rear roll stopper bracket to sub frame 50 ~ 65 500 ~ 650 36 ~ 47
Rear roll stopper insulator bolt and nut 50 ~ 65 500 ~ 650 36 ~ 47
Transaxle mounting bracket bolt 50 ~ 65 500 ~ 650 36 ~ 47
Transaxle mounting insulator bolt 90 ~ 110 900 ~ 1,100 65 ~ 80
Fuel hose clamp to rear cylinder head
12 ~ 15 120 ~ 150 9 ~ 11
assembly
Transaxle mounting plate 10 ~ 12 100 ~ 120 7~9
Rear plate 10 ~ 12 100 ~ 120 7~9
Oil seal case 10 ~ 12 100 ~ 120 7~9
Crankshaft pulley bolt 180 ~ 190 1,800 ~ 1,900 130 ~ 138
Timing belt cover bolt 10 ~ 12 100 ~ 12 7~9
Engine hanger bracket to engine 20 ~ 27 200 ~ 270 14 ~ 20
Alternator mounting bracket to engine 20 ~ 30 200 ~ 300 14 ~ 22
Alternator mounting nut (Engine front case
20 ~ 30 200 ~ 300 14 ~ 22
side)
Alternator mounting bolt (Alternator
20 ~ 30 200 ~ 300 14 ~ 22
mounting bracket side)
Starter to transmission(nut) 20 ~ 30 200 ~ 300 14 ~ 22
Starter to transmission(bolt) 27 ~ 34 270 ~ 340 20 ~ 25
Drive belt pulley bolt 35 ~ 55 350 ~ 550 25 ~ 40
Drive belt tensioner bolt 20 ~ 27 200 ~ 270 14 ~ 20
Engine coolant pump to cylinder block bolt
15 ~ 22 150 ~ 200 11 ~ 16
(Head mark "7" mark)
Engine coolant temperature sensor 20 ~ 40 200 ~ 400 14 ~ 29
Page 6 of 142
Engine coolant inlet fitting attaching bolt 17 ~ 20 170 ~ 200 12 ~ 14
Throttle body to surge tank bolt 15 ~ 20 150 ~ 200 11 ~ 14
Oxygen sensor to exhaust manifold 40 ~ 50 400 ~ 500 29 ~ 36
Front exhaust pipe to exhaust manifold nut 30 ~ 40 300 ~ 400 22 ~ 29
Front exhaust pipe to catalytic converter bolt 40 ~ 60 400 ~ 600 29 ~ 43
Catalytic converter to center exhaust pipe
40 ~ 60 400 ~ 600 29 ~ 43
nut
Center exhaust pipe to main muffler nut 40 ~ 60 400 ~ 600 29 ~ 43
Main muffler hanger support bracket bolt 10 ~ 15 100 ~ 150 7 ~ 11
Delivery pipe installation bolt 10 ~ 15 100 ~ 150 7 ~ 11
Timing belt tensioner pulley bolt 43 ~ 55 430 ~ 550 31 ~ 40
Timing belt idler puley bolt 50 ~ 60 500 ~ 600 36 ~ 43
Timing blelt tensioner arm fixed bolt 35 ~ 55 350 ~ 550 25 ~ 40
Auto tensioner fixed bolt 20 ~ 27 200 ~ 270 14 ~ 20
Accelerator cable bracket 4~6 40 ~ 60 3~4
Spark plug 20 ~ 30 200 ~ 300 14 ~ 22
COMPRESSION
If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
1. Warm up and stop engine
Allow the engine to warm up to normal operating temperature.
2. Remove ignition coils. (See EE group - ignition)
3. Remove spark plugs.
Using a 16mm plug wrench, remove the 6 spark plugs.
4. Check cylinder compression pressure
A. Insert a compression gauge into the spark plug hole.
B. While cranking the engine, measure the compression pressure.
Always use a fully charged battery to obtain engine speed of 250 rpm or more.
Page 7 of 142
C. Repeat steps (a) through (b) for each cylinder.
This measurement must be done in as short a time as possible.
Compression pressure :
1,420kPa (14.5kgf/cm², 206psi)
Minimum pressure :
1,270kPa (13kgf/cm², 184psi)
Difference between each cylinder :
100kPa (1.0kgf/cm², 15psi) or less
D. If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder
through the spark plug hole and repeat steps (a) through (b) for cylinders with low compression.
• If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or
damaged.
• If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the
gasket.
5. Reinstall spark plugs. (See EE group - ignition)
6. Install ignition coils. (See EE group - ignition)
Engine Mechanical System > General Information > Special Service Tools
SPECIAL TOOLS
Crankshaft front oil seal installer Installation of the front oil seal
(09214-33000)
Camshaft oil seal installer Installation of the camshaft oil seal

(09214-21000)
Valve guide installer Remove and installation of the valve guide

(09221-3F100 A/B)
Valve stem oil seal installer Installation of the valve stem oil seal
(09222-22001)
Valve spring compressor

&amp;amp; adaptor
(09222-28000, 09222-28100)
Page 8 of 142
Valve spring compressor Removal and installation of the intake or
&amp;amp; adaptor exhaust valve
(09222-28000, 09222-28100)
Crankshaft rear oil seal installer 1. Installation of the engine rear oil seal
(09231-33000) 2. Installation of the crankshaft rear oil seal
Engine Mechanical System > General Information > Troubleshooting

TROUBLESHOOTING
Symption Suspect area Remedy (See page)
Engine misfire with Loose or improperly installed engine
Repair or replace the flywheel as required.
abnormal internal flywheel.
lower engine noises. Worn piston rings Inspect the cylinder for a loss of
(Oil cousumption may or may not cause the compression.
engine to misfire.) Repair or replace as required.
Worn crankshaft thrust bearings Replace the crankshaft and bearings as
required
Engine misfire with Stuck valves. Repair or replace as required
abnormal valve train (Carbon buidup on the valve stem)
noise.
Excessive worn or mis-aligned timing chain Replace the timing chain and sprocket as
required.
Worn camshaft lobes. Replace the camshaft and valve lifters.
Engine misfire with • Faulty cylinder head gasket and/or • Inspect the cylinder head and engine
coolant consumption cranking or other damage to the cylinder block for damage to the coolant passages
head and engine block cooling system. and/or a faulty head gasket.
• Coolant consumprion may or may not • Repair or replace as required.
cause the engine to overheat.
Engine misfire with Worn valves, guides and/or valve stem oil Repair or replace as required.
excessive oil seals.
consumption
Worn piston rings. • Inspect the cylinder for a loss of
(Oil consumption may or may not cause the compression.
engine to misfire) • Repair or replace as required.
Engine noise on start- Incorrect oil viscosity • Drain the oil.
up, but only lasting a • Install the correct viscosity oil.
few seconds.
Worn crankshaft thrust bearing. • Inspect the thrust bearing and crankshaft.
• Repair or replace as required.
Upper engine noise, Low oil pressure Repair or replace as required.
regardless of engine
Broken valve spring. Replace the valve spring.
speed.
Page 9 of 142
speed.
Worn or dirty valve lifters. Replace the valve lifters.
Stetched or broken timing chain and/or
Replace the timing chain and sprockets.
damaged sprocket teeth.
Replace the timing chain tensioner as
Worn timing chain tensioner, if applicable.
required.
Worn camshaft lobes. • Inspect the camshaft lobes.
• Replace the timing camshaft and valve
lifters as required.
Worn valve guides or valve stems. Inspect the valves and valve guides, then
repair as required.
Stuck valves. (Carbon on the valve stem or Inspect the valves and valve guides, then
valve seat may cause the valve to stay open. repair as required.
Lower engine noise, Low oil pressure. Repair or required.
regardless of engine Loose or damaged flywheel. Repair or replace the flywheel.
speed
Damaged oil pan, contacting the oil pump • Inspect the oil pan.
screen. • Inspect the oil pump screen.
Oil pump screen loose, damaged or • Inspect the oil pump screen.
restircted. • Repair or replace as required.
Excessive piston-to-cylinder bore clearance. • Inspect the piston, piston pin and cylinder
bore.
• Repair as required.
Excessive piston pin-to-connecting rod • Inspect the piston, piston pin and the
clearance connecting rod.
Excessive connecting rod bearing rod Inspect the following components and repair
clearance as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
• The crankshaft journal.
Excessive crankshaft bearing clearance Inspect the following components, and repair
as required.
• The crankshaft bearing.
• The crankshaft journals.
Incorrect piston, piston pin and connecting • Verify the piston pins and connecting
rod installation rods are installed correctly.
• Repair as required.
Engine noise under Low oil pressure Repair or replace as required.
load Excessive connecting rod bearing clearance Inspect the following components and repair
as required :
• The connecting rod bearings.
Page 10 of 142
• The connecting rods.
• The crankshaft
Excessive crankshaft bearing clearance Inspect the following components, and repair
as required.
• The crankshaft bearings.
• The crankshaft journals.
• The cylinder block crankshaft
Engine will not crank- Hydraulically locked cylinder 1. Remove spark plugs and check for fluid.
crankshaft will not • Coolant/antifreeze in cylinder. 2. Inspect for broken head gasket.
rotate • Oil in cylinder. 3. Inspect for cracked engine block or
• Fuel in cylinder cylinder head.
4. Inspect for a sticking fuel injector and/or
leaking fuel regulator.
Broken timing chain and/or timing chain 1. Inspect timing chain and gears.
gears. 2. Repair as required.
Material in cylinder 1. Inspect cylinder for damaged
• Broken valve components and/or foreign materials.
• Piston material 2. Repair or replace as required.
• Foreign material
Seized crankshaft or connecting rod 1. Inspect crankshaft and connecting rod
bearings. bearing.
2. Repair as required.
Bend or broken connecting rod. 1. Inspect connecing rods.
Broken crankshaft 1. Inspect crankshaft.
Engine Mechanical System > Timing System > Components and Components Location
COMPONENT
Page 11 of 142
Engine Mechanical System > Timing System > Repair procedures

REMOVAL
Engine removal is not required for this procedure.
2. Remove RH front wheel.
Page 12 of 142
3. Remove 2bolts(B) and RH side cover(A).
4. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover.
Always turn the crankshaft clockwise.

5. Remove drive belt(A) and belt tensioner(B).
Page 13 of 142
6. Remove the engine mount bracket.
(1) Set the jack to the engine oil pan.
Place wooden block between the jack and engine oil

pan.
(2) Remove the 2bolts, 2nuts and engine mount bracket(A).
7. Remove the power steering pump. (See ST group - power steering pump)
8. Remove the 7bolts(B) and timing belt upper cover(A).
Page 14 of 142
9. Remove the crankshaft pulley bolt and crankshaft pulley(A).
10. Remove the drive belt idler pulley(A).
11. Remove the 4bolts(B) and timing belt lower cover(A).
12. Remove the engine support bracket(A).
13. Check that timing marks of the camshaft timing pulleys and cylinder head covers are aligned.
If not, turn the crankshaft 1revolution(360°).
Page 15 of 142
14. Remove timing belt tensioner.
Alternately loosen the 2bolts, and remove the tensioner(A).
15. Remove the timing belt(A).
If the timing belt is reused, make an arrow indicating the turning direction to make sure that the belt is
reinstalled in the same direction as before.
16. Remove the tensioner pulley(A) and timing belt idler pulley(B).
17. Remove the crankshaft sprocket.

18. Remove camshaft sprockets.
Hold the hexagonal head wrench portion of the camshaft with a wrench and remove the bolt and camshaft
sprocket.
Be careful not to damage the cylinder head and valve lifter with the wrench.
INSTALLATION
Page 16 of 142
1. Install the crankshaft sprocket.
Align the pulley set key with the key groove the crankshaft sprocket and slide on the crankshaft sprocket.
2. Install the camshaft sprockets and tighten the bolts to the specified torque.
(1) Temporarily install the camshaft sprocket bolts.
(2) Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the camshaft sprocket
bolts.
Tightening torque
Camshaft sprocket bolt
90 ~ 110N.m (900 ~ 1100kgf.cm, 65 ~ 80lb-ft)
3. Install the idler pulley(B) and the tensioner pulley(A).
Tightening torque
Idler pulley bolt
50 ~ 60N.m (500 ~ 600kgf.cm, 36 ~ 43lb-ft)
Tensioner arm fixed bolt
35 ~ 55N.m (350 ~ 550kgf.cm, 25 ~ 40lb-ft)
Insert and install the idler pulley to the roll pin that is pressed in the water pump boss.
4. Align the timing marks of the camshaft sprocket and crankshaft sprocket with the No.1 piston placed at top dead
center of its compression stroke.
Page 17 of 142
5. Set timing belt tensioner.
(1) Using a press, slowly press in the push rod.
(2) Align the holes of the push rod and housing, then install a set pin through the holes to keep the push rod, in
position.
(3) Release the press.
6. Install the timing belt tensioner.
(1) Temporarily install the tensioner with the 2bolts.
(2) Alternately tighten the 2bolts.
Tightening torque
20 ~ 27N.m (200 ~ 270kgf.cm, 14 ~ 20lb-ft)
7. Install the timing belt.

(1) Remove any oil or water on the sprockets, and keep them clean.
(2) Install the timing belt in this order.
Crankshaft sprocket(A) → Idler pulley(B) → Camshaft sprocket LH side(C) → Water pump pulley(D) →
Camshaft sprocket RH side(E) → Tensioner pulley(F).
Page 18 of 142
8. Remove the set pin(A) from the tensioner.
9. Timing belt tensioner checking.

(1) Rotate the crankshaft 2turns clockwise and measure the projected length of the auto tensioner at TDC(#1
compression stroke) after 5 minutes.
(2) The projected length should be 7 ~ 9mm (0.27 ~ 0.31in.)
10. Install the engine support bracket(A).
Tightening torque
B : 60 ~ 70N.m (600 ~ 700kgf.cm, 43 ~ 51lb-ft)
C : 15 ~ 22N.m (150 ~ 220kgf.cm, 11 ~ 16lb-ft)
Page 19 of 142
11. Install the timing belt lower cover(A) with 4bolts(B).
Tightening torque
Timing belt cover bolt
10 ~ 12N.m (100 ~120kgf.cm, 7 ~ 9lb-ft)
12. Install the drive belt idler pulley(A).
Tightening torque
Idler pulley bolt
35 ~ 55N.m (350 ~ 550kgf.cm, 25 ~ 40lb-ft)
13. Install the crankshaft pulley(A).

Make sure that crankshaft sprocket pin fits the small hole in the pulley.
Tightening torque
Crankshaft pulley bolt
180 ~ 190N.m (1800 ~ 1900kgf.cm, 130 ~ 138lb-ft)
Page 20 of 142
14. Install the timing belt upper cover(A) with 7bolts(B).
15. Install the power steering pump. (See ST group - power steering pump)
16. Install the drive belt tensioner(B) and drive belt(A).
17. Install the engine mount bracket.

Install engine mount bracket with 2nuts and 2bolt.
Tightening torque
60 ~ 80N.m (600 ~ 800kgf.cm, 44 ~ 59lb-ft)
Page 21 of 142
18. Install RH side cover(A) with 2bolts(B).
19. Install RH front wheel.

20. Install engine cover.
INSPECTION
SPOCKETS, TENSIONER, IDLER
1. Check the camshaft sproket, 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 rotation and check for play or noise.
Replace as necessary.
3. Replace the pulley if there is a grease leak from its bearing.

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, check the belt carefully. If any of the following flaws are
evident, replace the belt.
• Do not bend, twist or turn the timing belt inside out.

• Do not allow the timing belt to come into contact with oil, water and steam.
Engine Mechanical System > Cylinder Head Assembly > Components and Components Location
COMPONENTS
Page 22 of 142
Page 23 of 142
Engine Mechanical System > Cylinder Head Assembly > Repair procedures
REMOVAL
Page 24 of 142
• Use fender covers to avoid damaging painted surfaces.

• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal
temperature before removing it.
• When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
• Mark all wiring and hoses to avoid misconnection.

• Inspect the timing belt before removing the cylinder head.
• Turn the crankshaft pulley so that the No. 1 piston is at top dead center. (See page EMA - 14).
2. Remove the cowl grill and wiper motor.(Refer to BE Gr.)

3. Remove the strut bar.
4. Disconnect the negative terminal from the battery.
5. Drain the engine coolant. (See page EMA - 70)

Remove the radiator cap to speed draining.
Page 25 of 142
7. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the AFS connector(A).
(2) Disconnect the breather hose(B) from air cleaner hose.
(3) Remove the intake air hose and air cleaner assembly(C).
8. Remove the coolant reservoir tank(A).
9. Remove the upper radiator hose(A) and lower radiator hose(B).
10. Remove the heater hoses(A) and throttle body heater hose(B).
11. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake
Page 26 of 142
manifold.
(1) TPS(Throttle Position Sensor) connector(A).
(2) ISA(Idle Speed Actuator) connector(B).
(3) PCSV(Purge Control Solenoid Valve) connector(C).
(4) VIS actuator connector(D).
(5) Injector connector(E).
(6) Knock sensor connectors(F).
(7) CMP(Camshaft Position Sensor) connector(G).
(8) Oxygen sensor(rear 1st) connector(H).
(9) PCSV(Purge Control Solenoid Valve) hose(I).
(10) ECT(Engine Coolant Temperature) sensor connector(A).

(11) Ignition coil connector(B).
(12) Crankshaft position sensor connector(C).
(13) Oxygen sensor(front 2nd) connector(D).
(14) Ground cable(E).
Page 27 of 142
(15) Three fuel injector connectors(A).
(16) Disconnect ground cable(A) from the cowl panel.
(17) IAT(Intake Air Temperature) sensor connector(A).

(18) VIS actuator connector(B).
(19) Oxygen sensor(rear 2nd) connector(C).
(20) Power steering pump switch(D).
(21) Oxygen sensor(front 1st) connetor(A).

(22) Air conditioner compressure switch connetor(B).
Page 28 of 142
(23) Oill pressure sensor connector(C).
12. Remove the fuel inlet hose(A) from delivery pipe.
13. Remove the brake booster vacuum hose(A).
14. Remove the accelerator cable by loosening the locknut, then slip the cable end out of the throttle linkage.
Page 29 of 142
15. Remove the PCV hose(A).
16. Remove the intake manifold. (See page EMA - 88)

17. Remove the power steering pump. (See ST group - power steering pump).
18. Remove the exhaust manifold. (See page EMA - 90)
19. Remove the timing belt. (See page EMA - 14)
20. Remove the spark plug cable. (See EE group - ignition)
21. Remove the cylinder head covers(A).
22. Remove the camshaft sprocket.

23. Remove the camshaft bearing caps(A).
Page 30 of 142
24. Remove the camshafts(A).
25. Remove the timing belt rear cover(A).
26. Remove the water temperature control assembly(A) and water pipe.
Page 31 of 142
27. Remove the cylinder head bolts, then remove the cylinder heads.
(1) Uniformly loosen and remove the 8 cylinder head bolts on each cylinder head in several passes and in the
sequence shown, then repeat for the other side, as shown. Remove the 16 cylinder head bolts and plate
washer.
Head warpage or cracking could result from removing bolts in an incorrect order.
(2) Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks
on a bench.
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
REPLACEMENT
VALVE GUIDE
1. Using the SST(09221-3F100A), withdraw the old valve guide toward the bottom of cylinder head.
2. Recondition the valve guide hole so that it can match the newly press-fitted oversize valve guide.
Page 32 of 142
3. Using the SST(09221-3F100A/B), press-fit the valve guide. The valve guide must be press-fitted from the upper
side of the cylinder head. Keep in mind that the intake and exhaust valve guides are different in length.
Over size mm(in.) Size mark Oversize valve guide hole size mm(in.)
11.05 ~ 11.068
0.05 (0.002) 5
(0.4350 ~ 0.4357)
11.25 ~ 11.268
0.25 (0.010) 25
(0.4429 ~ 0.4436)
11.50 ~ 11.518
0.50 (0.020) 50
(0.4528 ~ 0.4535)
Valve guide length

Intake : 39mm (1.535in.)
Exhaust : 43mm (1.693in.)
4. After the valve guide is press-fitted, insert a new valve and check for proper stem -to-guide clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as
necessary.
INSTALLATION
• Thoroughly clean all parts to be assembled.

• Always use a new head and manifold gasket.
• The cylinder head gasket is a metal gasket. Take care not to bend it.
• Rotate the crankshaft, set the No.1 piston at TDC. (See page EMA - 14).
Page 33 of 142
1. Install the cylinder head gaskets on the cylinder block.
Be careful of the installation direction.
2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
3. Install cylinder head bolts.
Tightening torque
25N.m (250kgf.cm, 18lb-ft) + 60° + 45°
(1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
(2) Install the plate washer to the cylinder head bolt.
(3) Install and uniformly tighten the cylinder head bolts on each cylinder head in servral passes and in the
sequence shown, then repeat for the other side, as shown.
If any of the cylinder head bolts dose not meet the torque specification, repeat the cylinder head bolt torque
tightening sequence.
Torque : 25N.m (250kgf.cm, 18lb-ft)

Page 34 of 142
(4) Retighten the cylinder head bolts by 60° in the numerical order shown.
(5) Retighten the cylinder head bolts by 45° in the numerical order shown.
4. Install the water pipe and water temperature control assembly(A).
Tightening torque
Water temperature control
15 ~ 20N.m (150 ~ 200kgf.cm, 11 ~ 14lb-ft)
5. Install the timing belt rear cover(A).
Tightening torque
Timing belt rear cover
10 ~ 12N.m (100 ~ 120kgf.cm, 7 ~ 9lb-ft)
Page 35 of 142
6. Install the camshafts.
(1) Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as
shown.
(2) Install the camshaft(A).
(3) Install the camshaft bearing caps(A).
Tightening torque
M6(38mm) :
10 ~ 12N.m (100 ~ 120kgf.cm, 7 ~ 9lb-ft)(Mark7)
M6(50mm) :
14 ~ 16N.m (140 ~ 160kgf.cm, 10 ~ 12lb-ft)(Mark10)
• Apply new engine oil to the thrust portion and journal of the camshafts.
• Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
Page 36 of 142
7. Using the SST (09214-21000), install the camshaft bearing oil seal.
8. Install the camshaft sprocket.

(1) Temporarily install the camshaft sprocket bolts.
(2) Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the camshaft sprocket
bolts.
Tightening torque
Camshaft sprocket bolt
90 ~ 110N.m (900 ~ 1100kgf.cm, 65 ~80lb-ft)
9. Install semi-circular packing.

10. Install the cylinder head cover.
(1) Install the cylinder head cover gasket(A) in the groove of the cylinder head cover(B).
• Before installing the head cover gasket, thoroughly clean the head cover gasket and the groove.
• When installing, make sure the head cover gasket is seated securely in the corners of the recesses
with no gap.
(2) Apply liquid gasket to the head cover gasket at the corners of the recess.
• Use liquid gasket, loctite No.5699.

• Check that the mating surfaces are clean and dry before applying liquid gasket.
• After assembly, wait at least 30 minutes before filling the engine with oil.
Page 37 of 142
(3) Install the cylinder head covers(A) with the 16bolts. Uniformly tighten the bolts in several passes.
Tightening torque
8 ~ 10N.m (80 ~ 100kgf.cm, 6 ~ 7.4lb-ft)
11. Install the spark plug cable. (See EE group - ignition)

12. Install the timing belt. (See page EMA - 17).
13. Install the exhaust manifold. (See page EMA - 92)
14. Install the power steering pump. (See ST group - power steering pump)
15. Install the intake manifold. (See page EMA- 91)
16. Install the PCV hose(A).
Page 38 of 142
17. Install the accelerator cable.
18. Install the brake booster vacuum hose(A).
19. Install the fuel inlet hose(A).
20. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
(1) Oil pressure sensor connector(C).
(2) Air conditioner compressure switch connector(B).
(3) Oxygen sensor (front 1st) connector(A).

Page 39 of 142
(5) Oxygen sensor (rear 2nd) connector(C).
(7) IAT(Intake Air Temperature) sensor connector(A).
(8) Connect the ground cable(A) to the cowl panel.

(11) Oxygen sensor connector(D).
Page 40 of 142
(14) ECT sensor connector(A).

(16) Oxygen sensor (rear 1st) connector(H).
(17) CMP(Camshaft position sensor) connector(G).
(18) Knock sensor connector(F).
(22) ISA connector(B).
(23) TPS connector(A).
21. Install the heater hoses(A) and throttle body heater hose(B).
Page 41 of 142
22. Install the upper radiator hose(A) and lower radiator hose(B).
23. Install the coolant reservoir tank(A).
24. Install the intake air hose and air cleaner assembly.
(1) Install the intake air hose and air cleaner assembly(C).
(2) Connect the breather hose(B) from air cleaner hose.
(3) Connect the AFS connector(A).
25. Install the engine cover.

26. Connect the negative terminal to the battery.
Page 42 of 142
27. Install the strut bar.
28. Install the cowl grill and wiper motor.(Refer to BE Gr.)
29. Install the air duct(A).
30. Filll with engine coolant.

31. Start the engine and check for leaks.
32. Recheck engine coolant level and oil level.
DISASSEMBLY
Identify HLA(Hydraulic Lash Adjuster), valves, valve springs as they are removed so that each item can be
reinstalled in its original position.
1. Remove HLAs(A).
2. Remove valves.
(1) Using SST(09222-28000, 09222-28100), compress the valve spring and remove retainer lock.
(2) Remove the spring retainer.

(3) Remove the valve spring.
(4) Remove the valve.
Page 43 of 142
(5) Using needle-nose pliers, remove the oil seal.
(6) Using a magnetic finger, remove the spring seat.
INSPECTION
CLENING
1. Clean top surfaces of pistons and cylinder block.
(1) Turn the crankshaft, and bring each piston to top dead center(TDC).
Using a gasket scraper, remove all the carbon from the piston top surface.
(2) Using a gasket scraper, remove all the gasket material from the cylinder block surface.
(3) Using compressed air, blow carbon and oil from the bolt holes.
2. Remove gasket material.
Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.
Be careful not to scratch the cylinder block contact surface.

3. Clean combustion cambers.
Using a wire brush, remove all the carbon from the combustion cambers.
Be careful not to scratch the cylinder block contact surface.
4. Clean cylinder heads.

Using a soft brush and solvent. throrghly clean the cylinder head.
5. Clean valves.
(1) Using a gasket scraper, chip off any carbon from the valve head.
(2) Using a wire brush throroghly clean the valve.
CYLINDER HEAD
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block for
warpage.
Flatness of cylinder head gasket surface

Standard : Less than 0.03mm(0.0012 in.)
Limit : 0.05mm ( 0.0020 in.)
Page 44 of 142
2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.
VALVE AND VALVE SPRING
1. Inspect valve stems and valve guides.
(1) Using a caliper gauge, measure the inside diameter or the valve guide.
Valve guide inside.
(2) Using a micrometer, measure the diameter of the valve stem.
(3) Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
[Standard]
Intake : 0.02 ~ 0.05mm (0.0008 ~ 0.0020in.)
Exhaust : 0.030 ~ 0.065mm (0.0012 ~ 0.0026in.)
[Limit]
Intake : 0.1mm (0.0040in.)
Exhaust : 0.13mm (0.0051in.)
If the clearance is greater than maximum, replace the valve and valve guide.
Page 45 of 142
2. Inspect valves.
(1) Check the valve is ground to the correct valve face angle.
(2) Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.
(3) Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
[Standard]
Intake : 1.0mm (0.0394in.)
Exhaust : 1.3mm (0.0512in.)
[Limit]
Intake : 0.5mm (0.0197in.)
Exhaust : 0.8mm (0.0315in.)
(4) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect valve seats
Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then
recondition the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width
should be within specifications and centered on the valve face.
Page 46 of 142
4. Inspect valve springs.
(1) Using a steel square, measure the out-of-square of the valve spring.
(2) Using a vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height : 42.5mm (1.6732in.)
Load : 21kg/35mm (48.4kg/1.378mm)
[Limit]
Free height : -1.0mm ( -0.0394 in.)
Out-of-square : 3°
If the free length is not as specified, replace the valve spring.

CAMSHAFT
1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 43.95 ~44.15mm (1.7303 ~ 1.7382in.)
Exhaust : 43.95 ~ 44.15mm (1.7303 ~ 1.7382in.)
If the cam lobe height is less than minimum, replace the camshaft.
Page 47 of 142
2. Inspect cam journals.
Using a micrometer, measure the journal diameter.
Journal diameter
Standard value
25.964 ~ 25.980mm (1.0222 ~ 1.0228in.)
If the journal diameter is not as specified, check the oil clearance.

3. Inspect camshaft bearings.
Check that bearing for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder
head as a set.
4. Inspect camshaft journal oil clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journal.
(4) Install the bearing caps. (See page EMA - 36)
Do not turn the camshaft.
(5) Remove the bearing caps.

(6) Measure the plastigage at its widest point.
Bearing oil clearance

Standard value : 0.02 ~ 0.061mm (0.0008 ~ 0.0024in.)
Limit : 0.1mm (0.0039in.)
If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and
Page 48 of 142
cylinder head as a set.
(7) Completely remove the plastigage.
(8) Remove the camshafts.
5. Inspect camshaft end play.
(1) Install the camshafts. (See page EMA - 36).
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play

Standard value : 0.1 ~ 0.15mm (0.004 ~ 0.0059in.)
If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and
cylinder head as a set.
(3) Remove the camshafts.
REASSEMBLY
Thoroughly clean all parts to be assembled.

Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.
1. Install valves.
(1) Install the spring seats.
Page 49 of 142
(2) Using SST(09222-22001), push in a new oil seal.
Do not reuse old valve stem seals.

Incorrect installation of the seal could result in oil leakage past the valve guides.
(3) Install the valve, valve spring and spring retainer.
Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then
installs the retainer.
(4) Using the SST(09222-28000, 09222-28100), compress the spring and install the retainer locks. After
installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring
compressor.
(5) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure
proper seating of the valve and retainer lock.
Page 50 of 142
2. Install HLAs.
Check that the HLA rotates smoothly by hand.
Engine Mechanical System > Engine And Transaxle Assembly > Repair procedures
REMOVAL
• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
• Mark all wiring and hoses to avoid misconnection.

• Inspection the timing belt before removing the cylinder head.
• Turn the crankshaft pulley so that the No. 1 piston is at top dead center. (See page EMA - 14)
2. Disconnect the neagative terminal from the battery.

Page 51 of 142
3. Drain the engine coolant.
Remove the radiator cap to speed draining.

5. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the AFS connector(A).
(2) Disconnect the breather hose(B) from air cleaner hose.
(3) Remove the intake air hose and air cleaner assembly(C).
6. Remove the upper radiator hose(A) and lower radiator hose(B).

Page 52 of 142
7. Remove the heater hoses(A).
8. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake
manifold.
(1) TPS(Throttle Position Sensor) connector(A).
(2) ISA(Idle Speed Actuator) connector(B).
(6) Knock sensor connector(F).
(7) CMP(Camshaft Position Sensor) connector(G).
(8) Oxgen sensor (rear 1st) connector(H).
(10) ECT(Engine Coolant Temperature) sensor(A) connector.

(13) Rear oxygen sensor(front 2nd) connector(D).
Page 53 of 142
(16) Disconnect ground cable(A) from the cowl panel.
(17) Intake air temperature sensor connector(A).

(19) Oxygen sensor(rear 2nd) connector(C).
Page 54 of 142
9. Disconnect front heated oxygen sensor(LH) connector(A), air compressure switch connector(B) and oil pressure
sensor connector(C).
10. Remove the fuel inlet from delivery pipe(A).
11. Remove the brake booster vacuum hose(A).
12. Remove the accelerator cable by loosening the locknut, then slip the cable end out of the throttle linkage.
Page 55 of 142
13. Remove the power steering pump hose(A).
14. Remove the battery body bracket.

Page 56 of 142
15. Disconnect the transaxle wire harness connector.
A. Disconnect the inhibitor switch connector(A).
B. Disconnect the transaxle range connector(B).
C. Disconnect the input shaft speed connector(C).
D. Disconnect the output shaft speed connector(A).

E. Disconnect the vehicle speed sensor connector(B).
16. Remove the control cable(A) transaxle range switch.
17. Remove the transaxle oil cooler hoses(A/T)(A).

Page 57 of 142
18. Remove the under cover(A).
19. Remove the front exhaust pipe(A).
20. Disconnect the ABS wheel speed sensor(A) from both front knuckles. (See DS group - front axle).
21. Remove the front strut lower mounting bolts and nuts. (See SS group - front strut).
Page 58 of 142
22. Remove the caliper and hang the caliper assembly(A).
23. Remove the steering u-joint mounting bolt(A). (See ST group - steering)
24. Install the jack for supporting engine and transaxle assembly.
25. Remove the engine mounting bracket(A).
26. Remove the transaxle mounting bracket(A).

Page 59 of 142
27. Remove the sub frame mounting bolts and nuts.
Tightening torque
A : 160 ~ 180N.m (1600 ~ 1800kgf.cm, 118 ~ 133lb-ft)
B : 70 ~ 90N.m (700 ~ 900kgf.cm, 52 ~ 66lb-ft)
28. Jack up the vehicle.
INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
• Adjust the shift cable.
• Adjust the throttle cable.
• Refill the engine with engine oil.
• Refill the transaxle with fluid.
• Refill the radiator with engine coolant.
• Bleed air from the cooling system with the heater valve open.
Page 60 of 142
• Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent
corrosion.
• Inspect for fuel leakage.
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for
approximately two seconds and fuel line pressureizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
Engine Mechanical System > Cylinder Block > Components and Components Location
COMPONENT
Page 61 of 142
Page 62 of 142
Engine Mechanical System > Cylinder Block > Repair procedures

DISASSEMBLY
1. A/T : remove drive plate.
2. Install engine to engine stand for disassembly(A).
3. Remove timing belt. (See page EMA - 14).
4. Remove cylinder head. (See page EMA - 23)
5. Remove oil level gauge assembly.
Page 63 of 142
6. Remove the alternator. (See EE group - alternator).
7. Remove the air compressor. (See HA group - air compressor)
8. Remove the power steering pump bracket(A).
9. Remove water pump. (See page EMA - 72)

10. Remove knock sensors(A).
11. Remove the lower oil pan(A).
12. Remove oil screen.

Remove the 2bolts(B), oil screen(A) and gasket.
Page 64 of 142
13. Remove the upper oil pan(A).
14. Check the connecting rod end play. (See page EMA - 53)
15. Remove the connecting rod caps and check oil clearance. (See page EMA - 53)
16. Remove piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
• Keep the bearings, connecting rod and cap together.

• Arrange the piston and connecting rod assemblies in the correct order.
17. Remove front case. (See page EMA - 80)

18. Remove oil seal case.
Remove the 3bolts(B) and oil seal case(A).
19. Check the crankshaft end play. (See page EMA - 57)
20. Remove crankshaft bearing cap and check oil clearance. (See page EMA - 55)
Page 65 of 142
21. Lift the crankshaft(A) out of the engine, being careful not to damage journals.
Arrange the main bearings and trust washers in the correct order.
22. Check fit between piston and piston pin.

Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a
set.
23. Remove piston rings.
(1) Using a piston ring expender, remove the 2 compression rings.
(2) Remove the 2side rails and oil ring by hand.
Arrange the piston rings in the correct order only.
24. Disconnect connecting rod from piston.

DISASSEMBLY
1. A/T : remove drive plate.
2. Install engine to engine stand for disassembly(A).
3. Remove timing belt. (See page EM - 13).
4. Remove cylinder head. (See page EM - 23)
5. Remove oil level gauge assembly.
6. Remove the alternator. (See EE group - alternator).
7. Remove the air compressor. (See HA group - air compressor)
8. Remove the power steering pump bracket(A).
9. Remove water pump. (See page EM - 79)

Page 66 of 142
10. Remove knock sensors(A).
11. Remove the lower oil pan(A).
12. Remove oil screen.

Remove the 2bolts(B), oil screen(A) and gasket.
13. Remove the upper oil pan(A).
14. Check the connecting rod end play. (See page EM - 59)
15. Remove the connecting rod caps and check oil clearance. (See page EM - 59)
Page 67 of 142
16. Remove piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
• Keep the bearings, connecting rod and cap together.

• Arrange the piston and connecting rod assemblies in the correct order.
17. Remove front case. (See page EM - 85)

18. Remove oil seal case.
Remove the 3bolts(B) and oil seal case(A).
19. Check the crankshaft end play. (See page EM - 63)

20. Remove crankshaft bearing cap and check oil clearance. (See page EM - 61)
21. Lift the crankshaft(A) out of the engine, being careful not to damage journals.
Arrange the main bearings and trust washers in the correct order.
Page 68 of 142
22. Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a
set.
23. Remove piston rings.
(1) Using a piston ring expender, remove the 2 compression rings.
(2) Remove the 2side rails and oil ring by hand.
Arrange the piston rings in the correct order only.
24. Disconnect connecting rod from piston.
INSPECTION
CONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod end play.
Using a dial indicator, measure the end play while moving the connecting rod back and forth.
Standard end play : 0.1~ 0.25mm(0.004 ~ 0.010in.)

Maximum end play : 0.4mm(0.016in.)
A. If out-of-tolerance, replace the connecting rod assembly.

B. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting road bearing oil clearance.
(1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove the 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and bearing half.
(4) Clean the crank pin and bearing.
(5) Place plastigage across the crank pin.
(6) Reinstall the bearing half and cap, and torque the bolts.
Tightening torque
16 ~ 20N.m (160 ~ 200kgf.cm, 12 ~ 15lb-ft) + 90°
Do not turn the crankshaft.

Page 69 of 142
(7) Remove the 2bolts, connecting rod cap and bearing half.
Standard oil clearance

0.018 ~ 0.036mm(0.0007 ~ 0.0014in.)
(9) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new,
complete bearing with the same color mark (select the color as shown in the next column), and recheck the
clearance.
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed
above or below that one), and check clearance again.
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.
If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent or detergent.
Connecting rod mark location
Discrimination of connecting rod

Page 70 of 142
CLASS MARK INSIDE DIAMETER
51.000 ~ 51.006mm
0 A
(2.0079 ~ 2.0081in.)
51.006 ~ 51.012mm
1 B
(2.0081 ~ 2.0083in.)
51.012 ~ 51.018mm
2 C
(2.0083 ~ 2.0086in.)
Crankshaft pin mark location
Discrimination of crankshaft
CLSASS MARK OUTSIDE DIAMETER OF PIN
47.994 ~ 48.000mm
I A
(1.8895 ~ 1.8898in.)
47.988 ~ 47.994mm
II B
(1.8893 ~ 1.8895in.)
47.982 ~ 47.988mm
III C
(1.8890 ~ 1.8893in.)
Place of identification mark (Connecting rod bearing)
Discrimination of connecting rod bearing

Page 71 of 142
CLASS MARK THICKNESS OF BEARING
1.500 ~ 1.503mm
A BLUE
(0.0590 ~ 0.0591in.)
1.497 ~ 1.500mm
B BLACK
(0.0589 ~ 0.0590in.)
1.494 ~ 1.497mm
C NONE
(0.0588 ~ 0.0589in.)
1.491 ~ 1.494mm
D GREEN
(0.0587 ~ 0.0588in.)
1.488 ~ 1.491mm
E YELLOW
(0.0586 ~ 0.0587in.)
(11) Selection
CONNECTING ROD ASSEMBING
CRANKSHAFT
IDENTIFICATION CLASSIFICATION OF
INDENTIFICATION MARK
MARK BEARING
0 (A) E (YELLOW)
I (A) 1 (B) D (GREEN)
2 (C) C (NONE)
0 (A) D (GREEN)
II (B) 1 (B) C (NONE)
2 (C) B (BLACK)
0 (A) C (NONE)
III (C) 1 (B) B (BLACK)
2 (C) A (BLUE)
3. Check the crankshaft bearing oil clearance.

(1) To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.
(2) Clean each main journal and bearing half with a clean shop tower.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the bearings and caps, then torque the bolts.
Tightening torque
M8
13 ~ 19N.m (130 ~ 190kgf.cm, 10 ~ 14lb-ft) + 90°
M10
27 ~ 33N.m (270 ~ 330kgf.cm, 19.5 ~ 24lb-ft) + 90°

Page 72 of 142
(5) Remove the cap and bearing again, and measure the widest part of the plastigage.

0.004 ~ 0.022mm (0.00016 ~ 0.00087in.)
clearance.
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace
the crankshaft and start over.
Connecting rods
1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match.
When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the
same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough
surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair
limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.
Allowable bend of connecting rod

0.05mm / 100mm (0.0020 in./3.94 in.) or less
Allowable twist of connecting rod
0.1mm / 100mm (0.0039 in./3.94 in.) or less
Letters have been stamped on the end of the block as a mark for the size of each of the 4 main journal bores.
Page 73 of 142
Discrimination of cylinder block

CALSS MARK INSIDE DIAMETER
66.000 ~ 66.006mm
a A
(2.5984 ~ 2.5986in.)
66.006 ~ 66.012mm
b B
(2.5986 ~ 2.5989in.)
66.012 ~ 66.018mm
c C
(2.5989 ~ 2.5991in.)
Crankshaft journal mark location
CLASS MARK OUTSIDE DIAMETER OF JOURNAL
61.994 ~ 62.000mm
I A
(2.4407 ~ 2.4409in.)
61.988 ~ 61.994mm
II B
(2.4405 ~ 2.4407in.)
61.982 ~ 61.988mm
III C
(2.4402 ~ 2.4405in.)
Place of identification mark (Crankshaft bearing)

Page 74 of 142
Discrimination of crankshaft bearing

2.007 ~ 2.010mm
A BLUE
(0.0790 ~ 0.0791in.)
2.004 ~ 2.007mm
B BLACK
(0.0789 ~ 0.0790in.)
2.001 ~ 2.004mm
C NONE
(0.0788 ~ 0.0789in.)
1.998 ~ 2.001mm
D GREEN
(0.0787 ~ 0.788in.)
1.995 ~ 1.998mm
E YELLOW
(0.0785 ~ 0.0787in.)
Selection
ASSEMBLING
CRANKSHAFT IDENTIFICATION CRANKSHAFT BORE
CLASSIFICATION OF
MARK IDENTIFICATION MARK
BEARING
a (A) E (YELLOW)
I (A) b (B) D (GREEN)
c (C) C (NONE)
a (A) D (GREEN)
II (B) b (B) C (NONE)
c (C) B (BLACK)
a (A) C (NONE)
III (C) b (B) B (BLACK)
c (C) A (BLUE)
Page 75 of 142
4. Check crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard end play

0.07 ~ 0.25mm (0.0027 ~ 0.0098in.)
Limit : 0.30mm (0.0118in.)
If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness

2.05 ~ 2.09mm (0.081 ~ 0.082in.)
5. Inspect main journals and crank pins

Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter

61.982 ~ 62.000mm (2.4402 ~ 2.4409in.)
Crank pin diameter
47.982 ~ 48.000mm (1.8890 ~ 1.8898in.)
CYLINDER BLOCK
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
Page 76 of 142
3. Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for
warpage.
Flatness of cylinder block gasket surface

Limit : 0.05mm ( 0.0020 in.)
4. Inspect cylinder bore diameter

Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder liner.
Using a cylinder bore gauge, measure the cylinder bore diameter at position A, B and C in the thrust and axial
directions.
Standard diameter
86.70 ~ 86.73mm (3.4134 ~ 3.4145in.)
Page 77 of 142
6. Check the cylinder bore size code(A) on the cylinder block bottom face.
Size
Class Cylinder bore inner diameter
code
A 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) A
B 86.71 ~ 86.72mm (3.4137 ~ 3.4141in.) B
C 86.72 ~ 86.73mm (3.4141 ~ 3.4145in.) C
7. Check the piston size code(A) on the piston top face.
Stamp the grade mark of basic diameter with rubber

stamp.
Size
Class Piston diameter
code
A 86.68 ~ 86.69mm (3.4126 ~ 3.4130in.) A
B 86.69 ~ 86.70mm (3.4130 ~ 3.4133in.) None
C 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) C
8. Select the piston related to cylinder bore class.
Clearance : 0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)
Boring Cylinder
Page 78 of 142
1. Oversize pistons should be selected according to the largest bore cylinder.
Identification Mark Size
0.25 0.25mm (0.010in.)
0.50 0.50mm (0.0250in.)
The size of piston is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.
3. According to the measured O.D., calculate the new bore size.
New bore size = Piston O.D + 0.01 to 0.03mm

(0.0004 to 0.0012 in.) (clearance between piston and
cylinder) - 0.01 mm (0.0004 in.) (honing margin.)
4. Bore each of the cylinders to the calculated size.
To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the
firing order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard : 0.01 ~ 0.03mm (0.0004 ~ 0.0012 in.)
When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to
the oversize.
PISTON AND RINGS
1. Clean piston
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.
Do not use a wire brush.

Page 79 of 142
2. The standard measurement of the piston outside diameter is taken 38.5mm (1.516in.) from the top land of the
piston.
Standard diameter
86.68 ~ 86.71mm (3.4126 ~ 3.4138in.)
3. Calculate the difference between the cylinder bore diameter and the piston diameter.
Piston-to-cylinder clearance
0.01 ~ 0.03mm(0.0004 ~ 0.0012in.)
4. Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
Piston ring side clearance

No. 1 : 0.04 ~ 0.08mm (0.0016 ~ 0.0031 in.)
No. 2 : 0.03 ~ 0.07mm (0.0012 ~ 0.0028 in.)
Limit
No. 1 : 0.1mm (0.004in.)
No. 2 : 0.1mm (0.004in.)
If the clearance is greater than maximum, replace the piston.

Page 80 of 142
5. Inspect piston ring end gap.
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. If the gap is too large, recheck the cylinder bore diameter against the
wear limits on page EMA - 58, If the bore is over the service limit, the cylinder block must be rebored. (See
page EMA - 58).
Piston ring end gap

Standard
No.1 : 0.20 ~ 0.35mm (0.0079 ~ 0.0138in.)
No.2 : 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.)
Limit
Oil ring : 0.2 ~ 0.7mm (0.0079 ~ 0.0276in.)
PISTON PINS
1. Measure the diameter of the piston pin.
Piston pin diameter

21.001 ~ 21.007mm (0.8268 ~ 0.8270in.)
2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance

0.007 ~ 0.022mm (0.00027 ~ 0.00086in.)
Page 81 of 142
3. Check the difference between the piston pin diameter and the connecting rod small end diameter.
Piston pin-to-connecting rod interference

0.016 ~ 0.033mm (0.00063 ~ 0.00130in.)
OIL PRESSURE SWITCH

1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even
when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50kpa (7psi) vacuum is applied throgh the oil hole, the switch is operaing
properly.
Check for air leakage. If air leaks, the diahragm is broken. Replace it.
INSPECTION
CONNECTING ROD AND CRANKSHAFT
Page 82 of 142
1. Check the connecting rod end play.
Using a dial indicator, measure the end play while moving the connecting rod back and forth.
Standard end play : 0.1~ 0.25mm(0.004 ~ 0.010in.)

Maximum end play : 0.4mm(0.016in.)
A. If out-of-tolerance, replace the connecting rod assembly.

B. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting road bearing oil clearance.
(1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove the 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and bearing half.
(4) Clean the crank pin and bearing.
(5) Place plastigage across the crank pin.
(6) Reinstall the bearing half and cap, and torque the bolts.
Tightening torque
16 ~ 20N.m (160 ~ 200kgf.cm, 12 ~ 15lbf.ft) + 90°
(7) Remove the 2bolts, connecting rod cap and bearing half.
Page 83 of 142

0.018 ~ 0.036mm(0.0007 ~ 0.0014in.)
clearance.
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.
Connecting rod mark location
Discrimination of connecting rod

Page 84 of 142
CLASS MARK INSIDE DIAMETER
51.000 ~ 51.006mm
0 A
(2.0079 ~ 2.0081in.)
51.006 ~ 51.012mm
1 B
(2.0081 ~ 2.0083in.)
51.012 ~ 51.018mm
2 C
(2.0083 ~ 2.0086in.)
Crankshaft pin mark location
CLSASS MARK OUTSIDE DIAMETER OF PIN
47.994 ~ 48.000mm
I A
(1.8895 ~ 1.8898in.)
47.988 ~ 47.994mm
II B
(1.8893 ~ 1.8895in.)
47.982 ~ 47.988mm
III C
(1.8890 ~ 1.8893in.)
Place of identification mark (Connecting rod bearing)
Discrimination of connecting rod bearing

Page 85 of 142
1.500 ~ 1.503mm
A BLUE
(0.0590 ~ 0.0591in.)
1.497 ~ 1.500mm
B BLACK
(0.0589 ~ 0.0590in.)
1.494 ~ 1.497mm
C NONE
(0.0588 ~ 0.0589in.)
1.491 ~ 1.494mm
D GREEN
(0.0587 ~ 0.0588in.)
1.488 ~ 1.491mm
E YELLOW
(0.0586 ~ 0.0587in.)
(11) Selection
CONNECTING ROD ASSEMBING
CRANKSHAFT
IDENTIFICATION CLASSIFICATION OF
INDENTIFICATION MARK
MARK BEARING
0 (A) E (YELLOW)
I (A) 1 (B) D (GREEN)
2 (C) C (NONE)
0 (A) D (GREEN)
II (B) 1 (B) C (NONE)
2 (C) B (BLACK)
0 (A) C (NONE)
III (C) 1 (B) B (BLACK)
2 (C) A (BLUE)
3. Check the crankshaft bearing oil clearance.

(1) To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.
(2) Clean each main journal and bearing half with a clean shop tower.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the bearings and caps, then torque the bolts.
Tightening torque
M8
13 ~ 19N.m (130 ~ 190kgf.cm, 10 ~ 14lbf.ft) + 90°
M10
27 ~ 33N.m (270 ~ 330kgf.cm, 19.5 ~ 24lbf.ft) + 90°

Page 86 of 142
(5) Remove the cap and bearing again, and measure the widest part of the plastigage.

0.004 ~ 0.022mm (0.00016 ~ 0.00087in.)
clearance.
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace
the crankshaft and start over.
Connecting rods
1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match.
When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the
same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough
surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair
limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.
Allowable bend of connecting rod

0.05mm / 100mm (0.0020 in./3.94 in.) or less
Allowable twist of connecting rod
0.1mm / 100mm (0.0039 in./3.94 in.) or less
Letters have been stamped on the end of the block as a mark for the size of each of the 4 main journal bores.
Page 87 of 142
Discrimination of cylinder block

CALSS MARK INSIDE DIAMETER
66.000 ~ 66.006mm
a A
(2.5984 ~ 2.5986in.)
66.006 ~ 66.012mm
b B
(2.5986 ~ 2.5989in.)
66.012 ~ 66.018mm
c C
(2.5989 ~ 2.5991in.)
Crankshaft journal mark location
CLASS MARK OUTSIDE DIAMETER OF JOURNAL
61.994 ~ 62.000mm
I A
(2.4407 ~ 2.4409in.)
61.988 ~ 61.994mm
II B
(2.4405 ~ 2.4407in.)
61.982 ~ 61.988mm
III C
(2.4402 ~ 2.4405in.)
Place of identification mark (Crankshaft bearing)

Page 88 of 142
Discrimination of crankshaft bearing

2.007 ~ 2.010mm
A BLUE
(0.0790 ~ 0.0791in.)
2.004 ~ 2.007mm
B BLACK
(0.0789 ~ 0.0790in.)
2.001 ~ 2.004mm
C NONE
(0.0788 ~ 0.0789in.)
1.998 ~ 2.001mm
D GREEN
(0.0787 ~ 0.788in.)
1.995 ~ 1.998mm
E YELLOW
(0.0785 ~ 0.0787in.)
Selection
ASSEMBLING
CRANKSHAFT IDENTIFICATION CRANKSHAFT BORE
CLASSIFICATION OF
MARK IDENTIFICATION MARK
BEARING
a (A) E (YELLOW)
I (A) b (B) D (GREEN)
c (C) C (NONE)
a (A) D (GREEN)
II (B) b (B) C (NONE)
c (C) B (BLACK)
a (A) C (NONE)
III (C) b (B) B (BLACK)
c (C) A (BLUE)
Page 89 of 142
4. Check crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard end play

0.07 ~ 0.25mm (0.0027 ~ 0.0098in.)
Limit : 0.30mm (0.0118in.)
If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness

2.05 ~ 2.09mm (0.081 ~ 0.082in.)
5. Inspect main journals and crank pins

Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter

61.982 ~ 62.000mm (2.4402 ~ 2.4409in.)
Crank pin diameter
47.982 ~ 48.000mm (1.8890 ~ 1.8898in.)
CYLINDER BLOCK
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
Page 90 of 142
3. Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for
warpage.
Flatness of cylinder block gasket surface

Limit : 0.05 mm ( 0.0020 in.)

Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder liner.
Using a cylinder bore gauge, measure the cylinder bore diameter at position A, B and C in the thrust and axial
directions.
Standard diameter
86.70 ~ 86.73mm (3.4134 ~ 3.4145in.)
Page 91 of 142
6. Check the cylinder bore size code(A) on the cylinder block bottom face.
Size
Class Cylinder bore inner diameter
code
A 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) A
B 86.71 ~ 86.72mm (3.4137 ~ 3.4141in.) B
C 86.72 ~ 86.73mm (3.4141 ~ 3.4145in.) C
7. Check the piston size code(A) on the piston top face.
Stamp the grade mark of basic diameter with rubber

stamp.
Size
Class Piston diameter
code
A 86.68 ~ 86.69mm (3.4126 ~ 3.4130in.) A
B 86.69 ~ 86.70mm (3.4130 ~ 3.4133in.) None
C 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) C
8. Select the piston related to cylinder bore class.
Clearance : 0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)
Boring Cylinder
Page 92 of 142
1. Oversize pistons should be selected according to the largest bore cylinder.
Identification Mark Size
0.25 0.25mm (0.010in.)
0.50 0.50mm (0.0250in.)
The size of piston is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.
3. According to the measured O.D., calculate the new bore size.
New bore size = Piston O.D + 0.01 to 0.03mm

(0.0004 to 0.0012 in.) (clearance between piston and
cylinder) - 0.01 mm (0.0004 in.) (honing margin.)
4. Bore each of the cylinders to the calculated size.
To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the
firing order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard : 0.01 ~ 0.03mm (0.0004 ~ 0.0012 in.)
When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to
the oversize.
PISTON AND RINGS
1. Clean piston
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.
Do not use a wire brush.

Page 93 of 142
2. The standard measurement of the piston outside diameter is taken 38.5mm (1.516in.) from the top land of the
piston.
Standard diameter
86.68 ~ 86.71mm (3.4126 ~ 3.4138in.)
3. Calculate the difference between the cylinder bore diameter and the piston diameter.
Piston-to-cylinder clearance
0.01 ~ 0.03mm(0.0004 ~ 0.0012in.)
4. Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
Piston ring side clearance

No. 1 : 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.)
No. 2 : 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in.)
Limit
No. 1 : 0.1mm (0.004in.)
No. 2 : 0.1mm (0.004in.)
If the clearance is greater than maximum, replace the piston.

Page 94 of 142
5. Inspect piston ring end gap.
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. If the gap is too large, recheck the cylinder bore diameter against the
wear limits on page EM - 65, If the bore is over the service limit, the cylinder block must be rebored. (See page
EM - 65).
Piston ring end gap

Standard
No.1 : 0.20 ~ 0.35mm (0.0079 ~ 0.0138in.)
No.2 : 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.)
Limit
Oil ring : 0.2 ~ 0.7mm (0.0079 ~ 0.0276in.)
PISTON PINS
1. Measure the diameter of the piston pin.
Piston pin diameter

21.001 ~ 21.007mm (0.8268 ~ 0.8270in.)
2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance

0.007 ~ 0.022mm (0.00027 ~ 0.00086in.)
Page 95 of 142
3. Check the difference between the piston pin diameter and the connecting rod small end diameter.
Piston pin-to-connecting rod interference

0.016 ~ 0.033mm (0.00063 ~ 0.00130in.)
OIP PRESSURE SWITCH

1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even
when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50kpa (7psi) is applied throgh the oil hole, the switch is operaing properly.
Check for air leakage. If air leaks, the diahragm is broken. Replace it.
REASSEMBLY
• Thoroughly clean all parts to assembled.

• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with new parts.
Page 96 of 142
1. Assemble piston and connecting rod.
(1) Use a hydraulic press for installation.
(2) The piston front mark(A) and the connecting rod front mark(B) must face the timing belt side of the engine.
2. Install piston rings.

(1) Install the oil ring expander and 2 side rails by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.
3. Install connecting rod bearings.

(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings in the connecting rod and connecting rod cap.
Page 97 of 142
4. Install main bearings.
Upper 1, 2, 3, 4 bearings have an oil groove of oil holes; Lower bearings do not.
(1) Align the bearing claw with the claw groove of the cylinder block, push in the 4upper bearings(A).
(2) Align the bearing claw with the claw groove of the main bearing cap(A), and push in the 4lower bearings(B).
5. Install thrust bearings.

Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil grooves facing
outward.
Page 98 of 142
6. Place crankshaft(A) on the cylinder block.
7. Place main bearing caps on cylinder block.

8. Install main bearing cap bolts.
• The main bearing cap bolts are tightened in 2 progressive steps.

• If any of the bearing cap bolts in broken or deformed, replace it.
Tightening torque
Main bearing cap bolt
M8 : 13 ~ 19N.m
(130 ~ 190kgf.cm, 10 ~ 14lb-ft) + 90° ~ 94°
M10 : 27 ~ 33N.m
(270 ~ 330kgf.cm, 19.5 ~ 24lb-ft) + 90° ~ 94°
(1) Apply a light coat of engine oil on the threads and under the bearing cap bolts.
(2) Install and uniformly tighten the 16bearing cap bolts, in several passes, in the sequence shown.
Tightening torque
M8(A) : 13 ~ 19N.m (130 ~ 190kgf.cm, 10 ~ 14lb-ft)
M10(B) : 27 ~ 33N.m (270 ~ 330kgf.cm, 19.5 ~ 24lb-ft)
Page 99 of 142
(3) Retighten the bearing cap bolts by 90° ~ 94° in the numerical order shown.
(4) Check that the crankshaft turns smoothly.

9. Check crankshaft end play. (See page EMA - 57)
10. Install piston and connecting rod assemblies.
Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
(1) Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the
connecting rod bolts.
(2) Install the ring compressor, check that the bearing is securely in place, then position the piston in the
cylinder, and tap it in using the wooden handle of a hammer.
(3) Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before
pushing the piston into place.
(4) Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
Tightening torque
16 ~ 20N.m (160 ~ 200kgf.cm, 12 ~ 15lb-ft) + 90° ~ 94°
Maintain downward force on the ring compressor to prevent the rings from expanding before entering
the cylinder bore.
Page 100 of 142
11. Apply liquid gasket to the oil seal case and install the oil seal case(A).
Tightening torque
10 ~ 12N.m (100 ~ 120kgf.cm, 7.3 ~ 8.8lb-ft)
• Use liquid gasket MS721-40A or equivalent

• Check that the mating surfaces are clean and dry.
12. Install rear oil seal.

(1) Apply engine oil to a new oil seal lip.
(2) Using SST(09231-33000) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal
retainer edge.
13. Install front case. (See page EMA - 83)

Page 101 of 142
14. Install the upper oil pan.
(1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces.
Check that the mating surfaces are clean and dry before applying liqued gasket.
(2) Install the oil pan(A) with the 17bolts.

Uniformly tighten the bolts in several passes.
Tightening torque
19 ~ 28N.m (190 ~ 280kgf.cm, 14 ~ 20lb-ft) : (1 ~ 15)
5 ~ 7N.m (50 ~ 70kgf.cm, 4 ~ 5lb-ft) : (16,17)
• To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
• Do not install the parts if five minutes or more have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the residue.
Page 102 of 142
15. Install oil screen.
Install a new gasket and oil screen(A) with 2bolts(B).
Tightening torque
15 ~ 22N.m (150 ~ 220kgf.cm, 11 ~ 16lb-ft)
16. Install the lower oil pan.

(1) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Use liquid gasket MS 721-40A or equivalent.
(2) Install the lower oil pan 10bolts.

Uniformly tighten the bolts serveral passes
Tightening torque
10 ~12N.m (100 ~ 120kgf.cm, 7.3 ~ 8.8lb-ft)
Page 103 of 142
17. Install oil pressure sensor.
(1) Apply adhesive to 2 or 3 threads.
Adhesive : THREE BOND TB2403 or equivalent.
(2) Install the oil pressure sensor(A).
Tightening torque
15 ~ 22N.m (150 ~ 220kgf.cm, 11 ~ 16lb-ft)
18. Install knock sensor(A).
Tightening torque
17 ~ 26N.m (170 ~ 260kgf.cm, 12.5 ~ 19lb-ft)
19. Install water pump. (See page EMA - 75)

Page 104 of 142
20. Install the power steering pump bracket(A).
Tightening torque
35 ~ 55N.m (350 ~ 550kgf.cm, 25.8 ~ 40.6lb-ft)
21. Install the air compressor. (See HA group - air compressor)

22. Install the alternator. (See EE group - alternator)
23. Install oil level gauge assembly.
(1) Install a new O-ring on the oil level gauge.
(2) Apply engine oil on the O-ring.
(3) Install the oil level gauge assembly (A) with the bolt.
Tightening torque
12 ~ 15N.m (120 ~ 150kgf.cm, 9 ~ 11lb-ft)
24. Install cylinder head. (See page EMA - 35)

25. Install timing belt. (See page EMA - 17)
26. Remove engine stand.
27. Install drive plate.
Tightening torque
73 ~ 77N.m (730 ~ 770kgf.cm, 53 ~ 56lb-ft)
REASSEMBLY
• Thoroughly clean all parts to assembled.

• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with new parts.
Page 105 of 142
1. Assemble piston and connecting rod.
(1) Use a hydraulic press for installation.
(2) The piston front mark(A) and the connecting rod front mark(B) must face the timing belt side of the engine.
2. Install piston rings.

(1) Install the oil ring expander and 2 side rails by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.
3. Install connecting rod bearings.

(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings in the connecting rod and connecting rod cap.
Page 106 of 142
4. Install main bearings.
Upper 1, 2, 3, 4 bearings have an oil groove of oil holes; Lower bearings do not.
(1) Align the bearing claw with the claw groove of the cylinder block, push in the 4upper bearings(A).
(2) Align the bearing claw with the claw groove of the main bearing cap(A), and push in the 4lower bearings(B).
5. Install thrust bearings.

Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil grooves facing
outward.
Page 107 of 142
6. Place crankshaft(A) on the cylinder block.
7. Place main bearing caps on cylinder block.

8. Install main bearing cap bolts.
• The main bearing cap bolts are tightened in 2 progressive steps.

• If any of the bearing cap bolts in broken or deformed, replace it.
Tightening torque
Main bearing cap bolt
M8
13 ~ 19N.m (130 ~ 190kgf.cm, 10 ~ 14lbf.ft) + 90° ~ 94°
M10
27 ~ 33N.m (270 ~ 330kgf.cm, 19.5 ~ 24lbf.ft) + 90° ~ 94°
(1) Apply a light coat of engine oil on the threads and under the bearing cap bolts.
(2) Install and uniformly tighten the 16bearing cap bolts, in several passes, in the sequence shown.
Tightening torque
M8(A) : 13 ~ 19N.m (130 ~ 190kgf.cm, 10 ~ 14lbf.ft)
M10(B) : 27 ~ 33N.m (270 ~ 330kgf.cm, 19.5 ~ 24lbf.ft)
Page 108 of 142
(3) Retighten the bearing cap bolts by 90° ~ 94° in the numerical order shown.
(4) Check that the crankshaft turns smoothly.

9. Check crankshaft end play. (See page EM - 63)
10. Install piston and connecting rod assemblies.
Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
(1) Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the
connecting rod bolts.
(2) Install the ring compressor, check that the bearing is securely in place, then position the piston in the
cylinder, and tap it in using the wooden handle of a hammer.
(3) Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before
pushing the piston into place.
(4) Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
Tightening torque
16 ~ 20N.m (160 ~ 200kgf.cm, 12 ~ 15lbf.ft) + 90° ~ 94°
Maintain downward force on the ring compressor to prevent the rings from expanding before entering
the cylinder bore.
Page 109 of 142
11. Apply liquid gasket to the oil seal case and install the oil seal case(A).
Tightening torque
10 ~ 12N.m (100 ~ 120kgf.cm, 7.3 ~ 8.8lbf.ft)
• Use liquid gasket MS721-40A or equivalent

• Check that the mating surfaces are clean and dry.
12. Install rear oil seal.

(1) Apply engine oil to a new oil seal lip.
(2) Using SST(09231-33000) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal
retainer edge.
13. Install front case. (See page EM - 88)

Page 110 of 142
14. Install the upper oil pan.
(1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces.
Check that the mating surfaces are clean and dry before applying liqued gasket.
(2) Install the oil pan(A) with the 17bolts.

Tightening torque
19 ~ 28N.m (190 ~ 280kgf.cm, 14 ~ 20lbf.ft) : (1 ~ 15)
5 ~ 7N.m (50 ~ 70kgf.cm, 4 ~ 5lbf.ft) : (16,17)
Page 111 of 142
15. Install oil screen.
Install a new gasket and oil screen(A) with 2bolts(B).
Tightening torque
15 ~ 22N.m (150 ~ 220kgf.cm, 11 ~ 16lbf.ft)
16. Install the lower oil pan.

(1) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Use liquid gasket MS 721-40A or equivalent.
(2) Install the lower oil pan 10bolts.

Uniformly tighten the bolts serveral passes
Tightening torque
10 ~12N.m (100 ~ 120kgf.cm, 7.3 ~ 8.8lbf.ft)
Page 112 of 142
17. Install oil pressure sensor.
(1) Apply adhesive to 2 or 3 threads.
Adhesive : THREE BOND TB2403 or equivalent.
(2) Install the oil pressure sensor(A).
Tightening torque
15 ~ 22N.m (150 ~ 220kgf.cm, 11 ~ 16lbf.ft)
18. Install knock sensor(A).
Tightening torque
17 ~ 26N.m (170 ~ 260kgf.cm, 12.5 ~ 19lbf.ft)
19. Install water pump. (See page EM - 80)

Page 113 of 142
20. Install the power steering pump bracket(A).
Tightening torque
35 ~ 55N.m (350 ~ 550kgf.cm, 25.8 ~ 40.6lbf.ft)
21. Install the air compressor. (See HA group - air compressor)

23. Install oil level gauge assembly.
(1) Install a new O-ring on the oil level gauge.
(2) Apply engine oil on the O-ring.
(3) Install the oil level gauge assembly (A) with the bolt.
Tightening torque
12 ~ 15N.m (120 ~ 150kgf.cm, 9 ~ 11lbf.ft)
24. Install cylinder head. (See page EM - 36)

25. Install timing belt. (See page EM - 17)
26. Remove engine stand.
27. Install drive plate.
Tightening torque
73 ~ 77N.m (730 ~ 770kgf.cm, 53 ~ 56lbf.ft)
Engine Mechanical System > Cooling System > Description and Operation
Engine Coolant Refilling and Bleeding
Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high
pressure escaping from the radiator.
When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or
the paint. If any coolant spills, rinse it off immediately.
1. Slide the heater temperature control lever to maximum heat. Make sure the engine and radiator are cool to the
touch.
2. Remove radiator cap.
Page 114 of 142
3. Loosen the drain plug, and drain the coolant.
4. Tighten the radiator drain plug(A) securely.

5. Remove, drain and reinstall the reservoir. Fill the tank halfway to the MAX mark with water, then up to the MAX
mark with antifreeze.
6. Fill fluid mixture with coolant and water(4 : 6) slowly through the radiator cap. Push the upper/lower hoses of the
radiator so as bleed air easily.
• Use only genuine antifreeze/coolant.

• For best corrosion protection, the coolant concentration must be maintained year-round at 50%
minimum. Coolant concentrations less than 50% may not provide sufficient protection against corrosion
or freezing.
• Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended.
• Do not mix different brands of antifreeze/coolants.

• Do not use additional rust inhibitors or anti-rust products; they may not be compatible with the coolant.
7. Start the engine and allow the coolant circulates through the system.
When the cooling fan cycles ON, fill coolant through the radiator cap.
8. Repeat step 7 until the cooling fan cycles ON/OFF three to five times in order to allow air to sufficiently bleed out
of the system.
9. Install the radiator cap and fill the reservoir tank to the "MAX" line with coolant.
10. Run the vehicle under idle until the cooling fan operates 2 ~ 3 times.
11. Stop the engine and wait coolant gets cool.
12. Repeat 6 to 11 until the coolant level doesn't fall any more, bleed air out of the cooling system.
As it is to bleed air out to the cooling system and refill coolant when coolant gets cool completely,
recheck the coolant level in the reservoir tank for 2 ~ 3 days after replacing coolant.
Cap Testing
Page 115 of 142
1. Remove the radiator cap, wet its seal with engine coolant, then install it no pressure tester.
2. Apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm², 14 ~ 19psi)

3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.
Testing
1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then
install it on the pressure tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm² 14 ~ 19psi).
3. Inspect for engine coolant leaks and a drop in pressure.

4. Remove the tester and reinstall the radiator cap.
Check for engine oil in the coolant and/or coolant in the engine
oil.
Engine Mechanical System > Cooling System > Components and Components Location
COMPONENT
Page 116 of 142
Page 117 of 142
Engine Mechanical System > Cooling System > Repair procedures

REMOVAL
WATER PUMP
Page 118 of 142
1. Drain the engine coolant.
System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant,
remove the cap only when the engine is cool.
2. Remove drive belts. (See page EMA - 14)
4. Remove the timing belt idler. (See page EMA - 16)
5. Remove the water pump.
Remove the water pump(A) and gasket(B).
THERMOSTAT
Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove
the thermostat, even if the engine tends to overheat.
2. Drain engine coolant so its level is below thermostat.
3. Remove the lower hose.
4. Remove water inlet(A) and thermostat(B).
RADIATOR
Page 119 of 142
2. Drain the engine coolant. Remove the radiator cap to speed draining.

Page 120 of 142
4. Remove the battery and tray.
5. Remove the coolant reservoir tank(A).

6. Remove the radiator upper hose(B).
7. Remove the radiator lower hose(A).

8. Remove the ATF oil cooler hose(B).
9. Remove the cooling fan motor connector(A).

10. Remove the cooling fan motor assembly mounting bolt(B).
11. Remove the ATF oil cooler pipe(C).
12. Remove the cooling fan motor assembly with pulling it from the radiator.
Page 121 of 142
13. Remove the radiator bracket(A,B).
14. Remove the condenser mounting bolt(A).

15. Remove the condenser bracket(B) with pulling the condenser from the radiator.
16. Remove the radiator from engine room.
INSTALLATION
WATER PUMP
Page 122 of 142
1. Install the water pump(A) and a new gasket(B) with the 8bolts.
Tightening torque
15 ~ 22N.m (150 ~ 220kgf.cm, 11 ~ 16lb-ft)
Bolt Size Number

A 8 × 25 4
B 8 × 30 2
C 8 × 32 1
D 8 × 40 1
2. Install the timing belt idler. (See page EMA - 17)

3. Install the timing belt. (See page EMA - 17)
4. Install drive belt.
5. Fill with engine coolant. (See page EMA - 70)
6. Start engine and check for leaks.
7. Recheck engine coolant level.
THERMOSTAT
Page 123 of 142
1. Place thermostat in thermostat housing.
(1) Install the thermostat with the jiggle valve upward.
(2) Install a new to the thermostat(B).
2. Install water inlet(A).
Tightening torque
17 ~ 20N.m (170 ~ 200kgf.cm, 12.5 ~ 14lb-ft)
3. Install the lower hose.

4. Fill with engine coolant.
INSPECTION
WATER PUMP
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, and replace the coolant pump assembly if
necessary.
3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly
A small amount of "weeping" from the bleed hole is normal.

THERMOSTAT
1. Immerse the thermostat in water and gradually heat the water.
Page 124 of 142
2. Check the valve opening temperature.
Valve opening temperature : 82°C (177°F)

Full opening temperature : 95°C (205°F)
If the valve opening temperature is not as specified, replace the thermostat.

3. Check the valve lift.
Valve lift : 8mm(0.3in.) or more at 95°C (205°F)
If the valve lift is not as specified, replace the thermostat.
Engine Mechanical System > Lubrication System > Description and Operation
OIL AND FILTER
• Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to
dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which
may cause skin cancer.
• Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear
protective clothing and gloves. Wash your skin thoroughly with soap and water, or use water-less hand cleaner,
to remove any used engine oil. Do not use gasoline, thinners, or solvents.
• In order to preserve the environment, used oil and used oil filter must be disposed of only at designated
disposal sites.
1. Drain engine oil.
A. Remove the oil filter cap.
B. Remove the oil drain plug(A), and drain the oil into a container.
2. Replace oil filter.

A. Remove the oil filter(B).
B. Check and clean the oil filter installation surface.
C. Check the part number of the new oil filter is as same as old one.
D. Apply clean engine oil to the gasket of a new oil filter.
E. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
F. Tighten it an additional 3/4 turn.
Page 125 of 142
3. Refill with engine oil filter.
A. Clean and install the oil drain plug with a new gasket.
Tightening torque
35 ~ 45N.m (350 ~ 450kgf.cm, 26 ~ 33lb-ft)
B. Fill with fresh engine oil
Capacity
Drain and refill
W/Oil filter change : 4.5l (4.74U.S.qts, 3.95lmp qts)
W/O Oil filter change : 4.2l (4.30U.S.qts, 3.65lmp qts)
C. Install the oil filter cap.

4. Start engine and check for oil leaks.
5. Recheck engine oil level.
INSPECTION
1. Check engine oil quality
Check the oil for deterioration, entry of water, discoloring or thinning.
If the quality is visibly poor, replace the oil.
2. Check engine oil level.
After warming up the engine and then 5 minutes after the engine stop, oil level should be between the "L" and "F"
marks on the dipstick.
If low, check for leakage and add oil up to the "F" mark.
Do not fill with engine oil above the "F" mark.

SELECTION OF ENGINE OIL
Recommended SAE viscosity grades :
Page 126 of 142
For best performance and maximum protection of all types of operation, select only those lubricants which :
1. Satisfy the requirement of the API classification.
2. Have proper SAE grade number for expected ambient temperature range.
3. Lubricants that do not have both an SAE grade number and API service classification on the container should
not be used.
Engine Mechanical System > Lubrication System > Components and Components Location
COMPONENT
Page 127 of 142
Engine Mechanical System > Lubrication System > Repair procedures

REMOVAL
1. Drain engine oil.
2. Remove RH front wheel.
3. Remove RH side cover.
4. Remove the front exhaust pipe. (See page EMA - 46)
Page 128 of 142
5. Remove the alternator from engine. (See EE group - alternator)
6. Remove the drive belt. (See page EMA - 14)
7. Turn the crankshaft and align the white groove on the crankshaft pulley with the pointer on the lower cover. (See
page EMA - 14)
9. Remove the oil pan and oil screen.(see page EMA - 51)
10. Remove the oil pump case(A).
(1) Remove the screws(B) from the pump housing, then separate the housing and cover(A).
(2) Remove the inner and outer rotors.
INSTALLATION
1. Install oil pump.
(1) Place the inner and outer rotors into front case with the marks facing the oil pump cover side.
(2) Install the oil pump cover(A) to front case with the 8screws(B).
Tightening torque
8 ~ 12N.m (80 ~ 120kgf.cm, 6 ~ 8.8lb-ft)
Page 129 of 142
2. Check that the oil pump turns freely.
3. Install the oil pump on the cylinder block.
(1) Remove any old liquid gasket and be careful not to drop any oil on the contact surfaces of the oil pump and
cylinder block.
A. Using a razor blade and gasket scraper, remove all the old liquid gasket from the gasket surfaces and
sealing grooves.
B. Using a non-residue solvent, clean both sealing surfaces.
(2) Apply liquid gasket to the oil pump as shown in the illustration.
Use liquid gasket MS 721-40A.
(3) Place a new O-ring on the cylinder block.

(4) Engage the spline teeth of the oil pump drive gear with large teeth of the crankshaft, and slide the oil pump on
the crankshaft.
(5) Install the oil pump with 5bolts.
Tightening torque
12 ~ 15N.m (120 ~ 150kgf.cm, 8.8 ~ 11lb-ft)
Page 130 of 142
Bolt Size Number
A 8 × 25 3
B 8 × 35 1
C 8 × 45 1
4. Apply a light coat of oil to the seal lip.

5. Using the special tool(09214-33000), install the oil seal.
6. Install the oil pan and oil screen. (See page EMA - 65)
7. Install the timing belt. (See page EMA - 17)
8. Install the drive belt
10. Install the front exhaust pipe. (See page EMA - 92)
11. Install the RH front wheel.
12. Fill engine with oil.
14. Recheck engine oil level.
DISASSEMBLY
1. Remove the relief plunger.
Remove the plug(A), spring(B) and relief plunger(C).
INSPECTION
1. Inspect relief plunger.
Coat the valve with engine oil and check that it falls smoothly into the plunger hole by its own weight.
If it does not, replace the relief plunger. If necessary, replace the front case.
Page 131 of 142
2. Inspect relief valve spring.
Inspect for distorted or broken relief valve spring.
Standard value
Free height : 43.8mm (91.724in.)
Load : 4.6kg/39.1mm (10lb/1.547in.)
3. Inspect rotor side clearance.

Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight
edge.
Side clearance
0.04 ~ 0.095mm (0.0016 ~ 0.0037in.)
If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.
4. If the tip clearance is greater than maximum, replace the rotor as a set.
5. Inspect rotor body clearance.
Using a feeler gauge, measure the clearance between the outer rotor and body.
Body clearance
0.100 ~ 0.181mm (0.0039 ~ 0.0017in.)
If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.
REASSEMBLY
Page 132 of 142
1. Install relief plunger.
Install relief plunger(C) and spring(B) into the front case hole, and install the plug(A).
Tightening torque
40 ~ 50N.m (400 ~ 500kgf.cm, 30 ~ 37lb-ft)
Engine Mechanical System > Intake And Exhaust System > Components and Components Location
COMPONENT
INTAKE MANIFOLD
Page 133 of 142
EXHAUST MANIFOLD
Page 134 of 142
MUFFLER
Page 135 of 142
Engine Mechanical System > Intake And Exhaust System > Repair procedures
REMOVAL
INTAKE MANIFOLD
2. Remove air cleaner hose.
3. Remove surge tank assembly.
Page 136 of 142
(1) Disconnect the accelerator cable.
(2) Disconnect the TPS connector(A).

(3) Disconnect the ISA connector(B).
(4) Disconnect the VIS actuator connector(C).
(5) Disconnect the injector connector(D).
(6) Disconnect the PCSV connector(E).
(7) Disconnect the PCSV hose.

(8) Disconnect the brake booster vacuum hose(A).
(9) Disconnect the PCV hose.

(10) Disconnect the IAT sensor connector(A).
Page 137 of 142
(11) Disconnect the VIS actuator connector(B).
(12) Disconnect the ground cable(A) from the surge tank assembly.
(13) Remove the surge tank stay.

Page 138 of 142
(14) Remove the surge tank assembly(A).
4. Remove the injector assembly(A).
5. Remove the intake manifold(A) and gasket.
EXHAUST MANIFOLD
Page 139 of 142
2. Remove the front exhaust pipe(A).
3. Disconnect the oxygen sensor connector.

4. Remove the cooling fan motor assembly. (Refer to EMA - 73)
5. Remove the Air conditioner compressor. (Refer to HA Gr.)
6. Remove the LH heat protector(A).
7. Remove the LH exhaust manifold(A) and gasket(B).
8. Remove the alternator. (Refer to EE Gr.)

9. Remove the RH drive shaft. (Refer to DS Gr.)
10. Remove the RH heat protector.
11. Remove the RH exhaust manifold and gasket.
INSTALLATION
INTAKE MANIFOLD
Page 140 of 142
1. Install the intake manifold and gasket.
Tightening torque
19 ~ 21N.m (190 ~ 210kgf.cm, 14 ~ 15lb-ft)
2. Install the injector assembly. (See FL group - injector)

3. Install the surge tank assembly(A).
(1) Install the surge tank assembly.
Tightening torque
15 ~ 20N.m (150 ~ 200kgf.cm, 11 ~ 15lb-ft)
(2) Install the surge tank stay.
Tightening torque
15 ~ 20N.m (150 ~ 200kgf.cm, 11 ~ 15lb-ft)
(3) Install the ground cable.

(4) Connect the VIS actuator connector.
(5) Connect the IAT sensor connector.
(6) Connect the PCV hose.
(7) Connect the brake booster vacuum hose.
(8) Connect the PCSV hose.
(9) Connect the PCSV connector.
(10) Connect the injector connector.
(11) Connector the VIS actuator connector.
Page 141 of 142
(12) Connector the ISA connector.
(13) Connector the TPS connector.
(14) Connector the actuator cable.
4. Install the air cleaner hose.
5. Install the engine cover.
EXHAUST MANIFOLD
1. Install the RH exhaust manifold and gasket.
Tightening torque :
30 ~ 35 N.m (300 ~ 350kgf.cm, 22 ~ 26lb-ft)
2. Install the RH heat protector.
Tightening torque :
17 ~ 22 N.m (170 ~ 220kgf.cm, 12 ~ 16lb-ft)
3. Install the RH drive shaft. (Refer to DS Gr.)

4. Install the alternator. (Refer to EE Gr.)
5. Install the exhaust manifold(A) and gasket(B).
Tightening torque
30 ~ 35N.m (300 ~ 350kgf.cm, 22 ~ 26lb-ft)
6. Install the LH heat protector(A).
Tightening torque
12 ~ 15N.m (120 ~ 150kgf.cm, 9 ~ 11lb-ft)
Page 142 of 142
7. Install the Air conditioner compressor. (Refer to HA Gr.)
8. Install the cooling fan motor assembly. (Refer to EMA - 73)
9. Connect the oxygen sensor connector.
10. Install the front exhaust pipe(A).
Tightening torque
30 ~ 40N.m (300 ~ 400kgf.cm, 22 ~ 30lb-ft)
11. Install the under cover(A).

Page 1 of 491
SPORTAGE(KM) > 2008 > G 2.7 DOHC > Fuel System
Fuel System > General Information > Special Service Tools

SPECIAL SERVICE TOOLS
Tool
Illustration Application
(Number and name)
09353-24100 Measuring the fuel line pressure
Fuel Pressure Gauge
09353-38000 Connection between the delivery pipe and

Fuel Pressure Gauge fuel feed line
Adapter
09353-24000 Connection between Fuel Pressure Gauge

Fuel Pressure Gauge (09353-24100) and Fuel Pressure Gauge
Connector Adapter (09353-38000)
Fuel System > General Information > Troubleshooting

BASIC TROUBLESHOOTING
BASIC TROUBLESHOOTING GUIDE
Page 2 of 491
CUSTOMER PROBLEM ANALYSIS SHEET

1. VEHICLE INFORMATION
(I) VIN:
(II) Production Date:
(III) Odometer Reading: (miles)
Page 3 of 491
2. SYMPTOMS
□ Engine does not turn over □ Incomplete combustion
□ Unable to start
□ Initial combustion does not occur
□ Difficult to start □ Engine turns over slowly □ Other_________________
□ Rough idling □ Incorrect idling
□ Poor idling □ Unstable idling (High: ______ rpm, Low: ______rpm)
□ Other __________________________________
□ Soon after starting □ After accelerator pedal depressed
□ After accelerator pedal released □ During A/C ON
□ Engine stall □ Shifting from N to D-range
□ Other
_______________________________________________
□ Poor driving (Surge) □ Knocking □ Poor fuel economy
□ Others □ Back fire □ After fire □ Other
____________________________
3. ENVIRONMENT
□ Constant □ Sometimes (_________________) □ Once only
Problem frequency □ Other
___________________________________________
□ Fine □ Cloudy □ Rainy □ Snowy □ Other
Weather
__________________
Outdoor temperature Approx. _____ °C/°F
□ Highway □ Suburbs □ Inner City □ Uphill □ Downhill
Place □ Rough road □ Other
___________________________________
Engine temperature □ Cold □ Warming up □ After warming up □ Any temperature
□ Starting □ Just after starting (____ min) □ Idling □ Racing
□ Driving □ Constant speed □ Acceleration □ Deceleration
Engine operation
□ A/C switch ON/OFF □ Other
_____________________________
4. MIL/DTC
MIL (Malfunction Indicator
□ Remains ON □ Sometimes lights up □ Does not light
Lamp)
Normal check □ Normal □ DTC (_______________________________________)
(Pre-check) □ Freeze Frame Data
DTC
□ Normal □ DTC (_______________________________________)
Check mode
□ Freeze Frame Data
BASIC INSPECTION PROCEDURE

The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be
measured at ambient temperature (20°C, 68°F), unless there is any notice.
Page 4 of 491
The measured resistance in except for ambient temperature (20°C, 68°F) is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again
during testing. An example would be if a problem appears only when the vehicle is cold but has not appeared when
warm. In this case, technician should thoroughly make out a "CUSTOMER PROBLEM ANALYSIS SHEET" and
recreate (simulate) the environment and condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent, broken or corroded
pins, and then verify that the connectors are always securely fastened.
3. Slightly shake the connector and wiring harness vertically and horizontally.
4. Repair or replace the component that has a problem.
5. Verify that the problem has disappeared with the road test.
● SIMULATING VIBRATION
1) Sensors and Actuators
: Slightly vibrate sensors, actuators or relays with finger.
Strong vibration may break sensors, actuators or relays
2) Connectors and Harness

: Lightly shake the connector and wiring harness vertically and then horizontally.
● SIMULATING HEAT
1) Heat components suspected of causing the malfunction with a hair dryer or other heat sourre.
• DO NOT heat components to the point where they may be damaged.

• DO NOT heat the ECM directly.
● SIMULATING WATER SPRINKLING

Page 5 of 491
1) Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
DO NOT sprinkle water directly into the engine compartment or electronic components.
● SIMULATING ELECTRICAL LOAD

1) Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
CONNECTOR INSPECTION PROCEDURE
1. Handling of Connector
A. Never pull on the wiring harness when disconnecting connectors.
B. When removing the connector with a lock, press or pull locking lever.
C. Listen for a click when locking connectors. This sound indicates that they are securely locked.
Page 6 of 491
D. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire
harness side.
E. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed
from harness side.
• Use a fine wire to prevent damage to the terminal.

• Do not damage the terminal when inserting the tester lead.
2. Checking Point for Connector

A. While the connector is connected:
Hold the connector, check connecting condition and locking efficiency.
B. When the connector is disconnected:
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
C. Check terminal tightening condition:
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
D. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
Page 7 of 491
3. Repair Method of Connector Terminal
A. Clean the contact points using air gun and/or shop rag.
Never use sand paper when polishing the contact points, otherwise the contact point may be
damaged.
B. In case of abnormal contact pressure, replace the female terminal.

WIRE HARNESS INSPECTION PROCEDURE
1. Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly.
2. Check whether the wire harness is twisted, pulled or loosened.
3. Check whether the temperature of the wire harness is abnormally high.
4. Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part.
5. Check the connection between the wire harness and any installed part.
6. If the covering of wire harness is damaged; secure, repair or replace the harness.
ELECTRICAL CIRCUIT INSPECTION PROCEDURE
1. Procedures for Open Circuit
A. Continuity Check
B. Voltage Check
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method)
or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
When measuring for resistance, lightly shake the wire harness above and below or from side to side.
Specification (Resistance)
1Ω or less → Normal Circuit
1MΩ or Higher → Open Circuit
Page 8 of 491
A. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as shown in [FIG.
2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1MΩ and below 1 Ω respectively.
Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point, check sub line of line 1 as
described in next step.
B. Disconnect connector (B), and measure for resistance between connector (C) and (B1) and between (B2)
and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1MΩ and the open circuit
is between terminal 1 of connector (C) and terminal 1 of connector (B1).
3. Voltage Check Method

A. With each connector still connected, measure the voltage between the chassis ground and terminal 1 of each
connectors (A), (B) and (C) as shown in [FIG. 4].
The measured voltage of each connector is 5V, 5V and 0V respectively. So the open circuit is between
connector (C) and (B).
Page 9 of 491
4. Test Method for Short to Ground Circuit
A. Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing below Step 2
(Continuity Check Method with Chassis Ground) as shown below.
5. Continuity Check Method (with Chassis Ground)
Lightly shake the wire harness above and below, or from side to side when measuring the resistance.
Specification (Resistance)
1Ω or less → Short to Ground Circuit
1MΩ or Higher → Normal Circuit
A. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis Ground as
shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ω and higher than 1MΩ respectively.
Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken point, check the sub
line of line 1 as described in the folowing step.
Page 10 of 491
B. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and
between (B1) and chassis ground as shown in [FIG. 7].
The measured resistance between connector (B1) and chassis ground is 1Ω or less. The short to ground
circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
SYMPTOM TROUBLESHOOTING GUIDE CHART

MAIN SYMPTOM DIAGNOSTIC PROCEDURE ALSO CHECK FOR
Unable to start 1. Test the battery
(Engine does not turn 2. Test the starter
over) 3. Inhibitor switch (A/T) or clutch start switch (M/T)
1. Test the battery • DTC
Unable to start 2. Check the fuel pressure • Low compression
(Incomplete 3. Check the ignition circuit • Intake air leaks
combustion) 4. Troubleshooting the immobilizer system (In case of • Slipped or broken timing belt
immobilizer lamp ON) • Contaminated fuel
• DTC
1. Test the battery
• Low compression
2. Check the fuel pressure
Difficult to start • Intake air leaks
3. Check the ECT sensor and circuit (Check DTC)
• Contaminated fuel
4. Check the ignition circuit
• Weak ignition spark
2. Check the Injector • DTC
Poor idling 3. Check the long term fuel trim and short term fuel trim • Low compression
(Rough, unstable or (Refer to CUSTOMER DATASTREAM) • Intake air leaks
incorrect Idle) 4. Check the ISCA and ISCA circuit (Check DTC) • Contaminated fuel
5. Inspect and test the Throttle Body • Weak ignition spark
6. Check the ECT sensor and circuit (Check DTC)
1. Test the Battery
• DTC
• Intake air leaks
Engine stall 3. Check the ISCA and ISCA circuit (Check DTC)
• Contaminated fuel
4. Check the ignition circuit
• Weak ignition spark
5. Check the CKPS Circuit (Check DTC)
2. Inspect and test Throttle Body • DTC
3. Check the ignition circuit • Low compression
Poor driving
Page 11 of 491
Poor driving
4. Check the ECT Sensor and Circuit (Check DTC) • Intake air leaks
(Surge)
5. Test the exhaust system for a possible restriction • Contaminated fuel
6. Check the long term fuel trim and short term fuel trim • Weak ignition spark
(Refer to CUSTOMER DATASTREAM)
2. Inspect the engine coolant • DTC
Knocking
3. Inspect the radiator and the electric cooling fan • Contaminated fuel
4. Check the spark plugs
1. Check customer's driving habits
• Is A/C on full time or the defroster mode on?
• Are tires at correct pressure? • DTC
• Is excessively heavy load being carried? • Low compression
Poor fuel economy • Is acceleration too much, too often? • Intake air leaks
2. Check the fuel pressure • Contaminated fuel
3. Check the injector • Weak ignition spark
4. Test the exhaust system for a possible restriction
5. Check the ECT sensor and circuit
1. Test the canister close valve
2. Inspect the fuel filler hose/pipe
• Malfunctioning gas station
Hard to refueling • Pinched, kinked or blocked?
filling nozzle (If this problem
(Overflow during • Filler hose is torn
occurs at a specific gas
refueling) 3. Inspect the fuel tank vapor vent hose between the station during refueling)
EVAP. canister and air filter
4. Check the EVAP. canister
Fuel System > General Information > Specifications

SPECIFICATIONS
FUEL DELIVERY SYSTEM
Items Specification
Fuel Tank Capacity 65 L
Fuel Retrun System Type Returnless
Fuel Filter Type High pressure type (built in Fuel Pump Assembly)
Type Built in fuel pump assembly
Fuel Pressure Regulator Regulated Fuel
343 kpa (3.5 kg/cm², 49.8 psi)
Pressure
Fuel Pump Type Electrical, in-tank type
ENGINE MANAGEMENT SYSTEM

SENSORS Mass Air Flow Sensor (MAFS) Type Hot film type
Output Voltage Idle: about 0.5V
3000 rpm: about 1.0V
Page 12 of 491
Intake Air Temperature Sensor (IATS) Type Thermistor type
Resistance -40°C(-40°F) 45.3 kΩ
-10°C(14°F) 9.2 kΩ
20°C(68°F) 2.5 kΩ
80°C(176°F) 0.33 kΩ
130°C(256°F) 0.09 kΩ
Engine Coolant Temperature Sensor Type Thermistor type
(ECTS)
Resistance -40°C(-40°F) 48.14 kΩ
14.13 ~ 16.83
-20°C(-4°F)
kΩ
0°C(32°F) 5.79 kΩ
2.31 ~ 2.59
20°C(68°F)
kΩ
40°C(104°F) 1.15 kΩ
60°C(140°F) 0.59 kΩ
80°C(176°F) 0.32 kΩ
Throttle Position Sensor (TPS) Type Variable Resistor Type
Resistance 1.6 ~ 2.4 kΩ
Output Voltage C.T 0.25 ~ 0.8V
W.O.T 4.25 ~ 4.7V
SENSORS Heated Oxygen Sensor (HO2S) Zirconia Sensor (including
Type
Heater)
Output Voltage 0 ~ 1V
Heater
3.0 ~ 4.0Ω at 23±5°C
Resistance
Knock Sensor Type Piezo-electric type
Capacitance 0.8 ~1.6 nF
Camshaft Position Sensor (CMPS) Type Hall Effect Sensor
Output Voltage 0 ~ 5.0V
Crankshaft Position Sensor (CKPS) Type Hall Effect Sensor
Output Voltage 0 ~ 5.0V
Fuel Tank Pressure Sensor (FTPS) Type Piezo - Resistavity Type
Output Voltage Approx. 2.5 V at idle
Fuel Level Sensor (FLS) Type Variable Resistor Type
ACTUATORS Injector Type Electromagnetic Type
Number 6
Coil Resistance 13.8 ~ 15.2 Ω at 20°C
Page 13 of 491
Purge Control Solenoid Valve (PCSV) Type Duty Control Type
Canister Close Valve (CCV) Type ON/OFF Control Type
Coil Resistance 23.0 ~ 26.0 Ω at 20°C (68°F)
Idle Speed Control Actuator (ISCA) Type Double Coil Type
Coil Resistance 17.0 ~ 18.2 Ω
CLOSE
(at 20°C)
14.9 ~ 16.1 Ω
OPEN
(at 20°C)
ACTUATORS Intake Manifold Tuning Valve #1
(Surge Tank Side)
Intake Manifold Tuning Valve #2
(Intake Manifold Side)
Ignition Coil Type Mold Coil type
Primary Coil 0.74±10% Ω
Secondary Coil 13.3±15% kΩ
TIGHTENING TORQUES
ENGINE CONTROL SYSTEM
Items N·m kgf·m lbf·ft
ECM bracket installation bolt/nut 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Mass air flow sensor clamp installation 2.9 ~ 4.9 0.3 ~ 0.5 2.2 ~ 3.6
Crankshaft position sensor installation
3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
bolt
Crankshaft position sensor connector
19.6 ~ 21.6 2.0 ~ 2.2 14.5 ~ 15.9
bracket installation bolt
Crankshaft position sensor wheel
4.9 ~ 5.9 0.5 ~ 0.6 3.6 ~ 4.3
installation screw
Knock sensor installation bolt 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
Knock sensor connector bracket
3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
installation bolt
Engine coolant temperature sensor
19.6 ~ 39.2 2.0 ~ 4.0 14.5 ~ 28.9
installation
Heated Oxygen Sensor (Bank 1,
39.2 ~ 49.1 4.0 ~ 5.0 28.9 ~ 36.2
Sensor 1)
39.2 ~ 49.1 4.0 ~ 5.0 28.9 ~ 36.2
Sensor 2)
39.2 ~ 49.1 4.0 ~ 5.0 28.9 ~ 36.2
Sensor 1)
Page 14 of 491
39.2 ~ 49.1 4.0 ~ 5.0 28.9 ~ 36.2
Sensor 2)
Camshaft position sensor connector
3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
bracket installation bolt
Oil pressure switch installation 14.7 ~ 21.6 1.5 ~ 2.2 10.9 ~ 15.9
Intake air temperature sensor
19.6 ~ 29.4 2.0 ~ 3.0 14.5 ~ 21.7
installation
Throttle position sensor installation
1.0 ~ 2.5 0.15 ~ 0.25 0.7 ~ 1.8
screws
Idle speed control actuator installation
5.9 ~ 7.8 0.6 ~ 0.8 4.3 ~ 5.8
bolts
FUEL DELIVERY SYSTEM

Items N·m kgf·m lbf·ft
Delivery pipe installation
9.8 ~ 14.7 1.0 ~ 1.5 7.2 ~ 10.9
bolts
Throttle body installation
14.7 ~ 19.6 1.5 ~ 2.0 10.9 ~ 14.5
bolt/nut
Accelerator pedal
7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
installation bolt
Fuel tank mounting nut 39.2 ~ 54.0 4.0 ~ 5.5 28.9 ~ 39.8
SEALANTS
Engine Coolant Temperature Sensor (ECTS)
LOCTITE 962T or equivalent
assemby
SERVICE STANDARD
Basic Idle rpm (After A/C OFF 700±100 rpm
warm up) A/C ON 750±100 rpm
Ignition Timing(After
BTDC 12°±5°
warm up, at idle)
Fuel System > Engine Control System > Description and Operation
OBD-II REVIEW
1. OVERVIEW
The California Air Resources Board (CARB) began regulation of On Board Diagnostics (OBD) for vehicles sold in
california beginning with the 1988 model year. The first phase, OBD-I, required monitoring of the fuel metering
system, Exhust Gas Recirculation (EGR) system and additional emission related components. The Malfunction
Indicator Lamp (MIL) was required to light and alert the driver of the fault and the need for repair of the emission
control system. Associated with the MIL was a fault code or Diagnostic Trouble Code (DTC) idenfying the specific
area of the fault.
Page 15 of 491
The OBD system was proposed by CARB to improve air quality by identifying vehicle exceeding emission
standards. Passage of the Federal Clean Air Act Amendments in 1990 has also prompted the Environmental
Protection Agency (EPA) to develop On Board Diagnostic requirements. CARB OBD-II regulations will be
followed until 1999 when the federal regulations will be used.
The OBD-II system meets government regulations by monitoring the emission control system. When a system or
component exceeds emission threshold or a component operates outside tolerance, a DTC will be stored and the
MIL illuminated.
The diagnostic executive is computer program in the Engine Control Module (ECM) that coordinates the OBD-II
self-monitoring system. This program controls all the monitors and interactions, DTC and MIL operation, freeeze
frame data and scan tool interface.
Freeze frame data describes stored engine conditions, such as state of the engine, state of fuel control, spark, RPM,
load and warm status at the point the first fault is detected. Previously stored conditions will be replace only if a fuel
or misfire fault is detected. This data is accessible with the scan tool to assist in repairing the vehicle.
The center of the OBD-II system is a microprocessor called the Engine Control Module (ECM).
The ECM receives input from sensors and other electronic components (switches, relays, and others) based on
information received and programmed into its memory (keep alive random acess memory, and others), the ECM
generates output signals to control various relays, solenoids and actuators.
2. CONFIGURATION OF HARDWARE AND RELATED TERMS
Page 16 of 491
The Malfunction Indicator Lamp (MIL) is connected between ECM-terminal Malfunction Indicator Lamp and
battery supply (open collector amplifier).
In most of car, the MIL will be installed in the instrument panel. The lamp amplifier can not be damaged by a short
circuit.
Lamps with a power dissipation much greater than total dissipation of the MIL and lamp in the tester may cause a
fault indication.
At ignition ON and engine revolution (RPM) < MIN. RPM, the MIL is switched ON for an optical check by the
driver.
When the ECM detects a malfunction related emission during the first driving cycle, the DTC and engine data are
stored in the freeze frame memory. The MIL is illuminated only when the ECM detects the same malfunction related
the DTC in two consecutive driving cycles.
● Misfire and Fuel System Malfunctions:
For misfire or fuel system malfunctions, the MIL may be eliminated if the same fault does not reoccur during
monitoring in three subsequent sequential driving cycles in which conditions are similar to those under which the
malfunction was first detected.
● All Other Malfunctions:
For all other faults, the MIL may be extinguished after three subsequent sequential driving cycles during which the
monitoring system responsible for illuminating the MIL functions without detecting the malfunction and if no other
malfunction has been identified that would independently illuminate the MIL according to the requirements outlined
above.
The diagnostic system may erase a fault code if the same fault is not re-registered in at least 40 engine warm-up
cycles, and the MIL is not illuminated for that fault code.
• Bidirectional line
• K-Line is defined as the line which provides information in a serial digital form from ECM to the diagnostic tester.
K-Line is used bidirectionally, in which case it may carry commands or data from the diagnostic tester to the
ECM. K-Line is also used to initialize the serial communication.
A driving cycle consists of engine start up, and engine shut off.
A warm-up cycle means sufficient vehicle operation such that the engine coolant temperature has risen by at least 40
degrees Fahrenheit from engine starting and reaches a minimum has risen by at least 40 degrees Fahrenheit from
engine starting and reaches a minimum temperature of at least 160 degrees Fahrenheit.
A trip means vehicle operation (following an engine-off period) of duration and driving mode such that all
components and systems are monitored at least once by the diagnostic system except catalyst efficiency or
Page 17 of 491
evaporative system monitoring when a steady-speed check is used, subject to the limitation that the manufacturer-
defined trip monitoring conditions shall all be encountered at least once during the first engine start portion of the
applicable FTP cycle.
• Diagnostic Trouble Code (SAE J2012)
• DTCs used in OBD-II vehicles will begin with a letter and are followed by four numbers.
The letter of the beginning of the DTC identifies the function of the monitored device that has failed. A "P" indicates a
powertrain device, "C" indicates a chassis device. "B" is for body device and "U" indicates a network or data link
code. The first number indicates if the code generic (common to all manufacturers) or if it is manufacturer specific. A
"0" & "2" indicates generic, "1" indicates manufacturer-specific. The second number indicates the system that is
affected with a number between 1 and 7.
The following is a list showing what numbers are assign to each system.
1) Fuel and air metering
2) Fuel and air metering(injector circuit malfunction only)
3) Ignition system or misfire
4) Auxiliary emission controls
5) Vehicle speed controls and idle control system
6) Computer output circuits
7) Transmission
The last two numbers of the DTC indicates the component or section of the system where the fault is located.
When a freeze frame event is triggered by an emission related DTC, the ECM stores various vehicle information as it
existed the moment the fault ocurred. The DTC number along with the engine data can be useful in aiding a
technician in locating the cause of the fault. Once the data from the 1st driving cycle DTC ocurrence is stored in the
freeze frame memory, it will remain there even when the fault ocurrs again (2nd driving cycle) and the MIL is
illuminated.
• Freeze Frame List
1) Calculated Load Value
2) Engine RPM
3) Fuel Trim
4) Fuel Pressure (if available)
5) Vehicle Speed (if available)
6) Coolant Temperature
7) Intake Manifold Pressure (if available)
8) Closed-or Open-loop operation
9) Fault code
3. OBD-II SYSTEM READINESS TESTS
The catalyst efficiency monitor is a self-test strategy within the ECM that uses the downstream Heated Oxygen
Sensor (HO2S) to determine when a catalyst has fallen below the minimum level of effectiveness in its ability to
control exhaust emission.
Misfire is defined as the lack of proper combustion in the cylinder due to the absence of spark, poor fuel metering,
or poor compression. Any combustion that does not occur within the cylinder at the proper time is also a misfire.
The misfire detection monitor detects fuel, ignition or mechanically induced misfires. The intent is to protect the
catalyst from permanent damage and to alert the customer of an emission failure or an inspection maintenance failure
by illuminating the MIL . When a misfire is detected, special software called freeze frame data enabled. The freeze
frame data captures the operational state of the vehicle when a fault is detected from misfire detection monitor
strategy.
The fuel system monitor is a self-test strategy within the PCM that monitors the adaptive fuel table The fuel control
system uses the adaptive fuel table to compensate for normal variability of the fuel system components caused by
wear or aging. During normal vehicle operation, if the fuel system appears biased lean or rich, the adaptive value
table will shift the fuel delivery calculations to remove bias.
Page 18 of 491
The cooling system monitoring is a self-test strategy within the ECM that monitors ECTS (Engine Coolant
Temperature Sensor) and thermostat about circuit continuity, output range, rationality faults.
OBD-II regulations require monitoring of the upstream Heated O2 Sensor (H2OS) to detect if the deterioration of
the sensor has exceeded thresholds. An additional HO2S is located downstream of the Warm-Up Three Way
Catalytic Converter (WU-TWC) to determine the efficiency of the catalyst.
Although the downstream H2OS is similar to the type used for fuel control, it functions differently. The downstream
HO2S is monitored to determine if a voltage is generated. That voltage is compared to a calibrated acceptable
range.
The EVAP. monitoring is a self-test strategy within the ECM that tests the integrity of the EVAP. system. The
complete evaporative system detects a leak or leaks that cumulatively are greater than or equal to a leak caused by
a 0.040 inch and 0.020 inch diameter orifice.
The A/C system monitoring is a self-test strategy within the ECM that monitors malfunction of all A/C system
component at A/C ON.
The comprehensive components monitoring is a self-test strategy within the ECM that detects fault of any electronic
powertrain components or system that provides input to the ECM and is not exclusively an input to any other OBD-
II monitor.
Fuel System > Engine Control System > Components and Components Location
COMPONENTS LOCATION
Page 19 of 491
Page 20 of 491
1. Mass Air Flow Sensor (MAFS) 2. Intake Air Temperature Sensor (IATS)
4. Throttle Position Sensor (TPS)

8. Idle Speed Contorl Actuator (ISCA)
3. Engine Coolant Temperature Sensor (ECTS)
22. Intake Manifold Tuning Valve #1 (Surge Tank
Side)
5. Camshaft Position Sensor (CMPS) 6. Crankshaft Position Sensor (CKPS)

Page 21 of 491
7.Injector 10. Knock Sensor
11. Fuel Pump Relay 14. Purge Control Solenoid Valve (PCSV)
15. Main Relay
18. Heated Oxygen Sensor (Bank 1, Sensor

16. Ignition Coil
1)
Page 22 of 491
19. Heated Oxygen Sensor (Bank 1, Sensor 2) 20. Heated Oxygen Sensor (Bank 2, Sensor 1)
23. Intake Manifold Tuning Valve #2 (Intake Manifold

21. Heated Oxygen Sensor (Bank 2, Sensor 2)
Side)

Fuel System > Engine Control System > Engine Control Module (ECM) > Repair procedures
ECM PROBLEM INSPECTION PROCEDURE
1. TEST ECM GROUND CIRCUIT: Measure resistance between ECM and chassis ground using the backside of
ECM harness connector as ECM side check point. If the problem is found, repair it.
Specification (Resistance): 1Ω or less

Page 23 of 491
2. TEST ECM CONNECTOR: Disconnect the ECM connector and visually check the ground terminals on ECM
side and harness side for bent pins or poor contact contact pressure. If the problem is found, repair it.
3. If problem is not found in Step 1 and 2, the ECM could be faulty. If so, replace the ECM with a new one, and
then check the vehicle again. If the vehicle operates normally then the problem was likely with the ECM.
4. RE-TEST THE ORIGINAL ECM : Install the original ECM (may be broken) into a known-good vehicle and
check the vehicle. If the problem occurs again, replace the original ECM with a new one. If problem does not
occur, this is intermittent problem (Refer to INTERMITTENT PROBLEM PROCEDURE in BASIC
INSPECTION PROCEDURE).
VIN PROGRAMMING PROCEDURE
VIN (Vehicle Identification Number) is a number that has the vehicle's information (Maker, Vehicle Type, Vehicle
Line/Series, Body Type, Engine Type, Transmission Type, Model Year, Plant Location and so forth. For more
information, please refer to the group "GI" in this SERVICE MANUAL). When replacing an ECM, the VIN must
be programmed in the ECM. If there is no VIN in ECM memory, the fault code (DTC P0630) is set.
The programmed VIN cannot be changed. When writing the VIN, confirm the VIN carefully
1. Select "Vehicle" and "Engine" (For example, SEDONA 3.5L V6).
2. Select "VIN WRITING".

Page 24 of 491
3. Check the ECM status.
• VIRGIN: VIN is not programmed

• LEARNT: VIN has been already
programmed
Is the ECM status "VIRGIN"?
Go to next step 4.
END
4. Write the VIN with cursor, function and number keys.
Before pressing the "ENTER" key, confirm the VIN again because the programmed VIN cannot be
changed.
5. After verifying the written VIN, press the "ENTER" key.

Page 25 of 491
6. Turn the ignition switch OFF, and then turn ON.
7. Verify the programmed VIN in the ECM memory.
Fuel System > Engine Control System > Engine Control Module (ECM) > Specifications
ENGINE CONTROL MODULE (ECM)
1. ECM HARNESS CONNECTOR
2. ECM TERMINAL FUNCTION

CONNECTOR [C68-1]
Pin
Description Connected to Remark
No.
1 Ignition switch signal input Ignition Switch
2 Not connected
Data Link Connector
3 Diagnostic Data Line (k-Line)
(DLC)
4 ECM ground Chassis ground
5 Power stage ground Chassis ground
6 Power stage ground Chassis ground
7 Battery voltage supply Battery
Battery Voltage Supply after Main
8 Main Relay
Relay
Battery Voltage Supply after Main
9 Main Relay
Relay
CONNECTOR [C68-2]
Page 26 of 491
Pin No. Description Connected to Remark
Heated Oxygen Sensor Heater Heated Oxygen Sensor
1
(B1/S1) control (B1/S1)
2 Not connected
3 Not connected
4 Not connected
5 Not connected
6 Not connected
Heated Oxygen Sensor (B1/S2) Heated Oxygen Sensor
7
Heater control (B1/S2)
8 Not connected
9 Not connected
10 Not connected
11 Not connected
12 Not connected
13
Heated Oxygen Sensor (B1/S1) signal Heated Oxygen Sensor
14
input (B1/S1)
15
input (B2/S1)
16
input (B1/S2)
17 Fuel Consumption signal output Trip Computer
18
input (B2/S2)
19
20
ground (B1/S1)
21
ground (B2/S1)
22
ground (B1/S2)
23 Main Relay control output Main Relay
24
ground (B2/S2)
CONNECTOR [C68-3]
Page 27 of 491
1 Mass Air Flow Sensor signal input Mass Air Flow Sensor (MAFS)
2 Not connected
3 Not connected
4 Not connected
5 Not connected
6 Not connected
7 Not connected
Crankshaft Position Sensor
8 Crankshaft Position Sensor signal input
(CKPS)
9 Not connected
10 Throttle Position Sensor supply Throttle Position Sensor (TPS)
11 Not connected
12 Not connected
13 Not connected
14 Not connected
15 Not connected
16 Not connected
17 Mass Air Flow Sensor ground Mass Air Flow Sensor (MAFS)
18 Not connected
19 Throttle Position Sensor signal input Throttle Position Sensor (TPS)
20 Throttle Position Sensor ground Throttle Position Sensor (TPS)
Crankshaft Position Sensor
21 Crankshaft Position Sensor ground
(CKPS)
Intake Air Temperature Sensor
22 Intake Air Temperature Sensor signal input
(IATS)
Intake Air Temperature Sensor
23 Intake Air Temperature Sensor ground
(IATS)
Engine Coolant Temperature Sensor signal Engine Coolant Temperature
24
input Sensor (ECTS)
Engine Coolant Temperature
25 Engine Coolant Temperature Sensor ground
Sensor (ECTS)
26 Power Steering Load input Power Steering Switch
27 Not connected
28 Not connected
29 Knock Sensor #1 (Cyl. #1, 3, 5) signal input Knock Sensor (KS) #1
30 Knock Sensor #1 (Cyl. #1, 3, 5) ground Knock Sensor (KS) #1
Page 28 of 491
33 Injector (Cyl. 1) control output Injector (Cyl. 1)
39 Not connected
40 Not connected
41 Not connected
Purge Control Solenoid Valve
42 Purge Control Solenoid Valve PWM output
(PCSV)
43 Not connected
44 Not connected
Intake Manifold Tuning Valve #1 (Surge Intake Manifold Tuning Valve #1
45
Tank Side) control output (Surge Tank Side)
Idle Speed Control Actuator PWM output 2 Idle Speed Control Actuator
46
(OPEN) (ISCA)
Idle Speed Control Actuator PWM output 1 Idle Speed Control Actuator
47
(CLOSE) (ISCA)
48 Knock Sensor Shield Knock Sensor (KS)
49 Not connected
50 Not connected
51 Not connected
Intake Manifold Tuning Valve #2 (In-mani Intake Manifold Tuning Valve #2
52
Side) control output (In-mani Side)]
CONNECTOR [C68-4]
1 Not connected
2 Not connected
3 Not connected
Fuel Tank Pressure Sensor
4 Fuel Tank Pressure Sensor Supply
(FTPS)
5 Fuel Level Sensor Supply Input Fuel Level Sensor (FLS)
6 Not connected
Camshaft Position Sensor
7 Camshaft Position Sensor signal input
(CMPS)
Camshaft Position Sensor
8 Camshaft Position Sensor ground
(CMPS)
Page 29 of 491
9 Not connected
10 Fuel Pump Relay control output Fuel Pump Relay
11 Not connected
12 Not connected
13 Throttle Position PWM output Other control modules
14 Fuel Tank Pressure Sensor ground
(FTPS)
15 Fuel Level Sensor ground Fuel Level Sensor (FLS)
16 Not connected
17 Engine Speed signal output Tachometer
18 Cooling Fan Relay [Low] control output Cooling Fan Relay
19 Not connected
Malfunction Indicating Lamp
20 Malfunction Indicating Lamp (MIL) output
(MIL)
21 Not connected
22 Vehicle speed signal input ABS Control Module - With ABS
Air conditioner switch [Low/High] signal
23 Triple Switch
input
24 Air conditioner switch signal input Air Conditioner Switch
25 Air conditioner switch [Middle] signal input Triple Switch
26 Not connected
27 Not connected
28 Not connected
Air Conditioner Compressor Relay control Air Conditioner Compressor
29
output Relay
30 Canister Close Valve Control Output Canister Close Valve (CCV)
31 Not connected
32 Not connected
33 Not connected
34 Fuel Tank Pressure Sensor Signal Input
(FTPS)
35 Not connected
Other control modules (TCM,
36 CAN [HIGH]
ABS, etc.)
Other control modules (TCM,
37 CAN [LOW]
ABS, etc.)
38 Wheel Speed Sensor (WSS) ground Wheel Speed Sensor (WSS)
- Wthout ABS
39 Wheel Speed Sensor (WSS) signal input Wheel Speed Sensor (WSS)
CONNECTOR [C68-5]
Page 30 of 491
40 Cooling Fan Relay [High] control output Cooling Fan Relay
CONNECTOR [C68-5]
Ignition coil #3 (Cyl. #3,6) control
1 Ignition coil #3 (Cyl. #3,6)
output
output
output
4 Not connected
Ignition Coil and Chassis
5 Ignition Coil shield
ground
6 Not connected
7 Not connected
8 Not connected
9 Not connected
3. ECM TERMINAL INPUT/OUTPUT SIGNAL

CONNECTOR [C68-1]
Pin Description Type Vehicle State Level Test Result
IG OFF Max. 0.5 V 14.69V
1 Ignition switch signal input DC
IG ON Vbatt 0V
2 Not connected
Hi: Min. Vbatt×80% High: 10.687V
When
Lo: Max. Low: 0.125V
transmitting
Vbatt×20% Vbatt: 14V
3 Diagnostic Data Line (k-Line) Pulse
Hi: Min. Vbatt×70%
When receiving Lo: Max.
Vbatt×30%
4 ECM ground DC Idle Max. 50 mV -
5 Power stage ground DC Idle Max. 50 mV -
6 Power stage ground DC Idle Max. 50 mV -
7 Battery voltage supply DC Always Vbatt 14.625V
Battery Voltage Supply after Main IG OFF Max. 1.0 V 14.3V
8 DC
Relay IG ON Vbatt 0.0625V
Battery Voltage Supply after Main IG OFF Max. 1.0 V 14.3V

9 DC
Relay IG ON Vbatt 0.0625V
CONNECTOR [C68-2]
Page 31 of 491
High: Vbatt 14.687V
Heated Oxygen Sensor Heater
1 Pulse Engine Run Low: Max. 1.0V 0.25V
(B1/S1) control
Freguency: 10Hz
2 Not connected
3 Not connected
4 Not connected
5 Not connected
6 Not connected
High: Vbatt 14.5V
Heated Oxygen Sensor (B1/S2)
Heater control
Freguency: 10Hz
8 Not connected
9 Not connected
10 Not connected
11 Not connected
12 Not connected
High: Vbatt 14.562V
Heater control
Freguency: 10Hz
Heated Oxygen Sensor (B1/S1) Rich: 0.6 ~ 1.0V 0.83V

14 DC When racing
signal input Lean: 0 ~ 0.4V 0.37V
15 DC When racing
16 DC When racing
High: Vbatt or Vcc 13.812V
17 Fuel Consumption signal output Pulse Idle Low: Max. 0.5V 0V
Freguency: 4Hz
18 DC When racing
High: Vbatt 14.562V
Heater control
Freguency: 10Hz
20 DC Idle Max. 50mV 15.573mV
ground
Page 32 of 491
ground
ground
Relay ON Max. 1.0V 0.75V
23 Main Relay control output DC
Relay OFF Vbatt 12.5V
ground
CONNECTOR [C68-3]
Idle 0 ~ 2.0V 0.788V
1 Mass Air Flow Sensor signal input Analog
3000 rpm 1.0 ~ 4.5V 1.942V
2 Not connected
3 Not connected
4 Not connected
5 Not connected
6 Not connected
7 Not connected
High: Vcc or Vbatt 4.988V
8 Crankshaft Position Sensor signal input Pulse Idle Low: Max. 1.0V 0.188V
Frequency: 524Hz
9 Not connected
IG OFF Max. 0.5V 0V
10 Throttle Position Sensor supply DC
IG ON 4.9 ~ 5.1V 5.0375V
11 Not connected
12 Not connected
13 Not connected
14 Not connected
15 Not connected
16 Not connected
17 Mass Air Flow Sensor ground DC Idle Max. 50 mV 31.43mV
18 Not connected
C.T 0.25 ~ 0.9V 0.35V
19 Throttle Position Sensor signal input Analog
W.O.T Min. 4.0V 4.18V
20 Throttle Position Sensor ground DC Idle Max. 50 mV 21.14mV
21 Crankshaft Position Sensor ground DC Idle Max. 50 mV 11.85mV
Page 33 of 491
Intake Air Temperature Sensor signal 1.525V at
22 Analog Idle 0 ~ 5V
input 78°C
23 Intake Air Temperature Sensor ground DC Idle Max. 50 mV 11.93mV
Engine Coolant Temperature Sensor
24 Analog Idle 0.5 ~ 4.5V 1.09V at 93°C
signal input
Engine Coolant Temperature Sensor
25 DC Idle Max. 50 mV 12.27mV
ground
S/W ON Max. 0.5V 0V
26 Power Steering Load input DC
S/W OFF Vbatt 11.5V
27 Not connected
28 Not connected
Knock Sensor #1 (Cyl. #1, 3, 5) Knocking -0.3 ~ 0.3 V
29 Frequency
signal input Normal 0V
Knock Sensor #1 (Cyl. #1, 3, 5)
30
ground
Knock Sensor #2 (Cyl. #2, 4, 6) Knocking -0.3 ~ 0.3 V
31 Frequency
signal input Normal 0V
Knock Sensor #2 (Cyl. #2, 4, 6)
32
ground
33 Injector (Cyl. 1) control output High: Vbatt 14V
34 Injector (Cyl. 2) control output Low: Max . 1.0V 0.25V
35 Injector (Cyl. 3) control output Vpeak : Max. 70V 48.625V
Pulse Idle
36 Injector (Cyl. 4) control output Frequency: 5.5Hz
37 Injector (Cyl. 5) control output
38 Injector (Cyl. 6) control output
39 Not connected
40 Not connected
41 Not connected
High: Vbatt 14.312V
Purge Control Solenoid Valve PWM Inactive Low: Max. 1.0V 0.125V
42 Pulse
output Active Vpeak: Max. 70V 48.375V
Frequency: 20Hz
43 Not connected
44 Not connected
Intake Manifold Tuning Valve #1 DC Inactive Max. 1.0 V 0.0625V
45
(Surge Tank Side) control output (20Hz) Active Vbatt 15.125V
Page 34 of 491
High: Vbatt 15.125V
Idle Speed Control Actuator PWM
46 Pulse Idle Low: Max . 1.0V 0.125V
output 2 (OPEN)
Frequency: 100Hz
High: Vbatt 15.187V
Idle Speed Control Actuator PWM
47 Pulse Idle Low: Max . 1.0V 0.0625V
output 1 (CLOSE)
Frequency: 100Hz
48 Knock Sensor Shield DC Idle Max. 50 mV 11.63mV
49 Not connected
50 Not connected
51 Not connected
Intake Manifold Tuning Valve #2 (In- DC Inactive Max. 1.0 V 0V
52
mani Side) control output (20Hz) Active Vbatt 15.125V
CONNECTOR [C68-4]
1 Not connected
2 Not connected
3 Not connected
IG OFF Max. 0.5V 0V
4 Fuel Tank Pressure Sensor supply DC
IG ON 4.9 ~ 5.1V 5.05V
5 Fuel Level Sensor signal input DC IG ON 0V ~ Vbatt 2.93V
6 Not connected
High: Vcc or Vbatt 5V
7 Camshaft Position Sensor signal input Pulse Idle Low: Max . 1.0V 0.625V
Frequency: 10.99Hz
8 Camshaft Position Sensor ground DC Idle Max. 50 mV -
9 Not connected
Relay OFF Vbatt 12.38V
10 Fuel Pump Relay control output DC
Relay ON Max. 1.0V 0.125V
11 Not connected
12 Not connected
High: Vbatt 11.75V
13 Throttle Position PWM output Pulse Idle Low: Max. 0.5V 0V
Frequency: 100Hz
14 Fuel Tank Pressure Sensor ground DC Idle Max. 50 mV 23.78V
15 Fuel Level Sensor ground DC Idle Max. 50 mV 14.92V
16 Not connected
Page 35 of 491
High: Vbatt 14.25V
17 Engine Speed signal output Pulse Idle Low: Max. 0.5V 0V
Frequency: 38.76Hz
Cooling Fan Relay [Low] control Relay OFF Vbatt 14.312V
18 DC
output Relay ON Max. 1.0V 0.25V
19 Not connected
Malfunction Indicating Lamp (MIL) Lamp OFF Vbatt 13.812V
20 DC
output Lamp ON Max. 1.0VVbatt 0.0625V
21 Not connected
High: Min. 5.0V
22 Vehicle speed signal input Pulse Vehicle Run Low: Max. 0.5V 252Hz
Frequency: 250Hz
Air conditioner switch [Low/High] A/C OFF Max. 0.5V 0V
23 DC
signal input A/C ON Vbatt 13.812V
A/C OFF Max. 1.0V 0V
24 Air conditioner switch signal input DC
A/C ON Vbatt 12.937V
Air conditioner switch [Middle] signal MID OFF Max. 0.5V 12.625V
25 DC
input MID ON Vbatt 0.0625V
26 Not connected
27 Not connected
28 Not connected
Air Conditioner Compressor Relay A/C OFF Vbatt 14.125V
29 DC
control output A/C ON Max. 1.0V 0.125V
High: Vbatt 14.125V
Active
30 Canister Close Valve control output DC Low: Max. 1.0V 0.125V
Inactive
Frequency: 10Hz
31 Not connected
32 Not connected
33 Not connected
34 Fuel Tank Pressure Sensor signal input DC Idle 0.4 ~ 4.6V 2.501V
35 Not connected
Recessive 2.0 ~ 3.0 V 2.275V
36 CAN [HIGH] Pulse
Dominant 2.75~4.5 V 2.953V
Recessive 2.0 ~ 3.0 V 2.254V
37 CAN [LOW] Pulse
Dominant 0.5~2.25 V 1.552V
38 Wheel Speed Sensor (WSS) ground DC Idle Max. 50 mV 40.83mV
Page 36 of 491
Wheel Speed Sensor (WSS) signal Sine Vp-p: Min.0.2V 2.625V (10
39 Vehicle Run
input Wave Frequency: 100Hz mile)
Cooling Fan Relay - High control Relay OFF Vbatt 14.625V
40 DC
output Relay ON Max. 1.0V 0.188V
CONNECTOR [C68-5]
1st Voltage:
362V
Ignition coil #3 (Cyl. #3,6) control 300~400V
1 Pulse Idle
output ON Voltage: Max.
1.5V
2.0V
1st Voltage:
363.25V
2 Pulse Idle
1.5V
2.0V
1st Voltage:
361.75V
3 Pulse Idle
1.5V
2.0V
4 Not connected
5 Ignition Coil shield DC Idle Max. 50 mV -12.575mV
6 Not connected
7 Not connected
8 Not connected
9 Not connected
Fuel System > Engine Control System > Injector > Repair procedures
INSPECTION
1. Measure resistance between the terminal 1 and 2 of the injector.
Injector Resistance: 13.8 ~ 15.2 Ω at 20°C (68°F)

Page 37 of 491
2. If the resistance is not within specification, replace the injector.
Fuel System > Troubleshooting > Troubleshooting

INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES (DTC)
DTC Description MIL PAGE
U0101 Serial Communication Problem with TCM (Timeout) ●
P0030 HO2S Heater Control Circuit (Bank 1 / Sensor 1) ●
P0031 HO2S Heater Circuit Low (Bank 1 / Sensor 1) ●
P0032 HO2S Heater Circuit High (Bank 1 / Sensor 1) ●
P0101 Mass or Volume Air Flow Circuit Range/Performance ●
P0102 Mass or Volume Air Flow Circuit Low Input ●
P0103 Mass or Volume Air Flow Circuit high Input ●
P0111 Intake Air Temperature Sensor1 Circuit Range/Performance ●
P0112 Intake Air Temperature Sensor1 Circuit Low Input ●
P0113 Intake Air Temperature Sensor1 Circuit High Input ●
P0116 Engine Coolant Temperature Circuit Range/Performance ●
P0117 Engine Coolant Temperature Circuit Low Input ●
P0118 Engine Coolant Temperature Circuit High Input ●
P0119 Engine Coolant Temperature Circuit Intermittent ●
Throttle/Pedal Position Sensor/Switch "A" Circuit
P0121 ●
Range/Performance
P0122 Throttle/Pedal Position Sensor/Switch "A" Circuit Low Input ●
P0123 Throttle/Pedal Position Sensor/Switch "A" Circuit High Input ●
P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control ●
Coolant Thermostat (Coolant Temp. below Thermostat Regulating
P0128 ●
Temp.)
P0130 HO2S Circuit (Bank 1/ Sensor 1) ●
P0131 HO2S Circuit Low Voltage (Bank 1 / Sensor 1) ●
Page 38 of 491
P0132 HO2S Circuit High Voltage (Bank 1 / Sensor 1) ●
P0133 HO2S Circuit Slow Response (Bank 1 / Sensor 1) ●
P0134 HO2S Circuit No Activity Detected (Bank 1 / Sensor 1) ●
P0156 HO2S Circuit (Bank 2 / Sensor 2) ●
P0170 Fuel Trim (Bank 1) ●
P0171 System Too Lean (Bank 1) ●
P0172 System Too Rich (Bank 1) ●
P0173 Fuel Trim (Bank 2) ●
P0174 System Too Lean (Bank 2) ●
P0175 System Too Rich (Bank 2) ●
P0230 Fuel Pump Primary Circuit ▲
P0261 Cylinder 1-Injector Circuit Low ●
P0262 Cylinder 1-Injector Circuit High ●
Page 39 of 491
P0300 Random/Multiple Cylinder Misfire Detected ●
P0301 Cylinder 1-Misfire detected ●
P0315 Segment Time Acquisition Incorrect ▲
P0325 Knock Sensor 1 Circuit ▲
P0330 Knock Sensor 2 Circuit ▲
P0335 Crankshaft Position Sensor A Circuit ●
P0340 Camshaft Position Sensor A Circuit Malfunction(Single Sensor) ●
P0350 Ignition Coil Primary / Secondary Circuit ▲
P0351 Ignition Coil 'A' Primary / Secondary Circuit ▲
P0352 Ignition Coil 'B' Primary / Secondary Circuit ▲
P0353 Ignition Coil 'C' Primary / Secondary Circuit ▲
P0354 Ignition Coil 'D' Primary / Secondary Circuit ▲
P0355 Ignition Coil 'E' Primary / Secondary Circuit ▲
P0356 Ignition Coil 'F' Primary / Secondary Circuit ▲
P0420 Catalyst System Efficiency below Threshold (Bank 1) ●
P0430 Catalyst System Efficiency below Threshold (Bank 2) ●
P0441 Evap. Emission System Incorrect Purge Flow ●
P0442 Evap. Emission System-Leak detected (small leak) ●
P0444 Evap. Emission System-Purge Ctrl. Valve Circuit Open ●
P0445 Evap. Emission System-Purge Ctrl. Valve Circuit Shorted ●
P0447 Evap. Emission System-Vent Control Circuit Open ●
P0448 Evap. Emission System-Vent Control Circuit Shorted ●
P0449 Evap. Emission System-Vent valve / Solenoid circuit ●
P0451 Evap. Emission System-Pressure Sensor Range / Performance ●
P0452 Evap. Emission System-Pressure Sensor Low Input ●
P0453 Evap. Emission System-Pressure Sensor High Input ●
P0454 Evap. Emission System-Pressure Sensor Intermittent ●
P0455 Evap. Emission System-Leak detected (Large leak) ●
P0456 Evap. Emission System-Leak detected (Very small leak) ●
P0461 Fuel Level Sensor "A" Circuit Range/Performance ▲
Page 40 of 491
P0462 Fuel Level Sensor "A" Circuit Low Input ▲
P0463 Fuel Level Sensor "A" Circuit High Input ▲
P0464 Fuel Level Sensor "A" Circuit Intermittent ▲
P0501 Vehicle Speed Sensor A Range/Performance ●
P0506 Idle Air Control System-RPM lower than expected ●
P0507 Idle Air Control System-RPM higher than expected ●
P0551 Power Steering Pressure Sensor/Switch Circuit Range/Performance ▲
P0560 System Voltage ▲
P0562 System Voltage Low ●
P0563 System Voltage High ●
P0605 Internal Control Module Read Only Memory(ROM) Error ●
P0630 VIN not Programmed or Incompatible-ECM/PCM ●
P0650 Malfunction Indicator Lamp(MIL) Control Circuit ▲
P0661 Intake Manifold Tuning Valve Control Circuit Low (Bank 1) ▲
P0662 Intake Manifold Tuning Valve Control Circuit High (Bank 1) ▲
P0664 Intake Manifold Tuning Valve Control Circuit Low (Bank 2) ▲
P0665 Intake Manifold Tuning Valve Control Circuit High (Bank 2) ▲
P0700 TCM Request for MIL On ●
P1505 Idle Charge Actuator Signal Low of Coil #1 ●
P1506 Idle Charge Actuator Signal High of Coil #1 ●
P1507 Idle Charge Actuator Signal Low of Coil #2 ●
P1508 Idle Charge Actuator Signal High of Coil #2 ●
P1642 Non-Immobilizer-EMS connected to an Immobilizer ▲
●: MIL ON & FAULT CODE MEMORY

▲: MIL OFF & FAULT CODE MEMORY
Fuel System > Troubleshooting > P0030

COMPONENT LOCATION
Page 41 of 491
GENERAL DESCRIPTION
The normal operating temperature of the HO2S(Heated Oxygen Sensor) ranges from 350 to 850°C(662 to
1562°F). The HO2S heater greatly decreases the amount of time required for fuel control to become active. The
ECM provides a pulse width modulated control circuit to adjust current through the heater. When the HO2S is cold,
the value of the resistance is low and the current in the circuit is high. On the contrary, if the temperature in the
resistor of the sensor rises, the current drops gradually.
DTC DESCRIPTION
The ECM determines if a front HO2S heater fault has occurred and sets DTC P0030 if the front HO2S heater
control driver inside the ECM fails, if HO2S is not operational (after an elapse of predetermined time) since engine
start, or when the front HO2S tip temperature is out of normal working range. The ECM illuminates the MIL on the
second consecutive driving cycle that the diagnostic runs and fails.

• Evaluate O2 sensor element temperature via
DTC Strategy
measuring element resistance
• Sensor preheating and full heating phases finished • Related fuse blown or missing
• Time after start elapsed: 240 sec. • Heater control circuit open or
Enable Conditions • 11V<Battery voltage<16V short
• 1%<Heater power<99% • Power supply circuit open or
• Exhaust gas temp.model<610°C(1,130°F) short
Threshold Value • O2 sensor element resistance >1100Ω • Contact resistance in
connectors
Diagnostic Time • 5 min. • Faulty HO2S
Fail Safe • Heater open loop control
SIGNAL WAVEFORM
Page 42 of 491
SPECIFICATION
HO2S Normal Parameter

Heater 20°C (68°F)
Heater
Approx. 3~4Ω
Resistance
SCHEMATIC DIAGRAM
Page 43 of 491
MONITOR DTC STATUS

Repair" procedure.

or damage.

1. Ignition "OFF".
2. Disconnect HO2S connector.
Page 44 of 491
4. Measure voltage between terminal 3 of the HO2S heater harness connector and chassis ground.
Check for an open in the power supply circuit between the main relay and the Injector.
Especially check for "10A O2 Sensor fuse" is installed and not blown.
1. Check for open in control harness
(1) Ignition "OFF".
(2) Disconnect ECM connector
(3) Measure resistance between terminals 4 of the HO2S heater harness connector and 1 of the ECM harness
connector(C68-2).

Page 45 of 491
(1) Measure resistance between terminal 4 of the HO2S heater harness connector and chassis ground.
Specification : infinite

3. Check for short to power in control circuit.
(2) Measure voltage between terminal 4 of the HO2S heater harness connector and chassis ground
Page 46 of 491
1. Measure resistance between terminals 3 and 4 of the sensor connector (Component side).
Specification : 3~4Ω[at 20°C(68°F)]
procedure
Check HO2S for contamination, deterioration, or damage. Substitute with a known-good HO2S and check
for proper operation. If the problem is corrected, replace HO2S and then go to "Verification of Vehicle Repair"
procedure


COMPONENT LOCATION
Page 47 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0031 if the ECM detects that the front HO2S heater control circuit is short to ground.

• Check short circuit to ground on front HO2S heater
DTC Strategy
line
• Related fuse blown or missing
• Battery voltage>10V • Open or short to ground in
Enable Conditions
• 1% <Heater power<99% power supply or control
Threshold Value • Short to ground harness
Diagnostic Time • 20 sec connectors
Fail Safe • Heater open loop control • Faulty HO2S
SIGNAL WAVEFORM
SPECIFICATION
Page 48 of 491

Heater
Approx. 3~4Ω
Resistance
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 49 of 491
Repair" procedure.

or damage.

1. Ignition "OFF".
Page 50 of 491
(1) Ignition "OFF".
connector(C68-2).

Page 51 of 491
procedure
procedure


COMPONENT LOCATION
Page 52 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0032 if the ECM detects that the front HO2S heater control line is open or short to battery circuit.

• Check open or short circuit to battery line on front
DTC Strategy
HO2S heater line
• Battery voltage>10V • Open or short to battery in
Enable Conditions
• 1%<Heater power<99% control harness
Threshold Value • Open or short to Battery • Contact resistance in
connectors
Diagnostic Time • 20 sec. • Faulty HO2S
SIGNAL WAVEFORM
SPECIFICATION
Page 53 of 491

Heater
Approx. 3~4Ω
Resistance
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 54 of 491
Repair" procedure.

or damage.

(1) Ignition "OFF".
(2) Disconnect HO2S and ECM connectors.
connector(C68-2).

Page 55 of 491
(1) Reconnect the ECM connector.
(3) Measure voltage between terminal 4 of the HO2S heater harness connector and chassis ground.
1. Ignition "OFF".
procedure.
procedure.

Page 56 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION
The ECM determines rear HO2S heater fault and sets DTC P0036 if measured rear HO2S resistance is lower than
the predetermined threshold. The ECM illuminates the MIL on the second consecutive driving cycle that the
diagnostic runs and fails.

Page 57 of 491
DTC Strategy
• Time after start elapsed:180 sec. • Heater control circuit open or
Enable Conditions • 11V< Battery voltage<16V short
• 1%< Heater power< 99% • Power supply circuit open or
connectors
Diagnostic Time • 5 min. • Faulty HO2S
SIGNAL WAVEFORM
SPECIFICATION
Heater
Approx. 3~4Ω
Resistance
SCHEMATIC DIAGRAM
Page 58 of 491
MONITOR DTC STATUS

Page 59 of 491
Repair" procedure.

or damage.

1. Ignition "OFF".
Check for an open in the power supply circuit between the main relay and the HO2S.
Page 60 of 491
(1) Ignition "OFF".
connector(C68-2).


Page 61 of 491
procedure
procedure

Page 62 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0037 if the ECM detects that the rear HO2S heater control line is short to ground.

DTC Strategy
line
• Battery voltage>10V • Open or short to ground in
Enable Conditions
• 1%<Heater power<99% power supply or control

Page 63 of 491
SIGNAL WAVEFORM
SPECIFICATION
Heater
Approx. 3~4Ω
Resistance
SCHEMATIC DIAGRAM
Page 64 of 491
MONITOR DTC STATUS

Repair" procedure.

or damage.

1. Ignition "OFF".
Page 65 of 491
(1) Ignition "OFF".
connector(C68-2).

Page 66 of 491
procedure
procedure

Page 67 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
The normal operating temperature of the HO2S(Heated Oxygen Sensor) ranges 350 to 850°C(662 to 1562°F).
The HO2S heater greatly decreases the amount of time required for fuel control to become active. The ECM
provides a pulse width modulated control circuit to adjust current through the heater. When the HO2S is cold, the
value of the resistance is low and the current in the circuit is high. On the contrary, the temperature in the resistor of
the sensor rises, the current drops gradually.
DTC DESCRIPTION
ECM sets DTC P0038 if the ECM detects that the rear HO2S heater control line is open or short to battery line.

DTC Strategy
HO2S heater line
• Battery voltage>10V • Open or short to battery in
Enable Conditions
• 1%<Heater power<99% control harness
Threshold Value • Open or short to Battery • Contact resistance in
connectors
Diagnostic Time • 20 sec. • Faulty HO2S
Page 68 of 491
SIGNAL WAVEFORM
SPECIFICATION
Heater
Approx. 3~4Ω
Resistance
SCHEMATIC DIAGRAM
Page 69 of 491
MONITOR DTC STATUS

Repair" procedure.

or damage.

Page 70 of 491
(1) Ignition "OFF".
connector(C68-2).

1. Ignition "OFF".
Page 71 of 491
procedure.
procedure.


COMPONENT LOCATION
Page 72 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
The ECM determines if a front HO2S heater fault has occurred and sets DTC P0050 if the front HO2S heater
control driver inside the ECM fails, if HO2S is not operational (after an elapse of predetermined time) since engine
start, or when the front HO2S tip temperature is out of normal working range. The ECM illuminates the MIL on the
second consecutive driving cycle that the diagnostic runs and fails.

Item Detecting condition Possible Cause
DTC Strategy
• Time after start elapsed:240 sec. • Heater control circuit open or
Enable Conditions • 11V<Battery voltage<16V short
• 1%<Heater power<99% • Power supply circuit open or
connectors
Diagnostic Time • 5 min • Faulty HO2S
SIGNAL WAVEFORM
Page 73 of 491
SPECIFICATION

Heater
Approx. 3~4Ω
Resistance
SCHEMATIC DIAGRAM
Page 74 of 491
MONITOR DTC STATUS

memory was not cleared. Thoroughly check connectors for loose or poor connection, bending, corrosion,
Repair" procedure.

or damage.
Repair as necessary and go to "Verification of Vehicle Repair" procedure .

1. Ignition "OFF".
Page 75 of 491
Specification : B+
1. Check for open in control harness.
(1) Ignition "OFF".
(2) Disconnect ECM connectors.
connector(C68-2).

Page 76 of 491
2. Check for short to ground in control circuit .
Go to "Component Inspection" procedure .
Repair open or short to ground in control circuit and go to "Verification of Vehicle Repair" procedure.
Repair open or short to ground in control circuit and go to "Verification of Vehicle Repair" procedure
Page 77 of 491
procedure.
procedure.

2. Press F4DTAL) and confirm that "DTC Readiness Flag" indicates "Complete". If not, drive the vehicle within
conditions noted in the freeze frame data or enable conditions .

COMPONENT LOCATION
Page 78 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0051 if the ECM detects that the front HO2S heater control line is short to ground.

DTC Strategy
line
• Battery voltage > 10V • Open or short to ground in
Enable Conditions
• 1%< Heater power < 99% power supply or control
SIGNAL WAVEFORM
SPECIFICATION
Page 79 of 491

Heater
Approx. 3~4Ω
Resistance
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 80 of 491
Repair" procedure.

or damage.

1. Ignition "OFF".
Specification : B+
Page 81 of 491
(1) Ignition "OFF".
(2) Disconnect ECM and HO2S connectors.
connector(C68-2).

Page 82 of 491
procedure.
procedure.


COMPONENT LOCATION
Page 83 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0052 if the ECM detects that the front HO2S heater control line is open or short to battery line.

DTC Strategy
HO2S heater line.
• Battery voltage > 10V • Open or short to battery in
Enable Conditions
• 1%< Heater power < 99% control harness
Threshold Value • Short to Battery or line break • Contact resistance in
connectors
Diagnostic Time • 20 sec • Faulty HO2S
SIGNAL WAVEFORM
SPECIFICATION
Page 84 of 491

Heater
Approx. 3~4Ω
Resistance
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 85 of 491
Repair" procedure.

or damage.

(1) Ignition "OFF".
connector(C68-2).

Page 86 of 491
2. Check for short to power in control circuit
1. Ignition "OFF".
procedure.
procedure.

Page 87 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION
The ECM determines when a rear HO2S heater fault occurs and sets DTC P0056 if measured rear HO2S
resistance is lower than the predetermined threshold.
The ECM illuminates the MIL on the second consecutive driving cycle that the diagnostic runs and fails.

Page 88 of 491
• Evaluate O2 sensor element temperature via measuring
DTC Strategy
element resistance
• Sensor preheating and full heating phases finished • Related fuse blown or
• Time after start elapsed:180 sec. missing
Enable
• 11V<Battery voltage<16V • Heater control circuit open
Conditions
• 1%<Heater power<99% or short
• Exhaust gas temp.model<710°C(1,310°F) • Power supply circuit open
or short
Threshold Value • O2 sensor element resistance >3000Ω
Diagnostic Time • 5 min connectors
MIL On
Condition
SIGNAL WAVEFORM
SPECIFICATION
Heater
Approx. 3~4Ω
Resistance
Page 89 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 90 of 491
Repair" procedure.

or damage.

1. Ignition "OFF".
Specification : B+
Page 91 of 491
(1) Ignition "OFF".
(2) Disconnect ECM connectors.
connector(C68-2).

Page 92 of 491
Repair open or short to ground in control circuit and go to "Verification of Vehicle Repair" procedure
procedure.
procedure.

Page 93 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0057 if the ECM detects that the rear HO2S heater control line is short to ground.

• Check short circuit to ground on rear HO2S heater
DTC Strategy
line
• Battery voltage > 10V • Open or short to ground in
Enable Conditions
• 1%< Heater power < 99% power supply or control

Page 94 of 491
SIGNAL WAVEFORM
SPECIFICATION
Heater
Approx. 3~4Ω
Resistance
SCHEMATIC DIAGRAM
Page 95 of 491
MONITOR DTC STATUS

Page 96 of 491
Repair" procedure.

or damage.

1. Ignition "OFF".
Specification : B+
Page 97 of 491
(1) Ignition "OFF".
connector(C68-2).

Page 98 of 491
procedure.
procedure.


COMPONENT LOCATION
Page 99 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0058 if the ECM detects that the rear HO2S heater control line is open or short to battery line.

• Check short circuit to ground on rear HO2S heater
DTC Strategy
line
• Battery voltage > 10V • Open or short to battery in
Enable Conditions
• 1%< Heater power < 99% control harness
Threshold Value • Short to ground • Contact resistance in
connectors
Diagnostic Time • 20 sec • Faulty HO2S
SIGNAL WAVEFORM
SPECIFICATION
Page 100 of 491

Heater
Approx. 3~4Ω
Resistance
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 101 of 491
Repair" procedure.

or damage.

(1) Ignition "OFF".
connector(C68-2).

Page 102 of 491
2. Check for short to power in control circuit
1. Ignition "OFF".
procedure.
procedure.

Page 103 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
The Mass Air Flow Sensor (MAFS) is located between the air cleaner assembly and the throttle body. The MAFS
uses a hot film type sensing element to measure the mass of intake air entering the engine. This hot film type air flow
sensor consists of a hot film sensor, housing and metering ducts. Mass air flow rate is measured by detection of heat
transfer from a hot film probe. The change in air flow rate causes change in the amount of heat being transferred
from the hot film probe surface to the air. A large amount of intake air represents acceleration or high load
conditions while a small amount of intake air represents deceleration or idle. The mass of intake air should increase
at acceleration and be stable during constant engine speed. The ECM uses this information to determine the injection
duration and ignition timing for the desired air/fuel ratio.
DTC DESCRIPTION
The ECM compares the actual measured Mass Air Flow signal to the modeled Mass Air Flow value and sets the
DTC P0101 when the difference between these two value is too high or too low with lambda deviation in opposite
direction.
The modeled Mass Air Flow value is determined by engine speed, throttle angle and ICA valve duty.

Page 104 of 491
DTC Strategy • Compare calculated MAF with MAF signal
• Dirty air cleaner.
• 1500< Engine speed(RPM)< 3500
Enable • Oil Cap or Dipstick missing
• 150< Measured Mass Air Flow(mg/stk) <350 or not installed correctly.
Conditions
• Coolant temperature > 60°C(140°F)
• Air leak in intake system
Threshold Value • Measured MAF/Calculated MAF <0.5 or >1.3 • Contact resistance in
connectors.
• Faulty MAFS or TPS
SIGNAL WAVEFORM
SPECIFICATION
MAF DATA TPS DATA
Test Condition Output Voltage Mass Air Flow Output Voltage
Resistance (kΩ)
(V) (kg/h) (V)
Idle 0.6~1.0 11~20 0.25~0.80 0.71~1.38
Idle & A/C "ON" 1.0~1.3 20~30 - -
W.O.T - - 4.25~4.7 0.2~3.4
SCHEMATIC DIAGRAM
Page 105 of 491
MONITOR DTC STATUS
If any codes relating to TPS or MAFS are stored, do ALL REPAIRS associated with those codes before
proceeding with further troubleshooting
Page 106 of 491
Repair" procedure.

AIR CLEANER INSPECTION
1. Check air cleaner condition. Is air cleaner clogged with dirt?
Replace air cleaner and go to "Verification of Vehicle Repair" procedure.
Go to "Air Leakage Inspection" procedure.

or damage.
Go to "Conponent Inspection" procedure.
AIR LEAKAGE INSPECTION

1. Check intake tube, breather hose and MAFS for source of any air leaks. Are there any cracks in intake tube,
MAFS or breather hose.
2. Verify oil cap and dipstick are properly installed and oil cap screwed on completely.
Repair or Replace as necessary and go to "Verification of Vehicle Repair" procedure.
Go to "TPS Inspection" procedure.

TPS INSPECTION
2. Connect Scantool and monitor the "THROTTLE P. SENSOR(V)" parameter on the Scantool data list.
Specification : Approx. 0.5V(Closed throttle Valve) / Approx 4.25~4.7V(Wide Open Throttle)

Page 107 of 491
3. Is "THROTTLE P. SENSOR(V)" within specification?
Inspect TP sensor and W/harness and repair or replace as necessary. Go to "Verification of Vehicle Repair"
procedure.
1. Engine "ON".
2. Connect Scantool and monitor the "MASS AIR FLOW(V)" parameter on the Scantool data list.
3. Monitor the "MASS AIR FLOW(V)" parameter on the Scantool.
Specification :
Approx. 0.6 ~ 1.0V at idle & No load
Approx. 1.0 ~ 1.3V at idle & A/C "ON"
4. Is MAF sensor voltage within the specification?
procedure
Check MAFS for contamination, deterioration, or damage. Substitute with a known-good MAFS and check
for proper operation. If the problem is corrected, replace MAFS and then go to "Verification of Vehicle Repair"
procedure

Page 108 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION
MAF sensor.

• 1500< Engine speed(RPM)< 3500 • Open or short to ground in
Enable signal circuit
• 150< Measured Mass Air Flow(mg/stk) <350
Conditions
• Coolant temperature > 60°C(140°F) • Open in power supply circuit
Threshold Value • Measured MAF<2kg/h
connections.
Diagnostic Time • 200 sec. • Faulty MAF sensor
Page 109 of 491
SIGNAL WAVEFORM
SPECIFICATION
MAF DATA TPS DATA
Resistance (kΩ)
(V) (kg/h) (V)
Idle 0.6~1.0 11~20 0.25~0.80 0.71~1.38
Idle & A/C "ON" 1.0~1.3 20~30 - -
W.O.T - - 4.25~4.7 0.2~3.4
SCHEMATIC DIAGRAM
Page 110 of 491
MONITOR DTC STATUS

Repair" procedure.

or damage.

1. Ignition "OFF".
2. Disconnect MAF connector.
Page 111 of 491
4. Measure voltage between terminal 3 of the MAF sensor heater harness connector and chassis ground.
Specification : B+
Check for an open or short to ground in the power supply circuit between the MAF sensor and main relay.
1. Check for open in signal harness.
(1) Ignition "OFF".
(3) Measure resistance between terminals 2 of the MAF sensor harness connector and 1 of the ECM harness
connector(C68-3).
Check for an open in signal harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.
Page 112 of 491
2. Check for short to ground in signal harness.
(1) Ignition "OFF".
(2) Measure resistance between terminal 2 of the MAF sensor harness connector and chassis ground.
Repair open or short in harness and go to "Verification of Vehicle Repair" procedure.
1. Engine "ON".
Specification :
Page 113 of 491
procedure.
procedure.


COMPONENT LOCATION
GENERAL DESCRIPTION
Page 114 of 491
DTC DESCRIPTION
MAF sensor.

• 500< Engine speed(RPM)< 3500 • Open in ground harness
Enable
• 150< Measured Mass Air Flow(mg/stk) <350 • Short to battery in signal
Conditions
• Coolant temperature > 60°C(140°F) harness
Threshold Value • Measured MAF > 700 kg/h
connections.
Diagnostic Time • 200 mSec. • Faulty MAF sensor
SIGNAL WAVEFORM
SPECIFICATION
MAF DATA TPS DATA
Resistance (kΩ)
(V) (kg/h) (V)
Idle 0.6~1.0 11~20 0.25~0.80 0.71~1.38
Idle & A/C "ON" 1.0~1.3 20~30 - -
W.O.T - - 4.25~4.7 0.2~3.4
SCHEMATIC DIAGRAM
Page 115 of 491
MONITOR DTC STATUS

Repair" procedure.

Page 116 of 491
or damage.

1. Ignition "OFF".
2. Disconnect MAF sensor connector.
3. Measure resistance between terminal 1 of the sensor harness connector and chassis ground.
Check for an open or short to battery in harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.
2. Measure voltage between terminal 2 of the MAF sensor harness connector and chassis ground.
Repair short to battery in harness and go to "Verification of Vehicle Repair" procedure.

Page 117 of 491
1. Engine "ON".
Specification :
procedure.
procedure.


Page 118 of 491
COMPONENT LOCATION
GENERAL DESCRIPTION
The Intake Air Temperature Sensor (IATS) is installed into the Mass Air Flow Sensor (MAFS). The IATS uses a
thermistor whose resistance changes with the temperature. The electrical resistance of the IATS decreases as the
temperature increases, and increases as the temperature decreases. The 5 V power source in the ECM is supplied
to the IATS via a resistor in the ECM. That is, the resistor in the ECM and the thermistor in the IATS are connected
in series. When the resistance value of the thermistor in IATS changes according to the intake air temperature, the
signal voltage also changes. Using this signal, the information of the intake air temperature, the ECM corrects basic
fuel injection duration and ignition timing.
DTC DESCRIPTION
The purpose of this diagnosis is to detect a stuck air temperature signal. The diagnostic function checks whether
after a variation of the calculated air temperature also a variation of the measured air temperature is detected.
ECM sets DTC P0111 when the variation of measured intake air temperature is smaller than threshold while
variation of calculated intake air temperature by ECM is greater than threshold.

• Time after Start > 300 sec.
Enable • Coolant temperature > 75°C(167°F)
Conditions • Coolant temperature increase after Start >
40°C(104°F)
• Air temp. at present time - air temp. at engine start < • Contact resistance in
5.25°C(41.5°F) connections.
• Minimum air temp. - air temp. at engine start < • Faulty IAT sensor
Threshold Value
1.5°C(34.7°F)
• Maximum air temp. - air temp. at engine start <
1.5°C(34.7°F)
Page 119 of 491
SIGNAL WAVEFORM
SPECIFICATION
Temperature Resistance Temperature Resistance
(°C) (°F) (kΩ) (°C) (°F) (kΩ)
-20 -4 14.26~16.02 40 104 1.11~1.19
0 32 5.50~6.05 60 140 0.57~0.60
20 68 2.35~2.54 80 176 0.31~0.32
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 120 of 491
Repair" procedure.
Go to next step as below

or damage.
Page 121 of 491
1. Measure resistance between terminals 1 and 2 of the sensor connector(Component side).
Temperature Resistance (kΩ)
-20°C (-4°F) Approx. 14.26~16.02
20°C (68°F) Approx. 2.35~2.54
80°C (176°F) Approx. 0.31~0.32
2. Is IAT sensor data within the specification?
procedure.
Check IAT sensor for contamination, deterioration, or damage. Substitute with a known-good IAT sensor and
check for proper operation. If the problem is corrected, replace IAT sensor and then go to "Verification of


COMPONENT LOCATION
Page 122 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
IATS.

Enable • 6< Battery voltage(V) <16 • Short to ground in signal
Conditions • After 250 seconds from engine start harness
Threshold Value • Measured intake air temperature > 118°C(244°F)
connections.
Diagnostic Time • 50 sec. • Faulty IAT sensor
SIGNAL WAVEFORM
Page 123 of 491
SPECIFICATION
(°C) (°F) (kΩ) (°C) (°F) (kΩ)
-20 -4 14.26~16.02 40 104 1.11~1.19
0 32 5.50~6.05 60 140 0.57~0.60
20 68 2.31~2.59 80 176 0.31~0.32
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 124 of 491
Repair" procedure.
Go to "Monitor Scantool Data" procedure.

2. Disconnect IAT sensor connector.
3. Connect Scantool and monitor the "INT.AIR TEMP. SNSR(V)" parameter on the Scantool data list.
Page 125 of 491
4. Is displayed IAT data within the specification?
Possibility of sensor malfunction. Go to "Component Inspection" procedure.
Possibility of signal circuit short to ground. Go to "Signal Circuit Inspection" procedure.

1. Ignition "OFF".
2. Disconnect IAT sensor connector.
3. Measure resistance between terminal 1 of the IAT sensor harness connector and chassis ground.
Repair short to ground in harness and go to "Verification of Vehicle Repair" procedure.

or damage.
Page 126 of 491
-20°C (-4°F) Approx. 14.26~16.02
20°C (68°F) Approx. 2.31~2.59
80°C (176°F) Approx. 0.31~0.32
2. Is IAT sensor data within the specification?
procedure.


COMPONENT LOCATION
Page 127 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
IATS.

• Short to battery in signal
Enable • 6< Battery voltage(V) <16 harness
Conditions • After 250 seconds from engine start • Open in signal or ground
circuit
Threshold Value • Measured intake air temperature > -38°C(-36°F)
Diagnostic Time • 50 sec. connections.
• Faulty IAT sensor
SIGNAL WAVEFORM
Page 128 of 491
SPECIFICATION
(°C) (°F) (kΩ) (°C) (°F) (kΩ)
-20 -4 14.26~16.02 40 104 1.11~1.19
0 32 5.50~6.05 60 140 0.57~0.60
20 68 2.31~2.59 80 176 0.31~0.32
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 129 of 491
Repair" procedure.

2. Disconnect IATS sensor connector.
3. Connect Scantool and monitor the "INT.AIR TEMP. SNSR(V)" parameter on the Scantool data list.
4. Jumper the terminals 1 and 2 of the IAT sensor harness connector together.
Specification : Approx. 0v
Page 130 of 491
5. Is IAT data within the specification?

6. Jumper the terminal 1 of the IAT sensor harness connector to chassis ground.
7. Observe the "IAT SENSOR" parameter on the Scantool.
8. Is IAT data within the specification?
Possibility of open in IAT ground circuit Go to "Ground circuit inspection" procedure.
Possibility of open or short to battery in IAT signal circuit. Go to "Signal Circuit Inspection" procedure.

1. Ignition "OFF".
3. Measure resistance between terminal 2 of the IATsensor harness connector and 23 of the ECM harness
connector(C68-3).
Go to "Terminal and Connetor Inspection" procedure.
Repair open circuit and go to "Verification of Vehicle Repair" procedure

Page 131 of 491
1. Check for open in signal circuit
(1) Measure resistance between terminals 1 of the IAT sensor harness connector and 22 of the ECM harness
connector(C68-3).

2. Check for short to battery in signal circuit.
(2) With IATS and ECM connector still disconnected, measure voltage between terminals 1 of the IAT sensor
harness connector and 22 of the ECM harness connector(C68-3).
Repair open circuit and go to "Verification of Vehicle Repair" procedure.

or damage.
Page 132 of 491
1. Ignition "OFF"
2. Measure resistance between terminals 1 and 2 of the IAT sensor connector(Component side).
Specification : (at 20°C (68°F))

-20°C (-4°F) Approx. 14.26~16.02
20°C (68°F) Approx. 2.31~2.59
80°C (176°F) Approx. 0.31~0.32
procedure.


COMPONENT LOCATION
Page 133 of 491
GENERAL DESCRIPTION
The Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the cylinder head for
detecting the engine coolant temperature. The ECTS uses a thermistor whose resistance changes with the
temperature. The electrical resistance of the ECTS decreases as the temperature increases, and increases as the
temperature decreases. The reference 5 V in the ECM is supplied to the ECTS via a resistor in the ECM. That is,
the resistor in the ECM and the thermistor in the ECTS are connected in series. When the resistance value of the
thermistor in the ECTS changes according to the engine coolant temperature, the output voltage also changes.
During cold engine operation the ECM increases the fuel injection duration and controls the ignition timing using the
information of engine coolant temperature to avoid engine stalling and improve drivability.
DTC DESCRIPTION
The purpose of this diagnosis is to detect a stuck coolant temperature signal. The diagnostic function checks whether
after a variation of the calculated coolant temperature also a variation of the measured coolant temperature is
detected.ECM sets DTC P0116 when the variation of measured engine coolant temperature from engine start is
smaller than threshold while variation of calculated coolant temperature by ECM is greater than threshold.

DTC Strategy • Check coolant temperature signal stuck.
Enable • Engine coolant >20°C (68°F)
Conditions • After 100~1000 seconds from engine start
• TCOmodel increase > Threshold But TCO connections.
Threshold Value measuring increase <Threshold(Threshold depends
• Faulty ECT sensor
on Coolant start temp.)
SIGNAL WAVEFORM
Page 134 of 491
SPECIFICATION
(°C) (°F) (kΩ) (°C) (°F) (kΩ)
-20 -4 14.13~16.83 40 104 1.15
0 32 5.79 60 140 0.59
20 68 2.31~2.59 80 176 0.32
SCHEMATIC DIAGRAM
MONITOR DTC STATUS
Page 135 of 491
Repair" procedure.

or damage.
1. Ignition "OFF"
2. Disconnect ECTS connector
Page 136 of 491
3. Measure resistance between terminals 1 and 3 of the ECT sensor connector (Component side)
Specification :

-20°C (-4°F) Approx. 14.13~16.83
20°C (68°F) Approx. 2.31~2.59
80°C (176°F) Approx. 0.32
procedure.
Check ECT sensor for contamination, deterioration, or damage. Substitute with a known-good ECT sensor
and check for proper operation. If the problem is corrected, replace ECT sensor and then go to "Verification of


COMPONENT LOCATION
Page 137 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
ECTS.

Enable • Engine coolant >20°C (68°F) • Short to ground in signal
Conditions • After 100~1000 seconds from engine start harness
Threshold Value • Measured coolant temperature > 138°C(280°F).
connections.
Diagnostic Time • 5 sec. • Faulty ECT sensor
SIGNAL WAVEFORM
Page 138 of 491
SPECIFICATION
(°C) (°F) (kΩ) (°C) (°F) (kΩ)
-20 -4 14.13~16.83 40 104 1.15
0 32 5.79 60 140 0.59
20 68 2.31~2.59 80 176 0.32
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 139 of 491
Repair" procedure.

2. Disconnect ECTS connector.
3. Connect Scantool and monitor the "COOLANT TEMP. SNSR(V)" parameter on the Scantool data list.
Page 140 of 491
4. Is ECTS parameter within the specification?
Possibility of signal circuit short to ground. Go to "Signal Circuit Inspection" procedure.

1. Ignition "OFF".
2. Measure resistance between terminal 3 of the ECT sensor harness connector and chassis ground.
Repair short to ground in harness and go to "Verification of Vehicle Repair" procedure.

or damage.
Page 141 of 491
Specification :

-20°C (-4°F) Approx. 14.13~16.83
20°C (68°F) Approx. 2.31~2.59
80°C (176°F) Approx. 0.32
procedure.
Check ECTS for contamination, deterioration, or damage. Substitute with a known-good ECTS and check for
proper operation. If the problem is corrected, replace ECTS and then go to "Verification of Vehicle Repair"
procedure.


COMPONENT LOCATION
Page 142 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
ECTS.

DTC Strategy • Voltage range check • Short to battery in signal
Enable • Engine coolant >20°C (68°F) harness
Conditions • After 100~1000 seconds from engine start • Open in signal or ground
circuit
Threshold Value • Measured coolant temperature < -38°C(-36°F).
Diagnostic Time • 5 sec. connections.
SIGNAL WAVEFORM
Page 143 of 491
SPECIFICATION
(°C) (°F) (kΩ) (°C) (°F) (kΩ)
-20 -4 14.13~16.83 40 104 1.15
0 32 5.79 60 140 0.59
20 68 2.31~2.59 80 176 0.32
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 144 of 491
Repair" procedure.

3. Connect Scantool and monitor the "COOLANT TEMP. SNSR(V)" parameter on the Scantool data list.
4. Jumper the terminals 1 and 2 of the ECTS harness connector together.
Page 145 of 491
5. Is ECTS parameter within the specification?

6. Jumper the terminal 3 of the ECT sensor harness connector to chassis ground.
7. Observe the "ECT SENSOR" parameter on the Scantool.
8. Is ECT data within the specification?
Possibility of open in ECTS ground circuit. Go to "Ground Circuit Inspection" procedure.
Possibility of open or short to battery in ECTS signal circuit. Go to "Signal Circuit Inspection" procedure.

1. Ignition "OFF".
3. Measure resistance between terminals 1 of the ECT sensor harness connector and 25 of the ECM harness
connector(C68-3).
Go to "Terminal and connector Inspection" procedure.
Repair open circuit and go to "Verification of Vehicle Repair" procedure.

Page 146 of 491
(1) Measure resistance between terminals 3 of the ECT sensor harness connector and 24 of the ECM harness
connector(C68-3).

2. Check for short to battery in signal circuit.
(2) Measure voltage between terminals 3 of the ECT sensor harness connector and 24 of the ECM harness
connector(C68-3).
Go to "Terminal and Connector Inspection" procedure

or damage.
Page 147 of 491
1. Ignition "OFF"
Specification :

-20°C (-4°F) Approx. 14.13~16.83
20°C (68°F) Approx. 2.31~2.59
80°C (176°F) Approx. 0.32
procedure.
procedure.


COMPONENT LOCATION
Page 148 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0119 when the gradient of engine coolant temperature is abnomal.

DTC Strategy • Monitor the gradient of coolant temperature
Enable • Engine coolant >20°C (68°F)
Conditions • After 100~1000 seconds from engine start • Contact resistance in
connections.
Threshold Value • TCO Gradient < 10°C(50°F) / 0.5 sec.
SIGNAL WAVEFORM
Page 149 of 491
SPECIFICATION
(°C) (°F) (kΩ) (°C) (°F) (kΩ)
-20 -4 14.13~16.83 40 104 1.15
0 32 5.79 60 140 0.59
20 68 2.31~2.59 80 176 0.32
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 150 of 491
Repair" procedure.

or damage.
1. Ignition "OFF"
Page 151 of 491
Specification :

-20°C (-4°F) Approx. 14.13~16.83
20°C (68°F) Approx. 2.31~2.59
80°C (176°F) Approx. 0.32
procedure.
procedure.


COMPONENT LOCATION
Page 152 of 491
GENERAL DESCRIPTION
The Throttle Position Sensor (TPS) is mounted on the throttle body and detects the opening angle of the throttle
plate. The TPS has a variable resistor (potentiometer) whose characteristic is the resistance changing according to
the throttle angle. During acceleration, the TPS resistance between the reference 5V and the signal terminal
decreases and output voltage increases; during deceleration, the TPS resistance increases and TPS output voltage
decreases. The ECM supplies a reference 5V to the TPS and the output voltage increases directly with the opening
of the throttle valve. The TPS output voltage will vary from 0.2~0.8V at closed throttle to 4.3~4.8V at wide-open
throttle.
The ECM determines operating conditions such as idle (closed throttle), part load, acceleration/deceleration, and
wide-open throttle from the TPS. Also The ECM uses the Mass Air Flow Sensor (MAFS) signal along with the
TPS signal to adjust fuel injection duration and ignition timing.
DTC DESCRIPTION
The ECM compares the actual measured Mass Air Flow signal with the modeled Mass Air Flow value to detect
implausible TPS signal. Because throttle position is one of key parameters in determining the modeled MAF. The
modeled Mass Air Flow value is determined by engine speed, throttle angle and ISCA duty. The DTC P0121 is set
when the difference between these two value is too high or too low with lambda deviation in same direction for a
certain time.

DTC Strategy • Compare calculated MAF with MAF signa
• 1500< Engine speed(RPM) < 3500
Enable
• 150< Measured mass air flow(mg/stk) <350
Conditions • Contact resistance in
• Coolant temp. >60°C(140°F) connectors
Threshold Value • Measured MAF/Calculated MAF < 0.5 or > 1.3 • Faulty TP Sensor(TPS)
SIGNAL WAVEFORM
Page 153 of 491
SPECIFICATION
Normal parameter
TPS
C.T (Idle) W.O.T
Throttle Angle (°) 0~0.5° Approx. 85°
Signal Voltage (V) 0.25~0.8V 4.25~4.7V
0.71~1.38 kΩ at all
Terminal 2 and 3 2.7 kΩ at all temperature
Resistance (kΩ) temperature
Terminal 1 and 2 1.6~2.4 kΩ at all throttle position
SCHEMATIC DIAGRAM
Page 154 of 491
MONITOR DTC STATUS
Repair" procedure.
Go to "Air Leakage Inspection" procedure.

or damage.

Page 155 of 491
1. Visually/physically inspect the following items:
A. Vacuum hoses for splits, kinks and improper connections.
B. EVAP system for leakage.
C. PCV hose for proper installation.
1. Ignition "OFF".
2. Disconnect TPS connector.
3. Measure resistance between terminals 1 and 2 of the TPS connector(Component side).
Specification : Approx. 1.6 ~ 2.4 kΩ at all throttle position
4. With still TPS connector disconnected, measure resistance between terminals 2 and 3 of the sensor
connector(Component side)
5. Operate the throttle valve slowly from the idle position to the full open position and check the resistance changes
smoothly in proportion with the throttle valve opening angle.
Specification : 0.71 ~ 1.38 kΩ at closed throttle valve, 2.7 kΩ at wide open throttle
procedure.
Check TPS for contamination, deterioration, or damage. 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 156 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
throttle.
DTC DESCRIPTION
TPS.

Page 157 of 491
DTC Strategy • Voltage range check • Open in power supply
Enable harness
• 6 ≤ Battery voltage ≤ 16V
Conditions • Short to ground in power
supply or signal harness
Threshold Value • Voltage <0.14V
MIL On Condition • 2 Driving Cycles • Faulty TP sensor
SIGNAL WAVEFORM
SPECIFICATION
Normal parameter
TPS
C.T (Idle) W.O.T
0.71~1.38 kΩ at all
SCHEMATIC DIAGRAM
Page 158 of 491
MONITOR DTC STATUS

Repair" procedure.

Page 159 of 491
or damage.

1. Ignition "OFF".
4. Measure voltage between terminal 1 of the TPS harness connector and chassis ground.
Go to "Signal Circuit inspection" procedure.
Possibility of open or short to ground in 5V reference circuit.

Repair as necessary. Go to "Verification of Vehicle Repair" procedure.
2. Measure voltage between terminal 3 of the sensor harness connector and chassis ground.
Page 160 of 491
Check the short to ground in signal circuit.

1. Ignition "OFF".
Test Condition : Ignition "OFF"

procedure.
procedure.

Page 161 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
throttle.
DTC DESCRIPTION
TPS.

Page 162 of 491
• Open in signal or
Enable ground circuit
• 6 ≤ Battery voltage(V) ≤ 16
Conditions
• Short to battery in
Threshold Value • Voltage > 4.86V signal circuit
connectors
MIL On • Faulty TP sensor
Condition
SIGNAL WAVEFORM
SPECIFICATION
Normal parameter
TPS
C.T (Idle) W.O.T
0.71~1.38 kΩ at all
SCHEMATIC DIAGRAM
Page 163 of 491
MONITOR DTC STATUS

Repair" procedure.

Page 164 of 491
or damage.

1. Ignition "OFF".
Go to step "Signal Circuit Inspection" procedure.
Check the ground circuit for an open.

1. With sensor connector still disconnected, measure voltage between terminal 3 of the sensor harness connector
and chassis ground.
Page 165 of 491
Possibility of open or short to power in signal circuit.

1. Ignition "OFF".
procedure.
procedure.

Page 166 of 491

COMPONENT LOCATION
GENERAL DESCTIPTION
An Engine Coolant Temperature Sensor (ECTS) monitors the temperature of the coolant. This input is used by the
ECM for engine control and as an enabling criteria for related diagnostics. The air flow coming into the engine is
accumulated and used to determine if the engine has been driven within conditions that would allow the engine
coolant to heat up normally to the thermostat regulating temperature. If the coolant temperature does not reach
regulating temperature of the thermostat, diagnostics that use engine coolant temperature as enabling criteria, may
not run when expected.This DTC will set when there has been excessive time to reach a minimum coolant
temperature required for closed loop fuel control.
DTC DESCRIPTION
The purpose of this diagnosis is to monitor the minimum coolant temperature that enables lambda closed loop
control after start. Minimum coolant temperature to run lambda control must be reached before the threshold time
predetermined according to intake air temperature at start. If the lambda control is not active because of low engine
coolant temperature within predetermined minimum time after start, the ECM sets DTC P0125.

Page 167 of 491
• Check time to closed loop control start with coolant
DTC Strategy
temperature model.
• Engine coolant > 20°C(68°F)
Enable Conditions
• After 100~1000 seconds from engine start
• Measured coolant temperature< threshold When • Contact resistance in
Threshold value
modeled coolant temperature > threshold connectors.
Diagonostic Time • 0.5 sec. • Faulty cooling system.
• Faulty thermostat.
• Calculated engine coolant temperature is used for
• Faulty ECT sensor.
engine control.
Fall Safe • Cooling/Condenser fan is active with MAX speed.
• EVAP. emission control function is controlled in
minimum operation mode.
SIGNAL WAVEFORM
SPECIFICATION
[ECTS]
Temp.(°C) Temp.(°F) Resistance(kΩ)
-20 -4 14.13 ~ 16.83
0 32 5.79
20 68 2.31 ~ 2.59
40 104 1.15
60 140 0.59
80 176 0.32
Page 168 of 491
[THERMOSTAT]
Thermostat Normal Parameter
Valve Opening Temp. 80~84°C(176~183°F)
Valve Closing Temp. 77°C(170.6°F)
Above 10mm at
Full Open Lift
95°C(203°F)
SCHEMATIC DIAGRAM
MONITOR DTC STATUS
If any codes relating to ECTs are stored, do ALL REPAIRS associated with those codes before proceeding with
this troubleshooting.
Page 169 of 491
Repair" procedure.

or damage.
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:
A. Stuck or damaged
B. Verify the temperature at which the valve begins to open.
Valve opening temperature : 80~84°C(176~183.2°F)
Valve opening temperature : 95°C(203°F)
4. Is a problem found?
Page 170 of 491
5. Repair as necessary and go to "Verification of Vehicle Repair" procedure.
6. Go to next step as below.
1. Ignition "OFF" .
Specification
Temp.(°C) Temp.(°F) Resistance(kΩ) Temp.(°C) Temp.(°F) Resistance(kΩ)
-20 -4 14.13~16.83 40 104 1.15
0 32 5.79 60 140 0.59
20 68 2.31~2.59 80 176 0.32
procedure.
procedure.

1. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode
conditions noted in the freeze frame data or enable conditions
3. Read "DTC Status" parameter

COMPONENT LOCATION
Page 171 of 491
GENERAL DESCRIPTION
The HO2S is used to supply the ECM with information regarding the composition of the air/fuel mixture. The HO2S
is positioned in the exhaust pipe ahead of the TWC. To measure the oxygen content, the HO2S requires a supply of
ambient air as a reference. Since this is supplied through the wiring, the lead must not be clamped or damaged in any
other way. The HO2S produces a voltage that varies between 0.1V and 0.9V under normal operating conditions.
The Engine Control Module (ECM) monitors this voltage and determines if the exhaust gas is lean or rich. If the
voltage input at the ECM is under approx. 0.45V the exhaust is lean, and if the voltage input is over approx. 0.45V
the exhaust is rich. The ECM constantly monitors the HO2S signal during closed loop operation and compensates
for a rich or lean condition by decreasing or increasing injector pulse width as necessary.
DTC DESCRIPTION
ECM sets DTC P0130 if the ECM detects that the front HO2S signal circuit is open.

DTC Strategy • Check open circuit on rear HO2S
• Sensor preheating and full heating phases finished • Open in signal harness
Enable Condition • Battery voltage >10V • Open in ground harness
• Lambda control active • Contact resistance in
connectors
Threshold Value • 0.4V < Sensor voltage <0.5V
• Faulty Heated O2
Diagnostic Time • 10 Seconds Sensor(HO2S)
SIGNAL WAVEFORM
Page 172 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 173 of 491
Repair" procedure.

or damage.

1. Ignition "OFF"
Page 174 of 491
3. Measure resistance between terminals 2 of the HO2S harness connector and 20 of the ECM harness
connector(C68-2).
Repair open in the ground circuit and go to "Verification of Vehicle Repair" procedure
connector(C68-2).
Is resistance within the specification?
Repair open in the ground circuit and go to "Verification of Vehicle Repair" procedure.
1. Visually/physically inspect following items:
A. Inspect the front HO2S 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, replace contaminated sensor and go to next step.
2. Warm up the engine to normal operating temperature and check that HO2S signal is active.
Page 175 of 491
3. Connect Scantool and monitor the "FR OXYGEN SNSR-B1" parameter on the Scantool data list.
Specification : Verify signal is switching from rich(above 0.45V) to lean(below 0.45V) a minimum of
3 times in 10 seconds (voltage will vary between 0.1 and 0.9V).
4. Is sensor switching properly?
procedure.
procedure.


COMPONENT LOCATION
Page 176 of 491
GERNERAL DESCRIPTION
DTC DESCRIPTION
The control unit of the linear oxygen sensor built inside the ECM monitors short circuit errors on all front Heated
Oxygen Sensor (HO2S) control lines and the ECM sets P0131 with short circuit to ground.

ITEM DETECING CONDITION POSSIBLE CAUSE
DTC Strategy • Sensor voltage low
• Sensor preheating and full heating phases finished
Enable Conditions • Short to ground in signal harness
• Battery voltage >10V
• Contact resistance in connectors
• Sensor voltage <0.02V and element resistance
Threshold Value • Faulty Heated O2
<10Ω
Sensor.(HO2S)
SIGNAL WAVEFORM
Page 177 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 178 of 491
Repair" procedure.

or damage.

1. Ignition "OFF"
Page 179 of 491
3. Measure resistance between terminal 1 of the HO2S harness connector and chassis ground.
Repair open in the signal circuit and go to "Verification of Vehicle Repair" procedure.
B. If contamination is evident on the HO2S, replace contaminated sensor and go to next step.
Page 180 of 491
procedure.
procedure.


COMPONENT LOCATION
Page 181 of 491
DTC DESCRIPTION
The control unit of the linear oxygen sensor built inside the ECM monitors short circuit errors on all front Heated
Oxygen Sensor (HO2S) control lines and the ECM sets P0132 with short circuit to battery.

DTC Strategy • Sensor voltage high
• Short to ground in signal
Enable Conditions harness
Threshold Value • Sensor voltage >1.3V connectors
Sensor.(HO2S)
SIGNAL WAVEFORM
SCHEMATIC DAIGRAM
Page 182 of 491
MONITOR DTC STATUS

Page 183 of 491
Repair" procedure.

or damage.

1. Ignition "OFF"
Page 184 of 491
procedure.
for proper operation.
If the problem is corrected, replace HO2S and then go to "Verification of Vehicle Repair" procedure.


COMPONENT LOCATION
Page 185 of 491
DTC DESCRIPTION
The ECM monitors front oxygen sensor amplitude level and compares it to predetermined minimum amplitude value
which could increase emission or disturb lambda control by the effect of aging on the oxygen sensor. The ECM sets
DTC P0133 when the amplitude of oxygen sensor is equal to or less than minimum amplitude threshold.

• Comparison of O2 sensor lean/rich period with
DTC Strategy
calculated period
• 400°C(752°F)< Catalyst Temp.Model
<600°C(1112°F) • Leak in intake or exhaust
• Coolant temp. >70°C(158°F) system
Enable Conditions • 800 <Engine speed(RPM) <2500 • Faulty fuel system.
• Mass air flow <250 mg/stk • Front and rear HO2S
• No misfire detected connections reversed.
• Not transient condition • Contact resistance in
connectors
• Sum of O2 sensor lean/rich period > calculated
Threshold Value • HO2S contamination
period
Diagnostic Time • 80 lambda controller cycles.
Page 186 of 491
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
MONITOR DTC STATUS
If any misfire, Purge Solenoid Valve, Mass Air Flow Sensor or O2 Sensor heater codes are present, DO ALL
Page 187 of 491
Repair" procedure.
VISUAL/PHYSICAL INSPECTION
A. Ensure that the HO2S is securely installed.
C. Check for terminal tension ( at the HO2S and at the ECM).
D. Check for damaged wiring.
E. Check the HO2S ground circuit for a good connection.
2. Check front and rear HO2S for connections being reversed. If HO2S connections reversed, switch connections
properly.
Go to "Air Leakage Inspection" procedure

B. Exhaust system between HO2S and Three way catalyst for air leakage.
C. EVAP system for leakage.
D. PCV hose for proper installation.
Page 188 of 491
Go to "Fuel Pressure Inspection" procedure.

FUEL PRESSURE INSPECTION
1. Check the fuel for excessive water, alcohol, or other contaminants. Replace contaminated fuel as necessary.
2. Install a fuel pressure gage.
3. Inspect fuel pressure with engine idling at normal operating temperature.
Test Condition : Engine "ON" & Vacuum hose disconnected at Idle.

Specification : 343 kPa(3.5 kg/cm², 49.8 psi)
4. Is the fuel pressure within the specified value?
Go to "Fuel Injector Inspection" procedure as below.
Repair as necessary refer to inspection note as below and go to "Verification of Vehicle Repair" procedure.
1) Check if fuel line pressure decreases when accelerating quickly.

- If it does, check fuel pump maximum pressure. If pressure is OK, check fuel line and filter for
clogging.
2) If fuel pressure is lower than specification : Check for fuel line pressure while pinching fuel return hose.
- If pressure quickly increases, check pressure regulator.
- If pressure gradually increases, check for clogging between fuel pump and pressure regulator. If hose
is not clogged, check fuel pump maximum pressure.
3) If fuel pressure is higher than specification : Is fuel line clogged?
- If it is not, replace pressure regulator.
- If it is, replace it.
FUEL INJECOTR INSPECTION
Page 189 of 491
procedure.


COMPONENT LOCATION
Page 190 of 491
DTC DESCRIPTION
Due to possible oxygen sensor defects (e.g. reference air poisoning) or faults in the injection system (e.g. leaking fuel
injector), the rear oxygen sensor may not provide the expected lean or rich signal level during fuel cut-off or full load
condition. Hence, the oxygen sensor signal is checked for plausibility during this engine operating states.

DTC
• Signal plausibility during fuel cut off
Strategy
• Fuel Cut Off active
Enable
• Integrated Mass Air Flow since begin fuel cut-off >
Conditions
Case1) 20g
Threshold
• Voltage with fuel cut off > 0.2V
Value
Diagnostic
• 5 Sec. • Related fuse blown or missing
Time
DTC
• Signal stroke plausibility connectors
Strategy
• HO2S contamination
Enable
Page 191 of 491
• 5 Cycles of A/F Closed Loop passed after lambda
Enable
control active.
Conditions
Case2) • Lambda controller is not on the limit
Threshold
• Sensor voltage < 0.25V
Value
Diagnostic
• 2 min.
Time
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
Page 192 of 491
MONITOR DTC STATUS
Page 193 of 491
Repair" procedure.

or damage.
Go to "HO2S Fuse Inspection" procedure

HO2S FUSE INSPECTION
1. Ignition "OFF" & Engine "OFF"
2. Verify "10A Sensor fuse" is installed and not blown.
3. If OK, go to "Component Inspection" procedure.
If NG, replace fuse and repair any shorts as necessary and go to "Verification of Vehicle Repair" procedure.
Page 194 of 491
3. Connect Scantool and monitor the "O2 SNSR VOLT.(B1/S1)" parameter on the Scantool data list.
Test Condition : Engine "ON"

procedure.
procedure.


COMPONENT LOCATION
Page 195 of 491
The rear heated oxygen sensor is mounted on the rear side of the Catalytic Converter (warm-up catalytic converter)
or in the rear exhaust pipe, which detects the catalyst efficiency. The rear heated oxygen sensor (HO2S) produces a
voltage between 0V and 1V. This rear heated oxygen sensor is used to estimate the oxygen storage capability. If a
catalyst has good conversion properties, the oxygen fluctuations are smoothed by the oxygen storage capacity of the
catalyst. If the conversion provided by the catalyst is low due to aging, poisoning or misfiring, then the oxygen
fluctuations are similar to signals from the front oxygen sensor.
DTC DESCRIPTION
ECM sets DTC P0136 if the ECM detects that the rear HO2S signal circuit is open.

ITEM DETECTING CONDITION POSSIBL ECAUSE
Enable Condition • No relevant failure • Open in ground harness
• 10<Battery voltage(V) <16 • Contact resistance in
connectors
Threshold Value • Sensor element resistance > 60kΩ
Diagnostic Time • 30 sec. Sensor(HO2S)
SIGNAL WAVEFORM
Page 196 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 197 of 491
Repair" procedure.

or damage.

1. Ignition "OFF"
Page 198 of 491
connector(C68-2).
Repair open in the ground circuit and go to "Verification of Vehicle Repair" procedure
connector(C68-2).
Is resistance within the specification?
Page 199 of 491
2. Connect Scantool and monitor the "RR OXYGEN SNSR-B1" parameter on the Scantool data list.
Test Condition : Engine "ON" & In Idle("Closed Loop")condition

Specification : Above 0.6V
3. Is "RR OXYGEN SNSR-B1" sensor data near the specification?
procedure
procedure


COMPONENT LOCATION
Page 200 of 491
or in the rear exhaust pipe, which is able to detect catalyst efficiency. The rear heated oxygen sensor (HO2S)
produces a voltage between 0V and 1V. This rear heated oxygen sensor is used to estimate the oxygen storage
capability. If a catalyst has good conversion properties, the oxygen fluctuations are smoothed by the oxygen storage
capacity of the catalyst. If the conversion provided by the catalyst is low due to aging, poisoning or misfiring, then
the oxygen fluctuations are similar to signals from the front oxygen sensor.
DTC DESCRIPTION
ECM sets DTC P0137 if the ECM detects signal voltage lower than the possible range of a properly operating rear
heated oxygen sensor (HO2S).

• Sensor preheating and full heating phases finished • Short to ground in signal
Enable Conditions
• Battery voltage >10V harness
Threshold Value connectors
<10Ω
Diagnostic Time • 30 sec. Sensor.(HO2S)
SIGNAL WAVEFORM
Page 201 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 202 of 491
Repair" procedure.

or damage.

1. Ignition "OFF"
Page 203 of 491
2. Install Scantool and monitor the "RR OXYGEN SNSR-B1" parameter on the Scantool data list.

3. Is "RR OXYGEN SNSR-B1" sensor data within the specification?
procedure
procedure
Page 204 of 491

COMPONENT LOCATION
DTC DESCRIPTION
ECM sets DTC P0138 if the ECM detects signal voltage higher than the possible range of a properly operating rear

Page 205 of 491
• Short to Battery in signal
Sensor.(HO2S)
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
Page 206 of 491
MONITOR DTC STATUS

Repair" procedure.

or damage.

1. Ignition "OFF"
Page 207 of 491
4. Measure voltage between terminal 1 of the HO2S harness connector and chassis ground.

3. Is sensor display within the specification?
procedure.
procedure.
Page 208 of 491

COMPONENT LOCATION
DTC DESCRIPTION
The ECM monitors rich-lean switching time of rear heated oxygen sensor (HO2S) after fuel cut-off to validate
dynamic behaviour of rear heated oxygen sensor (HO2S). After detection of fuel cut-off engine operating state, the
ECM measures rich-lean switching time of the rear heated oxygen sensor (HO2S) signal and compares it to the
predetermined limit value. DTC P0139 is set when the switching time is bigger than the limit value. If same error
code is set in the next driving cycle, the ECM illuminates the MIL.

Page 209 of 491
• Slow response(Switching time check at entry in fuel
DTC Strategy
cut off)
• Leak in intake or exhaust
• Fuel cut-off phase
system
• Sensor preheating and full phase finished
Enable Condition • Faulty fuel system.
• Catalyst temp.model >350°C(662°F)
• Front and rear HO2S
• Coolant temp>70°C(158°F) connections reversed.
• Average ratio(between measured and maximum • Contact resistance in
Threshold Value
allowed switching time at entry in fuel cut-off) > 1 connectors
Diagnostic Time • 5 fuel cut-off phases
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
Page 210 of 491
MONITOR DTC STATUS
Page 211 of 491
1) History (Not Present) fault : DTC occurred but has been cleared.
2) Present fault : DTC is occurring at present time.
Repair" procedure.
VISUAL / PHYSICAL INSPECTION

B. Check for corrosion on terminals
C. Check for terminal tension ( at the HO2S and at the ECM)
D. Check for damaged wiring
E. Check the HO2S ground circuit for a good connection
properly.
Go to "Exhaust System Inspection" procedure.

1. Check the exhaust system for an exhaust leak near the engine.
2. Was an exhaust leak found?
Go to "Air Leakage Inspection " procedure.

B. Exhaust system between HO2S and Three way catalyst for air leakage
C. EVAP system for leakage
D. PCV hose for proper installation
'Repair as necessary and go to "Verification of Vehicle Repair" procedure

2. Install a fuel pressure gage
Page 212 of 491
Test Condition : Ignition "ON" & Engine "ON" & Vacuum hose disconnected at Idle

clogging.
FUEL INJECTOR INSPECTION
A. Ensure that the sensor is securely installed.
C. Check for damaged wiring.
Repair as necessary and go to next step.
3. Connect Scantool and monitor the "O2 SNSR VOLT.(B1/S2)" parameter on the Scantool data list.
Test Condition : Ignition "ON" & Engine "ON" & In Idle("Closed Loop")condition
Page 213 of 491
4. Is sensor data near the specified value?
procedure.
procedure.


COMPONENT LOCATION
Page 214 of 491
DTC DESCRIPTION
There are 3 cases which DTC P0140 sets.
(I) Signal monitoring during fuel cut-off: The ECM monitors rear O2 sensor signal level during fuel cut-off which
normally shows near 0V and sets DTC P0140 when signal level is too high.
(II) Signal monitoring after fuel cut-off: The ECM monitors rear O2 sensor signal level for a certain time after leaving
fuel cut-off and sets DTC P0140 when signal variation during checked period is too small.
(III) Signal monitoring during full load: The ECM monitors rear O2 sensor signal during full load which applies rich
air-fuel mixture and sets DTC P0140 when rear O2 sensor signal is too low.
DTP DETDCING CONDITION

Page 215 of 491
DTC Strategy • Sensor voltage excursion for Lean and Rich mixture
Enable • Full Phase finished
Conditions • Integrated MAF in Fuel cut-Off>18g
• Integrated MAF after Fuel cut-Off>40g
Case1)
Threshold
• Signal increase < 30mV
Value
Diagnostic
• 0.3 sec. • Contact resistance in
Time
connectors
• Sensor preheating and full heating phases finished • HO2S contamination
Enable
Conditions
• Integrated MAF after starting fuel cut-off>20g
Case2) Threshold
Value
Diagnostic
• 5 after fuel cut off phase
Time
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
Page 216 of 491
MONITOR DTC STATUS
Page 217 of 491
Repair" procedure.

or damage.
Go to "HO2S Fuse Inspection" procedure.

Page 218 of 491
procedure
procedure


COMPONENT LOCATION
Page 219 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0150 if the ECM detects that the front HO2S signal circuit is open.

DTC Strategy • Check open circuit on front HO2S
Enable Condition • Battery voltage >10V • Open in ground harness
• Lambda control active • Contact resistance in
connectors
Threshold Value • 0.4V < Sensor voltage <0.5V
Diagnostic Time • 10 Seconds Sensor(HO2S)
SIGNAL WAVEFORM
Page 220 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 221 of 491
Repair" procedure.

or damage.

1. Ignition "OFF"
2. Disconnect HO2S and ECM connectors.
Page 222 of 491
3. Measure resistance between terminal 2 of the HO2S harness connector and 21 of the ECM harness
connector(C68-2).
connector(C68-2).
Page 223 of 491
Fig 1 ) Normal value with idle after warm up : Signal is switching form rich (above 0.45V) to lean (below 0.45V) a
minimum of 3 times in 10
Fig 2) Open in signal circuit with ignition ON : Approx. 0.4~0.5V
procedure
procedure.


COMPONENT LOCATION
Page 224 of 491
DTC DESCRIPTION
The control unit of the linear oxygen sensor built inside the ECM monitors short circuit error on all front Heated
Oxygen Sensor (HO2S) control lines and ECM sets P0151 with short circuit to ground.

Enable Conditions
• Sensor voltage <0.02V and element resistance • Short to ground in signal
Threshold Value
<10Ω harness
Diagnostic Time • 60 sec. • Contact resistance in
connectors
• Reset lambda adaptation and fuel trim adaptation.
• Front HO2S heater is controlled in open loop Sensor.(HO2S)
Fail Safe control.
• EVAP. Emission control function is controlled in
minimum operation mode.
SIGNAL WAVEFORM
Page 225 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 226 of 491
Repair" procedure.

or damage.

1. Ignition "OFF"
Page 227 of 491
Page 228 of 491
procedure.
for proper operation.. If the problem is corrected, replace HO2S and then go to "Verification of Vehicle Repair"
procedure.


COMPONENT LOCATION
Page 229 of 491
DTC DESCRIPTION
The control unit of the linear oxygen sensor built inside the ECM monitors short circuit error on all front Heated
Oxygen Sensor (HO2S) control lines and ECM sets P0152 with short circuit to battery.

Sensor.(HO2S)
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
Page 230 of 491
MONITOR DTC STATUS

Page 231 of 491
Repair" procedure.

or damage.
Go to " Signal Circuit Inspection" procedure.

1. Ignition "OFF"
4. Measure voltage between terminal 1 of the HO2S harness connector and chassis ground.
Go to "Component Circuit Inspection" procedure.
Page 232 of 491
procedure.
procedure.


COMPONENT LOCATION
Page 233 of 491
DTC DESCRIPTION
The ECM monitors front oxygen sensor amplitude level and compares it to predetermined minimum amplitude value
which could increase emission or disturb lambda control by the effect of aging on the oxygen sensor. The ECM sets
DTC P0153 when the amplitude of oxygen sensor is equal to or less than minimum amplitude threshold.

• Comparison of O2 sensor lean/rich period with
DTC Strategy
calculated period
• 400°C(752°F)< Catalyst Temp.Model
<600°C(1112°F) • Leak in intake or exhaust
• Coolant temp. >70°C(158°F) system
Enable Conditions • 800 <Engine speed(RPM) <2500 • Faulty fuel system.
• Mass air flow <250 mg/stk • Front and rear HO2S
• No misfire detected connections reversed.
• Not transient condition • Contact resistance in
connectors
• Sum of O2 sensor lean/rich period > calculated
Threshold Value • HO2S contamination
period
Page 234 of 491
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
MONITOR DTC STATUS
Page 235 of 491
Repair" procedure.
C. Check for terminal tension ( at the HO2S and at the ECM).
D. Check for damaged wiring.
E. Check the HO2S ground circuit for a good connection.
properly.

Page 236 of 491

B. Exhaust system between HO2S and Three way catalyst for air leakage.
C. EVAP system for leakage.
D. PCV hose for proper installation.
Go to "Fuel Pressure Inspection" procedure

Test Condition : Engine "ON" & Vacuum hose disconnected at Idle.


clogging.
FUEL INJECOTR INSPECTION
Page 237 of 491
3. Install Scantool and monitor the "FR OXYGEN SNSR-B2" parameter on the Scantool data list.
Test Condition : Ignition "ON" & Engine "ON"

procedure.


COMPONENT LOCATION
Page 238 of 491
DTC DESCRIPTION

DTC
• Signal plausibility during fuel cut off
Strategy
• Fuel Cut Off active
Enable
• Integrated Mass Air Flow since begin fuel cut-off
Conditions
Case1) >20g
Threshold
Value
Diagnostic
• 5 Sec. • Related fuse blown or missing
Time
DTC
• Signal stroke plausibility connectors
Strategy
Enable
Page 239 of 491
• 5 Cycles of A/F Closed Loop passed after lambda
Enable
control active.
Conditions
Case2) • Lambda controller is not on the limit
Threshold
• Sensor voltage < 0.25V
Value
Diagnostic
• 2 min.
Time
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
Page 240 of 491
MONITOR DTC STATUS
Page 241 of 491
Repair" procedure.

or damage.
Go to "HO2S Fuse Inspection" procedure

1. Ignition "OFF" & Engine "OFF"
Page 242 of 491
3. Install Scantool and monitor the "FR OXYGEN SNSR-B2" parameter on the Scantool data list.
Test Condition : Ignition "ON" & Engine "ON"

procedure.


COMPONENT LOCATION
Page 243 of 491
or in the rear exhaust pipe, which detects the catalyst efficiency. The rear heated oxygen sensor (HO2S) produces a
voltage between 0V and 1V. This rear heated oxygen sensor is used to estimate the oxygen storage capability. If a
catalyst has good conversion properties, the oxygen fluctuations are smoothed by the oxygen storage capacity of the
catalyst. If the conversion provided by the catalyst is low due to aging, poisoning or misfiring, then the oxygen
fluctuations are similar to signals from the front oxygen sensor.
DTC DESCRIPTION
ECM sets DTC P0136 if the ECM detects that the rear HO2S signal circuit is open.

ITEM DETECTING CONDITION POSSIBL ECAUSE
Enable Condition • No relevant failure • Open in ground harness
• Battery voltage > 10V • Contact resistance in
connectors
Threshold Value • Sensor element resistance > 60 kΩ
Diagnostic Time • 30 sec. Sensor(HO2S)
SIGNAL WAVEFORM
Page 244 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 245 of 491
Repair" procedure.

or damage.

1. Ignition "OFF"
2. Disconnect HO2S and ECM connectors.
Page 246 of 491
3. Measure resistance between terminal 2 of the sensor harness connector and 24 of the ECM harness connector.
connector(C68-2).
Page 247 of 491
Test Condition : Engine "ON" & In Idle("Closed Loop")condition.

Specification : Above 0.6V.
3. Is sensor data within the specification?
procedure.
procedure.


COMPONENT LOCATION
Page 248 of 491
or in the rear exhaust pipe, which is able to detect the catalyst efficiency. The rear heated oxygen sensor (HO2S)
DTC DESCRIPTION

DTC Strategy • Sensor Voltage Low
• Sensor preheating and full heating phases finished • Short to ground in signal
Enable Conditions
<10Ω
Diagnostic Time • 30 sec Sensor(HO2S)
SIGNAL WAVEFORM
Page 249 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 250 of 491
Repair" procedure.
TERMINAL & CONNECTOR INSECTION

or damage.

1. Ignition "OFF"
Page 251 of 491
3. Measure resistance between terminal 1 of the sensor harness connector and chassis ground.
Repair open or short to ground in signal circuit and go to "Verification of Vehicle Repair" procedure.

procedure.
procedure.
Page 252 of 491

COMPONENT LOCATION
or in the rear exhaust pipe, which is able to detect the catalyst efficiency. The rear heated oxygen sensor (HO2S)
DTC DESCRIPTION

Page 253 of 491
DTC Strategy • Sensor Voltage High
Diagnostic Time • 1 sec
Sensor(HO2S)
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
Page 254 of 491
MONITOR DTC STATUS

Page 255 of 491
Repair" procedure.
TERMINAL & CONNECTOR INSECTION

or damage.

1. Ignition "OFF".
Page 256 of 491

3.
procedure.
procedure.


COMPONENT LOCATION
Page 257 of 491
DTC DESCRIPTION
The ECM monitors rich-lean switching time of rear heated oxygen sensor (HO2S) after fuel cut-off to validate
dynamic behaviour of rear heated oxygen sensor (HO2S). After detection of fuel cut-off engine operating state, the
ECM measures rich-lean switching time of the rear heated oxygen sensor (HO2S) signal and compares it to the
predetermined limit value. DTC P0159 is set when the switching time is bigger than the limit value. If same error
code is set in the next driving cycle, the ECM illuminates the MIL.

DTC Strategy • Slow response(Switching time check at entry in fuel cut off)
Enable • Sensor preheating and full phase finished • Leak in intake or exhaust
Conditions • Catalyst temp.model >350°C(662°F) system
• Coolant temp >70°C(158°F) • Faulty fuel system.
• Front and rear HO2S
Threshold • Average ratio(between measured and maximum allowed connections reversed.
Value switching time at entry in fuel cut-off) > 1 • Contact resistance in
Diagnostic connectors
• 5 fuel cut-off phases
Time • HO2S contamination
MIL On
Condition
SIGNAL WAVEFORM
Page 258 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS
Page 259 of 491
Repair" procedure.
VISUAL / PHYSICAL INSPECTION

B. Check for corrosion on terminals
C. Check for terminal tension ( at the HO2S and at the ECM)
D. Check for damaged wiring
E. Check the HO2S ground circuit for a good connection
properly.


Page 260 of 491
B. Exhaust system between HO2S and Three way catalyst for air leakage
C. EVAP system for leakage
D. PCV hose for proper installation
'Repair as necessary and go to "Verification of Vehicle Repair" procedure

2. Install a fuel pressure gage
Test Condition : Ignition "ON" & Engine "ON" & Vacuum hose disconnected at Idle

clogging.
Page 261 of 491
3. Is sensor data near the specified value?
procedure.
procedure.


COMPONENT LOCATION
Page 262 of 491
DTC DESCRIPTION
There are 3 cases which DTC P0160 sets.
(I) Signal monitoring during fuel cut-off: The ECM monitors rear O2 sensor signal level during fuel cut-off which
normally shows near 0V and sets DTC P0160 when signal level is too high.
(II) Signal monitoring after fuel cut-off: The ECM monitors rear O2 sensor signal level for a certain time after leaving
fuel cut-off and sets DTC P0160 when signal variation during checked period is too small.
(III) Signal monitoring during full load: The ECM monitors rear O2 sensor signal during full load which applies rich
air-fuel mixture and sets DTC P0160 when rear O2 sensor signal is too low.
DTP DETDCING CONDITION

Page 263 of 491
DTC Strategy • Sensor voltage excursion for Lean and Rich mixture
Enable • Full Phase finished
Conditions • Integrated MAF in Fuel cut-Off>18g
• Integrated MAF after Fuel cut-Off>40g
Case1)
Threshold
• Signal increase < 30mV
Value
Diagnostic
• 0.3 sec. • Contact resistance in
Time
connectors
• Sensor preheating and full heating phases finished • HO2S contamination
Enable
Conditions
• Integrated MAF after starting fuel cut-off>20g
Case2) Threshold
Value
Diagnostic
• 5 after fuel cut off phase
Time
SIGNAL WAVEFORM
SCHEMATIC DIAGRAM
Page 264 of 491
MONITOR DTC STATUS
Page 265 of 491
Repair" procedure.

or damage.
Go to "HO2S Fuse Inspection" procedure.

Page 266 of 491
procedure
procedure


COMPONENT LOCATION
Page 267 of 491
GENERAL DESCRIPTION
The Lambda closed-loop control system is included in the engine’ s control system. The control system regulates the
lambda upstream with the HO2S signal. Rich mixtures generate high concentrations of CO, H2, and HC. Lean
mixtures generate the high concentrations of NOx, and free oxygen.
DTC DESCRIPTION
If the lambda controller reaches the maximum or minimum threshold, then feedback control is no longer possible and
emissions will be increased. The ECM sets DTC P0170 if no proportional fuel adaptation occurs for a defined time
after the lambda controller has reached its minimum or maximum threshold.

DTC Strategy • Monitoring deviation of lambda controller • Air leakage or restriction in
intake or exhaust system
• Canister purge solenoid closed • Dirty engine oil or oil level too
Enable Conditions
• Coolant temperature>60°C(140°F) high
• Front HO2S or MAFS
Threshold Value • Lambda controller = +/-32%
contamination
Diagnostic Time • 2 min • Fuel system
• EVAP system
MIL On Condition • 2 Driving Cycles • Faulty sensor signals
MONITOR DTC STATUS
If any codes relating to fuel system, injectors, HO2S, ECT(Engine Coolant Temperature)Sensor, Throttle Position
sensor or Mass Air Flow Sensor are stored, do ALL REPAIRS associated with those codes before proceeding
Page 268 of 491
Repair" procedure.
Go to "Monitor Actuation Test" procedure.

The main purpose of this test is to identify potential engine mechanical condition problems and fuel and ignition
systems problems that are not common to all cylinders. For best results, perform this test while maintaining as steady
an rpm reading as possible.
Before beginning tests; set the parking brake, place gear selector in P or N and block drive wheels for safety.
1. Warm up the engine to normal operating temperature and let it idle.
2. Using a Scan Tool and select "INJECTOR #1" parameter on the Actuation Test mode shown in the figure.
3. Monitor engine rpm and shut off the injector #1 by pressing "STRT(F1)" key.
Page 269 of 491
4. Repeat procedure on all injectors and record the engine rpm.
Specification : All cylinders should show an even RPM drop.
5. Was each cylinder's rpm drop within the same value?
Go to " Check intake/exhaust system for restriction or leakage " procedure.
Cylinders with the least amount of RPM drop are not contributing their share of power. Go to "Fuel Injector
Inspection" procedure and check the suspect cylindersNote) If the RPM loss between cylinders is quite
large(200RPM or more) and engine has high mileage, there is possibility of engine wear. Perform compression
test with pressure gauge to check the engine wear.
CHECK INTAKE/EXHAUST SYSTEM FOR RESTRICTION OR LEAKAGE
1. Visually/physically inspect the air leakage in intake/exhaust system as following items.
B. Throttle body gasket.
C. Gasket between intake manifold and cylinder head.
D. Seals between intake manifold and fuel injectors.
E. Exhaust system between HO2S and Three way catalyst for air leakage.
2. Visually/physically inspect the restriction in intake/exhaust system as following items.
A. Air cleaner filter element for excessive dirt or for any foreign objects.
B. Throttle body inlet for damage or for any foreign objects.
C. Throttle bore, throttle plate and the IAC passages for chocking and for any foreign objects.
D. Restricted exhaust system.
Replace or repair as necessary and go to "Verification of Vehicle Repair" procedure
Go to " Check the engine oil contamination " procedure.

CHECK THE ENGINE OIL CONTAMINATION
1. Check the engine oil level. The oil level should be between the min. and max. marking. Fill to the correct oil level.
2. Warm up the engine to normal operating temperature
3. Connect Scantool and note the "SHORT TERM FUEL-B1" parameter on the Scantool data list.
4. Disconnect and plug the positive crankcase ventilation.
Page 270 of 491
5. Monitor the "SHORT TERM FUEL-B1" parameter on the Scantool data list once again.
Specification : The value should remain more or less unchanged
6. Is the displayed value within the specified value?
Go to "Sensor Contamination Inspection" procedure.
The engine oil is diluted with fuel. Chang the oil and oil filter and go to "Verification of Vehicle Repair"
procedure.
SENSOR CONTAMINATION INSPECTION
A. Remove and inspect the HO2S(B1S1) for any silicon contamination. This contamination will be indicated by a
white powdery coating and this will result in a but false voltage signal
B. Check MAFS for contamination, deterioration, or damage.
C. If contamination is evident on the HO2S or MAFS, replace contaminated sensor and go to next step.
CHECK FOR LEAKAGE IN EVAP SYSTEM
1. Check the EVAP. EM system for possible over.
(1) Remove the manifold side vacuum hose from the EVAP canister purge valve.
(2) Using a hand vacuum pump apply specified vacuum(Approx. 15 in, Hg) to the manifold side of the valve.
(3) Does the valve hold vacuum?
Go to "Fuel System Inspection" procedure
Repair air leakage and go to "Verification of Vehicle Repair" procedure.
FUEL SYSTEM INSPECTION

2. Disconnect the vacuum hose from the fuel pressure regulator and inspect the hose for the presence of fuel. If any
fuel is present in the vacuum hose, replace the fuel pressure regulator. Go to next step.
4. Start engine and let it idle. With the vacuum hose from the fuel pressure regulator disconnected, inspect fuel
pressure.

Page 271 of 491
5. Is fuel pressure within the specification?
Go to "Fuel Injector Inspection" procedure as below
Repair as necessary refer to inspection note as below and go to "Verification of Vehicle Repair"
procedure.(Inspection Note)

clogging
- If pressure quickly increases, check pressure regulator

1. Check the fuel injectors for clogging or any restrictions.
A. Test Condition : Ignition "OFF".
B. Specification : No clogging and restriction.
2. Is the fuel injector OK?
Visually/physically inspect the engine mechanical problem. Repair as necessary and go to "Verification of
Check injector for contamination, deterioration, or damage. Substitute with a known-good injector and check
for proper operation. If the problem is corrected, replace injector and then go to "Verification of Vehicle Repair"
procedure.


COMPONENT LOCATION
Page 272 of 491
GENERAL DESCRIPTION
In order to provide the best possible combination of drivability, fuel economy and emission control, the ECM uses a
closed loop air/fuel metering system. The ECM monitors the HO2S signal voltage and adjusts fuel delivery based it
in closed loop fuel control. Changes in fuel delivery will be indicated by the long-term and the short-term fuel trim
values. The ideal fuel trim value is around 0%. The ECM will add fuel when the HO2S signal is indicating a lean
condition. Additional fuel is indicated by fuel trim values that are above 0%. The ECM will reduce fuel when the
HO2S signal is indicating a rich condition. Reduction in fuel is indicated by fuel trim values that are below 0%. The
DTC relevant to fuel trim will be set when the amount reaches excessive levels because of a lean or rich condition.
DTC DESCRIPTION
Breaking lambda adaptation and lambda controller limits for a an extended period, which initially may have been
caused by failures in the fuel or intake system, will involve emission rise, and therefore shall be diagnosed by fuel
system monitoring.If same error code is set in the next driving cycle, the ECM illuminates the MIL. The lambda
controller deviations, including adaptive terms, are used for fuel system monitoring. The time counter is increased if
lambda controller deviations exceed a specific threshold and the ECM will then set DTC P0171 or P0172
respectively depending on the direction of the deviation. P0171 is set with positive deviation and P0172 is set with
negative deviation.

DTC Strategy • Monitoring deviation of fuel control
• Estimated canister loading >-11%
• Estimated altitude < 8000ft
Enable Conditions
• Coolant temp.>60°C (140°F) • Air leakage
• Fueling adaptation >14.5% • Leaking EVAP system
• Lambda controller +Trim value > 17%(lean A/F • Low fuel pressure
Threshold Value ratio) • Faulty sensor signals
• Lean A/F ratio: 400sec.
Page 273 of 491
MONITOR DTC STATUS
Repair" procedure.

Page 274 of 491

1. Visually/physically inspect the air leakage in intake/exhaust system as following items,
If OK, go to next step.
If NG, repair as necessary and go to "Verification of Vehicle Repair" procedure.
B. Throttle body gasket
C. Gasket between intake manifold and cylinder head
D. Seals between intake manifold and fuel injectors
E. Exhaust system between HO2S and Three way catalyst for air leakage
2. Check for air leakage in EVAP. Purge control valve.
Go to "Fuel System Inspection" procedure.

3. Install a fuel pressure gauge.
Page 275 of 491
pressure.

clogging

1. Check the fuel injector's for clogging or any restrictions.
procedure.
procedure.

Page 276 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION
system monitoring.
If same error code is set in the next driving cycle, the ECM illuminates the MIL. The lambda controller deviations,
including adaptive terms, are used for fuel system monitoring. The time counter is increased if lambda controller
deviations exceed a specific threshold and the ECM will then set DTC P0171 or P0172 respectively depending on
the direction of the deviation. P0171 is set with positive deviation and P0172 is set with negative deviation.

Page 277 of 491
DTC Strategy • Monitoring deviation of lambda fuel control
• Restricted intake or exhaust
system
Enable Conditions • Dirty engine oil or oil level too
• Coolant temp.>60°C (140°F) high
• Fueling adaptation >14.5% • Front HO2S or MAFS
• Lambda controller + Trim value <-27%(Rich A/F contamination
Threshold Value ratio) • Over purging of the EVAP
• Rich A/F ratio: 300sec. system
• High fuel pressure
• Faulty sensor signals
MONITOR DTC STATUS
Page 278 of 491
Repair" procedure.

CHECK FOR RESTRICTED INTAKE OR EXHAUST SYSTEM
Page 279 of 491
A. Air cleaner filter element for excessive dirt or for any foreign objects
B. Throttle body inlet for damage or for any foreign objects
C. Throttle bore, throttle plate and the ICA passages for chocking and for any foreign objects
D. Restricted exhaust system
Replace or repair as necessary and go to "Verification of Vehicle Repair" procedure.
Go to "Engine oil contamination Inspection" procedure.

ENGINE OIL CONTAMINATION INSPECTION
2. Warm up the engine to normal operating temperature.
4. Disconnect and plug the positive crankcase ventilation
6. Is the displayed value within the specification?
The engine oil is diluted with fuel. Change the oil and oil filter and go to "Verification of Vehicle Repair"
procedure.
A. Remove and inspect the front HO2S for any silicon contamination. This contamination will be indicated by a
white powdery coating and this will result in a but false voltage signal.
OVER PURGING OF THE EVAP SYSTEM

Page 280 of 491
pressure.

clogging

procedure.
procedure.
Page 281 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
The Lambda closed-loop control system is included in the engine’ s control system. The control system regulates the
lambda upstream with the HO2S signal. Rich mixtures generate high concentrations of CO, H2, and HC. Lean
mixtures generate the high concentrations of NOx, and free oxygen.
DTC DESCRIPTION
If the lambda controller reaches the maximum or minimum threshold, then feedback control is no longer possible and
emissions will be increased. The ECM sets DTC P0173 if no proportional fuel adaptation occurs for a defined time
after the lambda controller has reached its minimum or maximum threshold.

Page 282 of 491
DTC Strategy • Monitoring deviation of lambda controller • Air leakage or restriction in
intake or exhaust system
• Canister purge solenoid closed • Dirty engine oil or oil level too
Enable Conditions
• Coolant temperature>60°C(140°F) high
• Front HO2S or MAFS
Threshold Value • Lambda controller = +/-32%
contamination
Diagnostic Time • 2 min • Fuel system
• EVAP system
MIL On Condition • 2 Driving Cycles • Faulty sensor signals
MONITOR DTC STATUS
Repair" procedure.

Page 283 of 491
large200RPM or more) and engine has high mileage, there is possibility of engine wear. Perform compression test
with pressure gauge to check the engine wear.
CHECK INTAKE/EXHAUST SYSTEM FOR RESTRICTION OR LEAKAGE
1. Visually/physically inspect the air leakage in intake/exhaust system as following items.
2. Visually/physically inspect the restriction in intake/exhaust system as following items.
A. Air cleaner filter element for excessive dirt or for any foreign objects.
B. Throttle body inlet for damage or for any foreign objects.
C. Throttle bore, throttle plate and the IAC passages for chocking and for any foreign objects.
D. Restricted exhaust system.
Page 284 of 491
Replace or repair as necessary and go to "Verification of Vehicle Repair" procedure
Go to " Check the engine oil contamination " procedure.

CHECK THE ENGINE OIL CONTAMINATION
2. Warm up the engine to normal operating temperature
The engine oil is diluted with fuel. Chang the oil and oil filter and go to "Verification of Vehicle Repair"
procedure.
A. Remove and inspect the HO2S(B1S1) for any silicon contamination. This contamination will be indicated by a
CHECK FOR LEAKAGE IN EVAP SYSTEM
Go to "Fuel System Inspection" procedure

pressure.

Page 285 of 491

clogging

procedure.


COMPONENT LOCATION
Page 286 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
negative deviation.

DTC Strategy • Monitoring deviation of fuel centrol
Enable Conditions
• Coolant temp.>60°C (140°F)
• Fueling adaptation >14.5%
• Air leakage
• Lambda controller + Trim value > 17% (lean A/F • Leaking EVAP system
Threshold Value ratio) • Low fuel pressure
• Lean A/F ratio : 400 sec • Faulty sensor signals
Diagnostic Time • 900 sec
• EVAP. Emission control function is controlled in
Fail Safe
minimum operation mode
Page 287 of 491
MONITOR DTC STATUS
Mass Air Flow Sensor are stored, do ALL REPAIRS associated with those codes before proceeding with further
troubleshooting.
Repair" procedure.

Page 288 of 491

B. Throttle body gasket
C. Gasket between intake manifold and cylinder head
D. Seals between intake manifold and fuel injectors
E. Exhaust system between HO2S and Three way catalyst for air leakage
2. Check for air leakage in EVAP. Purge control valve.

3. Install a fuel pressure gauge.
Page 289 of 491
pressure.

clogging.

Visually/physically inspect the engine mechanical problem. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.
Check injector for contamination, deterioration, or damage. Substitute with a known-good injector and check for
proper operation. If the problem is corrected, replace injector and then go to "Verification of Vehicle Repair"
procedure.


COMPONENT LOCATION
Page 290 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
negative deviation.

DTC Strategy • Monitoring deviation of fuel control
• Restricted intake or exhaust
system
Enable Conditions • Dirty engine oil or oil level too
• Coolant temp.>60°C (140°F) high
• Fueling adaptation >14.5% • Front HO2S or MAFS
• Lambda controller +Trim value > -27%(Rich A/F contamination
Threshold Value ratio) • Over purging of the EVAP
• Rich A/F ratio: 300sec. system
• High fuel pressure
• Faulty sensor signals
Page 291 of 491
MONITOR DTC STATUS
Repair" procedure.

Page 292 of 491
C. Throttle bore, throttle plate and the ICA passages for chocking and for any foreign objects
D. Restricted exhaust system
Replace or repair as necessary and go to "Verification of Vehicle Repair" procedure.
Go to "Engine oil contamination Inspection" procedure.

Engine oil contamination Inspection
2. Warm up the engine to normal operating temperature.
3. Connect Scantool and note the "LONG FUEL-PART B2" parameter on the Scantool data list.
5. Monitor the "LONG FUEL-PART B2" parameter on the Scantool data list once again.
Go to "Sensor Contamination Inspection" procedure
The engine oil is diluted with fuel. Chang the oil and oil filter and go to "Verification of Vehicle Repair" procedure.
Page 293 of 491
A. Remove and inspect the front HO2S for any silicon contamination. This contamination will be indicated by a
OVER PURGING OF THE EVAP SYSTEM

pressure.
1) Check if fuel line pressure decreases when accelerating quickly

clogging.
2) If pressure quickly increases, check pressure regulator.

Page 294 of 491
Visually/physically inspect the engine mechanical problem. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.
Check injector for contamination, deterioration, or damage. Substitute with a known-good injector and check for
proper operation. If the problem is corrected, replace injector and then go to "Verification of Vehicle Repair"
procedure.


COMPONENT LOCATION
GENERAL DESCRIPTION
The ECM provides ground to one side of the coil in the fuel pump relay to control the fuel pump relay. The other
side of the fuel pump relay coil is connected to fuel pump relay, which activates when the ignition switch is ON. The
ECM monitors the control circuit between the fuel pump relay and the ECM. When the ignition switch is turned ON,
the ECM energizes the fuel pump relay, which sends power to the fuel pump.
DTC DESCRIPTION
ECM sets DTC P0230 if the ECM detects the fuel pump relay control circuit is open, shorted to ground or battery.

Page 295 of 491
• Check open or short to ground/battery in control
DTC Strategy
circuit
• Open or short in harness
Enable Conditions • Battery voltage>10V
Threshold Value • Short to ground, line break or short to battery connectors
• Faulty relay
MIL On Condition •-
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 296 of 491
Repair" procedure.

or damage.

1. Remove the fuel pump relay.
3. Measure the voltage between terminal 30 of the fuel pump relay harness connector and chassis ground.
Page 297 of 491
4. Measure the voltage between terminal 85 of the fuel pump relay harness connector and chassis ground.
Check for an open or short to ground in the power supply circuit. Repair as necessary and go to "Verification
(1) Ignition "OFF" & Relay connector : Disconnected.
(2) Measure resistance between terminal 86 of the relay harness connector and chassis ground.

Page 298 of 491
(2) Ignition "ON" and Engine "OFF".
(3) Measure voltage between terminal 86 of the relay harness connector and chassis ground.
Specification : Approx 0V

(1) Measure resistance between terminals 86 of the relay harness connector and 10 of the ECM harness
connector.
Specification : Approx 0Ω
Thoroughly check connectors for loose or poor connections, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair"
procedure.
1. Ignition "OFF".
2. Remove the fuel pump relay.
3. Apply 12V and a ground to 85 and 86 terminals of the fuel pump relay. (Component side)
4. Check if the fuel pump relay works well when it is energized. (If the fuel pump relay works normally, a clicking
sound can be heard.)
Page 299 of 491
5. Does the fuel pump relay operate normally?
Check relay for contamination, deterioration, or damage. Substitute with a known-good relay and check for
proper operation. If the problem is corrected, replace relay and then go to "Verification of Vehicle Repair"
procedure.


COMPONENT LOCATION
GENERAL DESCRIPTION
Based on information from various sensors, the ECM measures the fuel injection amount. The fuel injector is a
solenoid-operated valve and the fuel injection amount is controlled by length of time the fuel injector is held open.
The ECM controls each injector by grounding the control circuit. When the ECM energizes the injector by
grounding the control circuit, the circuit voltage should be low (theoretically 0V) and the fuel is injected. When the
ECM de-energizes the injector by opening the control circuit, the fuel injector is closed and circuit voltage should
momentarily peak.
DTC DESCRIPTION
ECM sets DTC P0261 if the ECM detects that injector (Cylinder #1) control circuit is shorted to ground.

Page 300 of 491
DTC Strategy • Driver Stage Check
• Open in power supply
Enable • 10< Battery voltage (V)<16 harness
Conditions • Engine speed (rpm)>30 • Short to ground in
Threshold Value • Short to ground control harness
connectors
MIL On • Faulty injector
Condition
SPECIFICATION
Temperature Resistance
(°F) (°F) (Ω)
20 68 13.8 ~ 15.2
SCHEMATIC DIAGRAM
Page 301 of 491
MONITOR DTC STATUS

Page 302 of 491
Repair" procedure.

or damage.

1. Ignition "ON".
2. Measure voltage between terminal 1 of the injector harness connector and chassis ground.
Check for a open in the power supply circuit between the main relay and the Injector.
Check for open or blown 15A injector fuse.
Page 303 of 491
(1) Ignition "OFF" & Relay connector : Disconnected.
(2) Measure resistance between terminal 2 of the relay harness connector and chassis ground.
procedure.
Repair open or short to ground in control harness and go to "Verification of Vehicle Repair" procedure.
1. Ignition "OFF".
2. Disconnect injector connector
3. Measure resistance between terminals 1 and 2 of the injector connector(Component side).
Specification : Approx. 13.8 ~ 15.2Ω at 20°C(68°F)
Check for intermittent fault. Observe the data parameter for a sudden change while wiggling the wiring and
tapping lightly on the suspect component.
Be careful not to damage wires or components during the test.

Repair as necessary and go to next step as below.
Check Injector for contamination, deterioration, or damage. Substitute with a known-good Injector and check
for proper operation. If the problem is corrected, replace Injector and then go to "Verification of Vehicle Repair"
procedure

Page 304 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
momentarily peak.
DTC DESCRIPTION

• 10< Battery voltage (V)<16 • Open or short to battery
Enable Conditions in control harness.
• Engine speed (rpm)>30
Threshold Value • Open or short to battery
connectors
Diagnostic Time • 1.5 sec • Faulty injector
Page 305 of 491
SPECIFICATION
(°F) (°F) (Ω)
20 68 13.8 ~ 15.2
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 306 of 491
Repair" procedure.

or damage.

1. Ignition "ON".
Page 307 of 491
(1) Ignition "OFF"
(2) Disconnect injector and ECM connectors.
(4) Measure voltage between terminal 2 of the injector harness connector and chassis ground.

2. Repair open or short to ground in control harness and go to "Verification of Vehicle Repair" procedure.
(1) Ignition "OFF".
(2) Measure resistance between terminals 2 of the injector harness connector and 33 of the ECM harness
connector(C68-3).
Page 308 of 491
procedure.
1. Ignition "OFF".
2. Disconnect injector connector.

procedure


COMPONENT LOCATION
Page 309 of 491
GENERAL DESCRIPTION
momentarily peak.
DTC DESCRIPTION

Enable • 10< Battery voltage (V)<16 harness
connectors
Condition
SPECIFICATION
(°F) (°F) (Ω)
20 68 13.8 ~ 15.2
SCHEMATIC DIAGRAM
Page 310 of 491
MONITOR DTC STATUS

Page 311 of 491
Repair" procedure.

or damage.

1. Ignition "ON".
Page 312 of 491
(1) Ignition "OFF".
(2) Measure resistance between terminal 2 of the injector harness connector and chassis ground.
procedure.
1. Ignition "OFF".

procedure

Page 313 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
momentarily peak.
DTC DESCRIPTION

• 10≤ Battery voltage (V)≤16 • Open or short to battery
Enable Conditions
• Engine speed (rpm)>30 in control harness.
connectors
Page 314 of 491
SPECIFICATION
(°F) (°F) (Ω)
20 68 13.8 ~ 15.2
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 315 of 491
Repair" procedure.

or damage.

1. Ignition "ON".
Page 316 of 491
(1) Ignition "OFF".

Page 317 of 491
2. Check for open in control circuit.
(1) Ignition "OFF".
connector(C68-3).
procedure.
1. Ignition "OFF".

procedure
Page 318 of 491


COMPONENT LOCATION
GENERAL DESCRIPTION
momentarily peak.
DTC DESCRIPTION

Page 319 of 491
Enable • 10≤ Battery voltage (V)≤16 harness
connectors
Condition
SPECIFICATION
(°F) (°F) (Ω)
20 68 13.8 ~ 15.2
SCHEMATIC DIAGRAM
Page 320 of 491
MONITOR DTC STATUS

Page 321 of 491
Repair" procedure.

or damage.

1. Ignition "ON".
Page 322 of 491
1. Check for short to ground in control circuit
(1) Ignition "OFF".
procedure.
1. Ignition "OFF".

procedure

Page 323 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
momentarily peak.
DTC DESCRIPTION

Enable Conditions in control harness.
• Engine speed (rpm)>30
connectors
Page 324 of 491
SPECIFICATION
(°F) (°F) (Ω)
20 68 13.8 ~ 15.2
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 325 of 491
Repair" procedure.

or damage.

1. Ignition "ON".
Page 326 of 491
(1) Ignition "OFF".
2. Repair open or short to ground in control harness and go to "Verification of Vehicle Repair" procedure.
(1) Ignition "OFF".
connector(C68-3).
Page 327 of 491
procedure.
1. Ignition "OFF".

procedure


COMPONENT LOCATION
Page 328 of 491
GENERAL DESCRIPTION
momentarily peak.
DTC DESCRIPTION

connectors
Condition
SPECIFICATION
(°F) (°F) (Ω)
20 68 13.8 ~ 15.2
SCHEMATIC DIAGRAM
Page 329 of 491
MONITOR DTC STATUS

Page 330 of 491
Repair" procedure.

or damage.

1. Ignition "ON".
Page 331 of 491
(1) Ignition "OFF".
procedure.
1. Ignition "OFF".

procedure

Page 332 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
momentarily peak.
DTC DESCRIPTION

• 10≤Battery voltage (V)≤16 • Open or short to battery
Enable Conditions
connectors
Page 333 of 491
SPECIFICATION
(°C) (°F) (Ω)
20 68 13.8 ~ 15.2
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 334 of 491
Repair" procedure.

or damage.

1. Ignition "ON".
Page 335 of 491
(1) Ignition "OFF".

Page 336 of 491
(1) Ignition "OFF".
connector(C68-3).
procedure.
1. Ignition "OFF".

procedure
Page 337 of 491


COMPONENT LOCATION
GENERAL DESCRIPTION
momentarily peak.
DTC DESCRIPTION

Page 338 of 491
connectors
Condition
SPECIFICATION
(°C) (°F) (Ω)
20 68 13.8 ~ 15.2
SCHEMATIC DIAGRAM
Page 339 of 491
MONITOR DTC STATUS

Page 340 of 491
Repair" procedure.

or damage.

1. Ignition "ON".
Page 341 of 491
1. Check for short to ground in control circuit
(1) Ignition "OFF".
procedure.
1. Ignition "OFF".

procedure

Page 342 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
momentarily peak.
DTC DESCRIPTION
ECM sets DTC P0274 if the ECM detects that injector (Cylinder #5) control circuit is open or short to battery
voltage.

Enable Conditions
connectors
Page 343 of 491
SPECIFICATION
(°C) (°F) (Ω)
20 68 13.8 ~ 15.2
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 344 of 491
Repair" procedure.

or damage.

1. Ignition "ON".
Page 345 of 491
(1) Ignition "OFF".
Repairas necessary and go to "Verfication of Vehicle Repair" procedure.

(1) Ignition "OFF".
connector(C68-3).
Page 346 of 491
procedure.
1. Ignition "OFF".

procedure


COMPONENT LOCATION
Page 347 of 491
GENERAL DESCRIPTION
momentarily peak.
DTC DESCRIPTION

connectors
Condition
SPECIFICATION
(°C) (°F) (Ω)
20 68 13.8 ~ 15.2
SCHEMATIC DIAGRAM
Page 348 of 491
MONITOR DTC STATUS

Page 349 of 491
Repair" procedure.

or damage.

1. Ignition "ON".
Page 350 of 491
(1) Ignition "OFF".
procedure.
1. Ignition "OFF".

procedure

Page 351 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
momentarily peak.
DTC DESCRIPTION

Enable Conditions
connectors
Page 352 of 491
SPECIFICATION
(°C) (°F) (Ω)
20 68 13.8 ~ 15.2
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 353 of 491
Repair" procedure.

or damage.

1. Ignition "ON".
Page 354 of 491
(1) Ignition "OFF".

Page 355 of 491
(1) Ignition "OFF".
connector(C68-3).
procedure.
1. Ignition "OFF".

procedure
Page 356 of 491


COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION
Because of the tolerance in mechanical machining and assembling process of the target wheel, the duration of each
segment are not always same but differ from segment to segment on the same engine. And this irregular segment
duration can disturb misfiring detection which is based on the difference of engine rotational speed between the firing
and the misfiring cylinder. The ECM compares segment duration of 4 cylinders during fuel cut-off and deceleration
period. With this comparison ECM perform segment adaptation to adapt the difference of each segment duration.
The ECM sets DTC P0315 if any of segment adaptation value is on the limit.

Page 357 of 491
DTC Strategy • Monitor segment time adaptation
• 11 ≤ Battery voltage(V) ≤ 16
• 2,000 < Engine speed < 3,000 • Improperly installed target
Enable Conditions wheel
• No failure on injector, MAFS, CKPS, CMPS and
PCSV • Contact resistance in
connectors
Threshold Value • Segment adaptation value = 5/1000
SIGNAL WAVEFORM
MONITOR DTC STATUS
If any codes relating to CKPs are stored, do ALL REPAIRS associated with those codes before proceeding with
troubleshooting.
Page 358 of 491

Repair" procedure.
1. Start engine and let vehicle idle
2. Connect scantool and select "Current Data" mode.
3. Monitor "CKP T/WHEELS-LO CMP" & "CKP T/WHEELS-HI CMP" parameters on the Scantool data list.
Specification :
"CKP T/WHEELS-LO CMP" : 38 +/- 4 tooth
"CKP T/WHEELS-HI CMP" : 98 +/- 4 tooth
Page 359 of 491
4. Are "CKP T/WHEELS-LO CMP" & "CKP T/WHEELS-HI CMP" parameters within the specification?
Thoroughly check connectors between CKPS and ECM for loose or poor connections, bending, corrosion,
Repair" procedure.
A. Remove CKP and calculate air gap between sensor and flywheel/torque converter. Readjust as necessary
and go to next step.
Air gap [0.3~1.7 mm [0.012~0.067 in] = measure distance from hosing to teeth on flywheel/torque
converter (measurement "A") and from mounting surface on sensor to sensor tip (measurement "B")
subtract "B" from "A"
B. If failure to synchronize with CMP sensor, readjust timing system and go to next step.
Check CKP sensor for contamination, deterioration, or damage. Substitute with a known-good CKP sensor and
check for proper operation. If the problem is corrected, replace CKP sensor and then go to "Verification of


COMPONENT LOCATION
GENERAL DESCRIPTION
Page 360 of 491
DTC DESCRIPTION

DTC Strategy • Voltage Range Check
• Knock control enabled • Open/short in signal or
Enable Conditions
• Engine speed >1800 rpm ground circuit
Threshold Value • Mean value of sensor signal < 0.1V
connectors
Diagnostic Time • 10*720 crank angle • Faulty knock sensor
SCHEMATIC DIAGRAM
MONITOR DTC STATUS
proceeding with further troubleshooting.
Page 361 of 491

Repair" procedure.

or damage.

1. Ignition "OFF".
2. Disconnect Knock sensor connector.
Page 362 of 491
3. Measure resistance between terminals 1 of the sensor harness connector and 30 of the ECM harness
connector(C68-3).
Check for an open in the ground circuit. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.
(1) Ignition "OFF".
(2) Measure resistance between terminals 2 of the sensor harness connector and 29 of the ECM harness
connector(C68-3).

Page 363 of 491
(1) Ignition "OFF"
(2) Measure resistance between terminal 2 of the sensor harness connector and chassis ground

3. Check for short to power in signal harness.
(1) Ignition "OFF"
(4) Measure voltage between terminal 2 of the sensor harness connector and chassis ground
Page 364 of 491
1. Component resistance inspection.
(1) Ignition "OFF"
(2) Disconnect knock sensor connector
(3) Measure resistance between terminals 1 and 2 of the sensor connector(Component side).
Specification : Approx. 5MΩ at 20°C(68°F)
2. Output signal inspection

(1) Remove knock sensor from vehicle and secure (across mounting boss) in a shop vise.
(2) Set up an oscilloscope as follows :
Channel A (+): terminal 2 (-): terminal 1
(3) Rap on vise with a ball peen hammer while monitoring oscilloscope screen (there should be a spike of less
than 1 volt with each hammer strike).
Specification : knock sensor send a voltage spike with hammer strikes
3. Installation torque inspection.

(1) Check the installation torque of the knock sensor.
Specification : 16.7 ~ 25.5 N·m(1.7 ~ 2.6 kgf·m, 12.3 ~ 18.8 lb·ft)
Check knock sensor for contamination, deterioration, or damage. 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
procedure.

Page 365 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION

DTC Strategy • Voltage Range Check
• Knock control enabled • Open/short in signal or
Enable Conditions
• Engine speed >1800 rpm ground circuit
Threshold Value • Mean value of sensor signal < 0.1V
connectors
Diagnostic Time • 10*720 crank angle • Faulty knock sensor
SCHEMATIC DIAGRAM
Page 366 of 491
MONITOR DTC STATUS
proceeding with further troubleshooting.

Repair" procedure.

Page 367 of 491

or damage.

1. Ignition "OFF".
2. Disconnect Knock sensor connector.
3. Measure resistance between terminals 1 of the sensor harness connector and 32 of the ECM harness
connector(C68-3).
procedure.
Page 368 of 491
(1) Ignition "OFF".
connector(C68-3).

(1) Ignition "OFF"

Page 369 of 491
(1) Ignition "OFF"
1. Component resistance inspection.
(1) Ignition "OFF"
(2) Disconnect knock sensor connector
(3) Measure resistance between terminals 1 and 2 of the sensor connector(Component side).
Specification : Approx. 5MΩ at 20°C(68°F)
2. Output signal inspection

(1) Remove knock sensor from vehicle and secure (across mounting boss) in a shop vise.
(2) Set up an oscilloscope as follows :
Channel A (+): terminal 2 (-): terminal 1
(3) Rap on vise with a ball peen hammer while monitoring oscilloscope screen (there should be a spike of less
than 1 volt with each hammer strike).
Specification : knock sensor send a voltage spike with hammer strikes

Page 370 of 491
3. Installation torque inspection.
(1) Check the installation torque of the knock sensor.
Specification : Approx. 16.7 ~ 25.5 N·m(1.7 ~ 2.6 kgf·m, 12.3 ~ 18.8 lb·ft)
Check knock sensor for contamination, deterioration, or damage. 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
procedure.


COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION
Page 371 of 491
DTC
• Check Crankshaft Signal Switching
Strategy
Enable
• Before Synchronization
Conditions
• Valid Crankshaft Teeth not yet detected • Open or short in signal,
Threshold with Camshaft Signal ground or power supply
Case 1
Value • Can not detect TDC with valid circuit
Crankshaft Teeth and Camshaft Signal • Contact resistance in
Diagnosis connectors
• 4 revolutions • Damage to the connecting
Time
flange/flywheel
Enable • Misadjust crankshaft and
• After Synchronization
Conditions
camshaft pulley position
Threshold • Number of Crankshaft Tooth is not • Faulty CKP sensor
Case2
Value correct
Diagnosis
• 5 revolutions
Time
SINGAL WAVEFORM
SCHEMATIC DIAGRAM
Page 372 of 491
MONITOR DTC STATUS


Repair" procedure.

Page 373 of 491
or damage.

1. Ignition "OFF".
2. Disconnect CKP sensor connector.
Check for a open in the power supply circuit between the main relay and the crankshaft position sensor,
Especially check for open or blown 10A sensor fuse refer to "Component Circuit".
1. Ignition "OFF".
2. Measure resistance between terminals 3 of the sensor harness connector and chassis ground.
procedure.
Page 374 of 491
(1) Ignition "OFF".
connector(C68-3).


Page 375 of 491
2. Connect scantool and select "Current Data" mode
Specification :
Page 376 of 491
locks or poor terminal to wire connection. Repair as necessary and go to "Verification Vehicle Repair" procedure
.
A. Remove CKP and calculate air gap between sensor and flywheel/torque converter. Readjust as necessary
and go to next step.
Air gap [0.3~1.7 mm [0.012~0.067 in] = measure distance from hosing to teeth on flywheel/torque
converter (measurement "A") and from mounting surface on sensor to sensor tip (measurement "B")
subtract "B" from "A"
B. If fail to synchronize with CMP sensor, readjust timing system and go to next step.
Check CKP sensor for contamination, deterioration, or damage. Substitute with a known-good CKP sensor and
check for proper operation. If the problem is corrected, replace CKP sensor and then go to "Verification of


COMPONENT LOCATION
GENERAL DESCRIPTION
Page 377 of 491
DTC DESCRIPTION

DTC Strategy • Check camshaft signal switching • Open or short in signal,
ground or power supply
Enable
• No Crankshaft Position Sensor signal error circuit
Conditions
Threshold Value • No signal switching connectors
Diagnostic Time • 80 revolutions • Misadjust crankshaft and
camshaft pulley position
MIL On Condition • 2 Driving Cycles • Faulty CMP sensor
SINGAL WAVEFORM
SCHEMATIC DIAGRAM
Page 378 of 491
MONITOR DTC STATUS


Repair" procedure.

Page 379 of 491
or damage.

1. Ignition "OFF".
2. Disconnect CMP sensor connector.
Check for a open in the power supply circuit between the main relay and the crankshaft position sensor,
Especially check for open or blown 10A sensor fuse refer to "Component Circuit".
1. Ignition "OFF".
2. Measure resistance between terminals 3 of the sensor harness connector and chassis ground.
Page 380 of 491
Check for an open or short to battery in the ground circuit.

connector(C68-4).


Page 381 of 491
2. Connect scantool and select "Current Data" mode
Specification :
Page 382 of 491
.
A. Remove CKP and calculate air gap.

B. If fail to synchronize with CMP sensor, readjust timing system and go to next step.
Check CMP sensor for contamination, deterioration, or damage. Substitute with a known-good CMP sensor
and check for proper operation. If the problem is corrected, replace CMP sensor and then go to "Verification of


COMPONENT LOCATION
GENERAL DESCRIPTION
The fuel level sensor measures the fuel level in fuel tank and its signal is used to determine if the fuel level is too high
or too low to be able to accurately detect EVAP system failures.
DTC DESCRIPTION
The ECM sets DTC P0461 if ECM detects that fuel level change from maximum to minimum is less than the
threshold value
Page 383 of 491
DTC Strategy • Check signal stuck
Enable Conditions • Minimum mileage:322km(200 mile)
• Difference between filtered max./min.value and initial
value < 5%
• Faulty FLS
Diagnostic Time • Immediate
SPECIFICATION
Fuel
Resistance (Ω)
Level
E
Approx. 94~96
(Empty)
1/2 Approx. 89~91
F (Full) Approx. 3~4
SCHEMATIC DIAGRAM
MONITOR DTC STATUS
Page 384 of 491

2. No relevant DTC
Repair" procedure.

or damage.

FUEL LEVEL SENSOR (FLS) INSPECTION
1. Ignition "OFF"
2. Disconnect FLS harness connector
Page 385 of 491
3. Measure resistance between terminals 1 and 2 of the FLS connector(Component side).
Specification :
Fuel Level Resistance (Ω)

E (Empty) Approx. 94~96
1/2 Approx. 89~91
procedure
Check FLS for contamination, deterioration, or damage. Substitute with a known-good FLS and check for
proper operation. If the problem is corrected, replace FLS and then go to "Verification of Vehicle Repair"
procedure


2. No relevant DTC

Page 386 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION
threshold value

DTC Strategy • Voltage range check • Short to ground in signal
Enable Conditions
• Minimum time >200 sec. • Open in power supply
harness
Threshold Value • Short to ground or Line Break(Voltage < 0.02)
• Faulty FLS
SPECIFICATION
Fuel
Resistance (Ω)
Level
E
Approx. 94 ~ 96
(Empty)
1/2 Approx. 89 ~ 91
F (Full) Approx. 3 ~ 4
Page 387 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 388 of 491

or damage.

1. Ignition "OFF".
2. Disconnect Fuel Sender connector.
4. Measure voltage between terminal 3 of the Fuel Sender harness connector and chassis ground.
Check for a open/short in the power supply circuit. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.
Page 389 of 491
(1) Ignition "OFF".
(2) Disconnect FLS and ECM connector.
(3) Measure resistance between terminals 2 of the FLS harness connector and 5 of the ECM harness
connector(C68-4).

2. Check for short to ground in signal circuit
(1) Measure resistance between terminal 2 of the FTPS harness connector and chassis ground
Specification :Infinite

Page 390 of 491
Specification :

1/2 Approx. 89~91
procedure
procedure


COMPONENT LOCATION
Page 391 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
threshold value

• Short to battery in signal
Enable • Battery voltage >11V harness
Conditions • 200 seconds after starting • Open in power
Threshold Value • Signal voltage >4.95V supply/ground harness
connectors
MIL On • Faulty FLS
Condition
SPECIFICATION
Fuel
Resistance (Ω)
Level
E
Approx. 94 ~ 96
(Empty)
1/2 Approx. 89 ~ 91
SCHEMATIC DIAGRAM
Page 392 of 491
MONITOR DTC STATUS


Page 393 of 491

or damage.

1. Ignition "OFF"
2. Disconnect FLS and ECM connector
3. Measure resistance between terminals 1 of the FLS harness connector and 15 of the ECM harness
connector(C68-4).
Check for a open/short circuit. Repair as necessary and go to "Verification of Vehicle Repair" procedure.
2. Measure voltage between terminal 2 of the FLS harness connector and chassis ground.
(1)
Page 394 of 491

Specification :

1/2 Approx. 89~91
procedure
procedure


COMPONENT LOCATION
Page 395 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
The ECM sets DTC P0463 if ECM detects that fuel level signal is higher than the threshold value.

DTC Strategy • Check for signal fluctuation
• Engine state: part load
Enable Conditions • Minimum vehicle speed > 34km/h(21mph)
• Wheel speed gradient < 0.18% connectors
Threshold Value • Signal fluctuation > 50% • Faulty FLS
SPECIFICATION
Fuel
Resistance (Ω)
Level
E
Approx. 94 ~ 96
(Empty)
1/2 Approx. 89 ~ 91
SCHEMATIC DIAGRAM
Page 396 of 491
MONITOR DTC STATUS


Page 397 of 491

or damage.

1. Ignition "OFF"
2. Disconnect FLS harness connector
Specification :

1/2 Approx. 89~91
procedure
procedure

Page 398 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
The Wheel Speed Sensor (WSS) generates a waveform with a frequency proportional to the speed of the vehicle.
The signal generated by the WSS informs the ECM not only if the vehicle speed is low or high but also if the vehicle
is or is not moving. The ECM uses this signal to control the fuel injection, ignition timing, transaxle shift scheduling
and torque converter clutch scheduling. The WSS signal is also used to detect rough road conditions.
DTC DESCRIPTION
The ECM evaluates engine speed and mass air flow if there is no vehicle speed signal. This evaluation of both values
will detect open circuit or short circuit errors on the wheel speed sensor. The ECM sets DTC P0501 if there is no
vehicle speed signal from wheel speed sensor while both engine speed and mass air flow are higher than
predetermined threshold during the predetermined time.

DTC Strategy • Check vehicle speed signal
• Engine speed >2016 rpm
• Mass air flow >218mg/stk
Enable Conditions
• Coolant temperature > 60°C(140°F) • Open or short in harness
• No fuel shut-off • Contact resistance in
connectors
• Vehicle speed = 0 with high engine speed and high
Threshold Value • Faulty wheel speed sensor
load
Diagnostic Time • 60 sec. (AT)/40 sec. (MT)
Page 399 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

1. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)".
Page 400 of 491
[With ABS or Except Europe system] Go to "Monitor Scan tool Data" procedure.
[Europe & without ABS system] Go to "Signal Circuit Inspection[Without ABS]" procedure.
1. With vehicle raised on a lift , start the engine and place transaxle in Drive. Let vehicle idle and verify speedometer
indicates approx. 10km/h or more(6mph or more) on the instrument cluster.
2. [With ABS] Connect Scantool and select ABS system.
[Except Europe] Connect Scantool and select AUTOMATIC TRANSAXLE system.
3. [With Out]Monitor the "WHEEL SPD SENSOR-FR" parameter on the current data list.
[Except Europe]Monitor the "VEHICLE SPEED" parameter on the current data list.
Specification : 10km/h or more(6mph or more)

Page 401 of 491
4. Is value within the specification?
[With ABS]Wheel speed sensor is OK. Go to Go to "Signal Circuit Inspection[With ABS]" procedure.
[Except Europe]Vehicle speed sensor is OK. Open or short circuit between VSS and ECM control module.
If problems are found, repair as necessary and go to "Verification of Vehicle Repair" procedure.
Check the following conditions:

[With ABS]
A. Open or short circuit between wheel speed sensor(FR) and ABS(or ESP) control module
If problems are found, repair as necessary and go to "Verification of Vehicle Repair" procedure
If OK, check wheel speed sensor(FR). Repair as necessary and go to "Verification of Vehicle Repair"
procedure
[Except Europe]
A. Open or short circuit between VSS and ECM control module.
If problems are found, repair as necessary and go to "Verification of Vehicle Repair" procedure.
If OK, check VSS. Repair as necessary and go to "Verification of Vehicle Repair" procedure.

[With ABS]
Page 402 of 491
1. Check for open in circuit
(1) Ignition "OFF".
(2) Disconnect ECM and ABS or ESP Control Module connectors.
(3) Measure resistance between terminals 22 of the ECM harness connector and 3 of the ABS Control Module harness
connector(W/ABS).
Measure resistance between terminals 22 of the ECM harness connector and 6 of the ESP Control Module harness
connector(W/ESP).

2. Check for short to ground in circuit.
(1) Measure resistance between terminal 22 of the ECM harness connector and chassis ground
procedure.

[Without ABS]
Page 403 of 491
1. Check for open in circuit.
(1) Ignition "OFF".
(2) Disconnect ECM and wheel speed sensor(front right) harness connector.
(3) Measure resistance between wheel speed sensor harness connector and ECM harness connector.
[W/O 4WD]
A. Terminal 1(sensor) & Terminal 38(ECM)
B. Terminal 2(sensor) & Terminal 39(ECM)
[With 4WD]
A. Terminal 3(sensor) & Terminal 38(ECM)
B. Terminal 4(sensor) & Terminal 39(ECM)

Page 404 of 491
2. Check for short to ground in circuit.
(1) Measure resistance between terminal 38 of the ECM harness connector and chassis ground.
Check wheel speed sensor(FR) as follow:

A. Gap between ABS sensor and trigger wheel (Air gap : 0.3~1.1 mm(0.011 ~ 0.043 in))
B. Trigger wheel condition
C. Sensor resistance : Approx. 1,300~1,900Ω at 20°C(68°F)
Replace wheel speed sensor as necessary and go to "Verification of Vehicle Repair" procedure.


COMPONENT LOCATION
Page 405 of 491
GENERAL DESCRIPTION
When the TP sensor's signal indicates closed throttle position and the engine is idling, the ECM adjusts the idle
speed control actuator so that the engine runs at the correct idling speed, regardless of coolant temperature, load
and etc. When the additional load applied in the engine, the air flow through the idle speed control actuator is
increased momentarily to raise the idling speed.
DTC DESCRIPTION
The temperature of catalyst has an effect on emissions. Also, the PCM estimates the temperature of catalyst by
intake air mass. By the way, the intake air mass is in proportion to RPM controlled by ISCA during idling. So, if the
Integral of deviation between setpoint RPM and actual speed RPM is out of the threshold value, the PCM judges
that ISCA doesn't work properly. And it could be a reason of bad emissions.

• Plausibility check (Engine speed deviation monitor
DTC Strategy
under cold start)
• No relevant failure
• Catalyst heating active
• Restriction in intake or
Enable Conditions • Ambient Pressure > 800 hPa
exhaust system
• 11V < Battery voltage < 16V
• Under normal engine running conditions connectors
• Integral of deviation between setpoint RPM and • Faulty ISCA valve
Threshold Value
actual speed RPM is out of the threshold value.
Diagnostic Time • 10~20 sec.
SCHEMATIC DIAGRAM
Page 406 of 491
MONITOR DTC STATUS
If any TPS, MAFS or ISCA Valve circuit codes are present, do ALL REPAIRS associated with them before
proceeding with this troubleshooting tree.
2. Press F4(DTAL) to select DTC information from the DTCs menu.
Page 407 of 491
Repair" procedure.
Go to "Check for restricted intake or exhaust system" procedure.

C. Restricted exhaust system
Go to "W/harness Inspection" procedure.

or damage.
Go to "Componment Inspection" procedure.
1. Ignition "OFF".
2. Remove ISCA from Throttle body and Check for throttle bore, throttle plate and the ISCA passages for
chocking and for any foreign objects. Repair or clean as necessary .
4. Connect scan tool and select "IDLE SPEED ACTUATOR" parameter on the "ACTUATION TEST" mode.
5. Activates ISCA by pressing "STAT" key.
6. Check the ISCA for clicking sound and visually verifying valve closes and opens.
Repeat numerous times to ensure valve reliability.

Page 408 of 491
7. Is ISCA OK?
procedure.
Check ISCA valve for contamination, deterioration, or damage. Substitute with a known-good ISCA valve
and check for proper operation. If the problem is corrected, replace ISCA valve and then go to "Verification of

2. Press F4(DTAL) and confirm that "DTC Readiness Flag" indicates "Complete". If not, drive the vehicle within

COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION
The ECM monitors engine speed deviation from the target idle engine speed when the vehicle is stopped and the idle
speed valve opening is stable. The ECM sets DTC P0506 if the difference to the target idle engine speed is lower
than the predetermined threshold.
Page 409 of 491

• Compare engine speed and nominal idle speed in idle
DTC Strategy
state
• Vehicle speed =0
• Coolant temperature>75°C(167°F)
• Engine load <280 mg/stk • Restriction in intake or
Enable Conditions exhaust system
• Throttle angle:closed
• Carbonustment of the
• Minimum time after start:15sec.
accelerator cable
• Canister purge control <50%
• Target idle speed - Engine speed > 100rpm (Engine connectors
Threshold Value
speed too low) • Faulty ISCA valve
Fail Safe • Evaporative System monitoring is inhibited
SCHEMATIC DIAGRAM
MONITOR DTC STATUS
If any TPS, MAFS or ISCA Valve circuit codes are present, do ALL REPAIRS associated with them before
Page 410 of 491

Repair" procedure.

C. Restricted exhaust system

or damage.
Page 411 of 491
1. Ignition "OFF"
chocking and for any foreign objects. Repair or clean as necessary
5. Activates ISCA by pressing "STAT" key
6. Check the ISCA for clicking sound and visually verifying valve closes and opens
Repeat numerous times to ensure valve reliability

7. Is ISCA OK?
procedure
Vehicle Repair" procedure


COMPONENT LOCATION
Page 412 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
The ECM monitors engine speed deviation from the target idle engine speed when the vehicle is stopped and the idle
speed valve opening is stable. The ECM sets DTC P0507 if the difference to the target idle engine speed is lower
than the predetermined threshold.

• Compare engine speed and nominal idle speed in idle
DTC Strategy
state
• Vehicle speed =0
• A stuck or binding throttle
• Coolant temperature>75°C(167°F)
plate
• Engine load <280 mg/stk
Enable Conditions • Misadjustment of the
• Throttle angle:closed
accelerator cable
• Minimum time after start:15sec.
• Canister purge control <50% connectors
Threshold Value • Engine speed > (target RPM + 200) • Faulty ISCA valve

SCHEMATIC DIAGRAM
Page 413 of 491
MONITOR DTC STATUS
If any TPS, MAFS or ISCA circuit codes are present, do ALL REPAIRS associated with them before

Repair" procedure.
Go to "Accelerator Cable & Throttle plate Inspection" procedure.

ACCELERATOR CABLE & THROTTLE PLATE INSPECTION
1. Visually/physically inspect the following items. Repair or adjust as necessary and go to next step
A. Check that the Accelerator Cable is not sticking or moving sluggishly.
B. Check Accelerator Cable free play [0.040~0.120 in. (1.0~3.0 mm)].
2. Remove Intake Hose and inspect Throttle Plate for excessive carbon deposits.
3. Is Throttle Plate being held open with excessive carbon deposits?

or damage.
Page 414 of 491

2. Check for air leakage in EVAP. Purge control valve
(2) Using a hand vacuum pump apply specified vacuum(Approx. 15 in, Hg) to the manifold side of the valve
1. Ignition "OFF"
chocking and for any foreign objects. Repair or clean as necessary
5. Activates ISCA by pressing "STAT" key
6. Check the ISCA for clicking sound and visually verifying valve closes and opens
Repeat numerous times to ensure valve reliability
7. Is ISCA OK?
procedure

Page 415 of 491

COMPONENT LOCATION

DTC Strategy • Power steering switch check
• No vehicle speed error
Enable Conditions • Coolant temperature>75°C(167°F) • Open or short circuit
• Power steering switch is ON • Contact resistance in
• Power steering is ON with vehicle speed >100km/h connectors
Threshold Value
& time > 25.5 sec. • Faulty power steering switch
Diagnostic Time • 0.1 sec.
SCHEMATIC DIAGRAM
Page 416 of 491
MONITOR DTC STATUS


Repair" procedure.

or damage.
Page 417 of 491

1. Ignition "OFF".
2. Disconnect P/S switch connector.
3. Start the engine, and measure voltage between P/S switch harness connector and chassis ground referring to
specification.
Specification
Steering Wheel Voltage

Straight ahead Approx. B+
Turned Approx. 0V
1. Ignition "OFF".
2. Disconnect P/S switch connector.
3. Check continuity of the switch referring to specification.
Specification
Steering Wheel Continuity

Straight ahead No
Turned Yes
Page 418 of 491
procedure
Check P/S switch for contamination, deterioration, or damage. Substitute with a known-good P/S switch and
check for proper operation. If the problem is corrected, replace P/S switch and then go to "Verification of


COMPONENT LOCATION
GENERAL DESCRIPTION
A malfunction is detected by using a checksum technique for verifying data. The digital data is composed of zeros
and ones. A checksum is the total of all ones in a string of data. By comparing the checksum value with a stored
value, a malfunction can be detected.
DTC DESCRIPTION
The ECM monitors RAM areas and communication connections between microcontroller and output drivers and
sets DTC P0605 if failure is detected.

Page 419 of 491
DTC Strategy • Check RAM Area / Communication connections
Enable Conditions • Ignition ON
Threshold Value • Internal check connectors
• Faulty ECM

[2.7 GSL]
Item Detecting Condition & Fail Safe Possible Cause
DTC Strategy • Check COMMUNICATION • Faulty TCM(PCM)
• COMMUNICATION ERROR WITH
Enable Conditions
"EEPROM"
Threshold Value • Communication fail
Diagnostic Time
Fail safe
MONITOR DTC STATUS

Page 420 of 491
Repair" procedure.

BACK VOLTAGE INSPECTION
1. Ignition "OFF".
3. Turn ignition "ON" and measure voltage between terminal 7 of the ECM harness connector (C68-1) and chassis
ground
Specification : Remain stable at battery voltage
4. Are circuits remaining stable at battery voltage?
Test with a new ECM and check for proper operation. If problem is corrected, replace ECM and go to
If voltage fluctuates, check circuit Thoroughly for loose, bent or corroded terminals, Repair as necessary and
4. Using a "SCAN TOOL", Operate "LEARNING " Reset.
5. Perform the "LEARNING"
6. IG OFF ↔ IG ON (Repeat 2~3times),and then Monitor the "DTC"
Page 421 of 491
7. Is DTC Re-displayed ?
replace TCM(PCM) as necessary and then Go to "Verification of Vehicle Repair" procedure.
and TCM(PCM) memory was not cleared. And Go to Component Inspection procedure.
METHOD OF LEARNING RESET
A. SELECT LEVER POSITION IS "P" OR "N"
B. VEHICLE SPEED = Okm/h
C. IGNITION "ON", ENGINE "OFF"
A. USING A SCAN TOOL, OPERATE "LEARNING" RESET
B. IG "ON" ↔ IG "OFF"(2~3 TIMES)


GENERAL DESCRIPTION
Regulations require that all 2005 and subsequent model year vehicles shall have the Vehicle Identification
Number(VIN) available in a standardized format through the standardized data link connector in accordance with
SAE J1979 specifications. Using a scan tool, PERFORM "VIN WRITING" procedure after replacing or reflashing
a ECM.
DTC DESCRIPTION
The ECM monitors ROM areas and sets DTC P0630 if there is no Vehicle Identification Number(VIN)
information.

DTC Strategy • ECM Internal Check.
Enable Conditions • Ignition ON
Threshold Value • VIN not exist in boot area • ECM is Virgin(not
programmed) status
Diagnostic Time • Immediate.
MIL On
Condition
Page 422 of 491
MONITOR DTC STATUS


Repair" procedure.
SYSTEM INSPECTION
1. Was the ECM just replaced or reflashed?
Using a scan tool, perform "VIN WRITING" procedure. Refer to the latest reference manual for scan tool and
go to "Verification of Vehicle Repair" procedure
Using a scan tool, read VIN information.

If there is no proper VIN information, perform "VIN WRITING" procedure.
If VIN information exists, substitute with a known-good ECM and check for proper operation. If the problem.
And go to "Verification of Vehicle Repair" procedure.

Page 423 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
The Malfunction Indicator Lamp (MIL), which is located in the instrument cluster, comes on to notify the driver that
there may be a problem with the vehicle and that service is needed. Immediately after the ignition switch turns on, the
malfunction indicate that the MIL operates normally and goes off after starting.
DTC DESCRIPTION
ECM sets DTC P0650 if the ECM detects that the MIL control line is open or short circuit to ground or battery
line.

• Open or short between
Enable Conditions • Battery voltage >10V
MIL and ECM
Threshold Value • Open, short to ground or battery • Contact resistance in
connectors
• Burned out MIL bulb
SCHEMATIC DIAGRAM
Page 424 of 491
MONITOR DTC STATUS


Repair" procedure.

1. Ignition "OFF".
2. Disconnect ECM connector
Page 425 of 491
4. Using a suitable wire, jumper the terminal 20 of ECM harness connector to chassis ground.
5. Is MIL bulb illuminated?
Go to next step.
Remove instrument cluster and inspect MIL bulb. If it is burned out, replace bulb. If bulb is okay, locate
source of open between bulb and (20/C30-4) or between bulb and Meter Fuse. Repair as necessary and go to
6. Remove wire from ECM harness connector.
7. Does MIL bulb go out?
Thoroughly check for loose, bent, or corroded terminals in MIL circuit (including circuit board). Repair as
necessary and go to "Verification of Vehicle Repair" procedure.
Check for source of short to GND between bulb and ECM(20/C30-4). Repair as necessary. and go to


COMPONENT LOCATION
GENERAL DESCRIPTION
Intake manifold tuning valve is used to increase torque at lower rpm and increase horsepower at higher rpm. This
Page 426 of 491
engine has two intake runners for each cylinder. The primary intake runner is a long, thin tube in which the intake air
passes through. This allows a strong stream of air to blast into the cylinder, helping low-end torque. The secondary
intake runner is a short, fat tube. This allows a large volume of air to be sucked into the engine, increasing high-end
horsepower. At lower rpm range, the engine does not provide enough suction into the cylinders, starving the engine
of much needed oxygen. The skinny tube helps blast the air into the cylinder for more oxygen. At higher rpm, the
engine has plenty of suction but the intake runner is too small to provide the oxygen it needs. The short, fat tube
allows plenty of oxygen to be sucked in. The ECM controls this function utilizing a intake manifold tuning valve.
Based on engine RPM, the position of the shutter within the intake manifold is changed, thereby directing intake air
through a longer path for low rpm range or a shorter path for high rpm range.
DTC DESCRIPTION
ECM sets DTC P0661 if the ECM detects that intake manifold tuning valve control circuit is shorted to ground.

Enable • 10 < Battery voltage(V) <16 harness
Conditions • Engine speed(rpm) >30 • Short to ground in
connectors
MIL On • Faulty VICV
Condition
SPECIFICATION
(°C) (°F) (Ω)
20 68 29~35
SCHEMATIC DIAGRAM
Page 427 of 491
MONITOR DTC STATUS


Repair" procedure.

Page 428 of 491
or damage.

2. Measure voltage between terminal 1 of the valve harness connector and chassis ground.
Go to "Control Circuit Inspection"
Check for open or blown SNSR Fuse(2).

(1) Ignition "OFF".
(2) Measure resistance between terminal 2 of the valve harness connector and chassis ground
Page 429 of 491
1. Ignition "OFF".
2. Disconnect valve connector.
3. Measure resistance between terminals 1 and 2 of the valve connector(Component side).
Check valve for contamination, deterioration, or damage. Substitute with a known-good valve and check for
proper operation. If the problem is corrected, replace valve and then go to "Verification of Vehicle Repair"
procedure


COMPONENT LOCATION
Page 430 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0662 if the ECM detects that intake manifold tuning valve control circuit is open or shorted to
battery voltage.

• 10 < Battery voltage(V) <16 • Open or short to battery
Enable Conditions
• Engine speed(rpm) >30 in control harness.
connectors
Diagnostic Time • 1.5 sec. • Faulty VICV
SPECIFICATION
(°C) (°F) (Ω)
20 68 29~35
Page 431 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 432 of 491
Repair" procedure.

or damage.


Page 433 of 491
(1) Ignition "OFF".
(4) Measure voltage between terminal 2 of the valve harness connector and chassis ground.

2. Check for Open in Control Circuit.
(1) Ignition "OFF".
(2) Measure resistance between terminals 2 of the valve harness connector and 45 of the ECM harness
connector(C68-3).
procedure
1. Ignition "OFF".
Page 434 of 491
procedure


COMPONENT LOCATION
Page 435 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0664 if the ECM detects that intake manifold tuning valve control circuit is shorted to ground.

Enable • 10 < Battery voltage(V) <16 harness
Conditions • Engine speed(rpm) >30 • Short to ground in
connectors
MIL On • Faulty VICV
Condition
SPECIFICATION
(°C) (°F) (Ω)
20 68 29~35
SCHEMATIC DIAGRAM
Page 436 of 491
MONITOR DTC STATUS


Repair" procedure.

Page 437 of 491
or damage.


(1) Ignition "OFF".
(2) Measure resistance between terminal 2 of the valve harness connector and chassis ground
Page 438 of 491
1. Ignition "OFF".
procedure


COMPONENT LOCATION
Page 439 of 491
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P0665 if the ECM detects that intake manifold tuning valve control circuit is open or shorted to
battery voltage.

• 10 < Battery voltage(V) <16 • Open or short to battery
Enable Conditions
• Engine speed(rpm) >30 in control harness.
connectors
Diagnostic Time • 1.5 sec. • Faulty VICV
SPECIFICATION
(°C) (°F) (Ω)
20 68 29~35
Page 440 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS

Page 441 of 491
Repair" procedure.

or damage.


Page 442 of 491
(1) Ignition "OFF".
(4) Measure voltage between terminal 2 of the valve harness connector and chassis ground.

2. Check for Open in Control Circuit.
(1) Ignition "OFF".
(2) Measure resistance between terminals 2 of the valve harness connector and 52 of the ECM harness
connector(C68-3).
locks or poor terminal to wire connection. Repair as necessary and go to "Verification Vehicle Repair"
procedure
1. Ignition "OFF".
Page 443 of 491
procedure


GENERAL DESCRIPTION
The TCM can request activation of the MIL lamp Via a communication line to the ECM. This is only a request from
TCM to ECM to turn the MIL on. The fault code is stored in the TCM. Select Transaxle system on the Scantool
and monitor DTC related automatic transaxle system.
DO ALL REPAIRS associated malfunction with A/T.

Page 444 of 491
DTC Strategy • Freeze frame request via CAN
Enable • Battery voltage(V) >10V
Conditions • Engine speed(rpm) >256 rpm
Threshold
• MIL is requested by TCM • Transaxle system
Value
Diagnostic
• Immediate
Time
MIL On
• Immediate
Condition
MONITOR DTC STATUS

1. This is only a request from TCM to ECM to turn the MIL on. The fault code is stored in the TCM. The Freeze
Frame Data is stored in the ECM under the P0700 request code. Be sure to retrieve freeze frame data before
clearing code P0700 from ECM.
2. Check the transaxle system.

COMPONENT LOCATION
GENERAL DESCRIPTION
The HIVEC Automatic Transmission's function, of intelligence control, is based on the Fuzzy Control System. The
Fuzzy Control System determines optimal gear positions as related to driver's intention and current driving
conditions. The Brake Switch provides important information by deciding whether the vehicle is decelerating by the
depression of the brake pedal, or if the speed is decreasing because the vehicle is running on the uphill.
DTC DESCRIPTION
The TCM(PCM) sets this code if a Brake Switch signal is input continuously, for an extended period of time, when
the vehicle is supposed to be running (moving).

[2.7 GSL]
Page 445 of 491
DTC Strategy • Check signal for B+ Short • Short to battery in circuit
• Faulty Brake SWITCH
• Output speed≥240rpm
Enable Conditions Adjustment
• Brake Switch "ON"
Threshold value • +B Short • Faulty TCM(PCM)
Diagnostic Time • More than 5 min
Fail Safe • Intelligent-Shift is inhibited
[2.0 GSL]
DTC Strategy • check for Short to Battery • Short to battery in circuit
• Output speed ≥ 240rpm
Enable Conditions Adjustment
Case 1 • Brake Switch "ON"
Threshold value • Short to Battery • Faulty TCM(PCM)
Diagnostic Time • More than 5 min.
DTC Strategy • check for Voltage range
Enable Conditions • 2.24 V ≤ Input voltage ≤ 2.76 V
Case 2
Threshold value • Open
Diagnostic Time • More than 5 min.
Fail safe • Intelligent-Shift is inhibited
SPECIFICATION
DATA
BRAKE
VALUE
Operation ON
Non-operation OFF
SCHEMATIC DIAGRAM
Page 446 of 491
WAVEFORM INSPECTION

Page 447 of 491
3. Monitor the "BRAKE LAMP SWITCH" parameter on the scantool.
4. Depress and release Foot Brake.
5. Does "STOP LAMP SWITCH" follow the reference data?

or damage.

1. Ignition "ON" & "OFF".
2. Disconnect "STOP LAMP SWITCH" connector.
Page 448 of 491
3. Measure voltage between teminal "1" of the sensor harness connector and chassis ground.
Specification : 0V
Check for Short to power circuit in harness. Repair as necessary and Go to "Verification Vehicle Repair"
procedure.
1. Check "STOP LAMP SWITCH".
(1) Ignition "OFF".
(2) Disconnect "STOP LAMP SWITCH" connector and Remove "STOP LAMP SWITCH".
(3) Measure resistance between terminal "1" and "2" of the STOP LAMP SWITCH when plunger of the STOP LAMP
SWITCH is pushed in.
Page 449 of 491
Go to "Adjust STOP LAMP SWITCH" as below.
Replace "STOP LAMP SWITCH" as necessary and Go to "Verification Vehicle Repair" procedure.
2. Adjust "STOP LAMP SWITCH" Clearance.
(1) Ignition "OFF".
(2) Reinstall "STOP LAMP SWITCH".
(3) Adjust "STOP LAMP SWITCH" Clearance.
Specification : 0.9mm(0.04in)
(4) After Adjusting, Has problem been solved?
TCM/PCM as necessary and go to "Verification Vehicle Repair" procedure.

Page 450 of 491

COMPONENT LOCATION
GENERAL DESCRIPTION
The wheel speed sensor outputs pulse-signals according to the revolutions of the vehicle speed sensor. The TCM
can receive data from the Engine Control Module (ECM) or ABS control module, or it can send data to the ECM
and ABS ECU by using CAN communication. The CAN communication is one of the vehicle communication
methods, which is now widely used to transfer the vehicle data.
DTC DESCRIPTION
The ECM calculates the vehicle speed based on the frequency of the pulses. If the calculated value from this sensor
does not agree with the value determined by the wheel speed sensor, the TCM(PCM) sets this code by using the
CAN communication.

[2.7 GSL]
Page 451 of 491
DTC Strategy • Plausibility check • Open or short in harness
connectors
• Engine load >250 mg/rev
• Faulty wheel speed sensor
Enable Conditions • Coolant temperature > 60°C(140°F)
Case 1 • 10V < Battery voltage <16V
• No fuel shut-off
• Vehicle speed=0 with high engine speed
Threshold value
and engine load
Diagnostic Time • 60 seconds
DTC Strategy • Electrical check
• Vehicle speed >0
Enable Conditions
• 10V < Battery voltage <16V
Case 2
• TCM(PCM) detects abnormal input
Threshold value
voltage of the signal circuit
Diagnostic Time • 10 seconds

COMPONENT LOCATION
GENERAL DESCRIPTION
The Idle Speed Control Actuator (ISCA) is installed on the intake manifold and controls the intake airflow that is
bypassed around the throttle plate to keep constant engine speed when the throttle vlave is closed. The function of
the ISCA valve is to maintain idle speed according to various engine loads and conditons, and also to provide
additional air during starting. The ISCA vlave consists of an opening coil, a closing coil, and a permanent magnet.
Page 452 of 491
Based on information from various sensor, the ECM controls both coils by grounding their control circuits.
According to the control signals from the ECM, the valve rotor rotates to control the by pass airflow into the engine.
DTC DESCRIPTION
ECM sets DTC P1505 if the ECM detects that the ISCA(OPEN) control circuit is open or short to ground.

Enable • Open or short to
Conditions ground in harness
Threshold Value • Open or short to ground • Contact resistance in
connectors
• Faulty ISCA valve
MIL On
Condition
SIGNAL WAVEFORM
SPECIFICATION
SPECIFICATION
Opening Coil Closing Coil
14.9 ~ 16.1 Ω at 20°C (68°F) 17.0 ~ 18.2 Ω at 20°C (68°F)
SCHEMATIC DIAGRAM
Page 453 of 491
MONITOR DTC STATUS


Repair" procedure.

Page 454 of 491
or damage.

1. Ignition "OFF".
2. Disconnect ISCA connector.
4. Measure voltage between terminal 2 of the ISCA harness connector and chassis ground.
Check for an open or short to ground in the power supply circuit between the ISCA valve and fuel pump
relay. Repair as necessary and go to "Verification of Vehicle Repair" procedure.
Specification : Approx. 3~4V
Thoroughly check connectors for loose or poor connections, bending, corrosion, contamination, deterioration,
or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure

Page 455 of 491
4. Check for open in signal harness
(1) Ignition "OFF".
(2) Measure resistance between terminals 1 of the ISCA harness connector and 46 of the ECM harness
connector(C68-3).

(1) Ignition "OFF".
(2) Measure resistance between terminal 1 of the ISCA harness connector and chassis ground.
procedure
1. Ignition "OFF".
Page 456 of 491
3. Measure resistance between terminals 1 and 2 of the actuator connector(Component side).
Specification : 14.9 ~ 16.1 Ω at 20°C (68°F)
Check ISCA for contamination, deterioration, or damage. 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.


COMPONENT LOCATION
GENERAL DESCRIPTION
Page 457 of 491
DTC DESCRIPTION
ECM sets DTC P1506 if the ECM detects that the ISCA(OPEN) control circuit is short to battery.

Conditions harness
Threshold Value • Short to battery • Contact resistance in
connectors
MIL On
Condition
SIGNAL WAVEFORM
SPECIFICATION
SPECIFICATION
14.9 ~ 16.1 Ω at 20°C (68°F) 17.0 ~ 18.2 Ω at 20°C (68°F)
Page 458 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS


Repair" procedure.

Page 459 of 491

or damage.

1. Ignition "OFF".
Specification : Approx. 3~4V

Page 460 of 491

4. Check for short to power in signal harness
(1) Ignition "OFF".
(3) Ignition "ON"
(4) Measure voltage between terminal 1 of the ISCA harness connector and chassis ground
procedure
Repair short in harness and go to "Verification of Vehicle Repair" procedure.
1. Ignition "OFF".

Page 461 of 491
procedure.


COMPONENT LOCATION
GENERAL DESCRIPTION
DTC DESCRIPTION
ECM sets DTC P1507 if the ECM detects that the ISCA(OPEN) control circuit is open or short to ground.

Page 462 of 491
Enable • Open or short to
Conditions ground in harness
Threshold Value • Open or short to ground • Contact resistance in
connectors
MIL On
Condition
SIGNAL WAVEFORM
SPECIFICATION
SPECIFICATION
14.9 ~ 16.1 Ω at 20°C (68°F) 17.0 ~ 18.2 Ω at 20°C (68°F)
SCHEMATIC DIAGRAM
Page 463 of 491
MONITOR DTC STATUS


Repair" procedure.

Page 464 of 491
or damage.

1. Ignition "OFF".
Specification : Approx. 0.5~0.6V

Page 465 of 491
4. Check for open in signal harness
(1) Ignition "OFF".
(2) Measure resistance between terminals 3 of the ISCA harness connector and 47 of the ECM harness
connector(C68-3).

(1) Ignition "OFF".
(2) Measure resistance between terminal 3 of the ISCA harness connector and chassis ground.
procedure
1. Ignition "OFF".
Page 466 of 491
procedure.


COMPONENT LOCATION
GENERAL DESCRIPTION
Page 467 of 491
DTC DESCRIPTION
ECM sets DTC P1508 if the ECM detects that the ISCA(CLOSE) control circuit is short to battery.

Conditions harness
Threshold Value • Short to battery • Contact resistance in
connectors
MIL On
Condition
SIGNAL WAVEFORM
SPECIFICATION
SPECIFICATION
14.9 ~ 16.1 Ω at 20°C (68°F) 17.0 ~ 18.2 Ω at 20°C (68°F)
Page 468 of 491
SCHEMATIC DIAGRAM
MONITOR DTC STATUS


Repair" procedure.

Page 469 of 491

or damage.

1. Ignition "OFF".
Specification : Approx. 0.5~0.6V

Page 470 of 491

4. Check for short to power in signal harness
(1) Ignition "OFF".
(3) Ignition "ON"
(4) Measure voltage between terminal 3 of the ISCA harness connector and chassis ground
procedure
Repair short in harness and go to "Verification of Vehicle Repair" procedure.
1. Ignition "OFF".

Page 471 of 491
procedure.


Component Location
General Description
The immobilizer system consists of a passive challenge-response (mutual authentication) transponder inside the key
head, the encoded SMARTRA3 unit /key and the EMS can decode the secret code stored in the SMARTRA3.
The EMS communicates the encoded messages to the SMARTRA3 via a dedicated communication line and
confirms the key with the SMARTRA3.
The EMS carries out the immobilizer function, the SMATRA3 management and the key management. The
immobilizer function is the unlocking of EMS only after detection of a valid ignition key /the SMATRA3 and the
locking of EMS after switching off the engine.
The EMS related to immobilizer has the 3 kinds of software. At the first IGN on, the EMS concludes the software
of each option (smart key, non-encoded SMARTRA3, encoded SMARTRA3) by communication. It is called "The
autodection for EMS" The EMS keeps the previous option before being neural when it is setted to each option.
DTC Description
The PCM/ECM sets DTC P1610 if Non Immobilizer EMS is installed on vehicle equipped with Immobilizer.

Page 472 of 491
DTC Strategy
● Non Immobilizer PCM/ECM
Threshold value ● Invalid PCM/ECM
connected
Detecting time ● Immediately
FAIL SAFE

1. Check status
(2) Monitor the "ECM Status" Parameter on the Scantool.
learnt and SMARTRA3 has been learnt
(3) Has the ECM been learnt ?
Substitute with a ECM equipped with Immobilizer and perform the Key teaching procedure with scantool
and check for proper operation.
If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure.
If the EMS is only replaced using an existing key and SMARTRA3, after replacing the "virgin" or
"neutral" EMS, reteacing is possible by key Learning mode with scanner.
When the same PIN used in existing vehicle is only inputted, the SMARTRA3 Learning and key
Learnings are possible.


Page 473 of 491

Component Location
General Description
The ECM and the SMARTRA communicate by dedicated line. During this communication of ECM and
SMARTRA the K line of ECM cannot be used for communication. The ECM controls the communication either to
SMARTRA or to other devices(e.g. scanner) on K line by switching of a multiplexer and specific communication
procedures. The multiplexer is a part of ECM H/W.
DTC Description
The ECM sets DTC P1694 if Request from EMS is invalid.

DTC Strategy
Enable ● Faulty EMS
● IG ON Protocol layer
Conditions
violation
Threshold value
- Invalid request
Detecting time - Check sum error
FAIL SAFE

1. Check status
(1) IGN "ON" &Engine "OFF"
(2) Monitor the "ECU, KEY and Smartra STATUS" Parameter on the Scantool.
Page 474 of 491
damage on the ECM or SMARTRA. And this DTC has not been erased in previous repair. Repair or
replace as necessary and then go to "Verification of Vehicle Repair" procedure.
1. Check ECM
(1) IGN "ON" &Engine "OFF"
Substitute with a known-good ECM and perform the key teaching procedure.
ECM substitued for old one must be in "Virgin" or "Neutral" status and Pin code is requied to
Neutralize ECM and to Register transponder key

Fuel System > Troubleshooting > U0001

COMPONENT LOCATION
Page 475 of 491
GENERAL DESCRIPTION
The TCM can either receive data from the Engine Control Module or ABS control module, or it can send data to
the ECM and ABSCM by using CAN communication. The CAN communicaton is one of the vehicle
communication methods, which is now widely used to transfer the vehicle data.
DTC Description
When the TCM cannot read the data from the ECM through the CAN-BUS line, the TCM sets this code.
CAN-BUS circuit malfunctioning or ECM can be a posssible cause of this DTC.

[2.7 GSL]
DTC Strategy • Check voltage range • Open or Short in CAN
• IG switch ON
• Faulty ECM
• No actuator test
• Faulty TCM
• No FAIL SAFE status of 3rd gear holding
Enable Conditions • No FAIL in PG-A,B
• Power voltage ≥ 10V is detected for a series of
0.5 sec
• Engine STOP
Threshold value • In case of no ECU information
Diagnostic Time • 1.5 Sec
Fail Safe
[2.0 GSL]
Page 476 of 491
DTC Strategy • Check communication • Open or Short in CAN
• Input speed ≥ 1000rpm and 5000msec passed
Enable Conditions • Faulty ECM
from IG "on"
• Faulty TCM
Threshold value • CAN message transfer error
Fail Safe
SCHEMATIC DIAGRAM
Page 477 of 491
2. Engine "ON".
3. Monitor the "CAN COMMUNICATION SERVICE DATA (ENGINE RPM, VEHICLE SPEED SENSOR,
THROTTLE P. SENSOR)" parameters on the scantool.
4. Does "CAN BUS LINE DATA " follow the reference data?
memory was not cleared. And go to Verification of Vehicle Repair procedure.
Go to "Terminal & Connector Inspection" procedure.
Terminal & Connector Inspection

or damage.
memory was not cleared.And go to Verification of Vehicle Repair procedure.

Signal Circuit inspection
2. Disconnect the "TCM" connector.
Page 478 of 491
3. Measure resistance between terminal "3" and "4" of the "TCM" harness connector.
4. Is measured resistance within specifications?
Substitute with a known-good TCM and check for proper operation. If the problem is corrected, replace
TCM as necessary and then go to "Verification of Vehicle Repair" procedure.
Check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration or damage
of ECM. Repair as necessary and go to "Verification Vehicle Repair" procedure.

Fuel System > Troubleshooting > U0101

GENERAL DESCRIPTION
A communication line exists between the Engine Control Module(ECM) and the Transaxle Control Module(TCM).
The communication is through a Control Area Network(CAN). Without CAN communication, an independent pin
and wiring is needed to receive a sensor information from a ECM. The more information to be communicated, the
more wirings is required. In case of CAN communication type, all the information need to be communicated among
control modules such as ECM and TCM use CAN lines.
DTC DESCRIPTION
The ECM sets DTC U0101 if ECM detects that communication time via CAN exceeds threshold value.

Page 479 of 491
DTC Strategy • Missing messages TCU
Enable • Battery voltage >10V
Conditions • Engine speed > Approx. 260 rpm • Open or short in CAN line
Threshold Value • Time exceeded without message = 0.5 sec.
connectors
SIGNAL WAVEFORM
MONITOR DTC STATUS

Page 480 of 491
Fault is intermittent caused by poor contact in the sensor(s) and/or the ECM's connector was repaired and
ECM memory was not cleared. Thoroughly check connectors for loose or poor connections, bending, corrosion,
Repair" procedure

or damage.
Go to "CAN High line Inspection" procedure.

CAN HIGH LINE INSPECTION
1. Check for Open in harness
(1) Ignition "OFF".
(2) Disconnect ECM and TCM connectors.
(3) Measure resistance between terminals 36 of the ECM harness connector and 3 of the TCM harness
connector.

Page 481 of 491
2. Check for short to ground in harness.

3. Check for short to battery in harness.
(3) Measure voltage between terminal 36 of the ECM harness connector and chassis ground.
Go to "CAN Low Line Inspection" procedure

CAN LOW LINE INSPECTION
Page 482 of 491
1. Check for Open in harness.
(1) Ignition "OFF".
(2) Disconnect ECM and TCM connectors.
(3) Measure resistance between terminals 37 of the ECM harness connector and 4 of the TCM harness
connector.


Page 483 of 491
3. Check for short to battery in harness.
(3) Measure voltage between terminal 37 of the ECM harness connector and chassis ground.
procedure.

Fuel System > Fuel Delivery System > Components and Components Location
COMPONENTS LOCATION
Page 484 of 491
Fuel System > Fuel Delivery System > Repair procedures

FUEL PRESSURE TEST
Page 485 of 491
Page 486 of 491
Page 487 of 491
Fuel System > Fuel Delivery System > Fuel Tank > Repair procedures
REMOVAL
When lifting up or down vehicle, be sure to place blocks between vehicle and lifter to prevent fuel tank from being
damaged.
1. Remove the front and main muffler assembly (Refer to group “EM” in this Workshop Manual).
2. Remove the propeller-shaft (For 4WD only).
Page 488 of 491
3. Disconnect the fuel filler hose (A), fuel leveling hose (B) and ventilation hose (C).
4. Lift the vehicle and support the fuel tank with a jack, and then remove the two fuel tank band.
5. Remove the four parking brake mounting bolts(A).
6. Down the fuel tank slowly until work space is made, and then disconnect the fuel pump connector (A) and fuel
feed hose(B).
Page 489 of 491
7. Disconnect the sub fuel sender connector (A).
8. Remove the fuel tank.
Fuel System > Fuel Delivery System > Fuel Pump > Repair procedures
REMOVAL (INCLUDING FUEL FILTER AND FUEL PRESSURE REGULATOR)
1. Turn ignition switch to “OFF” and disconnect the battery negative (-) terminal.
2. Remove the rear seat cushion flame hinge bolts, and then lift the cushion (Refer to group “BD” in this Service
Manual).
3. Remove the service cover (A) under the carpet.
4. Disconnect the fuel pump wiring connector (A).
5. Remove the fuel feed hose (B) and suction hose (C).
6. Remove the fuel pump plate mounting bolts (D).
Page 490 of 491
7. Remove the fuel pump assembly.
Fuel System > Fuel Delivery System > Sub Fuel Sender > Repair procedures
REMOVAL
1. Turn ignition switch to “OFF” and disconnect the battery negative (-) terminal.
2. Remove the rear seat cushion flame hinge bolts, and then lift the cushion (Refer to group “BD” in this Service
Manual).
3. Remove the service cover (B) under the carpet.
4. Disconnect the fuel sender (Sub) wiring connector (A).
5. Disconnect the suction hose (B).

6. Remove the fuel sender (Sub) plate mounting bolt (C).
Page 491 of 491
7. Remove the fuel sender (Sub) assembly.
Page 1 of 171
SPORTAGE(KM) > 2008 > G 2.7 DOHC > Heating,Ventilation, Air Conditioning
Heating,Ventilation, Air Conditioning > General Information > Special Service Tools
SPECIAL TOOLS
Tool
Illustration Use
(Number and name)
09977-29000 Removal and installation of disc &
Dise & hub bolt hub
remover
Heating,Ventilation, Air Conditioning > General Information > Troubleshooting

TROUBLESHOOTING
Before replacing or repairing air conditioning components, first determine if the malfunction is due to the refrigerant
charge, air flow or compressor.
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.
After correcting the malfunction, check the complete system to ensure that performance is satisfactory.
STANDARD :
Symptom Suspect Area See page
No blower operation 1. Blower fuse -
2. Blower relay HA - 65
3. Blower motor HA - 63
4. Power mosfet HA - 67
5. Blower speed control switch HA - 72, 79
6. Wire harness -
No air temperature control 1. Engine coolant capacity -
2. Heater control assembly HA - 72, 79
No compressor operation 1. Refrigerant capacity HA - 3
2. A/C Fuse -
3. Magnetic clutch HA - 25
4. Compressor HA - 23
5. Triple pressure switch HA - 31
6. A/C switch -
7. Evaporator temperature sensor HA - 35
8. Wire harness -
No cool comes out 1. Refrigerant capacity HA - 3
Page 2 of 171
2. Refrigerant pressure HA - 3, 13
3. Drive belt HA - 21
7. Evaporator temperature sensor HA - 35
8. A/C switch -
10. Wire harness -
Insufficient cooling 1. Refrigerant capacity HA - 3
2. Drive belt HA - 21
5. Condenser HA - 28
6. Expansion valve HA - 54
7. Evaporator HA - 52
8. Refrigerant lines HA - 33
No engine idle-up when A/C 1. Engine ECU -
switch ON 2. Wire harness -
No air inlet control 1. Heater control assembly HA - 72, 79
No mode control 1. Heater control assembly HA - 72, 79
2. Mode actuator HA - 58
No cooling fan operation 1. Cooling fan fuse -
2. Fan motor -
3. Engine ECU -
4. Wire harness -
Heating,Ventilation, Air Conditioning > General Information > Specifications

SPECIFICATION
AIR CONDITIONER
Page 3 of 171
Specification
Item
β engine (2.0L) δ engine (2.7L)
Compressor Type 10PA15C 10PA17C
(Swash plate) (Swash plate)
Oil type & ND-OIL8 (PAG), ND-OIL8 (PAG),
Capacity 120 ~ 135cc 200 ~ 215cc
Pulley type 4PK-TYPE 6PK-TYPE
Displacement 155.3cc/rev 177.7cc/rev
Condenser Heat rejection 13,500 ± 5% kcal/hr
Triple switch High [psi(kg/cm²)] ON : 370 ± 2.8 (26.0 ± 0.2)
OFF : 455 ± 2.8 (32.0 ± 0.2)
Low ON : 28.6 ~ 36.3 (2.00 ~ 2.55)
([psi(kg/cm²)] OFF : 28.4 ± 2.8 (2.0 ± 0.2)
Medium ON : 220 ± 11.4 (15.5 ± 0.8)
[psi(kg/cm²)] OFF : 164 ± 17.1 (11.5 ± 1.2)
Expansion valve Type Block
Refrigerant Type R-134a
Capacity [oz.(g)] 18.0 ± 0.88 (510 ± 25)
BLOWER UNIT
Item Specification
Fresh and
Operating method Actuator
recirculation
Blower Type Sirocco
Auto + 8 speed (Automatic), 9 speed
Speed step
(Manual)
Speed control Power mosfet
Air filter Type Particle filter
HEATER AND EVAPORATOR UNIT

Page 4 of 171
Item Specification
Heater Type Pin & Tube type
Heating capacity 4,500 ± 5% kcal/hr
Mode operating
Actuator
method
Temperature
Actuator
operating method
Evaporator Temperature
Evaporator temperature sensor
control type
A/C ON/OFF OFF : 0.5 ± 0.5(32.9 ± 32.9),
[°C(°F)] ON : 2.5 ± 0.5(36.5 ± 32.9)
Heating,Ventilation, Air Conditioning > Air conditioning System > General Information
INSTRUCTIONS
WHEN HANDLING REFRIGERANT
1. R-134a liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite.
When handling the refrigerant, be sure to wear gloves.
2. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands. If the
refrigerant splashes into your eyes, wash them with clean water immediately.
3. The R-134a container is highly pressurized. Never leave it in a hot place, and check that the storage temperature
is below 52°C (126°F).
4. An electronic leak detector should be used to check the system for refrigerant leakage. Bear in mind that the R-
134a, upon coming into contact with flame, produces phosgene, a highly toxic gas.
5. Use only recommended the lubricant for R-134a systems. If lubricants other than the recommended one used,
system failure may occur.
6. PAG lubricant absorbs moisture from the atmosphere at a rapid rate, therefore the following precautions must be
observed :
A. When removing refrigerant components from a vehicle, cap immediately the components to prevent from the
entry of moisture.
B. When installing refrigerant components to a vehicle, do not remove the cap until just before connecting the
components.
C. Complete the connection of all refrigerant tubes and hoses without delay to prevent the A/C system from
taking on moisture.
D. Use the recommended lubricant from a sealed container only.
7. If an accidental discharge in the system occurs, ventilate the work area before resuming service.
Page 5 of 171
WHEN REPLACING PARTS ON A/C SYSTEM
1. Never open or loosen a connection before discharging the system.
2. Seal the open fittings of components with a cap or plug immediately to prevent intrusion of moisture or dust.
3. Do not remove the sealing caps from a replacement component until it is ready to be installed.
4. Before connecting an open fitting, always install a new sealing ring. Coat the fitting and seal with refrigerant oil
before making the connection.
WHEN INSTALLING CONNECTING PARTS

FLANGE WITH GUIDE PIN
Check the new O-ring for damage (use only the specified) and lubricate it using compressor oil. Tighten the nut to
specified torque.
Tightening torque (N.m (kg.m, lb-ft))

Size General bolt, nut
4T 7T
5~6 (0.5~0.6, 9~11 (0.9~1.1,
M6
3.6~4.3) 6.5~7.9)
12~14 (1.2~1.4, 20~26 (2.0~2.6,
M8
8.7~10) 14~18)
25~28 (2.5~2.8, 45~55 (4.5~5.5,
M10
18~20) 32~39)
Flange bolt, nut
Size
4T 7T
5~7 (0.5~0.7, 8~12 (0.8~1.2,
M6
3.6~5.0) 5.8~8.6)
10~15 (1.0~1.5, 19~28 (1.9~2.8,
M8
7~10) 14~20)
Page 6 of 171
21~31 (2.1~3.1, 39~60 (3.9~6.0,
M10
15~22) 28~43)
T means tensile intensity, which is stamped on the head of bolt only numeral.
HANDLING TUBING AND FITTINGS
The internal parts of the refrigeration system will remain in a state of chemical stability as long as pure moisture-free
refrigerant and refrigerant oil are used. Abnormal amounts of dirt, moisture or air can upset the chemical stability and
cause problems or serious damage.
THE FOLLOWING PRECAUTIONS MUST BE OBSERVED
1. When it is necessary to open the refrigeration system, have everything you will need to service the system ready
so the system will not be left open any longer than necessary.
2. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture.
3. All lines and components in parts stock should be capped or sealed until they are ready to be used.
4. Never attempt to rebind formed lines to fit. Use the correct line for the installation you are servicing.
5. All tools, including the refrigerant dispensing manifold, the gauge set manifold and test hoses, should be kept clean
and dry.
Heating,Ventilation, Air Conditioning > Air conditioning System > Description and Operation
REFRIGERATION CYCLE
Page 7 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > Components and Components
Location
COMPONENT LOCATION INDEX
ENGINE ROOM
Page 8 of 171
INTERIOR
Page 9 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > Troubleshooting

This is a method in which the trouble is located by using a gauge set. Read the gauge pressure when these conditions
are established.
TEST CONDITIONS
- Temperature at the air inlet with the switch set at recirculation 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.
Page 10 of 171
It should be noted that the gauge indications may vary slightly due to ambient temperature conditions.
1. Normally functioning refrigeration system.
Gauge reading :
2. Moisture present in refrigeration system.
Symptom seen in
Probable cause Diagnosis Remedy
refrigeration system
During operation, pressure Moisture entered in - Drier in over saturated - Replace drier
on low pressure side refrigeration system freezes state - Remove moisture in
sometimes becomes a at expansion valve orifice - Moisture in refrigeration cycle through repeatedly
vacuum and sometimes and temporarily stops system freezes at evacuating the system
normal cycle, but normal state is expansion valve orifice - Evacuate the system and
restored after a time when and blocks circulation of charge new refrigerant
the ice melts refrigerant to specified amount
Page 11 of 171
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 - Evacuate the system and
performance charge new refrigerant
to specified amount
- If indicated pressure
value is near 0 when
connected to gauge,
create the vacuum after
inspecting and repairing
the location of the leak
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
Page 12 of 171
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 the system and
receiver/drier or leakage from expansion charge new refrigerant
expansion valve valve to specified amount
- For gas leakage from
expansion valve, replace
expansion valve
6. Refrigerant overcharged or insufficient cooling of condenser

Page 13 of 171
Symptom seen in
Pressure too high on both - Unable to develop - Excessive refrigerant in - (1) Clean condenser
low and high pressure sides sufficient performance cycle → refrigerant - (2) Check cooling fan
due to excessive overcharged with fluid coupling
refrigerant - Condenser cooling → operation
- Insufficient cooling of condenser fins clogged - (3) If (1) and (2) are in
condenser or condenser fan faulty normal state, check
amount of refrigerant
Evacuate the system and
charge new refrigerant
to specified amount
7. Air present in refrigeration system
Symptom seen in
- Pressure too high on Air entered in refrigeration - Air present in - Check compressor oil
both low and high system refrigeration system to see if it is dirty or
pressure sides - Insufficient vacuum insufficient
- The low pressure piping purging - Evacuate the system and
hot to the touch charge new refrigerant
to specified amount
Page 14 of 171
8. Expansion valve functions 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 low on high Internal leak in compressor - Compression defective Repair or replace
pressure side - Valve leaking or broken compressor
- Pressure too high on low sliding parts
pressure side
Heating,Ventilation, Air Conditioning > Air conditioning System > Repair procedures
REFRIGERANT SYSTEM SERVICE BASICS
REFRIGERANT RECOVERY
Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove
HFC-134a(R-134a) from the air conditioning system.
Page 15 of 171
- 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.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
1. Connect a R-134a refrigerant.
Recovery/Recycling/Charging System (A) to the high-pressure service port (B) and the low-pressure service port
(C) as shown, following the equipment manufacturer's instructions.
2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be
sure to install the same amount of new refrigerant oil back into the A/C system before charging.
SYSTEM EVACUATION
Page 16 of 171
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 Recovery/Recycling/Charging System. (If the system has been open for
several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.)
Recovery/Recycling/Charging System (A) to the high-pressure service port (B) and the low-pressure service port
(C) as shown, following the equipment manufacturer's instructions.
3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 10 minutes, there is probably
a leak in the system. Partially charge the system, and check for leaks (see Leak Test.)
4. Remove the low pressure valve from the low-pressure service port.
SYSTEM CHARGING
Recovery/Recycling/Charging System (A) to the high-pressure service port (B) as shown, following the
equipment manufacturer's instructions.
Page 17 of 171
2. Add the same amount of new refrigerant oil to system that was removed during recovery. Use only Specified
refrigerant oil. Charge the system with 18.0 ± 0.88 oz. (510 ± 25g) of R-134a refrigerant. Do not overcharge the
system the compressor will be damaged.
REFRIGERANT LEAK TEST

Always conduct a leak test with an electronic leak detector whenever leakage of 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.
If a gas leak is detected, proceed as follows:
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 PERFORMANCE TESTS

Recovery/Recycling/Charging System to the high-pressure service port and the low-pressure service port,
following the equipment manufacturer's instructions.
2. Determine the relative humidity and air temperature.
3. Remove the glove box stopper and tension code and let the glove box hang down.
4. Insert a thermometer in the cool air outlet.
5. Place a thermometer near the blower unit inlet.
Page 18 of 171
6. Test condition
A. Avoid direct sunlight.
B. Open hood.
C. Open front doors.
D. Set the temperature control dial to Max cool, the mode control switch to Vent, and the recirculation control
switch to Recirculation.
E. Turn the A/C switch in and the fan switch to Max.
F. Run the engine at 1,500 rpm.
G. No driver or passenger in vehicle.
7. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature
from the thermometer in the cool air outlet, the intake temperature near the blower unit inlet, and the high and low
system pressure from the A/C gauges.
8. To complete the chart
A. Mark the delivery temperature along the vertical line
B. Mark the intake temperature along the bottom line
C. Draw a line straight up from the air temperature to the humidity
D. Mark a point 10% above and 10% below the humidity level
E. From each point
F. Draw a horizontal line across the delivery temperature
G. The delivery temperature should fall between the two lines
H. Complete the low side pressure test and high side pressure test in the same way
I. Any measurements outside the line may indicate the near for more further inspection
Page 19 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > Drive belt > Repair procedures
INSPECTION
1. Only Beta engine (2.0L). Compressor shall be operated once or twice a month even in seasons air conditioning is
not required, and compressor belt tension shall be adjusted from time to time.
Page 20 of 171
2. Apply a force of 98N(10kgf, 22lbf), and measure the deflection at the mid point (A) between the air condition
compressor and crankshaft pulley.
Item Capacity (when 10kg (22 lb) load applied) Tension
5 ~ 5.5 mm 65 ± 5 kg
New belt
(0.197 ~ 0.217 in.) (143 ± 11 lb)
6 ~ 7 mm 36 ± 5 kg
Used belt
(0.236 ~ 0.276 in.) (79 ± 11 lb)
8 mm 25 ~ 50 kg
Check after operation
(0.315 in.) (55 ~ 110 lb)
These items when adjusting belt tension :
A. If there are cracks or any damage evident on the belt, replace it with a new one.
B. "Used belt" means a belt which has been used for five minutes or more.
C. "New belt" means a belt which has been used for less than five minutes.
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(B).
3. Recheck the deflection of the A/C compressor belt.
Delta engine (2.7L) refer to the engine group.

Page 21 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Components and
Components Location
COMPONENT
Page 22 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Repair procedures
REMOVAL
1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few
minutes, then shut the engine off.
2. Disconnect the negative cable from the battery.
3. Recover the refrigerant with a recovery/charging station (See page HA-9).
4. Loosen the drive belt (See page HA-21).
5. Remove the bolts, then disconnect the suction line (A) and discharge line (B) from the compressor. Plug or cap
the lines immediately after disconnecting them to avoid moisture and dust contamination.
Page 23 of 171
6. Disconnect the compressor clutch connector (A), then remove the mounting bolts and the compressor (B).
INSTALLATION
1. Make sure of the length of compressor mounting bolts, and then tighten it A→B→C→D order.
Bolt β Engine (2.0L) δ Engine (2.7L)
A 118mm (4.65in.) 118mm (4.65in.)
B 102mm (4.02in.) 118mm (4.65in.)
C 102mm (4.02in.) 118mm (4.65in.)
D 126mm (4.96in.) 94mm (3.70in.)
2. Install in the reverse order of removal, and note these items.

A. If you're installing a new compressor, drain all the refrigerant oil from the removed compressor, and measure
its volume, Subtract the volume of drained oil from 120cc(4.20 oz.) the result is the amount of oil you should
drain from the new compressor (through the suction fitting).
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them.
Be sure to use the right O-rings for R-134a to avoid leakage.
C. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other
refrigerant oils.
D. Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.
E. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint,
wash it off immediately.
F. Adjust the drive belt (See page HA-21).
G. Charge the system and test its performance.
INSPECTION
1. Check the plated parts of the disc & hub for color changes, peeling or other damage. If there is damage, replace
the clutch set.
Page 24 of 171
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 disc & hub (B) all the way around. If the clearance is not
within specified limits, remove the disc & hub (See page HA-27) and add or remove shims as needed to increase
or decrease clearance.
Clearance : 0.5 ± 0.15mm (0.020 ± 0.006 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 operation 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.
DISASSEMBLY
Page 25 of 171
1. Remove the center bolt (A) while holding the disc & hub with a commercially available disc & hub bolt remover;
Special tool number 09977-29000.
2. Remove the disc & hub (A) and shim (B), taking care not to lose the shims. If the clutch needs adjustment,
increase or decrease the number and thickness of shims as necessary, then reinstall the disc & hub, and recheck
its clearance (See page HA-25).
3. If you removal the field coil, remove snap ring (A) with snap ring pliers.
- Be careful not to damage the pulley (B) and compressor during

removal/installation.
- Once snap ring (A) is removed, replace it with a new one.
Page 26 of 171
4. Remove the screw from the field coil ground terminal.
Remove the field coil (A) from the shaft with a puller (B). Be careful not to damage the coil and compressor.
5. Reassemble the compressor clutch in the reverse order of disassembly, and note these items :
A. Clean the pulley and compressor sliding surfaces with non-petroleum solvent.
B. Install new snap rings, and make sure they are fully seated in the groove.
C. Make sure that the pulley turns smoothly after it's reassembled.
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor oil > Repair procedures
OIL SPECIFICATION
- The HFC-134a system requires a synthetic (PAG) compressor oil whereas the R-12 system requires mineral
compressor oil. The two oils must never be mixed.
- Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of
compressor.
HANDLING OF OIL
• The oil should be free from moisture, dust, metal powder, etc.
• Do not mix with other oil.
• The water content in the oil increases when exposed to the air. After use, seal oil from air immediately.
(HFC-134a Compressor Oil absorbs moisture very easily.)
• The compressor oil must be stored in steel containers, not in plastic containers.
COMPRESSOR OIL CHECK
The oil used to lubricate the compressor is circulating with the refrigerant.
Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the
original amount of oil.
Oil total volume in system :

120~135cc (4.05~4.56 fl.oz ) - β engine (2.0L)
200~215cc (6.76~7.27 fl.oz) - δ engine (2.7L)
OIL RETURN OPERATION

There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with the refrigerant in the system. When checking the amount of
oil in the system, or replacing any component of the system, the compressor must be run in advance for oil return
operation. The procedure is as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to "ON" and set the blower motor control knob at its highest position.
3. Run the compressor for more than 20 minutes between 800 and 1,000 rpm in order to operate the system.
4. Stop the engine.
REPLACEMENT OF COMPONENT PARTS
Page 27 of 171
When replacing the system component parts, supply the following amount of oil to the component parts to be
installed.
Component parts to be
Amount of oil
installed
Evaporator 50 cc (1.70 oz.)
Condenser 30 cc (1.02 oz.)
Receiver/dryer 30 cc (1.02 oz.)
Refrigerant line
10 cc (0.34 oz.)
(One piece)
For compressor replacement, subtract the volume of oil drained from the removed compressor from the specified
volume, and drain the calculated volume of oil from the new compressor :
The specified volume - volume of removed compressor = volume to drain from the new compressor.
Even if no oil is drained from the removed compressor, don't drain more than 50cc from new compressor.
Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser > Components and
Components Location
COMPONENT
Page 28 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser > Repair procedures
INSPECTION
1. Check the condenser fins for clogging and damage. If clogged, clean them with water, and blow them with
compressed air. If bent, gently bend them using a screwdriver or pliers.
2. Check the condenser connections for leakage, and repair or replace it, if required.
REPLACEMENT
1. Recover the refrigerant with a recovery/recycling/charging station (See page HA-9).
2. Remove the coolant reservoir, but do not disconnect the reservoir hose from the coolant reservoir and the
radiator.
Page 29 of 171
3. Remove the bolt(A), then remove the radiator bracket(B) from the radiator.
4. Remove the nuts (A), then disconnect the discharge line and condenser line from the condenser.
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
5. Remove the bolts (A), then remove the condenser (B) by lifting it up. Be careful not to damage the radiator and
condenser fins when removing the condenser.
6. Install in the reverse order of removal, and note these items:

A. If you're installing a new condenser, add refrigerant oil ND-OIL8.
C. Be careful not to damage the radiator and condenser fins when installing the condenser.
D. Be sure to install the lower mount cushions of condenser securely into the holes.
E. Charge the system, and test its performance.
Heating,Ventilation, Air Conditioning > Air conditioning System > Receiver-Drier > Repair procedures
REPLACEMENT
Page 30 of 171
1. Remove the condenser, and then remove the receiver/drier after loosening the nuts (B) at the lower receiver/drier
(A).
2. Install in the reverse order of removal, and note these items :

A. If you're installing a new receiver/drier, add refrigerant oil ND-OIL8.
C. Be careful not to damage the radiator and condenser fins when installing the condenser.
D. Be sure to install the lower mount cushions of condenser securely into the holes.
E. Charge the system, and test its performance.
Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line > Components and
Components Location
COMPONENT LOCATION
Page 31 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line > Repair procedures
REPLACEMENT
1. Discharge refrigerant from refrigeration system (see page HA-9).
2. Replace faulty tube or hose.
Cap the open fittings immediately to keep moisture or dirt out of the
system.
Page 32 of 171
3. Tighten joint of bolt or nut to specified torque.
Connections should not be torque tighter than the specified

torque.
4. Evacuate air in refrigeration system and charge system with refrigerant (see page HA-9).
Specified amount : 510 ± 25g (18.0 ± 0.88 oz.)
5. Inspect for leakage of refrigerant.

Using a gas leak detector, check for leakage of refrigerant (see page HA-11).
6. Inspect A/C operation.
Part tightened N.m kg.cm lb-ft
Condenser x 3.7 ~
5~7 50 ~ 70
Discharge hose 5.2
Condenser x 3.7 ~
5~7 50 ~ 70
Liquid tube 5.2
Compressor x 100 ~ 7.2 ~
10 ~ 15
Discharge hose 150 10.8
Compressor x 100 ~ 7.2 ~
10 ~ 15
Suction hose 150 10.8
Expansion valve x 80 ~ 5.8 ~
8 ~ 12
Evaporator 120 8.7
Heating,Ventilation, Air Conditioning > Air conditioning System > Triple pressure switch > Description
and Operation
DESCRIPTION
The triple switch is a combination of a medium switch as well as conventional low pressure and high pressure
switches. The low pressure switch will be turned off to stop compressor operation if refrigerant pressure is low. The
high pressure switch will be turned off to stop compressor operation if refrigerant pressure is too high. The medium
switch will be turned on at medium level pressure to cool the A/C system operating radiator fan and condenser fan
at high speed.
Page 33 of 171
Pressure ON OFF
High
370 ± 2.8 455 ± 2.8
[psi
(26.0 ± 2.0) (32.0 ± 2.0)
(kg/cm²)]
Low 28.6 ~ 36.3
28.4 ± 2.8
[psi (2.01 ~
(2.0 ± 0.2)
(kg/cm²)] 2.55)
Medium
220 ± 11.4 164 ± 17.1
[psi
(15.5 ± 0.8) (11.5 ± 1.2)
(kg/cm²)]
LOW & HIGH PRESSURE
MEDIUM PRESSURE
Page 34 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > Triple pressure switch > Components
COMPONENT
Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator temperature sensor >
DESCRIPTION
The evaporator temperature sensor will detect the evaporator core temperature and interrupt compressor relay
power in order to prevent evaporator freezing by excessive cooling.
It is a negative type thermistor whose resistance is inversely proportional to temperature.
Page 35 of 171
DESCRIPTION
The evaporator temperature sensor will detect the evaporator core temperature and interrupt compressor relay
power in order to prevent evaporator freezing by excessive cooling.
It is a negative type thermistor whose resistance is inversely proportional to temperature.
COMPONENT
Page 36 of 171
COMPONENT
Page 37 of 171
Repair procedures
INSPECTION
1. Ignition "OFF"
2. Disconnect evaporator temperature sensor.
3. Using the multi-tester, Measure resistance between terminal "1" and "2" of evaporator temperature sensor.
Specification
Evaporator core temperature [°C(°F)] Resistance [KΩ]
-10(14) 13.6
0(32) 8.0
10(50) 4.9
15(59) 3.9
30(86) 2.0
40(104) 1.3
50(122) 0.9
INSPECTION
1. Ignition "OFF"
2. Disconnect evaporator temperature sensor.
3. Using the multi-tester, Measure resistance between terminal "1" and "2" of evaporator temperature sensor.
Specification
Page 38 of 171
Evaporator core temperature [°C(°F)] Resistance [KΩ]
-10(14) 13.6
0(32) 8.0
10(50) 4.9
15(59) 3.9
30(86) 2.0
40(104) 1.3
50(122) 0.9
4. If the measured resistance is not specification, substitute with a known-good evaporator temperature sensor and
5. If the problem is corrected, replace the evaporator temperature sensor.
Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Description and
Operation
DESCRIPTION
1. In-car air temperature sensor is located at the lower crush pad.
2. The sensor contains a thermistor which measures the temperature of the inside. The signal, decided by the
resistance value which changes in accordance with perceived inside temperature, is delivered to heater control
unit and according to this signal the control unit regulates incar temperature to intended value.
Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Components and
Components Location
COMPONENT
Page 39 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Repair procedures
INSPECTION
1. Ignition "OFF"
2. Disconnect in-car temperature sensor.
Page 40 of 171
3. Using the multi-tester, Measure resistance between terminal "2" and "4" of in-car sensor.
Specification
Resistance between terminals 2and 4
Temperature [°C(°F)]
(KΩ)
0 (32) 97.83 ± 2.61%
15 (59) 47.12 ± 1.45%
25 (77) 30.00 ± 1.20%
35 (95) 19.60 ± 1.44%
50 (122) 10.82 ± 2.26%
REPLACEMENT
2. Remove the lower crush panel (A) (Refer to the Body group).
3. Disconnect the connector of in-car sensor.
4. Loosen the mounting screws (B) and then remove the in-car sensor (C).
Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Description and
Operation
DESCRIPTION
1. The photo sensor is located at the center of defrost nozzle.
2. The photo sensor contains a photovoltaic (sensitive to sunlight) diode. The solar radiation received by its light
receiving portion, generates an electromotive force in proportion to the amount of radiation received which is
transferred to the automatic temperature control module so that the solar radiation compensation will be
performed.
Page 41 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Components and
Components Location
COMPONENT
Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Repair procedures
INSPECTION
1. Ignition "ON"
2. Using the scan tool.
3. Emit intensive light toward photo sensor using sunshine, and check the output absolute voltage change.
4. The absolute voltage will rise with higher intensive light and reduce with lower intensive light.
When checking photo sensor, select a place where sun shines directly on it.
Page 42 of 171
REPLACEMENT
2. Using the (-) driver, Remove the photo sensor (B) from the center of defrost nozzle (A).
3. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning > Air conditioning System > Water temperature sensor >
DESCRIPTION
1. Water temperature sensor(A) is located at the heater unit.
2. It detects coolant temperature. Its signal is used for cold engine lockout control. When the driver operates the
heater before the engine is warmed up, the signal from sensor causes the heater control unit to reduce blower
motor speed until coolant temperature reaches the threshold value.
Heating,Ventilation, Air Conditioning > Air conditioning System > Water temperature sensor >
COMPONENT
Page 43 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > Water temperature sensor > Repair
procedures
INSPECTION
1. Ignition "OFF"
2. Disconnect water temperature sensor.
3. Using the multi-tester, Measure resistance between terminal "1" and "2" of water temperature sensor.
Specification
Page 44 of 171
Coolant temperature
Resistance between terminals 1and 2 (KΩ)
[°C(°F)]
-15 (5) 73.6 ± 3%
0 (32) 32.9 ± 3%
15 (59) 15.8 ± 3%
25 (77) 10.0 ± 3%
35 (95) 6.0 ± 3%
60 (140) 2.5 ± 3%
4. If the measured resistance is not specification, substitute with a known-good water temperature sensor and check
5. If the problem is corrected, replace the water temperature sensor.
REPLACEMENT
1. Disconnect the negative(-) battery terminal.
2. Remove the passenger's center lower side cover(A) (Refer to the Body group).
3. Disconnect the connector(A) of water temperature sensor.

4. Remove the caulk of water temperature sensor by using the scraper.
5. Pull the water temperature sensor out at the heater unit with the clamp(C).
Take care that wire of water temperature sensor is not to be

damaged
Page 45 of 171
- Apply caulk to the water temperature

sensor.
- Make sure that there is no air leakage.
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Description and
Operation
DESCRIPTION
1. The ambient temperature sensor is located at the front of the condenser and detects ambient air temperature. It is
a negative type thermistor; resistance will increase with lower temperature, and decrease with higher
temperatures.
2. The sensor output will be used for discharge temperature control, temperature regulation door control, blower
motor level control, mix mode control and in-car humidity control.
If the ambient temperature is below 2.0°C (35.6°F), the A/C compressor will be stopped.
The compressor will be operated by manual operating.
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Components and
Components Location
COMPONENT
Page 46 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Repair procedures
INSPECTION
1. Ignition "OFF"
2. Disconnect ambient temperature sensor.
3. Check the resistance of ambient temperature sensor between terminals 1 and 2 whether it is changed by changing
temperature of the ambient temperature sensor.
Specification
Ambient temperature[°C(°F)] Resistance between terminals 1and 2 (kΩ)
-15 (5) 215.3±3%
0 (32) 97.5±3%
15 (59) 59.6±3%
25 (77) 30.0±3%
35 (95) 24.2±3%
60 (140) 16±3%
4. If the measured resistance is not specification, substitute with a known-good ambient temperature sensor and
Page 47 of 171
5. If the problem is corrected, replace the ambient temperature sensor.
REPLACEMENT
2. Remove the front bumper (Refer to the Body group).
3. Remove the ambient temperature sensor (B) after loosening the mounting screws(A).
Heating,Ventilation, Air Conditioning > Air conditioning System > Air Quality Sensor(AQS) >
DESCRIPTION
1. A.Q.S is located at center support in front of the engine radiator, and detects hazardous elements in ambient air
providing output signal to control.
2. It will detect sulfurous acid gas, carbon dioxide, carbon monoxide, hydrocarbon and allergen.
Heating,Ventilation, Air Conditioning > Air conditioning System > Air Quality Sensor(AQS) >
COMPONENT
Page 48 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > Air Quality Sensor(AQS) > Repair
procedures
INSPECTION
1. Ignition "ON"
3. Check the output voltage of AQS between terminals 2 and 3.
Specification
Condition Output signal Fresh/recirculation
Normal condition 4 ~ 5V Fresh
Hazardous gas
0 ~ 1V Recirculation
detection
Page 49 of 171
4. AQS diagnosis and fail safe.
Open signal detection period : 7 seconds (AQS switch OFF, IGN ON).
2.5V detected for ≥ 3.5 seconds during 7 second initialization period.
Fail safe: AQS function inoperative (AQS cannot be selected). Intake mode selection may be accomplished
manually.
When IG is turned ON, AQS sensor heats for 34±5 seconds, it will output below 1.0 voltage during this
time.
REPLACEMENT
2. Remove the front bumper (Refer to the Body group).
3. Remove the AQS (B) after loosening the mounting screws (A).
Heating,Ventilation, Air Conditioning > Air conditioning System > Humidity Sensor > Description and
Operation
DESCRIPTION
1. Humidity sensor is located at the lower crush pad and detects in-car humidity for in-car humidity control.
2. If ambient air temperature or in-car humidity is outside certain range, it will turn on A/C to control in-car humidity
preventing in car fogging.
Air conditioner operation depends on ambient temperature and humidity.
Heating,Ventilation, Air Conditioning > Air conditioning System > Humidity Sensor > Components and
Components Location
COMPONENT
Page 50 of 171
Heating,Ventilation, Air Conditioning > Air conditioning System > Humidity Sensor > Repair
procedures
INSPECTION
1. Ignition "ON"
Page 51 of 171
3. Check the frequency of humidity sensor between terminals 2 and 3.
Frequency between
Humidity (%)
terminals 2and 3(Hz)
30 6976 ± 5%
50 6728 ± 5%
60 6600 ± 5%
70 6468 ± 5%
80 6330 ± 5%
100 6033 ± 5%
4. If the measured resistance is not specification, substitute with a known-good humidity sensor and check for
proper operation.
5. If the problem is corrected, replace the Humidity sensor.
REPLACEMENT
2. Remove the lower crush panel (A) (Refer to the Body group).
3. Disconnect the connector of humidity sensor.
4. Loosen the mounting screws (B) and then remove the humidity sensor (C).
Heating,Ventilation, Air Conditioning > Heater > Heater Unit > Components and Components Location
COMPONENT LOCATION
Page 52 of 171
COMPONENTS
Page 53 of 171
Heating,Ventilation, Air Conditioning > Heater > Heater Unit > Repair procedures
REPLACEMENT
2. Recover the refrigerant with a recovery/recycling/charging station.
3. Remove the bolts (A) and the expansion valve (B) from the evaporator core.
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
Page 54 of 171
4. When the engine is cool, disconnect the inlet (D) and outlet (C) heater hoses from the heater unit.
Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let
coolant spill on electrical parts or painted surfaces. If any coolant spills, rinse it off immediately.
5. Remove the crash pad (Refer to the Body group).

6. Remove the cross member.
7. Disconnect the connectors from the temperature control actuator, the mode control actuator and the evaporator
temperature sensor, then remove the mounting nut (A) and the mounting bolts (B).
8. Remove the heater & evaporator unit after loosening the mounting screws (C).
9. Remove the self-tapping screws and the side bracket (A).

10. Be careful not to bend the inlet and outlet pipes during heater core (A) removal, and pull out the heater core.
11. Install the heater core in the reverse order of removal.

Page 55 of 171
12. Install in the reverse order of removal, and note these items :
A. If you're installing a new evaporator, add refrigerant oil (ND-OIL8).
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing
them. Be sure to use the right O-rings for R-134a to avoid leakage.
C. Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
D. Do not spill the refrigerant oil on the vehicle ; it may damage the paint ; if the refrigerant oil contacts the paint,
wash it off immediately.
E. Apply sealant to the grommets.
F. Make sure that there is no air leakage.
G. Charge the system and test its performance.
H. Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
I. Refill the cooling system with engine coolant.
Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Description and
Operation
DESCRIPTION
1. Heater unit includes mode control actuator and temperature control actuator.
2. Temperature control actuator is located at the heater unit. Signal from control unit adjusts position of temperature
door by operating temperature switch and then temperature will be regulated by the hot/cold air ratio determined
by position of temperature door.
Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Components and
Components Location
COMPONENT
Page 56 of 171
Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Repair procedures
INSPECTION
1. Ignition "OFF".
2. Disconnect the connector of temperature control actuator.
3. Verify that the temperature control actuator operates to the hot position when connecting 12V to the terminal 1
and grounding terminal 2.
4. Verify that the temperature control actuator operates to the cool position when the connections are reversed.
5. Check the voltage between terminals 3 and 4.

Specification
Door
Voltage (3-4) Error detecting
position
Max. Low voltage : 0.08V
0.3 ± 0.15V
cooling or less
Max. High voltage : 4.9V or
4.7 ± 0.15V
heating more
It will feed back current position of actuator to controls.

6. If the measured voltage is not within specification, substitute with a known-good temperature control actuator and
7. If the problem is corrected, replace the temperature control actuator.
REPLACEMENT
2. Remove the side cover (Refer to the Body group).
3. Disconnect the connector (A) of temperature control actuator after removing the air duct.
4. Loosen the mounting screw (B) and then remove the temperature control actuator (C).

Page 57 of 171
Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Description and Operation
DESCRIPTION
The mode control actuator is located at the heater unit.
It adjusts position of mode door by operating mode control actuator based on signal of A/C control unit. Pressing
mode select switch makes the mode control actuator shift in order of vent→ B/L → floor → mix.
Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Components and
Components Location
COMPONENT
Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Repair procedures
INSPECTION
1. Ignition "OFF"
2. Disconnect the connector of mode control actuator.
3. Verify that the mode control actuator operates to the vent position when connecting 12V to the terminal 1 and
grounding terminal 2.
Page 58 of 171
4. Verify that the mode control actuator operates to the defrost position when the connections are reversed.
5. Check the voltage between terminals 4 and 5.

Door
Voltage (4-5) Error detecting
position
Low voltage : 0.08V
Vent 0.3 ± 0.15V
or less
High voltage : 4.9V or
Defrost 4.7 ± 0.15V
more
It will feed back current position of actuator to controls.

6. If the measured voltage is not within specification, substitute with a known-good mode control actuator and
7. If the problem is corrected, replace the mode control actuator.
REPLACEMENT
2. Remove the lower crush panel (Refer to the Body group).
3. Disconnect the connector (A) of mode control actuator after removing the air duct.
4. Loosen the mounting screws (B) and then remove the mode control actuator (C).
Heating,Ventilation, Air Conditioning > Blower > Blower Unit > Components and Components Location
COMPONENT LOCATION
Page 59 of 171
COMPONENTS
Page 60 of 171
Heating,Ventilation, Air Conditioning > Blower > Blower Unit > Repair procedures
REPLACEMENT
2. Remove the heater unit (See page HA-20)
Page 61 of 171
3. Disconnect the connectors from the fresh and recirculation actuator, the blower relay, the blower motor and
power mosfet.
Remove the self-tapping screws (A), the mounting nut (B), the mounting bolt (C) and the blower unit (D).
Make sure that there is no air leaking out of the blower and duct joints.
Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Components and Components
Location
COMPONENTS
Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Repair procedures
INSPECTION
Page 62 of 171
1. Connect the battery voltage and check the blower motor rotation.
2. If the blower motor does not operate properly, substitute with a known-good blower motor and check for
proper operation.
3. If the problem is corrected, replace the blower motor.
REPLACEMENT
2. Disconnect the connector (A) of the blower motor.
3. Remove the blower motor (A) after loosening the mounting screws.
Heating,Ventilation, Air Conditioning > Blower > Blower Relay > Components and Components
Location
COMPONENT
Page 63 of 171
Heating,Ventilation, Air Conditioning > Blower > Blower Relay > Repair procedures
INSPECTION
No.1 and No.2 terminals.
Page 64 of 171
3. If the blower relay does not operate properly, substitute with a known-good blower relay and check for proper
operation.
4. If the problem is corrected, replace the blower relay.
REPLACEMENT
2. Disconnect the connector of the blower relay at the below blower unit.
3. Remove the blower relay (A) after loosening the mounting screw.
Heating,Ventilation, Air Conditioning > Blower > Power Mosfet > Components and Components
Location
COMPONENT
Heating,Ventilation, Air Conditioning > Blower > Power Mosfet > Repair procedures
Page 65 of 171
INSPECTION
1. Ignition "ON".
2. Manually operate the control switch and measure the voltage of blower motor between pin 1 and 2.
3. Select the control switch to raise voltage until high speed.
Specification
Motor Voltage
Fan
Manual Automatic
First speed 3.8 ±0.5V 3.8 ±0.5V
Second speed 4.8 ±0.5V 5.0 ±0.5V
Third speed 5.8 ±0.5V 6.2 ±0.5V
Fourth speed 6.8 ±0.5V 7.4 ±0.5V
Fifth speed 7.9 ±0.5V 8.6 ±0.5V
Sixth speed 8.9 ±0.5V 9.8 ±0.5V
Seventh speed 9.9 ±0.5V 11.0 ±0.5V
eighth speed 11.0 ±0.5V Battery(+)
Ninth speed Battery(+) -
4. If the measured voltage is not within specification, substitute with a known-good power mosfet and check for
proper operation.
5. If the problem is corrected, replace the power mosfet.
REPLACEMENT
Page 66 of 171
2. Disconnect the connector (A) of the power mosfet at the below blower unit.
3. Remove the power mosfet after loosening the mounting screws.

Heating,Ventilation, Air Conditioning > Blower > Climate control air filtar > Description and Operation
DESCRIPTION
This has particle filter which eliminates foreign materials and odor. The particle filter includes odor filter as well as
conventional dust filter to ensure comfortable interior environment.
Heating,Ventilation, Air Conditioning > Blower > Climate control air filtar > Repair procedures
REPLACEMENT
1. Open the glove box. Lower the glove box down completely by removing the tension cord (A) and the glove box
stopper (B) to the glove box.
2. Remove the filter cover (A) with pushing the knob.

Page 67 of 171
3. Replace the air filter (B).
In case of driving in an air-polluted area or rugged terrain, check and replace the air filter as frequently as
possible.
Replacement period: 15,000 km (9320 mile)
Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Description and Operation
DESCRIPTION
1. The fresh and recirculation actuator is located at the blower unit.
2. It regulates the intake door by signal from control unit.
3. Pressing the intake selection switch will shift between recirculation and fresh air modes.
Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Components and Components
Location
COMPONENT
Page 68 of 171
Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Repair procedures
INSPECTION
1. Ignition "OFF".
2. Disconnect the connector of fresh and recirculation actuator.
3. Verify that the fresh and recirculation actuator operates to the fresh position when connecting 12V to the terminal
1 and grounding terminal 2.
4. Verify that the fresh and recirculation actuator operates to the recirculation position when the connections are
reversed.
5. If the fresh and recirculation actuator does not operate properly, substitute with a known-good fresh and
recirculation actuator and check for proper operation.
6. If the problem is corrected, replace the fresh and recirculation actuator.
REPLACEMENT
2. Remove the glove box (Refer to the Body group).
Page 69 of 171
3. Disconnect the connector (A) of fresh and recirculation actuator.
4. Loosen the mounting screw (B) and then remove the fresh and recirculation actuator (C) from the blower unit
(D).
Heating,Ventilation, Air Conditioning > Blower > Control Panel > Schematic Diagrams
CIRCUIT DIAGRAM
Page 70 of 171
Page 71 of 171
Page 72 of 171
Heating,Ventilation, Air Conditioning > Blower > Control Panel > Components and Components
Location
COMPONENT
Page 73 of 171
CONNECTOR PIN FUNCTION

Page 74 of 171
CONNECTOR PIN FUNCTION CONNECTOR PIN FUNCTION
1 IG2 1 Intake (Recirculation)
2 Battery 2 Tail lamp(+)
3 Ground 3 Rheostat
4 Mode vent 4 Power mosfet (Gate)
5 Mode defrost 5 A/C select
Rear defogger
6 Mode feedback 6
Connector(A) indicator
7 Mix warm 7 Rear defogger switch
8 Mix cool Connector 8 -
9 Mix feedback (B) 9 -
10 Sensor voltage(5V) 10 -
11 Sensor ground 11 -
12 Intake (Fresh) 12 -
13 Power mosfet (Drain)
Evaporator
14
temperature sensor
15 Blower select
16 A/C output
Heating,Ventilation, Air Conditioning > Blower > Control Panel > Repair procedures
CONTROL LOGICS
1. Dissolution & reinstatement of logic
- When selecting MAX A/C: A/C is ON and vent mode is selected.

- When selecting other modes from MAX A/C: It goes back in previously selected condition.
Page 75 of 171
2. Dissolution & reinstatement of logic procedure
(1) Ignition "ON".
(2) Turn off the blower switch.
(3) Move to defrost mode.
(4) Press the intake button more than 5 times within 3 seconds.
(5) Indicator of intake button is flashed 3 times.
(6) Dissolution & reinstatement of logic is completed.
(7) A/C and intake status is initialized to "A/C off" and "fresh status"
When the battery happens to be disconnected or discharged, the logic is

reinstated.
CONTROL UNIT REPLACEMENT

2. Remove the center facia panel (C) after pulling it by using a screw driver (-) at part (A).
Take care of fixing clips (B).
3. Disconnect the connectors from the center facia.

4. Remove the blower and A/C control unit (A).
Heating,Ventilation, Air Conditioning > Controller > Manual Controller > Schematic Diagrams
CIRCUIT DIAGRAM
Page 76 of 171
Page 77 of 171
Page 78 of 171
Page 79 of 171
Heating,Ventilation, Air Conditioning > Controller > Manual Controller > Components and
Components Location
COMPONENT
Page 80 of 171
CONNECTOR PIN FUNCTION

Page 81 of 171
CONNECTOR PIN FUNCTION CONNECTOR PIN FUNCTION
CONNECTOR 1 Rheostat CONNECTOR 1 In car sensor
(A) (B)
2 Tail lamp (+) 2 A/C select signal
3 Battery (+) 3 Ambient sensor (+)
Evaporator temperature
4 Power mosfet (Gate) 4
sensor (+)
5 Power mosfet (Drain) 5 Speed sensor
6 - 6 Diagnostic tool
7 In car sensor motor (+) 7 Humidity sensor
8 In car sensor motor (-) 8 Sensor voltage (5V)
9 Mix cool 9 AQS
10 Intake fresh 10 Mix feedback
11 Rear defogger indicator 11 Mode feedback
12 IG2 12 Photo sensor (+)
13 Ground 13 Photo sensor ground
14 Mode vent 14 Water temperature output
15 Mode defrost 15 -
16 - 16 Sensor ground
17 A/C output
18 -
19 -
20 -
21 Rear defogger switch
22 Mix warm
23 Intake recirculation
24 Blower select signal
25 IG2
26 Ground
Heating,Ventilation, Air Conditioning > Controller > Manual Controller > Repair procedures
CONTROL LOGIC
Page 82 of 171
1. Intake & A/C control logic
Intake A/C
Mode System System
IG "ON" IG "ON"
"ON" "ON"
Vent, Bi-
Memory Previous Memory Previous
level
Floor Fresh (*1) Fresh (*1) Memory Previous
Mix,
Fresh (*1) Fresh (*1) ON (*2) Previous
Defrost
*1: User is able to select, *2 : User is not able to select.

2. Dissolution & reinstatement of defrost logic
Control Mix,
Specification KEY ON KEY OFF
factor Defrost
Initial A/C ON Previous OFF
(Reinstatement) Intake Fresh Fresh Fresh
A/C Previous Previous OFF
Dissolution
Intake Previous Previous Previous
3. Dissolution & reinstatement of defrost logic procedure

(1) Ignition "ON".
(2) Move to defrost mode.
(3) Press intake button more than 5 times within 3 seconds while holding A/C switch down.
(4) Graphics of the entire LCD display switch on and off 3 times with an interval of 0.5 seconds.
(5) Dissolution & reinstatement of logic is completed.
(6) A/C and intake status is initialized to "A/C off" and "fresh status".
When the battery happens to be disconnected or discharged, the logic is reinstated.
SELF-DIAGNOSIS
Self-diagnosis process
The F.A.T.C. module self test feature will detect electrical malfunction and provide error codes for system
components with suspected failures.
Page 83 of 171
DTC data can be retrieved from the control panel directly or from the DLC using the Hi-Scan Pro.
HOW TO READ SELF-DIAGNOSTIC CODE
1. After the display panel flickers three times every 0.5 second, the corresponding fault code flickers on the setup
temperature display panel every 0.5 second and will show two figures.
DTC's are displayed in numerical format.
Page 84 of 171
2. Fault code
Fault code
Scan Fail description
Control
tool
unit
(DTC)
00 - Normal
11 B1234 In-car temperature sensor open (High)
12 B1233 In-car temperature sensor short (Low)
13 B1238 Ambient temperature sensor open (High)
14 B1237 Ambient temperature sensor short (Low)
15 B1202 Water temperature sensor open (High)
16 B1203 Water temperature sensor short (Low)
17 B1242 Evaporator temperature sensor open (High)
18 B1241 Evaporator temperature sensor short (Low)
19 B1245 Air mix potentiometer open (Low) - Driver
19 B1246 Air mix potentiometer short (High) - Driver
20 B2406 Air mix motor (Driver)
21 B1249 Direction potentiometer open (Low) - Driver
21 B1250 Direction potentiometer short (High) - Driver
22 B2409 Direction control motor (Driver)
23 B1200 Humidity sensor open (High)
24 B1201 Humidity sensor short (Low)
3. Fault code display

(1) Continuance operation
Page 85 of 171
(2) Step operation
4. If a fault code is displayed during the DTC check, Inspect a malfunction cause by referring to the DTC code.
5. Fail safe
(1) In-car temperature sensor: Control with the value of 23°C(73.4°F)
(2) Ambient temperature sensor: Control with the value of 20°C(67°F)
(3) Evaporator temperature sensor: Control with the value of -2°C(28.4°F)
(4) Humidity sensor: Control with the value of 10%
(5) Photo sensor: None
(6) Temperature control actuator (Air mix potentiometer):
If temperature setting 17°C-24.5°C, fix at maximum cooling position.
If temperature setting 25°C-32°C, fix at maximum heating position.
(7) Mode control actuator (Direction potentiometer):
Fix vent position, while selecting vent mode.
Fix defrost position, while selecting all except vent mode.
REPLACEMENT
2. Remove the center facia panel (C) after pulling it by using a screw driver (-) at part (A).
Take care of fixing clips (B).
3. Disconnect the connectors from the center facia.

Page 86 of 171
4. Remove the blower And A/C control unit (A).
Heating,Ventilation, Air Conditioning > Troubleshooting > B1200

COMPONENT LOCATION
GENERAL DESCRIPTION
Humidity sensor located at crush pad, detects in-car humidity for in-car humidity control. If ambient air temperature
or in-car humidity is outside certain range, it will turn on A/C to control in-car humidity for preventing in-car fogging.
DTC DESCRIPTION
The A/C controller sets DTC B1200 if there is an open circuit in humidity sensor signal harness or the measured
frequency value of sensor is more than threshold value(about 7,224Hz)

Page 87 of 171
DTC Strategy • Frequency check • Open Circuit in
harness
Threshold value • > 7,224 Hz
• Faulty Humidity
Detecting time • 0.3 sec Sensor
• Control with the value • Faulty A/C control
FAIL SAFE unit
of 10%
SPECIFICATION
Relative Relative
Frequency(Hz) Frequency(Hz)
humidity(%) humidity(%)
10 7,224 55 6,664
15 7,162 60 6,600
20 7,100 65 6,534
25 7,038 70 6,468
30 6,976 75 6,399
35 6,915 80 6,330
40 6,853 85 6,258
45 6,791 90 6,186
50 6,728 95 6,110

1. Connect scantool to data dink connector(DLC).
2. Engine "ON"
3. Monitor the "Humidity Sensor" Parameter on the Scantool while drying the humidity sensor with a hair drier or heat
gun adjusted to a low heat setting.
Page 88 of 171
4. Are the DTC B1200 present and is parameter of "Humidity Sensor" fixed?
Parameter of "Humidity Sensor" will be fixed at 10%, if there is any fault in Humidity Sensor.
Go to "Inspection" procedure.
Fault is intermittent caused by poor contact in the sensor's and/or A/C controller's connector or was repaired and
A/C controller 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

or damage.

1. Check for open in harness.
(1) Ignition "OFF"
(2) Disconnect Humidity Sensor.
(3) Measure resistance between terminal "3" of Humidity Sensor and terminal "7" of A/C Control Unit.
Go to "Ground circuit Inspection " procedure.
Page 89 of 171
1. Check for open in ground harness.
(1) Ignition "OFF"
(3) Measure resistance between terminal "2" of Humidity Sensor and terminal "16" of A/C Control Unit.
Specification :Approx. 0 Ω
Go to "Component Inspection " procedure.
Check for open in ground harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure.
1. Check Humidity Sensor.
(1) Engine "ON"
(2) Connect Humidity Sensor.
(3) Measure Frequency between terminal "3" and "2" of Humidity sensor while increasing humidity.
Specification : Refer the specifications in fig 5.

Page 90 of 171
(4) Is the measured frequency within specifications in fig 5? (tolerance limits ± 5%)
Go to "Check A/C Control Unit" procedure.
Substitute with a known-good Humidity sensor and check for proper operation.
If the problem is corrected, replace Humidity sensor and then go to "Verification of Vehicle Repair" procedure.
Page 91 of 171
2. Check A/C Control Unit
(1) Engine "ON"
(3) Measure voltage value between terminal "7" of A/C control unit and chassis ground.
Specification : 5V
Check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage.
Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle Repair" procedure.

1. Connect scantool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.

COMPONENT LOCATION
Page 92 of 171
GENERAL DESCRIPTION
Humidity sensor located at crush pad, detects in-car humidity for in-car humidity control. If ambient air temperature
or in-car humidity is outside certain range, it will turn on A/C to control in-car humidity for preventing in-car fogging.
DTC DESCRIPTION
The A/C controller sets DTC B1201 if there is a short circuit in humidity sensor signal harness or the measured
frequency value of sensor is less than threshold value(about 6,100Hz)

DTC Strategy • Frequency check • Open Circuit in power
harness
Threshold value • < 6,100 Hz
• Short Circuit in signal
Detecting time • 10msec harnes
• Control with the value of • Faulty Humidity Sensor
FAIL SAFE • Faulty A/C control unit
10%
SPECIFICATION
Page 93 of 171
Relative Relative
Frequency(Hz) Frequency(Hz)
humidity(%) humidity(%)
10 7,224 55 6,664
15 7,162 60 6,600
20 7,100 65 6,534
25 7,038 70 6,468
30 6,976 75 6,399
35 6,915 80 6,330
40 6,853 85 6,258
45 6,791 90 6,186
50 6,728 95 6,110

2. Engine "ON"
3. Monitor the "Humidity Sensor" Parameter on the Scantool while drying the humidity sensor with a hair drier or heat
gun adjusted to a low heat setting.
4. Are the DTC B1201 present and is parameter of "Humidity Sensor" fixed?
Parameter of "Humidity Sensor" will be fixed at 10%, if there is any fault in Humidity Sensor.

Page 94 of 171
or damage.

(1) Ignition "OFF"
(3) Measure resistance between terminal "3" of Humidity Sensor and chassis ground.
Specification : Approx. ∞ Ω
Go to "Power circuit Inspection " procedure.
Check for short to ground in harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure.
Page 95 of 171
1. Check for open in power harness.
(1) Ignition "ON"
(3) Measure voltage value between terminal "5" of Humidity Sensor and chassis ground.
Specification : 5V
Check for open in power harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure.
1. Check Humidity Sensor.
(1) Engine "ON"
(2) Connect Humidity Sensor.
(3) Measure Frequency between terminal "3" and "2" of Humidity sensor while increasing humidity.

Page 96 of 171
(4) Is the measured frequency within specifications in fig 5? (tolerance limits ± 5%)
Substitute with a known-good Humidity sensor and check for proper operation.
If the problem is corrected, replace Humidity sensor and then go to "Verification of Vehicle Repair" procedure.
Page 97 of 171
(1) Engine "ON"
(3) Measure voltage value between terminal "7" of A/C control unit and chassis ground.
Specification : 5V


COMPONENT LOCATION
Page 98 of 171
GENERAL DESCRIPTION
A water temp. sensor located at heater unit, detects coolant temperature. Its signal is used for cold engine lockout
control. When the driver operates the heater before the engine is warmed up, the signal from sensor causes the
heater control unit to reduce blower motor speed until coolant temperature reaches the threshold value.
DTC DESCRIPTION
The A/C controller sets DTC B1202 if there is an open circuit in water temp. sensor signal harness or the measured
resistance value of the sensor is more than the threshold value(about 176.3kΩ)

DTC Strategy • Voltage check • Open Circuit in harness
Threshold value • > 4.9V • Faulty water temp.
Sensor
Detecting time • 0.3 sec • Faulty A/C control unit
• Control with the value of
FAIL SAFE
20°C(68°F)
SPECIFICATION
Temperature[°C(°F)] Resistance(kΩ) Temperature[°C(°F)] Resistance(kΩ)
-30(-22) 176.3 25(77) 10
-15(5) 73.6 35(95) 6.5
0(32) 32.9 60(140) 2.5
15(59) 15.8 80(176) 1.2

2. Engine "ON"
Page 99 of 171
3. Monitor the "WATER TEMP. SENSOR" Parameter on the Scantool.
4. Are the DTC B1202 present and is parameter of "WATER TEMP. SENSOR" fixed?
Parameter of "WATER TEMP. SENSOR" will be fixed at 20°C, if there is any fault in WATER TEMP.
SENSOR.

or damage.

Page 100 of 171
(1) Ignition "OFF"
(2) Disconnect water temp. sensor.
(3) Measure resistance between terminal "1" of water temp. sensor and terminal "14" of A/C Control Unit.
(1) Ignition "OFF"
(3) Measure resistance between terminal "2" of water temp. sensor and chassis ground.
Page 101 of 171
1. Check water temp. sensor.
(1) Ignition "OFF"
(3) Measure resistance between terminal "1" and "2" of water temp. sensor.

Page 102 of 171
(4) Is the measured resistance within specifications in fig 3)? (tolerance limits ± 3%)
Substitute with a known-good water temp. sensor and check for proper operation.
If the problem is corrected, replace water temp. sensor and then go to "Verification of Vehicle Repair" procedure.
(1) Engine "ON"
(3) Measure Voltage between terminal "14" of A/C Control Unit and chassis ground.


COMPONENT LOCATION
Page 103 of 171
GENERAL DESCRIPTION
A water temp. sensor located at heater unit, detects coolant temperature. Its signal is used for cold engine lockout
control. When the driver operates the heater before the engine is warmed up, the signal from sensor causes the
heater control unit to reduce blower motor speed until coolant temperature reaches the threshold value.
DTC DESCRIPTION
The A/C controller sets DTC B1203 if there is a short circuit in water temp. sensor signal harness or the measured
resistance value of sensor is less than threshold value(about 1.2kΩ)

DTC Strategy • Voltage check • Short circuit in harness
Threshold value • < 0.1V • Faulty water temp.
Sensor
FAIL SAFE
20°C(68°F)
SPECIFICATION
-30(-22) 176.3 25(77) 10
-15(5) 73.6 35(95) 6.5
0(32) 32.9 60(140) 2.5
15(59) 15.8 80(176) 1.2

2. Engine "ON"
Page 104 of 171
3. Monitor the "WATER TEMP. SENSOR" Parameter on the Scantool.
4. Are the DTC B1203 present and is parameter of "WATER TEMP. SENSOR" fixed?
Parameter of "WATER TEMP. SENSOR" will be fixed at 20°C, if there is any fault in WATER TEMP.
SENSOR.

or damage.

Page 105 of 171
(1) Ignition "OFF"
(3) Measure resistance between terminal "1" of water temp. sensor and chassis ground.
Specification : Approx. ∞Ω
1. Check water temp. sensor.
(1) Ignition "OFF"
(3) Measure resistance between terminal "1" and "2" of water temp. sensor.

Page 106 of 171
(4) Is the measured resistance within specifications in fig 3)? (tolerance limits ± 3%)
Substitute with a known-good water temp. sensor and check for proper operation.
If the problem is corrected, replace water temp. sensor and then go to "Verification of Vehicle Repair" procedure.
(1) Engine "ON"
Page 107 of 171


COMPONENT LOCATION
GENERAL DESCRIPTION
The incar temperature sensor located at crush pad, control unit contains a thermistor which measures the
temperature of the inside. The signal, decided by the resistance value which changes in accordance with perceived
inside temperature, is delivered to heater control unit and according to this signal, the control unit regulates incar
temperature to intended value.
DTC DESCRIPTION
The A/C controller sets DTC B1233 if there is a short circuit in incar temp. sensor signal harness or the measured

Page 108 of 171
• Faulty incar temp. Sensor
Threshold value • < 0.1V
• Faulty A/C control unit
Detecting time • 0.3 sec
FAIL SAFE
23°C(73°F)
SPECIFICATION
-30(-22) 528.2 25(77) 30
-15(5) 218.2 35(95) 19.6
0(32) 97.83 60(140) 7.478
15(59) 47.12 80(176) 3.225

2. Engine "ON"
3. Monitor the "INCAR TEMP. SENSOR" Parameter on the Scantool.
Page 109 of 171
4. Are the DTC B1233 present and is parameter of "INCAR TEMP. SENSOR" fixed?
Parameter of "INCAR TEMP. SENSOR" will be fixed at 23°C(73°F), if there is any fault in INCAR TEMP.
SENSOR.

or damage.

(1) Ignition "OFF"
(2) Disconnect incar sensor.
(3) Measure resistance between terminal "4" of incar sensor and chassis ground.
Page 110 of 171
1. Check incar temp. sensor.
(1) Ignition "OFF"
(3) Measure resistance between terminal "4" and "2" of incar sensor.
(4) Is the measured resistance within specifications in fig3? (tolerance limits ± 3%)
Substitute with a known-good incar sensor and check for proper operation.
If the problem is corrected, replace incar sensor and then go to "Verification of Vehicle Repair" procedure.
Page 111 of 171
(1) Engine "ON"


COMPONENT LOCATION
Page 112 of 171
GENERAL DESCRIPTION
The incar temperature sensor located at crush pad, control unit contains a thermistor which measures the
temperature of the inside. The signal, decided by the resistance value which changes in accordance with perceived
inside temperature, is delivered to heater control unit and according to this signal, the control unit regulates incar
temperature to intended value.
DTC DESCRIPTION
The A/C controller sets DTC B1234 if there is an open circuit in incar temp. sensor signal harness or the measured
resistance value of sensor is more than threshold value(about 528kΩ)

Threshold value • > 4.9V • Faulty incar temp. Sensor
• Faulty A/C control unit
FAIL SAFE
23°C(73°F)
SPECIFICATION
-30(-22) 528.2 25(77) 30
-15(5) 218.2 35(95) 19.6
0(32) 97.83 60(140) 7.478
15(59) 47.12 80(176) 3.225

2. Engine "ON"
Page 113 of 171
3. Monitor the "INCAR TEMP. SENSOR" Parameter on the Scantool.
4. Are the DTC B1234 present and is parameter of "INCAR TEMP. SENSOR" fixed?
Parameter of "INCAR TEMP. SENSOR" will be fixed at 23°C(73°F), if there is any fault in INCAR TEMP.
SENSOR.

or damage.

Page 114 of 171
(1) Ignition "OFF"
(2) Disconnect incar temp. sensor.
(3) Measure resistance between terminal "4" of incar temp. sensor and terminal "1" of A/C Control Unit..
(1) Ignition "OFF"
(2) Disconnect incar temp. sensor.
(3) Measure resistance between terminal "2" of incar temp. sensor and terminal "16" of A/C Control Unit.
Page 115 of 171
1. Check incar temp. sensor.
(1) Ignition "OFF"
(3) Measure resistance between terminal "4" and "2" of incar sensor.

Page 116 of 171
(4) Is the measured resistance within specifications in fig3? (tolerance limits ± 3%)
Substitute with a known-good incar sensor and check for proper operation.
If the problem is corrected, replace incar sensor and then go to "Verification of Vehicle Repair" procedure.
(1) Engine "ON"


COMPONENT LOCATION
Page 117 of 171
GENERAL DESCRIPTION
The ambient temperature senor located at the center stay of the condenser, detects ambient air temperature. It is a
negative type thermistor whose resistance is inversely proportional to temperature. Its output is used for discharge
temperature sensor, sensor fail-safe, temperature regulation door lock, blower motor level control, mix mode control
and in-car humidity control.
DTC DESCRIPTION
The A/C controller sets DTC B1237 if there is a short circuit in ambient temp. sensor signal harness or the measured

Threshold value • < 0.1V • Faulty ambient temp.
Sensor
FAIL SAFE
20°C(68°F)
SPECIFICATION
-30(-22) 507 25(77) 30
-15(5) 215.3 35(95) 24.2
0(32) 97.5 60(140) 16
15(59) 59.6 80(176) 10.8

2. Engine "ON"
Page 118 of 171
3. Monitor the "AMBIENT TEMP. SENSOR" Parameter on the Scantool.
4. Are the DTC B1237 present and is parameter of "AMBIENT TEMP. SENSOR" fixed?

or damage.

Page 119 of 171
(1) Ignition "OFF"
(2) Disconnect ambient temp. sensor.
(3) Measure resistance between terminal "1" of ambient temp. sensor and chassis ground.
1. Check Ambient temp. sensor.
(1) Ignition "OFF"
(3) Measure resistance between terminal "1" and "2" of ambient temp. sensor.

Page 120 of 171
(4) Is the measured resistance within specifications in fig3? (tolerance limits ±3%)
Substitute with a known-good ambient temp. sensor and check for proper operation.
If the problem is corrected, replace ambient temp. sensor and then go to "Verification of Vehicle Repair" procedure.
(1) Engine "ON"
(3) Measure voltage between terminal "3" of A/C Control Unit and chassis ground.
Page 121 of 171


COMPONENT LOCATION
GENERAL DESCRIPTION
The ambient temperature senor located at the center stay of the condenser, detects ambient air temperature. It is a
negative type thermistor whose resistance is inversely proportional to temperature. Its output is used for discharge
temperature sensor, sensor fail-safe, temperature regulation door lock, blower motor level control, mix mode control
and in-car humidity control.
DTC DESCRIPTION
The A/C controller sets DTC B1238 if there is an open circuit in ambient temp. sensor signal harness or the
measured resistance value of sensor is more than threshold value(about 507kΩ)

Page 122 of 171
• Faulty ambient temp.
Threshold value • > 4.9V
Sensor
FAIL SAFE
20°C(68°F)
SPECIFICATION
-30(-22) 507 25(77) 30
-15(5) 215.3 35(95) 24.2
0(32) 97.5 60(140) 16
15(59) 59.6 80(176) 10.8

2. Engine "ON"
3. Monitor the "AMBIENT TEMP. SENSOR" Parameter on the Scantool.
Parameter of "AMBIENT TEMP. SENSOR" will be fixed at 20°C(67°F), if there is any fault in AMBIENT
TEMP. SENSOR.
Page 123 of 171
4. Are the DTC B1238 present and is parameter of "AMBIENT TEMP. SENSOR" fixed?

or damage.

(1) Ignition "OFF"
(3) Measure resistance between terminal "1" of ambient temp. sensor and terminal "3" of A/C Control Unit.
Page 124 of 171
(1) Ignition "OFF"
(3) Measure resistance between terminal "2" of ambient temp. sensor and chassis ground.
1. Check Ambient temp. sensor.
(1) Ignition "OFF"
(3) Measure resistance between terminal "1" and "2" of ambient temp. sensor.

Page 125 of 171
Substitute with a known-good ambient temp. sensor and check for proper operation.
If the problem is corrected, replace ambient temp. sensor and then go to "Verification of Vehicle Repair" procedure.
(1) Engine "ON"
Page 126 of 171


COMPONENT LOCATION
GENERAL DESCRIPTION
The Evaporator temperature sensor located on heater unit, detects the core temperature and interrupts compressor
relay power, in order to prevent evaporator freezing by excessive cooling. It is a negative type thermistor whose
resistance is inversely proportional to temperature.
DTC DESCRIPTION
The A/C controller sets DTC B1241 if there is a short circuit in evaporator temp. sensor signal harness or the
measured resistance value of sensor is less than threshold value(about 0.9kΩ)

Page 127 of 171
• Faulty Evaporator temp.
Sensor
• Control with the value of -
FAIL SAFE
2°C(28.4°F)
SPECIFICATION
-10(14) 13.6 15(59) 3.9
0(32) 8 30(86) 2
5(41) 6.2 40(104) 1.3
10(50) 4.9 50(122) 0.9

2. Engine "ON"
3. Monitor the "EVAPORATIVE SENSOR" Parameter on the Scantool.
Page 128 of 171
4. Are the DTC B1241 present and is parameter of "EVAPORATIVE SENSOR" fixed?
Parameter of "EVAPORATIVE SENSOR" will be fixed at -2°C(28.4°F), if there is any fault in
EVAPORATIVE SENSOR.

or damage.

(1) Ignition "OFF"
(2) Disconnect evaporator temp. sensor.
(3) Measure resistance between terminal "1" of evaporator temp. sensor and chassis ground.
Page 129 of 171
1. Check evaporator temp. sensor.
(1) Ignition "OFF"
(3) Measure resistance between terminal "1" and "2" of evaporator temp. sensor.
Substitute with a known-good evaporator temp. sensor and check for proper operation.
If the problem is corrected, replace evaporator temp. sensor and then go to "Verification of Vehicle Repair"
procedure.
Page 130 of 171
(1) Engine "ON"


COMPONENT LOCATION
Page 131 of 171
GENERAL DESCRIPTION
The Evaporator temperature sensor located on heater unit, detects the core temperature and interrupts compressor
relay power, in order to prevent evaporator freezing by excessive cooling. It is a negative type thermistor whose
resistance is inversely proportional to temperature.
DTC DESCRIPTION
The A/C controller sets DTC B1242 if there is an open circuit in evaporator temp. sensor signal harness or the
measured resistance value of sensor is more than threshold value(about 13.6kΩ)

Threshold value • > 4.9V • Faulty Evaporator temp.
Sensor
• Control with the value of -
FAIL SAFE
2°C(28.4°F)
SPECIFICATION
-10(14) 13.6 15(59) 3.9
0(32) 8 30(86) 2
5(41) 6.2 40(104) 1.3
10(50) 4.9 50(122) 0.9

2. Engine "ON"
Page 132 of 171
3. Monitor the "EVAPORATIVE SENSOR" Parameter on the Scantool.
4. Are the DTC B1242 present and is parameter of "EVAPORATIVE SENSOR" fixed?
Parameter of "EVAPORATIVE SENSOR" will be fixed at -2°C(28.4°F), if there is any fault in
EVAPORATIVE SENSOR.

or damage.

Page 133 of 171
(1) Ignition "OFF"
(3) Measure resistance between terminal "1" of evaporator temp. sensor and terminal "4" of A/C Control Unit.
(1) Ignition "OFF"
(3) Measure resistance between terminal "2" of evaporator temp. sensor and chassis ground.
Page 134 of 171
1. Check evaporator temp. sensor.
(1) Ignition "OFF"
(3) Measure resistance between terminal "1" and "2" of evaporator temp. sensor.

Page 135 of 171
Substitute with a known-good evaporator temp. sensor and check for proper operation.
If the problem is corrected, replace evaporator temp. sensor and then go to "Verification of Vehicle Repair"
procedure.
(1) Engine "ON"


COMPONENT LOCATION
Page 136 of 171
GENERAL DESCRIPTION
Temperature control actuator located at heater unit, regulates the temperature by the procedure as follows. Signal
from control unit adjusts position of temp. door by operating temp. motor and then temperature will be regulated by
the hot/cold air ratio decided by position of temp. door.
DTC DESCRIPTION
The A/C controller sets DTC B1245 if there is an open circuit or poor connection in the air mix potentiometer.

DTC Strategy • Voltage check • Poor connection of connected
part
• Open circuit in harness
Detecting time • 0.3 sec • Short circuit in harness
• If temperature setting 17°C- • Faulty driver Air Mix
24.5°C(63~76°F) fix at max. potentiometer
cooling position.
FAIL SAFE
• If temperature setting 25°C-
32°C(77~90°F) fix at max.
heating position.
SPECIFICATION
Page 137 of 171

2. Engine "ON"
3. Monitor the "Driver Air Mix Potentiometer" Parameter on the Scantool while operating temp. switch.
4. Are the DTC B1245 present and is parameter of "Driver Air Mix Potentiometer" fixed?
Parameter of "Driver Air Mix Potentiometer" will be fixed at 100%(or any value above 90%), or 0% (or any
value below 10%), if there is any fault in Driver Air Mix potentiometer.

or damage.
Page 138 of 171

(1) Ignition "OFF"
(2) Disconnect Driver Air Mix potentiometer.
(3) Measure resistance between terminal "4" of Driver Air Mix Potentiometer and terminal "10" of A/C control unit.
Go to "Check for short to ground in harness" procedure.
Check for open in signal harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure.
(1) Ignition "OFF"
(3) Measure resistance between terminal "4" of Driver Air Mix Potentiometer and chassis ground.
Page 139 of 171
Go to "Power circuit Inspection" procedure.
Check for short to ground in signal harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.
1. Check for short or open in harness.
(1) Ignition "ON"
(2) Connect Driver Air Mix Potentiometer.
(3) Measure voltage between terminal "5" of Driver Air Mix Potentiometer and chassis ground.
Go to "Ground circuit Inspection" procedure.
Check for short or open in power harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.
Page 140 of 171
(1) Ignition "OFF"
(2) Disconnect Driver Air Mix Potentiometer.
1. Check actuator motor.
(1) Ignition "OFF"
(3) Verify that the temperature actuator operates to the hot position when connecting 12V to the terminal 1 and
(4) Verify that the temperature actuator operates to the cool position when the connections are reversed.
Page 141 of 171
(5) Dose the actuator work properly?
Go to "Check potentiometer" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is corrected, replace actuator
2. Check potentiometer
(1) Ignition "ON"
(2) Connect Driver Air Mix potentiometer.
(3) Measure voltage between terminal "3" and "4" of Driver Air Mix potentiometer while operating the temp. switch.
Specification : Refer the specifications in fig 3)
Door position Voltage (3-4) Error detecting

MAX. Cooling 0.3 ± 0.15V Low voltage : 0.08V or less
MAX. Heating 4.7 ± 0.15V High voltage : 4.9V or more
Page 142 of 171
(4) Is the measured voltage within specifications in fig3?


COMPONENT LOCATION
GENERAL DESCRIPTION
from control unit adjusts position of temp. door by operating temp. motor and then temperature will be regulated by
the hot/cold air ratio decided by position of temp. door.
DTC DESCRIPTION
The A/C controller sets DTC B1246 if there is a short to power in the air mix potentiometer.

Page 143 of 171
• Faulty driver Air Mix
potentiometer
24.5°C(63~76°F) fix at max.
cooling position.
FAIL SAFE
32°C(77~90°F) fix at max.
heating position.
SPECIFICATION

2. Engine "ON"
Page 144 of 171
4. Are the DTC B1246 present and is parameter of "Driver Air Mix potentiometer" fixed?
Parameter of "Driver Air Mix potentiometer" will be fixed at 100%(or any value above 90%), or 0% (or any
value below 10%), if there is any fault in Driver Air Mix potentiometer.

or damage.

1. Check for short in harness.
(1) Ignition "OFF"
(3) Measure resistance between terminal "5" and "4" of Driver Air Mix potentiometer.
Go to "Ground circuit Inspection" procedure.
Check for short to power harness in signal harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.
Page 145 of 171
(1) Ignition "OFF"
(1) Ignition "OFF"
Page 146 of 171
(1) Ignition "ON"

Page 147 of 171


COMPONENT LOCATION
GENERAL DESCRIPTION
The mode control actuator mounted on heater unit, adjusts position of mode door by operating Direction Motor
based on signal of A/C control unit. Pressing mode select switch makes the mode control actuator shift in order of
vent→ B/L → floor → mix.
DTC DESCRIPTION
The A/C controller sets DTC B1249 if there is an open circuit or poor connection in the Direction potentiometer.

Page 148 of 171
DTC Strategy • Voltage check • Poor connection of connected
part
Detecting time • 0.3 sec • Short circuit in harness
• Fix vent position, while selecting • Faulty driver direction
vent mode. potentiometer
FAIL SAFE
• Fix defrost position while
selecting except vent mode.
SPECIFICATION

2. Engine "ON"
3. Monitor the "DR. DIRECTION POTENTIO." parameter on the scantool while operating mode switch.
Page 149 of 171
4. Are the DTC B1249 present and is parameter of "DR. DIRECTION POTENTIO." fixed?
Parameter of "DR. DIRECTION POTENTIO." will be fixed at 100%(or any value above 90%), or 0% (or
any value below 10%), if there is any fault in Driver Direction potentiometer.

or damage.

(1) Ignition "OFF"
(2) Disconnect Driver mode Actuator.
(3) Measure resistance between terminal "4" of Driver Direction potentiometer and terminal "11" of A/C control unit.
Page 150 of 171
(1) Ignition "OFF"
(3) Measure resistance between terminal "4" of Driver Direction potentiometer and chassis ground.
Go to "Power circuit Inspection" procedure.
procedure.
1. Check for short or open in harness.
(1) Ignition "ON"
(2) Connect Driver Direction potentiometer.
(3) Measure voltage between terminal "3" of Driver Direction potentiometer and chassis ground.
Page 151 of 171
Check for short or open in power harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.
1. Check actuator.
(1) Ignition "OFF"
(2) Disconnect Driver Direction potentiometer.
(3) Verify that the mode actuator operates to the vent mode when connecting 12V to the terminal 1 and grounding
terminal 2.
(4) Verify that the mode actuator operates to the def mode when the connections are reversed.
(1) Ignition "ON"
Page 152 of 171
(3) Measure voltage between terminal "4" and "5" of Driver Direction potentiometer as the mode switch is operated.
Specification : Refer the specifications in fig 3

VENT 0.3 ± 0.15V
BI-LEVEL(1) 1.35 ± 0.4V
BI-LEVEL(2) 2.25 ± 0.4V Under voltage : 0.08V or less
FLOOR 3.0 ± 0.4V Over voltage : 4.92V or more
MIX 3.6 ± 0.4V
DEF 4.7 ± 0.15V
Page 153 of 171

COMPONENT LOCATION
GENERAL DESCRIPTION
The mode control actuator mounted on heater unit, adjusts position of mode door by operating Direction Motor
based on signal of A/C control unit. Pressing mode select switch makes the mode control actuator shift in order of
vent→ B/L → floor → mix.
DTC DESCRIPTION
The A/C controller sets DTC B1250 if there is a short to power in the Direction potentiometer.

• Faulty driver direction
potentiometer
• Fix vent position, while selecting
vent mode.
FAIL SAFE
• Fix defrost position while
selecting except vent mode.
Page 154 of 171
SPECIFICATION

2. Engine "ON"
3. Monitor the "DR. DIRECTION POTENTIO." parameter on the scantool while operating mode switch.
4. Are the DTC B1250 present and is parameter of "DR. DIRECTION POTENTIO." fixed?
Parameter of "DR. DIRECTION POTENTIO." will be fixed at 100%(or any value above 90%), or 0% (or
any value below 10%), if there is any fault in Driver Direction potentiometer.

Page 155 of 171
or damage.

1. Check for short in harness.
(1) Ignition "OFF"
(3) Measure resistance between terminal "3" and "4"of Driver Direction potentiometer.
Page 156 of 171
1. Check for open in ground harnesS.
(1) Ignition "OFF"
(3) Measure resistance between terminal "5" of evaporator sensor and chassis ground.
Specification :Approx. 0 Ω
1. Check actuator.
(1) Ignition "OFF"
terminal 2.
Page 157 of 171
(1) Ignition "ON"
Specification : Refer the specifications in fig 3

VENT 0.3 ± 0.15V
BI-LEVEL(1) 1.35 ± 0.4V
MIX 3.6 ± 0.4V
DEF 4.7 ± 0.15V
Page 158 of 171


COMPONENT LOCATION
Page 159 of 171
GENERAL DESCRIPTION
from control unit adjusts position of temp. door by operating temp. motor. then temperature will be regulated by the
hot/cold air ratio decided by position of temp. door.
DTC DESCRIPTION
The A/C controller sets DTC B2406 if the air mix actuator doesn't move to intended position within 40sec (In this
case, A/C controller try to move temp. door for 2sec. 3 times, every 20 sec. before setting DTC).

• Poor connection of
DTC Strategy • Voltage check
connected part
• Open circuit in
Threshold value • < 0.1V harness
• Short circuit in harness
Detecting time • 0.3 sec • Faulty driver Air Mix
potentiometer
• Fault A/C Control
FAIL SAFE -
Unit
SPECIFICATION

2. Engine "ON"
Page 160 of 171
4. Are the DTC B2406 present and is parameter of "Driver AIR MIX Potentiometer" fixed?
There is any fault in Driver AIR MIX Motor. If the parameter of "Driver AIR MIX DOOR" is 30% or less
when the actuator operates to the hot position, or If the parameter is 60% and more when the actuator operates
to the cold position.

or damage.

Page 161 of 171
(1) Ignition "OFF"
(3) Measure resistance between terminal "1,2" of Driver Air Mix Motor and terminal "9,22" of A/C control unit.
(1) Ignition "OFF"
(2) Disconnect Driver Air Mix Actuator.
(3) Measure resistance between terminal "1,2" of Driver Air Mix Motor and chassis ground.
Go to "Visual/Physical Inspection " procedure.
procedure.
Page 162 of 171
1. Check actuator.
Check if Driver Air Mix Actuator works properly through ACTUATION TEST.
(1) Ignition : ON
(2) Connect Scantool and select " ACTUATION TEST" mode and press [F1]
(3) Dose Driver Air Mix Actuator work properly?
(1) Ignition "OFF"
Page 163 of 171
(1) Ignition "ON"

Page 164 of 171
Go to "check A/C control unit" procedure.
3. Check A/C Control Unit.
(1) Engine "ON"
(2) Connect A/C Control Unit.
(3) Measure voltage between terminal "9" and "22" of A/C Control Unit while operating the temp. switch.
Specification :Approx. 12V


COMPONENT LOCATION
Page 165 of 171
GENERAL DESCRIPTION
The mode control actuator mounted on heater unit, adjusts position of mode door by operating Direction Motor in
accordance with signal of A/C control unit. Pressing mode select switch makes the mode control actuator shift in
order of vent→ B/L → floor → mix.
DTC DESCRIPTION
The A/C controller sets DTC B2409 if the direction motor doesn't move to intended position within 40sec(In this
case, A/C controller try to move mode door for 2sec. 3 times, every 20 sec. before setting DTC).

DTC Strategy • Voltage check • Poor connection of

connected part
• Short circuit in harness
• Faulty driver direction
potentiometer
• Fault A/C Control
FAIL SAFE - Unit.
SPECIFICATION
Page 166 of 171

2. Engine "ON"
3. Monitor the "DR DIRECTION POTENTIO" parameter on the scantool while operating mode switch.
4. Are the DTC B2409 present and is parameter of "Driver DIRECTION POTENTIO." fixed?
There is any fault in Driver Direction Motor. If the parameter of "Driver DIRECTION POTENTIO." is 10%
or less on "VENT" mode, or If the parameter is 90% or more on "DEF" mode.

or damage.

Page 167 of 171
(1) Ignition "OFF"
(3) Measure resistance between terminal "1,2" of Driver Direction Motor and terminal "14,15" of A/C control unit.
(1) Ignition "OFF"
(3) Measure resistance between terminal "1,2" of Driver Direction Motor and chassis ground.
Go to "Visual/Physical Inspection " procedure.
procedure.
Page 168 of 171
1. Check actuator.
Check if Driver Direction Actuator works properly through ACTUATION TEST.
(1) Ignition : ON
(2) Connect Scantool and select " ACTUATION TEST" mode and press [F1]
(3) Dose Driver Direction Actuator work properly?
1. Check actuator.
(1) Ignition "OFF"
terminal 2.
Page 169 of 171
(1) Ignition "ON"

VENT 0.3 ± 0.15V
BI-LEVEL(1) 1.35 ± 0.4V
MIX 3.6 ± 0.4V
DEF 4.7 ± 0.15V
Page 170 of 171
Go to "Check A/C control unit" procedure.
3. Check A/C Control Unit.
(1) Engine : "ON"
(2) Connect A/C Control Unit.
(3) Measure voltage between terminal "14" and "15" of A/C Control Unit while operating the mode switch.
Specification :Approx. 12V

Page 171 of 171

Page 1 of 271
SPORTAGE(KM) > 2008 > G 2.7 DOHC > Restraint
Restraint > General Information > General Safety Information and Caution
Precautions
General Precautions
Please read the following precautions carefully before performing the airbag system service. Observe the instructions
described in this manual, or the airbags could accidentally deploy and cause damage or injuries.
• Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative
cable from the battery, and wait at least three minutes before beginning work.
The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are
disconnectedfrom the battery.
• Use the replacement parts which are manufactured to the same standards as the original parts and quality.
Do not install used SRS parts from another vehicle.
Use only new parts when making SRS repairs.
• Carefully inspect any SRS part before you install it.
Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or
deformation.
• Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the
SRS connector.
Airbag Handling and Storage
Do not disassemble the airbags; it has no serviceable parts. Once an airbag has been deployed, it cannot be
repaired or reused.
For temporary storage of the air bag during service, please observe the following precautions.
• Store the removed airbag with the pad surface up.
Page 2 of 271
• Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly.
• Store the removed airbag on secure, flat surface away from any high heat source (exceeding 85°C/185°F).
• Never perform electrical inspections to the airbags, such as measuring resistance.
• Do not position yourself in front of the airbag assembly during removal, inspection, or replacement.
• Refer to the scrapping procedures for disposal of the damaged airbag.
• Be careful not to bump or impact the SRS unit or the side impact sensors whenever the ignition switch is ON,
wait at least three minutes after the ignition switch is turned OFF before begin work.
• During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the
SRS unit and the side impact sensor. The airbags could accidentally deploy and cause damage or injury.
• After a collision in which the airbags were deployed, replace the front airbags and the SRS unit. After a collision
in which the side airbag was deployed, replace the side airbag, the front impact sensor and side impact sensor on
the side where the side airbag deployed and the SRS unit. After a collision in which the airbags or the side air
bags did not deploy, inspect for any damage or any deformation on the SRS unit and the side impact sensors. If
there is any damage, replace the SRS unit, the front impact sensor and/or the side impact sensors.
• Do not disassemble the SRS unit, the front impact sensor or the side impact sensors
• Turn the ignition switch OFF, disconnect the battery negative cable and wait at least three minutes before
beginning installation or replacement of the SRS unit.
• Be sure the SRS unit, the front impact sensor and side impact sensors are installed securely with the mounting
bolts.
• Do not spill water or oil on the SRS unit,or the front impact sensor or the side impact sensors and keep them
away from dust.
• Store the SRS unit, the front impact sensor and the side impact sensors in a cool (less than 104°F/40°C) and dry
(less than 80% relative humidity, no moisture) area.
Wiring Precautions
SRS wiring can be identified by special yellow outer covering (except the SRS circuits under the front seats).
Observe the instructions described in this section.
Page 3 of 271
• Never attempt to modify, splice, or repair SRS wiring.
If there is an open or damage in SRS wiring, replace the harness.
• Be sure to install the harness wires so that they are not pinched, or interfere with other parts.
• Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal
contact. Poor grounding can cause intermittent problems that are difficult to diagnose.
Precautions for Electrical Inspections
• When using electrical test equipment, insert the probe of the tester into the wire side of the connector.
Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the
connector.
Page 4 of 271
• Use a u-shaped probe. Do not insert the probe forcibly.
• Use specificed service connectors for troubleshooting.
Using improper tools could cause an error in inspection due to poor metal contact.
Spring-loaded Lock Connector
Airbag Connector(I)
Connecting
1. To reconnect, hold the pawl-side connector half, and press on the back of the sleeve-side connector half in the
direction shown. As the two connectpr halves are pressed together, the sleeve (A) is pushed back by the pawl
(C). Do not touch the sleeve.
Page 5 of 271
2. When the connector halves are completely connected, the pawl is released, and the spring-loaded sleeve locks
the connector.
Airbag Connector(II)
Connecting
Hold both connector halves and press firmly until the projection (C) of the sleeve-side connector clicks to lock.
WARNING LAMP ACTIVATION

Page 6 of 271
1. Active fault or historical fault counter is greater or equal to 10
2. Normal or historical fault counter is less than 10
3. Loss of battery supply to the SRSCM : warning lamp turned on continuously.

4. Loss of internal operating voltage : warning lamp turned on continuously.
5. Loss of SRSCM operation : warning lamp turned on continuously.
6. SRSCM not connected : warning lamp turned on continuously through the shorting bar.
7. Reset by the Watchdog Trigger failure : warning lamp flashed or turned on continuously.
TELLTALE LAMP ACTIVATION
DESCRIPTION
The Telltale Lamp indicates the Passenger Airbag(PAB) enable disable status based on occupant status of
passenger seat. If the passenger seat is occupied with child (or child seat), the Passenger Airbag is disabled and the
Telltale Lamp is turned ON to inform the driver that the PAB is disabled.
As soon as operating voltage is applied to the SRSCM ignition input, the SRSCM activates telltale lamp prove out.
OCS will send an indeterminate status to the SRSCM as a default setting for passenger airbag deployment during
the prove out period. After crash if OCS gets reset and sends the indeterminate status, the telltale lamp will be ON
as long as the occupant status is in the indeterminate status. Occupant status information and telltale ststus are as
below table.
Occupant Status Telltale Status Indicator Passenger Airbag
Empty(buckled) ON Disable
Empty*unbuckled) OFF Disable
Small ON Disable
Large OFF Available
Indeterminate ON Disable
After ignition on, telltale lamp will turn on for 4 seconds and turn off for 3 seconds during the initialization phase and
be turned off afterward until receive first valid suppression message from OCS system.
Page 7 of 271
Restraint > General Information > General Information

Description
The supplemental restraint system (SRS) is designed to supplement the seat belt to help reduce the risk or severity
of injury to the driver and passenger by activating and deploying the driver, passenger, side airbag and belt pre-
tensioner in certain frontal or side collisions.
The SRS (Airbag) consists of : a driver side airbag module located in the center of the steering wheel, which
contains the folded cushion and an inflator unit ; a passenger side airbag module located in the passenger side crash
pad containsthe folded cushion assembled with inflator unit ; side airbag modules located in the driver and passenger
seat contain the folded cushion and an inflator unit ; curtain airbag modules located inside of the headliner which
contains folded cushions and inflator units. The Passenger Occupant classification System (OCS) utilizes bladder
placed between the passenger seat cushion and suspension to measure the occupant’s loading force on the vehicle
seat. Seat Track Position Sensor (STPS) located in driver and passenger seat interfaces with SRSCM and will help
in determining whether to suppress either stage of a multi-stage airbag system. SRSCM is located under the center
console. The impact sensing function of the SRSCM is carried out by electronic accelerometer that continuously
measure the vehicle's acceleration and delivers a corresponding signal through amplifying and filtering circuitry to the
microprocessor.
SRSCM (SRS Control Module)
SRSCM will detect front impact with front impact sensor, and side impact with side impact sensor, and determine
airbag module deployment.
1. DC/DC converter: DC/DC converter in power supply unit includes up/down transformer converter, and provide
ignition voltage for 2 front airbag ignition circuits and the internal operation voltage of the SRSCM. If the internal
operation voltage is below critical value setting, it will perform resetting.
2. Safety sensor: Safety sensor is located in airbag ignition circuit. Safety sensor will operate airbag circuit at any
deployment condition and release airbag circuit safely at normal driving condition. Safety sensor is a double
contact electro-mechanical switch that will close detecting deceleration above certain criteria.
3. Back up power supply: SRSCM has separate back up power supply, that will supply deployment energy
instantly in low voltage condition or upon power failure by front crash.
4. Self diagnosis: SRSCM will constantly monitor current SRS operation status and detect system failure while
vehicle power supply is on, system failure may be checked with trouble codes using scan tool. (Hi-Scan)
5. Airbag warning lamp on: Upon detecting error, the module will transmit signal to SRSCM indicator lamp located
at cluster. MIL lamp will indicate driver SRS error. Upon ignition key on, SRS lamp will turn on for about six
seconds.
6. Trouble code registration: Upon error occurrence in system, SRSCM will store DTC corresponding to the error.
DTC can be cleared only by Hi-Scan. However, if an internal fault code is logged or if a crash is recorded
thefault clearing should not happen.
7. Self diagnostic connector: Data stored in SRSCM memory will be output to Hi-Scan or other external output
devices through connector located below driver side crash pad.
8. Once airbag is deployed, SRSCM should not be used again but replaced.
9. SRSCM will determine whether passenger put on seat belt by the signal from built-in switch in seat belt buckle,
and deploy front seat airbag at each set crash speed.
Page 8 of 271
10. Side airbag deployment will be determined by SRSCM that will detect satellite sensor impact signal upon side
crash, irrespective to seat belt condition.
Restraint > General Information > Special Service Tools

SPECIAL SERVICE TOOLS
Tool(Number and
Illustration Use
Name)
Deployment tool Airbag deployment tool
0957A-34100A
Deployment adapter Use with deployment tool. (DAB,PAB)

0957A-38510
Deployment adapter Use with deployment tool. (SAB)

0957A-38100
Deployment adapter Use with deployment tool. (CAB,BPT)

0957A-38500
Dummy Simulator to check the resistance of each wiring

0957A-38200 harness
Dummy adapter
0957A-38300
Page 9 of 271
Dummy adapter Use with dummy (SAB)
0957A-38300
Dummy adapter Use with dummy (DAB,PAB,CAB,BPT)

0957A-2G000
DAB : Driver Airbag

PAB : Passenger Airbag
SAB : Side Airbag
CAB : Curtain Airbag
BPT : Belt Pretensioner
Restraint > General Information > Components and Components Location

airbag system
components
Page 10 of 271
COMPONENTS LOCATION
DRIVER AIRBAG (DAB) /PASSENGER AIRBAG (PAB)
Page 11 of 271
SIDE AIRBAG (SAB)
FRONT IMPACT SENSOR (FIS)

Page 12 of 271
SEAT BELT PRETENSIONER (BPT) / SIDE IMPACT SENSOR (SIS)
SRSCM
Page 13 of 271
Restraint > General Information > Specifications

SPECIFICATION
ITEM SPECIFICATION
Driver Airbag (DAB) Resistance (Ω) 1.5 ~ 5.7 Ω
Passenger Airbag
Resistance (Ω) 1.5 ~ 5.7 Ω
(PAB)
Side Airbag (SAB) Resistance (Ω) 1.5 ~ 5.7 Ω
Curtain Airbag (CAB) Resistance (Ω) 1.5 ~ 5.7 Ω
Seat Belt Pretensioner
Resistance (Ω) 1.5 ~ 5.7 Ω
(BPT)
TIGHTENING TORQUES
Page 14 of 271
ITEM kgf.m N.m lb.ft
Driver Airbag (DAB) 0.8 ~ 1.1 7.8 ~ 10.8 5.8 ~ 8.0
Passenger Airbag (PAB) 1.9 ~ 2.7 18.6 ~ 26.5 13.7 ~ 19.5
Side Airbag (SAB) 0.6 ~ 1 5.9 ~ 9.8 4.3 ~ 7.2
Curtain Airbag (CAB) 0.7 ~ 0.9 6.9 ~ 8.8 5.1 ~ 6.5
Seat Belt Lower Anchor bolt
4.0 ~ 5.5 39 ~ 54 29 ~ 40
(BPT)
SRSCM Mounting Bolt 0.7 ~ 0.9 6.9 ~ 8.8 5.1 ~ 6.5
Front Impact Sensor (FIS)
0.9 ~ 1.1 8.8 ~ 10.8 6.5 ~ 8.0
Mounting Bolt
Side Impact Sensor (SIS)
0.9 ~ 1.1 8.8 ~ 10.8 6.5 ~ 8.0
Mounting Bolt
Restraint > Supplemental Restraint System Control Module (SRSCM) > Schematic Diagrams
SYSTEM BLOCK DIAGRAM
Page 15 of 271
CIRCUIT DIAGRAM(1)
Page 16 of 271
CIRCUIT DIAGRAM(2)
Page 17 of 271
SRSCM CONNECTOR TERMINAL

Page 18 of 271
PIN Function PIN Function
1 Shorting Bar 26 Warning Lamp
2 Shorting Bar 27 Battery Ground
3 Battery Supply(Vbat) 28 K-Line Diagnostic
Seat Belt Pretensioner [Front-Driver] Seat Belt Pretensioner [Front-
4 29
Low Passenger] Low
Seat Belt Pretensioner [Front-Driver] Seat Belt Pretensioner [Front-
5 30
High Passenger] High
6 (2nd Stage) Passenger Airbag High 31 Buckle Switch [Front-Passenger] High
7 (2nd Stage) Passenger Airbag Low 32 Buckle Switch [Front-Passenger] Low
8 (2nd Stage) Driver Airbag Low 33 Buckle Switch [Driver] Low
9 (2nd Stage) Driver Airbag High 34 Buckle Switch [Driver] High
Seat Track Position Sensor [Passenger]
10 Curtain Airbag [Passenger] High 35
High
Seat Track Position Sensor [Passenger]
11 Curtain Airbag [Passenger] Low 36
Low
Seat Track Position Sensor [Driver]
12 Curtain Airbag [Driver] Low 37
Low
Seat Track Position Sensor [Driver]
13 Curtain Airbag [Driver] High 38
High
14 Side Airbag [Front-Passenger] High 39 Side Impact Sensor [Passenger] High
15 Side Airbag [Front-Passenger] Low 40 Side Impact Sensor [Passenger] Low
16 Side Airbag [Front-Driver] Low 41 Side Impact Sensor [Driver] Low
17 Side Airbag [Front-Driver] High 42 Side Impact Sensor [Driver] High
Occupant Classification (OC) Sensor
18 - 43
CAN Low
Occupant Classification (OC) Sensor
19 - 44
CAN High
20 - 45 Front Impact Sensor [Passenger] High
21 - 46 Front Impact Sensor [Passenger] Low
22 (1st Stage) Passenger Airbag High 47 Front Impact Sensor [Driver] Low
23 (1st Stage) Passenger Airbag Low 48 Front Impact Sensor [Driver] High
24 (1st Stage) Driver Airbag Low 49 Crash Output
25 (1st Stage) Driver Airbag High 50 Telltale Warning Lamp
Restraint > Supplemental Restraint System Control Module (SRSCM) > Troubleshooting
Hi-Scan check
1. Turn the ignition switch off.
Page 19 of 271
2. Connect the Hi-Scan Pro connector to the datalink connector located under the crash pad.
3. Connect the Hi-Scan Pro power cable.
4. Turn the ignition switch on and power on the Hi-Scan Pro.
5. Read DTCs.
6. Find and repair the trouble, and clear the DTCs using Hi-Scan Pro.
7. Disconnect the Hi-Scan Pro.
DIAGNOSTIC TROUBLESHOOTING FLOW
DIAGNOSTIC TROUBLE CODES (DTC)

CODE FAULT DESCRIPTION
B1101 Battery Voltage too High
Page 20 of 271
B1102 Battery Voltage too Low
B1326 Front Impact Sensor [Driver] Short to Ground
B1327 Front Impact Sensor [Driver] Short to Battery
B1328 Front Impact Sensor [Driver] Defect
B1329 Front Impact Sensor [Driver] Communication Error
B1330 Front Impact Sensor [Driver] Wrong ID
B1331 Front Impact Sensor [Passenger] Short to Ground
B1332 Front Impact Sensor [Passenger] Short to Battery
B1333 Front Impact Sensor [Passenger] Defect
B1334 Front Impact Sensor [Passenger] Communication Error
B1335 Front Impact Sensor [Passenger] Wrong ID
B1346 (1st Stage) Driver Airbag Resistance Too High
B1347 (1st Stage) Driver Airbag Resistance Too Low
B1348 (1st Stage) Driver Airbag Circuit Short to Ground
B1349 (1st Stage) Driver Airbag Circuit Short to Battery
B1352 (1st Stage) Passenger Airbag Resistance Too High
B1353 (1st Stage) Passenger Airbag Resistance Too Low
B1354 (1st Stage) Passenger Airbag Circuit Short to Ground
B1355 (1st Stage) Passenger Airbag Circuit Short to Battery
B1361 Seat Belt Pretensioner [Front-Driver] Resistance Too High
B1362 Seat Belt Pretensioner [Front-Driver] Resistance Too Low
B1363 Seat Belt Pretensioner [Front-Driver] Circuit Short to Ground
B1364 Seat Belt Pretensioner [Front-Driver] Circuit Short to Battery
B1367 Seat Belt Pretensioner [Front-Passenger] Resistance Too High
B1368 Seat Belt Pretensioner [Front-Passenger] Resistance Too Low
B1369 Seat Belt Pretensioner [Front-Passenger] Circuit Short to Ground
B1370 Seat Belt Pretensioner [Front-Passenger] Circuit Short to Battery
B1378 Side Airbag [Front-Driver] Resistance Too High
B1379 Side Airbag [Front-Driver] Resistance Too Low
B1380 Side Airbag [Front-Driver] Circuit Short to Ground
B1381 Side Airbag [Front-Driver] Circuit Short to Battery
B1382 Side Airbag [Front-Passenger] Resistance Too High
B1383 Side Airbag [Front-Passenger] Resistance Too Low
B1384 Side Airbag [Front-Passenger] Circuit Short to Ground
B1385 Side Airbag [Front-Passenger] Circuit Short to Battery
B1396 Seat Track Position Sensor [Driver] Open or Short to Ground
Page 21 of 271
B1397 Seat Track Position Sensor [Driver] Short or Short to Battery
B1398 Seat Track Position Sensor [Passenger] Open or Short to Ground
B1399 Seat Track Position Sensor [Passenger] Short or Short to Battery
B1400 Side Impact Sensor [Front-Driver] Defect
B1401 Side Impact Sensor [Front-Driver] Short to Ground
B1402 Side Impact Sensor [Front-Driver] Short to Battery
B1403 Side Impact Sensor [Front-Passenger] Defect
B1404 Side Impact Sensor [Front-Passenger] Short to Ground
B1405 Side Impact Sensor [Front-Passenger] Short to Battery
B1409 Side Impact Sensor [Front-Driver] Communication Error
B1410 Side Impact Sensor [Front-Passenger] Communication Error
B1414 Side Impact Sensor [Front-Driver] Wrong ID
B1415 Side Impact Sensor [Front-Passenger] Wrong ID
B1473 Side Curtain Airbag [Driver] Resistance Too High
B1474 Side Curtain Airbag [Driver] Resistance Too Low
B1475 Side Curtain Airbag [Driver] Circuit Short to Ground
B1476 Side Curtain Airbag [Driver] Circuit Short to Battery
B1477 Side Curtain Airbag [Passenger] Resistance Too High
B1478 Side Curtain Airbag [Passenger] Resistance Too Low
B1479 Side Curtain Airbag [Passenger] Circuit Short to Ground
B1480 Side Curtain Airbag [Passenger] Circuit Short to Battery
B1481 (2nd Stage) Driver Airbag Resistance Too High
B1482 (2nd Stage) Driver Airbag Resistance Too Low
B1483 (2nd Stage) Driver Airbag Circuit Short to Ground
B1484 (2nd Stage) Driver Airbag Circuit Short to Battery
B1485 (2nd Stage) Passenger Airbag Resistance Too High
B1486 (2nd Stage) Passenger Airbag Resistance Too Low
B1487 (2nd Stage) Passenger Airbag Circuit Short to Ground
B1488 (2nd Stage) Passenger Airbag Circuit Short to Battery
B1489 Passenger Occupant Classification (OC) ECU failure
B1490 Passenger Occupant Classification (OC) Sensor(Bladder) failure
B1493 Passenger Occupant Classification (OC) Communication Error
B1494 Passenger Occupant Classification (OC) Wrong ID
B1495 Belt Tension Sensor failure
B1521 Seat Belt Buckle Switch [Driver] Short or Short to Battery
B1522 Seat Belt Buckle Switch [Driver] Open or Short to Ground
Page 22 of 271
Seat Belt Buckle Switch [Front-Passenger] Short or Short to
B1523
Battery
Seat Belt Buckle Switch [Front-Passenger] Open or Short to
B1524
Ground
B1620 Airbag control unit Internal Fault (Replace airbag control unit)
Crash Recored in 1st Stage only (Frontal-Replace airbag control
B1650
unit)
B1651 Crash Recorded Driver Side (Replace airbag control unit)
B1652 Crash Recorded Passenger Side (Replace airbag control unit)
B1657 Crash Recorded - Belt Pretensioner Only
Belt Pretensioner 6 times Deployment (Replace airbag control
B1658
unit)
Crash Recorded in Full Stage (Frontal - Replace airbag control
B1670
unit)
B2500 Warning Lamp Fault
B2502 Telltale Lamp Fault
Restraint > Supplemental Restraint System Control Module (SRSCM) > SRS Control Module
(SRSCM) > Description and Operation
DESCRIPTION
The primary purpose of the advanced SRSCM (Supplemental Restraints System Control Module) is to discriminate
between an event that warrants restraint system deployment and an event that does not. The advanced SRSCM
must decide if and when to deploy the restraint system pretensioners and airbags. After determining that
pretensioners and/or airbag deployment is required, the advanced SRSCM must supply sufficient power to the
pretensioners and airbag igniters to initiate deployment. The advanced SRSCM determines that an impact may
require deployment of the pretensioners and airbags from data obtained from buckle switches, seat track position
sensors, occupant classification system, front impact sensors and side impact sensors in conjunction with a safing
function.
The advanced SRSCM will not be ready to detect a crash or to activate the restraint system devices until the signals
in the advanced SRSCM circuitry stabilize. It is possible that the advanced SRSCM could activate the safety
restraint devices in approximately 2 seconds but is guaranteed to fully function after prove-out is completed. The
advanced SRSCM must perform a diagnostic routine and light a system readiness indicator at key-on. The system
must perform a continuous diagnostic routine and provide fault annunciation through a warning lamp indicator in the
event of fault detection. A serial diagnostic communication interface will be used to facilitate servicing of the
advanced restraint control system.
Restraint > Supplemental Restraint System Control Module (SRSCM) > SRS Control Module
(SRSCM) > Repair procedures
REMOVAL
Page 23 of 271
1. Disconnect the negative (-) cable from battery and wait for at least three minutes.
2. Remove ignition key from the vehicle.

3. Disconnect the DAB, PAB, SAB, CAB and BPT connectors.
4. Remove the center console (Refer to BD group in the Service Manual).
5. Disconnect the SRSCM harness connector(A) from the SRSCM(B).
6. Remove the SRSCM mounting bolts from the SRSCM then remove the SRSCM.
INSTALLATION
3. Install the SRSCM with the SRSCM mounting bolts.
Tightening Torque (SRSCM Mounting Bolt)

: 6.9 ~ 8.8 N·m (5.1 ~ 6.5 lb·ft)
4. Connect the SRSCM harness connector.

5. Install the center console.
6. Connect the DAB, PAB, SAB, CAB and BPT connectors.
7. After installing the SRSCM, confirm proper system operation:
A. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go
off.
Restraint > Supplemental Restraint System Control Module (SRSCM) > Front Impact Sensor (FIS) >
DESCRIPTION
The release system for the front airbag consists of a SRSCM installed in the middle of the vehicle and two front
impact sensors (FIS) which are located in front of the vehicle. Only the SRSCM is capable of releasing the airbags
Page 24 of 271
or the seat-belt pretensioner system in the vehicle. In the dialog between the SRSCM and the front impact sensor it
is the SRSCM which takes the release decision.
The SRSCM is supported in connection with the front airbag function by the two front impact sensors, which act as
intelligent acceleration sensors and as such back up the central airbag controller. Both the front impact sensors
continuously report the current system status of the vehicle to the SRSCM.
If one of the two front impact sensor reports an acceleration level, the SRSCM must verify the acceleration signal
internally by means of a suitable plausibility check. The SRSCM does not release the appropriate airbag unless the
result of this verification is positive.
COMPONENTS
Repair procedures
removal
• Removal of the airbag must be performed according to the precautions/ procedures described previously.
• Before disconnecting the front impact sensor connector, disconnect the front airbag connector(s).
• Do not turn the ignition switch ON and do not connect the battery cable while replacing the front impact sensor.
1. Disconnect the negative battery cable, and wait at least three minutes before beginning work.
2. Remove the radiator guard (Refer to BD group).
3. Remove the bolt then remove the front impact sensor.
Page 25 of 271
4. Disconnect the SRS harness connector (A) from the front impact sensor (B).
INSTALLATION
• Be sure to install the harness wire so that they are not pinched or interfere with other parts.
• Do not turn the ignition switch ON and do not contact the battery cable while replacing the front impact sensor.
1. Install the new front impact sensor with bolt then connect the SRS harness connector to the front impact sensor.
Tightening torque
: 8.8 ~ 10.8 N·m(6.5 ~ 8.0 lb·ft)
2. Install the radiator guard.

3. Reconnect the negative battery cable.
4. After installing the front impact sensor, confirm proper system operation: Turn the ignition switch ON: the SRS
indicator light should be turned on for about six seconds and then go off.
Restraint > Supplemental Restraint System Control Module (SRSCM) > Side Impact Sensor (SIS) >
DESCRIPTION
The release system for the front airbag consists of a SRSCM installed in the middle of the vehicle and two side
impact sensors (SIS) which are located inside the B-Pillar.
They are remote sensor that detect acceleration due to collision at their mounting locations. The primary purpose of
the Side Impact Sensor (SIS) is to provide an indication of a collision. The Side ImpactSensor (SIS) sends
acceleration data to the SRSCM.
COMPONENTS
Page 26 of 271
Repair procedures
removal
• Removal of the airbag must be performed according to the precautions/procedures described previously.
• Before disconnecting the side impact sensor connector(s), disconnect the side airbag connector(s).
• Do not turn the ignition switch ON and do not connect the battery cable while replacing the side impact sensor.
1. Disconnect the negative battery cable, and wait at least three minutes before beginning work.
2. Remove the seat assembly (Refer to BD group).
3. Remove the front door sill trim.
4. Remove the center pillar trim.
5. Remove the lower anchor bolt.
6. Remove the belt pretensioner.
7. Remove the two bolts(A) then remove the side impact sensor(B).
8. Disconnect the SRS harness connector(B) from the side impact sensor.
Page 27 of 271
Installation
• Be sure to install the harness wires so that they are not pinched or interfere with other parts.
• Do not turn the ignition switch ON and do not connect the battery cable while replacing the side impact sensor.
1. Install the new side impact sensor with the two bolts then connect the SRS harness connector to the side impact
sensor.
Tightening torque
: 8.8 ~ 10.8 N·m(6.5 ~ 8.0 lb·ft)
2. Reinstall belt pretensioner.

4. After installing the side impact sensor, confirm proper system operation: Turn the ignition switch ON: the SRS
Restraint > Supplemental Restraint System Control Module (SRSCM) > Seat Track Position Sensor
(STPS) > Description and Operation
DESCRIPTION
The STPS operated via a non-contacting magnetic proximity sensing device combined with a simple electronic
circuit resulting in the ability of producing two separate and distinct logic level signals.
The STPS output signal is altered by the proximity of a separate ferro-magnetic shunt, which is linked via the seat
track. The logic signal produced is the result of the proximity device being activated (no shunt present) or
deactivated (shunt present).
When the seat is in the forward position zone of the track, the sensor gives a low current (prohibit) signal. When the
seat is in the rear positon zone of the track, it gives a high current (enable) signal.
Restraint > Supplemental Restraint System Control Module (SRSCM) > Seat Belt Buckle Switch (BS)
> Description and Operation
DESCRIPTION
The buckle status shall modify the SRSCM deployment. If the Buckle Status is Unbuckled, the corresponding
pretensioner will be deactivated.
Restraint > Supplemental Restraint System Control Module (SRSCM) > Occupant Classification
Sensor (OCS) > Description and Operation
DESCRIPTION
The system is intended to classify the occupancy status of the front passenger seat in a motor vehicle based upon the
measured force on the bottom seat cushion.
The system also communicates to the SRSCM whether to allow or inhibit the deployment of the passenger airbags
and/or pretensioner based upon this status.
The System also measured dynamic responses of the occupant. This information is used to idenitify when a child seat
is cinched down tightly with the seat belt, and to also determine if the seat is unoccupied.
However, the dynamic measurements are not intended, nor capable of monitoring the seating position of the
occupant, nor can they determine the proximity of the occupant to the inflator modules.
The system should not be confused with an occupant position recognition system, or any other occupant proximity
sensor.
Page 28 of 271
The Passenger Occupant Detecting System (PODS) utilizes bladder placed between the passenger seat cushion and
suspension to measure the occupant's loading force on the vehicle seat. The bladder is connected to pressure sensor
and ultimately to an electronic control unit (ECU), both of which are mounted under the seat pan. The quantitative
force determined by the system is compared to a given threshold for determination of passenger airbag suppression.
Restraint > Supplemental Restraint System Control Module (SRSCM) > Occupant Classification
Sensor (OCS) > Components and Components Location
COMPONENTS
Restraint > Airbag Module > Description and Operation

AIRBAG DISPOSAL
Special Tool Required
Before scrapping any airbags or side airbags (including those in a whole vehicle to be scrapped), the airbags or side
airbags must be deployed. If the vehicle is still within the warranty period, before deploying the airbags or side
airbags, the Technical Manager must give approval and/or special instruction. Only after the airbags or side airbags
have been deployed (as the result of vehicle collision, for example), can they be scrapped.
If the airbags or side airbags appear intact (not deployed), treat them with extreme caution. Follow this procedure.
Deploying Airbags In the vehicle
If a SRS equipped vehicle is to be entirely scrapped, its airbags or side airbags should be deployed while still in the
vehicle. The airbags or side airbags should not be considered as salvageable parts and should never be installed in
Page 29 of 271
another vehicle.
1. Turn the ignition switch OFF, and disconnect the battery negative cable and wait at least three minutes.
2. Confirm that each airbag or side airbag are securely mounted.
3. Confirm that the special tool is functioning properly by following the check procedure.
Driver's Airbag AND BPT :
1. Remove the driver's airbag and the install the SST(0957A-38500).
2. Install the driver's airbag on the steering wheel.
Front Passenger's Airbag :
1. Remove the glove box, then disconnect the 4P connector between the front passenger's airbag and SRS main
harness.
2. Install the SST(0957A-38100).
Buckle Pretensioner
1. Disconnect the 6p connect between the buckle pretensioner and buckle pretensioner wire Harness.
2. Install the SST(0957A - 2E210)
Side Airbag, CURTAIN AIRBAG:
1. Disconnect the 2P connector between the side airbag and side wire harness.
2. Install the SST (0957A-38100 : SAB, 0957A-38500 : CAB).
3. Place the deployment tool at least thirty feet (10 meters) away from the airbag.
4. Connect a 12 volt battery to the tool.
5. Push the tool's deployment switch. The airbag should deploy. Repeat for 2nd circuit if deploying DAB or PAB.
(deployment is both highly audible and visible: a loud noise and rapid inflation of the bag, followed by slow
deflection)
6. Dispose of the complete airbag. No part of it can be reused. Place it in a sturdy plastic bag and seal it securely.
Deploying the Airbag Out of the vehicle

If an intact airbag has been removed from a scrapped vehicle, or has been found defective or damage during transit,
storage or service, it should be deployed as follows :
1. Confirm that the special tool is functioning properly by following the check procedure on this page.
2. Position the airbag face up, outdoors on flat ground at least thirty feet (10meters) from any obstacles or people.
Disposal of Damaged Airbag
1. If installed in a vehicle, follow the removal procedure of driver's airbag, front passenger's and side airbag.
2. In all cases, make a short circuit by twisting together the two airbag inflator wires.
3. Package the airbag in exactly the same packing that the new replacement part come in.
Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring > Description and
Operation
DESCRIPTION
Page 30 of 271
Driver Airbag (DAB) is installed in steering wheel and electrically connected to SRSCM via clockspring. It protects
the driver from danger with deploying a bag when frontal crash occurs. The SRSCM determines deployment of
Driver Airbag (DAB) by using the Front Impact Sensor (FIS) signal. The driver airbag is two stage devices.
If the crash algorithm determines that only the first stage is to be activated, the second stage will be automatically
disposed of after a programmable time in milliseconds (120ms) has elapsed since the first stage deployment. The
driver firing loops (2 total) are backed up (BPS) for 150ms if the battery connection is lost in a crash.
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.
Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring > Components and
Components Location
COMPONENTS
Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring > Repair procedures
REMOVAL
Page 31 of 271
• Turn the front wheel to the straight-ahead position when removing/installing the Driver Airbag or Clokspring.
• Prior to installing the clock spring, set the colockspring on "NEUTRAL" position Refer to "clockspring"
section), 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 broken obstructing normal operation of the
SRS and possibly leading to serious injury to the vehicle's driver.
• 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 is 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 85°C(185°F).
• After deployment of an air bag, replace the clock spring with a new one.
• Wear gloves and safety glasses when handing an air bag that has 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 excessive force.
• The removed air bag module should be stored in a clean, dry place.
1. Disconnect the battery negative cable and wait at least three minutes before beginning work.
2. After removing the cover(A), then loosen the two airbag module mounting bolts(B).
Page 32 of 271
3. Remove the driver's airbag from the steering wheel, then disconnect the driver's airbag connectors.
The removed airbag module should be stored in a clean, dry place with the pad cover face
up.
4. Remove the steering wheel(Refer to ST group in the Service Manual).

5. After disconnecting the lock pin(A), disconnect the connector(B).
6. Loosen the mounting screw(C), then remove the clock spring(D).
INSTALLATION
Page 33 of 271

3. Connect the Driver Airbag (DAB) harness connectors, then install a Driver Airbag (DAB) module on the steering
wheel.
4. Secure the Driver Airbag (DAB) with the new mounting bolts.
Tightening Torque (DAB Mounting Bolt)

: 7.8 ~ 10.8 N·m (5.8 ~ 8.0 lb·ft)
5. Connect the battery negative cable.

6. After installing the airbag, confirm proper system operation:
off.
B. Make sure both horn buttons work.
INSPECTION
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.
Page 34 of 271
5. Install the airbag module to the steering wheel to check for fit or alignment with the wheel.
A. If, as a result of the following checks, even one abnormal point is discovered, replace the clock spring with a
new one.
B. Check connectors and protective tube for damage, and terminals for deformities.
Restraint > Airbag Module > Passenger Airbag (PAB) Module > Description and Operation
DESCRIPTION
The passenger Airbag (PAB) is installed inside the dash and protects the front passenger in the event of a frontal
crash. The SRSCM determines if and when to deploy the PAB but the front impact sensor (FIS) signal. The PAB is
a two-stage device; if the SRSCM determines that only the first stage should activate, the second stage will dispose
120 ms after first-stage deployment. In case of loss of vehicle power, the driver firing loops are have a 150 ms
battery backup.
injury.
Restraint > Airbag Module > Passenger Airbag (PAB) Module > Components and Components
Location
COMPONENTS
Page 35 of 271
Restraint > Airbag Module > Passenger Airbag (PAB) Module > Repair procedures
REMOVAL
• Never attempt to disassemble or repair the airbag module.

• Do not drop the airbag module or allow contact with water, grease or oil. Replace it if a dent, crack,
deformation or rust is detected.
• The airbag module should be stored on a flat surface and placed so that the pad surface is facing upward. Do
• Do not expose the airbag module to temperature over 85°C(185°F).
• An undeployed airbag module should only be disposed in accordance with the procedures.
• 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.
• 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.
Page 36 of 271
2. Remove the center facia panel (Refer to BD group - Crash pad), then disconnect the connector between the
SRS main harness connectors (A).
3. Remove the crash pad. (Refer to BD group - crash pad)

4. Remove the mounting nuts (A) from the crash pad, then remove the passenger's airbag (B).
After installing the clock spring, confirm proper system operation; Turn the ignition switch ON: the SRS
indicator light should be turned on for about 6 seconds and then go off.
INSTALLATION

3. Place a Passenger Airbag (PAB) on the instrument panel and tighten the Passenger Airbag (PAB) mounting nuts.
Tightening Torque
: 18.6 ~ 26.5 N·m(13.7 ~ 19.5 lb·ft)
Page 37 of 271
4. Install the instrument panel (Refer to BD group in this Service Manual).
5. Connect the Passenger Airbag (PAB) connectors, then install the center facia panel.
6. Reconnect the battery negative cable.
7. After installing the Passenger Airbag (PAB), confirm proper system operation:
off.
Restraint > Airbag Module > Side Airbag (SAB) Module > Description and Operation
DESCRIPTION
The two Side Airbags (SAB) are installed inside the driver and passenger seat and protect the driver and front
passenger from danger when side crash occurs. The SRSCM determines deployment of side airbag by using Side
Impact Sensor (SIS) signal.
injury.
Restraint > Airbag Module > Side Airbag (SAB) Module > Components and Components Location
COMPONENTS
Restraint > Airbag Module > Side Airbag (SAB) Module > Repair procedures
REMOVAL
Page 38 of 271
• Never attempt to disassemble or repair the airbag module.

• Do not drop the airbag module or allow contact with water, grease or oil. Replace it if a dent, crack,
deformation or rust is detected.
• The airbag module should be stored on a flat surface and placed so that the pad surface is facing upward. Do
• Do not expose the airbag module to temperature over 93°C(200°F).
• An undeployed airbag module should only be disposed in accordance with the procedures.
• 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.
• Whenever the SAB is deployed it should be replaced with a new one assembled with an extension wire. The
squib is melt down if the SAB is deployed making the extension wire useless.
2. Remove the front seat assambly.(Refer to BD group)
3. Remove the seat-back cover.
4. Loosen the nuts and remove the SAB(A) module.
After installing the side airbag, confirm proper system operation: Turn the ignition switch ON; the SRS
INSTALLATION
Be sure to install the harness wires so that they are not pinched or interfering with other parts.
• Do not open the lid of the side airbag cover.

• Use a new mounting nuts when you replace a side airbag.
• Make sure that the seat-back cover is installed properly. Improper installation may prevent the proper
deployment.
Page 39 of 271
3. Place a Side Airbag (SAB) on the seat back-frame and tighten the side airbag mounting nuts.
Tightening torque
: 5.9 ~ 9.8 N·m(4.3 ~ 7.2 lb·ft)
4. Install the new seat-back cover.

5. Install the seat assembly, then connect the Side Airbag (SAB) harness connector.
7. After installing the Side Airbag (SAB), confirm proper system operation:
off.
8. Recline and slide the front seat forward fully, make sure the harness wires are not pinched or interfering with
other parts.
Restraint > Airbag Module > Curtain Airbag (CAB) Module > Description and Operation
DESCRIPTION
The two Curtain Airbags (CAB) are installed inside the headliner and help to protect the vehicle passengers in the
event of a side crash. The SRSCM determines deployment of curtain airbag by using Side Impact Sensor (SIS)
signal.
injury.
Restraint > Airbag Module > Curtain Airbag (CAB) Module > Components and Components Location
COMPONENTS
Page 40 of 271
Restraint > Airbag Module > Curtain Airbag (CAB) Module > Repair procedures
removal
1. Disconnect the battery negative cable and wait for at least three minutes before beginning work.
2. Remove the following parts (Refer to BD group).
A. Front and rear seat
B. Interior trim
C. Trunk trim
D. Headlining
3. Disconnect the connector (A).
Page 41 of 271
4. After loosening the mounting bolts, remove the curtain airbag (B).
After installing the curtain airbag, confirm proper system operation: Turn the ignition switch ON; the SRS
indicator light should be turned on for about seconds and then go off.
INSTALLATION
• Be sure to install the harness wires so that they are not pinched or interfering with other parts.
3. Install a Curtain Airbag (CAB) on the mounting bracket.
Tightening Torque (CAB Mounting Bolt)

: 6.9 ~ 8.8 N·m (5.1 ~ 6.5 lb·ft)
• Never twist the airbag module when installing it. If the module is twisted, airbag module may operate
abnormally.
4. Install the inflator on the bracket.

5. Connect the CAB connector.
7. After installing the Curtain Airbag (CAB), confirm proper system operation:
off.
Page 42 of 271
Restraint > Seat Belt Pretensioner > Seat Belt Pretensioner (BPT) > Description and Operation
DESCRIPTION
The Seat Belt Pretensioners (BPT) are installed inside B-Pillar (LH & RH). When a vehicle crashes with a certain
degree of frontal impact, the pretensioner seat belt helps to reduce the severity of injury to the front seat occupants
by retracting the seat belt webbing. This prevents the front occupants from thrusting forward and hitting the steering
wheel or the instrument panel when the vehicle crashes.
Never attempt to measure the circuit resistance of the Seat Belt Pretensioner (BPT) even if you are using the
specified tester. If the circuit resistance is measured with a tester, the pretensioner will be ignited accidentally. This
will result in serious personal injury.
Restraint > Seat Belt Pretensioner > Seat Belt Pretensioner (BPT) > Components and Components
Location
COMPONENTS
Restraint > Seat Belt Pretensioner > Seat Belt Pretensioner (BPT) > Repair procedures
REMOVAL
1. Disconnect the battery negative cable, and wait at least three minutes before beginning work.
2. Remove the seat assembly (Refer to BD group)
3. Remove the front door scuff trim.
4. Remove the center pillar trim.
5. Remove the lower anchor bolt.
6. Remove the upper anchor bolt.
7. Disconnect the connector (A).
8. Lossen the mounting bolt.
Remove the pretensioner (B).
Page 43 of 271
INSTALLATION
3. Install the Seat Belt Pretensioner (BPT) with bolt.
4. Install the upper anchor bolt.
Tightening Torque (Seat Belt Upper Anchor Bolt)

: 39 ~ 54 N·m (29 ~ 40 lb·ft)
5. Install the lower anchor bolt.
Tightening Torque (Seat Belt Lower Anchor Bolt)

: 39 ~ 54 N·m (29 ~ 40 lb·ft)
6. Install the center pillar trim.

7. Install the front door scuff trim.
8. Install the seat assembly.
10. After installing the Seat Belt Pretensioner (BPT), confirm proper system operation:
off.
Restraint > Troubleshooting > B1101

DTC Description
The SRSCM sets above DTC(s) if it detects that the battery voltage of restraints system is too high or too low.
When the voltage returns to normal, the SRS warning light automatically goes off and a malfunction is no longer
indicated.

DTC Condition Probable cause
Battery Voltage > 16.5 V for 10 seconds after IG

B1101 • Battery
ON
• Alternator
• Wiring Harness
B1102 Battery Voltage < 9.0 V for 10 seconds after IG ON
• SRSCM
Specification
Voltage : 9.0 ≤ V ≤ 16.5 V
Schematic Diagram
Page 44 of 271

1. Visually inspect all connectors related to the affected circuit for damage and secure connection.
2. Inspect terminals for damage and corrosion.
Avoid damaging connectors during the inspection

process.
3. Are any problems found?
Go to next step.
After repairing the trouble part, check whether DTC occurs or not.
Inspection Procedure
1. PREPARATION
(1) Turn the ignition switch to LOCK.
(2) Disconnect the negative (-) terminal from the battery and wait for at least 3 minutes.
(3) Remove the DAB module and disconnect the DAB connector.
(4) Disconnect the connectors of the PAB, SAB, CAB, BPT, BUPT, FIS and SIS.
(5) Disconnect the SRSCM connector.
Page 45 of 271
2. CHECK SOURCE VOLTAGE
(1) Turn the ignition switch to ON.
(2) Measure voltage between the terminal 3 of SRSCM harness connector and chassis ground.
specification(voltage) : 9.0 ≤ V ≤ 16.5 V
(3) Is the measured voltage within specification?
Check the battery.
Replace the SRSCM with a new one, and then check the vehicle again. At this time, if the vehicle normally
operates with a new SRSCM, the fault may be the SRSCM(Replace SRSCM).
3. CHECK THE BATTERY
(1) Check the battery.
● Refer to "EE" group in this SERVICE MANUAL.
Is the battery normal?
Check the alternator.
Repair or replace the battery(Refer to "EE" group in this SERVICE MANUAL).

4. CHECK ALTERNATOR
(1) Check the altenator.
Is the alternator normal?
Check wiring harness.
Repair or replace the alternator(Refer to "EE" group in this SERVICE MANUAL).

5. CHECK WIRING HARNESS
(1) Check the wiring harness between the battery and SRSCM.
Is the wiring harness normal?
Check the DTC again.
Repair or Replace the wiring harness.

Page 46 of 271
6. CHECK THE DTC AGAIN
(1) Turn the ignition switch to LOCK and wait for at least 30 seconds.
Check again that the battery negative (-) terminal is disconnected from the
battery.
(2) Install the DAB module and connect the DAB connector.
(3) Connect the connectors of the PAB, SAB, CAB, BPT, BUPT, FIS and SIS.
(4) Connect the SRSCM connector.
(5) Connect the negative (-) terminal to the battery.
(6) Connect a Hi-Scan(Pro) to the data link connector.
(7) Turn the ignition switch to ON and check the vehicle again.
Does Hi-Scan (Pro) indicate any DTC?
Perform the troubleshooting procedures associated with those codes.
Problem is intermittent or was repaired and SRSCM memory was not cleared.

DTC Description
The SRSCM sets above DTC(s) if it detects that the battery voltage of restraints system is too high or too low.
When the voltage returns to normal, the SRS warning light automatically goes off and a malfunction is no longer
indicated.

Battery Voltage > 16.5 V for 10 seconds after IG

B1101 • Battery
ON
• Alternator
• Wiring Harness
B1102 Battery Voltage < 9.0 V for 10 seconds after IG ON
• SRSCM
Specification
Voltage : 9.0 ≤ V ≤ 16.5 V
Schematic Diagram
Page 47 of 271


process.
Go to next step.
1. PREPARATION
Page 48 of 271
(2) Measure voltage between the terminal 3 of SRSCM harness connector and chassis ground.
specification(voltage) : 9.0 ≤ V ≤ 16.5 V
Check the battery.
3. CHECK THE BATTERY
(1) Check the battery.
Is the battery normal?
Check the alternator.
Repair or replace the battery(Refer to "EE" group in this SERVICE MANUAL).

4. CHECK ALTERNATOR
(1) Check the altenator.
Is the alternator normal?
Check wiring harness.
Repair or replace the alternator(Refer to "EE" group in this SERVICE MANUAL).

5. CHECK WIRING HARNESS
(1) Check the wiring harness between the battery and SRSCM.
Is the wiring harness normal?
Check the DTC again.
Repair or Replace the wiring harness.

Page 49 of 271
Check again that the battery negative (-) terminal is disconnected from the
battery.
Perform the troubleshooting procedures associated with those codes.

DTC Description
The detecting system for front crash consists of the SRSCM and two Front Impact Sensors (FIS). The SRSCM
sets above DTC(s) if it detects that any FIS is defective or there is communication error between any FIS and the
SRSCM.

• Short to ground on
• Short to ground between FIS and SRSCM Wiring Harness
B1326
• Front Impact Sensor(FIS) Malfunction • Front Impact
B1331
• SRSCM Malfunction Sensor(FIS) squib
• SRSCM
Schematic Diagram
Page 50 of 271


process.
Go to next step.
1. PREPARATION
Page 51 of 271
2. CHECK FIS CIRCUIT
(1) Measure resistance between the terminal 1 of FIS harness connector and chassis ground(-).
specification(resistance) : ∞ Ω
(2) Is the measured resistance within specification?
Check Front Impact Sensor.
Repair or replace the wiring harness between the FIS and the SRSCM.
3. CHECK FRONT IMPACT SENSOR
(1) Replace the front impact sensor(FIS) with a new one.
● Refer to "Front Impact Sensor(FIS)" section in this SERVICE MANUAL.
Does Hi-Scan (Pro) indicate any DTC related to FIS?
Go to next step.
Replace the Front Impact Sensor(FIS).

Page 52 of 271
Check again that the battery negative (-) terminal is disconnected from the battery.
(3) Connect the connectors of the PAB,SAB,CAB,BPT,BUPT,FIS and SIS.

DTC Description
SRSCM.

• Short to battery line
• Short to battery line between FIS and SRSCM on Wiring Harness
B1327
B1332
• SRSCM
Schematic Diagram
Page 53 of 271


process.
Go to next step.
1. PREPARATION
Page 54 of 271
(3) Measure voltage between the terminal 1 of FIS harness connector and chassis ground(-).
specification(voltage) : Approximately 0 V
Repair the short to battery line circuit on wiring harness between the FIS and the SRSCM.
Go to next step.

Page 55 of 271

DTC Description
SRSCM.

• Wiring Harness
B1328
• Open between FIS and SRSCM • Front Impact
B1329
• Front Impact Sensor(FIS) Malfunction Sensor(FIS)
B1333
• SRSCM Malfunction squib
B1334
• SRSCM
Schematic Diagram
Page 56 of 271


process.
Go to next step.
1. PREPARATION
Page 57 of 271
(1) Measure resistance between the terminal 1 of FIS harness connector and the terminal 48(45) of SRSCM
harness connector.
harness connector.
specification(resistance) : below 1 Ω
Go to next step.

Page 58 of 271
4. CLEAR THE DTC AND CHECK THE VEHICLE AGAIN
(1) Clear the DTC stored in the SRSCM memory with the Hi-Scan(Pro).
(3) Turn the ignition switch to ON and wait for at least 30 seconds.
(4) Check the vehicle again with the Hi-Scan(Pro).
Does the above DTC(s) go off?

DTC Description
SRSCM.

• Wiring Harness
B1328
B1329
B1333
B1334
• SRSCM
Schematic Diagram
Page 59 of 271


process.
Go to next step.
1. PREPARATION
Page 60 of 271
harness connector.
harness connector.
Go to next step.

Page 61 of 271

DTC Description
The detecting system for front crash consists of the SRSCM and two Front Impact Sensors (FIS).
If above DTC is detected , replace two Front Impact Sensors(FIS).

DTC Description
SRSCM.

• Short to ground between FIS and SRSCM Wiring Harness
B1326
B1331
• SRSCM
Schematic Diagram
Page 62 of 271


process.
Go to next step.
1. PREPARATION
Page 63 of 271
(1) Measure resistance between the terminal 1 of FIS harness connector and chassis ground(-).
Go to next step.

Page 64 of 271
(3) Connect the connectors of the PAB,SAB,CAB,BPT,BUPT,FIS and SIS.

DTC Description
SRSCM.

• Short to battery line between FIS and SRSCM on Wiring Harness
B1327
B1332
• SRSCM
Schematic Diagram
Page 65 of 271


process.
Go to next step.
1. PREPARATION
Page 66 of 271
(3) Measure voltage between the terminal 1 of FIS harness connector and chassis ground(-).
Repair the short to battery line circuit on wiring harness between the FIS and the SRSCM.
Go to next step.

Page 67 of 271

DTC Description
SRSCM.

• Wiring Harness
B1328
B1329
B1333
B1334
• SRSCM
Schematic Diagram
Page 68 of 271


process.
Go to next step.
1. PREPARATION
Page 69 of 271
harness connector.
harness connector.
Go to next step.

Page 70 of 271

DTC Description
SRSCM.

• Wiring Harness
B1328
B1329
B1333
B1334
• SRSCM
Schematic Diagram
Page 71 of 271


process.
Go to next step.
1. PREPARATION
Page 72 of 271
harness connector.
harness connector.
Go to next step.

Page 73 of 271

DTC Description
The detecting system for front crash consists of the SRSCM and two Front Impact Sensors (FIS).
If above DTC is detected , replace two Front Impact Sensors(FIS).

DTC Description
The Driver Airbag circuit consists of the SRSCM, Clockspring and the Driver Airbag (DAB) which has two squib
circuits. The SRSCM sets above DTC(s) if it detects that the resistance of DAB squib is too high or low.

• Open or short circuit on
• Too high or low resistance between DAB high(+) and DAB low (-) wiring harness
B1346 • Driver Airbag (DAB) Malfunction • Driver Airbag (DAB)
B1347 • Clockspring Malfunction squib
• SRSCM Malfunction • Clockspring
• SRSCM
Specification
DAB resistance : 1.5 ≤ R ≤ 5.7 Ω
Schematic Diagram
Page 74 of 271


process.
Go to next step.
1. PREPARATION
Page 75 of 271
2. CHECK DAB RESISTANCE
Never attempt to measure the circuit resistance of the airbag module(squib) even if you are using the
specified tester.
(1) Connect the Dummy and the Dummy Adapter on DAB harness connector.
●Refer to "SPECIAL SERVICE TOOL" section in this SERVICE MANUAL for the SST No. of Dummy
and Dummy Adapter.
(2) Measure resistance between the terminal 24 and 25 of SRSCM harness connector.
Check open circuit.
Replace the Driver Airbag(DAB) module.

3. CHECK OPEN CIRCUIT
(1) Measure resistance between the terminal 1 of DAB harness connector and the terminal 25 of SRSCM
harness connector.
harness connector.
Page 76 of 271
Check short circuit.
Repair or replace the wiring harness between the DAB and the clockspring or between the clockspring
and the SRSCM.
4. CHECK SHORT CIRCUIT
(1) Measure resistance between the terminal 1 and 2 of DAB harness connector.
Go to next step.
and the SRSCM.
(6) Turn the ignition switch to ON .
Replace the SRSCM with a new one, and then check the vehicle again. At this time, if the vehicle
normally operates with a new SRSCM, the fault may be the SRSCM(Replace SRSCM).

DTC Description
Page 77 of 271

• SRSCM
Specification
Schematic Diagram


process.
Page 78 of 271
Go to next step.
1. PREPARATION
specified tester.
and Dummy Adapter.
Check open circuit.

Page 79 of 271
harness connector.
harness connector.
and the SRSCM.
Go to next step.
and the SRSCM.
Page 80 of 271

DTC Description
circuits. The SRSCM sets above DTC(s) if it detects short to ground on the DAB circuit.

• Short to ground circuit
• Short to ground between DAB and clockspring
on wiring harness
• Short to ground between clockspring and SRSCM
B1348 • Driver Airbag (DAB)
• Driver Airbag (DAB) Malfunction
B1483 squib
• Clockspring Malfunction
• Clockspring
• SRSCM Malfunction
• SRSCM
Schematic Diagram
Page 81 of 271


process.
Go to next step.
1. PREPARATION
Page 82 of 271
2. CHECK SHORT TO GROUND
(1) Measure resistance between the terminal 1 of DAB harness connector and chassis ground (DAB Stage 1).
specification(resistance) : infinite
Check the DAB Module.
and the SRSCM.
3. CHECK THE DAB MODULE
(1) Replace the Driver Airbag(DAB) with a new one.
● Refer to "Driver Airbag(DAB)" section in this SERVICE MANUAL.
Does Hi-Scan (Pro) indicate any DTC related to DAB?
Check the clockspring.
Replace the Driver Airbag(DAB).

4. CHECK THE CLOCKSPRING
(1) Check the clockspring. Is the clockspring normal?
Go to next step.
Replace the clockspring.

Page 83 of 271
(6) Turn the ignition switch to ON

DTC Description
circuits. The SRSCM sets above DTC(s) if it detects short to battery line on the DAB circuit.

• Short to battery line on
• Short to battery line between DAB and clockspring
wiring harness
• Short to battery line between clockspring and SRSCM
B1484 squib
• Clockspring
• SRSCM
Schematic Diagram
Page 84 of 271


process.
Go to next step.
1. PREPARATION
Page 85 of 271
2. CHECK SHORT TO BATTERY LINE
(3) Measure voltage between the terminal 1 of DAB harness connector and chassis ground(-) (DAB Stage 1).
Check the DAB module.
and the SRSCM.
● "Refer to "Driver Airbag(DAB)" section in this SERVICE MANUAL.

Go to next step.

Page 86 of 271

DTC Description
The Passenger Airbag circuit consists of the SRSCM and the Passenger Airbag (PAB) which has two squib circuits.
The SRSCM sets above DTC(s) if it detects that the resistance of PAB squib is too high or low.

• Too high or low resistance between PAB high(+) and PAB low (-) wiring harness
B1352
• Passenger Airbag (PAB) Malfunction • Passenger Airbag
B1353
• SRSCM Malfunction (PAB) squib
• SRSCM
Specification
PAB resistance : 1.5 ≤ R ≤ 5.7 Ω
Schematic Diagram

1. Check all the connectors related to the DTC for contact condition visually.
Page 87 of 271
2. Check the connector and the terminal.
(1) Check the connector for connection securely.
(2) Check the terminal for contact condition,deterioration,erosion and elasticity.
Do not deform the connector for revising contact.
Are confirmed trouble on the connector and the terminal?
Go to next step.
1. PREPARATION
(4) Disconnect the connectors of the PAB, SAB, CAB, BPT, FIS and SIS.
2. CHECK PAB RESISTANCE
specified tester.
(1) Connect the Dummy and the Dummy Adapter on PAB harness connector.
● Refer to "SPECIAL SERVICE TOOL" section in this SERVICE MANUAL for the SST No. of Dummy
and Dummy Adapter.
Replace the Passenger Airbag(PAB) module.
Check open circuit.

Page 88 of 271
(1) Measure resistance between the terminal 2 of PAB harness connector and the terminal 23 of SRSCM
harness connector.
harness connector.
Repair or replace the wiring harness between the PAB and the SRSCM.
(1) Measure resistance between the terminal 1 and 2 of PAB harness connector.
Go to next step.
(2) Connect the connectors of the PAB, SAB, CAB, BPT, FIS and SIS.

Page 89 of 271
DTC Description

B1352
B1353
• SRSCM
Specification
Schematic Diagram

1. Check all the connectors related to the DTC for contact condition visually.
2. Check the connector and the terminal.
(1) Check the connector for connection securely.
(2) Check the terminal for contact condition,deterioration,erosion and elasticity.
Do not deform the connector for revising contact.
Are confirmed trouble on the connector and the terminal?
Go to next step.
1. PREPARATION
Page 90 of 271
specified tester.
and Dummy Adapter.
Check open circuit.

harness connector.
harness connector.
Go to next step.
Page 91 of 271

DTC Description
The SRSCM sets above DTC(s) if it detects short to ground on the PAB circuit.

• Short to ground between PAB module and SRSCM wiring harness
B1354
B1487
• SRSCM
Schematic Diagram


process.
Page 92 of 271
Go to next step.
1. PREPARATION
(1) Measure resistance between the terminal 1 of PAB harness connector and chassis ground(PAB Stage 1).
Check the PAB Module.
3. CHECK THE PAB MODULE
(1) Replace the Passenger Airbag (PAB) with a new one.
● Refer to "Passenger Airbag (PAB)" section in this SERVICE MANUAL.
Does Hi-Scan (Pro) indicate any DTC related to PAB?
Go to next step.
Replace PAB module.

Page 93 of 271

DTC Description
The Passenger Airbag circuit consists of the SRSCM and the Passenger Airbag (PAB) which has two squib
circuits.The SRSCM sets above DTC(s) if it detects short to battery line on the PAB circuit.

circuit on wiring
• Short to battery line between PAB and SRSCM
B1355 harness
• Passenger Airbag (PAB) Malfunction
B1488 • Passenger Airbag
(PAB) squib
• SRSCM
Schematic Diagram

Page 94 of 271

process.
Go to next step.
1. PREPARATION
(3) Measure voltage between the terminal 1 of PAB harness connector and chassis ground(-) (PAB Stage 1).
Repair the short to battery line circuit on wiring harness between the PAB and the SRSCM.
Page 95 of 271
(1) Replace the Passenger Airbag(PAB) with a new one.
● Refer to "Passenger Airbag(PAB)" section in this SERVICE MANUAL.
Go to next step.
Replace PAB module.


DTC Description
The Seat Belt Pretensioner circuit consists of the SRSCM and two Seat Belt Pretensioners (BPT).
The SRSCM sets above DTC(s) if it detects that the resistance of BPT squib is too high or low.

Page 96 of 271
B1361
• Too high or low resistance between BPT high(+) and BPT low (-) wiring harness
B1362
• Seat Belt Pretensioner (BPT) Malfunction • Seat Belt Pretensioner
B1367
• SRSCM Malfunction (BPT) squib
B1368
• SRSCM
Specification
BPT resistance : 1.5 ≤ R ≤5.7 Ω
Schematic Diagram


process.
Page 97 of 271
Go to next step.
1. PREPARATION
2. CHECK BPT RESISTANCE
specified tester.
(1) Connect the Dummy and the Dummy Adapter on BPT harness connector.
and Dummy Adapter.
(2) Measure resistance between the terminal 5(30) and 4(29) of SRSCM harness connector.
BPT resistance : 1.5 ≤ R ≤ 5.7 Ω
Replace the Seat Belt Pretensioner(BPT) module.
Check open circuit.

Page 98 of 271
(1) Measure resistance between the terminal 1 of BPT harness connector and the terminal 5(30) of SRSCM
harness connector.
harness connector.
Repair or replace the wiring harness between the BPT and the SRSCM.
(1) Measure resistance between the terminal 1 and 2 of BPT harness connector.
Go to next step.
Page 99 of 271

DTC Description

B1361
B1362
B1367
B1368
• SRSCM
Specification
Schematic Diagram
Page 100 of 271


process.
Go to next step.
1. PREPARATION
Page 101 of 271
specified tester.
and Dummy Adapter.
Check open circuit.

harness connector.
harness connector.
Page 102 of 271
Go to next step.

DTC Description
The Seat Belt Pretensioner consists of the SRSCM and two Seat Belt Pretensioners (BPT). The SRSCM sets
above DTC(s) if it detects short to ground on the BPT circuit.

Page 103 of 271
• Short to ground
circuit on wiring
• Short to ground between BPT and SRSCM harness
B1363
• Seat Belt Pretensioner (BPT) Malfunction • Seat Belt
B1369
• SRSCM Malfunction Pretensioner (BPT)
squib
• SRSCM
Schematic Diagram


process.
Go to next step.
Page 104 of 271
1. PREPARATION
(1) Measure resistance between the terminal 1 of BPT harness connector and chassis ground.
Check the BPT Module.
3. CHECK THE BPT MODULE
(1) Replace the Belt Pretensioner (BPT) with a new one.
● Refer to "Belt Pretensioner (BPT)" section in this SERVICE MANUAL.
Does Hi-Scan (Pro) indicate any DTC related to Belt Pretensioner (BPT)?
Go to next step.
Replace BPT module.

Page 105 of 271

DTC Description
above DTC(s) if it detects short to battery line on the BPT circuit.

circuit on wiring
• Short to battery line between BPT and SRSCM
B1364 harness
• Seat Belt Pretensioner (BPT) Malfunction
B1370 • Seat Belt Pretensioner
(BPT) squib
• SRSCM
Schematic Diagram
Page 106 of 271


process.
Go to next step.
1. PREPARATION
Page 107 of 271
(3) Measure voltage between the terminal 1 of BPT harness connector and chassis ground(-).
Repair the short to battery line circuit on wiring harness between the BPT and the SRSCM.
Go to next step.
Replace BPT module.

Page 108 of 271

DTC Description

B1361
B1362
B1367
B1368
• SRSCM
Specification
Schematic Diagram
Page 109 of 271


process.
Go to next step.
1. PREPARATION
Page 110 of 271
specified tester.
and Dummy Adapter.
Check open circuit.

harness connector.
harness connector.
Page 111 of 271
Go to next step.

DTC Description

Page 112 of 271
B1361
B1362
B1367
B1368
• SRSCM
Specification
Schematic Diagram


process.
Page 113 of 271
Go to next step.
1. PREPARATION
specified tester.
and Dummy Adapter.
Check open circuit.

Page 114 of 271
harness connector.
harness connector.
Go to next step.
Page 115 of 271

DTC Description
above DTC(s) if it detects short to ground on the BPT circuit.

• Short to ground
circuit on wiring
• Short to ground between BPT and SRSCM harness
B1363
• Seat Belt Pretensioner (BPT) Malfunction • Seat Belt
B1369
• SRSCM Malfunction Pretensioner (BPT)
squib
• SRSCM
Schematic Diagram
Page 116 of 271


process.
Go to next step.
1. PREPARATION
Page 117 of 271
(1) Measure resistance between the terminal 1 of BPT harness connector and chassis ground.
Go to next step.
Replace BPT module.

Page 118 of 271

DTC Description
above DTC(s) if it detects short to battery line on the BPT circuit.

circuit on wiring
• Short to battery line between BPT and SRSCM
B1364 harness
• Seat Belt Pretensioner (BPT) Malfunction
B1370 • Seat Belt Pretensioner
(BPT) squib
• SRSCM
Schematic Diagram
Page 119 of 271


process.
Go to next step.
1. PREPARATION
Page 120 of 271
(3) Measure voltage between the terminal 1 of BPT harness connector and chassis ground(-).
Repair the short to battery line circuit on wiring harness between the BPT and the SRSCM.
Go to next step.
Replace BPT module.

Page 121 of 271

DTC Description
The Side Airbag circuit consists of the SRSCM and two Side Airbags (SAB). The SRSCM sets above DTC(s) if it
detects that the resistance of SAB squib is too high or low.

B1378
• Too high or low resistance between SAB high(+) and SAB low (-) wiring harness
B1379
• Side Airbag (SAB) Malfunction • Side Airbag (SAB)
B1382
B1383
• SRSCM
Specification
SAB resistance : 1.5 ≤ R ≤ 5.7 Ω
Schematic Diagram
Page 122 of 271


process.
Go to next step.
1. PREPARATION
Page 123 of 271
2. CHECK SAB RESISTANCE
specified tester.
(1) Connect the Dummy and the Dummy Adapter on SAB harness connector.
and Dummy Adapter.
Replace the Side Airbag(SAB) module.
Check open circuit.

(1) Measure resistance between the terminal 1(2) of SAB harness connector and the terminal 17(14) of SRSCM
harness connector.
harness connector.
Repair or replace the wiring harness between the SAB nd the SRSCM.
Page 124 of 271
(1) Measure resistance between the terminal 1(2) and 2(1) of SAB harness connector.
Is the measured resistance within specification?
Go to next step.
Repair or replace the wiring harness between the SAB and the SRSCM.

DTC Description

Page 125 of 271
B1378
B1379
B1382
B1383
• SRSCM
Specification
Schematic Diagram


process.
Go to next step.
Page 126 of 271
1. PREPARATION
specified tester.
and Dummy Adapter.
Check open circuit.

Page 127 of 271
harness connector.
harness connector.
Go to next step.
Page 128 of 271

DTC Description

B1378
B1379
B1382
B1383
• SRSCM
Specification
Schematic Diagram
Page 129 of 271


process.
Go to next step.
1. PREPARATION
Page 130 of 271
specified tester.
and Dummy Adapter.
Check open circuit.

harness connector.
harness connector.
Page 131 of 271
Go to next step.

DTC Description
detects short to ground on the SAB circuit.

Page 132 of 271
• Short to ground
circuit on wiring
• Short to ground between SAB and SRSCM
B1380 harness
• Side Airbag (SAB) Malfunction
B1384 • Side Airbag (SAB)
squib
• SRSCM
Schematic Diagram


process.
Go to next step.
Page 133 of 271
1. PREPARATION
(1) Measure resistance between the terminal 1(2) of SAB harness connector and chassis ground.
Check the SAB Module.
3. CHECK THE SAB MODULE
(1) Replace the Side Airbag(SAB) with a new one.
● Refer to "Side Airbag(SAB)" section in this SERVICE MANUAL.
(5) onnect the negative (-) terminal to the battery.
Does Hi-Scan (Pro) indicate any DTC related to Side Airbag(SAB)?
Go to next step.
Replace SAB module.

Page 134 of 271

DTC Description
detects short to battery line on the SAB circuit.

circuit on wiring
• Short to battery line between SAB and SRSCM
B1381 harness
squib
• SRSCM
Schematic Diagram
Page 135 of 271


process.
Go to next step.
1. PREPARATION
Page 136 of 271
(3) Measure voltage between the terminal 1(2) of SAB harness connector and chassis ground(-).
Repair the short to battery line circuit on wiring harness between the SAB and the SRSCM.
Go to next step.
Replace SAB module.

Page 137 of 271

DTC Description

B1378
B1379
B1382
B1383
• SRSCM
Specification
Schematic Diagram
Page 138 of 271


process.
Go to next step.
1. PREPARATION
Page 139 of 271
specified tester.
and Dummy Adapter.
Check open circuit.

harness connector.
harness connector.
Page 140 of 271
Is the measured resistance within specification?
Go to next step.

DTC Description
detects short to ground on the SAB circuit.

Page 141 of 271
• Short to ground
circuit on wiring
• Short to ground between SAB and SRSCM
B1380 harness
squib
• SRSCM
Schematic Diagram


process.
Go to next step.
Page 142 of 271
1. PREPARATION
(1) Measure resistance between the terminal 1(2) of SAB harness connector and chassis ground.
(5) onnect the negative (-) terminal to the battery.
Go to next step.
Replace SAB module.

Page 143 of 271

DTC Description
detects short to battery line on the SAB circuit.

circuit on wiring
• Short to battery line between SAB and SRSCM
B1381 harness
squib
• SRSCM
Schematic Diagram
Page 144 of 271


process.
Go to next step.
1. PREPARATION
Page 145 of 271
(3) Measure voltage between the terminal 1(2) of SAB harness connector and chassis ground(-).
Repair the short to battery line circuit on wiring harness between the SAB and the SRSCM.
Go to next step.
Replace SAB module.

Page 146 of 271

DTC Description
The Seat Track Position Sensor (STPS) circuit consists of the SRSCM and two STPS. The SRSCM sets above
DTC(s) if it detects open or short to ground on the STPS circuit. The "Seat Forward" status currently represents a
seat position in which the deployment of the second stage airbag is prohibited.

• Open or short to
• Open between STPS and SRSCM
ground circuit on wiring
B1396 • Short to ground between STPS and SRSCM
harness
B1398 • STPS Malfunction
• STPS
• SRSCM
Specification
Resistance(R) or
STPS Satus Related DTC(s)
Current (mA)
R < 70Ω (low line, STPS
Short to ground B1396, B1398
Reward)
"SEAT FORWARD"
4 < I < 7 mA
status
"SEAT REWARD" status 12 < I < 17 mA
Short to battery B1397, B1399
Forward)
Page 147 of 271
Schematic Diagram


process.
Go to next step.
Page 148 of 271
1. PREPARATION
(1) Measure resistance between the terminal 1 of STPS harness connector and the terminal 38(35) of SRSCM
harness connector.
(2) Measure resistance between the terminal 2(6) of STPS harness connector and the terminal 37(36) of
SRSCM harness connector.
Check short to ground.
Repair the open circuit on wiring harness between the STPS and the SRSCM.
(1) Measure resistance between the terminal 1 of STPS harness connector and chassis ground.
Check the STPS.
Repair or replace the wiring harness between the STPS and the SRSCM.
Page 149 of 271
4. CHECK THE SEAT TRACK POSITION SENSOR (STPS)
(1) Measure current between the terminal 1 of STPS and 38(35) of SRSCM.
Specification(current) : 12 ~ 17 mA (Reward status, 4 ~ 7 mA (Forward status)
(2) Is the measured current within specification?
Goto next stop.
Replace the STPS.


DTC Description
DTC(s) if it detects short or short to battery line on the STPS circuit. The "Seat Forward" status currently represents
a seat position in which the deployment of the second stage airbag is prohibited.

• Short or short to battery
• Short between STPS and SRSCM
line circuit on wiring
B1397 • Short to battery line between STPS and SRSCM
harness
• STPS
• SRSCM
Specification
Page 150 of 271
Resistance(R) or
Current (mA)
Reward)
"SEAT FORWARD"
4 < I < 7 mA
status
Foward)
Schematic Diagram


process.
Page 151 of 271
Go to next step.
1. PREPARATION
(1) Measure resistance between the terminal 1 and 2(6) of STPS harness connector.
Go to next step.
Page 152 of 271
(3) Measure voltage between the terminal 1 of STPS harness connector and chassis ground(-).
Check the STPS.
Repair the short to battery line circuit on wiring harness between the STPS and the SRSCM.
Specification(current) : 12 ~ 17 mA (Reward status), 4 ~ 7 mA (Forward status)
Goto next stop.
Replace the STPS.

Page 153 of 271

DTC Description
DTC(s) if it detects open or short to ground on the STPS circuit. The "Seat Forward" status currently represents a
seat position in which the deployment of the second stage airbag is prohibited.

• Open between STPS and SRSCM
B1396 • Short to ground between STPS and SRSCM
harness
• STPS
• SRSCM
Specification
Resistance(R) or
Current (mA)
Reward)
"SEAT FORWARD"
4 < I < 7 mA
status
Forward)
Schematic Diagram
Page 154 of 271


process.
Go to next step.
1. PREPARATION
Page 155 of 271
(1) Measure resistance between the terminal 1 of STPS harness connector and the terminal 38(35) of SRSCM
harness connector.
(2) Measure resistance between the terminal 2(6) of STPS harness connector and the terminal 37(36) of
Repair the open circuit on wiring harness between the STPS and the SRSCM.
(1) Measure resistance between the terminal 1 of STPS harness connector and chassis ground.
Check the STPS.
Page 156 of 271
Specification(current) : 12 ~ 17 mA (Reward status, 4 ~ 7 mA (Forward status)
Goto next stop.
Replace the STPS.


DTC Description
DTC(s) if it detects short or short to battery line on the STPS circuit. The "Seat Forward" status currently represents
a seat position in which the deployment of the second stage airbag is prohibited.

• Short between STPS and SRSCM
line circuit on wiring
B1397 • Short to battery line between STPS and SRSCM
harness
• STPS
• SRSCM
Specification
Page 157 of 271
Resistance(R) or
Current (mA)
Reward)
"SEAT FORWARD"
4 < I < 7 mA
status
Foward)
Schematic Diagram


process.
Page 158 of 271
Go to next step.
1. PREPARATION
(1) Measure resistance between the terminal 1 and 2(6) of STPS harness connector.
Go to next step.
Page 159 of 271
(3) Measure voltage between the terminal 1 of STPS harness connector and chassis ground(-).
Check the STPS.
Repair the short to battery line circuit on wiring harness between the STPS and the SRSCM.
Specification(current) : 12 ~ 17 mA (Reward status), 4 ~ 7 mA (Forward status)
Goto next stop.
Replace the STPS.

Page 160 of 271

DTC Description
The detecting system for side crash consists of the SRSCM and two Side Impact Sensors (SIS). The SRSCM sets
above DTC(s) if it detects that any SIS is defective or there is communication error between any front SIS and the
SRSCM.

• Wiring Harness
B1400
• Open between SIS and SRSCM • Side Impact
B1403
• Side Impact Sensor (SIS) Malfunction Sensor (SIS)
B1409
B1410
• SRSCM
Schematic Diagram

Page 161 of 271

process.
Go to next step.
1. PREPARATION
2. CHECK SIS CIRCUIT
(1) Measure resistance between the terminal 1 of SIS harness connector and the terminal 42(39) of SRSCM
harness connector.
harness connector.
Check Side Impact Sensor.
Repair or replace the wiring harness between the SIS and the SRSCM.
Page 162 of 271
3. CHECK THE SIDE IMPACT SENSOR
(1) Replace the Side Impact Sensor(SIS) with a new one.
● Refer to "Side Impact Sensor(SIS)" section in this SERVICE MANUAL.
Does Hi-Scan (Pro) indicate any DTC related to Side Impact Sensor(SIS)?
Go to next step.
Replace SIS.

DTC Description
above DTC(s) if it detects short to ground on the SIS circuit.

Page 163 of 271
• Short to ground
circuit on wiring
• Short to ground between SIS and SRSCM
B1401 Harness
• Side Impact Sensor (SIS) Malfunction
B1404 • Side Impact Sensor
(SIS) squib
• SRSCM
Schematic Diagram


process.
Go to next step.
Page 164 of 271
1. PREPARATION
(1) Measure resistance between the terminal 1 of SIS harness connector and chassis ground.
Check the SIS.
Go to next step.
Replace SIS module.

Page 165 of 271

DTC Description
above DTC(s) if it detects short to battery line on the SIS circuit.

circuit on wiring
• Short to battery line between SIS and SRSCM
B1402 Harness
(SIS) squib
• SRSCM
Schematic Diagram
Page 166 of 271


process.
Go to next step.
1. PREPARATION
Page 167 of 271
(3) Measure voltage between the terminal 1 of SIS harness connector and chassis ground(-).
specification(voltage) : Approximately 0V
Check the SIS Module.
Repair the short to battery line circuit on wiring harness between the SIS and the SRSCM.
3. CHECK THE SIS MODULE
Go to next step.
Replace SIS module.

Page 168 of 271

DTC Description
SRSCM.

• Wiring Harness
B1400 • Open between SIS and SRSCM • Side Impact
B1403
B1409
B1410
• SRSCM
Schematic Diagram
Page 169 of 271


process.
Go to next step.
1. PREPARATION
Page 170 of 271
harness connector.
harness connector.
Go to next step.
Replace SIS.
Page 171 of 271

DTC Description
above DTC(s) if it detects short to ground on the SIS circuit.

• Short to ground
circuit on wiring
• Short to ground between SIS and SRSCM
B1401 Harness
(SIS) squib
• SRSCM
Schematic Diagram
Page 172 of 271


process.
Go to next step.
1. PREPARATION
Page 173 of 271
(1) Measure resistance between the terminal 1 of SIS harness connector and chassis ground.
Check the SIS.
Go to next step.
Replace SIS module.

Page 174 of 271

DTC Description
above DTC(s) if it detects short to battery line on the SIS circuit.

circuit on wiring
• Short to battery line between SIS and SRSCM
B1402 Harness
(SIS) squib
• SRSCM
Schematic Diagram
Page 175 of 271


process.
Go to next step.
1. PREPARATION
Page 176 of 271
(3) Measure voltage between the terminal 1 of SIS harness connector and chassis ground(-).
Check the SIS Module.
Repair the short to battery line circuit on wiring harness between the SIS and the SRSCM.
3. CHECK THE SIS MODULE
Go to next step.
Replace SIS module.

Page 177 of 271

DTC Description
SRSCM.

• Wiring Harness
B1403
B1409
B1410
• SRSCM
Schematic Diagram
Page 178 of 271


process.
Go to next step.
1. PREPARATION
Page 179 of 271
harness connector.
harness connector.
Go to next step.
Replace SIS.
Page 180 of 271

DTC Description
SRSCM.

• Wiring Harness
B1403
B1409
B1410
• SRSCM
Schematic Diagram
Page 181 of 271


process.
Go to next step.
1. PREPARATION
Page 182 of 271
harness connector.
harness connector.
Go to next step.
Replace SIS.
Page 183 of 271

DTC Description
above DTC(s) if it detects SIS wrong ID.
If above DTC is detected, replace Side Impact Sensors(SIS).

DTC Description
above DTC(s) if it detects SIS wrong ID.
If above DTC is detected, replace Side Impact Sensors(SIS).

DTC Description
The CAB squib circuit consists of the SRSCM and CAB. It causes the SRS to deploy when the SRS deployment
conditions are satisfied. The above DTC is recorded when the CAB resistance too high or low is detected in the
CAB squib circuit.

Page 184 of 271
B1473
• Too high or low resistance between CAB high(+) and CAB low (-) wiring harness
B1474
• Curtain Airbag (CAB) Malfunction • Curtain Airbag (CAB)
B1477
B1478
• SRSCM
Specification
CAB resistance : 1.5 ≤ R ≤ 5.7 Ω
Schematic Diagram


process.
Page 185 of 271
Go to next step.
1. PREPARATION
2. CHECK CAB RESISTANCE
specified tester.
(1) Connect the Dummy and the Dummy Adapter on CAB harness connector.
and Dummy Adapter.
Replace the Curtain Airbag(CAB) module.
Check open circuit.

Page 186 of 271
(1) Measure resistance between the terminal 2 of CAB harness connector and the terminal 13(10) of SRSCM
harness connector.
harness connector.
Repair or replace the wiring harness between the CAB and the SRSCM.
(1) Measure resistance between the terminal 1 and 2 of CAB harness connector.
Go to next step.
Page 187 of 271

DTC Description
CAB squib circuit.

B1473 • Too high or low resistance between CAB high(+) and CAB low (-) wiring harness
B1474
B1477
B1478
• SRSCM
Specification
Schematic Diagram
Page 188 of 271


process.
Go to next step.
1. PREPARATION
Page 189 of 271
specified tester.
and Dummy Adapter.
Check open circuit.

harness connector.
harness connector.
Page 190 of 271
Go to next step.

DTC Description
conditions are satisfied. The above DTC is recorded when short to ground is detected in the CAB squib circuit.

Page 191 of 271
• Short to ground
circuit on wiring
• Short to ground between CAB and SRSCM
B1475 harness
• Curtain Airbag (CAB) Malfunction
B1479 • Curtain Airbag
(CAB) squib
• SRSCM
Schematic Diagram


process.
Go to next step.
Page 192 of 271
1. PREPARATION
(1) Measure resistance between the terminal 1 of CAB harness connector and chassis ground.
Check the CAB Module..
3. CHECK THE CAB MODULE
(1) Replace the Curtain Airbag(CAB) with a new one.
● Refer to "Curtain Airbag(CAB)" section in this SERVICE MANUAL.
Does Hi-Scan (Pro) indicate any DTC related to Curtain Airbag(CAB)?
Go to next step.
Replace CAB module.

Page 193 of 271

DTC Description
conditions are satisfied. The above DTC is recorded when short to battery is detected in the CAB squib circuit.

circuit on wiring
• Short to battery between CAB and SRSCM
B1476 harness
(CAB) squib
• SRSCM
Schematic Diagram
Page 194 of 271


process.
Go to next step.
1. PREPARATION
Page 195 of 271
(3) Measure voltage between the terminal 1 of CAB harness connector and chassis ground(-).
Check the CAB Module.
Repair the short to battery line circuit on wiring harness between the CAB and the SRSCM.
Go to next step.
Replace CAB module.

Page 196 of 271

DTC Description
CAB squib circuit.

B1473 • Too high or low resistance between CAB high(+) and CAB low (-) wiring harness
B1474
B1477
B1478
• SRSCM
Specification
Schematic Diagram
Page 197 of 271


process.
Go to next step.
1. PREPARATION
Page 198 of 271
specified tester.
and Dummy Adapter.
Check open circuit.

harness connector.
harness connector.
Page 199 of 271
Go to next step.

DTC Description
CAB squib circuit.

Page 200 of 271
B1473
• Too high or low resistance between CAB high(+) and CAB low (-) wiring harness
B1474
B1477
B1478
• SRSCM
Specification
Schematic Diagram


process.
Page 201 of 271
Go to next step.
1. PREPARATION
specified tester.
and Dummy Adapter.
Check open circuit.

Page 202 of 271
harness connector.
harness connector.
Go to next step.
Page 203 of 271

DTC Description
conditions are satisfied. The above DTC is recorded when short to ground is detected in the CAB squib circuit.

• Short to ground
circuit on wiring
• Short to ground between CAB and SRSCM
B1475 harness
(CAB) squib
• SRSCM
Schematic Diagram
Page 204 of 271


process.
Go to next step.
1. PREPARATION
Page 205 of 271
(1) Measure resistance between the terminal 1 of CAB harness connector and chassis ground.
Check the CAB Module..
Go to next step.
Replace CAB module.

Page 206 of 271

DTC Description
conditions are satisfied. The above DTC is recorded when short to battery is detected in the CAB squib circuit.

circuit on wiring
• Short to battery between CAB and SRSCM
B1476 harness
(CAB) squib
• SRSCM
Schematic Diagram
Page 207 of 271


process.
Go to next step.
1. PREPARATION
Page 208 of 271
(3) Measure voltage between the terminal 1 of CAB harness connector and chassis ground(-).
Check the CAB Module.
Repair the short to battery line circuit on wiring harness between the CAB and the SRSCM.
Go to next step.
Replace CAB module.

Page 209 of 271

DTC Description

• SRSCM
Specification
Schematic Diagram
Page 210 of 271


process.
Go to next step.
1. PREPARATION
Page 211 of 271
specified tester.
and Dummy Adapter.
Check open circuit.

(1) Measure resistance between the terminal 1 of DAB harness connector and the terminal 9 of SRSCM harness
connector.
connector.
Page 212 of 271
and the SRSCM.
Go to next step.
and the SRSCM.

DTC Description
Page 213 of 271

• SRSCM
Specification
Schematic Diagram


process.
Page 214 of 271
Go to next step.
1. PREPARATION
specified tester.
and Dummy Adapter.
Check open circuit.

Page 215 of 271
connector.
connector.
and the SRSCM.
Go to next step.
and the SRSCM.
Page 216 of 271

DTC Description
circuits. The SRSCM sets above DTC(s) if it detects short to ground on the DAB circuit.

• Short to ground circuit
• Short to ground between DAB and clockspring
on wiring harness
• Short to ground between clockspring and SRSCM
B1483 squib
• Clockspring
• SRSCM
Schematic Diagram
Page 217 of 271


process.
Go to next step.
1. PREPARATION
Page 218 of 271
Check the DAB Module.
and the SRSCM.
● Refer to "Driver Airbag(DAB)" section in this SERVICE MANUAL.

Go to next step.

Page 219 of 271
(6) Turn the ignition switch to ON

DTC Description
circuits. The SRSCM sets above DTC(s) if it detects short to battery line on the DAB circuit.

• Short to battery line on
• Short to battery line between DAB and clockspring
wiring harness
• Short to battery line between clockspring and SRSCM
B1484 squib
• Clockspring
• SRSCM
Schematic Diagram
Page 220 of 271


process.
Go to next step.
1. PREPARATION
Page 221 of 271
Check the DAB module.
and the SRSCM.
● "Refer to "Driver Airbag(DAB)" section in this SERVICE MANUAL.

Go to next step.

Page 222 of 271

DTC Description

B1485
B1486
• SRSCM
Specification
Schematic Diagram

Page 223 of 271

process.
Go to next step.
1. PREPARATION
specified tester.
and Dummy Adapter.
Check open circuit.

Page 224 of 271
(1) Measure resistance between the terminal 2 of PAB harness connector and the terminal 7 of SRSCM harness
connector.
connector.
Go to next step.

Page 225 of 271
DTC Description

B1485
B1486
• SRSCM
Specification
Schematic Diagram


process.
Go to next step.
1. PREPARATION
Page 226 of 271
specified tester.
and Dummy Adapter.
Check open circuit.

connector.
connector.
Go to next step.
Page 227 of 271

DTC Description
The SRSCM sets above DTC(s) if it detects short to ground on the PAB circuit.

• Short to ground between PAB module and SRSCM wiring harness
B1354
B1487
• SRSCM
Schematic Diagram


process.
Page 228 of 271
Go to next step.
1. PREPARATION
(1) Replace the Passenger Airbag (PAB) with a new one.
● Refer to "Passenger Airbag (PAB)" section in this SERVICE MANUAL.
Go to next step.
Replace PAB module.

Page 229 of 271

DTC Description
The Passenger Airbag circuit consists of the SRSCM and the Passenger Airbag (PAB) which has two squib
circuits.The SRSCM sets above DTC(s) if it detects short to battery line on the PAB circuit.

circuit on wiring
• Short to battery line between PAB and SRSCM
B1355 harness
• Passenger Airbag (PAB) Malfunction
B1488 • Passenger Airbag
(PAB) squib
• SRSCM
Schematic Diagram

Page 230 of 271

process.
Go to next step.
1. PREPARATION
Repair the short to battery line circuit on wiring harness between the PAB and the SRSCM.
Page 231 of 271
(1) Replace the Passenger Airbag(PAB) with a new one.
● Refer to "Passenger Airbag(PAB)" section in this SERVICE MANUAL.
Go to next step.
Replace PAB module.


DTC Description
The passenger occupant classification system consists of the SRSCM and the OC module. The above DTC is
recorded when a defect or communication error of the OC module is detected in the OC module circuit.

Page 232 of 271
Probable
DTC Condition
cause
• Wiring
B1489 Harness
B1490 • OC module Malfunction
• OC
B1493 • SRSCM Malfunction
module
B1494
• SRSCM
Schematic Diagram


process.
Go to next step.
Page 233 of 271
1. PREPARATION
(1) Measure resistance between the terminal 4 of OC module harness connector and the terminal 44 of SRSCM
harness connector.
harness connector.
Repair the open circuit on wiring harness between the OC module and the SRSCM.
(1) Measure resistance between the terminal 4 of OC module harness connector and chassis ground.
Repair or replace the wiring harness between the OC module and the SRSCM.
Page 234 of 271
(1) Measure resistance between the terminal 4 and 5 OC module harness connector.
Specification(resistance) : infinite
Goto next stop.
(1) Connect the negative(-) terminal to the battery.
(3) Measure voltage between the terminal 4 of OC module harness connector and chassis ground(-).
Check the OC module.
Repair the short to battery line on the wiring harness between the OC module and the SRSCM.
Page 235 of 271
6. CHECK THE OC MODULE
(1) Replace the OC module with a new one.
● Refer to OCS section in this SERVICE MANUAL.
(3) Connect the OC module connector.
(6) Connect Hi-Scan(Pro) to the data link connector.
Does Hi-Scan(Pro) indicate any DTC related to OC module?
Go to next step.
Replace OC module.

DTC Description

Page 236 of 271
Probable
DTC Condition
cause
• Wiring
B1489 Harness
• OC
module
B1494
• SRSCM
Schematic Diagram


process.
Go to next step.
Page 237 of 271
1. PREPARATION
harness connector.
harness connector.
Page 238 of 271
Goto next stop.
Page 239 of 271
Go to next step.
Replace OC module.

DTC Description

Page 240 of 271
Probable
DTC Condition
cause
• Wiring
B1489 Harness
• OC
module
B1494
• SRSCM
Schematic Diagram


process.
Go to next step.
Page 241 of 271
1. PREPARATION
harness connector.
harness connector.
Page 242 of 271
Goto next stop.
Page 243 of 271
Go to next step.
Replace OC module.

DTC Description

Page 244 of 271
Probable
DTC Condition
cause
• Wiring
B1489 Harness
• OC
module
B1494
• SRSCM
Schematic Diagram


process.
Go to next step.
Page 245 of 271
1. PREPARATION
harness connector.
harness connector.
Page 246 of 271
Goto next stop.
Page 247 of 271
Go to next step.
Replace OC module.

DTC Description
The passenger detecting system consists of the SRSCM and the OC module. The SRSCM sets above DTCs if it
detects short to battery line or short to ground between BTS and OC module.

Page 248 of 271
• Short to battery or
• Short to battery or ground between BTS and OC module
harness
• Open between BTS and OC module
B1495 • Open circuit on wiring
• BTS Malfunction
harness
• OC module Malfunction • BTS
• OC module
Schematic Diagram


process.
Go to next step.
Page 249 of 271
1. PREPARATION
(1) Measure resistance between the terminal 1 of BTS harness connector and chassis ground.
(2) Measure resistance between the terminal 2 and 3 of BTS harness connector.
Go to next step.
Repair or replace the wiring harness between the BTS and the OC module.
(3) Measure voltage between the terminal 1 of BTS harness connector and chassis ground(-).
Specification(voltage) : Approximately 0 V
Go to next stop.
Repair the short to battery line circuit on wiring harness between the BTS and the OC module.
Page 250 of 271
4. CHECK BTS CIRCUIT
(1) Disconnect the negative(-) terminal from the battery and wait for at least 3 minutes.
(2) Measure resistance between the terminal 1 of BTS harness connector and the terminal 3 of OC module
harness connector.
(3) Measure resistance between the terminal 2 of BTS harness connector and the terminal 2 of OC module
harness connector.
specification(resistanve) : below 1 Ω
Check Belt Tension Sensor.
Repair or replace the wiring harness between the BTS and the OC module.
5. CHECK THE BELT TENSION SENSOR
(1) Replace the Belt Tension Sensor with a new one.
(2) Connect the BTS connector.
Does Hi-Scan(Pro) indicate any DTC related to Belt Tension Sensor(BTS)?
Go to next step.
Replace BTS.
Page 251 of 271

DTC Description
The Seat Belt Buckle Switch (BS) circuit consists of the SRSCM and two BS. The SRSCM sets above DTC(s) if it
detects short or short to battery line on the BS circuit. This system decides whether the driver or passenger seat belt
is locked or not.

• Short between BS and SRSCM line circuit on wiring
B1521 • Short to battery line between BS and SRSCM harness
B1523 • Seat Belt Buckle Switch (BS) Malfunction • Seat Belt Buckle Switch
• SRSCM Malfunction (BS)
• SRSCM
Specification
Resistance(R) or
BS Satus Related DTC(s)
Current (mA)
R < 70Ω (low line, BS
Buckled)
"UNBUCKLED" status 4 < I < 7mA
"BUCKLED" status 12 < I < 17mA
Unbuckled)
Page 252 of 271
Schematic Diagram


process.
Go to next step.
1. PREPARATION
(1) Measure resistance between the terminal 7 and 2 of BS harness connector.
Go to next step.
Repair or replace the wiring harness between the BS and the SRSCM.
Page 253 of 271
(3) Measure voltage between the terminal 7 of BS harness connector and chassis ground(-).
Check the BS.
Repair the short to battery line circuit on wiring harness between the BS and the SRSCM.
4. CHECK THE SEAT BELT BUCKLE SWITCH (BS)
(1) Measure current between the terminal 7 of BS and 34(31) of SRSCM.
Specification(current) : 12 ~ 17 mA (Buckled status), 4 ~ 7 mA (Unbuckled status)
Goto next stop.
Replace the BS.


DTC Description
Page 254 of 271
detects open or short to ground on the BS circuit. This system decides whether the driver or passenger seat belt is
locked or not.

• Open between BS and SRSCM ground circuit on
B1522 • Short to ground between BS and SRSCM wiring harness
B1524 • Seat Belt Buckle Switch (BS) Malfunction • Seat Belt Buckle
• SRSCM Malfunction Switch (BS)
• SRSCM
Specification
Resistance(R) or
Current (mA)
Buckled)
"UNBUCKLED" status 4 < I < 7 mA
"BUCKLED" status 12 < I < 17 mA
Unbuckled)
Schematic Diagram


process.
Go to next step.
Page 255 of 271
1. PREPARATION
harness connector.
harness connector.
Repair the open circuit on wiring harness between the BS and the SRSCM.
(1) Measure resistance between the terminal 7 of BS harness connector and chassis ground.
Check the BS.
Go to next stop.
Replace the BS.

Page 256 of 271

DTC Description
detects short or short to battery line on the BS circuit. This system decides whether the driver or passenger seat belt
is locked or not.

• Short between BS and SRSCM line circuit on wiring
B1521 • Short to battery line between BS and SRSCM harness
B1523 • Seat Belt Buckle Switch (BS) Malfunction • Seat Belt Buckle Switch
• SRSCM Malfunction (BS)
• SRSCM
Specification
Resistance(R) or
Current (mA)
Buckled)
"UNBUCKLED" status 4 < I < 7mA
"BUCKLED" status 12 < I < 17mA
Unbuckled)
Page 257 of 271
Schematic Diagram


process.
Go to next step.
1. PREPARATION
(1) Measure resistance between the terminal 7 and 2 of BS harness connector.
Go to next step.
Page 258 of 271
(3) Measure voltage between the terminal 7 of BS harness connector and chassis ground(-).
Check the BS.
Repair the short to battery line circuit on wiring harness between the BS and the SRSCM.
Goto next stop.
Replace the BS.


DTC Description
Page 259 of 271
detects open or short to ground on the BS circuit. This system decides whether the driver or passenger seat belt is
locked or not.

• Open between BS and SRSCM ground circuit on
B1522 • Short to ground between BS and SRSCM wiring harness
B1524 • Seat Belt Buckle Switch (BS) Malfunction • Seat Belt Buckle
• SRSCM Malfunction Switch (BS)
• SRSCM
Specification
Resistance(R) or
Current (mA)
Buckled)
"UNBUCKLED" status 4 < I < 7 mA
"BUCKLED" status 12 < I < 17 mA
Unbuckled)
Schematic Diagram


process.
Go to next step.
Page 260 of 271
1. PREPARATION
harness connector.
harness connector.
Repair the open circuit on wiring harness between the BS and the SRSCM.
(1) Measure resistance between the terminal 7 of BS harness connector and chassis ground.
Check the BS.
Go to next stop.
Replace the BS.

Page 261 of 271

DTC Description
The SRSCM shall also cyclically monitor the following :
1. Functional readliness of the firing circuit activation transistors.
2. Adequacy of deployment energy reserves.
3. Safing sensor integtity : detection of faulty closure.
4. Plausibility of accelerometer signal.
5. Operation of SRSCM components.
The SRSCM must be replaced once the fault codes except B1657 mentioned above are confirmed. Be able to
reuse SRSCM 5 times, when B1657 is only monitored.

DTC Description

Page 262 of 271
DTC Description

DTC Description

DTC Description

DTC Description
Page 263 of 271

DTC Description

DTC Description
The SRS warning lamp is located in the cluster. When the airbag system is normal, the SRS warning lamp flashes for
approx. 6 seconds after the ignition switch is turned ON, and then turns off automatically. If there is a malfunction in
the airbag system, the SRS warning lamp lights up to inform the driver of the abnormality. The SRSCM shall
measure the voltage at the SRS warning lamp output pin, both when the lamp is on and when the lamp is off, to
detect whether the commanded state matches the actual state.

• Airbag fuse
• Warning Lamp Bulb • Fuse
• Open between warning lamp and SRSCM • Warning lamp bulb
B2500
• Short to ground or battery line between the warning lamp and • Wiring Harness
SRSCM • SRSCM
Schematic Diagram
Page 264 of 271


process.
Go to next step.
1. PREPARATION
Page 265 of 271
2. CHECK THE FUSE
(1) Remove the airbag fuse and the airbag warning lamp fuse from junction block.
(2) Inspect the fuses.
Are the fuses normal?
Check the warning lamp bulb.
Repair or replace the fuses.

3. CHECK THE WARNING LAMP BULB
(1) Remove the bulb from the instrument cluster.
(2) Inspect the bulb. Is the bulb normal?
Check source voltage.
Repair or replace the bulb.

(3) Measure voltage between the terminal 7 of the instrument Cluster harness connector (M06-2) and chassis
ground(-).
specification(voltage) : 9 ~ 16.5 V
Check short to battery line.
Repair or replace the wiring harness between ignition switch and the Warning Lamp.
Page 266 of 271
(1) Measure voltage between the terminal 6 of the instrument Cluster harness connector (M06-2) and chassis
ground(-).
Check short or short to ground.
Repair the short to battery line circuit on wiring harness between the SRSCM and the Warning Lamp.
6. CHECK SHORT OR SHORT TO GROUND
(2) Disconnect the negative(-) terminal from the battery.
(3) Measure resistance between the terminal 6 of the instrument cluster harness connector (M06-2) and chassis
ground.
(4) Measure resistance between the terminal 6 and 7 of the Instrument Cluster harness connector (M06-2).
Check open circuit.
Repair the short or short to ground circuit on wiring harness between the SRSCM and the Warning Lamp.
Page 267 of 271
(1) Measure resistance between the terminal 6 of the Instrument Cluster connector (M06-2) and the terminal 26
of SRSCM harness connector.
Go to next step.
Repair the open circuit on wiring harness between the SRSCM and the Warning Lamp.

DTC Description
The Telltale Lamp circuit consisits of the Telltale Lamp and the SRSCM. SRSCM set the above DTC that the
Telltale Lamp failure is detected.

Page 268 of 271
• Airbag fuse
• Telltale Lamp Bulb • Fuse
• Open between Telltale Lamp and SRSCM • Telltale Lamp Bulb
B2502
• Short to ground or battery line between the Telltale Lamp and • Wiring Harness
SRSCM • SRSCM
Schematic Diagram


process.
Go to next step.
Page 269 of 271
1. PREPARATION
2. CHECK THE FUSE
(1) Remove the airbag fuse and the airbag telltale lamp fuse from junction block.
(2) Inspect the fuses. Are the fuses normal?
Check the telltale lamp bulb.
Repair or replace the fuses.

3. CHECK THE TELLTALE LAMP BULB
(1) Remove the bulb from the instrument cluster.
(2) Inspect the bulb. Is the bulb normal?
Check source voltage.
Repair or replace the bulb.

(3) Measure voltage between the terminal 1 of the Telltale Lamp harness connector and chassis ground(-).
specification(voltage) : 9 ~ 16.5 V
Check short to battery line.
Repair or replace the wiring harness between ignition switch and the Telltale Lamp.
Page 270 of 271
(1) Measure voltage between the terminal 4 of the Telltale Lamp harness connector and chassis ground(-).
Check short or short to ground.
Repair the short to battery line circuit on wiring harness between the SRSCM and the Telltale Lamp.
6. CHECK SHORT OR SHORT TO GROUND
(2) Disconnect the negative(-) terminal from the battery.
(3) Measure resistance between the terminal 4 of the Telltale Lamp harness connector and chassis ground.
(4) Measure resistance between the terminal 1 and 4 of the Telltale Lamp harness connector.
Check open circuit.
Repair the short or short to ground circuit on wiring harness between the SRSCM and the Telltale Lamp.
Page 271 of 271
(1) Measure resistance between the terminal 4 of the Telltale Lamp harness connector and the terminal 50 of
Go to next step.
Repair the open circuit on wiring harness between the SRSCM and the Telltale Lamp.
Page 1 of 43
SPORTAGE(KM) > 2008 > G 2.7 DOHC > 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, apply a force of 5 N (1.1 lb) to the steering
wheel in the peripheral direction.
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 tie rod ends.
CHECKING STEERING ANGLE
1. Place the front wheel on a turning radius gauge and measure the steering angle.
Standard value :
Wheel angle
Inner wheel : 36.77° ± 1°30'
Outer wheel : 31.8°
2. If the measured value is not within the standard value, adjust the linkage.
CHECKING THE TIE ROD END BALL JOINT STARTING TORQUE
Page 2 of 43
1. Disconnect the tie rod(A) and knuckle(B) by using the special tool (09568-34000).
2. Shake the ball joint stud 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 (0.05 ~ 0.25 kgf·m, 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 nece ssary.
CHECKING STATIONARY STEERING EFFORT
1. Place 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).
Page 3 of 43
3. Measure the turning force with a spring scale(A) by turning the steering wheel(B) clockwise and
counterclockwise one and a quarter turns.
Standard value :
Stationary steering effort :
29 N (3.0 kg, 6.5lbs) or less
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 of the lower arm ball joint and tie rod end.
(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.
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 70° or more.
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 somewhatdecreased.
CHECKING POWER STEERING BELT TENSION

Page 4 of 43
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 standardvalue.
Standard value :
New belt : 8.8 ~ 11.0 mm
Used belt : 12.5 ~ 14.3 mm
2. If the belt deflection is beyond the standard value, adjust the belt tension as follows.
(1) Loosen the adjusting bolt(A) and the bolt hinged(B).
(2) Put a bar(A) or equivalent, between the bracket(B) and the oil pump(C) and adjust the tension so that the
belt deflection is within the standard value.
(3) Tighten the adjusting bolt(A) and the bolt hinged(B).
Tightening torque :
35 ~ 50 Nm (3.5 ~ 5.0 kgf·m, 25.3 ~ 37 lb-ft)
Page 5 of 43
(4) Check the belt deflection and adjust it again if necessary.
After turning the V belt in the no rmal rotation direction more than once, recheck the belt deflection.
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 of the car and support them with jackstands.
2. Disconnect the return hose from the oil reservoir and plug the oil reservoir.
3. Connect a hose to the disconnected return hose, and drain the oil into a container.
4. Disconnect the high-tension cables and ignition coils.
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 cl ip.
6. Fill the power steering fluid reservoir with the specified fluid.
PSF-3 : 0.8~0.9 lit.

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
1. Fill the power steering fluid reservoir up to the "MAX" position with specified fluid.
2. Jack up the front wheels.
Page 6 of 43
3. 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. When bleeding fluid, replenish with the fluid so that the level does not fall below the bottom of the filter.
2. Perform air bleeding only while cranking to avoid excessive fluid aeration.
4. Connect the high tension cable , and then start the engine (idling).
5. Turn the steering wheel to the left and then to the right, until there are no air bubbles in the oil reservoir.
Do not hold the steering wheel turned all the way to either side for more than ten seconds.
6. Confirm that the fluid is not milky and that the level is between "MAX" and "MIN" mark on the reservoir.
7. 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(B) from the pump(A). 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, measure the fluid temperature by
Temperature gauge so that the fluid temperature can rise to approximately 50°C (122°F).
3. Increase the engine speed to 1,000 rpm.
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 :
Oil pump pressure
Relief pressure :
2.0(I4), 2.7(V6) :
8.6 ~ 9.1 MPa (88 ~ 93 kg.cm², 1251 ~ 1322 psi)
Do not keep the shut-off valve on the pressure gauge closed for more than ten seconds.
Page 7 of 43
5. Remove the special tools, and tighten the pressure hose(B) against the oil pump (A) using the specified torque.
Tightening torque :
55 ~ 65 Nm (5.5 ~ 6.5 kgf·m, 39.7 ~ 47 lb-ft)
6. Air bleed the system. (see page ST-10)
Steering System > General Information > Special Service Tools

SPECIAL TOOLS
09222-32100 Installing the pinion gear bearing
Valve stem oil seal installer
09432-21600 Installing the pinion gear bearing

Bearing installer
09434-14200 Installing the gear box oil seal.

Counter shaft bearing installer
09561-11002 Removing the steering wheel.

Steering wheel puller
09565-11100
Prelo ad socket
Page 8 of 43
09565-11100 Measuring the mainshaft preload.
Prelo ad socket
09555-21000 Removing & installing the oil seal.

Bar
09568-34000 Separating the tie rod end ball joint.

Ball joint puller
09572-21000 Measuring the power steering oil pressure

Oil pressure gauge (use with 09572-21200, 09572-22100)

Oil pressure gauge adapter (use with 09572-21000, 09572-22100)

Oil pressure gauge adapter (use with 09572-21000, 09572-21200)
09573-21000 Installing the back-up washer and oil seal.

Oil seal installer gauge (use with 09573-21100, 09573-21200,
09517-11000, 09555-21000)
09573-21100 Installing the back-up washer and oil seal.

Oil seal installer (use with 09573-21000, 09573-21200,
09555-21000)
09573-21200 1. Removing the gear box oil seal and back

Oil seal guide washer (use with 09573-21000)
2. Installing the gear box oil seal and back
washer (use with 09555-21000, 09573-
21000)
Steering System > General Information > Troubleshooting

TROUBLESHOOTING
Page 9 of 43
Symptom Probable cause Remedy
Excessive play in steering 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 V-belt slippage
smooth (Insufficient power Damaged V-belt Readjust
assist) Low fluid level Replace
Air in the fluid Replenish
Twisted or damaged hoses Bleed air
Insufficient oil pump pressure Correct the routing or replace
Sticky flow control valve Repair or replace the oil pump
Excessive internal oil pump leakage Replace
Excessive oil leaks from rack and pinion in Replace the damaged parts
gear box Replace the damaged parts
Distorted or damaged gear box or valve body Replace
seals
Steering wheel does not return Ex cessive turning resistance of tierod end Replace
properly Yoke plug excessively tight Adjust
Tie rod and/or ball joint cannot turn smoothly Replace
Loose mounting of gear box mounting bracket Retighten
Worn steering shaft joint and/or body grommet Correct or replace
Distorted rack Replace
Damaged pinion bearing Replace
Twisted or damaged hoses Reposition or replace
Damaged oil pressure control valve Replace
Damaged oil pump input shaft bearing Replace
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 when 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
Rattling or chucking noise in Interference with hoses from vehicle body Reposition
the 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
Steering System > General Information > Specifications

SPECIFICATIONS
Page 10 of 43
Rack and pinion
140 ± 1 mm (lock to lock : 3.06
Steering gear type
turns)
Rack stroke
Vane type
Power steering pump type
Oil pump displacement
9.6cc/rev. MAX. (0.59 in³/rev.
2.0(I4)
MAX)
2.7(V6)
10.5cc/rev. MAX. (0.64 in³/rev.
MAX)
SERVICE STANDARD
0 ~ 30 mm (0 ~ 1.1 in)
Steering wheel free play
36.77° ± 1°30´
Steering angle
31.8°
Inner wheel
29 N (3.0 kg, 6.5 lbs) or less
Outer wheel
Stationary steering effort
8.8 ~ 11.0 mm
Belt deflection [under 98N (10kg, 22lb) force]
12.5 ~ 14.3 mm
New belt
Used belt
8.6 ~ 9.1 MPa (88 ~ 93 kg/cm², 1251 ~ 1322
Oil pump relief pressure
psi)
2.0 (I4), 2.7 (V6)
0.6 ~ 1.3 Nm (0.06 ~ 0.13 kgf·m, 5.2 ~ 11.3 lb-
Total pinion preload
in)
Tie rod swing resistance
2 ~ 5 Nm (0.2 ~ 0.5 kgf·m, 1.4 ~ 3.6 lb-ft)
Ball joint starting torque
0.5 ~ 2.5 Nm (0.05 ~ 0.25 kgf·m, 0.36 ~ 1.78
lb-ft)
TIGHTENING TORQUE
Item Nm kgf·m lb-ft
Power steering column and shaft
Steering column and shaft mounting bolt 13 ~ 18 1.3 ~ 1.8
9.6 ~ 13.3
Power steering wheel lock nut 40 ~ 50 4.0 ~ 5.0
28.9 ~ 36.1
Pinion gear and joint assembly 15 ~ 20 1.5 ~ 2
10.8 ~ 14.8
Steering column shaft and universal joint 15 ~ 20 1.5 ~ 2
10.8 ~ 14.8
assembly
Power steering gear box
Gear box mounting bolt
60 ~ 80 6~8 44 ~ 59
Tie rod end ball joint and knuckle arm
45 ~ 60 4.5 ~ 6 32.5 ~ 43.4
mounting nut
10 ~ 16 1 ~ 1.6 7.4 ~ 11.8
Feed tube to gear box
20 ~ 30 2~3 14.8 ~ 21.7
Gear box to valve body
50 ~ 70 5~7 37 ~ 50
Yoke plug lock nut
Power steering oil pump
Pressure hose to oil pump 55 ~ 65 5.5 ~ 6.5 39.7 ~ 47
Oil pump adjusting bolt 35 ~ 50 3.5 ~ 5 25.3 ~ 37
Page 11 of 43
Oil pump mounting bolt
2.0 (I4), 2.7 (V6) 35 ~ 50 3.5 ~ 5 25.8 ~ 37
Oil pump bracket mounting bolt 35 ~ 50 3.5 ~ 5 25.8 ~ 37
Power steering hose
Power steering reservoir mounting bolt 17 ~ 26 1.7 ~ 2.6 12.3 ~ 18.8
Power steering hose mounting bolt 7 ~ 11 0.7 ~ 1.1 5 ~ 7.9
Power steering tube mounting bolt 7 ~ 11 0.7 ~ 1.1 5 ~ 7.9
LUBRICANTS
Item Recommended lubricant Quantity
ALVANIA #2 OR #3
Bearing of steering shaft As required
( KEUK DONG SHELL, KOREA)
SHOWA SUNLIGHT
Ball joint of tie rod end 4g
MB-2 OR equivalent
ONE-LUBER RP GREASE
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 & tie SILICON GREASE
As required
rod (SPEC NO : MS511-41)
0.8 ~ 0.9 liter
Power steering fluid PSF-3
(0.84 ~ 0.95 qts.)
Steering System > Steering Column & Shaft > Steering Column-Shaft > Components and Components
Location
COMPONENTS
Page 12 of 43
Steering System > Steering Column & Shaft > Steering Column-Shaft > Repair procedures
REMOVAL
Page 13 of 43
1. Disconnect the negative (-) terminal(A) from the battery.
2. Take away the bolts (A) in the illustration, and then remove the driver's airbag module(B).
3. Remove the steering wheel lock nut(A).
4. After aligning the marks on the steering shaft and wheel(A), remove the steering wheel using the special tool
(09561-11002).
Do not hammer on the steering wheel to remove it: it may damage the steering column.
Page 14 of 43
5. Remove the steering column upper(A) and lower shrouds(B).
6. Disconnect two tightening bolt(A) and remove the lower crash pad(B).
7. Remove the connectors of the multifunction switch(A).
8. After removing three bolts(A) in the illustration, remove the multifunction switch assembly(B).
Page 15 of 43
9. Remove the bolts connecting the steering column shaft(A) and the universal joint(B) as shown in the illustration.
Keep the neutral-range to prevent the damage of the clock spring inner cable when you handlethe steering
wheel.
10. After removing the mounting bolts and nuts on the steering column and shaft assembly, remove the steering
column and shaft assembly(A).
INSTALLATION
Assembly is the reverse of removal.
When installing the clock spring, refer the RT group to prevent the damage of clock spring inner cable.
DISASSEMBLY AND REASSEMBLY

KEY LOCK ASSEMBLY
1. If it is necessary to remove the key lock assembly(A), use a punch to make a groove on the head of the special
bolt(B), and then use a screwdriverto remove the key lock assembly mounting bracket(C).
Page 16 of 43
2. Disassemble the key lock assembly(A) from the steering column and shaft assembly(B).

UNIVERSAL JOINT ASSEMBLY
1. Remove the bolt(C) connecting the universal joint assembly(A) and the steering column and shaft assembly(B).
2. Remove the universal joint assembly(B) from the steering column and shaft assembly(A).
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 > Hydraulic Power Steering System > Power Steering Gear Box > Components and
Components Location
COMPONENTS
Page 17 of 43
Page 18 of 43
Steering System > Hydraulic Power Steering System > Power Steering Gear Box > Repair procedures
REMOVAL
Page 19 of 43
1. Disconnect the cover fixing clip(A) on the universal joint indoor driver inside, loosen the noise covers(B).
2. Loosen the universal joint and the gear box mounting bolt and disconnect the universal joint from the gear box.
Keep the neutral-range to prevent the damage of the clock spring inner cable when you handlethe steering
wheel.

4. Remove the front tires (RH/LH).
5. Remove the engine under cover.
6. After removing the split pin, disconnect the tie rod(A) from the knuckle(B) by using the special tool (09568-
34000).
Page 20 of 43
7. Remove the stabilizer link(B) from the strut assembly(A).
8. Remove the two bolts(A) for lower arm ball joint.
9. Remove the propeller shaft(A) and the front muffler assembly(B).
10. Drain oil from the transfer case(A). then remove the rear flange assembly(B).
11. Drain power steering oil.

Page 21 of 43
12. Remove the connecting bolt(A) for pressure tubes.
13. Remove two engline mounting bolts(B,C) and six subframe mounting bolts in order to remove the subframe(A).
Tightening torque :
engine mounting bolts
50 ~ 65 Nm (5 ~ 6.5 kgf·m, 37 ~ 47.8 lb-ft)
14. Remove the powersteering gearbox(A) after removing four mounting bolts(B) of the powersteering gearbox.
INSTALLATION
1. Installation is the reserve of removal.
2. Add power steering fluid.
3. Air bleed the system.
DISASSEMBLY
Page 22 of 43
1. Remove the tie rod end(A) from the tie rod(B).
2. After mounting the tie rod end(A) in a vise, remove the dust cover(B) from the ball joint.
3. Remove the bellows band(A).
4. Remove the bellows clip(A).

Page 23 of 43
5. Pull the bellows out toward the tie rod.
Check for rust on the rack when the bellows are

replaced.
6. Remove the feed tube from the rack housing.
7. While moving the rack slowly, drain the fluid from the rack housing.
8. Unstake the tab washer(C) which fixes the tie rod(A) and rack(B) with a chisel.
9. Remove the tie rod(B) from the rack(A).
Remove the tie rod(B) from the rack(A), taking care not to twist the
rack.
10. Remove the yoke plug locking nut(A), and then remove the yoke plug.
Page 24 of 43
11. Remove the lock nut(A), yoke plug(B), rack support spring(C), rack support yoke(D) and bushing(E) from the
gear box.
12. Remove the valve body housing(B) by loosening the two bolts(A).
13. Remove the rack bushing and the rack from the rack housing.
14. Remove the O-ring(A) from the rack bushing(B).
15. Remove the oil seal(B) from the rack bushing(A).

Page 25 of 43
16. Remove the pinion vlave assembly(C) from the valve body housing(B) with a soft hammer(A).
17. Using the special tool, remove the oil seal and ball bearing from the valve body housing.
18. Remove the oil seal and O-ring from the rack housing.
Be careful not to damage the pinion valve cylinder inside of the rack
housing.
19. Using the special tool(06573-21200, 09555-21000), remove the oil seal(B) from the rack housing(A).
Be careful not to damage the rack cylinder inside of the rack housing.
INSPECTION AND ADJUSTMENT BEFORE DISASSEMBLY
When mounting the gear box in a vise, ensure the gear box is mounted as shown in the follwing illustration to avoid
damage.
Page 26 of 43
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 :
Total pinion preload :
0.6 ~ 1.3 Nm (0.06 ~ 0.13 kgf·m, 0.4 ~ 1 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(A) swing resistance with a spring scale(B).
Standard value :
Total rod swing resistance :
8 ~ 22 N (1.9~4.6 lb) [2 ~ 5 Nm (0.2 ~ 0.5 kgf·m, 17 ~ 43 lb-in)]
3. If the measured value exceeds the standard value, replace the tie rod as sembly.
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 4.3 N (0.9 lb) [100 Ncm (8.7 lb-in)], replace the tie
rod.
BELLOWS INSPECTION
1. Inspect the bellows for damage or deterioration.
Page 27 of 43
2. Make sure the bellows are secured in the correct position.
3. If the bellows are defective, replace them with new ones.
REASSEMBLY
1. Apply the specified fluid to the entire surface of the rack oil seal.
Recommended fluid : PSF-3
2. Install the oil seal(A) 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(B) in the rack bushing(A).
5. Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.
Page 28 of 43
6. Apply the specified grease to the rack teeth.
Recommended grease :
Multipurpose grease SAE J310, NLGI No.2
Do not plug the vent hole(A) in the rack with grease.
7. Insert the rack into the rack housing and install the rack bushing and rack stopper.
8. Install the oil seal and the ball bearing in the valve body.
9. After appling the specified fluid and grease to the pinion valve assembly(A), 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(B)
and O-ring in the gear box(A).
Page 29 of 43
11. Install the tab washer and the tie rod and stake the tab washer(A) end at two points over the tie rod.
1. Align the tab washer pawls with the rack grooves.

2. Always use a new tab washer.
12. Install the bushing(A), rack support yoke(B), rack support spring(C), lock nut(E) and yoke plug(D) in the order
shown in the illustration. Apply semi-drying sealantto to the threaded section of the yoke plu g before
installation.
13. With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to
15 Nm (1.5 kgf·m, 11 lbf·ft). Loosen the yoke plug approximately from 30° to60° and tighten the locking nut to
the specified torque.
Tightening torque :
50 ~ 70 Nm (5 ~ 7 kgf·m, 37 ~ 52 lb-ft)
14. Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.
Page 30 of 43
15. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
: 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.
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 grooveof the tie rod end.
Recommended greas :
A : POLY LUB GLY 801K or equivalent
B : SHOWA SUNLIGHT MB2 or equivalent
Dust cover inner side and lip : THREE BOND
Page 31 of 43
19. Install the tie rods so that the length of the left and right tie rods equals the standard value.
Standard value :
Tie rod free length : 112.2 mm
20. Check for total pinion preload.

0.6 ~ 1.3 Nm (0.06 ~ 0.13 kgf·m, 5.2 ~ 11.3 lb-ft)
INSPECTION AND ADJUSTMENT BEFORE DISASSEMBLY
When mounting the gear box in a vise, ensure the gear box is mounted as shown in the follwing illustration to avoid
damage.
TOTAL PINION PRELOAD

Page 32 of 43
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 (0.06 ~ 0.13 kgf·m, 0.4 ~ 1 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(A) swing resistance with a spring scale(B).
Standard value :
Total rod swing resistance :
8 ~ 22 N (1.9~4.6 lb) [2 ~ 5 Nm (0.2 ~ 0.5 kgf·m, 17 ~ 43 lb-in)]
3. If the measured value exceeds the standard value, replace the tie rod as sembly.
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 4.3 N (0.9 lb) [100 Ncm (8.7 lb-in)], 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.
Page 33 of 43
3. If the bellows are defective, replace them with new ones.
Steering System > Hydraulic Power Steering System > Power Steering Hoses > Components and
Components Location
COMPONENTS
Steering System > Hydraulic Power Steering System > Power Steering Hoses > Repair procedures
REMOVAL
Page 34 of 43
1. Drain the power steering oil.
2. Remove both the pressure tube fitting(A) and the return hose clamp(B) from the gearbox, after lifting the vehicle.
3. Remove the pressure tube connecting bolt(A) and the pressure hose mounting bolt(B), then remove the return
hose clamp(C).
4. Remove the pressure tube mounting bolt(A) and the return tube mounting bolt(B).
Tightening torque :
A: 90 ~ 100 Nm (9 ~ 10 kgf·m, 65 ~ 72 lb-ft)
B: 7 ~ 11 Nm (0.7 ~ 1.1 kgf·m, 5 ~ 7.9 lb-ft)
Page 35 of 43
5. Remove the pressure tube bolt(A) and clamp(B), after lowering the vehicle.
6. Remove the pressure tube(A) and the return tube(B).
INSTALLATION
2. Add power steering fluid.
• While installing the tube and hose assembly, be sure to align white marks(A) on each fitting.
• Install the pressure hose and tube so that they are not twisted and they do not come in contact with any
other parts.
• After installation, air bleed the system.
Page 36 of 43
Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Components and
Components Location
COMPONENTS
Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Repair procedures
REMOVAL
Page 37 of 43
1. Loosen the bolt fixing the wiring bracket, and then move the wiring sideward.
2. Remove the pressure hose(A) from the oil pump(B), and then disconnect the suction hose(C) from the suction
connector and drain the fluid into a container. (see page ST-11)
3. Loosen the tension adjusting bolt(A) on the power steering "V" belt.
4. Remove the "V" belt(A) from the power steering oil pump pulley.
Page 38 of 43
5. Loosen the power steering oil pump mounting bolt and the tension adjusting bolt, and then remove the steering oil
pump assembly(A).
6. Remove the power steering oil pump mounting bracket(A).
INSTALLATION
1. Install the oil pump(A) to the oil pump bracket.
Page 39 of 43
2. Hang the "V" belt on the oil pump and connect the suction hose(A) and the pressure hose(B).
Install the hose being careful so that it does not twist and come in contact with other
components.
3. Insert a bar(C) or similar tod between the bracket(A) and the oil pump(B) to produce tension and confirm that
belt deflection is within the standard value.
4. Add power steering fluid. (see page to ST-10)

5. Air bleed the system. (see page to ST-10)
6. Check the oil pump pressure. (see page to ST-11)
DISASSEMBLY
1. Remove two bolts(A) from the oil pump body, and then remove the suction pipe(B) and O-ring(C).
2. Loosen the four bolts and remove the oil pump cover assemb ly.
3. Remove the cam ring.
4. Remove the rotor and vanes.
Page 40 of 43
5. Remove the oil pump side plate.
6. Remove the inner O-ring(A) and outer O-ring(B).
7. Remove the snap ring and take out the pulley and the drive shaft assembly(A).
8. Remove the oil seal(A) from the oil pump body.

Page 41 of 43
9. Remove the connector from the oil pump body, and take out the flow control valve and the flow control spring.
INSPECTION
1. Check the free length of the flow control spring.
Free length of the flow control spring : 36.5mm
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. Install the flow control spring, the flow control valve and the connector into the pump body.
Page 42 of 43
2. Install the oil seal in the pump body by using the special tool(09222-32100).
3. Install the pump pulley(A).
4. Assengle the inner O-ring and the outer O-ring and install the site plate(A).
5. Install the cam ring attending to the groove and the direction of the front housing.
6. Install the rotor.

Page 43 of 43
7. Install vanes(A) to the rotor(B).
Be sure to place vanes with a round side

out.
8. Install the O-ring and the oil pump cover assembly.

9. Install the suction pipe(A) and O-ring.
Page 1 of 138
SPORTAGE(KM) > 2008 > G 2.7 DOHC > Suspension System
Suspension System > General Information > Specifications

SPECIFICATIONS
Model Macpherson strut type
Shock absorber
Type Gas type
Stroke mm(in) 160.7(6.33)
Identification color Orange
Coil spring GSL2.0 M/T, A/T GSL2.7 A/T
[2WD]
Inside dia. mm(in) Ø137.8(5.42) Ø137.7(5.42)
Front suspension Outside dia. mm(in) Ø166.2±1.5(6.54±0.059) Ø166.3±1.5(6.54±0.059)
Load rate Kgf/mm 2.8±0.14 2.8±0.14
Free height mm(in) 346.8(13.65) 348.5(13.72)
Identification color BLUE RED
[4WD]
Inside dia. mm(in) Ø137.5(5.42) Ø137.6(5.41)
Outside dia. mm(in) Ø166.3±1.5(6.54±0.059) Ø166.4±1.5(6.55±0.059)
Load rate Kgf/mm 2.9±0.15 2.9±0.15
Free height 34.16(13.44) 348.5(13.72)
mm(in)Identification color WHITE-WHITE RED-RED
Model Dual link
Shock absorber
Type Gas type
Stroke mm(in) 191.0(7.52)
Identification color BLUE
Coil spring 2WD 4WD
Rear suspension
Inside dia. mm(in) Ø100 (3.94) Ø100 (3.94)
Outside dia. mm(in) Ø170 (6.69) Ø170 (6.69)
Load rate Kgf/mm 2.3±12 2.6±0.13
Measurement range 155~313(6.1~12.32) 158~310(6.22~12.2)
of rate mm(in)
Free height mm(in) 356.3(14.38) 360.1(14.17)
Identification color BLUE-BLIE GREEN
Wheel alignment Front Rear
Toe-in(Total) -2mm~2mm 4.6+3,-1 mm (=0.19°)
Camber 0°±30' -0°55'±30'
Caster 3°36'±30' -
King pin 12°46'±30' -
Wheel & Tire Wheel AL wheel

Size 6.5JX16
Run out mm(in) Radial : 0.(0.01), Lateral : 0.3(0.1)
Page 2 of 138
Tire
Size
P215/65R16, P235/60R16
Inflation pressure kg/cm²
2.1±0.07(30+1.0)
(psi)
TIGHTENING TORQUE
Items Nm Kgf·m Ibf·ft
Front suspension
Wheel nut 90~110 9~11 66.4~81.2
Strut upper mounting nut 45~60 4.5~6 33.2~44.3
Strut lower mounting nut 140~160 14~16 103.3~118.0
Strut mounting self-locking nut 60~70 6~7 44.3~51.6
Speed sensor cable mounting bolt 7~11 0.7~1.1 5.2~8.1
Lower arm mounting nut 80~90 8~9 59.0~66.4
Lower arm bush(A) mounting bolt 100~120 10~12 73.8~88.5
Lower arm bush(G) mounting bolt 140~160 14~16 103.3~118.0
Lower arm ball joint mounting bolt 100~120 10~12 73.8~88.5
Stabilizer bracket mounting bolt 45~55 4.5~5.5 33.2~40.6
Stabilizer link mounting nut 100~120 10~12 73.8~88.5
Tie rod end ball joint mounting nut 45~60 4.5~6 33.2~44.3
Tie rod toe adjustment nut 50~60 5~6 36.9~44.3
Stabilizer bar link mounting nut 100~120 10~12 73.8~88.5
Rear suspension
Wheel nut 90~110 9~11 66.4~81.2
Strut upper mounting nut 30~40 3~4 22.1~29.5
Strut lower mounting nut 140~160 14~16 103.3~118.0
Strut mounting self-locking nut 52~70 5.2~7.0 37.6~50
Speed sensor cable mounting bolt 7~11 0.7~1.1 5.2~8.1
Stabilizer bracket mounting bolt 45~55 4.5~5.5 33.2~40.6
Stabilizer link mounting nut 100~120 10~12 73.8~88.5
Tie rod toe adjustment nut 50~60 5~6 36.9~44.3
Suspension arm mounting 160~180 16~18 118.0~132.8
bolt[2WD] 140~160 14~16 103.3~118.0
Suspension arm mounting 100~120 10~12 73.8~88.5
bolt[4WD] 100~120 10~12 73.8~88.5
Cross member mounting bolt 100~120 10~12 73.8~88.5
Trailing arm bracket mounting bolt 90~120 9~12 59.0~88.5
Trailing arm to carrier mounting bolt
Differential mounting bolt
Replace the self-locking nuts with new ones after removal.

LUBRICANTS
Item Quantity
In insulator of
As required
strut
Page 3 of 138
Suspension System > General Information > Special Service Tools
SPECIAL TOOLS
Tool(Number and Name) Illusstration Use
09261-2100 Removal & installation of lower arm
Mount bushing remover and bushing(G)
installer
09214-32000 Removal & installation of lower arm

Mount bushing remover and bushing(G)
installer
09529-21000 Removal & installation of trailing arm

Trailing arm bushing remover bushing
installer
09546-26000 Compression of the coil spring

Strut spring compressor
Suspension System > General Information > Troubleshooting

TROUBLESHOOTING
Trouble sysmptom Probable cause See page
Hard steering Improper front wheel alignment SS - 39
Excessive turning resistance of lower arm ball joint -
Flat tire -
No power assist -
Poor return of steering wheel
Improper front wheel alignment SS - 39
to center
Poor ride quality Improper front wheel alignment SS - 39
Damaged shock absorber SS - 7,22
Varied or dameged stabilizer SS - 17,36
Varied or dameged coil spring SS - 9
Worn lower arm bushing SS - 14
Abnormal tire wear Improper front wheel alignment SS - 39
Worn of shock absorber SS - 7,22
Page 4 of 138
Wandering Improper front wheel alignment SS - 39
Poor turning resistance of lower arm ball joint -
Loose or worn lower arm bushing SS - 14
Vehicle pulls to one side Improper front wheel alignment SS - 39
Varied or dameged coil spring SS - 9,25
Bent lower arm SS - 13
Improper tire inflation pressure -
Steering wheel shimmy Improper front wheel alignment SS - 39
Varied or dameged stabilizer SS - 17
Worn lower arm bushing SS - 14
Worn of shock absorber SS - 7
Varied or dameged coil spring SS - 9
Improper front wheel alignment -
Bottoming Broken or worn spring SS - 9,25
Malfunction of shock absorber SS - 7,22
WHEEL AND TIRE DIAGNOSIS

Radid wear at the center Rapid wear at both shoulders Wear at one shoulder
• Underinflated tires • Toe adjustment out of

• Center-tread down to fabric due to excessive
• Worn suspension specification
over inflated tires
components • Camber out of specification
• Lack of rotation
• Excessive cornering • Damaged strut
• Excessive toe on drive wheels
speeds • Damaged lower arm
• Heavy acceleration on drive
• Lack of rotation
WHEEL AND TIRE DIAGNOSIS

Partial wear Feathered edge Wear pattern
• Cansed by irreqular burrs on brak • Toe adjustment out of • Excessive toe on non-drive
drums. specification wheels
• Damaged or worn tie rods • Lack of rotation
• Damaged knuckle
Page 5 of 138
Suspension System > Front Suspension System > Front Strut Assembly > Components and
Components Location
COMPONENTS
Suspension System > Front Suspension System > Front Strut Assembly > Repair procedures
DISASSEMBLY
Page 6 of 138
1. Remove the dust cover(A) with a flat-tipped (-) screw driver.
2. Open the dust cover and wipe off grease in the insulator.
3. Using the special tool (09546-26000), compress the coil spring(A) until there is only a little tension of the spring
on the strut.
4. Remove the self-locking nut(C) from the strut assembly(B).

5. Remove the insulator, spring seat, coil spring and dust cover from the strut assembly.
INSPECTION
1. Check the strut insulator bearing for wear or damage.
2. Check rubber parts for damage or deterioration.
Page 7 of 138
3. Compress and extend the piston rod(A) and check that there is no abnormal resistance or unusual sound during
operation.
REASSEMBLY
1. Install the spring lower pad(D) so that the protrusions(A) fit in the holes(C) in the spring lower seat(B).
2. Compress coil spring using special tool (09546-26000).

Install compressed coil spring into shock absorber.
1) Indicated two identification color marks on the coil spring one follows model option (see page SS-2)
the other follows load classification according to the below.
Pay attention to distiuguish between the two marks and then install them.
2) Install the coil spring wth the idenftification mark directed toward the knuckle.
3. After fully extending the piston rod, install the spring upper seat and insulator assembly.
4. After seating the upper and lower ends of the coil spring(A) in the upper and lower spring seat grooves(B)
correctly, tighten new self-locking nut temporarily.
5. Remove the special tool(09546-26000).

Page 8 of 138
6. Tighten the self-locking nut to the specified torque.
Tightening torque :
60~70 Nm(6~7 kgf·m, 44.3~51.6 lb-ft)
7. Apply grease to the strut upper bearing and install the insulator cap.
When applying the grease, be careful so that it isn't smeared on the insulator
rubber.
DISPOSAL
1. Fully extend the piston rod.
2. Drill a hole on the A section to remove gas from the cylinder.
The gas coming out is harmless, but be careful of chips that may fly when
drilling.
REMOVAL
Bej careful not to damage the hub bolts(C) then remove the front wheel and
tire(A).
Page 9 of 138
3. Remove the brake hose bracket(B) and speed sensor cable mounting bolt(C) from the strut assembly(A).
4. Remove the speed sensor cable mounting bolt(B) and speed sensor(A).
5. Remove the nut(B) from the stabilizer bar link(A).
6. Remove the strut upper mounting nuts(A).

Page 10 of 138
7. Remove the strut lower mounting bolts(A) and then remove the strut assembly(B).
INSTALLATION
1. Install the strut assembly(B) and then install the strut lower mounting bolts(A).
Tightening torque :
140~160 Nm (14~16 Kgf·m, 103.3~118.0 lb-ft)
2. Install the strut upper mounting nuts(A).
Tightening torque :
45~60 Nm (4.5~6 Kgf·m, 33.2~44.3 lb-ft)
Page 11 of 138
3. Install the nut(B) on the stabilizer bar link(A).
Tightening torque :
100~120 Nm (10~12 Kgf·m, 73.8~88.5 lb-ft)
4. Install the speed sensor cable mounting bolt(B) and speed sensor(A).
Tightening torque :
7~11 Nm (7~1.1 Kgf·m, 5.2~8.1 lb-ft)
5. Install the brake hose bracket(B) and speed sensor cable mounting bolt(C) on the strut assembly(A).
Tightening torque :
7~11 Nm (7~11 Kgf·m, 5.2~8.1 lb-ft)
Page 12 of 138
Tightening torque :
90~110 Nm (9~11 Kg·m, 66.4~81.2 lb-ft)
Suspension System > Front Suspension System > Front Lower Arm > Components and Components
Location
COMPONENTS
Page 13 of 138
Suspension System > Front Suspension System > Front Lower Arm > Repair procedures
REMOVAL
Page 14 of 138
tire(A).
4. Remove the lower arm mounting bolts(A).
REPLACEMENT
Page 15 of 138
1. Using the special tools(09214-32000 & 09216-211000), remove the bushing from the lower arm.
2. Apply soap solution to the following parts.

A. Outer surface of the bushing.
B. Inner surface of the lower bushing mounting part.
3. Using the special tools(09214-32000 & 09216-21100), install the busing on the lower arm.
Insert bushing in the direction as shown in the illustration.
Separation force is over 8000 N (800 Kgf, 1763 lbf)
INSTALLATION
Page 16 of 138
1. Install the lower arm mounting bolts(A).
Tightening torque :
A bushing :
100~120 Nm (10~12 Kgf·m, 73.8~88.5 lb-ft)
G bushing :
140~160 Nm (14~16 Kgf·m, 103.3~118.0 lb-ft)
2. Install the lower arm ball joint mounting bolts(A).
Tightening torque :
100~120 Nm (10~12 Kgf·m, 73.8~88.5 lb-ft)
Tightening torque :
90~110 Nm (9~11 Kgf·m, 66.4~81.2 lb-ft)
Page 17 of 138
Suspension System > Front Suspension System > Front Stabilizer Bar > Components and Components
Location
COMPONENTS
Page 18 of 138
Suspension System > Front Suspension System > Front Stabilizer Bar > Repair procedures
REMOVAL
3. Remove the stabilizer bar link(B) from the strut assmembly(A).
4. Remove the two bolts(A) for lower arm ball joint.
5. Remove the propeller shaft(A) and the front muffler assembly(B).

Page 19 of 138
6. Drain oil from the transfer case(A). then remove the rear flange assmbly(B).
7. Drain power steering oil.

8. Remove the connecting bolt(A) for pressure tubes.
9. Remove two engine mounting bolts(B,C) and six subframe mounting bolts in order to remove the subframe(A).
10. Remove both two stabilizer brackets and two bushes respcetively.
Page 20 of 138
11. Remove the stabilizer bar.
Be careful not to do damage to pressure

tubes.
INSTALLATION
1. Install the bushing(B) on the stabilizer bar(A).
Bring clamp(C) of stabilizer bar(A) into contact with

bushing(B).
2. Install the bracket on the bushing(B).

3. After tightening the bolts of the bushing bracket temporarily, install the bushing bracket on the opposite side.
Tightening torque :
45~55 Nm (4.5~5.5 Kgf·m, 33.2~40.6 lb-ft)
4. Install the six subframe mounting bolts, then the two engine mounting bolts(B,C).
Tightening torque :
50~65 Nm (5~6.5 Kgf·m, 36.9~48.0 lb-ft)
Page 21 of 138
5. Install the connecting blot(A) for pressure tubes.
Be sure to align the white marks(A) on the tube and the

hose.
6. Install the rear flange assembly(B) to the transfer case(A).
7. Install the propeller shaft(A), then the front mufler assembly(B).

Page 22 of 138
8. Install the two bolts(A) for the lower arm ball joint.
Tightening torque :
100~120 Nm (10~12 Kgf·m, 73.8~88.5 lb-ft)
9. Install the nut(B) on the stabilizer bar link(A).
Tightening torque :
100~120 Nm (10~12 Kgf·m, 73.8~88.5 lb-ft)
10. Install the front wheel and tire(A) on thr front hub(B).
Tightening torque :
90~110 Nm (9~11 Kgf·m, 66.4~81.2 lb-ft)
Page 23 of 138
INSPECTION
1. Check the stabilizer bar for deterioration and damage.
2. Check all bolts for damage and deformation.
3. Check the stabilizer link dust cover for cracks or damage.
Suspension System > Rear Suspension System > Rear Strut Assembly > Components and Components
Location
COMPONENT LOCATION
Page 24 of 138
Page 25 of 138
COMPONENTS
Page 26 of 138
Suspension System > Rear Suspension System > Rear Strut Assembly > Repair procedures
REMOVAL
Page 27 of 138
tire(A).
3. Remove the speed sensor cable monting bolt(A).
Drum brake type :

Remove the speed sensor cable mounting bolts(2EA) and the brake hose
bracket.
Disc brake type :
Remove the speed sensor cable mounting bolt(1EA)
4. Remove the stabilizer bar link nut(B).

5. Remove the strut upper mounting nut(A).
Page 28 of 138
6. Remove the strut lower mounting bolts(A) and then remove the strut assembly(B).
INSTALLATION
1. Install the strut assembly(B) and then install the strut lower mounting bolts(A).
Tightening torque :
140~160 Nm (14~16 Kgf·m, 103.3~118.0 lb-ft)
2. Install the strut upper mounting nuts(A).
Tightening torque :
30~40 Nm (3~4 Kgf·m, 22.1~29.5 lb-ft)
Page 29 of 138
3. Install stabilizer bar link nut(B).
Tightening torque :
100~120 Nm (10~12 Kgf·m, 73.8~88.5 lb-ft)
4. Install the speed sensor cable mounting bolt(A).
Tightening torque :
7~11 Nm (0.7~1.1 Kgf·m, 5.2~8.1 lb-ft)
Drum brake type :

Install the speed sensor cable mounting bolts(2EA) and the brake hose bracket.
Disc brake tyep :
Install the speed sensor cable mounting bolt(1EA)
Tightening torque :
90~110 Nm (9~11 Kgf·m, 66.4~81.2 lb-ft)
DISASSEMBLY
Page 30 of 138
1. Using the special tool(09545-26000), compress the coil spring(A).
2. Remove the self-locking nut(C) from the strut(B).

3. Remove the pipe, insulator, spring seat, coil spring and dust cover from the strut(B).
INSPECTION
1. Check the insulator for wear or damage.
2. Check rubber parts for damage or deterioration.
3. Compress and extend the piston rod(A) and check that there is no abnormal resistance or unusual sound during
operating.
REASSEMBLY
1. Install the spring lower pad(D) so that the protrusions(A) fit in the holes(C) in the spring lower seat(B).
Page 31 of 138
2. Compress coil spring using special tool(09546-26000).
Install compressed coil spring into shock absorber.
1) There are two color marks on the coil spring. One corresponds to model option (see page SS-2), and
the other corresponds to load clssification. Ensure that the correct parts are being installed.
2) Install the coil spring with the identification mark directed toward the knuckle.
3. After fully extending the piston rod, install the spring upper seat and insulator assembly.
4. After seating the upper and lower ends of the coil spring(A) in the upper and lower spring seat grooves(B)
correctly, tighten new self-locking nut temporarily.
5. Remove the special tool(09546-26000).

6. Tighten the self-locking nut to the specified torque.
Tightening torque :
52~70 Nm (5.2~7.0 Kgf·m, 37.6~50 lb-ft)
DISPOSAL
1. Fully extend the piston rod.
2. Drill a hole on the A section to remove gas from the cylinder.
The gas coming out is harmless, but be careful of chips that may fly when
drilling.
Suspension System > Rear Suspension System > Rear Suspension Arm > Components and
Components Location
Page 32 of 138
COMPONENTS
Page 33 of 138
Suspension System > Rear Suspension System > Rear Suspension Arm > Repair procedures
REPLACEMENT
[2WD]
Page 34 of 138
1. Remove the trailing arm mounting bolt(A) and suspension arm mounting bolt(B).
2. Remove the opposite side trailing arm mounting bolt and suspension arm mounting bolt.
3. After supporting the rear cross member assembly(B) with the jack(A), remove the cross member mounting bolts
and nuts(C).
4. Remove the suspension arm bracket mounting bolts(A).
5. Remove the suspension arm(B).

Page 35 of 138
6. Install the suspension arm bracket mounting bolts(A).
Tightening torque :
160~180 Nm (16~18 Kgf·m, 118.0~132.8 lb-ft)
7. Make sure that the arrow mark(B) on the rear cross member(A) should place the front face of the vehicle.
8. Rear suspension arm(C)-to-rear carrier bolts should be temporarily tightened, and then fully tightened with the
vehicle on the ground in unloaded condition.
Tightening torque :
160~180 Nm (16~18 Kgf·m, 118.0~132.8 lb-ft)
[4WD]
1. Remove the muffler(A).
Page 36 of 138
2. Remove the suspension arm mounting bolts(A).
3. Remove the opposite side suspension mounting bolts.

4. Remove the coupling control connector(A).
5. After supporting the rear cross member assembly(B) with a jack(A), remove the cross member mounting bolts
and nuts(C).
6. Remove the propeller shaft. (see page DS-propeller shaft)

7. Remove the rear differential(A) from the cross member(B).
Page 37 of 138
8. Remove the suspension arm bracket mounting bolts(A).
9. Remove the suspension arm(B).

10. Install the suspension arm bracket mounting bolts(A).
Tightening torque :
140~160 Nm (14~16 Kgf·m, 103.3~118.0 lb-ft)
11. Install the rear differential(A) on the cross member(B).
Tightening torque :
90~120 Nm (9~12 Kgf·m, 59.0~88.5 lb-ft)
12. Install the propeller shaft. (see page DS-propeller shaft)

Page 38 of 138
13. After supporting the rear cross member assembly(B) with the jack(A), install the cross member mounting bolts
and nuts(C).
Tightening torque :
100~120 Nm (10~12 Kgf·m, 73.8~88.5 lb-ft)
14. Install the coupling control connector(A).
15. Rear suspension arm-to-rear carrier bolts(A) should be temporarily tightened, and then fully tightened with the
vehicle on the ground in unloaded condition.
Tightening torque :
140~160 Nm (14~16 Kgf·m, 103.3~118.0 lb-ft)
Suspension System > Rear Suspension System > Trailing Arm > Components and Components
Location
COMPONENTS
Page 39 of 138
Suspension System > Rear Suspension System > Trailing Arm > Repair procedures
REMOVAL
Page 40 of 138
1. Remove the trailing arm mounting bolts(A).
2. Remove the bracket mounting bolt, nut of the vehicle side.

3. Remove the trailing arm(B).
REPLACEMENT
TRAILING ARM BUSHING
1. Install the special tools(09529-21000 & 09216-21100) on the trailing arm(A).
2. Remove the bushing from the trailing arm(A).

3. Using the special tools(09529-21000 & 09216-21100), press-fit the rear trailing arm bushing.
Separation force is over 3000 N (300 Kgf, 661 lbf)
Insert bush as to arrow direct toward trailing arm length.
INSTALLATION
1) Install the trailing arm mounting bolt(A).
Tightening torque :
100~120 Nm (10~12 Kgf·m, 73.8~88.5 lb-ft)
Page 41 of 138
2) Install the trailing arm bracket mounting bolt, nut.
Tightening torque :
100~120 Nm (10~12 Kgf·m, 73.8~88.5 lb-ft)
The trailing arm mounting bolts, then fully tightened with the vehicle on the ground in unloaded condition.
Suspension System > Rear Suspension System > Rear Stabilizer Bar > Components and Components
Location
COMPONENTS
Page 42 of 138
Suspension System > Rear Suspension System > Rear Stabilizer Bar > Repair procedures
REMOVAL
Page 43 of 138
tire(A).
3. Remove the stabilizer bar link mounting nut(A).
4. Remove the stabilizer bar mounting bolts(A) and then remove the stabilizer bracket(B).
5. Employ the same manner described above step 3 and 4 to the other side.
6. Remove the stabilizer bar.
INSTALLATION
Page 44 of 138
1. Install the bushing(B) on the stabilizer bar(A).
Bring clamp(C) of stabilizer bar(A) into contact with

bushing(B).
2. Install the stabilizer bracket(B) and then install the stabilizer bar mounting bolts(A).
3. One side bracket should be temporarily tightened, and then install the bushing on the opposite side.
Tightening torque :
45~55 Nm (4.5~5.5 Kgf·m, 32.5~39.7 lb-ft)
4. Install the stabilizer bar link mounting nut(A).
Tightening torque :
100~120 Nm (10~12 Kgf·m, 73.8~88.5 lb-ft)
5. Repeat step 3 and 4 for the other side.

Page 45 of 138
Tightening torque :
90~110 Nm (9~11 Kgf·m, 66.4~81.2 lb-ft)
INSPECTION
1. If there is a crack and damage in the dust cover, replace the stabilizer bar link.
2. Mount the self-locking nut on the ball joint, and then measure the ball joint rotating torque.
Tightening torque :
0.7~2 Nm (0.07~0.2 Kgf·m, 05~1.4 lb-ft)
3. If the rotating torque is above the upper limit of the standard value, replace the stabilizer link.
4. 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 > Tires/Wheels > Alignment > Description and Operation
DESCRIPTION
WHEEL ALIGNMENT
TOE
Page 46 of 138
ITEM Description
Positive (+) toe
A-B<0
(toe in)
Negative (-) toe
A-B>0
(toe out)
Standard value
Toe-in
Total : -2mm~2mm
• Toe-in adjustment should be made by turning the right and left tie rods at 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.
Tie rod end lock nuts(A) tightening torque :

50~60 Nm (5~6 Kgf·m, 36.9~44.3 lb-ft)
CAMBER
Page 47 of 138
ITEM Description
Positive
A
camber angle
B True vertical
Strut
C
centerline
When the wheel tilts out at the top, then the camber is positive (+).
When the wheel tilts in at the top, then the camber is negative (-).
The stering knuckle which is installed with the strut assembly is pre-set to the specified camber at the factory and
doesn't need to be adjusted.
If the camber in not within specification, inspect for damaged components and replace as needed.
Camber : 0°±30'
CASTER
Caster : 3°36'±30'
• The worn loose or damaged parts of the front suspension assembly must be replaced prior to measuring front
wheel alignment.
• Camber and caster are pre-set to the specified value at the factory and don't need to be adjusted.
• If the camber and caster are not within specifications, replace bent or damaged parts.
• The difference of left and right wheels about the camber and the caster must be within the range of 0°±0.5°.
Page 48 of 138
DESCRIPTION
TOE-IN
Standard value
Toe-in
Total : 4.6+3,-1mm (=0.19°)
Left tie rod : Clockwise direction → toe-in

Right tie rod : Clockwise direction → toe-out
• Each of toe must be 2.8±1mm

• After adjusting the tie rod(C), tighten both nuts(B) to the specified torque.
Specified torque
50~60 Nm (5~6 kgf·m, 37~43 lb-ft)
CAMBER
ITEM Description
Positive camber
A
angle
B True vertical
C Pivot centerline
Page 49 of 138
Camber :-0°55'±30'
Camber is pre-set at the factory and doesn't need to be adjusted. If the camber is not within the standard value,
replace the bent or damaged parts.
Suspension System > Tires/Wheels > Wheel Runout > Description and Operation
DESCRIPTION
1. Jack up the vehicle and support it with jack stands.
2. Measure the wheel runout with a dial indicator as illustrated.
3. Replace the wheel if the wheel runout exceeds the limit.
Limit Radial Axial
Runout mm(in) 0.3(0.012) 0.3(0.012)
Suspension System > Tires/Wheels > Wheel Nut Tightening > Description and Operation
DESCRIPTION
1. Tightening torque.
Tightening torque :
90~110 Nm (9~11 Kgf·m, 66.4~81.2 lb-ft)
When using an impact gun, final tightening torque should be checked using a torque wrench.
Page 50 of 138
2. Tightening order.
Check the torque again after tightening the wheel nuts diagonally.
Suspension System > Tires/Wheels > Tire Wear-Rotation > Description and Operation
DESCRIPTION
1. Measure the tread depth of the tires.
Tread depth of tire [Limit] : 1.6 mm (0.06 in)
2. If the remaining tread(A) 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(B) will
appear.
DISCRIPTION
LEAD/PULL CORRECTION CHART
Page 51 of 138
ROTATION
Page 52 of 138
Suspension System > Tire Pressure Monitoring System > Components and Components Location
components
Page 53 of 138
Suspension System > Tire Pressure Monitoring System > Schematic Diagrams
SCHEMATIC DIAGRAM
Page 54 of 138
circuit diagram
Page 55 of 138
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
Page 56 of 138
PIN-OUT PIN-OUT
NO NO
ASSIGNMENT ASSIGNMENT
1 Battery 11 -
2 Ground(TPMS receiver) 12 -
3 - 13 -
4 - 14 -
5 - 15 -
6 - 16 TREAD lamp
7 - 17 Diagnostic lamp (TPMS)
8 - 18 Speed signal
9 K-LINE 19 Ignition 1(+)
10 - 20 -
Suspension System > Tire Pressure Monitoring System > Description and Operation
DESCRIPTION
WARNING LAMPS
TREAD Lamp
- Tire Under Inflation / Leak Warning.
1. Turn on condition
A. When tire pressure is below allowed threshold
B. When rapid leak is detected by the sensor.
C. Indicates that tire needs to be re-inflated to placard pressure / repaired.
2. Turn off condition
A. Under-inflation ; When tire pressure is above (warning threshold + hysteresis).
B. Rapid Leak ; When tire pressure is above (leak warning threshold).
DTC Warning
Page 57 of 138
1. Turn on condition
A. When the system detects a fault that is external to the receiver/ sensor.
B. When the system detects a receiver fault.
C. When the system detects a sensor fault.
2. Turn off condition
A. If the fault is considered as 'critical', then the lamp is held on throughout the current Ignition cycle (even if the
DTC has been demoted). This is because it is important to bring the problem to the drivers attention. On the
following Ignition cycle, the demotion conditions will be re-checked. If the demotion conditions occur, the
lamp will be turned off. It will be held on until DTC demotion checking is completed.
B. 'Non critical' faults are those that can occur temporarily e.g. vehicle battery under voltage. The lamp is
therefore turned off when the DTC demotion condition occurs.
SYSTEM FAULT
1. General Function
A. The system monitors a number of inputs across time in order to determine that a fault exists.
B. Faults are prioritized according to which has the most likely cause.
C. Maximum fault store is equal to 15.
D. Certain faults are not covered through DTC. The main ones are:
1) Speed input. This is important since it is required for Auto-Learn & DTC. Requires diagnostic check
of speed while driving vehicle to diagnose.
2) Sensor thermal shutdown (over 257°F/125°C).
3) Control module Micro-controller lock up ; requires observation of lamps at Ignition ON to diagnose.
4) Ignition Line stuck ; requires observation of lamps at Ignition ON to diagnose.
Suspension System > Tire Pressure Monitoring System > TPMS Sensor > Description and Operation
DESCRIPTION
Page 58 of 138
1. MODE
(1) Configuration State
A. All sensors should be in the Low Line (Base) state.
B. In Low Line (Base) configuration, sensor transmissions occur every 3 minutes 20 seconds (nominal) and
pressure is measured every 20 seconds.
(2) Normal Fixed Base State
A. Sensor transmissions continue at the Low Line (Base) configuration defined rates until the state is either
changed by LF command or by the sensor detecting a condition that requires a temporary change to
another state.
B. The LF command to this state must contain the sensors ID.
(3) Storage Base State:
A. This state is a Low current consumption state.
B. Sensors are in this state when they first arrive at the dealership (either on the vehicle or as replacement
spares).
C. In this state, the sensor does not measure pressure / temperature / battery level.
D. The sensor will not transmit in this state unless requested to do so by the initiate command.
(4) Alert State:
A. The sensor automatically enters this state if the measured temperature exceeds 230 °F(110 °C) and over
temperature shutdown is likely.
B. In this state, pressure is measured every 4 seconds and RF data transmitted every 4 seconds.
C. The state lasts for 1 minute if it is pressure triggered.
D. After state is alse entered when a 3 psi change in pressure from the last RF transmission occurs.
Suspension System > Tire Pressure Monitoring System > TPMS Sensor > Repair procedures
REMOVAL
Tire Removal
1. Deflate tire & remove balance weights.
• The tire bead should be broken approx. 180° from the valve side of the wheel. The bead breaker
should not be set too deep.
• Avoid tire/tool contact with the valve on dismount.
• Dismount should end near the valve.
Page 59 of 138
Sensor Removal
Handle the sensor with care.

1. Remove the valve nut.
The valve nut should not be re-used.
2. Discard the valve assembly.
INSTALLATION
Sensor Fit
• Handle the sensor with care.

• Avoid lubricant contact if possible.
Page 60 of 138
1. Assemble valve to sensor and turn valve 3 times with the square part of the screw in the slot.
• The fit should not be tight i.e. it should still be possible to easily adjust valve angle.
• Ensure that the wheel to be fitted is designed for sensor mount. There should normally be a mark to
indicate this.
• Ensure that the valve hole and mating face of the wheel are clean.
2. Mount assembly to wheel.
Ensure sensor feet are against the wheel throughout the remainder of the assembly
process.
3. Tighten washer and nut by hand until the valve thread meets the nut built-in calibrated stop.
Ensure that the grommet remains in contact with the wheel.

Page 61 of 138
4. Using a torque wrench, tighten the nut to 2.95±0.37 lb-ft (4.0±0.5 Nm) It is normal to feel a break as the 1.7 lb-
ft (2.3Nm) calibrated stop in the nut snaps and the torque falls.
• Increase torque smoothly in order to achieve a clean break of the stop.

• Do not exceed allowed torque.
• Do not use electric or pneumatic tools.
Tire Fit
Only use wheels designed to accommodate the TPMS sensor.

1. Lubricate the tire bead not the rim. Excessive lubrication should not be applied.
2. Start tire mounting approx. 5.9 in(15 cm) from valve.
3. Move the mounting tool away from the valve.
Avoid tire / tool contact with the valve.

4. Finish with mounting tool near to valve.
5. Carry out inflation / pressure correction and then fit valve cap.
Sensor Initiating Procedure
The sensor's default state will be Storage Auto (High Line).

Page 62 of 138
1. Change the sensor mode to Normal Fixed Base(Low Line) with the 'TPMS exciter'.
2. Read the four sensor's ids starting with sensor 1 (1 normally front left, 2 front right, 3 rear left, 4 rear right).
Note that sensors which were already configured as Base (Low Line) will take longer to read.
Page 63 of 138
3. Connect 'TPMS exciter' to the diagnostic connector.
4. Register the four sensor's ids to the receiver.
5. Cycle Ignition, wait 4 minutes and check that Normal Receiver State is now indicated (see SS- ).
Suspension System > Tire Pressure Monitoring System > TPMS Receiver > Description and
Operation
DESCRIPTION
Page 64 of 138
1. Mode
(1) Virgin State
A. The receiver as a sole part is shipped in this state. Replacement parts should therefore arrive in this state.
B. In this state, there is no sensor monitoring and no DTC monitoring.
C. The state indicates that platform specific parameters must be written to the receiver and that sensors are
un-learned.
(2) Normal State

A. In order for tire inflation state and DTC monitoring to occur, the receiver must be in this state.
B. In this state, automatic sensor learning is enabled.
2. Overview
A. Receives RF data from sensor.
B. Uses sensor data to decide whether to turn on TREAD Lamp.
C. Uses sensor information, distance traveled, background noise levels, Auto-learn status, short circuit output
status, vehicle battery level, internal receiver states to determine if there is a system or a vehicle fault.
OPERATION
1. General Function
A. Auto-learn takes place only once per Ignition cycle.
B. On successful completion, 4 road wheel sensor ID's are latched into memory for monitoring.
C. Until Auto-learn completes, previously learned sensors are monitored for under inflation / leak warnings.
2. General Conditions to Learn New Sensors:
A. Receiver must determine that it is confident that sensor is not temporary:
1) Uses vehicle speed.
2) Uses confidence reduction of previously learned sensors.
B. Typical time at driving over 12.4 mph(20 kph) to learn a new sensor is up to 20 minutes.
Page 65 of 138
3. General Conditions to Un-Learn a sensor that is removed:
A. It takes less than 20 minutes at 12.4~18.6 mph(20~30kph).
B. Confidence reduction is dependent on vehicle speed greater than or equal to 12.4 mph(12 kph).
Suspension System > Tire Pressure Monitoring System > TPMS Receiver > Repair procedures
REPLACEMENT
When the receiver first arrives for replacement:

1) It will be in Virgin State.
2) It will not be configured for any specific platform.
3) It will not have any sensor ID's memorized.
It is important to make sure that the correct receiver is used to replace the faulty part i.e. it must be Low Line (PN
95800-2E500) and not High Line (PN 95800-26000) in order to have the correct inflation warning thresholds set.
1. Disconnect vehicle battery.
2. Remove faulty part and fit bracket assembly to new part.
3. Secure new part to vehicle and fit connector.

4. Re-connect battery and turn Ignition on.
5. Check that DTC flash rate matches Virgin State indication (see SS- ).
Page 66 of 138
6. Connect 'TPMS exciter' to the diagnostic connector.
7. Write vehicle name to receiver. receiver will now automatically update monitoring parameters.
8. Read sensor's ids with the 'TPMS exciter'.

(Refer to 'SENSOR INITIATING PROCEDURE')
Page 67 of 138
9. Register sensor's ids to receiver.
10. Register VIN number of the vehicle.(17 digits)

Page 68 of 138
11. Change receiver state from Virgin to Normal.
12. Disconnect diagnostic link.

13. Turn ignition off for approximately 10 seconds then turn it back on and check that Normal State is now
indicated (see SS- ).
Suspension System > Tire Pressure Monitoring System > Troubleshooting

TROUBLESHOOTING
- the lamp check should occur and then all lamps / LED's should turn off.
- If the lamp test does not occur:
• Check connectors and fuse/harnessing - open / short circuits.
• Check DTC's.
• If diagnostics cannot be entered, replace the receiver with a known good one (follow configuration & learning
procedure).
TREAD warnings
- Information to ascertain (TREAD Lamp):
• Was puncture repair fluid used (it should not be)?
- This can cause the sensor pressure port to block and incorrect warning to occur.
• What temperature were tires last inflated at?
At what temperature did warnings occur?
- Pressure change is approx. 1.5psi / 10°C increase.
• Have the tires been checked / inflated since the lamp first came on?
- If the TREAD Lamp is on:
Page 69 of 138
• Check for short circuits.
• Enter Diagnostics and read TREAD Warnings Local Identifier Data.
• Check to see if warning type is under inflation or leak.
• If the warning is for under inflation, then:
a. Re-inflate the wheel with the matching sensor ID to it's desired Placard pressure.
b. Check to make sure that the TREAD lamp turns off (this may take up to 4 minutes if the tire is not rapidly
re-inflated).
• If the warning is for a leak, then:
a. Fix any puncture and re-inflate the tire to the desired Placard pressure.
b. Wait up to 4 minutes and make sure that the TREAD lamp turns off and the lamp does not turn on again.
c. If lamp comes on again:
d. Re-check pressure for signs of a puncture and Re-Check TREAD Warnings Local Identifier Data.
- If the Placard pressure is OK and the TREAD lamp still does not turn off:
• Turn wheel a quarter turn and again wait 4 minutes (the sensor may be in an RF null).
• If the lamp still does not turn off:
check for loose receiver wiring and replace the receiver with a known good one if necessary (follow
configuration &amp;amp; learning procedure).
- If the problem still exists, replace sensor.
- Ensure that all tires are inflated to their correct Placard pressures.
- Clear TREAD warnings.
- Test drive the vehicle and ensure that the TREAD lamp does not come back on.
DTC's
- Information to ascertain (DTC Lamp):
• At what temperature did the DTC occur? Under certain conditions (approx.-40°C/F), a RF channel missing /
hardware failure DTC may occur. This is due to the battery behavior.
- DTC's should be retrieved by using Hi-Scan diagnostic tool.
- The fault should then be diagnosed and rectified.
- DTC's should then be cleared.
DTC Warning Type Trouble Description Diagnostic Lamp
C1121 Battery Level Sensor 1 Battery Low. Permanent during
detection.
C1122 Sensor 2 Battery Low.
C1126 Vehicle / TPMS receiver Battery Low.
C1127 Vehicle / TPMS receiver Battery High.
C1212 Speed input 1 Speed input 1 open / short circuit
Permanent during detction
C1240 Speed input 2 Speed input 2 open / short circuit
LF / RF External Permanent during
C1300 LF/RF Interference Failure.
Interference detection.
C1306 RF Internal Interference Internal vehicle RF source e.g. scanner. Permanent
C1312 Individual RF channel Sensor RF Failure. Permanent
C1313 failure. Sensor RF Failure.
C1314 Sensor RF Failure.
C1315 Sensor RF Failure.
Page 70 of 138
Sensor over Temperature Sensor 1 / Front Left Sensor over Permanent
C1322
230°F(110°C).
Sensor 2 / Front Right Sensor over
C1323
230°F(110°C).
Sensor 3 / Rear Left Sensor over
C1324
230°F(110°C).
Sensor 4 / Rear Right Sensor over
C1325
230°F(110°C).
C1332 Sensor Failure Sensor 1 / Front Left Sensor Fault. Permanent
C1333 Sensor 2 / Front Right Sensor Fault.
C1334 Sensor 3 / Rear Left Sensor Fault.
C1335 Sensor 4 / Rear Right Sensor Fault.
C1660 System Hardware TPMS receiver RF circuit. Permanent
C1661 EEPROM Failure TPMS receiver EEPROM Failure. Permanent
C1668 Micro controller error Internal failure detection. Permanent
C2510 Lamp Short Circuit TREAD lamp short circuit to 12 V. Permanent
C2511 Diagnostic lamp short circuit to 12 V. Permanent
Suspension System > Troubleshooting > C1121

Component Location
General Description
Page 71 of 138
between 0 mph (0 kph) and 186 mph (300 kph). Operating Temperature Range is -40 to 248 °F(40 to 120 °C).
The accuracy of the sensor is 23 to 44.6 °F(-5 to 7 °C)at this temperature. The sensor shall exit thermal shutdown
once the temperature is less than or equal to 212 °F(100 °C). The transmitter shall have the capability to measure
the internal battery voltage as an indicator of the end of life of the sensor. Since the unit is sealed, this parameter
cannot be verified with a production unit..
measurement tolerance shall be ±37.4 °F(±3 °C) from -4 to 158 °F(-20 to 70 °C) and to ±41 °F(±5 °C) from -40
to 248 °F(40 to 120 °C)..
DTC Description
This DTC indicates that the sensor battery voltage level is Low. The most likely cause is battery passing it's
expected life / excessively Low temperatures / sensor failure.

DTC strategy • Sensor battery check
Enable • Latest Lowest sensor Temp. > -4 °F(-20 °C) • Sensor temperature
conditions • Distance travelled during 12 min. > 4 km low
Threshold • Sensor battery low
• Sensor voltage <2.2 V • Faulty TPMS
value
sensor
Diagnosis
• 12 ~13 minutes
time

1. Park the vehicle on a level surface.
Page 72 of 138
2. Connect 'TPMS exciter' or scantool to Data Link Connector(DLC).
3. Select "TPMS DIAGNOSIS" mode.

4. Select the "FULL" mod of "CURRENT DATA" function.
5. Monitor the parameter of SENSOR 1 on the 'TPMS exciter' or scantool after 13 minutes.
Specification : 'Sensor Temp.' is more than -68 °F( -20 °C)and 'Sensor battery value' is 'Normal'.
6. Is parameter within specifications?
Fault is intermittent. It has been repaired and TPMS receiver module memory is not cleared yet.
1. Turn ON 'TPMS exciter'.
2. Select "TIRE SNSR CONFIG(EXCITER)" mode.
Page 73 of 138
3. Execute "SET SENSOR STATUS" of each wheel.
Specification : 'Sensor battery value' is 'Normal' and 'Sensor Temp.' is more than -68 °F( -20 °C).
4. Is any sensor data outside specification?
The sensor which displays data above the specification is SENSOR 1.

Check wheel / tire where abnormal sensor data was detected. Check for tire / wheel damage and overheated
brake condition.
Repair or replace if necessary and go to "Verification of Vehicle Repair" procedure.
If it is OK, go to "Check wheel / tire" as follows.
Check for sensor if unable to retrieve data with 'TPMS exciter'.

Replace TPMS sensor if necessary and register sensor ID with 'TPMS exciter'.


Component Location
Page 74 of 138
General Description
to 248 °F(40 to 120 °C)..
DTC Description
Page 75 of 138
value
sensor
Diagnosis
• 12 ~13 minutes
time


Page 76 of 138

brake condition.



Page 77 of 138
Component Location
General Description
to 248 °F(40 to 120 °C)..
DTC Description
Page 78 of 138

value
sensor
Diagnosis
• 12 ~13 minutes
time


Page 79 of 138

brake condition.



Page 80 of 138
Component Location
General Description
to 248 °F(40 to 120 °C)..
DTC Description
Page 81 of 138

value
sensor
Diagnosis
• 12 ~13 minutes
time


Page 82 of 138

brake condition.



Page 83 of 138
Component Location
General Description
TPM Receiver is integrated with the TPM module installed at the bottom of the steering column. The operating
battery of TPM module is supplied from the vehicle battery. Data such as Tire pressure, Tire Temperature, TPM
sensor battery status and TPM sensor valve ID from TPM sensors are transmitted to TPM receiver in the form of
RF signal. TPM module accomplishes Tire Monitoring and Warning Logic with received data.
DTC Description
This indicates that the receiver battery level is Low. The most likely cause is battery / harness / receiver input / A-D
failure.

DTC
• Battery level check
strategy • Faulty
charging
Enable
• Battery voltage level low system
conditions
• Vehicle
Threshold battery low
• Battery voltage < 9V
value
• Faulty TPMS
Diagnosis Receiver
• 2 sec.
time

1. Start engine and turn headight and rear defroster.
Page 84 of 138

4. Select the "FULL" mode of "CURRENT DATA" function.
5. Maintaining ENG. RPM at 2,500RPM(idle) over 2 minutes.
6. Monitor the parameter of BATT. VOLT on the 'TPMS exciter' or scantool
Specification : 'BATT. VOLT' is more than 10 V
7. Is parameter normal?
Fault is intermittent. It has been repaired and TPM receiver module memory is not cleared yet.
Go to "Inspection/Repair" procedure.

1. Many malfunctions in the electrical system are caused by poor harness and terminal condition. Faults can also be
Go to "Charging System Inspection" procedure.
Charging System Inspection

Page 85 of 138
1. Engine "ON".
2. headight and rear defroster "ON".
3. Measure voltage between terminal (+) and (-) of battery maintaining ENG. RPM at 2,500 RPM(idle) over 2
minutes.
Specification : more than 10 V
4. Is the measured voltage within specifications?
Substitute with a known-good TPM receiver and check for proper operation.
If the problem is corrected, replace TPM receiver and then go to "Verification of Vehicle Repair" procedure.
Check for fault in charging system and check for tension of generator drive belt, ENG.idle rpm or open/short
in harness from battery to generator.


Component Location
Page 86 of 138
General Description
DTC Description
This indicates that the receiver battery level is High. The most likely cause is receiver input / A-D failure.

DTC
• Battery level check
strategy • Faulty
charging
Enable
• Battery voltage level high system
conditions
• Vehicle
Threshold battery high
• Battery voltage > 17.5 V
value
• Faulty TPMS
Diagnosis Receiver
• 2 sec.
time

1. Start engine and turn headight and heatwire on.

Page 87 of 138
5. Maintaining ENG. RPM at 2,500RPM(idle) over 2 minutes.
6. Monitor the parameter of BATT. VOLT on the 'TPMS exciter' or scantool.
Specification : 'BATT. VOLT' is less than 16.5 V
Go to "Inspection/Repair" procedure.

Go to "Charging System Inspection" procedure.
Charging System Inspection

1. Engine "ON".
2. headight and rear defroster "ON".
Page 88 of 138
3. Measure voltage between terminal (+) and (-) of battery maintaining ENG. RPM at 2,500 RPM(idle) over 2
minutes.
Specification : less than 16.5 V
Check for fault in charging system and thoroughly check all connectors (and connections) for looseness,
bending, corrosion, contamination, deterioration, and/or damage.
Repair or replace if necessary and then go to "Verification of Vehicle Repair" procedure.


Component Location
Page 89 of 138
General Description
DTC Description
This DTC indicates that system is not functioning due to High interference levels from external sources.

DTC strategy • LF/RF check • LF/RF Interference
from external
Enable
• System not functioning due to High RF interference levels sources(unless C1306
conditions
also exists as historic. If
• No valid RF data for 8 min from any sensor this is the case then
Threshold value interference source is
• Distance travelled during 8 minutes ≤ 1.68 mile(2.7 km)
likely to be internal to
Diagnosis time • 8 - 9 minutes the vehicle)


Page 90 of 138
5. Monitor the parameter of RF RSSI background on the 'TPMS exciter' or scantool after 9 minutes.
Specification : "RSSI background" is less than 1.9 V
Substitute with a known-good TPM receiver module and check for proper operation.
If the problem is corrected, replace TPM receiver module and then go to "Verification of Vehicle Repair"
procedure.


Component Location
Page 91 of 138
General Description
DTC Description
This DTC indicates that system is not functioning due to High interference levels, which are most likely being
generated in the vehicle.

DTC strategy • LF/RF check
Enable • System not functioning due to High RF interference (Internal)
conditions levels • Internal vehicle noise
• No valid RF data for 8 min from any sensor source
Threshold value
• Distance travelled during 8 minutes > 1.68 mile(2.7 km)
Diagnosis time • 8 - 9 minutes


Page 92 of 138
5. Monitor the parameter of RF RSSI background on the 'TPMS exciter' or scantool after 9 minutes..
Specification : "RSSI background" is less than 1.9V
procedure.


Component Location
Page 93 of 138
General Description
tire will not interfere such as due to the simultaneous transmission. Wheel sensors shall support usage on steel or
aluminum rims.
between 0 mph (0 kph) and 186 mph (300 kph). Operating Temperature Range is -40 to 120 °C. Transmitter shall
enter thermal shutdown once the measured temperature is greater than or equal to 125 °C. The accuracy of the
sensor is ± 5°C at this temperature. The sensor shall exit thermal shutdown once the temperature is less than or
equal to 100 °C. The transmitter shall have the capability to measure the internal battery voltage as an indicator of
the end of life of the sensor. Since the unit is sealed, this parameter cannot be verified with a production unit.
a frequency of 315 MHz, 5 kBaud. Tire pressure measurement tolerance shall be ±7 kPa from 0 to 50 °C and
±17.5 kPa from -40 to 120°C with a range of 100 to 450 kPa. Tire temperature measurement tolerance shall be ±3
°C from -20 to 70 °C and to ±5 °C from -40 to 120 °C.
DTC Description
This DTC indicates that the sensor has either failed to learn OR has successfully learned and the receiver did not
receive messages from the learned sensor for 12 minutes.

Page 94 of 138
• Faulty TPMS sensor
• Incorrectly configured
DTC strategy • RF message from sensor1 check
TPMS sensor e.g.Low
Line vehicle with High
Line sensors.
• Low Line vehicle
Enable sensors in storage state.
• 2.48 mile < Distance travelled during 12 min. < 24.85 mile
conditions • Wrong receiver type
fitted e.g. Low Line
receiver to a High Line
vehicle.
• Failure to Learn Sensors1 Correctly. • Shielding in vehicle.
Threshold value
• No RF message received from sensor1 over 12 min. • Un-approved
wheels/tires i.e. a
vehicle set up that has
not been approved for
good RF performance.
Diagnosis time • 12 ~ 20 minutes.
• Incorrectly fitted sensor
/ receiver.

1. Connect ''TPMS exciter' or scantool to Data Link Connector(DLC).

Page 95 of 138
4. Is data unable to be retrieved for any sensor?
Replace affected TPM sensor and register sensor ID with 'TPMS exciter'.
procedure.

Page 96 of 138

Component Location
General Description
aluminum rims.
Page 97 of 138
DTC Description

TPMS sensor e.g.Low
Line sensors.
vehicle.
Threshold value
wheels/tires i.e. a
/ receiver.


Page 98 of 138
procedure.

Page 99 of 138

Component Location
General Description
aluminum rims.
Page 100 of 138
DTC Description

TPMS sensor e.g.Low
Line sensors.
vehicle.
Threshold value
wheels/tires i.e. a
/ receiver.


Page 101 of 138
procedure.

Page 102 of 138

Component Location
General Description
aluminum rims.
Page 103 of 138
DTC Description

TPMS sensor e.g.Low
Line sensors.
vehicle.
Threshold value
wheels/tires i.e. a
/ receiver.


Page 104 of 138
procedure.

Page 105 of 138

Component Location
General Description
aluminum rims.
Page 106 of 138
DTC Description
This DTC indicates that the sensor has seen a temperature in excess of 110°C. At 125°C, the sensor will shut down
and the warning is therefore so that the driver knows that there is a problem with the vehicle that may affect tire
performance.

DTC strategy • Temperature of sensor check
Enable • Damaged tire
• 2 consecutive Alert State temperature > 230°F(110°C) • Excessive braking
conditions
• Driving while the
Threshold value • Sensor temperature > 230°F(110°C)
parking brake is on.
Diagnosis time • < 10 sec.

5. Monitor the parameter of SENSOR 1 temperature on the 'TPMS exciter' or scantool after 4 minutes.
Specification : Less than 230 °F(110 °C)

Page 107 of 138
Check TPM SENSOR 1
Execute "SET SENSOR STATUS" of each wheel.
3. Monitor the parameter of each sensor temperature on the 'TPMS exciter'.

Check wheel / tire of SENSOR 1 if Damaged tire, Excessive braking, Driving while the parking brake is on is
detected.
If it is OK, go to "Check wheel / tire" as fellows.
Substitute with a known-good TPMS receiver module and check proper operation.
If the problem is corrected, replace TPMS receiver module and go to "Verification of Vehicle Repair"
procedure.
Check wheel / tire
1. Cool the heat of the SENSOR 1 wheel / tire.
2. IG OFF & IG ON.
Page 108 of 138
3. Monitor the parameter of sensor 1 temperature on the 'TPMS exciter' or scantool after 4 minutes.
Fault can be because of temporary overheating.

Replace TPMS sensor and register sensor ID with 'TPMS exciter'.



Component Location
General Description
Page 109 of 138
aluminum rims.
DTC Description
performance.

conditions
Threshold value • Sensor temperature > 230°F(110°C) parking brake is on.

Page 110 of 138
Check TPM SENSOR 1

Page 111 of 138

detected.
procedure.
Check wheel / tire
2. IG OFF & IG ON.




Component Location
Page 112 of 138
General Description
aluminum rims.
DTC Description
performance.
Page 113 of 138
conditions

Check TPM SENSOR 1
Page 114 of 138

detected.
procedure.
Check wheel / tire
2. IG OFF & IG ON.



Page 115 of 138

Component Location
General Description
aluminum rims.
Page 116 of 138
DTC Description
performance.

conditions


Page 117 of 138
Check TPM SENSOR 1

detected.
procedure.
Check wheel / tire
2. IG OFF & IG ON.



Page 118 of 138

Component Location
General Description
aluminum rims.
Page 119 of 138
DTC Description
This DTC indicates that the sensor has detected that it has an internal fault. The most likely cause is sensor failure.

DTC
• Sensor check
strategy
Enable • Damage to
• An internal fault in the TPMS sensor
conditions sensor
Threshold • Faulty TPMS
• TPMS sensor fault sensor
value
Diagnosis
• < 9 minutes
time


Page 120 of 138
5. Monitor each sensor's temperature parameter on the 'TPMS exciter' or scantool after 9 minutes.
Check for damaged of TPMS sensor on affected wheel.

procedure.

Page 121 of 138

Component Location
General Description
aluminum rims.
Page 122 of 138
DTC Description

DTC
• Sensor check
strategy
conditions sensor
value
Diagnosis
• < 9 minutes
time


Page 123 of 138

procedure.

Page 124 of 138

Component Location
General Description
aluminum rims.
Page 125 of 138
DTC Description

DTC
• Sensor check
strategy
conditions sensor
value
Diagnosis
• < 9 minutes
time


Page 126 of 138

procedure.

Page 127 of 138

Component Location
General Description
aluminum rims.
Page 128 of 138
DTC Description

DTC
• Sensor check
strategy
conditions sensor
value
Diagnosis
• < 9 minutes
time


Page 129 of 138

procedure.

Page 130 of 138

Component Location
General Description
DTC Description
This DTC indicates that the receiver has not received any RF messages. The most likely cause is receiver RF circuit
failure / RF screening.

DTC strategy • Internal RF circuit check of Receiver module • Low Line - all sensors
in storage state and no
Enable • No valid RF data for 12 min from any sensor other RF transmissions
conditions • RF messages and the signal levels are unexpected received
• Low Line - receiver RF
Threshold value • Internal RF circuit fault shielding
• Faulty TPMS Receiver
Diagnosis time • 12 ~13 minutes module
Page 131 of 138
Check status of all TPM sensor
3. Are status of all sensors "normal"?
Check TPM receiver RF shielding.

If it is OK, go to "Check TPM receiver" as fellows.
Repair if necessary and go to "Verification of Vehicle Repair" procedure.
Change status of all TPM sensors into "normal" status with 'TPMS exciter'.
Check TPM receiver
2. Clear DTC.
3. IG OFF & IG ON. Wait 4 minutes.
4. Execute "Diagnostic Trouble Codes(DTCs)".
5. Is 'C1660' present ?
Substitute with a known-good TPM Receiver module and check for proper operation.
If the problem is corrected, replace TPM Receiver module and go to "Verification of vehicle Repair"
procedure.
TPM receiver complete successful Auto-Learn.

System is OK.

Page 132 of 138

Component Location
General Description
DTC Description
This DTC indicates that the receiver has a problem reading or writing to EEPROM.

DTC strategy • Receiver module check
Enable • Transient over voltage
• Reading or writing problem to EEPROM due to vehicle fault (fault
conditions
would typically recover)
Threshold value • EEPROM in the receiver module fault • Faulty TPMS Receiver
Page 133 of 138
2. Clear DTC.
procedure.

System is OK.


Component Location
Page 134 of 138
General Description
DTC Description
This DTC indicates that the receiver has detected an internal error.

DTC strategy • Receiver module check
Enable • Transient over voltage
• An Internal error due to vehicle fault (fault
conditions
would typically recover)
Threshold value • TPMS Receiver module fault • Faulty TPMS Receiver
Diagnosis time • < 3 sec. - Carried out once at Ignition ON
2. Clear DTC.
procedure.

System is OK.

Page 135 of 138

Component Location
General Description
The TPMS receiver unit must provide two outputs continuously to drive the indicator lamps. One of the output turn
the TREAD indicator lamp on when pressure in one or more tires associated with the TPMS receiver unit have
reported a pressure below the warning level threshold. The other output turn the TPMS Warning indicator bulb on
when the TPMS receiver unit has detected a system fault.
Turn the TREAD indicator lamp on
1. When tire pressure is below allowed threshold.
2. When rapid leak is detected by the sensor.
3. Indicates that tire needs to be re-inflated to placard pressure / repaired.
Turn the TREAD indicator lamp off
1. Under-inflation : When tire pressure is above (warning threshold + hysteresis).
2. Leak : When tire pressure is above (leak warning threshold) OR on Ignition cycle off to on.
DTC Description
This DTC indicates that the TREAD(Tire Under Inflation / Leak Warning) / DTC Warning lamp is short circuit and
therefore cannot be turned on. The most likely failure is harness / instrument cluster / connector / receiver short
circuit.

DTC strategy • Input lamp current check
Enable
• TREAD / Diagnostic lamp circuit short to 12 V • Short circuit to 12 V
conditions
between lamp and
• TREAD / Diagnostic lamp - 200 mA allowed each (after in rush TPMS receiver
Threshold value
time). 50 mA margin built in.
Diagnosis time • < 3s
Page 136 of 138

Control Circuit Inspection
1. Engine "OFF".
2. Disconnect instrument cluster connector and TPM receiver connector.
3. Engine "ON".
4. Measure voltage between terminal "16" of TPMS receiver harness connector and chassis ground.
Specification : 0 V
Check for short to power in control harness.



Component Location
Page 137 of 138
General Description
The TPMS receiver unit must provide two outputs continuously to drive the indicator lamps. One of the output turn
the TREAD indicator lamp on when pressure in one or more tires associated with the TPMS receiver unit have
reported a pressure below the warning level threshold. The other output turn the TPMS Warning indicator bulb on
when the TPMS receiver unit has detected a system fault.
Turn the TPMS DTC Warning indicator lamp on
1. When the system detects a fault that is external to the receiver / sensor.
2. When the system detects a receiver fault.
3. When the system detects a sensor fault.
Turn the TPMS DTC Warning indicator lamp off
1. If the fault is considered as 'critical', then the lamp is held on throughout the current Ignition cycle (even if the DTC
has been demoted). This is because it is important to bring the problem to the drivers attention. On the following
Ignition cycle, the demotion conditions will be re-checked. If the demotion conditions occur, the lamp will be turned
off. It will be held on until DTC demotion checking is completed.
2. 'Non critical' faults are those that can occur temporarily e.g. vehicle battery under voltage. The lamp is therefore
turned off when the DTC demotion condition occurs.
DTC Description
This DTC indicates that the TREAD(Tire Under Inflation / Leak Warning) / DTC Warning lamp is short circuit and
therefore cannot be turned on. The most likely failure is harness / instrument cluster / connector / receiver short
circuit.

DTC strategy • Input lamp current check
Enable
• TREAD / Diagnostic lamp circuit short to 12 V • Short circuit to 12 V
conditions
between lamp and
• TREAD / Diagnostic lamp - 200 mA allowed each (after in rush TPMS receiver
Threshold value
time). 50 mA margin built in.
Diagnosis time • < 3s

Page 138 of 138

Control Circuit Inspection
1. Engine "OFF".
2. Disconnect instrument cluster connector and TPM receiver connector.
3. Engine "ON".
4. Measure voltage between terminal "17" of TPMS receiver harness connector and chassis ground.
Specification : 0 V
Check for short to power in control harness.



Page 1 of 16
SPORTAGE(KM) > 2008 > G 2.7 DOHC > Transfer System
Transfer System > Transfer Case Assembly > Description and Operation (M5GF1)
POWER FLOW MECHANISM
• Normal driving situation: 2WD base driving
• 4WD driving in driving situations (rapid activation, cornering etc.)
• Input the information from each sensor in vehicle
- Input torque (Throttle position sensor)
- Cornering situation (Steering angle sensor)
- Vehicle speed and different wheel speed front & rear (Wheel speed sensor)
- Braking situation (Brake signal and ABS signal)
• Distributed the required driving force after 4WD ECU operates.
• EMC (Electric Magnetic Clutch) operates the primary clutch.
• Control the cam's opening gap by operation of primary clutch.

Page 2 of 16
• Control the slip of inner & outer plate.

Control variably the driving force distribution to optimize front & rear driving force.
Page 3 of 16
SYSTEM SCHEMATICS
Page 4 of 16
ITM confroller
1. NON-ABS controller
Page 5 of 16
2. ABS/TCS controller
3. ESP controller
Page 6 of 16
Lock Mode Description

• Based on a driver request for lock mode, the system will supply a fixed torque to the ITM-I clutch.
• When the vehicle exceeds 30KPH the system will begin to disable lock mode by ramping down the ITM clutch
torque. When the vehicle exceeds 40 KPH the ITM clutch is reduced to its minimum torque value. Lock mode is
re-enabled following the same speed-to-torque map.
• Lock mode is activated based on part number.
• Lock mode will override all other system requests except for during an ABS event. During an ABS event the
ITM clutch is turned off.
• If there is a speed sensor signal fault, the speeds are no longer considered reliable and lock mode will be
disabled.
Control Algorithm Flow Chart
The base control algorithm of the ITM ECM is defined by the following flowchart:
Page 7 of 16
Transfer System > Transfer Case Assembly > Troubleshooting (M5GF1)

DTC TROUBLESHOOTING
4WD ECM DTC INDEX
Page 8 of 16
SEE
DTC No. DESCRIPTION 4WD MIL
PAGE
STEERING WHEEL ANGLE SENSOR
P1716 TR-22
SIGNAL(CAN ERROR)
STEERING WHEEL ANGLE SENSOR 1-INPUT
P1717 TR-26
SIGNAL
STEERING WHEEL ANGLE SENSOR 2-INPUT
P1718 TR- 33
SIGNAL
STEERING WHEEL ANGLE SENSOR C-INPUT
P1719 TR-39
SIGNAL
P1726 THROTTLE POSITION SENSOR SIGNAL TR -46
P1728 EMC OPEN/SHORTED to BATTERY TR-50
P1729 EMC SHORTED to GROUND TR-57
P1738 4WD ECU INVALID PART NUMBER TR-61
P1750A WHEEL SPEED SENSOR SIGNAL(FL)-with ABS TR-64
Whenever the DTCs relevant to
P1750B WHEEL SPEED SENSOR SIGNAL(FL)-without ABS 4WD ECM are set, 4WD TR-69
P1751A WHEEL SPEED SENSOR SIGNAL(FR)-with ABS MIL(*) will blink. TR-77
WHEEL SPEED SENSOR SIGNAL(FR)-without
P1751B TR-80
ABS
P1752A WHEEL SPEED SENSOR SIGNAL(RL)-with ABS TR-86
WHEEL SPEED SENSOR SIGNAL(RL)-without
P1752B TR-89
ABS
P1753A WHEEL SPEED SENSOR SIGNAL(RR)-with ABS TR-95
WHEEL SPEED SENSOR SIGNAL(RR)-without
P1753B TR-98
ABS
P1764 ECU-ITM CAN ERROR TR-104
P1765 TCS-ITM CAN ERROR TR-109
P1766 CAN COMMUNICATIOM BUS OFF TR-113
P1767 ABS ACTIVE SIGNAL (CAN ERROR) TR-116
4WD ECM PIN DESCRIPITION

Page 9 of 16
Wire
Terminal Number Description
Color
1 R BATTERY INPUT
2 - BRAKE INPUT
3 B ECU GROUND
4 G CAN L
5 O CAN H
6 L GND RTN 4
7 Br GND RTN 3
8 L GND RTN 2
9 Br GND RTN1
10 R LOCK SWITCH INPUT
11 L/B STEERING REF C
12 B/O STEERING REF RTN
13 B EMC RTN
14 W ISO9141 K LINE
C01(2.0GSL) 15 R/B IGNITION INPUT
C51(2.7GSL)
4WHEEL DRIVE
16 Gr/O
INDICATOR
FRONT RIGHT SPEED
17 O
SENSOR
FRONT LEFT SPEED
18 R
SENSOR
REAR LEFT SPEED
19 R
SENSOR
REAR RIGHT SPEED
20 O
SENSOR
21 Y DIAGNOSTIC OUT
22 - TPS INPUT
23 Gr/O STEERING 1 INPUT
24 L STEERING 2 INPUT
25 Gr/B STEERING REF 5V
26 R EMC OUTPUT
Page 10 of 16
Transfer System > Transfer Case Assembly > Transfer Case > Components and Components Location
(M5GF1)
COMPONENTS(1)
COMPONENTS(2)
Page 11 of 16
Transfer System > Transfer Case Assembly > Transfer Case > Repair procedures (M5GF1)
REMOVAL
1. Remove the battery (-) terminal.
3. Remove the propellar shaft (See 'DS' group-'PROPELLAR SHAFT')
Page 12 of 16
4. Remove the front muffler(A).
5. Remove the RH driveshaft (See 'DS' group-'DRIVESHAFT').

6. Loosen the oil drain plug and drain the fluid.
7. After draining, re-tighten the oil drain plug.
Tightening torque:
39.2 ~ 58.8 Nm (400 ~ 600 kgf.cm, 28.9 ~ 43.4 lb-ft)
8. Support the transfer assembly with a jack.

9. Remove the transfer assembly by loosening the mounting bolts.
Remove the transfer bracket mounting bolts(2EA)

together.
REPLACEMENT
TRANSFER OIL
1. Replace the oil every 100,000km(62,137miles) in a general condition and every 40,000km(24,854miles) in
severe usage conditions.
1. Severe usage (marked '*') is defined as

1) Frequent driving on rough road (Bumpy road, gravel road, snowy road, unpaved road . Etc.)
2) Frequent driving on mountain road, ascent/descent.
3) Police, taxi, commercial type operation or trailer towing. Etc.)
2. Transfer & diff carrier lubricants should be changed anytime transfer & diff carrier have been submerged
in water.
INSTALLATION
1. Remove the filler plug(A).
Page 13 of 16
2. Refill the specification to the specified quantity.
Specification : SAE 80w/90

Quantity : 0.8L (0.8 US qt, 0.7 lmp qt)
3. Fix it in proper position with mounting bolts.
TRANSFER OIL
1. Check and replenish the transfer oil every 40,000km(24855 miles).
Transfer System > Transfer Case Assembly > Coupling Assembly > Repair procedures (M5GF1)
REMOVAL
1. Remove the 4WD coupling bolts (A-3EA) mounted to the rear propellar shaft.
Tightening torque :
49.1~68.7N.m (5.0~7.0kgf.m, 36.2~50.6lb-ft)
2. Using a flat tool(A), separate the propellar shaft(C) from 4WD coupling(B).
Page 14 of 16
3. Remove the rear axle (B-Differential carrier) bolts mounted to the 4WD coupling(A) by a socket(C).
Tightening torque :
58.9~63.8N.m (6.0~6.5kgf.m, 43.4~47.0lb-ft)
4. Remove the electric magnetic clutch connector(A).
5. Using a flat tool(A), separate the 4WD coupling assembly(B) from the rear differential carrier(C).
6. Remove the 4WD coupling assembly(A).
INSTALLATION
Installation is the reverse of the removal.
DISASSEMBLY
Page 15 of 16
Don't disassemble the coupling assembly more than bleow procedure because its performance may get bad
influence after disassembling.
1. Remove the coupling(A) flange(B) mounting nut(C).
2. Remove the flange spacer(A).
3. Remove the coupling flange oil seal(A).
4. Using a general tool, 3-way puller(A), remove the flange assembly(B) from the coupling(C).
Page 16 of 16
5. Remove the flange oil seal(A) using special tool (09432-33200).
6. Remove the coupling case assembly(A).

Sportage 2.7L 2008

Uploaded by

Copyright:

Available Formats

Sportage 2.7L 2008

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sportage 2.7L 2008

Uploaded by

Copyright:

Available Formats

Page 1 of 28

SPORTAGE(KM) > 2008 > G 2.7 DOHC > General Information

General Information > General Information > General Information

IDENTIFICATION NUMBER DESCRIPTION

1 - 3 : Make / Vehicle type

ENGINE IDENTIFICATION NUMBER

AIR BAG WARNING / CAUTION LABEL

AIR BAG WARING / CAUTION LABEL (CONT'D)

WARNING / CAUTION LABEL (cont'd)

Detach connector before unmounting. Assemble strictly according to manual instructions.

C : PASSENGER MODULE CAUTION

D : SUPPLEMENTAL RESTRAINT SYSTEM (AIRBAG) INFORMATION

BATTERY CAUTION LABEL DESCRIBTION

LIFT AND SUPPORT POINTS

TIGHTENING TORQUE TABLE OF STANDARD PARTS

Bolt nominal diameter 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 Kia motors parts and recommedended fluid.

Capacities : [liter (U.S.qts, Imp.qts)]

3. Cleaning parts for reuse

Depending on their location.

RUBBER PARTS AND TUBES

MEASURING BODY DIMENSIONGS

MEASURING ACTUAL DIMENSIONS

CHECKING CABLES AND WIRES

SERIVICING THE ELECTRICAL SYSTEM

PRECAUTIONS FOR CATALYTIC CONVERTER

SCHEDULE 2 - SEVERE MAINTENANCE

09431-39000 Installation of differential oil seal.

09433-21000 1. Removal of transafer driven gear taper

09500-11000 Installation of differential bearing outer race.

09455-33200 Installation of differential ball bearing and

09453-21100 Removal and installation of the low and

09453-21000 1. Removal and installation of low and reverse

09452-33100 Removal of the oil pump.

09452-21200 Installation of the oil pump oil seal.

09456-39100 Measurement of low and reverse brake and

09456-39000 Removal and installation of low and reverse

Automatic Transaxle System > General Information > Specifications (F4A42-2)

1) O : OWC is operated when shifts from 1st gear to 2nd gear.

REVERSE CLUTCH AND OVERDRIVE CLUTCH

OUTPUT SHAFT/TRANSFER DRIVEN GEAR

MANUAL CONTROL SYSTEM

1st GEAR POWER FLOW

2nd GEAR POWER FLOW

3rd GEAR POWER FLOW

4th GEAR POWER FLOW

Rev GEAR POWER FLOW

Hydraulic Control System

• Better and smoother shift quality.

D position : 1st gear

D position : 2nd gear

D position : 3rd gear

D position : 4th gear

ELECTRIC CONTROL LOCATION

OPERATING COMPONENTS AND FUNCTIONS

HIVEC INHIBIT CONDITIONS

Controller Area Network (CAN)

Input signals to TCM(PCM) through 'CAN communication'