Tucson 2.7L 2009

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TUCSON(JM) > 2009 > G 2.7 DOHC > General Information
General Information > General Information > General Information

Identification Number Locations
Identification Number Description

Vehicle Identification Number
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1. Geographic zone
- K : Korea
2. Manufacturer
- M : Hyundai motor company
3. Vehicle type
- 8 : MPV
4. Vehicle line
- J : TUCSON
5. Model & Series
- L : STANDAD (L)
- M : DELUXE (GL)
- N : SUPER DELUXE (GLS)
- P : GRAND SALON (GDS)
- R : SUPPER GRAND SALON (HGS)
6. Body type
- 1 : WAGON FRONT WHEEL DRIVE
- 7 : WAGON ALL WHEEL DRIVE
7. Restraint system
- 0 : Class A
- 1 : Class B
- 2 : Class C
- 3 : Class D
- 4 : Class E
- 5 : Class F
- 6 : Class G
- 7 : Class H
8. Engine type
- B : Gosoline 2.0 DOHC
- D : Gosoline 2.7 DOHC
9. Check digit
- Check digit : 0 ~ 9, x
10. Production year
- 7 : 2007, 8 : 2008, 9 : 2009
11. Plant of production
- U : Ulsan (korea)
12. Vehicle production sequence number
- 000001 ~ 999999
Paint Code
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Code Color
NW Noble White
EB Ebony Black
VA Red Land
NS Deep Green
OL Marine Blue
VN Golden Sand
YK Warm Silver
Light
JQ
Chardonna
HE Teal Blue
New Mild
BW
Silver
BU Aqua Silver
Engine Identification Number
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
- 7 : 2007, 8 : 2008, 9 : 2009
6. Engine production sequence number
- 000001 ~ 999999
Transmission Identification Number
Manual
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1. Model
- L : M5GF1
2. Production year
- 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
- 5 : 2005, 6 : 2006, 7 : 2007
3. Gear ratio
- N : 4.042
- O : 4.407
- R : 4.626
4. Detailed chassification
- AD : 2.0 2WD
- BD : 2.0 4WD
- FD : 2.7 4WD
- HD : 2.7 2WD
5. Spare
6. Transaxle production sequence number
- 000001 ~ 999999
Warning / Caution Label Locations
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Air Bag Warning / Caution Label

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Air Bag Waring / Caution Label (Cont'd)

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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 seal.
• For further information, see the owner's manual.
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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

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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.
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• 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.
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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.
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• 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

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Bolt niminal Torque Nm (kg.cm, lb.ft)
diameter Pich (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)
M8 1.25 12 ~ 15 (120 ~ 150, 9 ~ 11) 20 ~ 25 (200 ~ 250, 14.5 ~ 18.0 )
M10 1.25 25 ~ 30 (250 ~ 300, 18 ~ 22) 30 ~ 50 (300 ~ 500, 22 ~ 36)
M12 1.25 35 ~ 45 (350 ~ 450, 25 ~ 33) 60 ~ 80 (600 ~ 800, 43 ~ 58)
M14 1.5 75 ~ 85 (750 ~ 850, 54 ~ 61) 120 ~ 140 (1,200 ~ 1,400, 85 ~ 100)
180 ~ 210 (1,800 ~ 2,100, 130 ~
M16 1.5 110 ~ 130 (1,100 ~ 1,300, 80 ~ 94)
150)
160 ~ 180 (1,600 ~ 1,800, 116 ~ 260 ~ 300 (2,600 ~ 3,000, 190 ~
M18 1.5
130) 215)
220 ~ 250 (2,200 ~ 2,500, 160 ~ 360 ~ 420 (3,600 ~ 4,200, 260 ~
M20 1.5
180) 300)
290 ~ 330 (2,900 ~ 3,300, 210 ~ 480 ~ 550 (4,800 ~ 5,500, 350 ~
M22 1.5
240) 400)
360 ~ 420 (3,600 ~ 4,200, 260 ~ 610 ~ 700 (6,100 ~ 7,000, 440 ~
M24 1.5
300) 505)
1. The torques shown in the table are standard values under the following conditions :
• Nuts and bolts are made of galvanized steel bar.
• Galvanized plain steel washers are inserted.
• All nuts, bolts and plain washers are dry.
2. The torques shown in the table are not applicable :
• When spring washers, toothed washers and the like are inserted.
• If plastic parts are fastened.
• If self-tapping screws or self-locking nuts are used.
• If threads and surfaces are coated with oil.
3. If you reduce the torques in the table to the percentage 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
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Parts Oil & Grease Standard
Engine Oil Gasoline API SH or ABOVE SAE 5W -20 (Below -10°C) *1, *2
SAE 5W -30 (Below 10°C)
SAE 5W -40 (Below 20°C)
SAE 10W -30 (-25°C ~ 40°C)
SAE 10W -40, 10W -50 (Above -25°C)
API SH or ILAS SAE 10W -30, 10W -40
GF-1 and ABOVE SAE 5W-30, 5W-40
*1. Restricted to driving condition and area.
*2. Not recommended for sustained high speed vehicle operation.
Transaxle Manual HYUNDAI GENUINE PART MTF 75W/90 (API GL - 4)
Auto DIAMOND ATF SP-III, SK ATF SP-III
Power Steering PSF - 3
Brake DOT 3, DOT 4 or equivalent
Coolant Ethlyene glycol base for aluminium radiator
Transaxle linkage, parking breake cable
mechanism, hood, door latch, seat adjuster, Multipurpose grease NIGL grade #2
tailgate latch, door hinges, tailgate hinge
Always use Genuine Hyundai parts and recommedended fluid.

Using any other type of parts and fluid can cause serious damaged if the vehicle.RECOMMENDED
LUBRICANTS
Lubricants Capacities
Description Gasoline 2.7 Gasoline 2.0
4.8L (5.07US qts, 4.1L (4.33US qts, 3.60
Oil quantity(Total)
4.22lmp.qts) lmp.qts)
4.2L (4.44US qts, 3.7L (3.91US qts,
Engine oil Oil quantity(Oil pan)
3.70lmp.qts) 3.26lmp.qts)
Oil quantity(Drain and refill including 4.5L (4.76US qts,
oil filter) 3.96lmp.qts) 4.0L (4.23US qts,
7.0L (7.4US qts., 3.52lmp.qts)
Cooling system
6.1lmp.qts)
2.1 L(2.3US qts,
Manual transaxle M5GF1 -
1.86lmp.qts)
Automatic 7.8L (8.2US qts, 7.8 L (8.2US qts,
F4A42
transaxle 6.9lmp.qts) 6.9lmp.qts)
Selection Of Engine Oil

Recommended API classification : SH OR ABOVE
Recommended SAE viscosity grades :
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For best performance and maximum protection of all types of operation, select only those lubricants which :
1. Satisfy the requirements of the API classification.
2. Have the proper SAE grade number for expected ambient temperature range.
Lubricants which do not have both an SAE grade number and an 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.
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Removal Of Parts
First find the cause of the problem and then determine whether removal or disassembly before starting the job.
Disassembly
If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled
in a way that will not aggect their performance or external appearance.
1. Inspection of parts
Each part, when removed, should be carefulley on spected for malfunction, deformation, damage, and other
problems.
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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 HYUNDAI genuine parts.
Replacement
Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
If removed, the following parts should always be replaced with new ones.
1. Oil seals
2. Gaskets
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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.
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.
Ruber Parts And Tubes

Always prevent gasoline or from touching rubber parts or tubing.
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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.
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.
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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).
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)
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Serivicing The Electrical System

1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground
cable.
In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble
code retained by the computer will be cleared. 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.
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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.
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.
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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.
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11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the
harness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until
contacts the terminal, being careful not to damage the insulation of the wires.
12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration,
and determine the 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.
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TUCSON(JM) > 2009 > G 2.7 DOHC > Automatic Transaxle System
Automatic Transaxle System > General Information > Specifications (F4A42-2)

Specifications
Item F4A42
3-element, 1-stage, 2-phase
Torque converter type
type
4-speed forward, 1-speed
Transaxle type
reverse
Engine displacement 2.0L GSL 2.7 GSL
1st 2.842 ←
2nd 1.592 ←
Gear ratio 3rd 1.000 ←
4th 0.712 ←
Reverse 2.480 ←
2WD 4.626 4.042
Final gear ratio
4WD ↑ ↑
Shift pattern Variable
Shift range 4range ( P-R-N-D) + Sports mode
Shift range valve PWM ; 5EA(Duty control)
2EA(Output planetary/Overdrive
Planetary gear
planetary)
Clutch 3EA
Brake 2EA
OWC 1EA
Service Specifications
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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
Tightening Torques
Item N·m kgf·cm lb-ft
Wiring harness bracket 20 ~ 26 200 ~ 260 14.8 ~ 19.1
Control cable bracket bolt 20 ~ 26 200 ~ 260 14.8 ~ 19.2
Oil cooler feed tube 10 ~ 12 100 ~120 7.4 ~ 8.9
Input shaft speed sensor 10 ~ 12 100 ~ 120 7.4 ~ 8.9
Output shaft speed sensor 10 ~ 12 100 ~ 120 7.4 ~ 8.9
Manual control lever 18 ~ 25 180 ~ 250 13.3 ~ 18.4
Transaxle range switch 10 ~ 12 100 ~ 120 7.4 ~ 8.9
Speedometer gear 4~6 40 ~ 60 3.0 ~ 4.4
Valve body cover 8 ~ 10 80 ~ 100 5.9 ~ 7.4
Valve body mounting bolt 10 ~ 12 100 ~ 120 7.4 ~ 8.9
Oil temperature sensor 10 ~ 12 100 ~ 120 7.4 ~ 8.9
Oil filler plug 29 ~ 34 290 ~ 340 21.4 ~ 25.1
Oil drain plug 29 ~ 34 290 ~ 340 21.4 ~ 25.1
Differential drive gear to
130 ~ 140 1300 ~ 1400 95.9 ~ 103.3
subframe bolts
Solenoid valve support 5~7 50 ~ 70 3.7 ~ 5.2
Pressure check plug 8 ~ 10 80 ~ 100 5.9 ~ 7.4
Front roll stopper bracket to
40 ~ 55 400 ~ 550 29.5 ~ 40.6
subframe bolts
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Front roll stopper insulator bolt
50 ~ 65 500 ~ 650 36.9 ~ 47.9
and nut
Front roll stopper bracket to
60 ~ 80 600 ~ 800 44.3 ~ 59.0
transaxle bolts
Rear roll stopper bracket 40 ~ 55 400 ~ 550 29.5 ~ 40.6
Rear roll stopper insulator bolt
50 ~ 65 500 ~ 650 36.9 ~ 47.9
and nut
Rear roll stopper bracket to
60 ~ 80 600 ~ 800 44.3 ~ 59.0
transaxle bolts
Transaxle mounting sub bracket
60 ~ 80 600 ~ 800 44.3 ~ 59.0
nut
Transaxle mounting bracket bolts 40 ~ 55 400 ~ 550 29.5 ~ 40.6
Transaxle mounting insulator bolt 90 ~ 110 900 ~ 1100 66.4 ~ 81.1
Lubricants
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 > General Information > Special Service Tools (F4A42-2)
Special Service Tools
Tool
Illustration Use
(number and name)
09200 - 38001 Removal and installation of transaxle.
Engine support fixture
09432 - 33200 Removal of 4WD coupling flange oil seal

Bearing removing plate
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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
electrically-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 drastically compared to previous T/M such as alpha, Bcta or KM series automatic transaxles.
All 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
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
Better shift quality controlled 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.
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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
1. Reverse clutch 10. Torque converter

2. Overdrive planetary gear 11. Input shaft
set 12. Oil pump
3. Second brake 13. Converter housing
4. Low-reverse brake 14. Differential
5. Output plantary gear set 15. Transfer driven gear
6. Oneway clutch 16. Output shaft
7. Oneway clutch inner 17. Rear cover
race 18. Overdrive clutch
8. Transfer drive gear
9. Underdrive clutch
Mechanical System
Operation Components And Function
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 & reverse annulus gear
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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
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.
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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
overdrive planetary carrier and low-reverse annulus gear.
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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
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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.
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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.
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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.
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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.
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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.
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• 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.
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)
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Electric Control Location

The TCM is located below the dashboard. However, in the ß-engine vehicles, there is not TCM but PCM.
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Operating Components And Functions

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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
APS(Diesel) Accelerator position sensor
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 In case of CAN communication
HIVEC
In addition to the variable shift pattern control, the HIVEC system with neural network is also adopted for the first
time in HMC. 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 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. On the basis of mapping data,
TCM decides the driving condition from throttle opening, vehicle speed and brake signal. And then TCM controls
the gear position optimally. Optimal gear position is achieved under various driving condition by HIVEC logic.
Optimal Control For All Driving Condition
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HIVEC Inhibit Conditions
- ATF temperature below 40°C.
- 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 is 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
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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
Clutch To Clutch Shift Control

As can be seen in the solenoid valve layout below, there are major differences between the previous A/T and New
A/T.
In previous A/T, there were only two solenoid valves to enable shift and one solenoid valve to control hydraulic
pressure which resulted in inaccurate shift and rough ride.
In the new A/T which is adopted for the EF and XG-Car, there are solenoid valves for each clutch&brake which
enable control of both the disengaging and engaging clutch simultaneously for independent control. This system
provides a much smoother shift and comfortable ride as well as preventing Engine run-up or clutch interlock. In
additionto advanced shift feeling, the 1st gear is selected at the creep state for eliminating the shift shock during 2nd
gear → 1st gear.
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Skip Shift Control
Feedback Shift Control

The turbine speed is monitored and controlled during shifting to satisfy target turbine speed which is accomplished
by feedback control of solenoid valve duty value. Therefore the compensation of torque for the outworn engine or
A/T is possible. This has resulted in the ability to control the change in torque during shifting and produce smooth
shift and better shift feeling. Feedback shift control is also applicable in N→D and N→R.
Damper Clutch Control

The Lock-up clutch is designed in a torque converter for the fuel economy. The lock-up clutch works in low speed
range as minor slip.And it operates in high speed range as Full lock-up. Low fuel consumption and silence can be
obtained with combination of Partial lock-up and Full lock-up control.The damper clutch is operated in 3rd and 4th
gear in 4-speed ATA, 4th and 5th gear in 5ATA. In addition, Lock-up control is adapted in order to improve the
fuel economy, when reducing vehicle speed too.
Damper Clutch Operating Range
As all the conditions below are satisfied, it locks up. The cross point of throttle opening and turbine rpm is within
shadowed area.
- D range (more than 2nd speed), but damper clutch operating in 2nd speed, the ATF temperature must be higher
than 125 °C.
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- The TCM does not control under N → D or N → R.
- Oil temperature is above 50°C under full lock-up.
- Oil temperature is above 70°C under minor slip.
- The system is not under Fail - Safe (3rd gear hold) condition.
Uphill (above 5%) longer than 1.5sec. : Reducing speed Lock-up During this control, the vehicle is running uphill
(less than 2.5%) for 1sec., the partial lock-up control is functioned again.
Serial Communication Interface (SCI)
This uses a integrated computer which contains both the ECM and the TCM within the same unit. We will refer to
this unit as integrated ECM.
Communication Speed: 15.625Kbit/sec

Frequency: 20ms
If a fault occurs in either ECM or TCM, the entire integrated ECM must be replaced.
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. This method does not use a integrated ECM.
Input signals to TCM 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 through 'CAN communication'
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- Request signal for torque reduction
- ATF temperature, TCM type, TCM error or not
- Damper clutch ON, OFF / Gear position
TCM Pin Descripition
Terminal Number Wire Color Description

1 G SOLENOID VALVE(UD)
POWER 1(SOLENOID
2 P
VALVE)
POWER 2(SOLENOID
3 P
VALVE)
4 - -
5 - -
6 - -
7 - -
8 - AUTO CRUISE
9 - -
10 - -
11 O POWER(IG.1)
12 B EARTH FOR POWER
C24-1 13 B EARTH FOR POWER
14 Br SOLENOID VALVE(OD)
15 R/W SOLENOID VALVE(DCC)
16 W SOLENOID VALVE(2ND)
17 - -
18 - -
19 P POWER FOR FLASH ROM
20 - -
21 G/O SHIFT POSITION SIGNAL
22 - -
23 - -
24 O POWER(IG.1)
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1 W SENSOR-INPUT SPEED
2 W SENSOR-OUTPUT SPEED
3 - -
4 - -
5 - -
6 - -
7 - -
8 R/O POWER FOR S-RAM
C24-2
9 - -
10 - -
11 - -
12 - -
13 Br EARTH FOR SENSOR
14 Gr OIL TEMPERATURE SENSOR
15 - -
16 - -
1 - -
2 - -
3 O CAN-'HIGH'
4 G CAN-'LOW'
5 L INHIBITOR SW.(P)
6 P INHIBITOR SW.(N)
7 Y SPT SELECT SW.
8 W/B SPT DOWN SW.
9 W/B STOP LAMP SW.
10 - -
11 - -
C24-3
12 P SOLENOID VALVE(LR/DIR)
13 G/B K-LINE
14 - -
15 - -
16 Br INHIBITOR SW.(R)
17 Y INHIBITOR SW.(D)
18 R/B SPT UP SW.
19 - -
20 - -
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21 P A/T CONTROL RELAY
22 B EARTH FOR SIGNAL
Terminal Wire
PIN Description
NO. Color
1 - -
2 - -
3 - -
4 - -
5 W/B Sports down switch
6 P Inhibiter switch(N)
7 - -
8 - -
9 - -
10 - -
11 W Auto cruise
12 - -
13 R/B Sports up switch
C130- 14 Br Inhibiter switch(R)
2 15 - -
16 - -
17 - -
18 Br Sensor ground
19 W/B Stop switch
20 W Output speed sensor
21 Y Sports select switch
22 L Inhibiter switch(P)
23 - -
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24 G/O Shift signal(PWM)
25 - -
26 Gr Oil temperature sensor
27 - -
28 W Input speed sensor
29 Y Inhibiter switch(D)
30 - -
31 - -
32 P A/T relay
33 B Solenoid valve(OD)
C130- 34 - -
2 35 R/B Solenoid valve(DCC)
36 P Power source(SOL.)
37 B Ground1
38 L Solenoid valve(LR)
39 W Solenoid valve(2ND)
40 G Solenoid valve(UD)
TCM Input/output Signal Voltage Check Sheet

(Gasoline 2.7 Engine)
Input/Output Signal Test
No. Signal Name Condition Remark
Type Level Result
HI : V_BAT 14.5V
1 UD Solenoid Shifting Pulse
LO : Max . 1.0V 0.31V
2 IG Off Max. 1.0V 0.0mV
A/T PWR Source DC "L"
3 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
C24- 9 N.A - - - -
1
10 N.A - - - -
11 IG Off Max. 0.5 V 0.0mV
V_IG DC TCM
24 IG On V_BAT 12.4V
12 GND_PWR1 Idle DC Max. 50 mV 0.0mV
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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 - - - -
C24-
1 21 N.A - - - -
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
C24- 8 Key removal Below 1.0 mA 0.41mA
V_BAT vol. TCM
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 - - - -
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1 N.A - - - -
2 N.A - - - -
Recessive 2.0 ~ 3.0V 2.51V (Commnicatio speed :
3 CAN_HI Pulse
Dominant 2.75~4.5V 3.52V 500kbps)
Recessive 2.0 ~ 3.0V 2.48V (Commnicatio speed :
4 CAN_LO Pulse
Dominant 0.5~2.25V 1.49V 500kbps)
P Position V_BAT 13.8V
5 P Range Selection DC
C24- 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
Selection Otherwise Max. 1.0V 21mV
SPT Down Down Position V_BAT 13.9V
8 DC
Selection Otherwise Max. 1.0V 26mV
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 . 1.0V 0.27V
HI : Min V_BAT
GST 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 - - - -
R Position V_BAT 13.4V
C24- 16 R Range Selection Otherwise
DC
Max. 1.0V 0mV
3
D Position V_BAT 13.8V
17 D Range Selection DC
Up Position V_BAT 13.9V
18 SPT Up Selection 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 Signal
Automatic Transaxle System > Automatic Transaxle System > Repair procedures (F4A42-2)
Service Adjustment Procedure
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Page 28 of 153
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.
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) 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, 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. Ineither 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 shere it may be mistaken for a leak.
6. Insert the oil level gauge(A) 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 dve, 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 by the following
Page 29 of 153
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 sperated).
2. Start the engine and let the fluid drain out.
Running conditions : "N" range with engine idling.
The engine should be stooped 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 via the fasket, and tighten it the specified torque.
Tightening torque :
29 ~ 34Nm (290 ~ 340 kgf·cm, 21.4 ~ 25.1 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 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.
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Page 30 of 153
12. Firmly insert the oil level gauge(A) into the oil filler tube.
Automatic Transaxle System > Automatic Transaxle System > Troubleshooting (F4A42-2)
Troubleshooting
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.
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How To Select Vehicle And System

Operation Flow
1. Select "HYUNDAI VEHICLE DIAGNOSIS"
2. Select "VEHICLE NAME"
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Page 32 of 153
3. Select "AUTOMATIC TRANSAXLE SYSTEM"
Basic Application
Having connected and turned on scan tool, the vehicle and system selection must be made from the 1.0 HYUNDAI
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)
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 Troubleshooting Index
[Gasoline 2.0]
Page 33 of 153
DTC
No Description MIL Remark
code
1 P0707 Transmission Range Sensor Circuit Low Input ●
2 P0708 Transmission Range Sensor Circuit High Input ●
3 P0711 Transmission Fluid Temperature Sensor "A" Circuit Range/Performance ●
4 P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input ●
5 P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input ●
6 P0717 Input/Turbine Speed Sensor "A" Circuit No Signal ●
7 P0721 Output Speed Sensor (Pulse Generator B) Circuit Range / Performance ●
8 P0722 Output Speed Sensor (Pulse Generator B) Circuit No Signal ●
9 P0731 Gear 1 Incorrect Ratio ●
13 P0741 Torque Converter Clutch Circuit Performance or Stuck Off ●
14 P0743 Torque Converter Clutch Circuit Electrical ●
Shift Control Solenoid Valve "A" (Low-Reverse Brake Control Solenoid)-Open
15 P0750 ●
or Short
16 P0755 Shift Control Solenoid Valve "B" (Under Drive Solenoid)-Open or Short ●
17 P0760 Shift Control Solenoid Valve "C" (2nd Brake Control Solenoid) -Open or Short ●
18 P0765 Shift Control Solenoid Valve "D" (Over Drive Solenoid)-Open or Short ●
19 P0885 TCM Power Relay Open or Short (Ground) ●
20 U0001 CAN Communication Bus Off X
21 U0100 Lost Communication With ECM/PCM "A" X
[Gasoline 2.7]
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DTC
No Description MIL Remark
code
1 P0560 System Voltage X
2 P0605 Internal Control Module Read Only Memory(ROM) Error X
3 P0703 Stop Lamp (Brake) Switch Circuit Malfunction X
4 P0707 Transmission Range Sensor Circuit Low Input ●
5 P0708 Transmission Range Sensor Circuit High Input ●
6 P0711 Transmission Fluid Temperature Sensor "A" Circuit Range/Performance ●
7 P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input ●
8 P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input ●
9 P0715 Input/Turbine Speed Sensor "A" Circuit No Signal ●
10 P0720 Output Speed Sensor (Pulse Generator B) Circuit No Signal ●
15 P0741 Torque Converter Clutch Circuit Performance or Stuck Off ●
16 P0742 Torque Converter Clutch Circuit Stuck On ●
17 P0743 Torque Converter Clutch Circuit Electrical ●
Shift Control Solenoid Valve "A" (Low-Reverse Brake Control Solenoid)-Open
18 P0750 ●
or Short
19 P0755 Shift Control Solenoid Valve "B" (Under Drive Solenoid)-Open or Short ●
20 P0760 Shift Control Solenoid Valve "C" (2nd Brake Control Solenoid) -Open or Short ●
21 P0765 Shift Control Solenoid Valve "D" (Over Drive Solenoid)-Open or Short ●
22 P0885 TCM Power Relay Open or Short (Ground) ●
23 P1500 Vehicle Speed Sensor Signal Circuit Malfunction X
24 U0001 CAN Communication Bus Off X
25 U0100 Lost Communication With ECM/PCM "A" X
*: Malfunction Indication Lamp(MIL) will not be turned ON or blinked by only TCM DTCs. If MIL is on or
blinking, check the fuel or emission system.
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%
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700 Input speed rpm. Always output rpm
4 INPUT SPEED(PG-A) rpm 0 rpm
rpm when turning start ON
Output speed rpm. Always output
5 OUTPUT SPEED(PG-B) rpm 0 rpm 0 rpm
rpm when driving
DCC(TCC) SOLENOID Control 0% → 100% when operating
6 % 0%
DUTY Damper Clutch
DAMPER CLUTCH 260
7 rpm Current Damper clutch slip ratio 0 rpm
SLIP rpm
Control 100% → 0% when operating
8 LR SOLENOID DUTY % 100% 0%
brake
9 UD SOLENOID DUTY % 100% 0%
clutch
10 2ND SOLENOID DUTY % 100% 0%
clutch
11 OD SOLENOID DUTY % 100% 0%
clutch
12 OIL TEMPERATURE °C 40°C Current Oil temperature 80°C
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
15 HOLD/STD SWITCH -/-/HOLD/STD - -
OFF/ON/-/NOT
16 A/CON SWITCH OFF -
SUPP
OFF/ON/-/NOT
17 IDLE STATUS ON When idling, ON
SUPP
OFF/ON/-/NOT
18 BRAKE SWITCH ON When braking, ON
SUPP
OFF/ON/-/NOT
19 CRUISE SWITCH
SUPP
SPORT MODE SELECT OFF/ON/-/NOT
20 ON When selecting sport mode, ON
SW SUPP
OFF/ON/-/NOT
21 SPORT MODE UP SW ON When Selecting Sport mode up, ON
SUPP
SPORT MODE DOWN OFF/ON/-/NOT When selecting sport mode down,
22 ON
SW SUPP ON
A/T CONTROL RELAY
23 V 12.9V 0V
VOLT
24 ENGINE TORQUE % 20%
A/B/C/D is control mode, F is release
25 HIVEC MODE A/B/C/D/-/F F F
mode
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HIVEC -SAT(Siemens Adaptive Transmission Control) Mode (Shift Patten)
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 sportyt 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)
2 UD SOLENOID(SCSV B)
3 2ND SOLENOID(SCSV C) 1. IG Key ON
4 OD SOLENOID(SCSV D) Driving solenoid valve indicated 2. Inhibitor SW normal
by Scan tool for 5 sec. 3. P range
TORQUE CONVERTER SOLENOID
5 (Other solenoid valve is not 4. Vehicle speed 0km/h
VALVE
continuity) 5. Engine stop
6 1ST SHIFT INDICATOR LAMP Blinking for 3 sec. 6. No failure
7 2ND SHIFT INDICATOR LAMP 7. TPS < 1V
8 3RD SHIFT INDICATOR LAMP

9 4TH SHIFT INDICATOR LAMP
10 A/T CONTROL RELAY OFF for 3 sec.
11 INTELIIGENT SHIFT PROHIBIT Prohibit until IG off
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
C. Engine coolant temperature : 80~100°C
2. Prevent all the wheel from moving during the test.
3. Pull the parking brake lever up, with the brake pedal fully depressed.
4. Start the engine.
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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.
• 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 tue same test again.
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.
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.
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5. If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test
diagnosis table.
Standard Hydraulic Pressure Test

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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-
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-
1,010-1,050 500-700
1st gear 2,500 - - 1,050 -
(146-152) (73-101)
(146-152)
1,010-
1,010-1,050 500-700
2nd gear 2,500 - - - 1,050
D (146-152) (73-101)
(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
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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
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Clogged oil filter
Clogged oil cooler
Malfunction of the relief valve
Incorrect valve body installation
Hydraulic pressure is abnormal in "R" range only Malfunction of the regulator valve
Clogged orifice
Hydraulic pressure is abnormal in "3" or "4" range only Malfunction of the regulator valve
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 abnormal Malfunction of the oil seal K
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 abnormal Malfunction of the oil seal A
Malfunction of the oil seal B
Malfunction of the oil seal C
Clogged orifice
Only overdrive hydraulic pressure is abnormal Malfunction of the oil seal D
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
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Clogged orifice
Only low and reverse hydraulic pressure is abnormal Malfunction of the oil seal I
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 abnormal Malfunction of the oil cooler
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 > P0560 System Voltage
Component Location
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General Description
TCU saves "LEARNING VALUE" and keeps it at certain value. through this process,In order to "LEARNING
VALUE" is protected from being erased at disconnecting Battery cable and maintaining related components.
DTC Description
The TCM is detected an unexpected communication error with "EEPROM", the TCM sets this code.
DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC
• Check Voltage range
Strategy
• Ne is normal
Enable
• Ne ≥ 400rpm • Faulty TCM
Conditions
• Vb(Backup-line) ≥ 9V • Faulty in
Threshold harness
• Backup-line ≥7 Volt
Value
Diagnostic
• 10sec
Time
Power Circuit Inspection

1. Ignition "ON" Engine "OFF".
2. Disonnect the "C24-2" of PCM/TCM connector
3. Measure the voltage between terminal "8" of the "C24-2" of PCM/TCM harness connector and chassis ground.
Specification : Approx. B+
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4. Is voltage within specifications?
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.And Go to Component Inspection
procedure.
Check the Fuse37-10A is installed or not blown.
Check for open in harness. Repair as necessary and Go to "Verification Vehicle Repair"
procedure.
Component Inspection
1. Connect scantool to data link connector.
2. Ignition "ON" & Engine "OFF".
3. Monitor the "DTC"
4. Is DTC Re-displayed ?
Substitute with a known-good PCM/TCM and check for proper operation. If the problem
is corrected, replace PCM/TCM as necessary and then go to "Verification of Vehicle Repair"
procedure.
Go to "Verification of 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 you DTCs present?
Go to the applicable troubleshooting
procedure.
System performing to specification at this time.
Automatic Transaxle System > Automatic Transaxle System > P0605 Internal Control Module Read
Only Memory(ROM) Error
Component Location
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General Description
TCU saves "LEARNING VALUE" and keeps it at certain value. through this process,In order to "LEARNING
VALUE" is protected from being erased at disconnecting Battery cable and maintaining related components.

DTC Strategy • Check COMMUNICATION
Enable • COMMUNICATION ERROR WITH
Conditions "EEPROM"
• Faulty TCM
Threshold Value • Communication fail
Diagnostic Time •-
Fail Safe •-
2. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode.
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"
7. Is DTC Re-displayed ?
is corrected, replace PCM/TCM as necessary and then Go to "Verification of Vehicle Repair"
procedure.
or was repaired and TCM(PCM) memory was not cleared.And Go to Component Inspection
procedure.
METHOD OF LEARNING RESET

IT IS NECESSARY TO LEARNING RESET, AFTER REPLACED TRANSMISSION
1. ERASING CONDITION
(1) SELECT LEVER POSITION IS "P" OR "N"
(2) VEHICLE SPEED = 0 km/h
(3) IGNITION "ON" , ENGINE "OFF"
2. USING A SCAN TOOL, OPERATE "LEARNING" RESET
3. IG "ON" ↔ IG "OFF"(2~3 TIMES),AFTER RESET

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procedure.
Automatic Transaxle System > Automatic Transaxle System > P0703 Stop Lamp (Brake) Switch
Circuit Malfunction
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).

DTC Strategy • Check signal for B+ Short
• No(Output Speed Sensor) ≥ 240rpm • Short to battery in circuit
Enable Conditions
• Brake Switch "ON" • Faulty Brake SWITCH
Adjustment
Threshold Value • +B Short
• Faulty Brake SWITCH
Diagnostic Time • More than 5 min. • Faulty PCM
Fail Safe • Intelligent-Shift is inhibited
Monitor Scantool Data

1. Connect scantool to data link connector(DLC)
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3. Monitor the "BRAKE LAMP SWITCH" parameter on the scantool.
4. Depress and release Foot Brake.
Fig 1) Release foot brake status.

Fig 2) Depress foot brake status.
5. Does "STOP LAMP SWITCH" follow the referance data?
or was repaired and TCM(PCM) memory was not cleared. Throughly 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 "W/Harness Inspection" procedure.
Terminal and 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 "Signal Circuit Inspection" procedure.
Signal Circuit Inspection

2. Disconnect "BRAKE LAMP SWITCH" connector.
3. Measure voltage between teminal"1" of the sensor harness connector and chassis ground.
Specification : 0V

Go to "Component Inspection" procedure.
Check for Short to power circuit in harness. Repair as necessary and Go to "Verification
Vehicle Repair" procedure.
■ Check "STOP LAMP SWITCH"
1. Ignition "OFF"
2. Disconnect "STOP LAMP SWITCH" connector and Remove "STOP LAMP SWITCH" .
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3. Measure resistance between terminal "1" and "2" of the STOP LAMP SWITCH when plunger of the STOP
LAMP SWITCH is pushed in.
Specification : Infinite
Fig 1) Brake pedal is released-∞Ω

Fig 2) Brake pedal is depressed-0Ω
4. Is resistance within specifications ?
Go to "Adjust STOP LAMP SWITCH" as below.
Replace "STOP LAMP SWITCH" as necessary and Go to "Verification Vehicle Repair"
proceduredure.
■ Adjust "STOP LAMP SWITCH" Clearance

1. Ignition "OFF"
2. Reinstall "STOP LAMP SWITCH" .
3. Adjust "STOP LAMP SWITCH" Clearance as below
Specification : 0.9mm(0.04In)
Fig 1) Method of adjust : Screw in the "STOP LAMP SWITCH" until its plunger is fully de-pressed(threaded
end (A) touching the pad (B) on the pedal arm). Then back off the switch 3/4 turn to make 0.9mm(0.04In) of
clearance between the threaded end and pad Tighten the locknut firmly.Connect the "STOP LAMP SWITCH"
connector. Make sure that the stop lamp go off when the pedal is released.
4. After Adjusting, Has problem been solved ?
Go to "Verification 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 go to "Verification Vehicle Repair"
procedure.

procedure.
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Automatic Transaxle System > Automatic Transaxle System > P0707 Transmission Range Sensor
Circuit Low Input
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(PCM) sets this code when the Transaxle Range Switch has no output signal for more than 30 seconds.

DTC Strategy • Check for No signal
Enable Conditions • Continuous
• Open or short in circuit
Threshold Value • No signal detected • Faulty Shift cable adjustment
Diagnostic Time • More than 30sec • Faulty Inhibitor switch and
Manual control lever position
• Recognition as previous signal
adjustment
- When P-D or R-D or D-R SHIFT is detected, it is
regarded as N-D or N-R though "N" signal is not • Faulty TRANSAXLE
RANGE SWITCH
Fail Safe detected.
- When sports mode S/W is ON without P,R,N, D- • Faulty TCM(PCM)
RANGE signals, it is regarded sports mode.(DTC is
not set)
Signal Waveform
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1. Connect scantool to data link connector(DLC).
3. Monitor the "TRANSAXLE RANGE SWITCH" parameter on the scantool.
4. Move selector lever from "P" range to "L" range.
Fig 1) "P,N" RANGE

Fig 2) "R" RANGE
Fig 3) "D" RANGE
Fig 4) "3" RANGE
Fig 5) "2" RANGE
Fig 6) "L" RANGE
5. Does "TRANSAXLE RANGE SWITCH" follow the referance data?
Fault is intermittent caused by poor contact in the sensor's and/or TCM(PCM)'s connector
damage.Repair or replace as necessary and go to "Verification Vehicle Repair" procedure
Go to "W/Harness Inspection" procedure
Most of fault about inhibitor switch, result from faulty shift cable adjustment or incorrect location of manual
control lever and inhibitor switch. So, when DTC which related Inhibitor switch or engine start defectiveness at "P"
range happen, After check the shift cable adjustment or location of manual control lever and inhibitor switch, repair
or replace as necessary.

or damage.
procedure.
Go to "Power Circuit Inspection" procedure.

■ Check Power To Range Switch,,
1. Disconnect "TRANSAXLE RANGE SWITCH" connector.
Specification : approx. B+
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Go to "Signal Circuit Inspection" procedure
Check that Fuse24-10A is installed or not blown.
procedure

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 :
Pin No of "TRANSAXLE RANGE
C208 No1 C208 No3 C208 No4 C208 No7
SWITCH"
Pin No of "TCM(PCM)" harness C224-3No17 C224-3No5 C224-3No6 C224-3No16
Specification 0Ω 0Ω 0Ω 0Ω
4. Is resistance within specifications?

Check for Open in harness. Repair as necessary and Go to "Verification Vehicle Repair"
procedure.
1. Ignition "OFF".
2. Remove "TRANSAXLE RANGE SWITCH"
3. Measure the resistance between each teminal of the sensor.
Specification : Approx. 0 Ω
[ RANGE SWITCH continuity check table (Case of SPORTS MODE vehicle has no 3,2,L range) ]
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Terminal
Range
P R N D 3 2 L
1 ●
2 ●
3 ●
4 ●
5 ● ●
6
7 ●
8 ● ● ● ● ● ● ●
9 ● ●
10 ● ●

procedure.
Replace "TRANSAXLE RANGE SWITCH" as necessary and Go to "Verification Vehicle
Repair" procedure.

procedure.
Automatic Transaxle System > Automatic Transaxle System > P0708 Transmission Range Sensor
Circuit High Input
Component Location
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General Description
The Transaxle Range Switch sends the shift lever position information to the TCM 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 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.

DTC Strategy • Check for multiple signals
Threshold Value • Multiple signal • Open or short in
TRANSAXLE RANGE
Diagnostic Time • More than 30sec SWITCH
• Recognition as previous signal • Faulty TRANSAXLE
- When signal is input "D" and "N" at the same RANGE SWITCH
time,TCM regards it as "N" RANGE. • Faulty PCM
Fail Safe
- After PCM/TCM Reset,If the if the PCM/TCM
detects multiple signal or no signal, then it holds the
3rd gear position.
Signal Waveform

1. Connect scantool to data link connector(DLC).
3. Monitor the "TRANSAXLE RANGE SWITCH" parameter on the scantool.
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4. Shift selector lever from "P" range to other range.
Fig 1) "P,N" RANGE

Fig 2) "R" RANGE
Fig 3) "D" RANGE
Fig 4) "3" RANGE
Fig 5) "2" RANGE
Fig 6) "L" RANGE
5. Does "TRANSAXLE RANGE SWITCH" follow the referance data?
Fault is intermittent caused by poor contact in the sensor's and/or TCM(PCM)'s connector
damage.Repair or replace as necessary and go to "Verification Vehicle Repair" procedure
Most of fault about inhibitor switch, result from faulty shift cable adjustment or incorrect location of manual
control lever and inhibitor switch. So, when DTC which related Inhibitor switch or engine start defectiveness at "P"
range happen, After check the shift cable adjustment or location of manual control lever and inhibitor switch, repair

or damage.
procedure.

1. Disconnect "TRANSAXLE RANGE SWITCH" connector.
3. Measure voltage between each teminal(C09) of the sensor harness connector and chassis ground.
Specification :
Terminal(C15) 1 3 4 7 8 9 10
Specification 0V 12V(PULL UP) 12V(PULL UP) 0V 7V 0V 0V
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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 teminals of the sensor harness to check for Short.

Check for Short in harness. Repair as necessary and Go to "Verification Vehicle Repair"
procedure.
1. Ignition "OFF".
2. Remove "TRANSAXLE RANGE SWITCH"
3. Measure continuity(resistance) between each teminals of the sensor.
[ RANGE SWITCH continuity check table (Case of SPORTS MODE vehicle has no 3,2,L range) ]
Terminal
Range
P R N D 3 2 L
1 ●
2 ●
3 ●
4 ●
5 ● ●
6
7 ●
8 ● ● ● ● ● ● ●
9 ● ●
10 ● ●
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procedure.
Replace "TRANSAXLE RANGE SWITCH" as necessary and Go to "Verification Vehicle
Repair" procedure.

procedure.
Automatic Transaxle System > Automatic Transaxle System > P0711 Transmission Fluid Temperature
Sensor \'A\' Circuit Range/Performance
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 supplies a 5V reference
voltage to the sensor, and the output voltage of the sensor changes when the ATF temperature varies. The automatic
TRANSAXLE fluid(ATF) temperature provides very important data for the TCM’s control of the Torque
Converter Clutch, and is also used for many other purposes.
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 regards the ATF
temperature as fixed at a value of 80 °C(176°F).
Page 57 of 153

AT 2.7
Item Detecting Condition Possible cause
DTC Strategy • Check rationality
Enable Conditions1) • -4 °F ≤ OIL TEMP ≤ 248 °F, In condition that Oil TEMP
JUMP is changed over 10 degrees during 10 sec
Enable Conditions2)
• OIL TEMP ≥ 86°F and In case of OIL TEMP is higher 15
STUCK ON HIGH
degrees than WATER TEMP
TEMP
• Sensor signal circuit is
• OIL TEMP ≤ 86 °F short to ground.
Enable Conditions3)
• Ne ≥ 1000rpm • Faulty sensor
STUCK ON LOW
• Maintenance time : 10minutes • Faulty PCM
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
AT 2.0
DTC
• Rationality
Strategy
• Engine speed >1000rpm
• Output speed >1000rpm
Case Enable • Accumulated time in above two condition 5min
1 Conditions • A/T oil temp. at start-up and ambient temp. (<50°C)
and (>-7°C) or A/T oil temp. at start-up <30°C
Engine coolant temp. increase since start-up >40°C
Threshold
• A/T oil temp. change since start-up <2°C
Value
DTC
• Rationality stuck-high
Strategy
• A/T oil temp. at previous engine-off >50°C ATF T/S :Automatic
• Engine coolant temp. at previous engine-off >73.5°C Transmission Fluid Temperature
Case Enable • Engine coolant temp. drop from the previous engine- Sensor
2 Conditions off >34°C • OPEN OR SHORT IN
• Intake air temperature < 35°C CIRCUIT
• Time after TCM turns on 0.5sec • Faulty ATF T/S 1
• TCM
Threshold
• A/T oil temp. drop from the previous engine-of <2°C
Value
DTC
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Page 58 of 153
DTC
• Rationality-low
Strategy
Case Enable
3 Conditions
• Accumulated time in above two condition 5min
Threshold
• A/T oil temp. ≤-23°C
Value
Diagnostic Time • 1 event
Fail Safe
Specification
Temp.(°F) Resistance(kΩ) Temp.(°F) Resistance(kΩ)
-40(-40°F) 139.5 80(176°F) 1.08
-20(-4°F) 47.7 100(212°F) 0.63
0(32°F) 18.6 120(248°F) 0.38
20(68°F) 8.1 140(284°F) 0.25
40(104°F) 3.8 160(320°F) 0.16
60(140°F) 1.98

2. Engine "ON".
3. Monitor the "TRANSAXLE FLUID TEMPERATURE SENSOR" parameter on the scantool
Specification : Increasing Gradually
Fig 1) Normal
Fig 2) Signal harness Open
Fig 3) Signal harness Short
4. Does "TRANSAXLE FLUID TEMPERATURE SENSOR " follow the referance data?

Page 59 of 153
or damage.
procedure.
■ 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°F) 139.5 80(176°F) 1.08
-20(-4°F) 47.7 100(212°F) 0.63
0(32°F) 18.6 120(248°F) 0.38
20(68°F) 8.1 140(284°F) 0.25
40(104°F) 3.8 160(320°F) 0.16
60(140°F) 1.98

Go to "CHECK PCM/TCM " as below.
Replace "TRANSAXLE FLUID TEMPERATURE SENSOR" as necessary and Go to
"Verification Vehicle Repair" procedure.
■ 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.
Fig 1) INPUT 1.02V → 215°F

Fig 2) INPUT 2.02V → 154°F
The values are subject to change according to vehicle model or conditions.
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Page 60 of 153
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.
procedure.

procedure.
Sensor \'A\' Circuit Low Input
Component Location
General Description
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 regards the ATF
Page 61 of 153
temperature as fixed at a value of 80 °C(176°F).

DTC Strategy • Check for ground short
• Sensor signal circuit is short
Threshold Value • Voltage <0.49V to ground.
• Faulty sensor
Diagnostic Time • More than 1sec
• Faulty PCM
Fail Safe
• Fluid temperature is regarded as 80°C(176°F).
Specification
-40(-40°F) 139.5 80(176°F) 1.08
-20(-4°F) 47.7 100(212°F) 0.63
0(32°F) 18.6 120(248°F) 0.38
20(68°F) 8.1 140(284°F) 0.25
40(104°F) 3.8 160(320°F) 0.16
60(140°F) 1.98

2. Engine "ON".
Fig 1) Normal
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Page 62 of 153
or damage.
procedure.

3. Measure the voltage between terminal "1" of the "TRANSMISSION FLUID TEMPERATURE SENSOR"
harness connector and chassis ground.
Specification : Approx. 5 V
4. Is voltage within specifications ?

Check for short to ground in harness. Repair as necessary and Go to "Verification Vehicle
Repair" procedure.
1. Ignition "OFF"
SENSOR".
[Reference data]
TEMP.(°F) RESISTANCE(kΩ) TEMP.(°F) RESISTANCE(kΩ)
-40(-40°F) 139.5 80(176°F) 1.08
-20(-4°F) 47.7 100(212°F) 0.63
0(32°F) 18.6 120(248°F) 0.38
20(68°F) 8.1 140(284°F) 0.25
40(104°F) 3.8 160(320°F) 0.16
60(140°F) 1.98
Page 63 of 153

Replace "TRANSAXLE FLUID TEMPERATURE SENSOR" as necessary and Go to
■ Check TCM
4. Simulate voltage (0→5V) to "TRANSMISSION FLUID TEMPERATURE SENSOR" signal circuit.
Fig 1) INPUT 1.02V → 215°F

Fig 2) INPUT 2.02V → 154°F
procedure.

procedure.
Sensor \'A\' Circuit High Input
Component Location
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Page 64 of 153
General Description
DTC Description
This DTC code is set when the ATF temperature output voltage is higher than a value generated by thermistor
resistance, in a normal operating range, for an extended period of time . The TCM regards the ATF temperature as
fixed at a value of 80 °C(176°F).

DTC Strategy • Check voltage range
• Engine speed > 2000rpm ,
Enable
• Output speed > 1000rpm
Conditions(1)
• Accumulated time in above condition : 10 min
Enable Conditions(1) or
Enable • Engine speed > 700rpm , • Open in circuit.
Conditions(2) • Engine Coolant Temperature > 35 °C • Faulty sensor
• Accumulated time in above condition : 60 sec • Faulty PCM/TCM
Threshold Value • Voltage > 4.5V
• Learning control and Intelligent shift are
Fail Safe inhibited.
Specification
Page 65 of 153
-40(-40°F) 139.5 80(176°F) 1.08
-20(-4°F) 47.7 100(212°F) 0.63
0(32°F) 18.6 120(248°F) 0.38
20(68°F) 8.1 140(284°F) 0.25
40(104°F) 3.8 160(320°F) 0.16
60(140°F) 1.98

2. Engine "ON".
Fig 1) Normal

or damage.
procedure.

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Page 66 of 153
3. Measure the voltage between terminal "1" of the "TRANSMISSION FLUID TEMPERATURE SENSOR"

Go to "Ground circuit inspection" procedure.
Repair" procedure.
Ground Circuit Inspection

1. Ignition "OFF"
3. Measure the resistance between terminal "2" of the "TRANSMISSION FLUID TEMPERATURE SENSOR"

procedure.
1. Ignition "OFF"
Page 67 of 153
SENSOR".
[Reference data]
-40(-40°F) 139.5 80(176°F) 1.08
-20(-4°F) 47.7 100(212°F) 0.63
0(32°F) 18.6 120(248°F) 0.38
20(68°F) 8.1 140(284°F) 0.25
40(104°F) 3.8 160(320°F) 0.16
60(140°F) 1.98

Replace OIL TEMPERATURE SENSOR as necessary and Go to "Verification Vehicle
Repair" procedure.
■ Check TCM
4. Simulate voltage (0→5V) to OIL TEMPERATURE SENSOR signal circuit.
Fig 1) INPUT 1.02V → 215°F

Fig 2) INPUT 2.02V → 154°F
procedure.

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Page 68 of 153
procedure.
Automatic Transaxle System > Automatic Transaxle System > P0715 Input/Turbine Speed Sensor \'A\'
Circuit No Signal
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 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 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 if this code is detected.

DTC Strategy • Speed rationality check
• Vehicle speed is over 19 Mile/h(30 Km/h) in
D,3,2,L(A/T range swhitch) and SP(SPORTS
MODE) • Signal circuit is open or short.
Enable Conditions
• But do not check the DTC in below condition • Sensor power circuit is open
- A/T oil temp sensor voltage >4.5 V • Sensor ground circuit is open
- Eng revolution < 2600 rpm • Faulty INPUT SPEED
SENSOR
Threshold Value • No signal
• Faulty PCM/TCM
• Locked into 3rd or 2nd gear.
Fail Safe
• Manual shifting is possibe(2nd → 3rd, 3rd → 2nd)
Page 69 of 153
Specification
Input shaft & Output shaft speed sensor
• Type : Hall sensor
• Current consumption : 22mA(MAX)
• Sensor body and sensor connector have been unified as one.
Signal Waveform

2. Engine "ON".
3. Monitor the "INPUT SPEED SENSOR" parameter on the scantool
4. Driving at speed of over 19 Mile/h(30 Km/h)
Fig 1) Idling
Fig 2) Accelerating
5. Does "Input Speed Sensor " follow the referance data?

or damage.
procedure.

2. Disconnect the "INPUT SPEED SENSOR" connector
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Page 70 of 153
3. Measure voltage between terminal "2" of the INPUT SPEED SENSOR harness connector and chassis ground .
Specification : Approx. 5V

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 PCM/TCM" of the "Component Inspection"
procedure.


Go to "Ground Circuit Inspection" procedure.
procedure.
Ground Circuit inspection

3. Measure resistance between terminal "1" of the INPUT SPEED SENSOR harness connector and chassis ground
.

procedure.
If ground circuit in harness is OK, Go to "Check PCM/TCM" of the "Component
Inspection" procedure.
■ Check "INPUT SPEED SENSOR"
Page 71 of 153
1. Ignition "OFF"
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
Input sensor Above 4 MΩ
Resistance
Output sensor Above 4 MΩ
High 4.8 ~ 5.2V
Voltage
Low Below 0.8V

Replace "INPUT SPEED SENSOR" as necessary and Go to "Verification Vehicle Repair"
procedure.
■ Check PCM/TCM
2. Connect "INPUT SPEED SENSOR" connector.
3. Install scantool and slect a SIMU-SCAN,
4. Simulate frequency to INPUT SPEED SENSOR signal circuit.
Fig 1) INPUT 150Hz → 150rpm

5. Is "INPUT SPEED SENSOR" signal value changed according to simulation frequency?
procedure.

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Page 72 of 153
procedure.
Automatic Transaxle System > Automatic Transaxle System > P0717 Input/Turbine Speed Sensor \'A\'
Circuit No Signal
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 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 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 if this code is detected.

• Vehicle speed is over 19 Mile/h(30 Km/h) and
Enable Conditions Ne≥2000rpm in D,3,2,L(A/T range swhitch) and • Signal circuit is open or short.
SP(SPORTS MODE) • Sensor power circuit is open
• Sensor ground circuit is open
• Faulty INPUT SPEED
Diagnostic Time • 4sec SENSOR
• Locked into 3rd or 2nd gear • Faulty PCM/TCM
Fail Safe • Manual shifting is possibe (2 nd → 3 rd ,3 rd → 2
nd)
Page 73 of 153
Specification
Signal Waveform

2. Engine "ON".
3. Monitor the "INPUT SPEED SENSOR" parameter on the scantool
Fig 1) Idling
Fig 2) Accelerating
5. Does "Input Speed Sensor " follow the referance data?

or damage.
procedure.

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Page 74 of 153

Repair" procedure.
procedure.


procedure.

3. Measure resistance between terminal "1" of the INPUT SPEED SENSOR harness connector and chassis ground
.

procedure.
■ Check "INPUT SPEED SENSOR"
Page 75 of 153
1. Ignition "OFF"
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
Resistance
High 4.8 ~ 5.2V
Voltage
Low Below 0.8V

Replace "INPUT SPEED SENSOR" as necessary and Go to "Verification Vehicle Repair"
procedure.
■ Check PCM/TCM
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?
procedure.

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Page 76 of 153
procedure.
Automatic Transaxle System > Automatic Transaxle System > P0720 Output Speed Sensor (Pulse
Generator B) Circuit No Signal
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 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 will initiate the fail
safe function if this code is detected.

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D,3,2,L(A/T range swhitch) and SP(SPORTS
MODE)
Enable Conditions
• But do not check the DTC in below condition • Signal circuit is open or short.
- A/T oil temp sensor voltage >4.5 V
• Sensor power circuit is open
- Eng revolution < 2600 rpm(In 1st or 2nd gear)
• If the output from the output speed sensor is • Faulty OUTPUT SPEED
Threshold Value continuously 50% lower than the value calculated by SENSOR
vehicle speed sensor. • Faulty PCM
Fail Safe • Apply an electric current to Solenoide valve
Specification
Signal Waveform

2. Engine "ON".
3. Monitor the "OUTPUT SPEED SENSOR" parameter on the scantool
Fig 1) Low-speed
Fig 2) High-speed
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Page 78 of 153
5. Does "Output Speed Sensor" follow the referance data?

or damage.
procedure.

2. Disconnect the "OUTPUT SPEED SENSOR" connector
3. Measure voltage between terminal "2" of the OUTPUT SPEED SENSOR harness connector and chassis ground
.

Repair" procedure.
procedure.

.
Page 79 of 153
procedure.

3. Measure resistance between terminal "1" of the OUTPUT SPEED SENSOR harness connector and chassis
ground .

procedure.
■ Check "OUTPUT SPEED SENSOR"
1. Ignition "OFF"
3. Measure resistance between terminal "1","2" and "2","3" and "1","3" of the "OUTPUT SPEED SENSOR"
connector.
[Reference data]
Data Reference Data
Current 22 mA
Input sensor 1.3 mm
Air Gap
Resistance
High 4.8 ~ 5.2V
Voltage
Low Below 0.8V
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Page 80 of 153
Replace "OUTPUT SPEED SENSOR" as necessary and Go to "Verification Vehicle
Repair" procedure.
■ Check PCM/TCM
2. Connect "OUTPUT SPEED SENSOR" connector.
4. Simulate frequency to OUTPUT SPEED SENSOR signal circuit.
Fig 1) OUTPUT 150Hz → 150rpm

5. Is "OUTPUT SPEED SENSOR" signal value changed according to simulation frequency?
procedure.

procedure.
Automatic Transaxle System > Automatic Transaxle System > P0721 Output Speed Sensor Circuit
Range/Performance
Component Location
Page 81 of 153
General Description
DTC Description

Enable Conditions D,3,2,L(A/T range swhitch) and SP(SPORTS
MODE) • Signal circuit is open or short.
• Sensor power circuit is open
• If the output from the output speed sensor is
Threshold Value continuously 50% lower or higrer than the value • Sensor ground circuit is open
calculated by vehicle speed sensor. • Faulty OUTPUT SPEED
SENSOR
Diagnostic Time • More than 1sec • Faulty PCM
Specification
Signal Waveform [email protected]

Page 82 of 153

2. Engine "ON".
Fig 1) Low-speed
Fig 2) High-speed

or damage.
procedure.

.
Page 83 of 153
Repair" procedure.
procedure.

.

procedure.

ground .

procedure.
1. Ignition "OFF"
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Page 84 of 153
connector.
[Reference data]
Data Reference Data
Current 22 mA
Input sensor 1.3 mm
Air Gap
Resistance
High 4.8 ~ 5.2V
Voltage
Low Below 0.8V

Repair" procedure.
■ Check PCM/TCM

procedure.

Page 85 of 153
procedure.
Automatic Transaxle System > Automatic Transaxle System > P0722 Output Speed Sensor Circuit No
Signal
Component Location
General Description
DTC Description

• Vehicle speed is over 19 Mile/h(30 Km/h) and
Enable Conditions Ne≥2000rpm in D,3,2,L(A/T range swhitch) and • Signal circuit is open or short.
SP(SPORTS MODE) • Sensor power circuit is open
• Faulty OUTPUT SPEED
Diagnostic Time • More than 1sec SENSOR
• Locked into 3rd or 2nd gear. • Faulty PCM
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Page 86 of 153
Specification
Signal Waveform

2. Engine "ON".
Fig 1) Low-speed
Fig 2) High-speed

or damage.
procedure.

Page 87 of 153
.

Repair" procedure.
procedure.

.

procedure.

ground .

procedure.
Component Inspection [email protected]

Page 88 of 153
1. Ignition "OFF"
connector.
[Reference data]
Data Reference Data
Current 22 mA
Input sensor 1.3 mm
Air Gap
Resistance
High 4.8 ~ 5.2V
Voltage
Low Below 0.8V

Repair" procedure.
■ Check PCM/TCM

procedure.

Page 89 of 153
procedure.
Automatic Transaxle System > Automatic Transaxle System > P0731 Gear 1 Incorrect Ratio
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.
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Page 90 of 153
DTC Strategy • 1st gear incorrect ratio
• Shift stage 1st. gear
Enable Conditions • Input speed >0rpm
• A/T oil temp sensor voltage <4.5V • Faulty Input speed sensor
• Voltage of Battery >10V • Faulty output speed sensor
• TRANSAXLE RANGE SWITCH is normal • Faulty UD clutch or LR brake
• | Input speed/1st gear ratio - output speed| ≥200rpm or Oneway clutch
Threshold Value
/ 1st.gear ratio
• Locked into 3rd gear.(If diagnosis code P0731 is
Fail Safe output four times, the transaxle is locked into 3rd
gear)
Signal Waveform
A : INPUT SPEED SENSOR

B : OUTPUT SPEED SENSOR

2. Engine "ON".
3. Monitor the "ENGINE SPEED, INPUT SPEED SENSOR, OUTPUT SPEED SENSOR, GEAR POSITION"
parameter on the scantool
4. Perform the "STALL TEST" with gear position "1"
Specification : 2000~2700 engine rpm
Operating Element Of Each Shifting Range

P ●
R ● ●
N ●
D1 ● ● ○
D2 ● ●
D3 ● ●
D4 ● ●
Page 91 of 153
Low & Reverse Brake is released When the vehicle speed over the 5MPH(7km/h)
Stall test procedure in D1 and reason

Procedure
1. Warm up the engine
2. 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
1. If there is no mechanical defaults in A/T, every slippage occur in torque converter.
2. Therfore, engine revolution is output, but input and output speed revolution must be "zero" due to
wheel's lock.
3. If 1st gear operating part has faults, input speed revolution will be out.
4. If oupput speed revolution is output. It means that the foot brake force is not applied fully. Remeasuring
is required.
5. Is "STALL TEST " within specifications?
Go to "Component inspection" procedure
1. Do not let anybody stand in front of or behind the vehicle while this test is being carried out.
2. 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 : 176 °F~ 212 °F (80~100 °C).
● Engine coolant temperature : 176 °F~ 212 °F (80~100 °C).
3. Chock both rear wheel(left and right).
4. Pull the parking brake lever on with the brake pedal fully depressed.
5. The throttle should not be left fully open for more than eight second.
6. 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
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Page 92 of 153
5. Is "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.
1. Connect Oil pressure guage 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 :
Measurement Condition Standard hydraulic pressure kPa
Low and D
Under drive Overdrive Second Damper
Select Engine reverse c
Shift clutch Reverse clutch clutch brake clutch
level speed brake r
position pressure pressure(REV) pressure pressure apply
position rpm pressure pr
(UD) (OD) (2ND) pressure(DA)
(LR)
P - 2,500 - - - 260~340 - - 22
R Reverse 2,500 - - 1,270~1,770 - - 50
N Neutral - - - - 260~340 - - 22
1st gear 2,500 1,010~0,050 - - 1,010~0,050 - - 50
2nd
2,500 1,010~0,050 - - - 1,010~0,050 - 50
D gear
3rd gear 2,500 780~880 - 780~880 - - More than 750 45
4th gear 2,500 - - 780~880 - 780~880 More than 750 45
The values are subject to change according to vehicle model or conditions

5. Is oil pressure value within specifications?
Repair AUTO TRANSAXLE(Clutch or Brake) as necessary and Go to "Verification
Replace AUTO TRANSAXLE (BODY CONTROL VALVE faulty) as necessary and Go
to "Verification Vehicle Repair " procedure.

Page 93 of 153
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 2nd
gear ratio, while the transaxle is engaged in the 2nd gear. For example, if the output speed is 1000 rpm and the 2nd
gear ratio is 1.529, then the input speed is 1529 rpm.
DTC Description
2nd gear ratio, while the transaxle is engaged in 2nd gear. This malfunction is mainly caused by mechanical troubles
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Page 94 of 153
• Shift stage 2nd. gear,
• TRANSAXLE RANGE SWITCH is normal • Faulty UD clutch or 2nd
• Input speed/2nd gear ratio - output speed brake
Threshold Value
≥200rpm /2nd. gear ratio
• Locked into 3 rd gear.(If diagnosis code P0732 is
gear)
Signal Waveform


2. Engine "ON".
4. Perform the "STALL TEST" with gear position "2"

P ●
R ● ●
N ●
D1 ● ● ○
D2 ● ●
D3 ● ●
D4 ● ●
Page 95 of 153

Procedure
2. After positioning the select lever in "D" or "ON" of the HOLD SW ( Operate UP SHIFT in case of
"SPORTS MODE"),depress the foot brake pedal fully after that, depress the accelerator pedal to the
maximum
* The slippage of 2ND BRAKE can be detected by stall test in D2
wheel’s lock.
3. If 2nd brake system(2nd gear operating part) has faults, input speed revolution will be out.
4. If oupput speed revolution is output. It means that the foot brake force is not applied fully. Remeasuring
is required.
5. Is "STALL TEST " within specifications?


1. Connect Scantool
2. Engine "ON".
4. Accelerate the Engine speed until about 2000 rpm in the 1st gear
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Page 96 of 153
Repair" procedure.
1. Connect Oil pressure guage to "UD" and "2ND" port.
2. Engine "ON".
3. Drive a car with gear position 2 in "SPORTS MODE".
Specification :
Low and D
level speed brake r
(LR)
P - 2,500 - - - 260~340 - - 22
R Reverse 2,500 - - 1,270~1,770 - - 50
N Neutral - - - - 260~340 - - 22
1st gear 2,500 1,010~0,050 - - 1,010~0,050 - - 50
2nd
2,500 1,010~0,050 - - - 1,010~0,050 - 50
D gear
3rd gear 2,500 780~880 - 780~880 - - More than 750 45
4th gear 2,500 - - 780~880 - 780~880 More than 750 45


Page 97 of 153
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
gear ratio is 1.000, then the input speed is 1,000 rpm.
DTC Description
3rd gear ratio, while the transaxle is engaged in 3rd gear. This malfunction is mainly caused by mechanical troubles
[email protected]
Page 98 of 153
DTC Strategy • 3rd gear incorrect ratio
• Shift stage 3rd. gear
• TRANSAXLE RANGE SWITCH is normal • Faulty UD clutch or OD
• | Input speed/3rd gear ratio - output speed| clutch
Threshold Value
≥200rpm/3rd. gear ratio
• Locked into 3rd gear. (If diagnosis code P0733 is
gear)
Signal Waveform


2. Engine "ON".
4. Disconnect the solenoide valve connector and perform the "STALL TEST"

P ●
R ● ●
N ●
D1 ● ● ○
D2 ● ●
D3 ● ●
D4 ● ●
Page 99 of 153

Procedure
2. After making 3rd gear hold by disconnecting the solenoid connector, and Then depress the foot brake
pedal fully After that, step on the accelerator pedal to the maximum
* The slippage of OD clutch can be detected by stall test in D3.
wheel’s lock.
3. If OD clutch system(3rd gear operating part) has faults, input speed revolution will be output.
4. If output speed revolution is output. It means that the foot brake force is not applied fully. Remeasuring
is required.
5. Does "STALL TEST " within specifications?

1. Connect Scantool
2. Engine "ON".
4. Accelerate the Engine speed until about 2000 rpm in the 3rd gear
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Page 100 of 153
Repair" procedure.
1. Connect Oil pressure guage to "UD" and "OD" port.
2. Engine "ON".
3. Drive a car with gear position 3 in fail mode
Specification :
Low and D
level speed brake r
(LR)
P - 2,500 - - - 260~340 - - 22
R Reverse 2,500 - - 1,270~1,770 - - 50
N Neutral - - - - 260~340 - - 22
1st gear 2,500 1,010~0,050 - - 1,010~0,050 - - 50
2nd
2,500 1,010~0,050 - - - 1,010~0,050 - 50
D gear
3rd gear 2,500 780~880 - 780~880 - - More than 750 45
4th gear 2,500 - - 780~880 - 780~880 More than 750 45


Page 101 of 153
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
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Page 102 of 153
• Shift stage 4th. gear
• TRANSAXLE RANGE SWITCH is normal • Faulty UD clutch or 2nd
• Input speed/4th gear ratio - output speed brake
Threshold Value
≥200rpm /4th. gear ratio
• Locked into 3rd gear.(If diagnosis code P0734 is
gear)
Signal Waveform


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

1. Connect Scantool
2. Engine "ON".
Page 103 of 153
4. Accelerate the Engine speed until about 2000 rpm in the 4th gear

Repair" procedure.
1. Connect Oil pressure guage to "OD" and "2nd" port.
2. Engine "ON".
3. Drive a car with gear position "4 "
Specification :
Low and D
level speed brake r
(LR)
P - 2,500 - - - 260~340 - - 22
R Reverse 2,500 - - 1,270~1,770 - - 50
N Neutral - - - - 260~340 - - 22
1st gear 2,500 1,010~0,050 - - 1,010~0,050 - - 50
2nd
2,500 1,010~0,050 - - - 1,010~0,050 - 50
D gear
3rd gear 2,500 780~880 - 780~880 - - More than 750 45
4th gear 2,500 - - 780~880 - 780~880 More than 750 45


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Page 104 of 153
procedure.
Automatic Transaxle System > Automatic Transaxle System > P0741 Torque Converter Clutch Circuit
Performance or Stuck Off
General Description
The PCM/TCM 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 PCM/TCM 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 PCM/TCM 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 PCM/TCM increases
the duty ratio by appling more hyraulic pressure. When slip rpm does not drop under some value with 100% duty
ratio, the PCM/TCM determines that the Torque Converter Clutch is stuck OFF and sets this code.

DTC Strategy • Stuck "OFF"
• A/T range switch D,SP(sports mode) TORQUE
Enable Conditions
• Solenoid valve stetus is 100% duty CONVERTER(DAMPER)
• Calculated slip(engine speed-input speed) > CLUTCH : TCC
Threshold Value • Faulty TCC or oil pressure
160rpm(need to verify Threshold value)
system
Diagnostic Time • More than 4sec • Faulty TCC solenoid valve
• Damper clutch abnormal system(If diagnosis code • Faulty body control valve
P0741 is output four times, TORQUE • Faulty PCM/TCM
Fail Safe
CONVERTER(DEMPER) CLUTCH is not
controlled by PCM/TCM)

2. Engine "ON".
3. Sellect "D RANGE" and drive vehicle
Page 105 of 153
4. Monitor the "TORQUE CONVERTER(DAMPER) CLUTCH" parameter on the scantool
Specification : TCC SLIP<160RPM(In condition that TCC SOL. DUTY > 80% )
Fig 1) Normal status

5. Are "TCC SOLENOID DUTY and TCC SLIP" within specifications ?
■ Check Torque Converter Clutch Solenoid Valve
3. Select A/T Solenoid valve Actuator test and Operate Actuator test.
4. Can you hear operating sound 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.
■ Check Oil Pressure

1. Connect Oil pressure guage to "DA" port.
2. Engine "ON".
3. After connecting Scantool and monitor the "TCC SOLENIOD VALVE DUTY" parameter on the Scantool data
list.
4. Operate vehicle with 3rd or 4tf gear and operate the "TCC SOLENIOD VALVE DUTY" more than 85%.
Specification : Oil pressure guage approx 735.4960KPa(7.5kg/cm²)-(In condition that TCC

SOL. DUTY > 85%)

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 Vehicle Repair " procedure.

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Page 106 of 153
procedure.
Stuck On
General Description
The PCM/TCM 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 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 PCM/TCM 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
applies 0% duty ratio value, then the TCM determines that the Torque Converter Clutch is stuck ON and sets this
code.

DTC Strategy • Stuck "ON"
• Throttle position >1.5V
Enable Conditions • Solenoid status OFF TORQUE
• A/T range switch D,SP CONVERTER(DAMPER)
• Time after TCC release >5secs CLUTCH : TCC
• (Rationality-low) Calculated slip (engine speed-input • Faulty TCC or oil pressure
Threshold Value speed)<5rpm or (rationality-high) Calculated slip >- system
5rpm • Faulty TCC solenoid valve
• Faulty body control valve
• Faulty TCM(PCM)
• Damper clutch abnormal system (If diagnosis code
P0741 is output four times, TORQUE
Fail Safe
CONVERTER(DEMPER) CLUTCH is not
controlled by PCM/TCM)

2. Engine "ON".
3. Sellect "D RANGE" and drive vehicle
Page 107 of 153
4. Monitor the "TORQUE CONVERTER(DAMPER) CLUTCH" parameter on the scantool
Specification : TCC SLIP>5RPM
Fig 1) Normal status

5. Are "TCC SOLENOID DUTY and TCC SLIP" within specifications ?
■ Check Torque Converter Clutch Solenoid Valve
3. Select A/T Solenoid valve Actuator test and Operate Actuator test.
Go to "CHECK OIL PRESSURE" as below.
Replace "TCC SOLENOID VALVE" as necessary and Go to "Verification Vehicle Repair"
procedure.
■ Check Oil Pressure

1. Connect Oil pressure guage 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

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 Vehicle Repair " procedure.

[email protected]
Page 108 of 153
procedure.
Electrical
Component Location
General Description
The PCM/PCM/TCM 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 PCM/PCM/TCM 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 PCM/PCM/TCM 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 PCM/PCM/TCM judges that
DCCSV circuit is malfunctioning and sets this code.

TORQUE
• Solenoid status Either solid On or OFF CONVERTER(DAMPER)
Enable Conditions CLUTCH : TCC
• Voltage of Battery >10V
Threshold Value • Voltage <3V
• Faulty TCC SOLENOID
Diagnostic Time • More than 320 ms VALVE
• Faulty PCM/TCM
Fail Safe • Locked in 3 rd gear.(Control relay off)
Page 109 of 153
Specification
Solenoid Valve for Pressure Control
- Sensor type : Normal open 3-way
- Operating temperature : -30°C~130°C
- Frequency : LR, 2ND, UD, OD, RED : 61.27Hz (at the ATF temp. -20°C above)
DCC : 30.64Hz
KM series : 35Hz
- Internal resistance : 2.7~3.4Ω(20°C)
- Surge voltage : 56 V

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%
Fig 1) P,N
Fig 2) "R"
Fig 3) "D 1st" grar
Fig 4) "2nd" gear
Fig 5) "3rd" gear
Fig 6) "4th" gear
5. Does "TCC SOLENOID DUTY " follow the referance data?
Go to "W/Harness Inspection " procedure.

or damage.
procedure.

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Page 110 of 153
1. Disconnect "A/T SOLENOID VALVE" connector.
3. Turn ignition switch OFF → ON
Specification: 12V is measured only for approx. 0.5sec

Check that A/T-30A Fuse in engine room junction is installed or not blown.
procedure.

■ Check Signal Circuit Open Inspection
1. Ignition "OFF"
2. Disconnect "A/T SOLENOID VALVE" connector and "PCM/TCM" connector
3. Measure resistance between terminal "7" of the ATM SOLENOID VALVE harness connector and terminal "15"
of the TCM harness connector
Specification: Approx. 0 Ω

Go to "Check signal circuit short Inspection" procedure.
Check for open in harness. Repair as necessary and Go to "Verification of Vehicle Repair"
procedure.
■ Check Signal Circuit Short Inspection

1. Engine "OFF".
3. Measure resistance between terminal "7" of the ATM SOLENOID VALVE harness and chassis ground.
Specification: Infinite

Repair" procedure.
■ Check Solenoid Valve
Page 111 of 153
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)

Go to "CHECK PCM/TCM" as below.
Replace TCC SOLENOID VALVE as necessary and go to "Verification Vehicle Repair"
procedure .
■ Check PCM/TCM
3. Select A/T Solenoide valve Actuator test and Operate Actuator test.
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

procedure.
Automatic Transaxle System > Automatic Transaxle System > P0750 Shift Control Solenoid Valve \'A\'
(Low-Reverse Brake Control Solenoid)-Open or Short
Component Location [email protected]
Page 112 of 153
General Description
The Automatic Transmission changes the gear position of the transmission by utilizing a combination of Clutches and
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 checks the Low and Reverse 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 judges that the Low and Reverse
control solenoid circuit is malfunctioning and sets this code.

• Solenoid status Either solid On or OFF
Enable Conditions • Open or short in circuit
• Faulty LR SOLENOID
Threshold Value • Voltage <3V VALVE
• Faulty PCM/TCM
Diagnostic Time • More than 320 ms
Specification
DCC : 30.64Hz
KM series : 35Hz
Page 113 of 153
2. Engine "ON".
3. Monitor the "LR SOL. VALVE" parameter on the scantool
4. Shift gear position 1st to 2nd.
Specification: 1st → 0.0%, 2nd → 100%
Fig 1) P,N
Fig 2) "R"
Fig 3) "D 1st" gear
Fig 4) "2nd" gear
Fig 5) "3rd" gear
Fig 6) "4th" gear
5. Does "LR SOLENOID DUTY " follow the referance data?

or damage.
procedure.

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Page 114 of 153
procedure.

1. Ignition "OFF"
of the PCM/TCM harness connector.

procedure.

1. Engine "OFF".

Repair" procedure.
1. Ignition "OFF"
Page 115 of 153
3. Measure resistance between terminal "6" and terminal "10" of the ATM SOLENOID VALVE harness
connector.

Replace LR SOLENOID VALVE as necessary and go to "Verification Vehicle Repair"
procedure.
■ Check PCM/TCM
4. Can you hear operating sound for sound LR SOLENOID VALVE Actuator Testing Function ?
procedure.

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

procedure.
Automatic Transaxle System > Automatic Transaxle System > P0755 Shift Control Solenoid Valve \'B\'
(Under Drive Solenoid)-Open or Short
Component Location
[email protected]
Page 116 of 153
General Description
The Automatic Transmission changes the gear position of the transmission utilizing a combination of Clutches and
Clutch ), and RED ( Reduction Brake, only for 5 speed transmissions). The UD Clutch is engaged in the 1st gear,
2nd gear and 3rd gear positions.
DTC Description
The TCM checks the Under Drive Clutch Control Signal by monitoring the feedback signal from the solenoid valve
expected, or low voltage is detected when high voltage is expected), the TCM judges that Under Drive Clutch
contorl solenoid circuit is malfunctioning and sets this code.

• Faulty UD SOLENOID
• Faulty PCM/TCM
Specification
DCC : 30.64Hz
KM series : 35Hz
Page 117 of 153
2. Engine "ON".
3. Monitor the "UD SOL. VALVE" parameter on the scantool
4. Shift lever from "N" to "D"
Specification: P/N → 100%, D → 0.0%
Fig 1) P,N
Fig 2) "R"
Fig 3) "D 1st" gear
Fig 4) "2nd" gear
Fig 5) "3rd" gear
Fig 6) "4th" gear
5. Does "UD SOLENOID DUTY " follow the referance data?

or damage.
procedure.

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Page 118 of 153
procedure.

1. Ignition "OFF"

procedure.

1. Engine "OFF".

Repair" procedure.
1. Ignition "OFF"
3. Measure resistance between terminal "3" and terminal "9" of the ATM SOLENOID VALVE harness connector.

Page 119 of 153
Replace UD SOLENOID VALVE as necessary and go to "Verification Vehicle Repair"
procedure.
■ Check PCM/TCM
4. Can you hear operating sound for using LR SOLENOID VALVE Actuator Testing Function ?
procedure.

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

procedure.
Automatic Transaxle System > Automatic Transaxle System > P0760 Shift Control Solenoid Valve \'C\'
(2nd Brake Control Solenoid) -Open or Short
Component Location
[email protected]
Page 120 of 153
General Description
Clutch ), and RED ( Reduction Brake, only for 5 speed transmissions). The 2ND Brake is engaged in the 2nd gear
and 4th gear positions.
DTC Description
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 judges that 2nd Brake drive contorl
solenoid circuit is malfunctioning and sets this code.

• Faulty 2nd SOLENOID
• Faulty PCM/TCM
Specification
DCC : 30.64Hz
KM series : 35Hz
Page 121 of 153
2. Engine "ON".
3. Monitor the "2nd SOL. VALVE" parameter on the scantool
4. Shift gear position 1st to 2nd.
Specification: 1st gear → 100%, 2nd gear → 0.0%
Fig 1) P,N
Fig 2) "R"
Fig 3) "D 1st" gear
Fig 4) "2nd" gear
Fig 5) "3rd" gear
Fig 6) "4th" gear
5. Dose "2ND SOLENOID DUTY " follow the referance data?

or damage.
procedure.

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Page 122 of 153
procedure.

1. Ignition "OFF"

procedure.

1. Engine "OFF".

Repair" procedure.
1. Ignition "OFF"

Page 123 of 153
Replace 2nd SOLENOID VALVE as necessary and go to "Verification Vehicle Repair"
procedure.
■ Check PCM/TCM
procedure.

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

procedure.
Automatic Transaxle System > Automatic Transaxle System > P0765 Shift Control Solenoid Valve \'D\'
(Over Drive Solenoid)-Open or Short
Component Location
[email protected]
Page 124 of 153
General Description
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
expected or low voltage is detected when high voltage is expected), the TCM judges that the OVER DRIVE
CLUTCH drive control solenoid circuit is malfunctioning and sets this code.

• Faulty OD SOLENOID
• Faulty PCM/TCM
Specification
DCC : 30.64Hz
KM series : 35Hz
Page 125 of 153
2. Engine "ON".
3. Monitor the "OD SOL. VALVE" parameter on the scantool
4. Shift gear position 2nd to 3rd.
Specification: 2nd gear → 100%, 3nd gear → 0.0%
Fig 1) P,N
Fig 2) "R"
Fig 3) "D 1st" gear
Fig 4) "2nd" gear
Fig 5) "3rd" gear
Fig 6) "4th" gear
5. Does "OD SOLENOID DUTY " follow the referance data?

or damage.
procedure.

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Page 126 of 153
procedure.

1. Ignition "OFF"

procedure.

1. Engine "OFF".

Repair" procedure.
1. Ignition "OFF"

Page 127 of 153
Replace OD SOLENOID VALVE as necessary and go to "Verification Vehicle Repair"
procedure
■ Check PCM/TCM
procedure.

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

procedure.
Automatic Transaxle System > Automatic Transaxle System > P0885 TCM Power Relay Open or
Short (Ground)
Component Location
[email protected]
Page 128 of 153
General Description
The HIVEC Automaic Transmission supplies the power to the solenoid valves by way of a control relay. When the
TCM sets the relay to ON, the relay operates and the battery power is supplied to all the sonenoid valves. When
the TCM 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 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 sets this code.

Enable • Voltage of Battery >9V
Conditions • Time after TCM turns on >0.5sec
• Faulty A/T control
Threshold Value • Voltage <7V relay
• Faulty PCM/TCM
Diagnostic Time • 0.1sec

3. Monitor the "A/T CON. RELAY VOLT" parameter on the scantool
Page 129 of 153
4. Is A/T RELAY VOLT within specifications?

or damage.
procedure.

2. Disconnect the "A/T CONTROL RELAY" connector.
3. Measure the voltage between terminal "1" of the "A/T CONTROL RELAY" harness connector and chassis
ground.

Go to "Signal circuit inspection" procedure.
Check for Open in harness. Repair as necessary and Go to "Verification Vehicle Repair"
procedure.

■ 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.
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Page 130 of 153
Go to "Check Supplying Power to solenoid valve" procedure.
procedure.
If signal circuit is OK,Substitute with a known-good PCM/TCM and check for proper
operation. If the problem is corrected, replace PCM/TCM and then go to "Verification of
■ Check Supplying Power to Solenoid Valve Harness

1. Ignition "OFF".
2. Disonnect the "A/T CONTROL RELAY" and PCM/TCM connector.
3. Measure the resistance between terminal "3" of the "A/T CONTROL RELAY" harness connector and terminal
"2, 3" of the PCM/TCM harness connector.

Check for Open in C-35(2.7 GAS) joint connector.
procedure.

1. Ignition "OFF".
2. Connect the "A/T CONTROL RELAY" connector.
3. Measure the resistance between terminal "2" of the "A/T CONTROL RELAY" harness connector and chassis
ground.

Go to "Component inspection" procedure.
procedure.
1. Ignition "OFF".
2. Remove "A/T CONTROL RELAY"
Page 131 of 153
3. Measure the resistance between each teminal of the sensor.
Specification:
Item Termianl No
1(red) - 3(black) INFINITE
Resistance
2(black) - 4(red)
Supply(B+) to number 4 and supply (B-)
1(red) - 3(black) 0Ω
to number 2
4. Is resistance with in specifications?

Replace ATM CONTROL RELAY as necessary and then go to "Verification of Vehicle
Repair" procedure.

procedure.
Automatic Transaxle System > Automatic Transaxle System > P1500 Vehicle Speed Sensor Signal
Circuit Malfunction
Component Location
[email protected]
Page 132 of 153
General Description
The vehicle speed sensor outputs pulse-signals according to the revolutions of the output shaft of the transmission.
The TCM determines the vehicle speed by counting the frequency of the pulses. This value is mainly used, by the
TCM, as comparison data for determining malfunctions of the OUTPUT SPEED SENSOR.
DTC Description
The TCM 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 OUTPUT SPEED SENSOR(PGB) , the TCM sets this code.

DTC Strategy • Plausibility check
• Engine speed >2100 rpm
• Engine load >250 mg/rev
Enable
• Coolant temperature > 60°C(140°F)
Conditions
Case1 • 10V< Battery voltage <16V
• No fuel shut-off
• Vehicle speed=0 with high engine speed and • Open or short in harness
Threshold Value
engine load • Contact resistance in
connectors
Diagnostic Time • 60 seconds
• Faulty wheel speed sensor
DTC Strategy • Electrical check
Enable • Vehicle speed > 0
Conditions • 10V< Battery voltage <16V
Case2
• PCM detects abnormal input voltage of the
Threshold Value
signal circuit
Diagnostic Time • 10 seconds
Automatic Transaxle System > Automatic Transaxle System > U0001 CAN Communication Bus Off
Component Location
Page 133 of 153
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
communications method, which is now widely used to transfer the vehicle data.
DTC Description
The TCM reads data on the CAN-BUS line and checks whether the data is equal to the data which the TCM sent
before. If the data is not the same the TCM decides that either the CAN-BUS line or TCM are malfuncting and sets
this code.

• IG switch on
• No actuator test
• 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 • Open or Short in CAN
• Engine STOP, communication harness
• Faulty TCM
Threshold Value • In case of no ECU information.
• INTELLIGENT SHIFT and is inhibited
• Learning for oil pressure control is inhibited
Fail Safe
• Torque Retard requirement is inhibited
• Direct connection control of TCC is inhibited

2. Engine "ON".
3. Monitor the "CAN COMMUNICATION SERVICE DATA (ENGINE RPM, VEHICLE SPEED SENSOR,
THROTTLE P. SENSOR)" parameters on the scantool
Fig 1) Low-RPM
Fig 2) High-RPM
5. Does "CAN BUS LINE DATA " follow the referance data?
Fault is intermittent caused by poor contact in the sensor’s and/or PCM/TCM’s connector
or was repaired and PCM/TCM memory was not cleared.And go to Verification of Vehicle
Repair procedure.
Replace PCM/TCM and then go to "Verification of Vehicle Repair" procedure.
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Page 134 of 153
or damage.
procedure.

1. Ignition "OFF" & Engine "OFF".
2. Disconnect the "PCM/TCM" connector
3. Measure resistance between terminal "3" and "4" of the "PCM/TCM" harness connector.
4. Is measured resistance within specifications ?

procedure.
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration or damage of ECM.and then Repair or replace Resistance for CAN
communication as necessary and go to "Verification Vehicle Repair" procedure.

procedure.
Automatic Transaxle System > Automatic Transaxle System > U0100 Lost Communication With
ECM/PCM \'A\'
Component Location
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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
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.

• IG switch on
• No actuator test
• 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 • Open or Short in CAN
sec
communication harness
• Engine STOP,
• Faulty ECM
Threshold Value • In case of no ECU information. • Faulty TCM
• INTELLIGENT SHIFT and is inhibited
• Learning for oil pressure control is inhibited
Fail Safe
• Torque Retard requirement is inhibited
• Direct connection control of TCC is inhibited

2. Engine "ON".
3. Monitor the "CAN COMMUNICATION SERVICE DATA (ENGINE RPM, VEHICLE SPEED SENSOR,
THROTTLE P. SENSOR)" parameters on the scantool
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Page 136 of 153
Fig 1) Low-RPM
Fig 2) High-RPM
5. Does "CAN BUS LINE DATA " follow the referance data?
Fault is intermittent caused by poor contact in the sensor’s and/or PCM/TCM’s connector
or was repaired and PCM/TCM memory was not cleared.And go to Verification of Vehicle
Repair procedure.
Replace PCM/TCM and then go to "Verification of Vehicle Repair" procedure.

or damage.
procedure.

2. Disconnect the "PCM/TCM" connector
3. Measure resistance between terminal "3" and "4" of the "PCM/TCM" harness connector.
4. Is measured resistance within specifications ?

procedure.
deterioration or damage of ECM.and then Repair or replace Resistance for CAN
communication as necessary and go to "Verification Vehicle Repair" procedure.

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procedure.
Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Repair
procedures (F4A42-2)
Removal
1. Remove the air duct.
2. Remove the battery.
3. Remove the battery tray.
4. Remove the air cleaner assembly.
5. Rmove the intercooler inlet pipe.
6. Disconnect the connectors relevant to a transaxle.
7. Disconnect the ground earth wire.
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Page 138 of 153
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).
10. Detach the hoses(A), loosening the oil cooler hose clamps.
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11. Using SST(09200-38001), support the engine.
12. Remove the trasaxle mounting bracket bolts(A).
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13. Remove the transaxle upper mounting bolts(A).
14. Remove the bolts which mount the transaxle to the front sub frame.
15. Lift up the vehicle.
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 mount the transaxle to the rear sub-frame.
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21. Remove the sub-frame. If it is 4 wheel 1 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. Installation is in the reverse order of removal.
2. After installation, reset the adaptive learning value of the TCM(Refer to TSB No.HT2005041303).
Automatic Transaxle System > Automatic Transaxle Control System > Input Speed Sensor >
Description and Operation (F4A51-3)
Description
Input Shaft Speed Sensor
- Type: Hall sensor
- Current consumption: 22mA (MAX.)
- Sensor body and sensor connector have been unified as one.
Hall Type Sensor: Specification
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Page 142 of 153
Air gap (mm) Input shaft speed sensor 1.3
Coil Resistance Input 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
Automatic Transaxle System > Automatic Transaxle Control System > Input Speed Sensor > Repair
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.
4. 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.

5. Apply a light coat of automatic transaxle fluid to the O-ring seal before installation.
6. Install the input shaft speed sensor.
7. Install the control cable mounting bracket.
8. Connect the input shaft speed sensor connector.
9. Install the holder of the control cable.
10. 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")
11. Installation is the reverse of removal.
Automatic Transaxle System > Automatic Transaxle Control System > Output Speed Sensor >
Description and Operation (F4A51-3)
Description
Output Shaft Speed Sensor
- Type: Hall sensor
- Current consumption: 22mA (MAX.)
- Sensor body and sensor connector have been unified as one.
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Hall Type Sensor: Specification

Air gap (mm) Output shaft speed sensor 0.85
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
Automatic Transaxle System > Automatic Transaxle Control System > Output Speed Sensor > Repair
Replacement
1. Remove the battery and air cleaner. (see "Transaxle range switch replacement")
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.
3. Apply a light coat of automatic transaxle fluid to the O-ring seal before installation.
Automatic Transaxle System > Automatic Transaxle Control System > Solenoid valve > Description
and Operation (F4A51-3)
Description
Actuators
- Sensor type: Normal open 3-way
- Operating temperature : -30°C~130°C(-22°F~266°F)
- Frequency:
LR, 2ND, UD, OD: 61.27Hz (at the ATF temp. above -20°C(-4°F))
DCC: 30.64Hz
- Internal resistance:
3.0 ± 0.5 Ω (LR, 2ND, UD, OD, TCC)
4.35 ± 0.5 Ω (VFS)
- Surge voltage: 56 V (Except VFS)
(LR, 2ND, UD, OD, DCC) [email protected]
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Location
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.
OFF ON ON ON OFF
mode)
N, P (Hold
ON OFF ON ON OFF
mode)
*: Reference value.
(DCC solenoid valve will be ON when the operating condition is satisfied)
Automatic Transaxle System > Automatic Transaxle Control System > Solenoid valve > Repair
Inspection
1. If the value is out of specification according to the chart below, remove the valve body cover.
2. Measure the resistance again after disconnecting solenoid valve connector.
Specification (20°C,68°F):
2.5 ~ 3.5 Ω (LR, 2ND, UD, OD, TCC)
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3. If the value is out of specification replace the solenoid valve.
Pin No. Name Resistance
7&10 DCC (TCC)
6&10 LR
4&9 2ND 2.5~3.5Ω (20°C,68°F)
3&9 UD
5&9 OD
Automatic Transaxle System > Automatic Transaxle Control System > VFS(Variable Force Solenoid)
Valve > Description and Operation (F4A51-3)
Description
Actuators
- Sensor type: Normal open 3-way
- Operating temperature : -30°C~130°C(-22°F~266°F)
- Frequency:
LR, 2ND, UD, OD: 61.27Hz (at the ATF temp. above -20°C(-4°F))
DCC: 30.64Hz
- Internal resistance:
3.0 ± 0.5 Ω (LR, 2ND, UD, OD, TCC)
4.35 ± 0.5 Ω (VFS)
- Surge voltage: 56 V (Except VFS)
(VFS)
Location
VFS Control pressure
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Page 146 of 153
Control Pressure (No line pressure)
Input Increasing Current Decreasing Current
Current(mA)
MAX. (Kgf/cm²)[Kpa MIN. (Kgf/cm²)[Kpa Δ (Kgf/cm²) [Kpa MIN. (Kgf/cm²)[Kpa
100 6.52 639 5.87 575 64

200 6.23 611 5.70 559 52 5.43 532
300 5.76 564 5.24 514 50 4.49 484
400 5.08 498 4.59 450 48 4.30 421
500 4.24 416 3.78 370 46 3.52 345
700 2.29 224 1.82 178 46 1.51 148
800 1.41 138 0.09 88 50 0.58 57
900 0.65 64 0.14 14 50 0 0
1,000 0.24 24 0 0 24
1,100 0.24 24 0 0 24
*Test condition:
Ps : Supply Pressure (Ps 7.1 ± 0.3 kgf/cm²)
Pc : Control Pressure
Pex : Exhaust Pressure (Atmosphere pressure)
ATF : DIAMOND ATF SP-
ATF temperature : 30 ± 3°C (86°F)
- Coil resistance : 4.35 ± 35Ω
- Dither Frequency : 600 ± 20Hz
In case of VFS solenoid valve, the relation between Duty and oil pressure can't be expressed.
Automatic Transaxle System > Automatic Transaxle Control System > VFS(Variable Force Solenoid)
Valve > Repair procedures (F4A51-3)
Inspection
1. If the value is out of specification according to the chart below, remove the valve body cover.
2. Measure the resistance again after disconnecting solenoid valve connector.
Specification (20°C,68°F): 4.3 ~ 4.4Ω (VFS)
3. If the value is out of specification replace the solenoid valve.

Pin No. Name Resistance
7&8 VFS 4.3~4.4Ω (20°C,68°F)
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Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Oil Temperature
Sensor > Description and Operation (F4A51-3)
Description
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
Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Oil Temperature
Sensor > Repair procedures (F4A51-3)
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.
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.
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Page 148 of 153
Automatic Transaxle System > Automatic Transaxle Control System > Inhibiter Switch > Description
and Operation (F4A51-3)
Description
Inhibitor Switch
- Type: Rotary contact type
- Range of temperature : -40°C~145°C(-40°F~293°F)
Inhibitor Switch - Continuity check(Sports mode)
Automatic Transaxle System > Automatic Transaxle Control System > Inhibiter Switch > Repair
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.
6. Remove the inhibiter switch connector.
7. Remove the shift cable mounting nut(A).
8. Remove the inhibiter switch loosening the mounting bolts.

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 procedures.
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 is 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.
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2. Loosen the control cable to manual control lever coupling nut to free the cable and lever.
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.
Tightening torque :
10~12Nm (1.0~1.2kgf.m, 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.
Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Repair
Removal
1. Remove the shift lever knob(A).
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2. Remove the console cover(B), disconnecting the shift lever connector(A).
3. Seperate the lever assembly(B) from the facia bracket assembly(A).
4. Disconnect the cable interlinked to lever assembly.

5. In case of 4WD vehicle, discconnect the 4WD ECM connector(A).
6. Remove the facia bracket assembly.
Installation
1. Install the facia bracket assembly.
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2. In case of 4WD vehicle, connect the 4WD ECM connector(A).
3. Connect the cable interlinked to lever assembly.

4. Install the lever assembly(B) to the facia bracket assembly(A).
5. Install the console cover(B) fixing the shift lever connector(A) on it.
6. Install the lever conver(B) completely connecting the terminals.
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Page 152 of 153
7. Install the shift lever knob(A).
Inspection
Check Points Of Shift Lock System
1. With shift lever at P position and brake pedal not depressed. Push button cannot be operated. (Shift lever cannot
be shifted to other positions from P) Push button can be operated at the positions except P.
2. With IG key at the position other than "LOCK" (May be at "ACC") and brake pedal stroke 15~25mm (With
shift lever at P position). Push button can be operated and shift lever can be shifted smoothly to other from P.
3. With brake pedal not depressed. Shift lever can be shifted smoothly to "P" positions from other positions.
4. Brake pedal must be operated smoothly without catching at all positions.
Adjusting Procedure For "P" Shift Lock Cable
1. Check that each lock cam is shown below.
2. Install shift lock cable in position according to this DWG. In this case, shift lock cable must be fixed to brake
pedal in position.
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3. Temporarily install shift lock cable to A/T lever assy as shown below. Securely insert cable end into fixing point
of shift lock cam.
4. Doing the work of 3. slightly pull outer casing of shift lock cable to direction "E" to stretch cable. In this case, shift
lock cam must not move.
5. After checking portion of cable end touches cable fixing pin of shift lock cam. Fix outer casing with a nut.
6. Check the installation condition of the shift lock cam.
Check Points Of Key Interlock System
1. With IG.KEY at "LOCK" position and brake pedal depressed, push button cannot be operated.
2. IG.KEY must be not turned to "LOCK" position
3. When shift lever shifted to "P" position again, IG.KEY must be turned to "LOCK" position smoothly.
Adjusting And Install Precedure For Key Inter Lock Cable
1. Install key inter lock cable in position according to this drawing.
2. After assembling C/PAD module and inserting the key into the lock cylinder, insert the lock cylinder into the lock
body thorugh the C/PAD key hole with "ACC" condition.
3. After assembling key inter lock cable and lock body assembly, fix the key inter lock cable with set screw.
4. Change the key "LOCK" state and check the AT lever is located at "P" position. At this time, slightly push the
KEY LOCK CAM to direction "Q"
5. After setting the key inter lock cable, fix the cable with nut. At this moment, the key inter lock cable shall not be
pulled the direction "Q".
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Page 1 of 113
TUCSON(JM) > 2009 > G 2.7 DOHC > Body (Interior and Exterior)
Body (Interior and Exterior) > General Information > Specifications

Specifications
HOOD
• Type Rear hinged, front opening type
FRONT DOOR
• Construction Front hinged, full door construction
• Regulator system X-arm type
• Locking system Pin-fork system
REAR DOOR
• Construction Front hinged, full door construction
• Regulator system X-arm type
• Locking system Pin-fork system
TAILGATE
• Type Inner hinged, Gas lifter
GLASS THICKNESS mm (in.) Laminated clear, tinted
• Windshield glass 5 (0.20)
• Front window glass 3.2 (0.13)
• Rear fixed glass 3.5 (0.15)
• Rear window glass 3.2 (0.13)
SEAT BELTS
• Type 3 point type with E.L.R (Emergency locking retractor)
Tightening Torques
Items Nm kgf·cm lbf·ft
Front and rear doors
• Door hinge to body 34 ~ 42 340 ~ 420 24.5 ~ 30
• Door hinge to door 13 ~ 26 130 ~ 260 10 ~ 19
• Glass mounting bolt 8 ~ 12 80 ~ 120 6~9
• Door latch mounting screw 7 ~ 11 70 ~ 110 5~8
• Outside handle mounting bolt 7 ~ 11 70 ~ 110 5~8
• Door striker mounting bolt 17 ~ 22 170 ~ 220 12 ~ 16
• Door checker to door 7 ~ 11 70 ~ 110 5~8
Tailgate
• Tailgate hinge to body 7~9 70 ~ 90 5 ~ 6.5
• Tailgate hinge to trunk lid 7~9 70 ~ 90 5 ~ 6.5
• Tailgate latch mounting bolt 7 ~ 11 70 ~ 110 5~8
• Tailgate straker mounting bolt 7 ~ 11 70 ~ 110 5~8
• Key cylinder mounting nut 7 ~ 11 70 ~ 110 5~8
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Hood
• Hood hinge to body 22 ~ 27 220 ~ 270 16 ~ 19.5
• Hood hinge to hood 22 ~ 27 220 ~ 270 16 ~ 19.5
• Hood latch to body 7 ~ 11 70 ~ 110 5 ~ 8.0
Seat
• Front seat to floor bolt and nut
44 ~ 66 440 ~ 460 33 ~ 47
• Rear seat back tilting bracket
17 ~ 26 170 ~ 260 12 ~ 19
• Rear seat cushion mounting
17 ~ 26 170 ~ 260 12 ~ 19
bolts
Seat belt
• Front seat belt buckle
• Front seat belt upper anchor
45 ~ 55 450 ~ 550 33 ~ 40
• Front seat belt retractor to
45 ~ 55 450 ~ 550 33 ~ 40
center pillar
45 ~ 55 450 ~ 550 33 ~ 40
• Front seat belt height adjuster
45 ~ 55 450 ~ 550 33 ~ 40
• Rear seat belt anchor 45 ~ 55 450 ~ 550 33 ~ 40
attaching bolt 45 ~ 55 450 ~ 550 33 ~ 40
• Rear seat belt retractor
mounting bolt
Body (Interior and Exterior) > General Information > Special Service Tools
Special Tools
Tool (Number and name) Illustration Use
09793-21000 Adjustment, removal and installation of the
Door hinge adjusting wrench door hinge
09800-21000 Trim removal

Ornament remover
09853-31000 Removal of the headliner clips

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

Sealant cut-out tool (use with 09861-31200)
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Page 3 of 113
09861-31200 Cutting the sealant of the windshield
Sealant cutting blade (use with 09861-31100)
09861-31000 Removal of the windshield moulding

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

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

Troubleshooting
Symptom Suspect Area Remedy (See page)
Water leaks from sunroof Dirt accumulated in drain tube Clear dirt inside of drain
Clogged drain tube Blow air into drain to remove dirt
Broken or dislocated drain tube, defective or Check tube installation and flange
cracked clip contact
Deteriorated roof lid weatherstrip Replace
Excessive roof lid-to-body clearance and Adjust
improperly fitted weatherstrip
Loose or deformed deflector, gaps in body
Wind noise around sunroof Retighten adjust or replace
work
Sunroof lid makes a noise when Foreign particles lodged in guide rail Check drive cable and guide rails
moved for foreign particles
Loose guide rails and lid Retighten
Motor runs but sunroof does not Foreign particles lodged in guide rail Check drive cable and guide rails
move or moves only partially for foreign particles
Incorrect engagement of motor pinion with Check for loose motor
drive cable installation and damaged pinion
Decrease in motor's clutch slipping force Adjust
Increased sunroof sliding resistance or Adjust or replace
interference of sunroof with drive cables,
weatherstrip, etc. due to maladjustment of
sunroof
Noise in motor (clutch slipping Incorrect engagement of motor pinion with Check pinion installation and
noise from motor when sunroof is drive cable retighten motor
fully opened or closed is not an
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fully opened or closed is not an
Worn out or damaged motor pinion bearing Replace motor assembly
unusual noise.)
Worn out or deformed drive cable Replace
Door glass fails to operate up Incorrect window glass installation Adjust position
and down Damaged or faulty regulator arm or regulator Correct or replace
Door does not open or close Incorrect door installation Adjust position
completely
Defective door check assembly Correct or replace
Door hinge requires grease Apply grease
Hood does not open or close Striker and latch not properly aligned Adjust
completely Incorrectly installed hood Adjust
Incorrect hood bumper height Adjust
Water leak through windshield Defective seal Fill with sealant
and rear window
Defective flange Correct
Wind noise around door Weatherstrip not holding firmly Adjust fit or door
Improperly installed weatherstrip Repair or replace
Improperly closed door Adjust

Improperly fit door Adjust
Improperly clearance between door glass Adjust
and division channel
Deformed door Repair or replace
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.
- When removing the clips, use a clip remover.
1. Disconnect the windshield washer nozzle connecting tube (A).
2. After loosening the hood hinge (B) mounting bolts, remove the hood (C).
- Make sure the hood opens properly and locks

securely.
- Adjust the hood alignment.
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Page 5 of 113
Hood Insulator Replacement

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 Latch Replacement

1. Remove the hood cover (A).
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2. Remove the hood latch (A) mounting bolts.
3. Disconnect the hood latch cable (B) and release cable (C).
- Make sure the hood latch cable is connected

properly.
- Make sure the hood locks securely.
Hood Release Cable Replacement

1. Remove the following items:
A. Hood release handle
B. Wheel guard
2. Using a clip remover, detach the clips from the body, then disconnect the hood latch cable (A) and release cable
(B).
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Page 7 of 113
Take care not to bend the cable.

properly.
- Replace any damaged clips.
Hood Release Handle Replacement

1. Remove the screws, then remove the hood release handle (A).
2. Disconnect the hood latch cable (B) from the hood release handle. Take care not to bend the cable.
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properly.
- Make sure the hood opens properly.
Hood Seal Weatherstrip Replacement

1. Detach the clips, then remove the hood weathersrip (A). Take care not to scratch the hood.
Replace any damaged clips.
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Page 9 of 113
Adjustment
Adjust Hood
1. After loosening the hood hinge (A) mounting bolt, adjust the hood (B) by moving it up or down, or right or left.
2. Adjust the hood height by turning the hood overslam bumpers (C).
3. After loosening the hood latch (D) mounting bolts, adjust the hood latch by moving it up or down, or right or left.
Body (Interior and Exterior) > Exterior > Tailgate > Repair procedures
Replacement
Tailgate Trim Replacement
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- When removing and installing the trunk lid, an assistant is necessary.

- Wear gloves to protect hands from injury.
1. Open the tailgate glass
2. After loosening the screws the remove the tailgate trim (A).
3. Remove the upper trim(B) and side trim(C).
Replace and damaged clips.
Tailgate Glass Replacement
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Page 11 of 113
- When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the
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 following items.
A. Rear wiper assembly [A(See page BE- “Rear wiper”)].
B. Tailgate lifter [B(See page BD- 18)].
C. High stop lamp [C(See page BE- “High stop lamp”)].
2. After loosening the mounting bolts remove the tailgate glass (D).
Tailgate Latch Replacement

1. Remove the tailgate trim (See page BD- 13).
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2. Disconnect the outside handle rod (A) and actuator rod (B).
3. Loosen the latch mounting bolts and disconnect the connector (A).
4. Remove the tailgate latch (B).
- Make sure the connector is connected properly and the connecting rod is connected
properly.
- Make sure the tailgate opens properly and locks securely.
Actuator Assembly
2. Disconnect the outside handle rod (A), actuator rod (B), glass latch rod (C), key cylinder rod (D) and connector.
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3. After loosening the mounting bolt and nuts, then remove the actuator assembly (E).
- Make sure the connector is connected properly and the connecting rod is connected
properly.
- Make sure the tailgate opens properly and locks securely.
Tailgate glass latch replacement

2. Disconnect the tailgate glass latch rod (A).
3. After loosening the mounting bolts, disconnect the connector (B).
4. Remove the tailgate glass latch (C).
Make sure the tailgate glass opens properly and locks

securely.
Key holder replacement
2. Remove the tailgate garnish (See page BD- 45).
3. Disconnect the key rod (A) and connector.
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4. Remove the key holder (B).

securely.
Glass weatherstrip replacement
1. After disconnecting the tailgate lifter, remove the glass weatherstrip (A).

Tailgate weatherstrip replacement
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1. Remove the tailgate weatherstrip (A).

Outside Handle Replacement
2. Disconnect the outside handle rod (A) and latch rod (B).
3. Loosen the inside handle (C) mounting bolts.
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securely.
Lifter Replacement
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.
Pull Handle Replacement

Push down the hook (A) on the upper part of the pull handle (B) by using the screwdriver or the remover.
Fuel Filler Door Release Cable Replacement
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A. Front seat (See page BD- 84).
B. Rear seat (See page BD- 92).
C. Front door scuff trim LH (See page BD- 69).
D. Rear door scuff trim LH.
E. Center pillar lower trim.
F. Luggage trim, left side.
2. Disconnect the fuel filler door release cable from the release handle (A).
3. Remove the release cable (B) from the clip, and disconnect the fuel filler door catch (C), then remove the fuel filler
door cable from the vehicle.
Fuel Fill Door Replacement

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1. Loosen the bolts, then remove the fuel filler door (A).
Make sure the fuel fill door opens properly and locks
securely.
3. Check that the fuel fill door (A) fits flush against the body. If necessary, adjust it.
Release Handle Replacement

1. Remove the front door scuff trim and center pillar lower trim (See page BD- 69).
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2. Loosen the release handle (A), mounting bolt.
Disconnect the release cable (B), then remove the release handle.
- Make sure the release cable is connected properly.

- Make sure the fuel filler door/trunk lid open
properly.
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 over slam bumper (B) and side bumper (C).
C. Adjust the striker (D) by moving it up or down, or right or left.
2. Tighten each bolt securely.
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3. Make sure the trunk lid opers and locks securely.
Body (Interior and Exterior) > Exterior > Front Door > Components and Components Location
Components
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Page 21 of 113
Page 22 of 113
Body (Interior and Exterior) > Exterior > Front Door > Repair procedures
Removal And Installation
FRONT DOOR TRIM
- Take care not to scratch the door trim and other parts.
- Put on gloves to protect your hands.
1. Remove the quadrant inner cove. [email protected]
Page 23 of 113
2. Remove the inside handle cover (A).
3. 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 (B), power mirror connector (C), and door
courtesy lamp connector (D).
4. Remove the door trim seal.

- Make sure the connectors is plugged in properly and each rod is connected
securely.
- Make sure the door locks and opens properly.
Replacement
Glass Replacement
Put on gloves to protect your hands.

1. Remove the door trim.
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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 and scratch the glass surface.

A. Roll the glass up and down to see if it moves freely without binding.
B. Make sure that there is no clearance between the glass and glass run channel when the glass is closed.
C. Adjust the position of the glass as necessary.
Rear Channel Replacement
2. Remove the glass.
3. Loosen the rear channel mounting nuts.
4. After disconnecting the glass molding, remove the rear channel (A).

Power Window Motor Replacement
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2. After disconnecting the connector (A), remove the power window motor (B).
Roll the glass up and down to see if it moves freely without

binding.
Door Module Replacement

1. Remove the front door trim,
2. Remove the glass,
3. Disconnect the wiring harness (A).
4. Disconnect the lock rod (A) and outside handle rod (B).
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5. Remove the door module (C).
6. Installation is the reverse or removal.
- Make sure the connectors is plugged in properly and each cable is connected
securely.
- Make sure the door locks and opens properly.
- Roll the glass and down to see if it moves freely without binding.

1. Remove the following parts.
A. Door trim (See page BD- 25).
B. Glass trim (See page BD- 26).
C. Rear channel (See page BD- 26).
2. Disconnect the outside handle rod (A) and lock rod (B).
3. After removing the outside handle mouting bolt, remove the outside handle base (C) and key cylinder.
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4. After removing the key cylinder (A) and outside handle base (B), remove the outside handle lever (C).

A. Make sure the connector is plugged in properly, and each rod is connected securely.
B. Make sure the door locks and opens properly.
Speaker Replacement
1. Remove the door trim (See page BD- 25)
2. Disconnect the speaker connector (A), and remove the speaker (B).

Inside handle replacement
1. Remove the front door trim (See page BD- 25).
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2. Loosen the inside handle (A) mounting screw.
Push the inside handle forward to disconnect from the door module.
3. Disconnect the lock cable and (A) inside handle connect cable (B).
4. Installation is the reverse of removal
Make sure the door locks and opens

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

Glass run channel replacement
1. Remove the front door trim.
3. Remove the glass run channel (A) from the lower part.

Door Weatherstrip Replacement
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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 (See page BD- 57)
B. Door trim (See page BD- 25)
2. Carefully move the glass (A) until you can see the glass mounting bolts (B), then loosen them.
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3. Push the glass (A) against the channel (C), then tighten the glass mounting bolts.
4. Check that the glass moves smoothly.
5. Raise the glass fully, and check for gaps. Check that the glass contacts the glass run channel evenly.
6. Check for water leaks. Run water over the roof and on the sealing area as shown, and note these items:
A. Use a 12mm (1/2in.)diameter hose (A).
B. Adjust the rate of water flow as shown (B).
C. Do not use a nozzle.
D. Hold the hose about 300mm (12in.) away from the door (C).
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.
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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.
3. Check that the door and body edges are parallel.
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4. Grease the pivot portions of the hinges indicated by the arrows.
5. Check for water leaks (See page BD- 32).

Door Striker Adjustment
Make sure the door latches 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.
1. Loosen the screws (B), then insert a shop towel between the body and striker.
2. Lightly tighten the screws.

3. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer. Do not tap the
striker too hard.
4. Loosen the screws and remove the shop towel.
5. Lightly tighten the screws.
6. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door
latches properly, tighten the screws and recheck.
Body (Interior and Exterior) > Exterior > Rear Door > Components and Components Location
Components
Page 34 of 113
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Page 35 of 113
Body (Interior and Exterior) > Exterior > Rear Door > Repair procedures
Removal And Installation
Remove Rear Door Trim
- Take care not to scratch the door trim and other parts.
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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 (B).
3. Remove the door trim seal.

4. Installation is the reverse of removal, make sure the connectors and courtesy light bulb socket are plugged in
properly.
Replacement
Glass And Quarter Glass Replacement
Put in gloves to protect your hands.

1. Remove the door trim (See page BD- 37).
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Page 37 of 113
2. After disconnecting the glass run (A) and weatherstrip (B), then remove the delta molding (C).
3. Carefully move the glass (A) until you can see the bolts, then loosen them.Carefully pull the glass out through the
window slot (B).
Take care not to drop the glass and scratch the glass surface.

A. Roll the glass up and down to see if it moves freely without binding.
B. Make sure that there is no clearance between the glass and glass run channel when the glass is closed.
C. Adjust the position of the glass as necessary (See page BD- 43).
Rear Channel Replacement
1. Remove the rear door trim (See page BD- 37).
2. Remove the glass (See page BD- 38).
3. After removing the rear channel mounting bolt and nut, remove the rear channel (A).

Power Window Motor Replacement
2. Disconnect the power window motor connector (A).
3. After loosening the mounting nut, remove the power window motor (B).
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- Make sure that there is no clearance between the glass and glass run channel when the glass is
closed.
- Adjust the position of the glass as necessary .
Rear Door Module Replacement

1. Remove the door trim .
2. Remove the glass .
3. Remove the rear channel.
4. Disconnect the power window motor connector (A), speaker connector (B) and actulator connector (C). Detach
the harness clip.
5. Remove the door module assembly (A).

properly.

1. Remove the door trim. [email protected]
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3. Remove the rear door module.
4. Remove the outside handle base (A).
5. Remove the outside hand lever (A) and cover (B).

properly.
Rear door latch replacement
1. Remove the rear door module (See page BD- 40).
2. Remove the latch cover, then disconnect the lock cable (A) and inside handle cable (B).
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3. Remove the rear door latch (C).

Speaker replacement
2. After disconnecting the speaker connector (A), remove the speaker (B).
Inside handle replacement

2. Loosen the inside handle (A) mounting screw.
Push the inside handle forward to disconnect from the door module.
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3. Disconnect the lock cable (A) and inside handle cannect cable (B).

properly.
Door belt weatherstrip replacement
2. Release the hooks (A), and then remove the door belt weatherstrip (B).
Adjustment
Glass Adjustment
Check the weatherstrips and glass run channel for damage or deterioration, and replace them if necessary.
1. Remove the door trim (See page BD- 37).
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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, then tighten the glass mounting bolts.
4. Check that the glass moves smoothly.
5. Raise the glass fully, and check for gaps. Check that the glass contacts the glass run channel evenly.
6. Check for water. Run water over the roof and on the sealing area as shown, and note these items:
A. Use a 12mm (1/2in.) diameter hose (A).
B. Adjust the rate of water flow as shown (B).
C. Do not use a nozzle.
D. Hold the hose about 300mm(12in.) away from the door (C).
Door Position And Striker Adjustment

Adjust the door position and striker.
Body (Interior and Exterior) > Exterior > Body Side Moldings > Repair procedures
Replacement
Roof Rack Replacement
- Take care not to scratch the body surface.
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Page 43 of 113
1. Remove the roof rack cover (A).
2. Remove the roof rack (B).

Front Mud Guard And Wheel Guard Replacement
1. Remove the mud guard (A).
2. Remove the wheel guard (B).
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Rear Mud Guard And Wheel Guard Replacement
1. Remove the mud guard (A).
2. Remove the wheel guard (B).
Tailgate Garnish Replacement

1. Remove the tailgate trim.
2. Remove the key cylinder.
3. Remove the tailgate garnish (A).
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Radiator Grille Replacement

1. Open the hood.
2. Remove the radiator grille (A).
Side Garnish And Side Sill Replacement
- Wrap the blade of a putty knife or flat tip screwdriver with protective tape to prevent damage to the door.
- Be careful not to pry too far or you may bend the garnish.
1. Prepare to remove the garnish from inside the vehicle.
A. Remove screws fraim the front and rear door panel (See page BD- 25, 37).
2. Remove the clips and screws and gently pry the side garnish (A) or side sill (B) away from the door while
removing the adhesive tape.
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Replace any damaged clips adhesive tape.
Body (Interior and Exterior) > Exterior > Sun Roof > Components and Components Location
Components
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Page 47 of 113
Body (Interior and Exterior) > Exterior > Sun Roof > Repair procedures
On-vehicle Inspection
Inspect Sunroof Glass Alignment
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1. Start the engine and check the operating time of the sunroof (A).
Operating time: Approx. 5 secs.
2. Check for abnormal noise or bending during operation.

3. With the sunroof fully closed, check for water leakage.
4. The roof panel (A) should be even with the glass (B) weatherstrip (C), to within the standard value "E" all the
way around. If not, make the following adjustment.
Standard value "E"

Front edge: 0 ~ 1.4mm
Rear edge: 1.0 ~ 1.4mm
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5. If the position is not as specified, lightly loosen the glass adjusting screw (A) to adjust the glass height and tighten
it.
Tightening torque:
2 ~ 4Nm (20 ~ 40kgf·cm, 1.5 ~ 2.9 lbf·ft)
6. Check for overlap between the sunroof weatherstrip (A) and the roof panel (B).
Standard value: 1.1mm
Replacement

Glass Replacement
1. Close the glass fully and slide the sunshade all the way back.
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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 (See page BD- 71).
2. Disconnect the motor connector (A), remove the screws and then remove the motor (B).
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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 (See page BD- 69).
B. Front, center and rear pillar trim (See page BD- 69).
C. Headlining (See page BD- 71).
D. Sunroof glass (See page BD- 49).
2. Disconnect the drain tubes (A).
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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 (See page BD- 52).
2. Remove the drip link (A) and sunshade stopper (B).
3. Remove the sunshade (C) and drip rail (D).
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Guide Assembly Replacement

1. Remove the sunroof assembly (See page BD- 52).
2. Remove a guide assembly (A) after lowering a guide thoroughly by pushing a slide (B) to rear.
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3. Remove the guide (A) and slide (B).
- Make sure to align the slide with the center of "A" and
"B".
- Make sure to initalize the motor.
Adjustment
How to initialize motor
1. Check that the glass has been installed.
A. Finished height adjustment.
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Page 55 of 113
2. Push the up switch. (Keeping on pushing the switch)
A. The slide moved 5mm forward after 15 seconds.
3. After moving the slide 5mm forward, turn OFF the switch and push the UP switch (Keeping on pushing the
switch with continuous operation)
A. If the operation above is normal condition, the sunroof once and closes.
4. When the sunroof is closed completely, turn OFF the UP switch initialize the motor completely.
When to initialize the motor
1. First operation the vehicle after manufacture it.
2. Initial value is erased or damaged because of short power electric discharge during operation
3. After altering into manual handle.
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.
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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 incomplete 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 (Interior and Exterior) > Exterior > Mirror > Components and Components Location
Components
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Page 57 of 113
Body (Interior and Exterior) > Exterior > Mirror > Repair procedures
Replacement
OUTSIDE REAR VIEW MIRROR REPLACEMENT
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1. Remove the quadrant inner cover (A), then disconnect the connector (B).
2. After disconnecting the connector (A), remove the outside rear view mirror (B).

Inside Rear View Mirror Replacement
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).
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Page 59 of 113
Body (Interior and Exterior) > Interior > Console > Components and Components Location
Components
Page 60 of 113
Body (Interior and Exterior) > Interior > Console > Repair procedures
Replacement
Floor Console Replacement
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Page 61 of 113
1. Remove the end cover (A).
2. Loosen the console mounting bolts and nuts.

3. After disconnecting the seat warmer connector (A), remove the console assembly (B).

Armrest Replacement
1. Remove the end cover.
2. After loosening the armrest mounting screw, remove the armrest (A).
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Pop-up Unit Replacement

1. Loosen the armrest cover (A) mounting screws.
2. Remove the pop-up unit (A).

Front Console Replacement
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- Take care not to scratch the trim and other parts.
1. Remove the crash pad center lower cover
(See page BD- 66).
2. Remove the front console upper cover (A) and disconnect the connector (B).
3. After loosening the mounting screw, remove the front console (A).
Body (Interior and Exterior) > Interior > Crash Pad > Components and Components Location
Components
Page 64 of 113
Body (Interior and Exterior) > Interior > Crash Pad > Repair procedures
Replacement
Cluster Facia Panel Replacement
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Page 65 of 113
• When prying with a screwdriver, wrap it with protective tape, and apply protective tape around the related
parts, to prevent damage.
• Take care not to scratch the crash pad and related parts.
1. Tilt the steering column down.
2. Remove the screws, and detach the clips.
3. After disconnecting the trip sensor connector (A), remove the cluster facia panel (B).
- Make sure the connector is plugged in

properly.
- Replace any damage clips.
Center Facia Panel Replacement

1. Remove the front console cover (See page BD- 59).
2. Remove the screw, and detach the clips.
3. Disconnect the following items to remove the center facia panel (A).
A. Hazard warning lamp connector (B).
B. Rear defroster connector (D).
C. Windshield deicer connector (C).
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D. Front fog lamp connector (E).
Make sure the connector is plugged in

properly.
Lower Crash Pad Panel Replacement
Take care not to scratch the crashpad and related parts.

1. Disconnect the hood release cable from the hood release handle (See page BD- 10).
2. Remove the screws, bolts and clips.
3. Disconnect the self-diagnosis connector (A), then remove the lower crash pad panel (B).

Heater Control Unit Replacement
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1. Remove the audio assembly (See page BD- 64).
2. Loosen the screws.
3. Remove the heater control unit (A).

properly.
Audio Assembly Replacement

1. Remove the center facia panel (See page BD- 62).
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3. Disconnect the audio connector (A) and antenna cable (B), then remove the audio assembly (C).

properly.
Glove Box Replacement
1. Disconnect the air damper wire (A) and guide (B) from the glove box (C).
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2. Disconnect the pin (A), then remove the glove box (C).

Cluster Replacement
1. Remove the cluster facia panel (See page BD- 62).
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3. Disconnect the cluster connector (A), then remove the cluster (B).

properly.
Air Vent Replacement
1. Wrap a flat-tip screwdriver with protective tape, and apply protective tape around the related parts to prevent
damage. Take care not to scratch the crash pad and related parts.
2. Remove the air vent (A) by detaching the clips.
3. Reinstall the hook portions of the vent first, then push the clip portions into place securely.
Cover Replacement
parts to prevent damage.
• Take care not to scratch the crash pad, body and other related parts.
• Put on gloves to protect your hands.
Remove the crash pad side cover (A), frout consolz side cover (B).
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Crash Pad Removal And Installation

SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the
SRS section before performing repairs or service (see page RT- "Airbag").
parts to prevent damage.
• An assistant is helpful when removing and installing the crash pad.
• Take care not to scratch the crash pad, body and other related parts.
• Put on gloves to protect your hands.
1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset
buttons.
2. Disconnect the negative cable from the battery.
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A. Front seat, both sides (See page BD- 84).
B. Front console (See page BD- 59).
C. Crash pad side trim, both sides
(See page BD- 66).
D. Front pillar trim, both sides (See page BD- 69).
E. Clutster tacia panel (See page BD- 62).
F. Lower crash pad panel (See page BD- 63).
G. Heater control unit (See page BD- 63).
H. Clutster (See page BD- 65).
I. Audio (See page BD- 63).
J. Glove box (See page BD- 64).
K. Steering wheel (See page ST- "Steering wheel")
4. Disconnect the passenger's air bag connector (A). Loosen the bolts and nut, then remove the crash pad (B).
5. Carefully remove the crash pad through the front door opening.
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Page 73 of 113
- Make sure the crash pad fits onto the guide pins correctly.
- Before tightening the bolts, make sure the crash pad wire harnesses are not pinched.
- Make sure the connectors are plugged in properly, and the antenna lead is connected
properly.
- Enter the anti-theft code for the radio, then enter the customer's radio station presets.
Body (Interior and Exterior) > Interior > Interior Trim > Repair procedures
Replacement
Floor And Side Area
1. Remove the trims.

- When prying with a flat-tip screwdriver, wrap it with protective tape to prevent
damage.
- Take care not to bend or scratch the trim and panels.

- Apply liquid thread lock to the front seat belt upper anchor bolt befor installation.
- Before installing the anchor bolts, make sure there are no twists or kinks in the
belts.
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Trunk Area

damage.
2. Installation is the reverse of removal, and replace any damaged clips.
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Page 75 of 113
Roof Area

damage.
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- Apply liquid thread lock to the front seat belt upper anchor bolt before
installation.
- Before installing the anchor bolts, make sure there are no twists or kinks in the
belts.
Body (Interior and Exterior) > Interior > Windshield Glass > Components and Components Location
Components
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Page 77 of 113
Body (Interior and Exterior) > Interior > Windshield Glass > Repair procedures
Replacement
Removal

- Use seat covers to avoid damaging any surfaces.
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1. Remove the following items:
A. Inside rear view mirror (See page BD- 57).
B. Sunvisors and holders, both sides, overhead console, Grab handles, both sides
(See page BD- 71).
C. Front pillar trim, both sides (See page BD- 69).
D. Windshield wiper arms and cowl cover
(See page BE- "Windshield wiper").
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)].
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Page 79 of 113
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).
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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).
6. Remove the windshield.
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Page 81 of 113
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.
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.
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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.
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).
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Page 83 of 113
Body (Interior and Exterior) > Interior > Quarter Fixed Glass > Repair procedures
Replacement
Removal

- Take care not to body surface and other parts.
1. Remove the following parts:
A. Rear seat assembly (See page BD- 92).
B. Rear door scuff trim (See page BD- 69).
C. Self covering trim (See page BD- 70).
D. Luggage side trim (See page BD- 70).
E. Rear seat belt upper anchor bolt
(See page BD- 100).
F. Rear pillar trim (See page BD- 69).
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
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1. With a putty 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.
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.
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Page 85 of 113
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
Replacement
- When prying with a flat-tip screwdriver,wrap it with protective tape, and apply protective tape around the
- Take care not to bend or scratch the cover and other parts.
Page 86 of 113
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Body (Interior and Exterior) > Bumper > Rear Bumper > Repair procedures
Replacement
- After remove the rear combination lamp.

- When prying with a flat-tip screwdriver,wrap it with protective tape, and apply protective tape around the
related parts to prevent damage.
- Take care not to bend or scratch the cover and other parts.
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Body (Interior and Exterior) > Seat & Power Seat > Front Seat > Components and Components
Location
Components
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Page 89 of 113
Body (Interior and Exterior) > Seat & Power Seat > Front Seat > Repair procedures
Seat Assembly Replacement
1. Remove the seat assembly mounting cover (A).
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2. After loosening the seat assembly mounting bolt and nut, remove the seat assembly (B).
3. Open the connector box (A).

4. Disconnect the connector (B), and remove the seat assembly.
• Be sure to perfrom PODS re-zero with Hi-Scan (pro) after replacing

parts(passenger's)
SEAT MOUNTING BOLT INSTALLATION PROCEDURE.

- Set the seat into the most rearward position.
Check then each slide is locked, and then tighten the front mounting bolt temporarily.
- Set the seat into the most forward position.
Check then each slide locked, and then tighten the rear mounting bolt completely.
- Set the seat into the most 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 lover (B).
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Page 91 of 113
2. Loosen the recliner mounting screw and clip, then remove the recliner cover (C).

parts(passenger's)
Seat Back Cover Replacement

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).
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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).
When removing the hogring clip, remove the hogring clip with pressing the wire not to separate the wire
from the sponge.
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Page 93 of 113
• Be sure to perfrom PODS re-zero with Hi-Scan (pro) after replacing parts(passenger's)
• 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 (See page BD- 84).
2. Disconnect the scuff band.
3. Remove the connector box (A).
4. Remove the connectors (A).After loosening the mounting bolts,remove the cushion (B)
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5. Disconnect the protector (A) from the cushion frame (B).
6. After removing the hogring clips (A) on the front of seat cushion and remove the seat cushion cover (B).
When removing the hogring clip, remove the hogring clip while pressing the wire so as not to separate the
wire from the sponge
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Page 95 of 113
• Be sure to perfrom PODS re-zero with Hi-Scan (pro) after replacing parts(passenger's)
• 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 Back Frame Replacement

1. Remove the seat back panel (See page BD- 85).
2. Remove the headrest guide (See page BD- 86).
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.
- Bdfore service, be fully aware of precautions and service procedure relevant to air
bag
(See page RT- "Airbag").

parts(passenger's)
Seat Track Replacement

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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 (See page BD- 87).

4. Remove the recliner cover,recliner knob and height adjuster knob (See page BD- 85).
5. Remove the seat track (A)

parts(passenger's)
Seat Back Heater Replacement

1. Remove the seat back cover (See page BD- 85).
2. Cut the heater (A) attached to the pad (B), as shown in the picture.
3. Take off the paper from the the backside of the heater assembly.
4. Attch the heater to the main part of pad
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5. Install the seat back cover.

parts(passenger's)
Seat Cushion Heater Replacement

1. Remove the seat cushion cover (See page BD- 87).
2. Cut the heater (A) attached to the pad (B), as shown in the picture.
3. Take off the paper from the the backside of the heater assembly.
4. Attach the heater to the main part of pad
5. Install the seat cushion cover.

parts(passenger's)
Body (Interior and Exterior) > Seat & Power Seat > Rear Seat > Components and Components
Location
Components
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Body (Interior and Exterior) > Seat & Power Seat > Rear Seat > Repair procedures
Replacement
Seat Assembly Replacement
1. After removing the cushion frame hinge cover (A), loosen the mounting bolts.Fold the cushion (B).
2. Loosen the recliner hinge (C) mounting nut and bolt, then rear seat assembly (D).
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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 completely the bolt on the back of the recliner hinge installaion 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 (See page BD- 92).
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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).
When removing the hogring clip, remove the hogring clip while pressing the wire so as not to separate the
wire from the sponge
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Page 101 of 113
- 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 Back Cover Replacement

1. Remove the headrest.
2. Remove the armrest (See page BD- 98).
3. Remove the back folding hinge cover (A).
4. After loosening the mounting bolts,remove the cushion (B).
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5. After folding the seat back,remove the shopping hook (A) from the back panel.
6. Remove the back panel (A).
7. Remove the recliner lever cover (A).
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8. Remove the hogring clip (A) and headrest guide (B), then remove the seat back assembly (C).
9. Remove the hogring clip (A) of the pad.
10. Disconnect the aplix (A) on the front of seat back, remove the back cover (B).
To prevent wrinkles, make sure the material is stretched evenly over the cover before securing the
aplix
Seat Back Frame And Recliner Replacement
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1. Remove the seat cushion assembly
(See page BD- 97).
2. Remove the seat back cover (See page BD- 94).
3. Remove the recliner cover (A).
4. 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 hinge mount bolt
(See page BD- 92).
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Page 105 of 113
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).
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2. Pushing the arm rest to the left, remove the arm rest.
3. Remove the armrest cover(A).

Recliner Lever Replacement

1. Remove the seat back frame (See page BD- 96).
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) and the bush (F), then remove the recliner lever (D).
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Page 107 of 113
Body (Interior and Exterior) > Seat Belt > Front Seat Belt > Components and Components Location
Components
Page 108 of 113
Body (Interior and Exterior) > Seat Belt > Front Seat Belt > Repair procedures
Replacement
Front Seat Belt Replacement
When installing the seat belt, make sure not to damage the pretensioner.
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Page 109 of 113
1. Remove the following items first.
A. Front seat assembly (See page BD- 84).
B. Front and rear door scarf trim (See page BD- 69).
2. After raise the lower anchor cover (A),loosen the lower anchor mounting bolt (B).
3. Remove the center pillar lower trim

(See page BD- 69).
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).
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Rear Seat Belt Replacement
When installing the seat belt, make sure not to damage the retractor.
A. Rear seat assembly (See page BD- 92).
B. Front and rear door scarf trim (See page BD- 69).
C. Self covering trim (See page BD- 70).
D. Luggage center trim (See page BD- 70).
2. Remove the lower anchor (A).
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Page 111 of 113
3. Remove the luggage side trim (B-See page BD- 70).
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).
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Front Seat Belt Buckle Replacement

A. Front seat assembly (See page BD- 84).
B. Front seat recliner cover (See page BD- 85).
2. Remove the seat belt buckle (A).
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Rear Seat Belt Buckle Replacement

1. After cushion frame hinge mounting bolts, fold the cushion (See page BD- 92).
2. Remove the seat belt buckle (A).
Page 1 of 243
TUCSON(JM) > 2009 > 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.
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Page 2 of 243
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.
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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, 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.
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Page 4 of 243
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.
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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 Check for short and
No.22 fuse (10A) blown replace fuse
Speedometer faulty Check speedometer
Vehicle speed sensor faulty Check vehicle speed
Wiring or ground faulty sensor
Repair if necessary
Tachometer does not operate No.22 fuse (10A) blown Check for short and
Tachometer faulty replace fuse
Wiring or ground faulty Check tachometer
Repair if necessary
Fuel gauge does not operate No.22 fuse (10A) blown Check for short and
Fuel gauge faulty replace fuse
Fuel sender faulty (Main, Check gauge
Suction) Check fuel sender
Wiring or ground faulty Repair if necessary
Low fuel warning lamp does not light up No.6 fuse (10A) blown Check for short and
Bulb burned out replace fuse
Fuel sender faulty (Main, Replace bulb
Suction) Check fuel sender
Water temperature gauge does not operate No.22 fuse (10A) blown Check for short and
Water temperature gauge faulty replace fuse
Water temperature sender Check gauge
faulty Check sender
Oil pressure warning lamp does not light up No.6 fuse (10A) blown Check for short and
Oil pressure switch faulty Replace bulb
Wiring or ground faulty Check switch
Repair if necessary
Low brake fluid warning lamp does not light up No.6 fuse (10A) blown Check for short and
Bulb burned out
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replace fuse
Page 6 of 243
Brake fluid level warning Replace bulb
switch faulty Check switch
Parking brake switch faulty
Repair if necessary
Open door warning lamp and tailgate warning lamp No.22 fuse (10A) blown Check for short and
do not light up Bulb burned out replace fuse
Door switch faulty Replace bulb
Tailgate switch faulty Check switch
Repair if necessary
Seat belt warning lamp does not light up No.6 fuse (10A) blown Check for short and
Seat belt switch faulty Replace bulb
Wiring or gound faulty Check switch
Repair if necessary
All illumination lights do not light up Battery fusible link (50A) Replace the fusible link
blown Check relay
Tail lamp relay faulty Check for short and
No.6, No.7 fuse (10A) blown replace fuse
Rheostat faulty Check rheostat
Lighting System
Symptom Possible cause Remedy
One lamp does not light Bulb burned out Replace bulb
(all exterior) Socket, wiring or ground faulty Repair if necessary
Head lamps do not light Bulb burned out Replace bulb
No.28 fuse (10A) blown Check for short and replace
Head lamp fuse (15A) blown fuse
Head lamp relay faulty Check for short and replace
Lighting switch faulty fuse
Wiring or ground faulty Check relay
Check switch
Repair if necessary
Tail lamps and license plate lamps do Replace bulb
Bulb burned out
not light Check for short and replace
No.3, No.7 fuse (10A) blown
fuse
Battery fusible link (50A) blown
Replace the fusible link
Tail lamp relay faulty
Check relay
ETACS module faulty
Check ETACS module
Lighting switch faulty
Check switch
Wiring or ground faulty
Repair if necessary
Stop lamps do not light Bulb burned out Replace bulb
Stop lamp switch faulty fuse
Wiring or ground faulty Adjust or replace switch
Repair if necessary
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Instrument lamps do not light Rheostat faulty Check rheostat
(Tail lamps light) Wiring or ground faulty Repair if necessary
Turn signal lamp does not flash on one Bulb burned out Replace bulb
side Turn signal switch faulty Check switch
Turn signal lamps do not light Bulb burned out Replace bulb
Flasher unit faulty fuse
Turn signal switch faulty Check flasher unit
Repair if necessary
Hazard warning lamps do not light Bulb burned out Replace bulb
Flasher unit faulty fuse
Hazard switch faulty Check flasher unit
Hazard relay faulty Check switch
Wiring or ground faulty Check relay
Repair if necessary
Flasher rate too slow or too fast Lamps' wattages are smaller or larger than Replace lamps
specified
Defective flasher unit Check flasher unit
Back up lamps do not light Bulb burned out Replace bulb
Back up lamp switch(M/T) faulty fuse
Transaxle range switch(A/T) faulty Check switch
Repair if necessary
Front fog lamps do not light Replace bulb
Bulb burned out
Check for short and replace
Front fog lamp fuse (15A) blown
fuse
Front fog lamp relay faulty
Check relay
Front fog lamp switch faulty
Check switch
Repair if necessary
Room lamp does not light Replace bulb
Bulb burned out
No.22 fuse (10A) blown
fuse
Room lamp switch faulty
Check switch
Door switch faulty
Check switch
ETACS module faulty
Check ETACS module
Repair if necessary
Map lamp does not light Replace bulb
Bulb burned out
No.25 fuse (15A) blown
fuse
Map lamp switch faulty
Check switch
Repair if necessary
Tailgate room lamp does not light Replace bulb
Bulb burned out
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Page 8 of 243
No.25 fuse (15A) blown fuse
Trunk room lamp switch (4 door) faulty
Tailgate switch (5 door) faulty Check switch
Repair if necessary
Audio
Customer Complaint Analysis Check Sheet
There are six areas where a problem can occur: wiring harness, the radio, the cassette tape deck, the CD player, the
speaker, and antenna. Troubleshooting enables you to confine the problem to a particular area.
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Chart 1
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Chart 2
Chart 3
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Chart 4
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Chart 5
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Chart 6
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Chart 7
Chart 8
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Chart 9
Windshield Wiper
Page 19 of 243
1. Wiper low and wiper high does not work.
2. When washer switch is on, wiper does not work.
Power Window
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Page 20 of 243
1. No windows operate from the main switch on the driver's door.
2. Driver's side window does not operate.

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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 fail, replace the door unlock relay.
2. Unlock function works but lock function does not work.
→ Since door lock relay is fail, replace the door lock relay.
3. When passenger side knob is controlled, all doors interlocks, but when driver side knob is controlled, all doors do
not interlock.
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Page 22 of 243
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4. When passenger side knob is controlled. All doors interlocks. But when the driver side knob is controlled, all doors
do not interlock.
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5. Both sides do not interlock either.
Keyless Entry & Burglar Alarm System

1. Alarm does not work. (Hazard lamp works)
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2. When hood is opened from inside the car with the alarm set. Horn does not work.
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Page 26 of 243
3. When door is opened from inside the car with the alarm set. Horn does not work (If tailgate and hood is opened,
alarm works)
4. When tailgate is opened inside the car like alarm test, horn does not work.
5. When the vehicle is locked by the transmitter, central door lock function works but hazard lamp doesn't blink.
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6. Engine does not start, when the alarm released condition.
7. Central door lock function works, but keyless entry system does not work.
Body Electrical System > General Information > Specifications

Specifications
Multifunction Switch
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Page 28 of 243
Items Specifications
Rated voltage DC 12 V
Operating temperature range -30°C ~ +80°C (-22 ~ +176°F)
Rated load
Dimmer & passing switch High : 1A (Relay load)
Low : 1A (Relay load)
Passing : 1A (Relay load)
Lighting switch Lighting : 1A (Relay load)
Turn signal & lane change switch 6.6±0.5A (Lamp load)
Wiper & mist switch Low, High : 5A (Motor load)
Intermittent : 0.22±0.05A (Relay
load)
Lock : Max. 28A (Motor load)
Washer switch Mist : 5A (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)
Instruments And Warning System

Warning lamps Bulb wattage (W) Color
Illumination LED White green
High beam LED Blue
Low fuel LED Amber
Turn signal (LH, RH) LED Green
Battery (charge) LED Red
Oil pressure 1.4 Red
Air bag 1.4 Red
Parking brake LED Red
Seat belt LED Red
Check engine 1.4 Amber
ABS LED Amber
Door ajar LED Red
Tailgate open LED Amber
Immobilizer LED Amber
Cruise LED Green
SET LED Green
Glow LED Amber
Water separater LED Red
4WD LED Green
4WD LOCK LED Amber
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TCS (ESP) LED Amber
TCS OFF (ESP OFF) LED Amber
Indicators And Gauge
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Page 30 of 243
Lighting System
Items Bulb wattage (W)
60W /55W (High / Low
Head lamp
beam)
Front turn signal lamp 27W x 2EA
Front position lamp 5W
Front fog lamp 27W
Rear combination lamps
Tail/stop lamp 8W / 27W
Back up lamp 17W
Turn signal lamp 27W
Side mark lamp 5W
Luggage & glove lamp 5W
Room lamp 10W
Cargo room lamp 10W
Center high mounted stop lamp LED
Map lamp 10W x 2
License plate lamp 5W
Audio
Item Specification
Model Radio/CD/MP3 Radio/CDC/MP3
Power supply DC 14.4V
Output max power Max 43W x 4 3.2 Vrms
Load impedance 4Ωx 4 2Ωx 4
Antenna 80PF 75Ω
Tuning type PLL synthesized type
Frequency FM 87.5 ~ 108.0 MHz/100 KHz
range / Channel AM 531 ~ 1602 KHz/9 KHz
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Windshield Wiper And Washer
Windshield wiper motor
Speed/current at 20kgf·cm load test Low : 40~48 rpm/4.0A or less
(2.0 Nm, 1.47 lbf·ft) High : 59~73 rpm/5.0A or less
Speed/current at 70kgf·cm load test Low : 34~42 rpm/7.0A or less
(7.0 Nm, 5.16 lbf·ft) High : 49~61 rpm/9.0A or less
Torque when locking Low : 38N.m/35A or less
High : 32N.m/37A or less
Windshield washer motor
Motor type
DC ferrite magnet
Pump type
Centrifugal type
Current
Max. 5.0A
Discharge pressure
Min. 1.8kgf/cm²
Flow rate
Min. 1,450cc/min.
Overload capacity (Continuous
operation)
Max. 60 sec.
With water
Max. 20 sec.
Dry
Rear wiper motor
Speed/current at no load test
28 rpm/Max. 2.2A
Speed/current at 10 kgf·cm load
21~29 rpm/Max. 3.5A
test
(1.0 Nm, 0.74 lbf·ft)
Min. 80 kgf·cm/Max.14A
Torque when locking
157° ± 3°
Wiping angle
Body Electrical System > Audio > Specifications

Specification
Item Specification
AM/FM/CD/MP3/XM AM/FM/CDC/MP3/XM
Model
(A200) (A300)
Power Supply DC 14.4V
Output Max. Power Max 43W x 4
Load Impedance 4Ω x 4 2Ω x 4
Antenna 80PF 75Ω
Turning type PLL synthesized type
Frequency FM 87.5 ~ 107.9 MHz/ 200 KHz
Range AM 530 ~ 1710 KHz/ 10 KHz
Body Electrical System > Audio > Components and Components Location
Components [email protected]
Page 32 of 243
1. Audio unit 5. Woofer speaker

2. Front door speaker 6. Antenna feeder
3. Rear door speaker cable
4. Roof antenna 7. External amp
Body Electrical System > Audio > Audio Unit > Components and Components Location
Components
Page 33 of 243
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Body Electrical System > Audio > Audio Unit > Repair procedures
Removal
1. Disconnect the negative(-) battery terminal.
2. Remove shift trim and bracket.
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3. Remove the upper plate from the transmission shift lever, then remove the 3 screws holding the center facia panel.
Remove the center facia panel(A) and disconnect the wire connectors.
4. Remove the audio unit(A) after removing 4 screws.
Body Electrical System > Audio > Speakers > Repair procedures
Inspection
1. Troubleshooting for Speaker
(1) Basic inspection of speaker
Inspect the sound from speaker after verifying that the speaker mounting screws is removed and the wiring
connector is connected precisely to remove vibration transmitted from body trims and surrounding parts.
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Page 36 of 243
(2) Case Troubleshooting
No. Case Inspection/Remedy
1. Before replacing the speaker, inspect that the mounting screw is installed normally.
Trembling
1 2. After re-installing the speaker, verify that no trembling sound is heard.
sound
3. When hearing a trembling sound again, replace the speaker with new one.
1. Check if the wiring connector is connected normally. If not, reconnect the wiring
connector.
2. In case of radio static, check if there is a noise from CD.
3. When a noise is heard on turning radio and CD on, replace the speaker with new
2 Noise one.
In case there is only radio static, this causes from poor radio reception. Thus the
speaker needs no repair and replacement.
Inspection of the wiring connection between the battery and the speaker
1. Before replacing the speaker, inspect the wiring connection between the battery
and the speaker is normal.
2. Check the supplying power to the speaker and the resistance, then inspect the
sound quality.
■ Specified impedance : 2 ~ 4Ω
Poor
3
working
3. If the speaker works poorly, replace it with new one.
- During dealing of speaker

- Do not damage the speaker with impact as like a drop and a throw.
- Be careful not to cover water and oil over the speaker.
- Caution during dealing of speaker because the material of diaphragm is paper which is easy to be
torn by impact and external force.
- When modifying audio system as customer pleases, this does electric damage to speaker.
- And, in this case the speakers are not covered by the manufacturer's warranty.
Removal
Front Door Speaker
1. Remove the front door trim panel (see BD group - front door).
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2. Remove the front door speaker after removing 4 screws.

Rear Door Speaker
1. Remove the rear door trim panel (see BD group - rear door).
2. Remove the rear door speaker after removing 4 screws.

Tweeter Speaker
1. Remove the delta cover from the front door then disconnect the 2P connector.
Remove the tweeter speaker(A).

Woofer Speaker
1. Remove the passenger side seat (see BD group - front seats)
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Page 38 of 243
2. Remove the woofer speaker(A) from the passenger side floor after removing 2 bolts and 2 nuts.

External AMP
1. Open the tailgate then remove the luggage floor mat and trim.
2. Remove the external amp(A) from the luggage right side floor.
Body Electrical System > Audio > Antenna > Components and Components Location
Components
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1. Roof antenna 3. Antenna feeder

2. Audito unit cable
Body Electrical System > Audio > Antenna > Repair procedures
Inspection
Antenna Cable
1. Remove the antenna jack from the audio unit and antenna.
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Page 40 of 243
2. Check for continuity between the center poles of antenna cable.
3. Check for continuity between the outer poles of antenna cable. There should be continuity.
4. If there is no continuity, replace the antenna cable.

5. Check for continuity between the center pole (A) and outer pole (B) of antenna cable. There should be no
continuity.
6. If there is continuity, replace the antenna cable.
Removal
1. Remove the rear roof trim (see BD group-roof trim).
2. Disconnect the 1P power connector(A) and antenna jack(B) from the roof antenna.
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3. Remove the roof antenna after removing a nut.
Body Electrical System > Audio > Troubleshooting

Troubleshooting
Customer Complaint Analysis Check Sheet
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Page 42 of 243
1. System Check Procedure
2. Radio Check Procedure

Chart 1
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Chart 2
Chart 3
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Chart 4
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Chart 5
Chart 6
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3. CD Check Procedure
Chart 1. CD Will Not Be Accepted
Chart 2. CD Sound Skips

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Chart 3
Body Electrical System > Multifunction switch > Components and Components Location
Components
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Page 48 of 243
Body Electrical System > Multifunction switch > Multi Function Switch > Repair procedures
Removal
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• Never attempt to disassemble or repair the air bag module or clock spring. If faulty, replace it.
• Do not drop the air bag module or clock spring or allow contact with water, grease or oil. Replace if a dent,
crack, deformation or rust are detected.
• The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward. Do
not place anything on top of it.
• Do not expose the air bag module to temperatures over 93°C (200°F).
• After deployment of an air bag, replace the clock spring with a new one.
• Wear gloves and safety glasses when handling an air bag that has already been deployed.
• An undeployed air bag module should only be disposed of in accordance with the procedures. mentioned in the
Restraints section.
• When you disconnect the air bag module-clock spring connector, take care not to apply excesive force to it.
• The removed air bag module should be stored in a clean, dry place.
• Prior to installing the clock spring, align the mating mark and "NEUTRAL" position indicator of the clock
spring, and, after turning the front wheels to the straight-ahead position, install the clock spring to the column
switch. If the mating mark of the clock spring is not properly aligned, the steering wheel may not completely
rotate during a turn, or the flat cable within the clock spring may be severed, obstructing normal operation of
the SRS and possibly leading to serious injury to the vehicle's driver. To inspect the clock spring, refer to the
Restraints section.
Prior to doing any further work after disconnection of the battery cable, wait at least 30
seconds.
2. Remove the 2 screws holding the air bag module with an asterix wrench. (Tor-x socket)
Disconnect the horn connector and the air bag module connector, and remove the air bag module(A).
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Page 50 of 243
3. Remove the steering wheel after removing a nut.
4. Align the steering shaft with wheel then remove the steering wheel using special tool (09561-11002).
Do not hammer on the steering wheel to remove it; dong so may damage the collapsible
mechanism.
5. Remove the steering column upper and lower shrouds after removing 3 screws and 1 bolt.
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6. Remove the 3 screwsholding the multi-function switch, then disconnect the wire connector.
Remove the multi-function switch assembly.
Inspection
Lighting Switch Inspection
Lighting Switch [M20-1]
Lighting Switch (With Auto-light Control) [M20-1]
Dimmer And Passing Switch [M20-1] [email protected]

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Turn Signal Switch [M20-1]
Wiper And Washer Switch Inspection
Wiper Switch [M20-2]
Washer Switch [M20-2]

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Body Electrical System > Horn > Components and Components Location
Components
Body Electrical System > Horn > Horn > Repair procedures
Removal
1. Remove the head lamps assembly.
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Page 54 of 243
2. Remove the horns(Low : A, High : B) assembly after removing a bolt, then disconnect the 2P connector.
Inspection
1. Test the horn by connecting battery voltage to the 1 terminal and ground the 2 terminal.
2. The horn should make a sound. If the horn fails to make a sound, replace it.
Adjustment
After adjustment, apply a small amount of paint around the screw head to keepit from loosening.
Horn Relay Inspection

1. Remove the horn relay(A) from the engine compartment relay box.
2. Check for continuity between the terminals.
3. There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the
No.4 and No.3 terminals.
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4. There should be no continuity between the No.1 and No.2 terminals when power is disconnected.
Body Electrical System > Keyless Entry And Burglar Alarm > Components and Components Location
Components
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Page 56 of 243
1. Hood switch 8. Rear door switch

2. Door warning switch 9. Tailgate lock actuator & switch
3. Burglar alarm horn 10. Tailgate switch
4. ETACS module 11. Rear door switch
5. Front door switch 12. Rear door lock actuator & switch
6. Front door lock actuator & switch 13. Front door lock actuator &
7. Rear door lock actuator & switch switch
14. Front door switch
Body Electrical System > Keyless Entry And Burglar Alarm > Description and Operation
Description
Burglar Alarm System
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The system is set off when any of these things occur :
• A door is forced open.
• A door is unlocked without using the transmitter or key.
• 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.
Keyless Entry System
Panic Mode
The panic mode causes the ETACS to sound the alarm with the remote transmitter in order to attract attention.
When the PANIC button is pressed and held for 2 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 key in.
The panic mode can be canceled by lock or unlock with the key.
Anti-theft Function
1. ARM Function
Pressing the remote key lock button will result in a 0.5-second pulse issued to lock all doors.
Pressing the remote unlock button once will result in a 0.5-second unlock pulse issued to unlock all doors the
drivers door.
Pressing the remote unlock button a second time right away will result in a 0.5-second unlock pulse issued to
unlock remain doors.
As part of the arming sequence the alarm first enters a pre-armed state before falling into the armed state. During
this pre-armed state alarm triggers are ignored. Pre-armed state can be reached from the alarmed state, the start
inhibit state or the disarmed state. Pre-Arming of the alarm can be achieved by a press of the lock button on the
remote key.
In the pre-armed state the visible and audible warnings are disabled.
This system enters the armed state if it is in the pre-armed state and,after 0.6 sec, check actuator lock and each
door, hood and tailgate close,and no door warning switch (no key in ignition).
On entering the arm state, a single flash of the hazard lamps is given,period of cycle 2 second, duty rate 50%.
If transmitter(TX) lock signal is received when a door, tailgate or hood is open,then lock output is given and a
flash of hazard is not given.
After the armed state is entered, if a closed signal is received then a single flash of the hazard lamps is given,
period of cycle 2 second, duty rate 50%.
Time specification
T1 : 0.5 ± 0.1 sec.
T2 : Max. 2 sec.
T3 : 1.0 ± 0.2 sec.
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2. Disarm Function
Disarming can be performed while the alarm is armed, or alarming, orafter alarming. The alarm can be disarmed
by the following methods :
A. Pressing the unlock button on the transmitter(TX) key. The hazard lamps shall be flashed twice for 1sec
period (of cycle), 50% duty rate.
B. If door warning switch is on, IGN1 and IGN2 are on in arm state,then arm state should be immediately
cancelled. This means that the driveris inside the vehicle before pushing TX lock, so system should not arm.
In the disarm state the visible and audible warnings are disabled and start is enabled.
In the disarm state, if TX key unlock command is received, then the hazard lamps shall be flashed twice for
period of cycle 1 sec, 50% duty rate.
The hazard lamps will be flashed in the same way when unlocking with the key.
Time specification
T1, T2 : 0.5 ± 0.1 sec.
3. Alarm Function
Once armed, should any door, hood or the tailgate be opened, then.
A. Start relay drive output is disabled, so starting is inhibited.
B. Audible (horn) and visual (hazard lamp) warnings are issued, for three cycles, each cycle 27±2 sec. duration
on, 10±1 sec. off. The horn warning is continuously occurring during the on period. The hazard lamps operate
with 1 sec period, 50 % duty rate during the on period.
After this time, the system maintains the start inhibit state, where no audible and visual warnings are issued but
engine starting is not possible.
Time specification
T1 : 27 ± 2 sec.
T2 : 10 ± 1sec.
T3 : 0.5 ± 0.1 sec.
4. Operation During Alarm Conditions
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(1) Cancelling audible alarm with the remote transmitter.
CASE 1 : Door closed
During or after alarming and then closing all doors and a transmitter (TX) lock signal is received Then
A. The lock command is executed with 0.5 sec. ON
B. Horn and start inhibition are OFF
C. Hazard lamp is flashed one time (period : 2 sec., duty: 50%, within2 sec.)
D. The state goes to arming mode (after a lock state check)
E. The start is enabled
Time specification
T1 : 0.5 sec.
T2 : 1.0 ± 0.2 sec.
CASE 2 : Door Open
During or after alarming, with a door open and a TX lock signal is received Then
A. The lock command is executed with 0.5 sec. ON
B. Horn is disabled and start is enabled after confirmation of actuator lock
At this time, when the door is closed,
A. Hazard lamp is flashed one time (period : 2 sec., duty 50%)
B. The state goes to arming mode
Time specification
T1 : 0.5 sec.
T2 : 1.0 ± 0.2 sec.
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(2) New alarm conditions
Second alarm condition during alarming.
When another alarm occurs during alarming, the starting is disabled,and the alarm continues to sound for the
remained time of warning signal.The alarm continues to sound after the second alarm condition is removed.
New alarm condition occurs after alarming (with all entrances closed)
If any entrance is opened again then
A. The horn is ON 3 times
B. Start is disabled
C. Hazard lamps flash during the ON time of horn
New alarm condition occur after alarming (with any entrance open).
If another entrance is opened, the ETACS module keeps start disabled and there is no horn output.
(3) Key operation during alarm

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

If the battery is disconnected to the ETACS module in the following states :
A. Alarm
B. After alarming
Upon restoring the battery, the alarm state shall be entered and the alarm cycle shall restarted (timer reset to 0).
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6. Panic Mode
(1) If the transmitter's PANIC alarm signal is detected, during T1, using the buggler alarm horn or HAZARD, the
PANIC alarm is ON.
(2) During the PANIC alarm is ON, in the case of "PANIC,TX LOCK/UNLOCK,KEY IN, DR/AS KEY
UNLOCK SW OFF→ON, DR/AS KEY LOCK SW OFF→ON, RELCOK, T/GATE KEY UNLOCK
SW OFF→ON", the PANIC alarm is OFF.
(3) The anti-theft function operates when ;
A. The tansmitter's PANIC alarm signal is detected during the anti-theft function operates,
B. The anti-theft function operates during the PANIC alarm is ON.
(4) The PANIC alarm signal, which is detected during the PANIC alarm is ON, is regarded as the same of the
pevious one.
T1 : 30s, T2 : 0.45s
The output of both the buggler alarm horn and HAZARD are not shown in the chart.
Body Electrical System > Keyless Entry And Burglar Alarm > Repair procedures
Etacs Module Input Signal Test
1. Disconnect the wire connector from the ETACS module.
2. Inspect the connector on wire harness side as shown in the below.
Terminals No. Test condition Standard value
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Door switch "ON"
Below 1Ω
(Door opened)
A17-B18 (GND)
Door switch "OFF"
1MΩ or higher
(Door closed)
Tailgate switch "ON"
Below 1Ω
(Tailgate opened)
C17-B18 (GND)
Tailgate switch "OFF"
1MΩ or higher
(Tailgate closed)
Engine hood switch "ON"
Below 1Ω
(Engine hood opened)
C15-B18 (GND)
Engine hood switch "OFF"
1MΩ or higher
(Engine hood closed)
Driver's door switch "ON"
Below 1Ω
(Driver's door opened)
A5-B18 (GND)
Driver's door switch "OFF"
1MΩ or higher
(Driver's door closed)
Assist door switch "ON"
Below 1Ω
(Assist door opened)
A16-B18 (GND)
Assist door switch "OFF"
1MΩ or higher
(Assist door closed)
Door warning switch "ON"
Battery voltage
(Key inserted)
A14-B18 (GND)
Door warning switch "OFF"
Below 1V
(Key removed)
A2-B18 (GND) Always Battery voltage
A13-B18 (GND) Ignition switch is turned to "ON" position Battery voltage
Driver's door lock switch "ON"
Below 1Ω
(Driver's door unlock detection)
C2-B18 (GND)
Driver's door lock switch "OFF"
1MΩ or higher
(Driver's door lock detection)
Assist door lock switch "ON"
Below 1Ω
(Assist door unlock detection)
C3-B18 (GND)
Assist door lock switch "OFF"
1MΩ or higher
(Assist door lock detection)
Rear door lock switch "ON"
Below 1Ω
(Rear door unlock detection)
C11-B18 (GND)
Rear door lock switch "OFF"
1MΩ or higher
(Rear door lock detection)
A4-B18 (GND) Engine Start Battery voltage
B18(GND) - Body ground Always Below 1Ω
B8-B18 (GND) Burglar alarm horn operation ON
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Inspection
Front Door Lock Actuator Inspection
1. Remove the front door trim panel. (see BD group-front door)
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. (see BD group-rear door)
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Page 64 of 243
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

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Tailgate Lock Actuator Inspection

1. Remove the tailgate trim panel.
(see BD group - tailgate)
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Tailgate Lock Switch Inspection

(see BD group - tailgate)
3. Check for continuity between the terminal in each switch position according to the table.
Door Switch Inspection
Remove the door switch and check for continuity between the terminals.
[Front Door Switch]
[Rear Door Switch]

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Tailgate Switch Inspection

2. Remove the tailgate latch after removing 3 bolts and disconnect the 2P connector from the tailgate switch.
3. Check for continuity between the terminals according to the table.
Hood Switch Inspection

1. Disconnect the 1P connector from the hood switch.
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2. Check for continuity between the terminal and ground according to the table.
Door Warning Switch Inspection

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

1. Remove the horn after removing a bolts and disconnect the 2P connector from the horn.
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2. Test the horn by connecting battery power to the terminal 1 and ground the terminal 2.
Test the horn by connecting battery power to the terminal 1 and ground the terminal 2.The horn should make a
sound. If the 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 door lock still does not operates, register the transmitter code, then try to lock and unlock the doors.
5. If the door lock still does not operates, replace the transmitter.
Transmitter Code Registration

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.
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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.
5. After press lock or unlock button, choose saving 2nd key or not.
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6. If you choose [YES], screen will be shown as "below"
7. After press lock or unlock button, code saving is completed.
Body Electrical System > BCM (Body Control Module) > Specifications
Specifications
Rated voltage DC 12V
Operating voltage DC 9 ~ 16V
Dark current 4mA Max
Insulation resistance 100KΩ With 500V
Rated load Room lamp DC 12V 12W(LAMPload)
Ign key illumi DC 12V2W(LAMPload)
lamp
Seat belt DC 12V(LEDload)
indicator
Tail lamp relay DC 12V 200mA(Inductive load)
/ drl
Rear fog relay DC 12V 200mA(Inductive load)
Door lock relay DC 12V 200mA(Inductive load)
Door unlock DC 12V 200mA(Inductive load)
relay
Dr door unlock DC 12V 200mA(Inductive load)
relay
Hazard relay DC 12V 200mA(Inductive load)
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Start inhibit DC 12V 200mA(Inductive load)
relay
Burglar horn DC 12V 200mA(Inductive load)
Power window DC 12V 200mA(Inductive load)
relay
Wiper relay DC 12V 200mA(Inductive load)
Rear defog DC 12V 200mA(Inductive load)
relay
Front deicer DC 12V 200mA(Inductive load)
relay
Chime bell DC 12V 350mA(Inductive load)
Tailgate safety DC 12V 200mA(Inductive load)
relay
Rear wiper DC 12V 200mA(Inductive load)
relay
Body Electrical System > BCM (Body Control Module) > Description and Operation
Description
ETACS module(A) receives various input switch signals,
and controls time and alarm such as intermittent wiper
timer, washer timer, rear defogger timer, seat belts
warning, decayed out room lamp, central door lock,
ignition key reminder, power window timer, door
warning, tail lamp auto cut, crash door unlock, ignition
key hole illumination, rear fog lamp control and keyless
entry & burglar alarm automatically.
Body Electrical System > BCM (Body Control Module) > ETACS Module > Schematic Diagrams
Circuit Diagram
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Body Electrical System > BCM (Body Control Module) > ETACS Module > Repair procedures
1. Disconnect the wire connector from the ETACS module.
2. Inspect the connector on wire harness side as shown in the below.
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Page 74 of 243
Terminal
Connector A Connector B Connector C
No.
1 Room lamp - Diagnosis
2 B+ - Drive door lock switch
3 IGN1 Rear wiper switch Assist door lock switch
4 Alternator (L) Front deicer relay Drive door key lock switch
5 Driver door switch Tail lamp relay Rear INT switch
6 Assist door key lock switch Seat belt indicator Tailgate key unlock switch
7 - Key illumination lamp -
8 Windshield deicer switch B/Horn relay Drive unlock relay
9 Front fog lamp switch - Unlock relay
10 Head lamp switch - Speed sensor
11 Washer switch Safety relay Rear door lock switch
12 Signal ground Rear defogger relay Auto door unlock
13 IGN2 DRL Assist door key unlock
switch
14 Door warning switch Power window relay Drive door key unlock
switch
15 - Wiper relay Hood switch
16 Assist door switch Rear fog relay Rear washer switch
17 4Door switch Chime bell Tailgate switch
18 Tail lamp switch Power GND Hazard relay
19 Code saving Start inhibit relay
20 Seat belt switch Lock relay
21 Rear defogger switch
22 Rear fog lamp switch
23 INT switch
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24 INT volume

ON/OFF voltage
Pin
Input signal name Logic state recognition Remarks
No
LEVEL(V)
A2 BAT ON=BAT 9V~16V BAT=BATTERY
ON = BAT(IGN KEY is ON or START 7V or more / 4V or
A3 IGN1
position)) less
7V or more / 4V or
A4 ALT “L” ON = BAT (starting state)
less
ON:DOOR
A5 Drive door switch OPEN = GND 1V or less /OPEN
OPEN
Assist door key lock
A6 ON = GND 1V or less /OPEN ON:LOCK
switch
A8 FR deicer switch ON = GND 1V or less /OPEN
A9 FR fog switch ON = GND 1V or less /OPEN
A10 Head lamp switch ON = GND 1V or less /OPEN
7V or more / 4V or
A11 Washer switch ON = BAT
less
ON = BAT (IGN KEY is ON 7V or more / 4V or
A13 IGN2
position) less
ON:DOOR
A16 Assist door switch OPEN = GND 1V or less /OPEN
OPEN
- Any one of Dr/Ar/Rr DOORDOOR
OPEN = GND ON:DOOR
A17 4door switch 1V or less/OPEN
- All Dr/Ar/Rr DOORs OPEN
CLOSE =OPEN
A18 Tail switch ON = GND 1V or less /OPEN
1V or less / 4V or
A19 Code saving ON = GND
more
Fasten = OPEN,
A20 Seat belt switch 1V or less /OPEN ON:unfasten
Unfasten = GND
A21 RR defog switch ON = GND 1V or less /OPEN
A22 RR fog switch ON = GND 1V or less /OPEN
7V or more / 4V or
A23 INT switch ON = BAT
less
A24 INT volume 0V ~ 2.5V - 0Ω~ 50KΩ
7V or more / 4V or
B3 Rear wiper switch ON = BAT
less
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Drive door lock LOCK = OPEN,
C2 1V or less /OPEN ON:UNLOCK
switch UNLOCK = GND
Assist door lock LOCK = OPEN,
C3 1V or less /OPEN ON:UNLOCK
switch UNLOCK = GND
Drive door key lock
C4 ON = GND 1V or less /OPEN ON:LOCK
switch
Tail gate key unlock
C6 ON = GND 1V or less /OPEN ON:UNLOCK
switch
Car speed input 1V or less / 4V or
C10 Speed sensor
(PULSE:0~5V) more
- Any one of TAIL GATE /
Rr(LH) / Rr(RH)
DOORUNLOCK = GND
C11 RR door lock switch 1V or less /OPEN ON:UNLOCK
- ALL TAIL GATE / Rr(LH) / Rr(RH)
DOORLOCK =
OPEN
Assist door key
unlock switch
Drive door key
unlock switch
C15 Hood switch OPEN = GND 1V or less /OPEN
7V or more / 4V or
C16 Rear washer switch ON = BAT
less
C17 Tail gate switch OPEN = GND 1V or less /OPEN
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the shift lever upper plate and lower trim.
3. Remove the ETACS module (A) after removing two bolts.
Installation
1. Install the ETACS module.
2. Install the shift lever upper plate and lower trim.
3. Connect the negative (-) battery terminal.
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Inspection
1. Variable INT Wiper
(1) Under IGN2=0N, INT wiper Intermittent operation is possible from intermittent volume setting rate if INT
WIPER SW is on.
Time specification
T1 : 0.3 sec (MAX)
T2 : 0.7 0.1SEC
T3 : T2+Cessation time 2.2 0.2sec(VR=0K )Min ~ 10 1sec (VR 50K )Max
2. Seat belt warning timer
(1) Since the ignition is switched ON, the seat belt warning indicator is illuminated (with period : 0.6 sec., duty
rate : 50%) and the buzzer is sounded (with period : 0.9 sec., duty rate : 50%) for total time 6 seconds.
(2) If the ignition is swithced off during the indicator and the buzzer output, the indicator and the buzzer are
switched OFF.
If the seat belt is sensed as fastened during the indicator and the buzzer output, the buzzer is switched OFF
immediately and the seat belt warning indicator is illuminated for the remained seconds.
(3) When the ignition is already switched ON, if the seat belt is removed, the warning indicator and the buzzer
are output for total time 6 seconds.
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Page 78 of 243
3. Key operated warning
(1) Buzzer sounds continuously when DRIVER DOOR is opened under IGN KEY switch = IN.
(2) Buzzer stops sounding if IGN KEY switch =OUT or Driver DOOR=CLOSE are met during CHIME
BUZZER output.
(3) In case of BELL, BELL is operated every 0.9sec(DUTY 50%) during BUZZER output time.
4. Front deicer timer

(1) After ALT “L”=ON, Front DEICER RELAY become ON for T1 when Front DEICER switch is turned
ON.
(2) On the state of OUTPUT =ON, Front DEICER RELAY become OFF if Front DEICER switch is turned
ON or ALT “L”=OFF.
Time specification
T1 : 20 min
5. Rear defogger timer
(1) REAR DEFOG RELAY is turned ON for T1 if REAR DEFOG switch is turned ON under ALT "L" = ON.
(2) REAR DEFOG RELAY is turned OFF if REAR DEFOG switch is turned ON again under output ON or
ALT”L” = OFF.
Time specification
T1 : 20 min
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6. Decayed room lamp
(1) Room Lamp lights 100% at D00R OPEN.
(2) Room Lamp phases out lighting up to 0% in T2 after lighting 100% for T1.
(But, if DOOR is opened continuously, Room Lamp is lighting up 100% for T4 then Room Lamp phases out
lighting up to 0% in T2.)
(3) Room Lamp is immediately turned OFF at All Door Lock Switch = ON or IGN = ON during T1.(phasing
out lighting for T2)
(4) Room Lamp is turned ON for T3 when Tx UNLOCK signal is received under DOOR CLOSE.
(5) Under ON state, Room Lamp signal output is extended for T3 if Tx UNLOCK signal is received again.
(6) Under T3 ON, Room Lamp lights for T4 continuously at D00R OPEN and operation in 2) is performed at
DOOR CLOSE.
(7) Room Lamp is turned off(phasing out for T2) at All DOOR Lock during Room Lamp ON.
7. Rear fog lamp

(1) REAR FOG RELAY is turned ON if pushing REAR FOG switch OFF → ON under HEAD LAMP
switch=ON (or FRONT FOG swtich=ON) & IGN1=ON & TAIL=ON.
(2) Output is turned OFF if pushing REAR FOG switch OFF → ON again under REAR FOG RELAY ON.
(3) REAR FOG RELAY is turned OFF unless the condition “IGN1=ON & TAIL switch =ON & HEAD
LAMP switch = ON (and FRONT FOG switch=ON)” is met.
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Page 80 of 243
8. Tail lamp auto cut
(1) TAIL RELAY is turned ON When TAIL switch is ON.
(2) TAIL RELAY is turned OFF when TAIL switch is OFF.
(3) TAIL RELAY is turned OFF(AUTO CUT) if the state is changed from IGN KEY switch = IN & TAIL
switch = ON to IGN KEY switch = OUT & TAIL switch = ON & Driver DOOR = OPEN.(automatic light
out)
(4) TAIL RELAY is turned ON when IGN KEY switch is turned ON after the operation in 3).
(5) Light out state is held at BATTERY ON/OFF after the automatic light out in 3).
9. IGN key hole illumination

(1) KEY ILLUMI LAMP is turned ON at IGN switch = OFF & DOOR = OPEN.
(2) KEY ILLUMI LAMP is turned ON for T1 at DOOR = CLOSE after the operation in 1).
(3) KEY ILLUMI LAMP is immediately turned OFF at IGN1 switch = ON during output.
(4) KEY ILLUMI LAMP is immediately turned OFF at transition to warning MODE during output.
Time specification
T1 : 30 sec.
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10. Auto door lock
(1) This does not activate when vehicle speed is less than 40km/h.
(2) LOCK signal is output if vehicle speed is 40km/h or more for at least 1sec under ALT”L” ON, IGN switch
= ON. But, LOCK signal is not output if all DOORs are locked or all DOORs are FAIL in advance.
(3) LOCK signal is output 3 times as Max if either one door is unlocked after LOCK signal output in 2). But,
DOOR, which is locked from UNLOCK state during 3-time output, is ignored.
(4) Relevant DOOR is FAIL if the state is UNLOCK after 3-time output.
(5) LOCK signal is output once if the FAIL DOOR is unlocked again after the DOOR is locked.
(6) LOCK signal is output once if locked doors, which are LOCK state after LOCK signal output in 2), are
unlocked again. But, LOCK signal is output once for the relevant DOOR even when UNLOCK state
continues after LOCK signal output.
(7) FAIL DOOR is cleared at IGN switch = OFF.
(8) AUTO DOOR LOCK function is not performed when CRASH UNLOCK condition is met.
Time specification
T1 : 1sec ± 0.5sec
T2 : 0.5sec
11. IGN key reminder
(1) This function is not performed when vehicle speed is 3km/h or more.
(2) ALL DOOR UNLOCK signals are output for T2 after T1 from when the state becomes IGN KEY switch
= IN & DOOR = OPEN & DOOR LOCK switch = LOCK.
(3) UNLOCK signal is output 3times as Max in case LOCK state is held even when UNLOCK signal is
output for 1s in 2).
(4) All Door Unlock signal is output for 1sec when DOOR LOCK switch = LOCK at DOOR CLOSE during
3).
Time specification
T1,T3 : 0.5 sec., T2 : 1 sec.,
T4 : Max.0.5 sec.
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Page 82 of 243
12. Crash door unlock
(1) UNLOCK signal is always output for T3 when AIR BAG signal is input under IGN switch = ON.
(2) UNLOCK signal is output for the remaining time even when IGN switch ON is turned to OFF during
UNLOCK output.
(3) UNLOCK signal is not output when IGN switch OFF is turned to ON after AIR BAG signal is input in
advance.
(4) UNLOCK signal is output for T3 when Driver, Assist or REAR DOOR LOCK SWITCH is locked from
UNLOCK.
Time specification
T1 : 0.2 sec
T2 : 40 ms
T3 : 0.5 sec
13. Power window timer
(1) POWER WINDOW RELAY it turned ON at IGN1 Switch = ON.
(2) POWER WINDOW RELAY is turned ON for T1 at IGN1 Switch = OFF.
(3) POWER WINDOW RELAY is immediately turned OFF if DOOR is opened under POWER WINDOW
RELAY ON for T1.
(4) POWER WINDOW RELAY is immediately turned OFF at IGN Switch ON → OFF under DOOR
OPEN.
Time specification
T1 : 30 sec
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14. Horn answer back
(1) If "LOCK" button of the transmitter is pushed, when 4 doors are closed, the burglar alarm horn operates for
'T2', 4 secs(T1) after engaging "LOCK" button.
(2) The buggler alarm horn does not operate when cancelling the anti-theft function during T1.
Body Electrical System > Seat Electrical > Components and Components Location
Components
Body Electrical System > Seat Electrical > Seat Heater Switch > Repair procedures
Inspection
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Page 84 of 243
2. Remove the seat warmer switch from the floor console upper cover.
Seat Warmer Inspection

1. Check for continuity and measure the resistance between the terminals.
Standard value : 2.6Ω ± 10%
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 2P connector.
Thermostat settiangs standard value

28 ± 3.5°C (Continuity) : Turn ON
37 ± 3.0°C (Short) : Turn OFF
Body Electrical System > Fuses And Relays > Components and Components Location
Components
Page 85 of 243
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Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Components and
Components Location
Components
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Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Repair procedures
Inspection
Power Relay Test (Type A)
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Page 88 of 243
Power Relay Test (Type B)

2. There should be continuity between the No.1 and No.4 terminals when power is disconnected.
Power Relay Test (Type C)

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Body Electrical System > Fuses And Relays > Relay Box (Passenger Compartment) > Components
and Components Location
Components
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Page 90 of 243
Page 91 of 243
Relay Box
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Page 92 of 243
Body Electrical System > Fuses And Relays > Relay Box (Passenger Compartment) > Repair
procedures
Inspection
Power Relay Test (Type A)
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Power Relay Test (Type B)

Power Relay Test (Type C)

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Page 94 of 243
Body Electrical System > Indicators And Gauges > Components and Components Location
Components
Page 95 of 243
Body Electrical System > Indicators And Gauges > Instrument Cluster > Components and Components
Location
Components
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Instrument Cluster
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Pin
Connector A Connector B Connector C
No.
1 IG (+) P TPMS(DIAG)
2 - R TPMS(WARN)
WATER
3 N CRUISE
SEPARATOR
4 - D SET
5 ILL(+) PWM SIGNAL 4WD LOCK
6 B+ - 4WD
7 TACHO METER - IMMOBILIZER
8 ILL(-) - TURN-R
9 TRUNK OPEN - HIGH SPEED
10 TURN-L - H-BEAM (+)
11 SPEED METER - -
12 POWER GND - TEMP/UNIT
13 ESC FUEL/UNIT
FUEL
14 ESC OFF
GND(MICOM)
15 AIR BAG(+) ABS
16 AIR BAG(-) OIL
17 SEAT BELT BRAKE
18 DOOR OPEN CHARGE
INJECTION
19 CHECK ENGINE
SIGNAL
TRIP COMPUTER
20 H-BEAM (-)
SW
Body Electrical System > Indicators And Gauges > Instrument Cluster > Schematic Diagrams
Circuit Diagram
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Page 98 of 243
Body Electrical System > Indicators And Gauges > Instrument Cluster > Repair procedures
Removal
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2. Remove the cluster facia panel(A) after removing 2 screws.
3. Remove the cluster(A) after removing 4 screws, then disconnect the wire connectors.
Inspection
Speedometer
1. Adjust the pressure of the tires to the specified level.
2. Drive the vehicle onto a speedometer tester. Use wheel chocks as appropriate.
3. Check if the speedometer indicator range is within the standard values.
Do not operate the clutch suddenly or increase/ decrease speed rapidly while
testing.
Tire wear and tire over or under inflation will increase the indication error.
Velocity
20 40 60 80 100
(km/h)
Tolerance
20~24 40~44 60.6~64.6 81.2~85.2 102.2~106.2
(km/h)
Velocity
120 140 160 180 200
(km/h)
Tolerance 206~211
122.4~127 143.4~148 185~190 185~190
(km/h)
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Page 100 of 243
Velocity
10 20 40 60 80 100 120
(MPH)
Tolerance
10~13 20~23 40~43 60.8~63.8 81.2~84.8 102~105.6 123~126.6
(MPH)
Vehicle Speed Sensor

1. Connect the positive (+) lead from battery to terminal 31and negative (-) lead to terminal 2.
2. Connect the positive (+) lead from tester to terminal 3 and the negative (-) lead to terminal 2.
3. Rotate the shaft.
4. Check that there is voltage change from approx. 0V to 11V or more between terminals 2 and 3.
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.
2. With the engine started, compare the readings of the tester with that of the tachometer. Replace the tachometer if
the tolerance is exceeded.
1. Reversing the connections of the tachometer will damage the transistor and diodes inside.
2. When removing or installing the tachometer, be careful not to drop it or subject it to severe shock.
Fuel Gauge
1. Disconnect the fuel sender connector from the fuel sender.
2. Connect a 3.4 watt, 12V test bulb to terminals 5 and 6 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.
Main Fuel Gauge Sender

1. Using an ohmmeter, measure the resistance between terminals 5 and 6 of main sender connector(A) at each float
level.
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2. Also check that the resistance changes smoothly when the float is moved from "F" to "E".
Position Resistance(Ω)
Sender (E) 104.8 ± 1
Warning lamp 89.9 ± 1
1/2 13.7 ± 1
Sender (F) 4.2 ± 1
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 "F" to "E".
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.
After completing this test, wipe the sender dry and reinstall it in the fuel
tank.
Engine Coolant Temperature Gauge
1. Disconnect the wiring connector(3 pins) from the engine coolant temperature sender in the engine compartment.
2. Turn the ignition switch ON. Check that the gauge needle indicates cool. Turn the ignition switch OFF.
3. Connect a 12V, 3.4 watt test bulb between the harness side connector terminal 2 and ground.
4. Turn the ignition switch ON.
5. Verify that the test bulb flashes and that the indicator moves to HOT.
If operation is not as specified, replace the engine coolant temperature gauge. Then recheck the system.
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Page 102 of 243
Engine Coolant Temperature Sender

1. Using an ohmmeter, measure the resistance between terminal 2 of sender connector and ground.
2. If the resistance value is not as shown in the table, replace the temperature sender.
Temperature (°C) 60 85 110 127.4
Gauge angle (°) -40 -10~-5 -10~-5 35±5
Resistance (Ω) 128.5 53.8 24 16.1
Oil Pressure Switch

1. Check that there is continuity between the oil press switch terminal and ground with the engine off.
2. Check that there is no continuity between the terminal and ground with the engine running.
3. If operation is not as specified, replace the switch.
Oil Pressure Warning Lamp

1. Disconnect the connector from the warning switch and ground the terminal on the wire harness side connector.
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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.
5. Verify that the warning lamp lights.
Parking Brake Switch

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

1. Remove the connector from the switch.
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2. Check for continuity between terminals.
Seat belt condition Continuity
Non-conductive
Fastened
(∞Ω)
Not fastened Conductive (0Ω)
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
Trip Switch
1. Remove the cluster facia panel (B).
2. Operate the switch (A) and check for continuity between terminals with an ohmmeter.
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Page 106 of 243
Body Electrical System > Power Door Locks > Components and Components Location
Components
Body Electrical System > Power Door Locks > Power Door Lock Actuators > Repair procedures
Inspection
Front Door Lock Actuator Inspection
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Rear Door Lock Actuator Inspection

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Page 108 of 243
Tailgate Lock Actuator Inspection

1. Remove the tailgate trim panel. (see BD group-tailgate)
Front Door Lock Switch Inspection

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Rear Door Lock Switch Inspection

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Page 110 of 243
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.
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3. Remove the door lock and unlock relay(A) from the cross member bracket, then check for continuity between
the terminals.
Body Electrical System > Power Door Locks > Power Door Lock Switch > Repair procedures
Inspection
Driver's Door Lock Switch Inspection
1. Remove the driver's door trim panel. (see BD group - front door)
2. Disconnect the 14P connector from the door lock switch assembly.
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Page 112 of 243
Passenger's Door Lock Switch Inspection

1. Remove the assist door trim panel. (see BD group - front door)
2. Disconnect the 10P connector from the door lock switch assembly.
Body Electrical System > Power Door Mirrors > Components and Components Location
Components
Page 113 of 243
Body Electrical System > Power Door Mirrors > Power Out Side Mirror Switch > Schematic Diagrams
Circuit Diagram
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Page 114 of 243
Body Electrical System > Power Door Mirrors > Power Out Side Mirror Switch > Repair procedures
Inspection
1. Remove the driver's door trim panel. (see BD group-front door)
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2. Disconnect the 8P connector from the power door mirror switch.
Body Electrical System > Power Door Mirrors > Power Door Mirror Actuator > Repair procedures
Inspection
1. Disconnect the power door mirror connector from the harness.
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Page 116 of 243
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 117 of 243
Body Electrical System > Power Windows > Power Window Motor > Repair procedures
Inspection
Front Power Window Motor Inspection
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Page 118 of 243
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.
[with driver's side safety window]
Rear Power Window Motor Inspection

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2. Disconnect the 2P connector from the motor.
3. Connect the motor terminals directly to battery voltage (12V) and check that the motor operates smoothly. Next,
reverse the polarity and check that the motor operates smoothly in the reverse direction. If the operation is
abnormal, replace the motor.
Body Electrical System > Power Windows > Power Window Switch > Schematic Diagrams
Circuit Diagram
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Page 120 of 243
Page 121 of 243
Body Electrical System > Power Windows > Power Window Switch > Repair procedures
Inspection
Power Window Main Switch
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Page 122 of 243
1. Remove the power window main switch from the driver's door trim panel.
Passenger's Power Window Switch

1. Remove the assist power window switch from the assist door trim panel.
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If continuity is not as specified in the table, replace the power window switch.
[without door lock switch]
[with door lock switch]
Rear Power Window Switch

1. Remove the rear power window switch from the rear door trim panel.

If continuity is not as specified in the table, replace the power window switch.
Body Electrical System > Power Windows > Power Window Relay > Repair procedures
Inspection
1. Remove the power window relay(A) from the passenger compartment junction block(B).
No.3 and No.2 terminals. [email protected]
Page 124 of 243
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.
If the alternator "L" is switched ON, and the deicer switch is ON, then deicer output is ON for 20 minutes.
Page 125 of 243
Body Electrical System > Windshield Deicer > Windshield Deicer > Repair procedures
Inspection
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Page 126 of 243
1. Disconnect the windshield glass deicer connetor(A) from the wiper motor linkage.
2. Check for continuity between the terminals of deicer lines.
3. Turn the ignition switch ON and the windshield deicer switch ON, then measure the voltage between the
terminals of harness side deicer connector.
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OK : approx. Battery voltage
Body Electrical System > Windshield Deicer > Windshield Deicer Switch > Repair procedures
Inspection
2. Remove the center facia panel then disconnect the 6P connector from the windshield glass deicer switch.
3. Check for continuity between terminals while operating the deicer switch.
Body Electrical System > Windshield Deicer > Windshield Deicer Timer > Repair procedures
Inspection
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Page 128 of 243
While operating the components, check whether the operations are normal as shown in the timing chart.
1. After ALT "L" ON, if the deicer is switched ON, the deicer output is ON for 20 minutes duration.
2. If the deicer switch is pressed again, or if the ignition is switched OFF during this time, deicer output is OFF.
T1 : 20 ± 1min.
Body Electrical System > Windshield Deicer > Windshield Deicer Relay > Repair procedures
Inspection
1. Remove the windshield deicer relay(A) from the passenger compartment relay box.
Page 129 of 243
Body Electrical System > Rear Glass Defogger > Components and Components Location
Components
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Page 130 of 243
Body Electrical System > Rear Glass Defogger > Rear Glass Defogger Printed Heater > Repair
procedures
Inspection
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Wrap tin foil around the end of the voltmeter test lead to prevent damaging the heater line. Apply finger pressure
on the tin foil, moving the tin foil along the grid line to check for open circuits.
1. Turn on the defogger switch and use a voltmeter to measure the voltage of each heater line at the glass center
point. If a voltage of approximately 6V is indicated by the voltmeter, the heater line of the rear window is
considered satisfactory.
2. If a heater line is burned out between the center point and (+) terminal, the voltmeter will indicate 12V.
3. If a heater line is burned out between the center point and (-) terminal, the voltmeter will indicate 0V.
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Page 132 of 243
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).
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Body Electrical System > Rear Glass Defogger > Rear Glass Defogger Switch > Repair procedures
Inspection
1. Remove the negative(-) battery terminal.
2. Remove the center facia panel then disconnect the 6P connector from the rear window defogger switch.
3. Check for continuity between terminals while operating the defogger switch.
Body Electrical System > Rear Glass Defogger > Rear Glass Defogger Relay > Repair procedures
Inspection
1. Remove the rear window defogger relay(A) from the passenger compartment junction block(B).
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Page 134 of 243
Body Electrical System > Windshield Wiper/Washer > Components and Components Location
Components
Body Electrical System > Windshield Wiper/Washer > Windshield Wiper-Washer Switch > Repair
procedures
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Inspection
Wiper Switch
Washer Switch
Body Electrical System > Windshield Wiper/Washer > Front Wiper Motor > Components and
Components Location
Components
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Page 136 of 243
Body Electrical System > Windshield Wiper/Washer > Front Wiper Motor > Repair procedures
Removal
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1. Detach the wiper cap, then remove the windshield wiper arm and blade after removing a nut(A).
Tightening torque
28~33 Nm (280~330 kgf·cm, 20.2~23.8 lbf·ft)
2. Remove the weatherstrip then remove the cowl top cover(A) after removing 3 screws(B).
3. Remove the windshield wiper motor and linkage assembly after removing 2 bolts.
Disconnect the wiper motor connector(A) and windshield deicer connector(B) from the wiper motor & linkage
assembly.
Tightening torque
7~11 Nm (70~110 kgf·cm, 5.1~8.0 lbf·ft)
Installation
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Page 138 of 243
1. Install the wiper arm and blade to the specified position.
Specified position A B
Distance (mm) 36 ± 5 36 ± 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.
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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 2 and 4.
5. Check that the motor stops running at the off position.
Body Electrical System > Windshield Wiper/Washer > Front Washer Motor > Repair procedures
Removal
- When servicing the washer pump, be careful not to damage the washer pump seal.
- Do not operate the washer pump before filling the washer reservoir.
Failure to do so could result in premature pump failure.
2. Remove the front bumper cover.
(see BD group-front bumper)
3. Remove the washer hose and the washer motor connector.
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4. Remove the washer reservoir after removing 2 bolts.
Before installing the pump motor, check the filter for foreign material or contamination. if necessary, clean
the filter into the pump motor.
Inspection
1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water.
Before filling the reservoir tank with water, check the filter for foreign material or contamination. if
necessary, clean the filter.
2. Connect positive (+) and negative (-) battery cables to terminals 2 and 1 respectively to see that the washer
motor runs and water sprays from the front nozzles.
3. Check that the motor operates normally.
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Body Electrical System > Rear Wiper/Washer > Components and Components Location
Components
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Body Electrical System > Rear Wiper/Washer > Rear Wiper Motor > Repair procedures
Removal
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1. Detach the wiper cap(A), then remove the rear wiper arm after removing a nut(B).
Tightening torque
Nut(B) : 14~17 Nm (140~170 kgf·cm, 10.1~12.3 lbf·ft)
2. Remove the handle(B) after removing a nut(A).
Tightening torque
Nut(A) : 10~13 Nm (100~130 kgf·cm, 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 (140~170 kgf·cm, 10.1~12.3 lbf·ft)
5. Installation is the reverse of removal. [email protected]

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Installation
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.
Body Electrical System > Rear Wiper/Washer > Rear Washer Switch > Repair procedures
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Inspection
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. Connect positive(+) and negative(-) battery cables to terminals 3 and 1 respectively to see that the washer motor
runs and water is pumped.
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3. 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 7~85%. But, when the reverse gear is
engaged, it stops functioning.
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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.
Automatic-dimming Function
To protect your vision during nighttime driving, your mirror will automatically dim upon detecting glare from the
vehicles traveling behind you. The auto-dimming function can be controlled by the Dimming ON/OFF Button:
1. Pressing and holding the Feature Control button for more than 3 but less than 6 seconds turns the auto-dimming
function OFF which is indicated by the green Status Indicator LED turning off.
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2. Pressing and holding the Feature Control button again for more than 3 but less than 6 seconds turns the auto-
dimming function ON which is indicated by the green Status Indicator LED turning on.
• The mirror defaults to the "ON" position each time the vehicle is started.
• The display may change state (ON/OFF) during this 3 second hold time.
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.
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.
Replacement
1. Push the inside rear view mirror base down to remove the inside rear view mirror assembly (A) after removing
the mirror wire cover.
Mirror it adheres closely in the mirror base (A) and it separates while removing the mirror (B).
Make sure the spring mounting bracket (C) of the mirror not to be damaged.
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Body Electrical System > Electro chromic Inside Rear View Mirror > Compass Mirror > Description
and Operation
Description
The compass feature is designed to be integrated into an electro chromic interior rearview mirror.
The mirror assembly shall display a compass heading.
The compass mirror then take the sensor information to determine static field strengths and rotating field information
to determine an accurate compass heading.
Specification
Item Standard value
Rate voltage DC 12V
Operating voltage
DC9 ~ 16V
range
Operating temperature
-30 ~ +65°C
range
Direction display 8
Renewal time 2 sec.
Switch Point Accuracy

The compass module shall, while compensating for the vehicle magnetic fields, until the Earth's varying magnetic
fields to determine direction.
[Switch points]
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Heading ±
Switch point
10°
N - NE 22.5
NE - E 67.5
E - SE 112.5
SE - S 157.5
S - SW 202.5
SW - W 247.5
W - NW 292.5
NW - N 337.5
There should be hysteresis at each switch point.

Switch points between the 8 cardinal directions, these switch points are ± 10°
Compass display interval

Compass display should be updated at every two seconds.
Function
The Compass can be turned ON and OFF and will remember the last state when the ignition is cycled. To turn the
display feature ON/OFF:
1. Press and release the Feature Control button(A) to turn the display feature OFF.
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2. Press and release the Feature Control button(A) again to turn the display back ON.
Additional options can be set with press and hold sequences of the Feature Control button(A) and are detailed
below.
There is a difference between magnetic north and true north. The compass in the mirror can compensate for this
difference when it knows the Magnetic Zone in which it is operating. This is set either by the dealer or by the user.
The operating Zone Numbers for North America are shown in the figure to the right.
Body Electrical System > Electro chromic Inside Rear View Mirror > Compass Mirror > Repair
procedures
Adjustment
Calibration procedure
If the display read "C", calibrate the compass.
1. Driving the vehicle in a circle at less than 8km/h 3 times or until the compass heading appears.
2. Driving in a circle in right-handed direction and opposite direction are possible, and if the calibration is
completed, the compass heading will appear.
3. Keep driving in a circle until a commpass heading appears.
To adjust the Zone setting:
1. Determine the desired Zone Number based upon your current location on the Zone Maps below.
2. Press and hold the Feature Control button(A) for more than 6 but less than 9 seconds, the current Zone Number
will appear on the display(B).
3. Pressing and holding the Feature Control button(A) again will cause the numbers to increment (Note: they will
repeat …13, 14, 15, 1, 2,..). Releasing the button when the desired Zone Number appears on the display will set
the new Zone.
4. Within about 5 seconds the compass will start displaying a compass heading again.
There are some conditions that can cause changes to the vehicle magnets. Items such as installing a ski rack or a CB
antenna or even some body repair work on the vehicle can cause changes to the vehicle's magnetic field. In these
situations, the compass will need to be re-calibrated to quickly correct for these changes.
To re-calibrate the compass:
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1. Press and hold the Feature Control button(A) for more than 9 seconds. When the compass memory is cleared, a
"C" will appear in the display(B).
2. To calibrate the compass, drive the vehicle is 2 complete circles at less than 5 MPH.
Body Electrical System > Sun Roof > Schematic Diagrams

Circuit Diagram
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Body Electrical System > Sun Roof > Components and Components Location
Components
Body Electrical System > Sun Roof > Sunroof Switch > Repair procedures
Inspection
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2. Detach the lens from the overhead console then remove the 2 screws holding the overhead console.
3. Disconnect the sunroof switch connector(6P) and map lamp connector(2P)then remove the overhead console
lamp assembly from the headliner.
Check for continuity between the terminals of sunroof switch connector. If the continuity is not as specified,
replace the sunroof switch.
Body Electrical System > Sun Roof > Sunroof Motor > Repair procedures
Inspection
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1. Remove the sunroof motor after removing 3 screws and disconnect the 10P connector from the sunroof motor.
2. Inspect the sunroof motor side connector while the battery voltage and ground are connected as below table.
3. Inspect the sunroof motor harness side, as shown in the chart.

Tester connection Condition Specified condition
3-Ground IGN2 switch ON Battery voltage
1-Ground Constant Continuity
6-Ground Constant Battery voltage
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 and then close the sunroof completely.
2. Release the sunroof control lever.
3. Press and hold the CLOSE button for more than 10 seconds until the sunroof closed and it has moved slightly.
4. Release the sunroof control lever.
5. Press and hold the CLOSE button once again within 5 seconds until the sunroof do as follows;
A. Tilt → Slide Open → Slide Close
Then release the lever.
6. Reset procedure of panorama system is finished.
Protecting The Overheated Motor
In order to protect the overheated sunroof motor by continuous motor operation, the sunroof ECU controls the
Run-time and Cool-time of motor as followings;
1. The Sunroof ECU detects the Run- time of motor
2. Motor can be operated continuously for the 1st Run-time(120 ± 10sec.).
3. The continuously operated motor stops operating after the 1st Run-time(120 ± 10sec.).
4. And then Motor is not operated for the 1st Cool-time(18 ± 2sec.).
5. Motor is operated for the 2nd Run-time(10 ± 2sec.) at the continued motor operation after 1st Cool-time(18 ±
2sec.)
6. The continuously operated motor stops operating after the 2st Run-time(120 ± 10sec.)
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7. Motor is not operated for the 2st Cool-time(18 ± 2sec.).
8. Motor repeats the 2nd Run-time and 2nd Cool-time at the continued motor operation.
A. In case that motor is not operated continuously, the Run-time which is limited for protecting the overheated
motor is increased.
B. The Run-Time of motor is initialized to "0" if the battery or fuse is reconnected after being disconnected,
discharged or blown.
T1 : 120 ± 10 sec., T2 : 18 ± 2 sec.,

T3 : 10 ± 2 sec., T4 : 18 ± 2 sec.
Body Electrical System > Sun Roof > Sunroof Relay > Repair procedures
Inspection
1. Disconnect the 10P connector (A) and 6P connector (B) from the sunroof controller(C).
2. Inspect the connectors on the wire harness side, as shown in the chart.
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Tester
Connector Condition Specified condition
connection
7-Ground Sunroof switch position (slide) CLOSE Continuity
6-Ground Sunroof switch position (slide) OPEN Continuity
4-Ground Ignition switch position ON Battery voltage
5-Ground Sunroof switch position (Tilt) UP Continuity
M94-1
8-Ground Sunroof switch position (Tilt) DOWN Continuity
2-10 No.1 limit switch OFF No continuity
2-10 No.1 limit switch ON Continuity
3-9 No.2 limit switch OFF No continuity
3-9 No.2 limit switch ON Continuity
Battery connection between terminal 6(+)
6(+) - 4(-) Motor turns clockwise
and 4(-)
M94-2
Battery connection between terminal 4(+) Motor turns counter-
4(+) - 6(-)
and 6(-) clockwise
Body Electrical System > Lighting System > Components and Components Location
Components
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Body Electrical System > Lighting System > Head Lamps > Repair procedures
Removal
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2. Remove the head lamp mounting bolts (2EA), then disconnect the lamp connectors.
3. Replace the head lamp bulb(A), position bulb(B) and turn signal bulbs(C).
Aiming Instructions
Head Lamp Aiming
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.
1. Inflate the tires to the specified pressure and remove any loads from the vehicle except the driver, spare tire, and
tools.
2. The vehicle should be placed on a flat floor.
3. Draw vertical lines (Vertical lines passing through respective head lamp centers) and a horizontal line (Horizontal
line passing through center of head lamps) on the screen.
4. With the head lamp and battery in normal condition, aim the head lamps so the brightest portion falls on the
vertical lines.
Make vertical adjustments to the lower beam using the adjusting wheel.
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Front Fog Lamp Aiming
Head Lamp And Fog Lamp Aiming Point
1. Turn the low beam on with driver.

The cut-off line should be projected in the allowable range (shaded region).
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1. Turn the front fog lamp on with driver.

The cut-off line should be projected in the allowable range (shaded region).
Inspection
Head Lamp Relay
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1. Pull out the head lamp relay(Low) (A) and head lamp relay (High) (B) from the engine compartment relay box.
Body Electrical System > Lighting System > Room Lamp > Repair procedures
Removal
2. Detach the lamp lens from the room lamp with a flat-tip screwdriver, then replace the bulb.
3. Remove the room lamp assembly after removing 2 screws and disconnecting the 3P connector.
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Inspection
Body Electrical System > Lighting System > Overhead Console Lamp > Repair procedures
Removal
2. Detach the lamp lens from the overhead console lamp with a flat-tip screwdriver, then replace the bulb.
3. Remove the overhead console lamp assembly after removing 2 screws and disconnecting the connector.
Inspection
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Body Electrical System > Lighting System > Hazard Lamp Switch > Repair procedures
Inspection
Hazard Lamp Switch
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

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1. Remove the hazard lamp relay (A) from the passenger compartment relay box.
Body Electrical System > Lighting System > Flasher Unit > Repair procedures
Inspection
1. Remove the flasher unit(A) from the passenger compartment relay box.
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3. Connect the two turn signal lamps in parallel to terminal 1. Check that the bulbs turn on and off.
The turn signal lamps should flash 60 to 120 times per minute. If one of the front or rear turn signal lamps
has an open circuit, the number of flashes will be more than 120 per minute. If operation is not as specified,
replace the flasher unit.
Body Electrical System > Lighting System > Front Fog Lamps > Repair procedures
Removal
2. Disconnect the 2P connector (A) then remove the front fog lamp from the front bumper.
Inspection
Front Fog Lamp Relay
1. Remove the front fog lamp relay (A) from the engine compartment relay box.
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Front Fog Lamp Switch

2. Remove the front fog lamp switch from the center facia panel and disconnect the 6P connector.
3. Operate the switch and check for continuity between terminals with an ohmmeter.
Body Electrical System > Lighting System > License Lamps > Repair procedures
Removal
2. Remove the license plate lamp after removing 2 screws.
3. Replace the bulb.
Body Electrical System > Lighting System > High Mounted stop lamp > Repair procedures
Removal
High Mounted Stop Lamp
2. Open the tailgate glass then pull up the cover(A).
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3. Remove the high mounted stop lamp assembly after removing 2 nuts, then disconnect the wire connector(B).
Body Electrical System > Lighting System > Trunk Lamps > Repair procedures
Removal
2. Remove the trunk room lamp lens with a flat-tip screwdriver and replace the bult.
3. Remove the trunk room lamp assembly after removing 2 screws, then disconnect the 3P connector.
Inspection
Remove the trunk room lamp assembly then check for continuity between terminals.
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Body Electrical System > Lighting System > Rear combination lamp > Repair procedures
Removal
2. Remove the 3 screws holding the rear combination lamp then disconnect the wire connector.
3. Remove the rear combination lamp and replace the bulbs; stop & tail lamp (A), turn signal lamp (B), back up
lamp (C), tail lamp(D).
Body Electrical System > Auto Lighting Control System > Schematic Diagrams
Circuit Diagram
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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 to "AUTO" position, the tail lamp and head lamp will be turned automatically on or off
according to external illumination.
Specifications
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Rated voltage 12V
Load Max. 200mA (Relay load)
Detection illuminations
Tail lamp/Head lamp ON : 24 ± 5.2 (Lux), 0.81 ±
0.05V
OFF : 48 ± 10.5 (Lux), 1.41
± 0.05V
Body Electrical System > Auto Lighting Control System > Components and Components Location
Components
Body Electrical System > Auto Lighting Control System > Auto Light Contorl unit > Repair procedures
Inspection
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1. Remove the photo & auto light sensor (A) from the center crash pad upper.
2. Disconnect the 8P connector (B) from the auto light unit then inspect the connector on the wire harness side, as
shown in the chart.
Tester
Condition Specified condition
connection
Constant 5V
2-Ground
Tail lamp switch ON 0V
3-Ground Ignition switch ON 12V
5-Ground Auto light switch ON Continuity
6-Ground Ignition switch ON 12V
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
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Body Electrical System > Daytime Running Lights > Schematic Diagrams
Circuit Diagram
Body Electrical System > Daytime Running Lights > Repair procedures
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Inspection
Operation Check
Inspect Circuits For Daytime Running Light System

1. Disconnect the wire connector to DRL module(A) from the right side strut housing.
2. Inspect the connector on wire harness side as shown.
Tester connection Condition Specified condition

Head lamp switch OFF No continuity
5-Ground
Head lamp switch ON Continuity
Ignition switch ON or START Battery voltage
9-Ground
Ignition switch ACC or LOCK No voltage
Engine Stop No voltage
3-Ground
Engine Running Battery voltage
If circuit is not as specified, refer to schematic diagram and inspect short or circuits.
Body Electrical System > Immobilizer System > Schematic Diagrams

Circuit Diagram (1)
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Circuit Diagram (2)
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Schematic Diagram
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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.
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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.
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)
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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]
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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 > Repair procedures

Teaching Procedures
1. Key Teaching Procedure
Key teaching must be done after replacing a defective PCM(ECM) or when providing additional keys to the
vehicle owner.
The procedure starts with an PCM(ECM) request for vehicle specific data (PIN code: 6digits) from the tester.
The "virgin" PCM(ECM) stores the vehicle specific data and the key teaching can be started. The "learnt"
PCM(ECM) 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 PCM(ECM) three times, the PCM(ECM) 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 PCM(ECM) stores the
relevant data in the EEPROM and in the transponder. Then the PCM(ECM) 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 PCM(ECM) 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
recognized by the PCM(ECM). This rejects the key and a message is sent to the tester.
The PCM(ECM) 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 PCM(ECM) detects different authenticators of a transponder and an PCM(ECM), the key is
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considered to be invalid.
The maximum number of taught keys is 8
If an error occurs during the Immobilizer Service Menu, the PCM(ECM) status remains unchanged and a specific
fault code is stored.
If the PCM(ECM) 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 PCM(ECM).
When teaching the 1st key, Smartra regists at the same time.
(1) PCM(ECM) learnt status.

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(2) PCM(ECM) virgin status.

After replacing new "PCM(ECM)" scantool displays that PCM(ECM) is virgin status in Key Teaching mode.
"VIRGIN" status means that PCM(ECM) has not matched any PIN code before.
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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
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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
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In case of putting wrong password, retry from first step after 10 seconds.
(2) User password changing
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Limp Home Function

1. LIMP HOME BY TESTER
If the PCM(ECM) detects the fault of the SMARTRA or transponder, the PCM(ECM) will allow limp home
function of the immobilizer. Limp home is only possible if the user password (4 digits) has been given to the
PCM(ECM) 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 PCM(ECM) via the special tester menu.
Only if the PCM(ECM) is in status "learnt" and the user password status is "learnt" and the user password is
correct, the PCM(ECM) 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 PCM(ECM) will reject the request of limp home for one hour.
Disconnecting the battery or any other action cannot reduce this time. After connecting the battery to the
PCM(ECM), the timer starts again for one hour.
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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 PCM(ECM) by
a special sequence of ignition on/off.
Only if the PCM(ECM) is in status "learnt" and the user password status is "learnt" and the user password is
correct, the PCM(ECM) 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 PCM(ECM) is locked if the timer has elapsed 8 seconds. For the next start, the input of the
user password is requested again.
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Page 191 of 243
Immobilizer Related Fault types Diagnostic codes
Faults
Transponder fault 1. Corrupted data from transponder P1693
2. More than one transponder in the - Transponder no response
magnetic field (Antenna coil) error/transponder invalid response,
3. No transponder (Key without Transponder status error, Transponder
transponder) in the magnetic field programming error
(Antenna coil)
4. Transponder not in the password
mode
5. Transponder transport data has
been changed6. Transponder
programming error
SMARTRA/ECM fault 1. Antenna coil error P1691(δ2.7)
- Antenna coil error
1. Communication line error P1678 (δ2.7)
(Open/Short etc.) - ECM no response message error
2. Invalid message from
SMARTRA/ICM to ECM
ECM internal permanent 1. ECM internal permanent memory P1677 (δ2.7)
memory(EEPROM) fault (EEPROM) fault - ECM has different VIN
2. Invalid write operation to
permanent memory (EEPROM)
ECM fault 1. Request from ECM is invalid P1679 (δ2.7)
(Protocol layer violation- Invalid - ECM message error
request, check sum error etc.)
Invalid TP TP has different PIN P1698 (δ2.7)
[2.0 - Smartra Type]

Immobilizer Related Faults Fault types Diagnostic codes
PCM(ECM) fault 1. Non-Immobilizer-EMS connected to an P1610
Immobilizer
Transponder key fault 1. Transponder not in password mode P1674
2. Transponder transport data has been changed. (Transponder status error)
Transponder key fault 1. Transponder programming error P1675
(Transponder programming
error)
SMARTRA fault 1. Invalid message from SMARTRA to P1676
PCM(ECM) (SMARTRA message error)
SMARTRA fault 1. Virgin SMARTRA at learnt EMS P169A
2. Neutral SMARTRA at learnt EMS (SMARTRA Authentication
3. Incorect the Authentication of EMS and fail)
SMARTRA
4. Locking of SMARTRA
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Page 192 of 243
SMARTRA fault 1. No response from SMARTRA P1690
2. Antenna coil error (SMARTRA no response)
3. Communication line error (Open/Short etc.)
4. Invalid message from SMARTRA to
PCM(ECM)
Antenna coil fault 1. Antenna coil open/short circuit P1691
(Antenna coil error)
Immobilizer indicator lamp fault 1. Immobilizer indicator lamp error (Cluster) P1692
(Immobilizer lamp error)
Transponder key fault 1. Corrupted data from transponder P1693
2. More than one transponder in the magnetic (Transponder no response
field (Antenna coil) error/invalid response)
3. No transponder (Key without transponder) in
the magnetic field (Antenna coil)
PCM(ECM) fault 1. Request from PCM(ECM) is invalid P1694
(Protocol layer violation- Invalid request, (PCM(ECM) message error)
check sum error etc.)
PCM(ECM) internal permanent 1. PCM(ECM) internal permanent memory P1695
memory (EEPROM) fault (EEPROM) fault (PCM(ECM) memory error)
2. Invalid write operation to permanent memory
(EEPROM)
Invalid key fault 1. Virgin transponder at PCM(ECM) status P1696
"Learnt"Learnt (Invalid) (Authentication fail)
Transponder at PCM(ECM) status
"Learnt"(Authentication fail)
Locked by timer 1. Exceeding the maximum limit of Twice IGN P1699
ON ( 32 times) (Twice IG ON over trial)
Problems And Replacement Parts :

Problem Part set Hi-scan (pro) required?
All keys have been lost Blank key (4) YES
Antenna coil unit does not work Antenna coil unit NO
ECM/ICM does not work ECM/ICM YES
Ignition switch does not work Ignition switch with Antenna coil YES
unit
Unidentified vehicle specific data Key, ECM/ICM YES
occurs
SMARTRA unit does not work SMARTRA unit NO
Replacement Of ECM/ICM And Smartra

In case of a defective ECM/ICM, the unit has to be replaced with a "virgin" or "neutral" ECM/ICM. All keys have
to be taught to the new ECM/ICM. Keys, which are not taught to the ECM/ICM, are invalid for the new
ECM/ICM (Refer to key teaching procedure). The vehicle specific data have to be left unchanged due to the unique
programming of transponder.
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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.
Neutralising Of ECM/ICM
The ECM/ICM can be set to the "neutral" status by a tester.
A valid ignition key is inserted and after ignition on is recorded, the ECM/ICM requests the vehicle specific data
from the tester. The communication messages are described at "Neutral Mode". After successfully receiving the
data, the ECM/ICM is neutralized.
The ECM/ICM remains locked. Neither the limp home mode nor the "twice ignition on" function, is accepted by the
ECM/ICM.
The teaching of keys follows the procedure described for the virgin ECM/ICM. 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.
Body Electrical System > Immobilizer System > P1610 Non-Immobilizer-EMS Connected to an
Immobilizer
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.

DTC Strategy •-
Enable
• IG ON
Conditions
• Invalid PCM/ECM
Threshold value • Non Immobilizer PCM/ECM connected
Detecting time • Immediately
FAIL SAFE •-
Diagnostic Circuit Diagram
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Page 195 of 243
1. Check status
(1) IGN "ON" & Engine "OFF"
(2) Monitor the "ECM 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) Has the ECM been learnt ?
deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle
Repair" procedure.
Substitute with a known good 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.

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.
3. Are any DTCs present?
procedure.
System is performing to specification at this
time.
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Body Electrical System > Immobilizer System > P1674 Immobilizer-Transponder status Error
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 Strategy •-
Enable Conditions • IG ON (On Registering TP Procedure)
• Key not in ‘VIRGIN’
Threshold value •-
Status or with invalid ID code
Detecting time •-
FAIL SAFE •-

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Page 198 of 243
1. Check status
(2) Monitor the "ECM, KEY and Smartra Status" Parameter on the Scantool.
(3) Has the key status been learnt?
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 "Component Inspection" Procedure.
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 ?

deterioration, or damage. Repair or replace as necessary and then go to "Verification of
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.
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procedure.
time.
Body Electrical System > Immobilizer System > P1675 Immobilizer-Transponder Programming Error
General Description
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 •-
• Invalid transponder
Enable Conditions • IG ON
Invalid characteristic data
Threshold value •- No transponder or more
than two transponder is
Detecting time •-
detected by coil antenna
FAIL SAFE •-
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Page 200 of 243

Page 201 of 243
1. Check status
(2) Monitor the "ECM, KEY and Smartra Status" Parameter on the Scantool.
SMARTRA3 has been learnt.
(3) Has the KEY status been learnt?
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.
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.
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(3) Are "KEY STATUS", "SMARTRA STATUS" and "ECU STATUS" Parameter within specifications?
deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle
Repair" procedure.
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.
Repair" procedure.

procedure.
time.
Body Electrical System > Immobilizer System > P1676 Immobilizer-Smartra Message Error
General Description
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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
Threshold • Faulty
•-
value SMARTRA
Detecting
•-
time
FAIL
•-
SAFE
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Page 204 of 243

Page 205 of 243
(1) IGN "ON" & Engine "OFF" with key intended to register
(2) Monitor the "ECU, KEY, Smartra STATUS" Parameter on the Scantool.
(3) Has the "SMARTRA" status been learnt?
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.
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
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(4) Are Neutralizing and Registering Key completed normally ?
deterioration, 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.

procedure.
time.
Body Electrical System > Immobilizer System > P169A Immobilizer-SMARTRA Authentication Fail
General Description
1. The sequence of the pin code storage are as follow :
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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 and • Locking of SMARTRA
SMARTRA
• Locking of SMARTRA
Detecting time •-
FAIL SAFE •-
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Page 208 of 243

1. Connect scantool to Data Link Connector(DLC).
2. IGN "ON" & Engine "OFF"
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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 and
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.
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.

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Page 210 of 243
procedure.
time.
Body Electrical System > Immobilizer System > P1690 Immobilizer-Smartra No Response
General Description
1. The sequence of the pin code storage are as follaws.
TP ID information.
DTC Description
The ECM sets DTC P1690 if there’s No Response from SMARTRA

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DTC Strategy •-
Enable • Open Circuit in
• IG ON signal harness
Conditions
• Short Circuit in
Threshold
•- signal harness
value
• Faulty
Detecting time •- SMARTRA
FAIL SAFE •-
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Page 212 of 243

3. Monitor the "ECU, KEY and Smartra STATUS" Parameter on the Scantool.
4. Has the "SMARTRA" status been learnt?
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.
procedure.
Power Supply Circuit Inspection

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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

(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
(5) Is the measured voltage within specifications?

Go to "Signal circuit Inspection" procedure.
Check for short in harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.
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Page 214 of 243
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

Check for open in harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.
1. Check SMARTRA
(2) Neutralize Both "SMARTRA" and "ECM" and Register transponder key by 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.

procedure.
time.
Body Electrical System > Immobilizer System > P1691 Immobilizer-Antenna Coil Error
General Description
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
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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.
DTC Description
The ECM sets DTC P1691 if there’s any fault in immobilizer antenna coil.

DTC
•-
Strategy
Enable • Open Circuit in
• IG ON antenna coil
Conditions
• Short Circuit in
Threshold
•- antenna coil
value
• Faulty antenna
Detecting coil
•-
time
FAIL SAFE •-
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Page 216 of 243

Page 217 of 243
3. Monitor the "ECU, KEY and Smartra STATU" Parameter on the Scantool.
4. Have the both "ECM, KEY and Smartra STATUS’ been learnt ?
And This DTC has not been erased in previous repair. Repair or replace as necessary and then
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
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Page 218 of 243
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.
Repair" procedure.

procedure.
time.
Body Electrical System > Immobilizer System > P1692 Immobilizer Indicator Lamp Error
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".
DTC Description
The ECM sets DTC P1692 if there’s short circuit in immobilizer lamp circuit.

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DTC Strategy •-
Enable • Short Circuit in
• IG ON
Conditions immobilizer lamp circuit
• Open/Short in control
Threshold value • Short to GND, Wiring open
harness
Detecting time •- • Faulty PCM/ECM
FAIL SAFE •-
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Page 220 of 243

2. 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.
procedure.
Control Circuit Inspection

(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
Visual / Physical Inspection

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?

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1. 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. Repair or replace as
necessary and then go to "Verification of Vehicle Repair" procedure.

procedure.
time.
Body Electrical System > Immobilizer System > P1693 Immobilizer-Transponder Error
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 P1693 if there’s abnormal response from transponder.

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Page 222 of 243
DTC Strategy •- • Corrupted data from
Enable Transponder
• IG ON
Conditions • More than one TP in
the magnetic field
Threshold value •-
• No TP(Key without
Detecting time •- TP) in the magnetic
FAIL SAFE •- field

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(2) Monitor the "ECU, KEY and Smartra STATUS" Parameter on the Scantool.
(3) Have both the ECM and KEY status been learnt ?
Check connectors for looseuess, poor connection, bending, corrosion, contamination
dererioration, damage on the ECM or SMARTRA.
And this DTC has not been erased in prerious repair. Repair or replace as necessary and then go

Repair" procedure.
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Page 224 of 243

procedure.
time.
Body Electrical System > Immobilizer System > P1694 Immobilizer-EMS Message Error
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
Conditions Protocol layer
violation
Threshold
•- - Invalid request
value
- Check sum
Detecting error
•-
time
FAIL SAFE •-

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1. Check status
(2) Monitor the "ECU, KEY and Smartra STATUS" Parameter on the Scantool.
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.
1. Check ECM

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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

procedure.
time.
Body Electrical System > Immobilizer System > P1695 Immobilizer-EMS Memory Error
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.).
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Page 228 of 243
DTC
•-
Strategy
Enable
• IG ON
Conditions
Threshold
•- • Faulty EMS
value
Detecting
•-
time
FAIL
•-
SAFE

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1. Check status
(2) Monitor the "KEY STATUS", "SMARTRA STATUS" and "ECU STATUS" Parameter on the Scantool.
1. Check ECM
Pin code is requried to Neutralize ECM and to Register transponder key

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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

procedure.
time.
Body Electrical System > Immobilizer System > P1696 Immobilizer-Authentication Fail
General Description
DTC Description
The ECM sets DTC P1696 if invaild key is inserted into key hole for Authentication
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Page 232 of 243
DTC Strategy •-
• Virgin TP at PCM/ECM status “Learnt”
Threshold value • Learnt(Invalid) TP at PCM/ECM status • Invalid transponder
“Learnt”
Detecting time • Immediately
FAIL SAFE •-

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Page 234 of 243
1. Check status
(2) Monitor the "ECM, Key and Smartra Status" Parameter on the Scantool.
(3) Have both the ECM and KEY status been learnt ?
Pin code is requied to Neutralize ECM and to Register transponder key

Repair" procedure.

Page 235 of 243
procedure.
time.
Body Electrical System > Immobilizer System > P1699 Immobilizer-Twice Overtrial
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 P1699 if the maximum limit of Twice IGN is Exceeded.

DTC
•-
Strategy
Enable
• IG ON
Conditions
• Twice IGN ≥
Threshold
•- 32 times
value
Detecting
•-
time
FAIL SAFE •-
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Page 236 of 243

Page 237 of 243
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.
And this DTC has not erased in previous repair. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure..

procedure.
time.
Body Electrical System > Immobilizer System > Immobilizer Control Unit > Repair procedures
Replacement
2. Remove the crash pad. (Refer to the Body group - "Crash pad").
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Page 238 of 243
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 shear bolt.
- 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]
4. Installation is the reverse of removal procedure.
- Tighten the shear bolt until the bolt head break

off.
Body Electrical System > Trip Computer > Description and Operation
Description
The trip computer is a microcomputer-controlled driver information gauge that displays information related to
driving, such as a tripmeter, distance to empty, average fuel consumption average speed, and drive time on the
LCD.
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Odometer (1)
The odometer records the total driving distance in kilometers or miles, and is useful for keeping a record for
maintenance intervals.
It is normal for a new vehicle to have the odometer indicating less than 50 km (30miles).
Pushing in the trip computer switch behind the right side of the steering wheel changes the display as follows;
1. Tripmeter
Trip A
Trip B
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Page 240 of 243
A. This mode indicates the total distance travelled since the last tripmeter reset.
Total distance is also reset to zero if the battery is disconnected.
B. Pressing the trip computer switch for more than 1 second, when the tripmeter is being displayed, clears the
tripmeter to zero.
C. The meter's working range is from 0.0 to 999.9 km (0.0 to 999.9 miles).
2. Distance to Empty
A. This mode indicates the estimated distance to empty from the current fuel in the fuel tank and distance to
empty symbol.
B. When refueling with more than 6 liters (1.6 gallons), the trip computer will recognize refueling.
C. For an accurate distance to empty, drive more than 50 km (30 miles).
D. When the distance to empty is less than 50 km (30 miles), the symbol will flash and the distance to empty
digits will indicate "---" until more fuel is added.
- The distance to empty can differ from the actual tripmeter according to driving conditions.
- The distance to empty can vary according to the driving conditions, driving pattern or vehicle speed.
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3. Average Fuel Consumption
A. This mode calculates the average fuel consumption from the total fuel used and the distance since the last
average consumption reset.
B. The total fuel used is calculated from the fuel consumption input.
C. For an accurate calculation, drive more than 50 km (30 miles).
D. The meter's working range is from 0.1 to 199.9 l/100 km (0.1 to 199.9 MPG).
4. Average Speed
A. This mode indicates the average speed since the last tripmeter reset.
B. Even if the vehicle is not in motion, the average speed keeps going while the engine is running.
C. The meter's working range is from 0 to 999 km/h (0 to 999 MPH).
D. Press the trip computer switch for more than 1 seconds, when the average speed is being displayed, clears
the average speed to "---".
5. Drive Time
A. This mode indicates the drive time since the last tripmeter reset.
B. Even if the vehicle is not in motion, the drive time keeps going while the engine is running.
C. The meter's working range is from 0:00 to 99:59.
D. Press the trip computer switch for more than 1 second, when the drive time is being displayed, clears the
drive time to zero.
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Page 242 of 243
Body Electrical System > Trip Computer > Repair procedures

Inspection
1. Remove the cluster facia panel (B).
2. Operate the switch (A) and check for continuity between terminals with an ohmmeter.
Replacement
parts, to prevent damage.
• Take care not to scratch the crash pad and related parts.
1. Tilt the steering column down.
2. Remove the screws, and detach the clips.
3. After disconnecting the trip computer switch connector (A), remove the cluster facia panel (B).
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- Make sure the connector is plugged in

properly.
Body Electrical System > Ignition Switch Assembly > Ignition Switch > Repair procedures
Inspection
1. Disconnect the ignition switch connector(6P) and the door warning switch connector(6P) under the steering
column.
3. If continuity is not as specified, replace the switch.
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Page 1 of 222
TUCSON(JM) > 2009 > G 2.7 DOHC > Brake System
Brake System > General Information > Specifications

Specifications
Item Specification
Master cylinder
· Type Tandem type
· I.D. mm(in.)(CBS/ABS) 22.22(0.875)
· Piston stroke mm(in) 3.1(1.22)
· Output port(CBS/ABS) 4port/2port
· Fluid level warning sensor Provided
Proportioning valve
· Cut-in pressure(Split point) 15Kgf /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)
· Type Floating type with ventilated disc
· Disc O.D. 280 mm
· Disc I.D. 172 mm (6.77 in.)
· Disc thickness 26 mm
· Pad thickness 11 mm
· 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.)
· 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
· Cable arrangement wheels
Lever
O.D : Outer Diameter

I.D : Inner Diameter
CBS : Conventional Brake System

Specification (ABS)
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Part Item Standard Valve Remark
HECU 4 channel 4 sensor ·ABS system: ABS & EBD control
System
(Hydraulic and (MGH-40) ·FTCS system: ABS & EBD control
Electronic Control (Both Brake and Engine control)
Motor, valve relay
Unit) Type
intergrated type
Operating voltage 10V~16V(DC)
Operating temperature -40~110°C(-40~230°F)
Motor power 210W
Warning lamp · ABS W/L: ABS failure
Operating voltage 12V
· Brake W/L: Parking, brake oil,
EBD failure
Current consumption 80mA
· TCS W/L: TCS failure
Active wheel speed Supply voltage 6 ~ 16V
sensor(ABS) Operating temperature -40~120°C (-40 ~ 248°F)
Output current low 5.9~8.4mA
Output current high 11.8~16.8mA
Frequency range 1~2000HZ
0.5~1.5mm
Air gap
(0.019~0.0591in)
Specification (ESC)
Part Item Standard valve Remark
HECU 4 channel 4 sensor ·ABS system: ABS & EBD control
System
(Hydraulic and (MGH-40) ·FTCS system: ABS & EBD control
Electronic Control (Both Brake and Engine control)
Motor, valve relay
Unit) Type
intergrated type
Operating voltage 10V~16V(DC)
Operating temperature -40~110°C(-40~230°F)
Motor power 240W
Warning lamp · ABS W/L: ABS failure
Operating voltage 12V
· Brake W/L: Parking, brake oil,
EBD failure
Current consumption 80mA
· ESC W/L: ESC failure
Active wheel speed Supply voltage DC12V
sensor
Operating temperature -40~120°C (-40 ~ 248°F)
Output current low 5.9~8.4mA
Output current high 11.8~16.8mA
Frequency range 1~2000HZ
Airgap 0.5~1.5mm
Steering Wheel Operating Voltage Current [email protected]
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Angle Sensor Consumption Max 100mA
High output voltage 3.0V~4.1V
Low output voltage 1.3V~2.0V
Operating
Max 1500°/sec
Angular velocity
ESC : Electronic Stability Control

Service Standard
Standard value Service limit
Brake pedal height 163mm( 0.209in.)
Brake pedal stroke 128 mm (5.04 in.)
Brake pedal free play 3~8mm(0.11~0.31in.)
Brake pedal to floorboard clearance 82mm( 3.23in.)
1 ~ 2 mm (0.04 ~ 0.08
Stop lamp switch outer case to pedal stopper clearance
in.)
Booster push rod to master cylinder piston clearance 0 (at 500 mmHg vacuum)
Parking brake lever stroke when lever assembly is pulled with
7~8 clicks
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 (10.24 in.) 24.4 mm ( 0.961in.)
Max.0.03 mm (
Front disc runout
0.001in.)
Max.0.005 mm
Front disc parallelism
(0.0002in.)
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.)
Max.0.03mm (
Rear disc runout
0.001in.)
Max.0.005 mm (
Rear disc parallelism
0.0002in.)
Tightening Torques
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N.m kgf.cm lbf.ft
Proportioning valve to master cylinder 35~55 350~550 25.8~40.6
Master cylinder to booster mounting nut 8~12 80~120 5.9~8.9
Brake booster mounting nut 13~16 130~160 9.6~11.8
Brake booster vacuum hose fitting to surge
15~18 150~180 11.1~13.3
tank
Bleeder screw 7~13 70~130 5.2~9.6
Brake tube nut, brake hose 13~17 130~170 9.6~12.5
Caliper guide rod bolt 22~32 220~320 16.2~23.6
Caliper pin bolt 35~45 350~450 25.8~33.2
Caliper assembly to knuckle 80~100 800~1000 59.0~73.8
Brake hose to front caliper 25~30 250~300 18.4~22.1
Brake hub flange nut 200~260 2000~2600 147.5~191.8
Push rod locking nut 16~22 160~220 11.8~16.2
Replace self-locking nuts with new one after removal.

Tightening Torques (ABS)
Item N.m kgf.cm Ibf.ft
Active wheel speed sensor
mounting bold on
8~9 80~90 5.6~6.6
the brake plate
8~9 80~90 5.6~6.6
·Front
·Rear
Hydraulic & electronic control
unit mounting 11~14 110~140 8.1~10.3
bolt
Hydraulic & electronic control
unit bracket mounting 17~26 170~260 12.5~19.2
bolt
Break tubes nut 12~16 120~160 9~12
Air bleeder screw 7~13 70~130 5~9.6
Tightening Torques (ESC)

Item N.m kgf.cm Ibf.ft
Yaw rate & lateral
4~6 40~60 2.9~4.4
acceleration sensor bolt
Steering wheel nut 40~50 400~500 28.9~36.9
Master cylinder pressure
22.4~26.5 224~265 16.5~19.5
sensor
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Page 5 of 222
Brake System > General Information > Special Service Tools

Tool(Number and
Iiiustration Use
Name)
09581-11000 Spreading the front brake piston
Piston expander
Brake System > General Information > Troubleshooting

Troubleshooting
Problem Symptoms Table
Symptom Suspect Area Reference
Lower pedal or spongy pedal 1. Brake system (Fluid leaks) repair
2. Brake system (Air in) air·bleed
3. Piston seals (Worn or damaged) relace
4. Rear brake shoe clearance(Out of adjustment) adjust
5. Master cylinder (Faulty) replace
Brake drag 1. Brake pedal free play (Minimal)

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 inefficient 1. Brake system (Fluid leaks)

repair
2. Brake system (Air in) air·bleed
3. Pad or lining (Worn) replace
6. Pad or lining (Oily) adjust
6. Pad or lining (Oily) Page 6 of 222
7. Pad or lining (Glazed) replace
repair
9. Booster system (Vacuum leaks)
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
replace
9. Shoe hold-down spring (Damage)
Brake System > Brake System > Repair procedures

Operation and Leakage Check
Check all of the following items:
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.
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Brake Booster Operating Test

For simple checking of the brake booster operation, carry out the following tests
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.
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1. 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.
2. 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.
Brake System > Brake System > Brake Booster > Components and Components Location
Components
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1. Vacuum hose 5. Master

2. Check valve cylinder
3. Snap pin 6. Nut
4. Seal 7. Brake booster
8. Pin
Brake System > Brake System > Brake Booster > Repair procedures
Removal
1. Remove the master cylinder.
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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) from the engine compartment.
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.)
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1. Insert the booster and tighten the nut (C).
2. Connect the booster push rod and brake pedal with a pin (B) and install a snap pin (A) to the pin (B).
Greaee the pin before installing the snap pin.

When installing the snap pin, it must be used new one.
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 > Brake Line > Components and Components Location
Component
Page 12 of 222
Brake System > Brake System > Brake Line > Repair procedures
Removal
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Page 13 of 222
1. Disconnect the brake hose(C) from the brake line(A) using a 10mm flare-nut wrench(B).
2. Remove the brake house clip(A) from the brake(B).

3. Remove the connector bolt (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 breacket (B) with a new brake hose clip (C).
3. Connect the brake line (D) to the brake hose.

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.
Brake System Bleeding

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• Do not reuse the drained fluid.

• Always use Genuine DOT3 or DOT 4 Brake Fluid. Using a non-Genuine DOT or 4 brake fluid can caese
corrosion and decrese the life of the system.
• Make sure no dirt of other foreign matter is allowed to contaminate the brake fluid.
• Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off
immediately with water.
• The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure
and checked after bleeding each brake caliper. Add fluid as required.
1. Make sure the brake fluid in the reservoir is at the MAX (upper) level line (A).
2. Have someone slowly pump the brake pedal several times, then apply pressure.
3. Lossen the right-rear brake bleed screw to allow air to escape from the system. Then tighen the bleed screw
securely.
4. Repeat the procedure for wheel in the sequence shown below unit air bubbles no longer appear in the fluid.
5. Refill the master cylinder reservoir to MAX(upper) level line.
Front Disc Brake
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Brake System > Brake System > Brake Pedal > Components and Components Location
Components
1. Member assembly bracket 5. Bolt 9. Bushing

2. Nut 6. Bushing 10. Return spring
3. Washer 7. Washer 11. Brake pedal
4. Stop lamp switch 8. Snap pin
Brake System > Brake System > Brake Pedal > Repair procedures
Brake Pedal Brake Switch Adjustment
Pedal Height
Page 16 of 222
1. Disconnect the brake swithch connector, loosen the brake switch locknut (A), and bake off the brake switch (B)
unil it is no longer touching the brake pedal.
2. Life up the carpet. At the insulator cutout, measure the pedal heigh (C) from the middle of the left-side center of
the pedal pad (D).
Standard pedal height( with carpet removed): 163mm(6.41 in.)
3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from
the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod
depressed.
Brake Switch Clearance

Screw in the brake switch until its plunger is fully depressed (threded end (A) touching the pad (B) on the pedal
arm) then brake off the switch 3/4 turn to make 1 ~ 2 mm (0.04 ~ 0.08 in.) of clearance between the brake switch
connector. Make sure that the brake lights go off when the pedal is released.
Pedal Free Play
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1. With the engine off, inspect the pedal free play (A) on the pedal pad (B) by pushing the pedal by hand.
Free play: 3~8mm (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
1. Check the blushing for wear.
2. Check the brake pedal for bending or twisting.
3. Check the brake pedal return spring for damage.
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-"crashped")
2. Pull down steering culum shafe after removing 4 bolts.
3. Remove the stop lamp switch connector (A).
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4. Remove the shift lock cable (A/T).
5. Remove the pin and snap pin.

6. Remove 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.
2. Before inserting the pin, apply the specified grease to the joint pin.
3. Install the nuts with speacified torque, when installing the brake pedal.
Torque ; 13~16N.m(1.3~1.6kgf.cm, 9.6~11.8lbf.ft)
4. Adjust the brake pedal height and free play.

5. Install the stop lamp switch.
Brake System > Brake System > Master Cylinder > Components and Components Location
Components
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Page 19 of 222
1. Reservoir cap 6. Retainer

2. Brake fluid filter 7. Primary piston
3. Reservoir assembly
4. Grommet 8. Secondary piston
5. Cylinder pin assembly
9. Master cylinder body
10. Proportioning valve
Brake System > Brake System > Master Cylinder > Repair procedures
Removal
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Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off
1. Remove air cleaner mounting bolts (B) and air cleaner body (A) from the air cleaner mounting bracket.
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.
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Page 21 of 222
2. Connect 2 brake tubes 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 mounting screw (A).
4. Remove the proportioning valves (A) - CBS only.
5. Remove the retainer ring by using the snap ring pliers then remove the primary piston assembly.
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6. Remove the pin with the secondary piston pushed completely using a screwdriver. Remove the secondary piston
assembly.-ABS/TCS/ESC
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.
2. Carefully insert the springs and pistons in the proper direction.
3. Press the piston with a screwdriver and install the cylinder pin.
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4. Press the piston with a screwdriver and install the retainer ring.
5. Mount two grommets.

6. Install the reservoir on the cylinder.
Tightening torque :
1.5~3.0 N.m(15~30kg.cm, 1.2~2.1 Ibf.ft)
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
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.

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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.
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.
Front Rear
(Output of master cylinder) (Output of proportioning valve)
A : 26 kg/cm² A' : 26 kg/cm²
(2.55MPa, 370psi) (2.55MPa, 370psi)
B : 80 kg/cm² B' : 40.6 ± 3 kg/cm²
(7.84MPa, 1137psi) (3.98 ± 0.3MPa, 577 ± 42psi)
Brake System > Brake System > Front Disc Brake > Components and Components Location
Components
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1. Wear indicator 5. Brake disc

2. Brake pads 6. Brake caliper
3. Brake pad 7. Guide rod bolt
shims
4. Pad retainers
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1. Guide rod bolt 6. Washer 11. Inner shim

2. Guide rod 7. Piston 12. Brake pad
3. Boot 8. Caliper body 13. Pad retainer
4. Bleeder screw 9. Piston seal 14. Outer shim
5. Caliper mounting bolt 10. Piston boot 15. Caliper bracket
Brake System > Brake System > Front Disc Brake > Repair procedures
Removal
1. Raise the rear of the vehicle and make sure it is securely supported. Remove the rear wheel.
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3. Remove the two guide rod bolt (B) and support the caliper assembly with a piece of wire so that it does not hang
from the brake hose.
4. Remove the pad shims (A), pad retainers(B), and pads (C).
Installation
1. Install the pad retainers (A) on the caliper bracket(B).
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.
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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).
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.
7. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
Brake System > Brake System > Rear Disc Brake > Components and Components Location
Components
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1. Bleeder screw 7. Piston boot 13. Inner shim

2. Caliper body 8. Pad retainer 14. Brake pad
3. Guide rod 9. Caliper mounting bolt 15. Pad retainer
4. Boot 10. Caliper mounting bolt 16. Outer shim
5. Piston 11. Guide rod 17. Caliper bracket
6. Piston seal 12. Boot
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.
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3. Remove the two guide rod bolt (B) and support the caliper assembly with a piece of wire so that it does not hang
from the brake hose.
4. Remove the pad shims (A), pad retainers(B), and pads (C).
Installation
1. Install the pad springs(A) to the carrier(B).
2. Check the foreign material at the pad shim (A) and the back of the pads (B).
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3. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
Insert the piston in the cylinder using the special tool(09581-11000).
4. Install the brake pads (B) and pad shim (A) on the capliper braket.
Install the inner pad with its wear indicator (C) facing down ward.
If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momtary loss of
braking efficiency.
5. Rotate the caliper piston (A) clockwise into the cylinder, the align the cutout (B) in the piston with the tab (C) on
the inner pad by turning the piston back.
Lubricate the boot with rubber grease to avoid twisting the piston boot.
If the piston boot is twisted, back it out so it is positioned properly.
6. Install the brake caliper (D).
7. Install and torque the guide rods (E) to proper specification.
8. Install the brake hose (F) onto the suspension arm with the brake hose clip (G).
9. After installation, check for leaks at hose and line joints and connections, and retighten if necessary.
10. 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 pedal will restore the normal pedal stroke.
Brake System > Parking Brake System > Components and Components Location
Components
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1. Rear brake caliper 6. Thrust spring 11. Ajuster

2. Parking brake lever 7. Thrust 12. Cup washer
3. Parking brake switch 8. Shoes & linings 13. Shoe hold down spring
4. Parking brake cable 9. Shoe guide 14. Return spring
5. Backing plate 10. Return spring 15. Shoe hold down pin
Brake System > Parking Brake System > Parking Brake Assembly > Repair procedures
Removal
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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 the parking brake cables.
3. Disconnect the connector(A) of the parking brake switch.
4. Remove the 4 bolts and parking brake lever assembly(A).

5. Remove the wheel and tire.
6. Remove the brake disc.
7. Remove the parking brake cable(A) from the brake shoe.
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8. Remove the parking brake cable retaining ring (B), from the parking brake cable (A).
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).
Parking Brake Check And Adjustment

Inspection
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 (B).
Lever locked clicks:7~8
2. Adjust the parking brake if the lever clicks are out of specification.
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.
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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 9
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.
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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 continuty 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 > ABS(Anti-Lock Brake System) > Components and Components Location
Components
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1. Cluster 4. Rear left wheel speed sensor

ABS Warning lamp 5. Rear right wheel speed sensor
EBD/Parking brake warning 6. Hydraulic line
lamp 7. Front right wheel speed sensor
2. Front left wheel speed sensor 8. Yaw-rate & lateral G sensor
3. ABS control module (HECU)
Brake System > ABS(Anti-Lock Brake System) > Description and Operation
Description
This specification applies to HCU(Hydraulic Control Unit) and ECU(Electronic Control Unit) of the
HECU.(Hydraulic and Electronic Control Unit)
This specification is for the wiring design and installation of ABS/TCS/ESC ECU.
This unit has the functions as follows.
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- Input of signal from Pressure sensor, Steering angle sensor, Yaw & Lateral G sensor,the wheel speed sensors
attached to each wheel.
- Control of braking force / traction force/ yaw moment.
- Failsafe function.
- Self diagnosis function.
- Interface with the external diagnosis tester.
Installation position : engine room
- Brake Pipe length from Master cylinder port to HECU inlet port should be max. 1m
- The position should not be close to the engine block and not lower than the wheel.
Operation
The ECU shall be put into operation by switching on the operating voltage (IGN).
On completion of the initialization phase, the ECU shall be ready for operation.
In the operating condition, the ECU shall be ready, within the specified limits (voltage and temperature), to process
the signals offered by the various sensors and switches in accordance with the control algorithm defined by the
software and to control the hydraulic and electrical actuators.
Wheel Sensor Signal Processing
The ECU shall receive wheel speed signal from the four active wheel sensors.
The wheel signals are converted to voltage signal by the signal conditioning circuit after receiving current signal from
active wheel sensors and given as input to the MCU.
Solenoid Valve Control
When one side of the valve coil is connected to the positive voltage that is provided through the valve relay and the
other side is connected to the ground by the semiconductor circuit, the solenoid valve goes into operation.
The electrical function of the coils are always monitored by the valve test pulse under normal operation conditions.
Voltage Limits
- Overvoltage
When overvoltage is detected(above 16.5V), the ECU switches off the valve relay and shuts down the system.
When voltage is returned to operating range, the system goes back to the normal condition after the initialization
phase.
- Undervoltage
In the event of undervoltage(below 10V), ABS control shall be inhibited and the warning lamp shall be turned on.
When voltage is returned to operating range, the warning lamp is switched off and ECU returns to normal
operating mode.
Pump Motor Checking
The ECU performs a pump motor test at a speed of 12km/h once after IGN is switched on.
Diagnostic Interface
Failures detected by the ECU are encoded on the ECU, stored in a EEPROM and read out by diagnostic
equipment when the ignition switch is turned on.
The diagnosis interface can also be used for testing the ECU during production of the ECU and for actuating the
HCU in the test line of manufactories (Air-bleeding line or Roll and Brake Test line).
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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 Warning Lamp Module
The active EBD warning lamp module indicates the self-test and failure status of the EBD.
However, in case the Parking Brake Switch is turned on, the EBD warning lamp is always turned on regardless of
EBD functions.
The EBD warning lamp shall be on:
- When the Parking Brake Switch is ON or brake fluid level is low.
- When the EBD function is out of order.
TCS Warning Lamp (TCS System)
The TCS warning lamp indicates the self-test and failure status of the TCS.
The TCS warning lamp is turned on under the following conditions.
- In the event of inhibition of TCS functions by failure.
- When driver trun off the TCS function by on/off switch.
TCS Function Lamp (TCS System)
The TCS function lamp indicates the self-test and operating status of the TCS.
The TCS Function lamp operates under the following conditions :
- When the TCS control is operating. (Blinking - 2Hz)
TCS On/Off Switch (TCS System)
The TCS On/Off Switch shall be used to toggle the TCS 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 TCS function is on and switch toggle the state.
ABS Control
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1. Normal braking without ABS
Under the normal braking, voltage is not supplied to solenoid valve, inlet valve is opened and outlet valve is
closed.When the brake is depressed, brake fluid is supplied to the wheel cylinder via solenoid valve to activate the
brake.When the brake is released, brake fluid is back to the master cylinder via inlet valve and check valve.
Pump
Solenoid valve State Valve Passage
motor
Master cylinder Wheel
Inlet valve (NO) OFF Open
cylinder OFF
Outlet valve (NC) OFF Close Wheel cylinder Reservoir
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2. Dump Mode
Under the emergency braking, if the wheels start to lock up, HECU sends a signal to the solenoid valve to decrease
the brake fluid, then voltage is supplied to each solenoid. At this time inlet valve is closed and brake fluid is blocked
from the master cylinder. Conversely outlet valve is opened and brake fluid passes through wheel cylinder to
reservoir, resulting in pressure decrease.
Pump
Solenoid State Valve Passage
motor
Master cylinder Wheel ON
Inlet valve (NO) ON Close
cylinder
Outlet valve (NC) ON Open Wheel cylinder Reservoir
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3. Hold Mode
When the brake fluid pressure is maximally decreased in wheel cylinder, HECU sends a signal to solenoid valve to
keep the fluid pressure, voltage is supplied to inlet valve but it is not supplied to outlet valve. At this time inlet and
outlet valves are closed and brake fluid is kept in wheel cylinder.
Pum
motor
Master cylinder Wheel OFF
Inlet valve (NO) ON Close
cylinder
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4. Increase Mode
If HECU determines there's no lock-up in the wheel, HECU cuts voltage to solenoid valve. So voltage is not
supplied to each solenoid valve, brake fluid passes through the inlet valve to wheel cylinder, resulting in pressure
increase.
Pump
motor
Master cylinder Wheel ON
Inlet valve (NO) OFF Open
cylinder
ABS Hecu External Diagram

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Hydraulic System Diagram
Brake System > ABS(Anti-Lock Brake System) > Schematic Diagrams

ABS Circuit Diagram [email protected]
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ABS 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
3 IGNITION1( )
Low voltage range:
7.0 ± 0.5V < V < 9.5 ± 0.5V
Max. current: I < 300mA
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Max leakage current : I < 0.8mA
POS. Operating voltage range:
2
BATTERY.(SOLENOID) 9.5 ± 0.5V < V < 17 ± 0.5V
Max current : I < 40A
9.5 ± 0.5V < V < 16.5 ± 0.5V
POS,
1 Rush current : I < 100A
BATTERY.(MOTOR)
Rated current : I < 300mA
26 GROUND
Max. current: I < 40A
Rush current : I < 100A
25 PUMP MOTOR GROUND
G SENSOR GROUND
10 - Rated current : I < 10mA
(4WD Only)
- Max Output current : I < 10mA
G SENSOR POWER
18 - Max Output voltage : 4.75V ≤ V ≤
(4WD Only)
5.25V
G SENSOR SIGNAL - Input voltage : 0V ≤ V ≤ 5.0V
7
(4WD Only) - Zero offset voltage : 2.5 ± 0.1V
Input voltage low: 0V ≤ V ≤ 3.0V
14 BRAKE LIGHT SWITCH
Input voltage High: 7.0V ≤ V ≤ 16.0V
SENSOR FRONT LEFT
23
POWER
SENSOR FRONT RIGHT
17
POWER - Output voltage : IGN[V] ± 1V
SENSOR REAR LEFT - Output current : Max 30mA
9
POWER
SENSOR REAR RIGHT
15
POWER
SENSOR FRONT LEFT
22
SIGNAL
- Input current LOW : 5.9 ~ 8.4mA
SENSOR FRONT RIGHT
24 - Input current HIGH : 11.8 ~
SIGNAL
16.8mA
SENSOR REAR LEFT - Frequency range : 1 ~ 2000Hz
8
SIGNAL
- Input duty : 50 ± 20%
SENSOR REAR RIGHT
16
SIGNAL
Input voltage :
VIL < 0.3 IGN[V]
DIAGNOSIS VIH > 0.7 IGN[V]
11
INPUT/OUTPUT Output voltage :
VOL < 0.2 IGN[V]
VOH > 0.8 IGN[V]
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13 CAN BUS LINE (LOW)
Max. current : I < 10mA
6 CAN BUS LINE (HIGH)
SENSOR FRONT RIGHT
4 External pull up resister : 1kΩ < R
OUTPUT
Output duty : 50 ± 20%
Current : I < 300mA (12V)
ABS/EBD W/LAMP
5 Voltage Range : 0 ~ 18V
DRIVE
Min. shunt Resistance : 500kΩ
Brake System > ABS(Anti-Lock Brake System) > Troubleshooting

Troubleshooting
Hi-scan (Pro) Check
1. Turn the ignition switch OFF.
2. Connector the Hi-scan (pro) to the 16P data link connector located the driver's side kick panel.
3. Turn the ignition switch ON.

4. Check for diagnostic trouble using the Hi-scan(pro).
5. After completion trouble of the repair or correction of the problm, erase the stored fault codes the clear key on
the Hi-scan(pro).
6. Disconnect the Hi-scan (pro) from the 16P date link connector.
Standard Flow Of Diagnostic Troubleshooting
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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 For road surfaces such as snow-covered and gravel roads, the braking distance
(Long braking 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

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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.
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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.
2. Verify that the normal code is output.
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3. 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+
3. 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

2. Check for continuity between terminals 25(45), 26(46) of the ABS(ESC) control module harness side connector
and ground point.
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3. Is there continuity?
Check the wheel speed sensor circuit.
Repair an open in the wire and ground
point.
Check the Wheel Speed Sensor Circuit

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

1. Refer to the hydraulic lines.
2. Inspect leakage of the hydraulic lines.
3. Is it normal?
The problem is still occurring, replace the ABS(ESC) control
module.
Repair the hydraulic lines for leakage.
Detecting Condition
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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.
3. 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

1. Refer to the DTC troubleshooting procedures.
2. 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.
Specification : approximately B+
3. 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.
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Check the Hydraulic Circuit for Leakage

1. Refer to the hydraulic lines.
2. Inspection leakage of the hydraulic lines.
3. 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
1. Measure the voltage between terminal 9 of the data link connector and body ground.
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2. 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.
Check the Ground Circuit for the Diagnosis

1. 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.
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Check the power source of ABS(ESC) control
module.
Repair an open in the wire.
Check the Power Source of 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.

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

1. 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
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Detecting Condition
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
1. Disconnect the connector the ABS(ESC) HECU and turn the ignition switch ON.
2. Does the ABS warning 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 (M15-1) and turn the ignition switch ON.
2. Measure the voltage between terminal (M15-1) 1 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

1. 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.
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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 - Faulty instrument cluster assembly
records a DTC in memory.Even though the normal code is output, - Faulty ABS warning lamp module
the ABS warning lamp remains ON, then the cause may be - Faulty 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.
3. Is DTC output?
Repair circuit indicated by code output.
Check instrument cluster.
Check Instrument Cluster

1. Disconnect the cluster connector and turn the ignition switch ON.
2. Does the ABS warning lamp remains ON?
Replace the instrument cluster.
Check for open the wire.
Check for Open in the Wire

1. 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
2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled
clear plastic bottle.
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3. Connect the 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 60 sec. before operating the air bleeding. (If not, you may damage the motor.)
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(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:

6.8 ~ 12.7 N.m (0.7 ~1.3 kgf.m, 5.1 ~ 9.4 lb-ft)
Diagnostic Trouble Code Chart(DTC)

DTC Warning lamp condition
Trouble description Remark
Code EBD ABS ESC
C1101 Battery Voltage High ● ● ● ABS/ESC
C1102 Battery Voltage Low ○/● ● ● ABS/ESC
C1112 Sensor source Voltage ○ ● ● ABS/ESC
C1200 Wheel Speed Sensor Front-LH Open/Short ○/● ● ● ABS/ESC
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Wheel Speed Sensor Front-LH Range /
C1201 Performance / ○/● ● ● ABS/ESC
Intermittent
C1202 Wheel Speed Sensor Front-LH Invalid/no Signal ○/● ● ● ABS/ESC
C1203 Wheel Speed Sensor Front-RH Open/Short ○/● ● ● ABS/ESC
Wheel Speed Sensor Front-RH Range /
Intermittent
C1205 Wheel Speed Sensor Front-RH Invalid/no Signal ○/● ● ● ABS/ESC
C1206 Wheel Speed Sensor Rear-LH Open/Short ○/● ● ● ABS/ESC
Wheel Speed Sensor Rear-LH Range /
Intermittent
C1208 Wheel Speed Sensor Rear-LH Invalid/no Signal ○/● ● ● ABS/ESC
C1209 Wheel Speed Sensor Rear-RH Open/Short ○/● ● ● ABS/ESC
Wheel Speed Sensor Rear-RH Range /
Intermittent
C1211 Wheel Speed Sensor Rear-RH Invalid/no Signal ○/● ● ● ABS/ESC
C1235 Primary Pressure Sensor-Electrical ○ ○ ● ESC only
C1237 Primary Pressure Sensor-Signal ○ ○ ● ESC only
C1259 Steering Angle Sensor - Electrical Malfunction ○ ○ ● ESC only
C1260 Steering Angle Sensor circuit-Signal ○ ○ ● ESC only
C1274 Longitudinal G Sensor Open/Short ○ ● ● 4WD only
C1275 Longitudinal G Sensor Range/Performance error ○ ● ● 4WD only
C1282 Yaw Rate & Lateral G Sensor-Electrical ○ ○ ● ESC only
C1283 Yaw Rate & Lateral G Sensor-Signal ○ ○ ● ESC only
C1503 ESC Switch Error ○ ○ ● ESC only
C1513 Brake Switch Error ○ ○ ● ESC only
C1604 ECU Hardware Error ○ ○ ● ABS/ESC
C1605 CAN Hardware Error ○ ○ ● ABS/ESC
C1611 CAN Time-out ECM ○ ○ ● ABS/ESC
C1612 CAN Time-out TCM ○ ○ ● ABS/ESC
C1613 CAN Wrong Message ○ ○ ● ABS/ESC
C1616 CAN Bus off ○ ○ ● ABS/ESC
C1647 CAN Hardware Error-Sensor channel ● ● ● ESC only
C2112 Valve Relay Error ○ ○ ● ABS/ESC
C2227 Excessive Temperature Of Brake Disc ● ● ● ESC only
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C2380 ABS / ESC Valve Error ○ ● ● ABS/ESC
C2402 Motor Failure ○ ● ● ABS/ESC
Brake System > ABS(Anti-Lock Brake System) > ABS Control Module > Components and
Components Location
Components
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1. Front-left tube 6. MC1
2. Rear-right tube 7. ABS control module
3. Rear-left tube connector(26 P)
4. Front-right tube 8. ABS control
5. MC2 module(HECU)
9. Damper
10. Bracket
Brake System > ABS(Anti-Lock Brake System) > ABS Control Module > Repair procedures
Removal
1. Disconnect the double lock from the HECU.
2. Disconnect the brake tube from the HECU by unlocking the nuts centerclockwise with a spanner.
• Do not spill brake fluild on vehicle; it may damage the pailt; if brake fluid gets on the paint, wash it off
• Take care not to damage or defrom the brake lines during remove and water.
• To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or
equivalent material.
3. Remove the three HECU brake mounting bolts disassembly the HECU with the bracket.
1. Never attempt to disassemble the HECU.

2. The HECU must be transported and stored in an upright production and with the ports
sealed.
4. Remove the three HECU mounting bolts and disassembly the HECU from the bracket.
Installation
2. Tighten the HECU mounting bolts and brake tube nuts to the specified torque.
Tighterning torque
HECU mounting bolt:
11~14N.m (110~140 kg.cm, 8.1~10.3 Ibf.ft)
HECU braket mounting bolt:
17~26 N.m (170~260 k.cm, 12.5~19.2 Ibf.ft)
Brake tube nut:
12~16 N.m (120~160 kg.cm, 9~12 Ibf.ft)
Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Components and
Components Location
Components
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1. Front wheel speed sensor 4. Rear wheel speed sensor connector

connector 5. Rear wheel speed sensor
2. Bolt
3. Front wheel speed sensor
Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Description and
Operation
Description
A toothed rotor is fixed to the rotating member of the wheel, the sensor 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
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signal is directly correlated to the wheel speed.
The controller monitors the sensor signal, compares the four wheel-speed signals and initiates action as required.
Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Specifications
Specifications
Item Standard Value Remark
Supply voltage DC 12V
Operating -40~120°C (-40~248°F) R=100Ω
temperature
Output current Low 7mA(5.9~8.4mA)
range
High 14mA(11.8~16.8mA)
Frequency 1~2000Hz
range
Airgap 0.5~1.5mm(0.0197~0.0591
in.)
Tone Number 48
wheel
Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Repair procedures
Removal
Front Wheel Speed Sensor [email protected]
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1. Remove the front wheel speed sensor mounting bolt (A).
2. Remove the front wheel guard (B), after removing the mud ground (A).
3. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector (A).
Rear Wheel Speed Sensor

1. Remove the rear wheel speed sensor mounting bolt (A).
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2. Remove the rear seat side pad then disconnect the rear wheel speed sensor connector (A).
Inspection
1. Measure the output voltage between the terminal of the wheel speed sensor and the body ground.
Must use the resistance(100Ω), as shown below, in order to protect the active wheel speed sensor, before
measuring the output voltage.
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 : 590mV ~ 840mV
• V : 1.18V ~ 1.68V
• Frequency range : 1~2,000Hz
Brake System > ABS(Anti-Lock Brake System) > G Sensor > Components and Components Location
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Components
Brake System > ABS(Anti-Lock Brake System) > 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
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3. Measure the output voltage between 2 and 3 terminals, posing the arrow mark on the G sensor downward.
Specification : 3.5V
4. Replace the G sensor if the output voltage is not on the specification.
Brake System > ABS(Anti-Lock Brake 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
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Brake System > ESC(Electronic Stability Control) System > Components and Components Location
Components
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1. HECU module 6. ESC OFF warning lamp

2. Yaw rate & Lateral G sensor 7. Front wheel speed sensor
3. Parking brake/EBD warning 8. Steering angle sensor
lamp 9. Rear wheel speed sensor
4. ABS Warning lamp 10. G-Sensor(ONLY 4WD)
5. ESC function lamp
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.
ESCis 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.
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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.
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 MK 20
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)
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Input And Output Diagram
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ESC Operation Mode

ESC Hydraulic System Diagram
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1. ESC Non-operation : Normal braking.

Solenoid Motor
Continuity Valve TC Valve
valve pump
IN (NO) OFF OPEN
OFF OFF
OUT (NC) OFF CLOSE
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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:
- In the event of inhibition of ABS functions by failure.
EBD Warning Lamp Module
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The active EBD warning lamp module indicates the self-test and failure status of the EBD.However, in case the
Parking Brake Switch is turned on, the EBD warning lamp is always turned on regardless of EBD functions.The
EBD warning lamp shall be on:
- When the Parking Brake Switch is ON or brake fluid level is low.
- When the EBD function is out of order .
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
ESC Circuit Diagram
Circuit Diagram(1)
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Circuit Diagram(2)
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Circuit Diagram(3)
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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 :
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7.0 ± 0.5V < V < 9.5 ± 0.5V
Operating voltage range :
1 POS.BATTERY.(SOLENOID)
9.5 ± 0.5V < V < 17 ± 0.5V
Max. current : I < 40A
9.5 ± 0.5V < V < 16.5 ± 0.5V
2 POS.BATTERY.(MOTOR) Rush current : I < 100A
Rated current : I <500mA
46 GROUND
Max. current: I < 40A
Rush current : I < 100A
45 PUMP MOTOR GROUND
YAW & LATERAL G
16 SENSOR Rated current : I <150mA
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
34 BRAKE LIGHT SWITCH Input voltage (Low) : 0V ≤ V ≤ 3.0V
Input voltage (High) : 7.0V ≤ V ≤
32 BRAKE SWITCH 16.0V
Input voltage (Low) : 0V ≤ V_Low ≤
3.0V
8 PARKING BRAKE SWITCH Input voltage (High) : 7.0V ≤ V_High
≤ 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
Input voltage (High) : 7.0V ≤ V ≤
18 ESC ON/OFF SWITCH
16.0V
Max input current:I <10mA
15 CAN BUS LINE(LOW)
14 CAN BUS LINE(HIGH)
SENSOR FRONT LEFT
4
POWER
SENSOR FRONT RIGHT
5
POWER Output voltage : IGN (V) ± 1V
Output current : Max 30mA
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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 ~ 2000Hz Typ. 14mA
12 Input duty : 50 ± 20%
SIGNAL
SENSOR REAR RIGHT
11
SIGNAL
24
PHASE 1 Input duty (ST1, ST2): 50 ± 10%
Phase difference (ST1, ST2): 2 ± Typ. 20deg
25 0.6deg Typ. 3.5V
PHASE 2
High voltage: 3.0 V < V < 4.1V Typ. 1.5V
STEERING ANGLE SENSOR 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)
21 Max. output current : I < 100mA
G SENSOR POWER (4WD
Max. output voltage : 4.75V ≤ V ≤
Only)
5.25V
23 G SENSOR SIGNAL (4WD Input voltage : 0V ≤ V ≤ 5.0V
Only) Zero offset voltage : 2.5 ± 0.1V
44 G SENSOR GROUND (4WD
Rated current : I < 10mA
Only)
37 ESC W/LAMP DRIVE
Current : I < 300mA (12V)
38 ABS/EBD W/LMAP DRIVE Voltage range : 0 ~ 18V
Min. shunt resistance : 500KΩ
40 ESC F/LAMP DRIVE
Sensor Input voltage : 0V ≤ V ≤ 5.0V
42 G SENSOR SIGNAL
Zero offset voltage : 2.5 ± 0.1V
Sensor Input voltage : 0V ≤ V ≤ 5.0V
43 YAW SENSOR SIGNAL
Zero offset voltage : 2.5 ± 0.1V
Brake System > ESC(Electronic Stability Control) System > Troubleshooting

Failure Diagnosis
1. In principle, ESC and TCS controls are prohibited in case of ABS failure.
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2. When ESC or TCS is fail, only the failed system control is prohibited.
3. However, when the solenoid valve relay should be turned off in case of ESC fail, refer to the ABS fail-safe.
4. Information on ABS fail-safe is identical with the fail-safe in which 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 409 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 fail 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
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. ESC operation lamp turn on for 3sec after IGN ON.
2. ESC operation lamp blinks when ESC Act.
3. ESC OFF warning lamp turn on in case of
A. ESC Switch OFF
B. ESC Failure Detect
C. 3sec after IGN ON
Diagnostic Trouble Code Chart(DTC)

DTC Warning lamp condition
Trouble description Remark
Code EBD ABS ESC
C1101 Battery Voltage High ● ● ● ABS/ESC
C1102 Battery Voltage Low ○/● ● ● ABS/ESC
C1112 Sensor source Voltage ○ ● ● ABS/ESC
C1200 Wheel Speed Sensor Front-LH Open/Short ○/● ● ● ABS/ESC
Wheel Speed Sensor Front-LH Range /
Intermittent
C1202 Wheel Speed Sensor Front-LH Invalid/no Signal [email protected]
○/● ● ● ABS/ESC
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C1203 Wheel Speed Sensor Front-RH Open/Short ○/● ● ● ABS/ESC
Wheel Speed Sensor Front-RH Range /
Intermittent
C1205 Wheel Speed Sensor Front-RH Invalid/no Signal ○/● ● ● ABS/ESC
C1206 Wheel Speed Sensor Rear-LH Open/Short ○/● ● ● ABS/ESC
Wheel Speed Sensor Rear-LH Range /
Intermittent
C1208 Wheel Speed Sensor Rear-LH Invalid/no Signal ○/● ● ● ABS/ESC
C1209 Wheel Speed Sensor Rear-RH Open/Short ○/● ● ● ABS/ESC
Wheel Speed Sensor Rear-RH Range /
Intermittent
C1211 Wheel Speed Sensor Rear-RH Invalid/no Signal ○/● ● ● ABS/ESC
C1235 Primary Pressure Sensor-Electrical ○ ○ ● ESC only
C1237 Primary Pressure Sensor-Signal ○ ○ ● ESC only
C1259 Steering Angle Sensor - Electrical Malfunction ○ ○ ● ESC only
C1260 Steering Angle Sensor circuit-Signal ○ ○ ● ESC only
C1274 Longitudinal G Sensor Open/Short ○ ● ● 4WD only
C1275 Longitudinal G Sensor Range/Performance error ○ ● ● 4WD only
C1282 Yaw Rate & Lateral G Sensor-Electrical ○ ○ ● ESC only
C1283 Yaw Rate & Lateral G Sensor-Signal ○ ○ ● ESC only
C1503 ESC Switch Error ○ ○ ● ESC only
C1513 Brake Switch Error ○ ○ ● ESC only
C1604 ECU Hardware Error ○ ○ ● ABS/ESC
C1605 CAN Hardware Error ○ ○ ● ABS/ESC
C1611 CAN Time-out ECM ○ ○ ● ABS/ESC
C1612 CAN Time-out TCM ○ ○ ● ABS/ESC
C1613 CAN Wrong Message ○ ○ ● ABS/ESC
C1616 CAN Bus off ○ ○ ● ABS/ESC
C1647 CAN Hardware Error-Sensor channel ● ● ● ESC only
C2112 Valve Relay Error ○ ○ ● ABS/ESC
C2227 Excessive Temperature Of Brake Disc ● ● ● ESC only
C2380 ABS / ESC Valve Error ○ ● ● ABS/ESC
C2402 Motor Failure ○ ● ● ABS/ESC
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Brake System > ESC(Electronic Stability Control) System > C1101 Battery Voltage High
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 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, supply circuit (IGN+)
the 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
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1. Connect scantool to Data Link Connector(DLC)
2. Ignition "ON" & Engine "ON".
3. Monitor the "BATTERY VOLTAGE" parameter on the scantool.
Specification : Below. 17.5V
Fig 1) Test Condition : Ignition "ON" & Engine "ON".

Normal Data
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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.
contamination, deterioration, or damage.
Repair or replace as necessary and then go to "Verification of Vehicle Repair" procedure.
Go to "Terminal and Connector Inspection" procedure.

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.
Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
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
Alternator Output Voltage Inspection

■ Charging System Check
2. Maintain ENG RPM 2,500RPM over 2 minutes.
3. Measure voltage between the battery terminal(+) and the battery terminal(-).
Specification : Below. 17±0.5V
4. Is the measured value within specifications?

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.

■ Open or Short Check
2. Measure voltage between the battery terminal(+) and power terminal of the HECU harness connector.
Specification : Approx. below 0.2V
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Check for open or blown 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.

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 "Verification of vehicle Repair" procedure.

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.
5. Are any DTCs present ?
procedure.
Brake System > ESC(Electronic Stability Control) System > C1102 Battery Voltage Low
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.
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• 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/ESP(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

(Low ABS/ESC control, allow the EBD control , The
voltage) ABS/ESC warning lamps are activated, When the • Poor connection in power
voltage recovers the normal operating range, erase supply circuit (IGN+)
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
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3. Monitor the "BATTERY VOLTAGE" parameter on the scantool.
Specification : Above. 9±0.5V

Normal Data
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Fault is intermittent caused by poor connection in power harness (IGN+) and/or HECU's

or damage.
Repair as necessary and then go to "Verification of Vehicle Repair"
procedure.
Go to "Alternator Output Voltage Inspection" procedure.
Alternator Output Voltage Inspection

■ Charging System Check
2. Maintain ENG RPM 2,500RPM over 2 minutes.
3. Measure voltage between the battery terminal(+) and the battery terminal(-).
Specification : Above. 9±0.5V

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
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Check for open or blown ABS fuse referring to "Circuit Diagram".


procedure.
ground and then go to "Verification of vehicle Repair" procedure.

1. Connect scantool and select "Diagnostic Trouble Codes(DTCs)" mode
procedure.
Brake System > ESC(Electronic Stability Control) System > C1112 Sensor source voltage
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.
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• During sensor power ON, If the voltage of sensor
power is out of the specified range for 500ms.
Enable Conditions • Faulty HECU
• 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/ESC functions are inhibited, EBD function is
Fail Safe allowed and the ABS/ESC warning lamps are
activated.

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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.
procedure.

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

procedure.
Brake System > ESC(Electronic Stability Control) System > C1200 Wheel Speed Sensor Front-LH
Open/Short
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 vehicle speed, in front wheel drive vehicles,
and if a difference between front and rear 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 sets this 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).
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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
1. Only one wheel failure : Inhibit the ABS/ESC
speed sensor circuit
control, allow the EBD control. The ABS/ESC
• Faulty Wheel speed sensor
warning lamps are activated, the EBD warning lamp
Fail Safe is not activated.
2. More than two wheels failure : The ABS/EBD/ESC
functions are inhibited. The ABS/EBD/ESC warning
lamps are activated.
Specification
Sensor Output Voltage Tooth
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

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Signal Waveform & Data
Fig 1) Normal waveform of wheel speed sensor (Active type)

- High : Approx. 1.4V, Low : Approx. 0.7V

3. Start and drive vehicle in gear and maintain vehicle speed at or above 10km/h. (6.2mph)
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.
Fig 1) Test Condition : Drive vehicle at a speed of 10km/h or more. (6.2mph or more)
Normal Data
Abnormal Data (Open)
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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.
procedure.

2. Measure voltage between power terminal of the wheel speed sensor harness connector and chassis ground.

Repair open or short in power circuit between HECU harness connector and wheel speed
sensorharness 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.
procedure.

■ Wheel speed sensor circuit check
1. Lift the vehicle.
3. Turn the wheel by hand.
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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
5. Is the measured waveform within specifications?

procedure.
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.
4. Measure waveform between signal terminal of the wheel speed sensor harness connector and chassis ground with
osciloscope.
Normal waveform
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Fault is intermittent caused by poor connection in wheel speed sensor harness (FL).
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))
procedure.
Range / Performance / Intermittent
General Description
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.

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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
condition is
lasted for 2 minutes.
• 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 one wheel exceed 126 times, or When
Enable the numbers at more two wheels exceed 20 times,
Conditions controller recognize the failure.
• Controller counts the number of the wheel • Improper installation of wheel
deceleration of -100g[(-25km/h) for 7ms]. When the speed sensor
numbers at each wheel exceed 56 times, controller • Abnormal Rotor and wheel
Case2 recognize the failure. bearing
• The wheel deceleration of –100g[(-25km/h) for • Faulty Wheel speed sensor
7ms] causes the controller to start monitoring this
failure and 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.
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Specification
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

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

Fig 1) Test Condition : Drive vehicle at a speed of 40km/h or more. (24mph or more)
Normal Data
Normal Graph
Abnormal Data
Abnormal Graph
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osciloscope.
Normal waveform

Fault is intermittent caused by faulty HECU, wheel speed sensor or external noise, an
interference between harnesses.
If there is no problem in signal circuit, Substitute with a known-good HECU and check for
proper operation.
procedure.
Check for improper installation of wheel speed sensor. If NG, repair as necessary and then
Check for damage of rotor teeth or wheel bearing. If NG, repair as necessary and then go to
"Verification of vehicle Repair" procedure.
Repair" procedure.
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maintain vehicle speed at or above 40kmh. (24mph))
procedure.
Invalid/no Signal
General Description
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.
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• 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
Case1
Enable exceeds 10km/h (6.2mph), the condition is
(Large
Conditions continued for 20 sec. Otherwise, In >0.4g, the
Air-Gap)
condition is 2 minutes.
• 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 speed sensor
less than 4km/h (2.5mph) under that those velocity is • Abnormal Rotor and wheel
more than 10km/h (6.2mph), if that conditions are bearing
continued 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
(long term Enable of 2km/h (1.2mph) is lasted for more than 12sec.
ABS Conditions • If the ABS control cycle is continued for more than
mode) 36sec.
Specification

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

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Normal Data
Abnormal Data
HECU'sconnector or was repaired and HECU memory was not cleared.
Page 110 of 222
osciloscope.
Normal waveform

procedure.
Repair" procedure.

procedure.
Brake System > ESC(Electronic Stability Control) System > C1203 Wheel Speed Sensor Front-RH
Open/Short
General Description
whether wheel lock occurs. [email protected]
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DTC Description

for 140msec.
warning lamps are activated, the EBD warning lamp • Faulty Wheel speed sensor
Specification
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

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4. Monitor the "WHEEL SPEED(FR)" parameter on the Scantool.

Normal Data
Fault is intermittent caused by poor connection in wheel speed sensor harness (FR) and/or

or damage.
procedure.

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proper operation.
procedure.

ground.
Normal waveform

procedure.
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Page 115 of 222
osciloscope.
Normal waveform

Fault is intermittent caused by poor connection in wheel speed sensor harness (FR).
Repair" procedure.

procedure.
General Description
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DTC Description

condition is lasted for 2 minutes.
Case1
numbers at more two wheels exceed 5 times,
the numbers at more two wheels exceed 20 times,
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
• The wheel deceleration of –100g[(-25km/h) for bearing
7ms] causes the controller to start monitoring this • Faulty Wheel speed sensor
Fail Safe is not activated. [email protected]
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Specification
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

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Normal Data
Normal Graph
Abnormal Data
Abnormal Graph
osciloscope.
Normal waveform
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interference between harnesses, was repaired and HECU memory was not cleared.
proper operation.
procedure.
Repair" procedure.

procedure.
Invalid/no Signal
General Description
DTC Description
abnormally.
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Page 121 of 222

Case1
(Large
Air-Gap)
10km/h (6.2mph).
mode) 36sec.
Specification
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type
Page 122 of 222


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Page 123 of 222

Normal Data
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osciloscope.
Normal waveform

procedure.
Repair" procedure.

procedure.
Brake System > ESC(Electronic Stability Control) System > C1206 Wheel Speed Sensor Rear-LH
Open/Short
General Description
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DTC Description

for 140msec.
Specification
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

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4. Monitor the "WHEEL SPEED(RL)" parameter on the Scantool.

Normal Data
Fault is intermittent caused by poor connection in wheel speed sensor harness (RL) and/or

or damage.
procedure.

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proper operation.
procedure.

ground with osciloscope.
Normal waveform

procedure.
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Page 129 of 222
osciloscope.
Normal waveform

Fault is intermittent caused by poor connection in wheel speed sensor harness (RL).
Repair" procedure.

procedure.
General Description
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DTC Description

Case1
Case2
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Specification
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

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Normal Data
Normal Graph
Abnormal Data
Abnormal Graph
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osciloscope.
Normal waveform

proper operation.
procedure.
Repair" procedure.
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procedure.
Invalid/no Signal
General Description
DTC Description
abnormally.
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Case1
(Large
Air-Gap)
10km/h (6.2mph).
mode) 36sec.
Specification

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

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Normal Data
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osciloscope.
Normal waveform

procedure.
Repair" procedure.

procedure.
Brake System > ESC(Electronic Stability Control) System > C1209 Wheel Speed Sensor Rear-RH
Open/Short
General Description
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DTC Description

for 140msec.
Specification
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

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4. Monitor the "WHEEL SPEED(RR)" parameter on the Scantool.

Normal Data
Fault is intermittent caused by poor connection in wheel speed sensor harness (RR) and/or

or damage.
procedure.

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proper operation.
procedure.

osciloscope.
Normal waveform

procedure.
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osciloscope.
Normal waveform

Fault is intermittent caused by poor connection in wheel speed sensor harness (RR).
Repair" procedure.

procedure.
General Description
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DTC Description

Case1
Case2
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Specification
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

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Normal Data
Normal Graph
Abnormal Data
Abnormal Graph
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osciloscope.
Normal waveform

proper operation.
procedure.
Repair" procedure.
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procedure.
Invalid/no Signal
General Description
DTC Description
abnormally.
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Page 149 of 222
Case1
(Large
Air-Gap)
10km/h (6.2mph).
mode) 36sec.
Specification

Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 10 0.4~1.5mm
Type

Page 150 of 222


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Normal Data
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osciloscope.
Normal waveform

procedure.
Repair" procedure.

procedure.
Brake System > ESC(Electronic Stability Control) System > C1235 Primary Pressure Sensor-Electrical
General Description
The pressure sensor, installed in the HECU, sense the brake oil pressure to judge driver's brake intention when ESP
is operating.
If pressure of master cyclinder is applied to pressure sensor, the strain of the piezo element is changed and then the
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Page 153 of 222
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.

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

3. Press the brake pedal.
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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".
5. Select "Diagnostic Trouble Codes(DTCs)" mode again.
procedure.
Fault is intermittent caused by faulty HECU.

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Page 155 of 222
procedure.
Brake System > ESC(Electronic Stability Control) System > C1237 Primary Pressure Sensor-Signal
General Description
The pressure sensor, installed in the HECU, sense the brake oil pressure to judge driver's brake intention when ESP
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
• Faulty pressure sensor
higher than 20bar and BLS is low for 3sec, ECU
detect the failure.
• Inhibit the ESC control and allow the ABS/EBD
Fail Safe control.

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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.
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Page 157 of 222
1. Ignition "OFF".
procedure.
Fault is intermittent caused by faulty HECU.

procedure.
Brake System > ESC(Electronic Stability Control) System > C1259 Steering Angle Sensor – Electrical
Malfunction
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.

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• 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.
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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

or damage.
procedure.

2. Measure voltage between power terminal of the steering angle sensor harness connector and chassis ground.

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Repair open or short in power circuit between steering angle sensor harness connector and
HECU harness connector, and then go to "Verification of vehicle Repair" procedure.
proper operation.
procedure.

2. Disconnect steering angle sensor connector.
3. 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

procedure.
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 : 2.9±0.1V ~ 4.4±0.1V, LOW : 1.2±0.1V ~ 2.1±0.1V

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connector.
Go to "Verification of vehicle Repair" procedure.
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.

procedure.
Brake System > ESC(Electronic Stability Control) System > C1260 Steering Angle Sensor Circuit-
Signal
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.

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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
• Faulty steering wheel sensor
3sec, 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.

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Page 163 of 222
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" : Output signal change ("LOW"
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.

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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?

or damage. [email protected]
Page 165 of 222
procedure.

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
("HIGH" → "LOW") is detected when steering wheel is passing by on center position.
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procedure.
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.
If there is no problem in Signal circuit, Substitute with a known-good HECU and check for
proper operation.
■ 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 ~
±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
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Page 167 of 222
("HIGH" → "LOW") is detected when steering wheel is passing by on center position.
connector.
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.

procedure.
Brake System > ESC(Electronic Stability Control) System > C1274 Longitudinal G sensor open/short
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.

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

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Page 169 of 222
3. Monitor the "G Sensor" parameter on the Scantool.
Specification : Approx. ±0.01G
Fig 1) Test Condition : Ignition "ON" & Engine "OFF".

Normal Data
Fig 2) Test Condition : Ignition "ON" & Engine "OFF"
G-sensor open circuit Data

or damage.
procedure.

2. Measure voltage between power terminal of the G sensor harness connector and chassis ground.
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Repair open or short in power circuit between the G sensor harness connector and HECU
harnessconnector and then, go to "Verification of vehicle Repair" procedure.
proper operation.
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.

procedure.
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.
2. Measure voltage between signal terminal of the G sensor harness connector and chassis ground.
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Page 171 of 222
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.

procedure.
Brake System > ESC(Electronic Stability Control) System > C1275 Longitudinal G Sensor
Range/Performance error
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
• Improper installation of G-
• When vehicle speed is >10km/h and the brake light
Sensor
switch is off, |G|>0.5G for 20sec continuously.
Enable Conditions • Abnormal Rotor and wheel
• When |min wheel speed| / dt ≥0.2G and |G| ≤0.1G
bearing
for 60sec continuously.
• Faulty G-Sensor
Fail Safe •-

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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
[email protected]
Page 173 of 222

or damage.
procedure.
■ 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.

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procedure.
System performing to specification at this
time.g
Brake System > ESC(Electronic Stability Control) System > C1282 Yaw Rate & Lateral G Sensor-
Electrical
General 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 ESP 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.
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.

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
Conditions voltage 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.

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Page 175 of 222

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
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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.
procedure.

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

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"
proper operation.
procedure.

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.
[email protected]
Page 177 of 222
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 "Verification of vehicle Repair" procedure.
■ Short Check (to battery)

3. Measure voltage between CAN LOW terminal, CAN HIGH terminal of the HECU harness connector and
chassis ground.

Repair short to battery in CAN signal circuit in case of abnormal voltage measured and then,
■ Internal Resistance Check

3. Measure resistance between CAN LOW terminal and CAN HIGH terminal of the HECU connector.

Go to "Component Circuit Inspection" procedure.
procedure.
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■ 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 sensorand check for proper operation.
If problem is corrected, replace the yaw rate & lateral G sensor and then go to "Verification of

procedure.
Brake System > ESC(Electronic Stability Control) System > C1283 Yaw Rate & Lateral G Sensor-
Signal
General Description
If yaw velocity reaches the specific velocity after it detects the vehicle' yawing, the ESP control is reactivated.
by later G.
to lateral G
sensor. [email protected]
Page 179 of 222
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.
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 measured value of the yaw rate sensor is lager than
Case1
Conditions Predefined value for specific time , ECU detects
failure.
• When the difference between estimated value and
Enable measured value of the lateral G sensor is lager than
Case2
Conditions Predefined value for specific time , ECU detects
failure.
• Faulty Yaw Rate & Lateral G
• Yaw signal is smaller than predefined value when sensor
CBIT is transmitted
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
Case4
Conditions for defined time
• Inhibit the ESP control and allow the ABS/EBD
Fail Safe control.

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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
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Page 181 of 222
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.
procedure.
1. Ignition "OFF".
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
2) Substitute with a known-good HECU and check for proper operation.
procedure.
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

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procedure.
Brake System > ESC(Electronic Stability Control) System > C1503 TCS/ESC(ESP) Switch error
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
control. • Faulty ESC switch
Fail Safe
Specification
ESC switch ESC switch
Engine ON HIGH LOW
7.0V ~ 16.0V 0V ~ 3.0V
[email protected]
Page 183 of 222

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 harness and/or HECU's
Page 184 of 222
or damage.
procedure.

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,
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 ESP switch and check for proper operation.
If problem is corrected, replace ESP switch and then go to "Verification of Vehicle Repair"
procedure.
Verification of Vehicle Repair [email protected]

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procedure.
Brake System > ESC(Electronic Stability Control) System > C1513 Brake switch error
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 pressed.
The brake light switch is a normally-open contact which runs to battery voltage when active (brake pressed).
When passive (brake released), 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 ESP control.
If an error is present, the warning lamp will illuminate.

DTC Strategy • Open circuit monitoring
• If both BLS(brake lamp switch) and BS(brake
switch) have a same state and MCP (Master
Cylinder Pressure) >20bar for 500ms.
• Outside an ABS/ESC control, and after normal
operation of MCP, If the pressure sensor signal is • Open circuit in brake switch
Enable Conditions
higher than 20bar and BLS is low for 3sec. line
• If the BLS/BS changed more than 40times and • Faulty brake light switch
MCP> 20bar for 5sec. • Faulty input stage in HECU
• While Vehicle speed > 10km/h, TPS>5%,
MCP<7bar, if BLS is high over 1min.
Fail Safe control.
Specification
Voltage Range of Voltage Range of
Brake Light Switch "High" "Low"
7.0V ~ 16.0V 0V ~ 3.0V
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4. Monitor the "BRAKE SWITCH" parameter on the scantool.
Specification : It is changed to ON/OFF.

Normal Data
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Page 187 of 222
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

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

Signal circuit inspection (brake pedal isn't pressed)
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 fuse referring to "Circuit Diagram".
Signal Circuit Inspection (brake pedal is pressed)

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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

connector.
Check for open or blown 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).
Resistance between the terminals of the brake switch - ∞Ω (when the plunger is not pushed down),
0Ω (when the plunger is pushed down).

connector.
Substitute with a known-good brake light switch and check for proper operation.
If pro blem is corrected, replace brake light switch and then go to "Verification of Vehicle
Repair" procedure.

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Page 189 of 222
procedure.
Brake System > ESC(Electronic Stability Control) System > C1604 ECU Hardware Error
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.

DTC Strategy • Internal Monitoring
• When the MCU can’t erase or write a data of the
EEPROM.
Enable Conditions • When the master/slave processor detects abnormal
• Faulty HECU
operation in RAM, status register, interrupt, timer,
A/D converter and cycle time.
• The ABS/EBD/ESC functions are inhibited.
Fail Safe

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or damage.
procedure.
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Page 191 of 222
procedure.
Fault is intermittent caused by faulty HECU or was repaired and HECU memory was not
cleared.

procedure.
Brake System > ESC(Electronic Stability Control) System > C1605 CAN Hardware error
General Description
The HECU send 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.

DTC Strategy • CAN RAM monitoring
Enable Conditions • CAN Hardware failure.
• Faulty HECU
• Inhibit the ESC control and allow the
Fail Safe ABS/EBD control.

Page 192 of 222

or damage.
procedure.
[email protected]
Page 193 of 222
procedure.
cleared.

procedure.
Brake System > ESC(Electronic Stability Control) System > C1611 CAN Time-out ECM
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.

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.
Page 194 of 222

or damage.
procedure.
[email protected]
Page 195 of 222
■ 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
4. Is the measured resistance within specifications?

Repair open in CAN BUS line between HECU harness connector and ECM harness
connector and then go to "Verification of Vehicle Repair" procedure.
1. Ignition "OFF"
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.
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.

procedure.
Brake System > ESC(Electronic Stability Control) System > C1612 CAN Time-out TCM
General Description
Page 196 of 222
DTC Description
The HECU checks the CAN communcation lines for normal ESC control, and sets this code if an 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 TCM message was not received for
Enable Conditions more than 500ms within normal voltage condition.
• Faulty PCM(TCM)
- The Monitoring starts 2000 ms after Power Up.
• Faulty HECU
Fail Safe control.
[email protected]
Page 197 of 222

or damage.
procedure.

■ Open Check
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LOW terminal terminal of the TCM harness connector.

Repair open in CAN BUS line between HECU harness connector and TCM harness
1. Ignition "OFF"
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

procedure.
Brake System > ESC(Electronic Stability Control) System > C1613 CAN Wrong Message
General Description
causes a Kickdown shift. [email protected]
Page 199 of 222
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.

• 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.

Page 200 of 222

or damage.
procedure.

■ Open Check
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Page 201 of 222
LOW terminal terminal of the ECM harness connector.

Repair open in CAN BUS line between HECU harness connector and ECM harness
1. Ignition "OFF"
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

procedure.
Brake System > ESC(Electronic Stability Control) System > C1616 CAN Bus off
General Description
Page 202 of 222
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.

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Page 203 of 222
or damage.
procedure.
Go to "CAN Signal Circuit Inspection" procedure.
CAN Signal Circuit Inspection

■ Short Check (to ground)
2. Disconnect the HECU connector.
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 "Verification of vehicle Repair" procedure.
In case of the resistance "∞ Ω" : Repair open in CAN signal circuit of the HECU and then go
to "Verification of vehicle Repair" procedure.
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"
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procedure.
Fault is intermittent caused by poor connection in CAN signal harness and/or HECU's
connector.

procedure.
Brake System > ESC(Electronic Stability Control) System > C1647 CAN Hardware Error - Sensor
Channel
General Description
If yaw velocity reaches the specific velocity after it detects the vehicle' yawing, the ESC control is reactivated.
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
malfunction is detected.

DTC Strategy • Internal Monitoring
Enable Conditions • Sensor CAN H/W failure. • Faulty HECU
• Inhibit the ESC control and allow the ABS/EBD • Faulty Yaw Rate & Lateral G
sensor
Fail Safe control.
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Page 205 of 222

or damage.
procedure.
procedure.
cleared.
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procedure.
Brake System > ESC(Electronic Stability Control) System > C2112 Valve Relay Error
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.

• 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
Case2 • If the valve relay is switched off and voltage of valve supply circuit (ABS2)
Enable • Faulty HECU
(Short or relay > 6±0.5V or < 2.5±0.5V continuously for
Conditions
leakage) 56ms, the failure is detected.
Fail Safe
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Monitor Actuation Test

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

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

or damage.
procedure.

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".

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Page 209 of 222
procedure.
ground, and then go to "Verification of vehicle Repair" procedure.

procedure.
Brake System > ESC(Electronic Stability Control) System > C2227 Excessive Temperature Of Brake
Disc
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
lamp OFF and operates the BTCS again.

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DTC Strategy • Internal monitoring
• When the calculated temperature of disc is higher
than predefined value(500°C).
If the calculated temperature drops below 300°C,
Enable Conditions the 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.
4. Connect scantool and select "Diagnostic Trouble Codes(DTCs)" mode
procedure.
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

procedure.
Brake System > ESC(Electronic Stability Control) System > C2380 ABS/TCS/ESC(ESP) valve error
General Description
The ABS HECU is composed of a ECU (Electronic Control Unit ) and an HCU( Hydraulic Control Unit), so the
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Page 211 of 222
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)

DTC Strategy • Internal monitoring
• 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

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4. Inspect operating status of all valves with Actuation Test.

Ex) Actuation Test on Front left valve(in)
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Page 213 of 222

or damage.
procedure.

procedure.
Brake System > ESC(Electronic Stability Control) System > C2402 Motor Failure
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.
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Case1
(Motor
• If the motor relay is switched ON and motor voltage
Relay
Enable <
Open
Conditions (IGN voltage – 4V±0.5V) continued for 49msec,
orMotor
the failure is detected.
Short to
GND)
• After motor relay is switched OFF, VMR is
measured.
Case2 If the time which VMR > 1±0.1V is less than
Enable
(Motor evaluation time, recheck is performed again for a
Conditions
Lock) maximum of three times.
When VMR is not normal even on the third recheck, • Open or short of power
the 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
Motor Conditions
1.8sec, 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
Fuse Conditions
for 1sec, the failure is detected.
Open)
• ABS/ESC functions are inhibited, EBD function is
activated.
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Page 215 of 222

4. Inspect operating status of Motor with Actuation Test.

Ex) Actuation Test on Motor
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or damage.
procedure.

2. Measure voltage between power(ABS1) terminal of the HECU harness connector and chassis ground.
Specification : B+

Check for open or blown 40A (ABS1) fuse referring to "Circuit Diagram".

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Page 217 of 222
procedure.
ground, and then go to "Verification of vehicle Repair" procedure.

maintain vehicle speed at or above 12kmh. (7.5mph)
procedure.
Brake System > ESC(Electronic Stability Control) System > Steering Angle Sensor > Description and
Operation
Description
The steering angle 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.
Operation
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.
Brake System > ESC(Electronic Stability Control) System > Steering Angle Sensor > Specifications
Specifications
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Item Specification
Operating Voltage 9V~16V
Operating
-30°C~75°C
temperature
Current
Max. 100mA
cousumption
Pulse duty 50±10%
Pulse width 8°/1pulse
Voltage(HIGH) 3.0V~4.1V
Voltage(LOW) 1.3V~2.0V
Steering angle
Max 1500°/sec
velocity
Brake System > ESC(Electronic Stability Control) System > Steering Angle Sensor > Schematic
Diagrams
Circuit Diagram
Brake System > ESC(Electronic Stability Control) System > Steering Angle Sensor > Repair
procedures
Output Characteristic
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Page 219 of 222
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 > ESC(Electronic Stability Control) System > Yaw-rate Sensor > Description and
Operation
Description
1. The yaw-rate & lateral G sensor is applied for the ESC system.
2. The yaw-rate is the angular velocity, when a vehicle turns a corner, and the lateral G is the acceleration to move a
vehicle out of the way when cornering.
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Brake System > ESC(Electronic Stability Control) System > Yaw-rate Sensor > Specifications
Specifications
Item Specification Remark
Operating voltage 8 ~ 17V
Current consumption Max 140mA
Output voltage range 0.5 ~4.5V
-40 ~ 85°C (-40
Operating temperature
~ 185°F)
Operating -75 ~ +75°/sec
Yaw-rate sensor Frequency
18~22Hz
response
-14.715 ~
Operating
14.715m/s
Lateral G. sensor
Frequency
50Hz±60%
response
Brake System > ESC(Electronic Stability Control) System > Yaw-rate Sensor > Repair procedures
Output Chracteristic
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Page 221 of 222
Brake System > ESC(Electronic Stability Control) System > Yaw-rate Sensor > Schematic Diagrams
External Diagram
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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.
2. Check the continuity between the switch terminals as the ESC OFF switch is engaged.
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Page 1 of 84
TUCSON(JM) > 2009 > G 2.7 DOHC > Driveshaft and axle
Driveshaft and axle > General Information > Specifications

Specifications
Specification
Items
Inner side Outer side
Front Joint type 2.0 GSL AT T.J B.J
driveshaft
2.0 GSL MT, 2.0 DSL AT T.J B.J
2.0 DSL MT D.O.J B.J
2.7 GSL AT S.F.J B.J
Max. permissible angle 2.0 GSL AT 23° 45.8°
2.0 GSL MT, 2.0 DSL AT 23° 46°
2.0 DSL MT 22° 46.5°
2.7 GSL AT 23° 46°
Rear driveshaft Joint type D.O.J B.J
Max. permissible angle 22° 45°
Differential Hypoid gear oil (GL-5,SAE
Oil type
80W/90)
Oil capacity L About 0.75 ~ 0.80
Reduction gear type Hypoid gear
Reduction gear ratio 3.091
0.10 ~ 0.15 (0.0039 ~
Final drive gear backlash mm(in.)
0.0059)
Differential gear backlash mm(in.) 0 ~ 0.076 (0 ~ 0.003)
B.J : Birfield Joint

D.O.J : Double Offset Joint
T.J : Tripot Joint
Tightening Torques
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Items N.m Kgf.cm lbf.ft
Front hub Wheel nut 90 ~ 110 900 ~ 1100 66.4 ~ 81.2
Driveshaft castle nut 200 ~ 280 2000 ~ 2800 147.5 ~ 206.6
Break caliper mounting bolt 50 ~ 60 500 ~ 600 36.9 ~ 44.3
Lower arm mounting bolt 100 ~ 120 1000 ~ 1200 73.8 ~ 88.5
Strut lower mounting bolt 140 ~ 160 1400 ~ 1600 103.3 ~ 118.0
Tie rod end ball joint mounting
45 ~ 60 450 ~ 600 33.2 ~ 44.3
nut
Rear Wheel nut 90 ~ 110 900 ~ 1100 66.4 ~ 81.2
Break caliper mounting bolt 50 ~ 60 500 ~ 600 36.9 ~ 44.3
Break disc mounting screw 5~6 50 ~ 60 3.7 ~ 4.4
Dust cover mounting bolt 50 ~ 60 500 ~ 600 36.9 ~ 44.3
Strut lower mounting nut 140 ~ 160 1400 ~ 1600 103.3 ~ 118.0
Trailing arm mounting bolt 100 ~ 120 1000 ~ 1200 73.8 ~ 88.5
Hub bearing flange nut[2WD] 200 ~ 260 2000 ~ 2600 147.5 ~ 191.8
Driveshaft castle nut[4WD] 200 ~ 280 2000 ~ 2800 147.5 ~ 206.6
Suspension arm mounting
160 ~ 180 1600 ~ 1800 118.0 ~ 132.8
nut[2WD]
Suspension arm mounting
140 ~ 160 1400 ~ 1600 103.3 ~ 118.0
nut[4WD]
Propeller shaft Front propeller shaft mounting
50 ~ 60 500 ~ 600 36.9 ~ 44.3
bolt
Propeller shaft center bearing
40 ~ 50 400 ~ 500 29.5 ~ 36.9
bracket mounting bolt
Rear propeller shaft mounting
100 ~ 120 1000 ~ 1200 73.8 ~ 88.5
bolt
Differential Rear differential mounting bolt 90 ~ 120 900 ~ 1200 66.4 ~ 88.5
Differential cover mounting bolt 40 ~ 50 400 ~ 500 29.5 ~ 36.9
Replace self-locking nuts with new ones after removal.
Lubricants
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Page 3 of 84
Items Recommended Quantity
BJ92 - TJ92 type driveshaft (For BETA AT)
BJ boot Centoplex 278M/136K 115 ± 6g
grease CASMOLY BJ Inside joint : 55 ± 3g
ROLLUBE BJ Inside boot : 60 ± 3g
Sunlight SW-2
TJ boot KLK TJ 41-182 120 ± 6g
grease CASMOLY TJ Inside joint : 75 ± 3g
ROLLUBE TJ Inside boot : 45 ± 3g
Oneluber MK
BJ95 - TJ95 type driveshaft (For BETA MT)
Sunlight SW-2
TJ boot KLK TJ 41-182 145 ± 6g
grease CASMOLY TJ Inside joint : 100 ± 3g
ROLLUBE TJ Inside boot : 45 ± 3g
Oneluber MK
BJ95 - SFJ95 type driveshaft (For DELTA AT)
BJ boot 278M/136K 120 ± 6g
Sunlight SW-2
SFJ boot 175 ± 6g
grease Inside joint : 120 ± 3g
-
Inside boot : 55 ± 3g
BJ87 - DOJ87 type driveshaft (For rear)

Sunlight SW-2
DOJ boot Amblygon TA10/2A 95 ± 6g
grease CASMOLY DOJ Inside joint : 60 ± 3g
DURALUBE DOJ Inside boot : 35 ± 3g
Variant SD-R2
Driveshaft and axle > General Information > Special Service Tools
Page 4 of 84
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
Trouble Symptom Probable cause
Vehicle pulls to one side Scoring of driveshaft ball joint
Wear, rattle or scoring of wheel
bearing
Defective front suspension and
steering
Vibartion Wear, damage or bending of
driveshaft
Driveshaft rattle and hub
serration
Wear, rattle or scratching of
wheel bearing
Shimmy Defective wheel balance
steering
Excessive noise Wear, damage or bending of
driveshaft
Rattle of driveshaft and worn hub
splines
Wear, rattle or scoring of wheel
bearing
Loose hub nut
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Page 5 of 84
steering
Driveshaft and axle > Front Axle Assembly > Front Hub - Axle > Components and Components
Location
Component Location
1. Disc 5. Lower arm

2. Caliper 6. Stabilizer bar
3. Knuckle 7. Stabilizer bar
4. Strut assembly link
8. Sub-frame
9. Tire
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Components
1. Disc 5. Snap ring

2. Hub 6. Dust ring
3. Hub bolt 7. Knuckle
4. Hub 8. Ball joint
bearing
Driveshaft and axle > Front Axle Assembly > Front Hub - Axle > Repair procedures
On-vehicle Inspection
Wheel Bearing Play Inspection
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Page 7 of 84
1. Inspect 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.
3. 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).
4. Remove the split pin(A), then remove castle nut(B) and washer(C) from the front hub under applying the break.
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5. Tighten the hub bearing nut by the following procedures.
A. Hub bearing nut must be fastened with a torque of 28kgf·m and front hub must be rotated 3 times as shown
below enough for secure placement of hub bearing.
B. Unfasten hub bearing nut until its tightening torque is 0kgf·m.
C. Hub bearing nut must be fastened again with torque 20kgf·m
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 split pin.
6. Check the hub for cracks and the splines for wear.
7. Check the brake disc for scoring and damage.
8. Check the knuckle for cracks.
9. Check the bearing for cracks or damage.
Removal
1. Loosen the wheel nuts slightly.
Raise the front of the vehicle, and make sure it is securely supported.
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Page 9 of 84
tire(A).
3. Remove the split pin(A), then remove castle nut(B) and washer(C) from the front hub while applying the brake.
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.
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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)
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7. Remove the lower arm ball joint mounting bolts(A).
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
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1. Install the hub and the knuckle assembly(B).
2. Install the strut lower mounting bolts(A).
Tightening torque
140 ~ 160Nm (1400 ~ 1600Kgfa·cm, 103.3 ~ 118lbf·ft)
3. Install the lower arm ball joint mounting bolts(A).
Tightening torque
100 ~ 120Nm (1000 ~ 1200Kgf·cm, 73.8 ~ 88.5lbf·ft)
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Page 13 of 84
4. Install the tie rod end ball joint(C) to the knuckle.
Tightening torque
45 ~ 60Nm (450 ~ 600Kgf·cm, 33.2 ~ 44.3lbf·ft)
A. Install the castle nut(B).

B. Install the split pin(A).
5. Install the wheel speed sensor(A).
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6. Install the brake caliper(B), and then tighten the mounting bolts(A).
Tightening torque
50 ~ 60Nm (500 ~ 600Kgf·cm, 36.9 ~ 44.3lbf·ft)
7. Install the washer(C), castle nut(B) and split pin(A) to the front hub.
Tightening torque
200 ~ 280Nm (2000 ~ 2800Kgf·cm, 147.5 ~ 206.6lbf·ft)
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Page 15 of 84
8. Install the front wheel and tire(A) on the front hub(B).
Tightening torque
90 ~ 110Nm (900 ~ 1100Kgf·cm, 66.4 ~ 81.2lbf·ft)
Be careful not to damage the hub bolts(C) then install the front wheel and tire(A).
9. Check the alignment. (Refer to SSgroup 'Tires/Wheels - alingment')
Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Components and Components
Location
Component Location
Page 16 of 84
1. Driveshaft (LH) 3. Transaxle

2. Circlip 4. Driveshaft
(RH)
Front Driveshaft (DOJ-BJTYPE)

Components
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Page 17 of 84
1. Split pin 5. BJ assembly 9. Dynamic damper band 12. DOJ boot big part
2. Castle nut 6. TPE boot 10. Dynamic damper band
3. Washer 7. BJ boot big part band 11. DOJ boot small part 13. DOJ boot
4. Dust cover & Tone 8. BJ boot small part band band 14. Snap ring
wheel 15. Circlip
16. DOJ assembly
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1. Split pin 5. BJ assembly 9. Dynamic damper band 12. DOJ boot big part
2. Castle nut 6. TPE boot 10. Dynamic damper band
3. Washer 7. BJ boot big part band 11. DOJ boot small part 13. DOJ boot
4. Dust cover & Tone 8. BJ boot small part band band 14. Snap ring
wheel 15. Circlip
16. DOJ assembly
Front Driveshaft (TJ-BJTYPE)

Components
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Page 19 of 84
1. Split pin 5. Clip A 9. Dynamic 13. Trunion

2. Castle nut 6. BJ boot band damper assembly
3. Washer 7. BJ boot 10. Shaft 14. Circlip
4. BJ assembly 8. Dynamic damper 11. TJ boot band 15. TJ assembly
band 12. TJ boot
Page 20 of 84
1. Split pin 5. Clip A 9. Dynamic damper 13. Trunion

2. Castle nut 6. BJ boot band 10. Shaft assembly
3. Washer 7. BJ boot 11. TJ boot band 14. Circlip
4. BJ assembly 8. Dynamic damper 12. TJ boot 15. TJ assembly
band
Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Repair procedures
Removal
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Page 21 of 84
tire(A).
3. Remove the split pin(A), then remove castle nut(B) and washer(C) from the front hub while applying the brake.
4. Remove the wheel speed sensor(B) from the knuckle(A).

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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)
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Page 23 of 84
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 or it may cause components inside the BJ or TJ(or DOJ)
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.
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.
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4. Check the dynamic damper for cracks, wear and position.
5. Check the driveshaft for cracks and wear.

Inspection (DOJ-BJ)
1. Check the DOJ. outer race, inner race, cage and ballsfor rust or damage.
2. Check splines for wear.
3. Check for water, foreign matter, or rust in the BJ. boot.
When the BJ. assembly(A) is to be reused, do notwipe away the grease. Check that there are noforeign
substances in the grease. If necessary, clean the BJ. assembly(A) and replace grease.
Installation
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Page 25 of 84
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 BJ. Into the knuckle.
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5. Install the lower arm mounting bolts(A).
Tightening torque
100 ~ 120Nm (1000 ~ 1200Kgf·cm, 73.8 ~ 88.5lbf·ft)
6. After installing the washer(B) with convex surface outward, install the castle nut(A) and the split pin(C).
Tightening torque
200 ~ 280Nm (2000 ~ 2800Kgf·cm, 147.5 ~ 206.6lbf·ft)
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Page 27 of 84
Tightening torque
90 ~ 110Nm (900 ~ 1100Kgf·cm, 66.4 ~ 81.2lbf·ft)
Be careful not to damage the hub bolts(C) then install the front wheel and tire(A).
Disassembly (DOJ-BJ)
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.
1. Remove the DOJ. boot bands and pull the DOJ. boot from the DOJ. outer race.
A. Using a plier or flat-tipped (-) screwdriver, remove the LH boot band and LH DOJ. boot band from the
driveshaft.
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B. Remove RH boot band and RH DOJ. boot band.
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 DOJ. outer race.

4. Remove the snap ring(A) and take out the inner race(B), cage(C) and balls(D) as an assembly.
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Page 29 of 84
5. Clean the inner race, cage and balls without disassembling.
Remove the BJ. boot bands and pull out the DOJ. 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).
Disassembly (TJ-BJ)
Driveshaft (RH)
• Do not disassemble the BJ. assembly.

1. Remove the circlip(B) from driveshaft splines(A) of the transaxle side TJ. case.
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2. Remove both boot clamps from the transaxle side TJ. case.
A. Using a plier or flat-tipped (-) screwdriver, remove both clamps(TJ. boot band(B), boot band(A)) of the
transaxle side.
3. Pull out the boot from the transaxle side joint(TJ).

4. While dividing joint(TJ) boot(A) of the transaxle side, wipe the grease in TJ. case(B) and collect them
respectively.
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Page 31 of 84
• Be careful not to damage the boot.

• According to the illustration below, put marks(D) on roller of trunion assembly(A), TJ. case(B) and
spline part(C), for providing assembly.
5. Using a plier or flat-tipped (-)screwdriver, remove the circlip(A).

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6. Remove the trunion assembly(B) from the driveshaft(A) using the special tool(09495-33000).
7. Clean the trunion assembly.

8. Remove the boot(A) of the transaxle side joint(TJ).
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).
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Page 33 of 84
10. Fix the driveshaft(A) with a vice(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.
12. Separate the dynamic damper(A) from the shaft(B) carefully.
13. Using a plier or flat-tipped (-) screwdriver, remove the clamp on the side of the wheel.
14. Pull out the joint(BJ) on the side of wheel in the transaxle direction.
Be carefull not to damage the boot.
Page 34 of 84
Reassembly (DOJ-BJ)
1. Wrap tape around the driveshaft splines (DOJ. side ) to prevent damage to the boots.
2. Apply grease to the driveshaft and install the boots. (See page DS - 4)
3. To install the dynamic damper, keep the BJ. and driveshaft in a straight line and secure the dynamic damper with
the dynamic damper band.
Standard value mm(in.) : 515(+2, 0), 20.3(+0.079,-0)
4. 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.
5. Apply the specified grease to the cage and fit the balls into the cage.
[email protected]
Page 35 of 84
6. Position the chamfered side(A) as shown in the illustration. Install the inner race on the driveshaft(B), and then the
snap ring.
7. Apply the specified grease to the outer race and install the BJ. outer race onto the driveshaft. (See page DS - 4)
8. Apply the specified grease into the DOJ. boot and install the boot with a clip. (See page DS - 4)
9. Tighten the DOJ. boot bands.
10. Add the specified grease to the BJ. as much as wiped away at inspection.
11. Install the boots.
12. Tighten the BJ. boot bands.
13. To control the air in the DOJ. boot, keep the specified distance between the boot bands when they are
tightened.
Reassembly (TJ-BJ)
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. (See page DS - 4)
3. Install the clamps to both boots.
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4. To reassemble the dynamic damper(A), keeping the shaft(B) straight, tighten the dynamic damper(A) with
dynamic band(C), as illustrated.
5. Install the TJ. boot bands and TJ. 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) with each other.
7. Add the specified grease to the TJ. as much as wiped away at inspection.
9. Tighten the TJ. boot bands.
10. To control the air in the T.J. boot, keep the specified distance between the boot bands when they are tightened.
Driveshaft and axle > Rear Axle Assembly > Rear Hub - Carrier > Components and Components
Location [email protected]
Page 37 of 84
Component Location
1. Disc brake 5. Strut assembly

2. Trailing arm 6. Cross member
3. Axle carrier 7. Stabilizer bar
4. Suspension 8. Tire
arm
Components
Page 38 of 84
1. Disc 6. Hub bolt

2. Hub cap 7. Dust cover
3. Castle nut mounting bolt
4. Washer 8. Rear parking brake
5. Hub assembly
9. Axle carrier
10. Bushing
Driveshaft and axle > Rear Axle Assembly > Rear Hub - Carrier > Repair procedures
On-Vehicle Inspection
Wheel Bearing Play Inspection
[email protected]
Page 39 of 84
1. Inspect the play of the bearing while the vehicle is jacked up.
2. If there is any play, loosen the wheel nuts slightly. Raise the rear of the vehicle, and make sure it is securely
supported.
3. 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 split pin(A), then remove castle nut(B) and washer(C) from the rear hub while applying the brake.
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5. Tighten the hub bearing nut by the following procedures.
A. Hub bearing nut must be fastened with torque 28kgf·m and rear hub must be rotated 3 times enough to secure
placement of hub bearing.
B. Unfasten hub bearing nut until its tightening torque is 0Kgf·m
C. Hub bearing nut must be fastened again with torque of 20Kgf·m
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 split pin.
6. Check the hub bearing for wear or damage.

7. Check the rotor for chipped teeth.
8. Check the carrier for cracks.
Removal
Raise the rear of the vehicle, and make sure it is securely supported.
[email protected]
Page 41 of 84
tire(A).
4. Remove the wheel speed sensor(B) from the axle carrier(A).

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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).
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Page 43 of 84
8. Remove the rear hub washer(A) and rear hub assembly(B).
• Be careful not to disassemble the rear hub assembly.

(For vehicles equipped with ABS.)
• Care must be taken not to scratch or damage the teeth of the rotor.
• 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.
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9. Loosen the rear dust cover mounting bolts(A) and then remove the rear parking brake assembly(B).
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
[email protected]
Page 45 of 84
1. Install the rear axle carrier(A).
A. Install the strut mounting nuts(D).
Tightening torque
140 ~ 160Nm (1400 ~ 1600Kgf·cm, 103.3 ~ 118.0lbf·ft)
B. Install the suspension arm mounting nut(C).
Tightening torque
160 ~ 180Nm (1600 ~ 1800Kgf·cm, 118.0 ~ 132.8lbf·ft)
C. Install the trailing arm mounting bolt(B).
Tightening torque
100 ~ 120Nm (1000 ~ 1200Kgf·cm, 73.8 ~ 88.5lbf·ft)
Replace the self-locking nut with new ones after removal.

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2. Install the rear dust cover(B) and then tighten the mounting bolts(A).
Tightening torque
50 ~ 60Nm (500 ~ 600Kgf·cm, 36.9 ~ 44.3lbf·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 ~ 260Nm (2000 ~ 2600Kgf·cm, 147.5 ~ 191.8lbf·ft)
Page 47 of 84
Replace the flange nut with new ones after removal.

5. Install the hub cap(A).
Replace the hub cap with new ones after

removal.
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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 ~ 0.06in.)
7. Install the brake disc(C) from the hub(B), then tighten the brake disc mounting screw(A).
Tightening torque
5 ~ 6Nm (50 ~ 60, 3.7 ~ 4.4lbf·ft)
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8. Install the brake caliper(B), then tighten the mounting bolt(A).
Tightening torque
50 ~ 60Nm (500 ~ 600Kgf·cm, 36.9 ~ 44.3lbf·ft)
9. Install the rear wheel and tire(A) on the rear hub(B).
Tightening torque
90 ~ 110Nm (900 ~ 1100kgf·cm, 66.4 ~ 81.2lbf·ft)
Be careful not to damage the hub bolts(C) then install the rear wheel and tire(A).
Driveshaft and axle > Rear Axle Assembly > Rear Hub - Axle > Components and Components
Location
Component Location
Page 50 of 84
1. Disc brake 5. Strut assembly

2. Trailing arm 6. Drive shaft
3. Axle carrier 7. Stabilizer bar
4. Suspension 8. Tire
arm
Driveshaft and axle > Rear Axle Assembly > Rear Hub - Axle > Repair procedures
Removal
Page 51 of 84
tire(A).
Page 52 of 84
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).
Inspection
1. Check the hub bearing for wear or damage.
2. Check the carrier for cracks.
INSTALLATION
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1. Install the rear axle assembly(A).
A. Install the strut mounting nuts(D).
Tightening torque
140 ~ 160Nm (1400 ~ 1600Kgf·cm, 103.3 ~ 118lbf·ft)
B. Install the suspension arm mounting nuts(C).
Tightening torque
140 ~ 160Nm (1400 ~ 1600Kgf·cm, 103.3 ~ 118lbf·ft)
C. Install the trailing arm mounting bolt(B).
Tightening torque
100 ~ 120Nm (1000 ~ 1200Kgf·cm, 73.8 ~ 88.5lbf·ft)
2. Install the brake caliper(B), then tighten the mounting bolt(A).
Tightening torque
50 ~ 60Nm (500 ~ 600Kgf·cm, 36.9 ~ 44.3lbf·ft)
Page 54 of 84
3. Install the washer(C), castle nut(B) and split pin(A) from the rear hub.
Tightening torque
200 ~ 280Nm (2000 ~ 2800Kgf·cm, 147.5 ~ 206.6lbf·ft)
4. Install the wheel speed sensor(B) from the axle carrier(A).
Tightening torque
90 ~ 110Nm (900 ~ 1100Kgf·cm, 66.4 ~ 81.2lbf·ft)
Page 55 of 84
Driveshaft and axle > Rear Driveshaft Assembly > Rear Driveshaft > Components and Components
Location
Rear Driveshaft (DOJ-BJ Type)
Component Location
Page 56 of 84
1. Disc brake 5. Driveshaft

assembly 6. Suspension
2. Trailing arm 7. Stabilizer bar
3. Axle carrier 8. Cross member
4. Strut assembly 9. Tire
Components
Page 57 of 84
1. Split pin 8. Boot small part band

2. Castle nut 9. Shaft
3. Washer 10. DOJ boot big part band
4. Dust cover & Tone 11. DOJ boot
wheel 12. Snap ring
5. BJ assembly 13. Circlip
6. BJ boot 14. DOJ assembly
7. BJ boot big part band
Driveshaft and axle > Rear Driveshaft Assembly > Rear Driveshaft > Repair procedures
Removal
Page 58 of 84
tire(A).
Page 59 of 84
5. Remove the trailing arm mounting bolt(B) from the knuckle(A).
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.
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• 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 or it may cause components inside the BJ or DOJ 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.
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.
4. Check the dynamic damper for cracks, wear and position.
5. Check the driveshaft for cracks and wears.

Inspection (DOJ-BJ)
1. Check the DOJ. outer race, inner race, cage and balls for rust or damage.
2. Check splines for wear.
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3. Check for water, foreign matter, or rust in the BJ. boot.
When the BJ. assembly(A) is to be reused, do not wipe away the grease. Check that there are no foreign
substances in the grease. If necessary, clean the BJ. assembly(A) and replace grease.
Disassembly
Driveshaft (RH)
• Do not disassemble the BJ assembly.

1. Remove the DOJ. boot bands and pull the DOJ. boot from the DOJ. outer race.
A. Using a plier or flat-tipped (-) screwdriver, remove the LH boot band and LH DOJ. boot band from the
driveshaft
B. Remove RH boot band and RH DOJ. 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).

Page 62 of 84
3. Pull out the driveshaft from the DOJ. 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 DOJ. 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).
Reassembly
1. Wrap tape around the driveshaft splines (DOJ. side ) to prevent damage to the boots.
2. Apply grease to the driveshaft and install the boots.
Page 63 of 84
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 DOJ. boot and install the boot with a clip. (See page DS - 4)
8. Tighten the DOJ. boot bands.
9. Add the specified grease to the BJ. as much as wiped away at inspection.
11. Tighten the BJ. boot bands.
12. To control the air in the DOJ. boot, keep the specified distance between the boot bands when they are
tightened.
Installation
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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.
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 ~ 160Nm (1400 ~ 1600Kgf·cm, 103.8 ~ 118lbf·ft)
Trailing arm mounting bolt(B)
100 ~ 120Nm (1000 ~ 1200Kgf·cm, 73.8 ~ 88.5lbf·ft)
Page 65 of 84
6. Install the washer(C), castle nut(B) and split pin(A) from the rear hub.
Tightening torque
200 ~ 280Nm (2000 ~ 2800Kgf·cm, 147.5 ~ 206.6lbf·ft)
7. Install the wheel speed sensor(B) from the knuckle(A).
Tightening torque
90 ~ 110Nm (900 ~ 1100Kgf·cm, 66.4 ~ 81.2lbf·ft)
Page 66 of 84
Driveshaft and axle > Propeller Shaft Assembly > Propeller Shaft > Components and Components
Location
Component Location
Page 67 of 84
Components
Page 68 of 84
1. Flange yoke 6. Spring washer 11. Companion 16. Rubber coupling

2. Universal joint 7. VL joint flange 17. Bolt
assembly 8. Sealing 12. Center bearing
3. Front tube 9. Nut 13. Rear tube
4. Snap ring(VL) 10. Spring washer 14. Plain washer
5. LJ boot 15. Center device
Driveshaft and axle > Propeller Shaft Assembly > Propeller Shaft > Repair procedures
Inspection
Vj Joint And Boots
1. Shift the transmission to Neutral.
Page 69 of 84
2. Raise the vehicle off the ground, and support it with safety stands in the proper locations.
3. Check the center support bearing for excessive play or rattle and rubber for dent. If the center support has
excessive play or rattle and rubber has dent, replace the propeller shaft assembly.
4. Check the VJ joint boots for damage and deterioration. If the boots are damaged or deteriorated. replace the
propeller shaft assembly.
5. Check the VJ 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. Repeat this procedure for the other propeller shaft.
Front Propeller Shaft Runout : 0.3mm (0.012in.)
Rear Propeller Shaft Runout : 0.3mm (0.012in.)

Page 70 of 84
3. If the runout on either propeller shaft exceeds the service limit, replace the propeller shaft assembly.
Removal
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).

Page 71 of 84
3. After making a match mark(C) on the flange yoke(A) and transaxle companion(B), remove the propeller shaft
mounting bolts(D).
Installation
Installation is the reverse of the removal procedures
Install according to match mark of transaxle companion (or rear differential companion) and propeller shaft.
Items N.m Kgf.cm lbf.ft
Front propeller shaft mounting
50 ~ 60 500 ~ 600 36.9 ~ 44.3
bolt
Center bearing bracket
40 ~ 50 400 ~ 500 29.5 ~ 36.9
mounting bolt
Rear propeller shaft mounting
100 ~ 120 1000 ~ 1200 73.8 ~ 88.5
bolt
Disassembly
Center bearing disassembly
1. After marking the alignment point on front or rear, loosen 6EA bolts on the C.V. Joint(A).
- The alignment point assembles in the direction to marked reassemble.

- It is to minimize the change of balance.
Page 72 of 84
2. After fixing the pipe on the circle vise, loosen the nut by using impact(A) (26mm).
- When you fix the pipe, you should use the circle vise or cleat.
- It is to prevent the crush of pipe.
3. Disassemble the key pliers as shown in the illustration.

Disassemble the flange(A) by using a tool.
Page 73 of 84
4. After disassembling by using the key pliers, disassemble the flange(A).
- Before disassembling flange, mark the alignment point.

- It is to assemble with alignment, when you reassemble flange.
5. If center bearing do not fall, lightly hit the center bearing as shown in the illustration. Then, center bearing(A) is
disassembly.
- When you hit strongly, appear the abrasion in the shape of the screw thread.
6. Installation is the reverse order of removal.

Universal joint disassembly
Page 74 of 84
1. After marking alignment point on flange yoke and tube yoke, disassemble snap ring(B) on tube yoke.
- The alignment point assembles in the direction on marked reassemble.

- It is to minimize the change of balance.
2. Disassemble the case(A) by using hammer as shown in the illustration.
Do not hit too strongly with hammer.

Page 75 of 84
3. Disassemble snap ring(A) on the yoke.
4. Disassemble the case(A) by using hammer as shown in the illustration.
- Do not hit too strongly with hammer.
5. Installation is the reverse order of removal.
Driveshaft and axle > Differential Carrier Assembly > Rear Differential Carrier > Components and
Components Location
Components
Page 76 of 84
1. Differential carrier 7. Inner pinion bearing 13. Differential 19. Differential cover
2. Pinion locking nut 8. Inner bearing adjust 14. Cam side gear mountin bolts
3. Oil seal guide shim 15. Pinion gear 20. Breather
4. Pinion oil seal 9. Driver gear 16. Thrust washer 21. Filler plug
5. Outer pinion bearing 10. Oil seal 17. Differential pinion
6. Pinion bearing spacer 11. Differential side shaft
bearing 18. Differential cover
12. Ring gear
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 - 53)
Page 77 of 84
3. Remove the propeller shaft. (See page DS - 63)
4. Support the differential assembly(B) with the jack(A).
5. Disconnect the coupling control connector(A).
6. After loosening the differential mounting bolts(A), remove the differential(B).

Page 78 of 84
7. After loosening the cover bolts(A), remove the differential cover(B).
Inspection
Install the differential carrier assembly(A) with the special tools(09517-43401 & 09517-43500).
Then carry out the following inspection.
Page 79 of 84
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 ~ 0.076mm (0 ~ 0.003in.)
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 : 0.05mm (0.002in.)
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 80 of 84
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 81 of 84
B. Insert a brass rod between the differential carrier and the differential case, and then rotate the drive gear 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 25~30Nm) 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 82 of 84
• 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.
Installation
1. After applying liquid gasket, install the differential cover(B), and install the mounting bolts(A).
Tightening torque
40 ~ 50Nm (400 ~ 500Kgf·cm, 29.5 ~ 36.9lbf·ft)
Page 83 of 84
2. After installing the differential(B), install the mounting bolts(A).
Tightening torque
90 ~ 120Nm (900 ~ 1200Kgf·cm, 66.4 ~ 88.5lbf·ft)
3. Using the transaxle jack(B), install the differential assembly(A).
4. Connect the coupling control connector(A).
5. Install the propeller shaft. (Refer to Propeller Shaft Assembly)

6. Install the rear drive shaft. (Refoer to Rear Driveshaft)
Page 84 of 84
7. Fill the gear oil.
Specified lubricant
Hypoid gear oil (GL-5, SAE 80W/90)
Oil quantity : Fill the reservoir to the plug hole
(About 0.75 ~ 0.80L)

Page 1 of 57
TUCSON(JM) > 2009 > 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 provides the following functions :
BATTERY TEST PROCEDURE

Page 2 of 57
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 displayed 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.
• CCA : Cold cranking amps, is an SAE specification for cranking batteries at -18°C (0°F).
• CCP : Cold cranking amps, is an SAE specification for korean manufacturer's for cranking batteries at
-18°C (0°F).
Page 3 of 57
4. Set the CCA value displayed 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) displayed 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.
The battery ratings (CCA) displayed on the tester must be identical to the ratings marked on battery label.
6. To conduct starter test, continuously, press ENTER.

BATTERY TEST RESULTS
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RESULT ON PRINTER REMEDY
Good battery No action is required
Battery is in a good state
Good recharge
Recharge the battery and use
Battery is not charged properly
Charge & Retest => Charge and test the battery again (Failure to charge
the battery fully may read incorrect measurement value)
=> Replace battery and recheck the charging system.
(Improper connection between battery and vehicle
cables may cause "REPLACE BATTERY", retest the
Replace battery
battery after removing cables and connecting the tester
to the battery terminal directly prior to replacing the
battery)
=> Charge and retest the battery. And then, test results
Bad cell-replace may cause "REPLACE BATTERY", replace battery
and recheck the charging system
Whenever filing a claim for battery, the print out of the battery test results must be attached.
STARTER TEST PROCEDURE
1. After the battery test, press ENTER immediately for the starter test.
2. After pressing ENTER key, start the engine.

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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.
CHARGING SYSTEM TEST PROCEDURE

1. Press ENTER to begin charging system test.
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2. 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 by pressing the accelerator pedal.
4. Press ENTER.
5. The MICRO 570 analyzer charging system output at idle for comparison to other readings.
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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 ripple normal Charging system is 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
Low charging voltage load to 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

TROUBLE SHOOTING
IGNITION SYSTEM
Symptom Suspect area Remedy
Engine will not start Ignition lock switch Inspect ignition lock switch, or replace as required
or is hard to start Ignition coil Inspect ignition coil, or replace as required
(Cranks OK) Spark plugs Inspect spark plugs, or replace as required
Ignition wiring disconnected or broken Repair wiring, or replace as required
Rough idle or stalls Ignition wiring Repair wiring, or replace as required
Ignition coil Inspect ignition coil, or replace as required
Engine hesitates/poor Spark plugs and spark plug cables Inspect spark plugs / cable, or replace as required
acceleration Ignition wiring Repair wiring, or replace as required
Poor mileage Spark plugs and spark plug cables Inspect spark plugs / cable, or replace as required
CHARGING SYSTEM
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Charging warning Fuse blown
Check fuses
indicator does not Light burned out
Replace light
light with ignition Wiring connection loose
Tighten loose connection
switch "ON" and Electronic voltage regulator
Replace voltage regulator
engine off.
Charging warning Drive belt loose or worn
Adjust belt tension or replace belt
indicator does not go Battery cable loose, corroded or worn
Inspect cable connection, repair or replace
out with engine Electronic voltage regulator or alternator
cable
running. (Battery Wiring
Replace voltage regulator or alternator
requires frequent
Repair or replace wiring
recharging)
Overcharge Electronic voltage regulator Replace voltage regulator
Voltage sensing wire Repair or replace wiring
Discharge Drive belt loose or worn Adjust belt tension or replace belt
Wiring connection loose or short circuit Inspect wiring connection, repair or replace
Electronic voltage regulator or alternator wiring
Poor grounding Replace voltage regulator or alternator
Worn battery Inspect ground or repair
Replace battery
STARTING SYSTEM
Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or worn out Repair or replace cables
Transaxle range switch (Vehicle with automatic Refer to TR group-automatic transaxle
transaxle only) Replace fuse
Fuse blown Replace
Starter motor faulty Replace
Ignition switch faulty
Engine cranks slowly Battery charge low Charge or replace battery
Battery cables loose, corroded or worn out Repair or replace cables
Starter motor faulty Replace
Starter keeps running Starter motor Replace
Ignition switch Replace
Starter spins but Short in wiring Repair wiring
engine will not crank Pinion gear teeth broken or starter motor Replace
Ring gear teeth broken Replace fly wheel or torque converter
Engine Electrical System > General Information > Specifications

SPECIFICATION
IGNITION SYSTEM
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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
CHAMPION - RC10PYPB4
Gap 1.0 mm ~ 1.1 mm
STARTING SYSTEM
Specifications
Item
2.7 2.0
Reduction drive (with
Type
planetary 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, 2,800rpm,
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
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Specifications
Item
2.7 2.0
Type Internal
Rated voltage 13.5V, 120A 13.5V, 90A
Speed 1,000 ~ 18,000 rpm
Alternator Voltage regulator Electronic built-in type

Regulator setting
14.55 ± 0.2V 14.55 ± 0.2V
voltage
Temperrature
-3.5 ± 1mV/°C -7 ± 3mV/°C
compensation
Type 56-26FL 48-23FL
Cold cranking
amperage at-18°C 600A 550A
Battery (0°F)
Reserve capacity 113min 92min
Specific gravity at
1.280 ± 0.01 1.280 ± 0.01
20°C (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.
- RESERVE 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)
TIGHTENING TORQUES
Items Nm kgf.m lb-ft
Alternator terminal
(B+) 5~7 0.5 ~ 0.7 3.6 ~ 5.1
Starter motor terminal 10 ~ 12 1.0 ~ 1.2 7.3 ~ 8.8
(B+) 4~6 0.4 ~ 0.6 2.9 ~ 4.3
Battery terminal 20 ~ 30 2.0 ~ 3.0 15 ~ 22
Spark plug
Engine Electrical System > Ignition System > Description and Operation
DESCRIPTION
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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.
2.7
1. Remove the engine cover.
2. Disconnect the VIS actuator connectors and injector connectors.
3. Remove the accelerator cable.
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4. Remove surge tank sub assembly.
5. Remove the spark plug cable.

6. Remvoe the spark plug.
7. Inspect the electrodes and ceramic insulator.
INSPECTION OF ELECTRODES
CONDITION DARK DEPOSITS WHITE DEPOSITS
• Fuel mixture too

lean
• Fuel mixture too
DESCRIPTION • Advanced ignition
rich
timing
• Low air intake
• Insufficient plug
tightening
1. Check the electrode gap(A).
Standard (New)
1.0~1.1 mm (0.039~0.043 in.) - Unleaded
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2. 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.
3. Connect the ohmmeter probes and measure resistance.
RESISTANCE : 5.6KΩ/m ± 20%
4. Resistance should not be higher than 10KΩ per meter of cable.

If resistance is higher, replace the cable.
INSPECT IGNITION COIL
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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)
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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.
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).
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Engine Electrical System > Charging System > Description and Operation
DESCRIPTION
GASOLINE
The charging system included a battery, an alternator with a built-in regulator, the charging indicator light, and wiring.
The alternator has six built-in diodes (three positive and three negtive), each rectifying AC current to DC current.
Therefore, DC curent appears at alternator "B" terminal.
In addition, the charging voltage of this alternator is regulated by the battery voltage detection system.
The main components of the alternator are the rotor, stator, rectifier, capacitor brushes, bearings and V-ribbed belt
pulley. The brush holder contains a built-in electronicvoltage regulator.
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Engine Electrical System > Charging System > Repair procedures

ON-VEHICLE INSPECTION
• 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 TERMINALS, FUSIBLE LINK AND FUSES
1. Check that the battery terminals are not loose or corroded.
2. Check the fusible link and fuses for continuity.
INSPECT DRIVE BELT
1. Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.
Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it
should be replaced.
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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.
- "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 lt.
4. Start the engine. Check that the light goes off.
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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.
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.
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 connectthe (-) 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.
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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
groundingis 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 andread 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
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.
50% of the rate voltage
• 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
to 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.
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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
voltmeterto 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.
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
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.
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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
(2.0)
Page 24 of 57
(2.7)
Engine Electrical System > Charging System > Alternator > Repair procedures
REPLACEMENT
1. Disconnect the battery negative terminal first, then the positive terminal.
Page 25 of 57
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).
Page 26 of 57

6. Adjust the alternator belt tension after installation.
DISASSEMBLY
(2.0)
1. Remove the rear cover(A).
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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).

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4. Unsolder between rectifier(A) and brush holder(B).
5. Remove the rear bracket(A).

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6. Remove the nut(A), pulley(B) and spacer(C)..
7. Disconnect the stator(A), rotor(B) and front bracket(C).

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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.
(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).
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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
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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 alternator.
ALTERNATOR BELT INSPECTION AND ADJUSTMENT
When using a new belt, first adjust the deflection or tension to the values for the new belt, then readjust the
deflection or tension to the values for the used belt after running engine for five minutes.
Deflection method :
Apply a force of 98N (10 kgf, 22 lbf), and measure the deflection between the alternator and crankshaft pulley.
Deflection
Used Belt : 5.0 ~ 6.0 mm (0.20 ~ 0.23 in)
New Belt : 4.0 ~ 5.0 mm (0.16 ~ 0.20 in)
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If the belt is worn or damaged, replace it.
Belt tension gauge method :

Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions.
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).
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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
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
Page 35 of 57
2. LOAD TEST
1. Perform the following steps to complete the load test procedure for maintenance free batteries.
Page 36 of 57
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 greater than shown in the table, the battery is good.
- If the voltage is less 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.
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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.
Page 38 of 57
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.
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 (see page EE-23).
7. Check the starter relay (see page EE-69).
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 S terminal and the M terminal.
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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 connect a fully-charged 12-volt battery to starter
motor as follows :
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat as shown in the illustration.
3. Connect a voltmeter (15-volt scale) across the 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 57
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. 2,800 rpm
Engine Electrical System > Starting System > Starter > Components and Components Location
COMPONENTS
GASOLINE
Page 41 of 57
Engine Electrical System > Starting System > Starter > Repair procedures
INSPECTION
ARMATURE INSPECTION AND TEST
1. Remove the starter (see page EE-57).
2. Disassemble the starter as shown at the beginning of this procedure.
Page 42 of 57
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 57
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 if it does not slide smoothly.
Page 44 of 57
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
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 57
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 57
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 57
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.
Page 48 of 57
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.
2. Remove the starter relay(A).
3. Inspect the relay continuity.

A. Using an ohmmeter, check that there is continuity between terminals 2 and 4.
If there is no continuity, replace the relay.
B. Check that there is no continuity between terminals 1 and 5.
If there is continuity, replace the relay.
Page 49 of 57
4. Inspect the relay operation.
A. Apply battery positive voltage across terminals 2 and 4.
B. Using an ohmmeter, check that there is continuity between terminals 1 and 5.
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 50 of 57
Engine Electrical System > Cruise Control System > Components and Components Location
COMPONENTS LOCATION
Page 51 of 57
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 52 of 57
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.
Page 53 of 57
2. Remove the brake switch(B).
3. Check for continuity between the terminals according to the table.
4. If necessary, replace the switch or adjust the switch.
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.)
Page 54 of 57
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 55 of 57
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).
Page 56 of 57
2. Disconnect the cover, actuator cable and connector.
3. Loosen the three mounting bolts(E), and remove the actuator(F) with the bracket.

CRUISE REMOCON SWITCH REPLACEMENT
1. Disconnect the battery negative cable, then 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).
Page 57 of 57
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 112
TUCSON(JM) > 2009 > 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) 44°
Closes (ATDC) 8
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.)
Page 2 of 112
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.)
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.)
21.9kg/34mm
Load 21kg/35mm (48.4lb/1.3780in.)
(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
Page 3 of 112
Compression ring type
No.1 Inner bevel type
No.2 Taper 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
2,450 ~ 12,225N
Piston pin installation force 0.4mm (0.016in.)
(250 ~ 1,250kg, 551 ~ 2,755lb)
Side clearance (big end) 0.10 ~ 0.25mm (0.0039 ~ 0.0098in.)
005mm or less/100mm
Bend
(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.)
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.)
When replacing a short
Oil quantity(Total) 4.8L(5.07US qt, 4.22lmp qt)
engine or a block assembly
When replacing an oil pan
Oil quantity(Oil pan) 4.2L(4.44US qt, 3.70lmp qt)
only
Oil quantity
4.5L(4.76US qt, 3.96lmp qt)
(Drain and refill including oil filter)
Oil quality Above API SJ/SL or SAE 5W-20
Oil pump
Page 4 of 112
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
50kPa (7.3psi) or more
Engine oil pressure [Conditions : Oil temperature is 75 to 90°C
(167 to 194°F)]
Engine coolant cooling, forced circulation
Cooling method
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
107.9 ± 14.7kPa
Main valve opening pressure
(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 5 of 112
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 Torques
Item Nm kgf.m lb-ft
Camshaft sprocket bolt 90 ~ 110 9.0 ~ 11.0 65 ~ 85
Cylinder head cover bolt 8 ~ 10 0.8 ~ 1.0 5.8 ~ 7.2
Main bearing cap bolt

19.5~24 +
M10 27~33 + (90°~94°) 2.7~3.3 + (90°~95°)
(90°~94°)
M8 13~19 + (90°~94°) 1.3~1.9 + (90°~95°)
10~14 + (90°~94°)
Connecting rod bolt 16~20 + (90°~94°) 1.6~2.0 + (90°~94°) 12~15 + (90°~94°)
23~27 + (58°~62°) 2.3~2.7 + (58°~62°) 17~20 + (58°~62°)
Cylinder head bolt(Cold engine)
+ (43°~47°) + (43°~47°) + (43°~47°)
Oil pan drain plug 35 ~ 45 3.5 ~ 4.5 25 ~ 33
Lower oil pan bolt 10 ~ 12 1.0 ~ 1.2 7~9
Upper oil pan bolt
[10 × 38mm (0.937 × 1.4961in.)] 30 ~ 42 3.0 ~ 4.2 22 ~ 30
[8 × 22mm (0.3150 × 0.8661in.)] 19 ~ 28 1.9 ~ 2.8 14 ~ 20
[161.5mm (6.3582in.)] 5~7 0.5 ~ 0.7 4~5
[152.5mm (6.0039in.)] 5~7 0.5 ~ 0.7 4~5
Oil screen bolt 15 ~ 22 1.5 ~ 2.2 11 ~ 16
Oil pump case bolt 12 ~ 15 1.2 ~ 1.5 9 ~ 11
Oil relief valve plug 40 ~ 50 4.0 ~ 5.0 29 ~ 36
Oil pressure switch 15 ~ 22 1.5 ~ 2.2 11 ~ 16
Oil pressure cover screw 8 ~ 12 0.8 ~ 1.2 6~9
Oil filter 12 ~ 16 1.2 ~ 1.6 9 ~ 12
Drive plate and adapte 73 ~ 77 7.3 ~ 7.7 53 ~ 56
Air cleaner body installation bolt 8 ~ 12 0.8 ~ 1.2 6~9
Surge tank stay 15 ~ 20 1.5 ~ 2.0 11 ~ 14
Air intake surge tank to intake manifold(bolt) 15 ~ 20 1.5 ~ 2.0 11 ~ 14
Air intake surge tank to intake manifold(nut) 15 ~ 20 1.5 ~ 2.0 11 ~ 14
Intake manifold to cylinder head 19 ~ 21 1.9 ~ 2.1 14 ~ 15
Heat protector exhaust manifold 17 ~ 22 1.7 ~ 2.2 12 ~ 16
Page 6 of 112
Exhaust manifold to cylinder head
30 ~ 35 3.0 ~ 3.5 22 ~ 26
(Self-locking nut)
Oil level gauge guide to engine 12 ~ 15 1.2 ~ 1.5 9 ~ 11
Water outlet fitting bolt 17 ~ 20 1.7 ~ 2.0 12 ~ 14
Power steering oil pump bracket to cylinder
17 ~ 26 1.7 ~ 2.6 12 ~ 19
head
Crank position sensor wheel screw 5~6 0.5 ~ 0.6 3.6 ~ 4.3
Engine mounting insulator bolt 50 ~ 65 5.0 ~ 6.5 36 ~ 47
Engine mounting bracket nut 60 ~ 80 6.0 ~ 8.0 43 ~ 58
Engine mounting bracket bolt 60 ~ 80 6.0 ~ 8.0 43 ~ 58
Engine support bracket bolt 60 ~ 70 6.0 ~ 7.0 43 ~ 51
Front roll stopper bracket sub frame bolt 50 ~ 65 5.0 ~ 6.5 36 ~ 47
Front roll stopper insulator bolt and nut 50 ~ 65 5.0 ~ 6.5 36 ~ 47
Rear roll stopper bracket to sub frame 50 ~ 65 5.0 ~ 6.5 36 ~ 47
Rear roll stopper insulator bolt and nut 50 ~ 65 5.0 ~ 6.5 36 ~ 47
Transaxle mounting bracket bolt 50 ~ 65 5.0 ~ 6.5 36 ~ 47
Transaxle mounting insulator bolt 90 ~ 110 9.0 ~ 11.0 65 ~ 80
Fuel hose clamp to rear cylinder head
12 ~ 15 1.2 ~ 1.5 9 ~ 11
assembly
Transaxle mounting plate 10 ~ 12 1.0 ~ 1.2 7~9
Rear plate 10 ~ 12 1.0 ~ 1.2 7~9
Oil seal case 10 ~ 12 1.0 ~ 1.2 7~9
Crankshaft pulley bolt 180 ~ 190 18 ~ 19 130 ~ 138
Timing belt cover bolt 10 ~ 12 10.0 ~ 12 7~9
Engine hanger bracket to engine 20 ~ 27 2.0 ~ 2.7 14 ~ 20
Alternator mounting bracket to engine 20 ~ 30 2.0 ~ 3.0 14 ~ 22
Alternator mounting nut (Engine front case
20 ~ 30 2.0 ~ 3.0 14 ~ 22
side)
Alternator mounting bolt (Alternator
20 ~ 30 2.0 ~ 3.0 14 ~ 22
mounting bracket side)
Starter to transmission(nut) 20 ~ 30 2.0 ~ 3.0 14 ~ 22
Starter to transmission(bolt) 27 ~ 34 2.7 ~ 3.4 20 ~ 25
Drive belt pulley bolt 35 ~ 55 3.5 ~ 5.5 25 ~ 40
Drive belt tensioner bolt 20 ~ 27 2.0 ~ 2.7 14 ~ 20
Engine coolant pump to cylinder block bolt
15 ~ 22 1.5 ~ 2.2 11 ~ 16
(Head mark "7" mark)
Engine coolant temperature sensor 20 ~ 40 2.0 ~ 4.0 14 ~ 29
Engine coolant inlet fitting attaching bolt 17 ~ 20 1.7 ~ 2.0 12 ~ 14
Page 7 of 112
Throttle body to surge tank bolt 15 ~ 20 1.5 ~ 2.0 11 ~ 14
Oxygen sensor to exhaust manifold 40 ~ 50 4.0 ~ 5.0 29 ~ 36
Front exhaust pipe to exhaust manifold nut 30 ~ 40 3.0 ~ 4.0 22 ~ 29
Front exhaust pipe to catalytic converter bolt 40 ~ 60 4.0 ~ 6.0 29 ~ 43
Catalytic converter to center exhaust pipe
40 ~ 60 4.0 ~ 6.0 29 ~ 43
nut
Center exhaust pipe to main muffler nut 40 ~ 60 4.0 ~ 6.0 29 ~ 43
Main muffler hanger support bracket bolt 10 ~ 15 1.0 ~ 1.5 7 ~ 11
Delivery pipe installation bolt 10 ~ 15 1.0 ~ 1.5 7 ~ 11
Timing belt tensioner pulley bolt 43 ~ 55 4.3 ~ 5.5 31 ~ 40
Timing belt idler puley bolt 50 ~ 60 5.0 ~ 6.0 36 ~ 43
Timing blelt tensioner arm fixed bolt 35 ~ 55 3.5 ~ 5.5 25 ~ 40
Auto tensioner fixed bolt 20 ~ 27 2.0 ~ 2.7 14 ~ 20
Accelerator cable bracket 4~6 0.4 ~ 0.6 3~4
Spark plug 20 ~ 30 2.0 ~ 3.0 14 ~ 22
Compression Pressure
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. (Refer to Ignition system in EE Group)
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 8 of 112
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. (Refer to Ignition system in EE Group)
6. Install ignition coils. (Refer to Ignition system in EE Group)
Engine Mechanical System > General Information > Troubleshooting

Troubleshooting
Symption Suspect area Remedy
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
Page 9 of 112
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.
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 clearance Inspect the following components and repair
as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
• The crankshaft journal.
Page 10 of 112
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.
• 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 > General Information > Special Service Tools
Page 11 of 112
Crankshaft front oil seal Installation of the front oil seal
installer
(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 & Removal and installation of the intake or

adaptor exhaust valve
(09222-28000, 09222-
28100)
Crankshaft rear oil seal 1. Installation of the engine rear oil seal
installer 2. Installation of the crankshaft rear oil seal
(09231-33000)
Torque angle adapter Installation of bolts & nunts needing an

(09221-4A000) angular method.
Engine Mechanical System > Engine And Transaxle Assembly > Repair procedures
Removal
Page 12 of 112
• 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.
1. Remove the air duct(A).
2. Disconnect the negative terminal from the battery.
3. Drain the engine coolant.

Remove the radiator cap to speed draining.

Page 13 of 112
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).
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).
(3) PCSV(Purge Control Solenoid Valve) connector(C).
(4) VIS actuator connector(D).
(5) Injector connector(E).
(6) Knock sensor connector(F).
Page 14 of 112
(7) CMP(Camshaft Position Sensor) connector(G).
(8) ECT(Engine Coolant Temperature) sensor(A) connector.

(9) Ignition coil connector(B).
(10) Crankshaft position sensor connector(C).
(11) Rear oxygen sensor connector(D).
(12) Three fuel injector connectors(A).

Page 15 of 112
(13) Disconnect ground cable(A) from the cowl panel.
(14) Intake air temperature sensor connector(A).

(15) VIS actuator connector(B).
9. Disconnect front heated oxygen sensor(LH) connector(A), air compressor switch connector(B) and oil pressure
sensor connector(C).
10. Disconnect rear heated oxygen sensor(RH) connector.

11. Remove the fuel inlet from delivery pipe(A).
12. Remove the PCSV hose.

Page 16 of 112
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.
15. Remove the power steering pump hose(A).

Page 17 of 112
16. Remove the battery body bracket.
17. 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).
Page 18 of 112
18. Remove the control cable(A) transaxle range switch.
19. Remove the transaxle oil cooler hoses(A/T)(A).
20. Remove the under cover(A).
21. Remove the front exhaust pipe(A).
22. Remove the front tires.

23. Disconnect the stabilizer bar link and remove the mounting bolts from the lower arm the front axles.
Page 19 of 112
24. Remove the steering u-joint mounting bolt(A). (Refer to Steering system in ST Group)
25. Install the jack for supporting engine and transaxle assembly.
26. Remove the engine mounting bracket(A).
27. Remove the transaxle mounting bracket(A).

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28. Remove the sub frame mounting bolts and nuts.
Tightening torque
A : 160 ~ 180Nm (16.0 ~ 18.0kgf.m, 118 ~ 133lb-ft)
B : 70 ~ 90Nm (7.0 ~ 9.0kgf.m, 52 ~ 66lb-ft)
29. Jack up the vehicle.
Installation
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.
• Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent
corrosion.
Page 21 of 112
• 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 > Timing System > Timing Belt > Components and Components Location
Components
1. Tensioner pulley 4. Timing belt lower cover 7. Engine support bracket

2. Idler pulley 5. Crankshaft pulley 8. Timing belt
3. Auto tensioner 6. Drive belt idler pulley 9. Timing belt upper cover
Page 22 of 112
Engine Mechanical System > Timing System > Timing Belt > Repair procedures
Removal
Engine removal is not required for this procedure.
2. Remove RH front wheel.
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).
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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. (Refer to Power steering pump in ST Group)
8. Remove the 7bolts(B) and timing belt upper cover(A).
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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°).
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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.

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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.
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.
Installation
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 ~ 110Nm (9.0 ~ 11.0kgf.m, 65 ~ 80lb-ft)
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3. Install the idler pulley(B) and the tensioner pulley(A).
Tightening torque
Idler pulley bolt
50 ~ 60Nm (5.0 ~ 6.0kgf.m, 36 ~ 43lb-ft)
Tensioner arm fixed bolt
35 ~ 55Nm (3.5 ~ 5.5kgf.m, 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 and its compression stroke.
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 pass a set pin through the holes to keep the setting position of the
push rod.
(3) Release the press.
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6. Install the timing belt tensioner.
(1) Temporarily install the tensioner with the 2bolts.
(2) Alternately tighten the 2bolts.
Tightening torque
20 ~ 27Nm (2.0 ~ 2.7kgf.m, 14 ~ 20lb-ft)
7. Install the timing belt.

(1) Remove any oil or water on the sprockets, and keep them clean.
(2) Install the tming 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).
8. Remove the set pin(A) from the tensioner.

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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 ~ 70Nm (6.0 ~ 7.0kgf.m, 43 ~ 51lb-ft)
C : 15 ~ 22Nm (1.5 ~ 2.2kgf.m, 11 ~ 16lb-ft)
11. Install the timing belt lower cover(A) with 4bolts(B).
Tightening torque
Timing belt cover bolt
10 ~ 12Nm (1.0 ~1.2kgf.m, 7 ~ 9lb-ft)
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12. Install the drive belt idler pulley(A).
Tightening torque
Idler pulley bolt
35 ~ 55Nm (3.5 ~ 5.5kgf.m, 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 ~ 190Nm (18.0 ~ 19.0kgf.m, 130 ~ 138lb-ft)
14. Install the timing belt upper cover(A) with 7bolts(B).
15. Install the power steering pump. (Refer to Power steering pump in ST Group)
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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 ~ 80Nm (6.0 ~ 8.0kgf.m, 44 ~ 59lb-ft)
18. Install RH side cover(A) with 2bolts(B).
19. Install RH front wheel.

20. Install engine cover.
Engine Mechanical System > Cylinder Head Assembly > Components and Components Location
Components
Page 32 of 112
1. Cylinder head cover 4. Cylinder head

2. Gasket gasket
3. Cylinder head 5. Cylinder block
Page 33 of 112
1. Camshaft sprocket 6. Oil seal 11. Valve spring retainer

2. Cylinder head 7. Valve 12. Valve stem seal
3. Camshaft 8. Valve seat 13. Valve spring
4. Camshaft bearing cap 9. HLA 14. Valve spring seat
5. Timing chain 10. Valve spring retainer lock 15. Valve guide
Engine Mechanical System > Cylinder Head Assembly > Repair procedures
Removal
• 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.
Page 34 of 112
• 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.
1. Remove the air duct(A).
2. Disconnect the negative terminal from the battery.

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).
Page 35 of 112
6. Remove the upper radiator hose(A) and lower radiator hose(B).
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 connectors(F).
(7) CMP(Camshaft Position Sensor) connector(G).
(8) ECT(Engine Coolant Temperature) sensor connector(A).

Page 36 of 112
(11) Oxygen sensor connector(D).
(13) Disconnect ground cable(A) from the cowl panel.
(14) IAT(Intake Air Temperature) sensor connector(A).

Page 37 of 112
9. Remove the fuel inlet hose(A) from delivery pipe.
10. Remove the PCSV hose.

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.
13. Remove the PCV hose(A).
14. Remove the intake manifold.

15. Remove the power steering pump. (Refer to Power steering pump in ST Group).
16. Remove the exhaust manifold.
17. Remove the timing belt.
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18. Remove the spark plug cable. (Refer to Ignition system in EE Group)
19. Remove the cylinder head covers(A).
20. Remove the camshaft sprocket.

21. Remove the camshaft bearing caps(A).
Page 39 of 112
22. Remove the camshafts(A).
23. Remove the timing belt rear cover(A).
24. Remove the water temperature control assembly(A) and water pipe.
Page 40 of 112
25. 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 41 of 112
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
Size mark Oversize valve guide hole size mm(in.)
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.
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).
Page 42 of 112
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.
(5) Using needle-nose pliers, remove the oil seal.
(6) Using a magnetic finger, remove the spring seat.
Inspection
Cleaning
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
Page 43 of 112
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 : 0.05 mm ( 0.0020 in.)
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.

Page 44 of 112
(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.
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.
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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 46 of 112
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.
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 47 of 112
cylinder head as a set.
(7) Completely remove the plastigage.
(8) Remove the camshafts.
5. Inspect camshaft end play.
(1) Install the camshafts.
(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.
(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.
Page 48 of 112
(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.
2. Install HLAs.
Check that the HLA rotates smoothly by hand.
Installation
Page 49 of 112
• 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.
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
23~27Nm (2.3~2.7kgf.m, 17~20lb-ft) + (58°~62°) + (43°~47°)
(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 several passes and in the
sequence shown, then repeat for the other side, as shown.
If only one of the cylinder head bolts dose not meet the torque specification, replace the cylinder head bolt.
Page 50 of 112
Tightening torque :
23~27Nm (2.3~2.7kgf.m, 17~20lb-ft) + (58°~62°) + (43°~47°)
(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 ~ 20Nm (1.5 ~ 2.0kgf.m, 11 ~ 14lb-ft)
5. Install the timing belt rear cover(A).
Tightening torque
Timing belt rear cover
10 ~ 12Nm (1.0 ~ 1.2kgf.m, 7 ~ 9lb-ft)
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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 ~ 12Nm (1.0 ~ 1.2kgf.m, 7 ~ 9lb-ft)
M6(50mm) : 14 ~ 16Nm (1.4 ~ 1.6kgf.m, 10 ~ 12lb-ft)
• 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.
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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 ~ 110Nm (9.0 ~ 11.0kgf.m, 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.
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(3) Install the cylinder head covers(A) with the 16bolts. Uniformly tighten the bolts in several passes.
Tightening torque
8 ~ 10Nm (0.8 ~ 1.0kgf.m, 6 ~ 7.4lb-ft)
11. Install the spark plug cable. (Refer to Ignition system in EE Group)
13. Install the exhaust manifold.
14. Install the power steering pump. (Refer to Power steering pump in ST Group)
15. Install the intake manifold.
16. Install the PCV hose(A).
Page 54 of 112
17. Install the accelerator cable.
18. Install the brake booster vacuum hose(A).
19. Install the PCSV hose.

20. Install the fuel inlet hose(A).
21. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
(2) IAT(Intake Air Temperature) sensor connector(A).
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(3) Connect the ground cable(A) to the cowl panel.
(5) Oxygen sensor connector(D).

(8) ECT sensor connector(A).
(9) CMP(Camshaft position sensor) connector(G).

(10) Knock sensor connector(F).
(14) ISA connector(B).
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(15) TPS connector(A).
22. Install the heater hoses(A).
23. Install the upper radiator hose(A) and lower radiator hose(B).
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).
Page 57 of 112
25. Install the engine cover.
26. Connect the negative terminal to the battery.
27. Install the air duct(A).
28. Filll with engine coolant.

29. Start the engine and check for leaks.
30. Recheck engine coolant level and oil level.
Engine Mechanical System > Cylinder Block > Components and Components Location
Components
Page 58 of 112
1. Cylinder block 5. Piston ring 8. Connecting rod

2. Upper oil pan 6. Piston 9. Connecting rod bearing
3. Oil pressure switch 7. Piston pin 10. Bearing cap
4. Lower oil pan
Page 59 of 112
1. Cylinder block 4. Main bearing 7. Bearing cap bridge

2. Crankshaft posotion sensor wheel 5. Thrust bearing 8. Oil seal
3. Crankshaft 6. Main bearing cap 9. Oil seal case
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.
4. Remove cylinder head.
5. Remove oil level gauge assembly.
6. Remove the alternator. (Refer to in EE Group).
7. Remove the air conditioner compressor. (Refer to in HA Group)
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8. Remove the power steering pump bracket(A).
9. Remove water pump.

10. Remove knock sensors(A).
11. Remove the lower oil pan(A).

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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.

15. Remove the connecting rod caps and check oil clearance.
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.

18. Remove oil seal case.
Remove the 3bolts(B) and oil seal case(A).
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19. Check the crankshaft end play.
20. Remove crankshaft bearing cap and check oil clearance.
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.
Inspection
Connecting Rod And Crankshaft
Page 63 of 112
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 ~ 20Nm (1.6 ~ 2.0kgf.m, 12 ~ 15lb-ft) + 90°
Do not turn the crankshaft.
(7) Remove the 2bolts, connecting rod cap and bearing half.
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(8) Measure the plastigage at its widest point.
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 65 of 112
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 66 of 112
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 Classification
Crankshaft Indentification Mark
Identification Mark Of 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 ~ 19Nm (1.3 ~ 1.9kgf.m, 10 ~ 14lb-ft) + (90°~95°)
M10 :
27 ~ 33Nm (2.7 ~ 3.3kgf.m, 19.5 ~ 24lb-ft) + (90°~95°)
Do not turn the crankshaft.

Page 67 of 112
(5) Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance

0.004 ~ 0.022mm (0.00016 ~ 0.00087in.)
(6) 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.
(7) 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 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 68 of 112
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
Discrimination Of Crankshaft
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 69 of 112
Discrimination Of Crankshaft Bearing

Class Mark Thickness Of 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
Crankshaft Bore Assembling Classification Of
Crankshaft Identification 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 70 of 112
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

1.925 ~ 1.965mm (0.076 ~ 0.077in.)
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
1. Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
Page 71 of 112
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
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

Standard : Less than 0.03mm(0.0012 in.)
Limit : 0.05 mm ( 0.0020 in.)
4. Inspect cylinder bore diameter

Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder liner.
5. Inspect cylinder bore diameter
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 72 of 112
6. Check the cylinder bore size code(A) on the cylinder block bottom face.
Size
Class Cylinder bore inner diameter
code
86.70 ~ 86.71mm
A A
(3.4133 ~ 3.4137in.)
86.71 ~ 86.72mm
B B
(3.4137 ~ 3.4141in.)
86.72 ~ 86.73mm
C C
(3.4141 ~ 3.4145in.)
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
86.68 ~ 86.69mm
A A
(3.4126 ~ 3.4130in.)
86.69 ~ 86.70mm
B None
(3.4130 ~ 3.4133in.)
86.70 ~ 86.71mm
C C
(3.4133 ~ 3.4137in.)
Page 73 of 112
8. Select the piston related to cylinder bore class.
Clearance : 0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)
Boring Cylinder
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.

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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 75 of 112
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. If the bore is over the service limit, the cylinder block must be rebored.
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.)
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2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance

0.011 ~ 0.018mm (0.00043 ~ 0.00071in.)
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) 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.
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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.
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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.
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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 ~ 19Nm (1.3 ~ 1.9kgf.m, 10 ~ 14lb-ft) + (90°~ 95°)
M10 :
27 ~ 33Nm (2.7 ~ 3.3kgf.m, 19.5 ~ 24lb-ft) + (90°~ 95°)
(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 ~ 19Nm (1.3 ~ 1.9kgf.m, 10 ~ 14lb-ft)
M10(B) : 27 ~ 33Nm (2.7 ~ 3.3kgf.m, 19.5 ~ 24lb-ft)
Page 80 of 112
(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.
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 ~ 20Nm (1.6 ~ 2.0kgf.m, 12 ~ 15lb-ft) + 90° ~ 94°
Maintain downward force on the ring compressor to prevent the rings from expanding before entering
the cylinder bore.
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11. Apply liquid gasket to the oil seal case and install the oil seal case(A).
Tightening torque
10 ~ 12Nm (1.0 ~ 1.2kgf.m, 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.

Page 82 of 112
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 liquid gasket.
(2) Install the oil pan(A) with the 17bolts.

Uniformly tighten the bolts in several passes.
Tightening torque
19 ~ 28Nm (1.9 ~ 2.8kgf.m, 14 ~ 20lb-ft) : (1 ~ 15)
5 ~ 7Nm (0.5 ~ 0.7kgf.m, 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.
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15. Install oil screen.
Install a new gasket and oil screen(A) with 2bolts(B).
Tightening torque
15 ~ 22Nm (1.5 ~ 2.2kgf.m, 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 ~12Nm (1.0 ~ 1.2kgf.m, 7.3 ~ 8.8lb-ft)
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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 ~ 22Nm (1.5 ~ 2.2kgf.m, 11 ~ 16lb-ft)
18. Install knock sensor(A).
Tightening torque
17 ~ 26Nm (1.7 ~ 2.6kgf.m, 12.5 ~ 19lb-ft)
19. Install water pump.

Page 85 of 112
20. Install the power steering pump bracket(A).
Tightening torque
35 ~ 55Nm (3.5 ~ 5.5kgf.m, 25.8 ~ 40.6lb-ft)
21. Install the air conditioner compressor. (Refer to HA Group)

22. Install the alternator. (Refer to EE Group)
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 ~ 15Nm (1.2 ~ 1.5kgf.m, 9 ~ 11lb-ft)
24. Install cylinder head.

25. Install timing belt.
26. Remove engine stand.
27. Install drive plate.
Tightening torque
73 ~ 77Nm (7.3 ~ 7.7kgf.m, 53 ~ 56lb-ft)
Engine Mechanical System > Cooling System > Components and Components Location
Components
Page 86 of 112
1. Cylinder block 5. O-ring 8. Water inlet pipe

2. Water pump 6. Engine coolant sensor 9. Thermostat
3. Water pump gasket 7. Gasket 10. Water outlet pipe
4. Water pipe
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.
Page 87 of 112
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.
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 slowly through the radiator cap. Gently squeeze 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 coolant to circulates.

When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.
8. Repeat 7 until the cooling fan 3 ~ 5times and bleed air sufficiently out of the cooling 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 allow coolant to cool.
12. Repeat steps 6 to 11 until the coolant level stays constant and all air is bleed out of the cooling system.
Recheck the coolant level in the reservoir tank for 2 ~ 3 days after replacing coolant.
Cap Testing
Page 88 of 112
1. Remove the radiator cap, wet its seal with engine coolant, then install it on the 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 > Repair procedures

Removal
Water Pump
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.
3. Remove the timing belt.
4. Remove the timing belt idler.
Page 89 of 112
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).
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
Page 90 of 112
1. Immerse the thermostat in water and gradually heat the water.
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 : 10mm(0.4in.) or more at 95°C (205°F)
If the valve lift is not as specified, replace the thermostat.
Installation
Water Pump
1. Install the water pump(A) and a new gasket(B) with the 8bolts.
Tightening torque
15 ~ 22Nm (1.5 ~ 2.2kgf.m, 11 ~ 16lb-ft)
Page 91 of 112
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.

4. Install drive belt.
5. Fill with engine coolant.
6. Start engine and check for leaks.
7. Recheck engine coolant level.
Thermostat
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 ~ 20Nm (1.7 ~ 2.0kgf.m, 12.5 ~ 14lb-ft)
3. Install the lower hose.

4. Fill with engine coolant.
Engine Mechanical System > Lubrication System > Components and Components Location
Components
Page 92 of 112
1. Cylinder block 6. Relief plunger 10. Oil screen

2. Outer rotor 7. Relief spring 11. Upper oil pan
3. Oil pump cover 8. Plug 12. Oil pressure switch
4. Inner rotor 9. Gasket 13. Lower oil pan
5. Crankshaft sprocket
Engine Mechanical System > Lubrication System > Description and Operation
Engine Oil And Filter Replacement
Page 93 of 112
• 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 filler 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.
3. Refill with engine oil filter.
A. Clean and install the oil drain plug with a new gasket.
Tightening torque
35 ~ 45Nm (3.5 ~ 4.5kgf.m, 26 ~ 33lb-ft)
B. Fill with fresh engine oil
Capacity
Total : 4.8L (5.07 US qts, 4.22 lmp qts)
Oil pan : 4.2 L (4.44 US qts, 3.70 lmp qts)
Drain and refill including oil filter :
4.5 L (4.76 US qts, 3.96 lmp qts)
Oil quality : Above API SJ/SL or SAE 5W-20
C. Install the oil filler cap.

4. Start engine and check for oil leaks.
5. Recheck engine oil level.
Page 94 of 112
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 :
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.
Page 95 of 112
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.
5. Remove the alternator from engine. (Refer to Alternator in EE group.)
6. Remove the drive belt.
7. Turn the crankshaft and align the white groove on the crankshaft pulley with the pointer on the lower cover.
8. Remove the timing belt. (Refer to Timing system in this group.)
9. Remove the lower oil pan(A).
• Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the
direction of arrow.
• After tapping the SST with a plastic hammer along the direction of arrow around more than 2/3 edge
of the oil pan, remove it from the ladder frame.
• Do not turn over the SST abruptly without tapping. It is result in damage of the SST.
10. Remove oil screen.

Remove the 2bolts(B), oil screen(A) and gasket.
Page 96 of 112
11. Remove the upper oil pan(A).
12. 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.
Disassembly
Page 97 of 112
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.
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.
Page 98 of 112
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
1. Install relief plunger.
Install relief plunger(C) and spring(B) into the front case hole, and install the plug(A).
Tightening torque
40 ~ 50Nm (4.0 ~ 5.0kgf.m, 30 ~ 37lb-ft)
Installation
Page 99 of 112
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 ~ 12Nm (0.8 ~ 1.2kgf.m, 6 ~ 8.8lb-ft)
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.
Page 100 of 112
(5) Install the oil pump with 5bolts.
Tightening torque
12 ~ 15Nm (1.2 ~ 1.5kgf.m, 8.8 ~ 11lb-ft)
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.
Page 101 of 112
6. 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 liquid gasket.
(2) Install the oil pan(A) with the 17bolts.

Tightening torque
18.6 ~ 23.5Nm (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft) : (1 ~ 15)
4.9 ~ 6.9Nm (0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lb-ft) : (16,17)
• 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 112
7. Install oil screen.
Install a new gasket and oil screen(A) with 2bolts(B).
Tightening torque
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
8. 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.
A. To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
B. 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.
C. After assembly, wait at least 30 minutes before filling the engine with oil.
(2) Install the lower oil pan 10bolts.
Uniformly tighten the bolts serveral passes
Tightening torque
9.8 ~11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
9. Install the timing belt. (Refer to Timing system in this group.)

10. Install the drive belt
11. Install the alternator. (Refer to Alternator in EE group.)
12. Install the front exhaust pipe.
13. Install the RH front wheel.
14. Fill engine with oil.
16. Recheck engine oil level.
Page 103 of 112
Engine Mechanical System > Intake And Exhaust System > Intake Manifold > Components and
Components Location
Components
1. Surge tank assembly

2. Intake manifold
Engine Mechanical System > Intake And Exhaust System > Intake Manifold > Repair procedures
Removal
2. Remove air cleaner hose.
3. Remove surge tank assembly.
Page 104 of 112
(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).
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(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 106 of 112
(14) Remove the surge tank assembly(A).
Remove the injector assembly(A).
4. Remove the intake manifold(A) and gasket.
Installation
Page 107 of 112
1. Install the intake manifold and gasket.
Tightening torque
19 ~ 21Nm (1.9 ~ 2.1kgf.m, 14 ~ 15lb-ft)
2. Install the injector assembly. (Refer to Injector in FL Group)

3. Install the surge tank assembly(A).
(1) Install the surge tank assembly.
Tightening torque
15 ~ 20Nm (1.5 ~ 2.0kgf.m, 11 ~ 15lb-ft)
(2) Install the surge tank stay.
Tightening torque
15 ~ 20Nm (1.5 ~ 2.0kgf.m, 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 108 of 112
(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.
Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold > Components and
Components Location
Components
1. Heat 3. Gasket
protector
2. Exhaust
manifold
Page 109 of 112
Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold > Repair procedures
Removal
1. Remove the under cover(A).
2. Remove the front exhaust pipe(A).
3. Disconnect the oxygen sensor connector.

4. Remove the heat protector(A).
Page 110 of 112
5. Remove the exhaust manifold(A) and gasket(B).
Installation
1. Install the exhaust manifold(A) and gasket(B).
Tightening torque
30 ~ 35Nm (3.0 ~ 3.5kgf.m, 22 ~ 26lb-ft)
Page 111 of 112
2. Install the heat protector(A).
Tightening torque
17 ~ 22Nm (1.7 ~ 2.2kgf.m, 12 ~ 16lb-ft)
3. Connect the oxygen sensor connector.

4. Install the front exhaust pipe(A).
Tightening torque
30 ~ 40Nm (3.0 ~ 4.0kgf.m, 22 ~ 30lb-ft)
5. Install the under cover(A).
Engine Mechanical System > Intake And Exhaust System > Front Exhaust Pipe > Components and
Components Location
Components
Page 112 of 112
1. Front muffler 3. Center

2. Gasket muffler
4. Rubber
hanger
Page 1 of 670
TUCSON(JM) > 2009 > G 2.7 DOHC > Fuel System
Fuel System > General Information > Specifications

Specifications
Fuel Delivery System
Items Specification
Fuel Tank Capacity 65 L (17.7 U.S.gal., 14.32 Imp.gal.)
Fuel Retrun System Type Returnless
High pressure type (built in Fuel Pump
Fuel Filter Type
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
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
-20°C(-4°F) 14.13 ~ 16.83 kΩ
0°C(32°F) 5.79 kΩ
20°C(68°F) 2.31 ~ 2.59 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) Type Zirconia Sensor (including Heater)
Page 2 of 670
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
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 (at
CLOSE
20°C)
14.9 ~ 16.1 Ω (at
OPEN
20°C)
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
Service Standard
A/C OFF 700±100 rpm
Basic Idle rpm (After warm up)
A/C ON 750±100 rpm
Ignition Timing(After warm up, at idle) BTDC 12°±5°
Page 3 of 670
Tightening Torques
Engine Control System
Items N.m kgf.m lb-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 bolt 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Crankshaft position sensor connector bracket
19.6 ~ 21.6 2.0 ~ 2.2 14.5 ~ 15.9
installation bolt
Crankshaft position sensor wheel installation screw 4.9 ~ 5.9 0.5 ~ 0.6 3.6 ~ 4.3
Knock sensor installation bolt 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
Knock sensor connector bracket installation bolt 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Engine coolant temperature sensor installation 19.6 ~ 39.2 2.0 ~ 4.0 14.5 ~ 28.9
Heated Oxygen Sensor (Bank 1, Sensor 1) 39.2 ~ 49.1 4.0 ~ 5.0 28.9 ~ 36.2
Camshaft position sensor connector bracket installation
3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
bolt
Oil pressure switch installation 14.7 ~ 21.6 1.5 ~ 2.2 10.9 ~ 15.9
Intake air temperature sensor installation 19.6 ~ 29.4 2.0 ~ 3.0 14.5 ~ 21.7
Throttle position sensor installation screws 1.0 ~ 2.5 0.15 ~ 0.25 0.7 ~ 1.8
Idle speed control actuator installation bolts 5.9 ~ 7.8 0.6 ~ 0.8 4.3 ~ 5.8
Fuel Delivery System

Items N.m kgf.m lb-ft
9.8 ~ 7.2 ~
Delivery pipe installation bolts 1.0 ~ 1.5
14.7 10.9
14.7 ~ 10.9 ~
Throttle body installation bolt/nut 1.5 ~ 2.0
19.6 14.5
Fuel tank mounting bolt 44.1 ~ 4.5 ~ 6.0 32.5 ~
58.8 43.4
Fuel System > General Information > Special Service Tools

Page 4 of 670
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 Adapter fuel feed line
09353-24000 Connection between Fuel Pressure Gauge

Fuel Pressure Gauge Connector (09353-24100) and Fuel Pressure Gauge
Adapter (09353-38000)
Fuel System > General Information > Troubleshooting

Basic Troubleshooting
Basic Troubleshooting Guide
Page 5 of 670
Customer Problem Analysis Sheet

Page 6 of 670
Basic Inspection Procedure

Measuring Condition of Electronic Parts' Resistance
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 stated otherwise.
The measured resistance in except for ambient temperature (20°C, 68°F) is reference value.
Intermittent Problem Inspection Procedure
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again
Page 7 of 670
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, the 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 source.
• DO NOT heat components to the point where they may be damaged.

• DO NOT heat the ECM directly.
● Simulating Water Sprinkling

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, rear window defogger,
etc.).
Page 8 of 670
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.
D. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire
harness side.
Page 9 of 670
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.
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.
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6. If the covering of wire harness is damaged; secure, repair or replace the harness.
Electrical Circuit Inspection Procedure
● Check Open Circuit
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 side to side.
Specification (Resistance)
1Ω or less → Normal Circuit
1MΩ or Higher → Open Circuit
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.
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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).
● Check Short Circuit

1. 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 Step 2
(Continuity Check Method with Chassis Ground) as shown below.
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2. Continuity Check Method (with Chassis Ground)
Lightly shake the wire harness above and below, or from side to side when measuring the 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 following step.
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)
Unable to start 1. Test the battery • DTC
(Incomplete 2. Check the fuel pressure • Low compression
combustion) 3. Check the ignition circuit • Intake air leaks
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4. Troubleshooting the immobilizer system • Slipped or broken
(In case of immobilizer lamp flashing) timing belt
• Contaminated fuel
Difficult to start 1. Test the battery • DTC
2. Check the fuel pressure • Low compression
3. Check the ECT sensor and circuit (Check DTC) • Intake air leaks
4. Check the ignition circuit • Contaminated fuel
• Weak ignition spark
Poor idling 1. Check the fuel pressure
(Rough, unstable or 2. Check the Injector • DTC
incorrect Idle) 3. Check the long term fuel trim and short term fuel trim • Low compression
(Refer to CUSTOMER DATASTREAM) • Intake air leaks
4. Check the idle speed control circuit (Check DTC) • Contaminated fuel
5. Inspect and test the Throttle Body • Weak ignition spark
6. Check the ECT sensor and circuit (Check DTC)
Engine stall 1. Test the Battery
• DTC
2. Check the fuel pressure
• Intake air leaks
3. Check the idle speed control circuit (Check DTC)
• Contaminated fuel
4. Check the ignition circuit
• Weak ignition spark
5. Check the CKPS Circuit (Check DTC)
Poor driving 1. Check the fuel pressure
(Surge) 2. Inspect and test Throttle Body • DTC
3. Check the ignition circuit • Low compression
4. Check the ECT Sensor and Circuit (Check DTC) • Intake air leaks
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)
Knocking 1. Check the fuel pressure
2. Inspect the engine coolant • DTC
3. Inspect the radiator and the electric cooling fan • Contaminated fuel
4. Check the spark plugs
Poor fuel economy 1. Check customer's driving habitsIs
· A/C on full time or the defroster mode on?
· Are tires at correct pressure? • DTC
· Is excessively heavy load being carried? • Low compression
· 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
Hard to refuel 1. Test the canister close valve
(Overflow during 2. Inspect the fuel filler hose/pipe
refueling) · Pinched, kinked or blocked?
· Filler hose is torn
Page 14 of 670
(Overflow during 2. Inspect the fuel filler hose/pipe • Malfunctioning gas
refueling) · Pinched, kinked or blocked? station filling nozzle (If
· Filler hose is torn this problem occurs at a
3. Inspect the fuel tank vapor vent hose between the EVAP. specific gas station
canister and air filter during refueling)
4. Check the EVAP. canister
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.
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 were followed
until 1999 when the federal regulations were 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 a computer program in the Engine Control Module (ECM) or PowertrainControl
Module (PCM) that coordinates the OBD-II self-monitoring system. This program controls all the monitors and
interactions, DTC and MIL operation, freeze 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 replaced 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) or Powertrain
Control Module(PCM).
The ECM or PCM receives input from sensors and other electronic components (switches, relays, and others)
based on information received and programmed into its memory (keep alive random access memory, and others),
the ECM or PCM generates output signals to control various relays, solenoids and actuators.
2. Configuration of hardware and related terms
1) GST (Generic scan tool)
Page 15 of 670
2) MIL (Malfunction indication lamp) - MIL activity by transistor
The Malfunction Indicator Lamp (MIL) is connected between ECM or PCM-terminal Malfunction Indicator Lamp
and battery supply (open collector amplifier).
In most cars, 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.
3) MIL illumination
When the ECM or PCM 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 or PCM detects the same
malfunction related to the DTC in two consecutive driving cycles.
4) MIL elimination
● 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:
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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.
5) Erasing a fault code
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.
6) K-Line
• Bidirectional line
• K-Line is defined as the line which provides information in a serial digital form from ECM or PCM 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 or PCM. K-Line is also used to initialize the serial communication.
7) Driving cycle
A driving cycle consists of engine start up, and engine shut off.
8) Warm-up cycle
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 temperature of at least 160 degrees Fahrenheit.
9) Trip cycle
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
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.
10) DTC format
• 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 is 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 assigned 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.
11) Freeze frame data
When a freeze frame event is triggered by an emission related DTC, the ECM or PCM 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
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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
1) Catalyst monitoring
The catalyst efficiency monitor is a self-test strategy within the ECM or PCM 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.
2) Misfire monitoring
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 is enabled. The freeze
frame data captures the operational state of the vehicle when a fault is detected from misfire detection monitor
strategy.
3) Fuel system monitoring
The fuel system monitor is a self-test strategy within the ECM or 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.
4) Engine cooling system monitoring
The cooling system monitoring is a self-test strategy within the ECM or PCM that monitors ECTS (Engine Coolant
Temperature Sensor) and thermostat about circuit continuity, output range, rationality faults.
5) O2 sensor monitoring
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.
6) Evaporative emission system monitoring
The EVAP. monitoring is a self-test strategy within the ECM or PCM 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.
7) Air conditioning system monitoring
The A/C system monitoring is a self-test strategy within the ECM or PCM that monitors malfunction of all A/C
system components at A/C ON.
8) Comprehensive components monitoring
The comprehensive components monitoring is a self-test strategy within the ECM or PCM that detects fault of any
electronic powertrain components or system that provides input to the ECM or PCM and is not exclusively an input
to any other OBD-II monitor.
9) A/C system component monitoring
Requirement:
If a vehicle incorporates an engine control strategy that alters off idle fuel and/or spark control when the A/C system
is on, the OBD II system shall monitor all electronic air conditioning system components for malfunctions that cause
Page 18 of 670
the system to fail to invoke the alternate control while the A/C system is on or cause the system to invoke the
alternate control while the A/C system is off.
Additionally, the OBD II system shall monitor for malfunction all electronic air conditioning system components that
are used as part of the diagnostic strategy for any other monitored system or component.
Implementation plan:
No engine control strategy incorporated that alters offidle fuel and/or spark control when A/C system is on.
Malfuction of A/C system components is not used as a part of the diagnostic strategy for other monitored system or
component.
Fuel System > Engine Control System > Components and Components Location
Components Location
Page 19 of 670
1. Mass Air Flow Sensor (MAFS) [With 12. Ignition Switch
CVVT] 13. ECM
2. Intake Air Temperature Sensor (IATS) 14. Purge Control Solenoid Valve (PCSV)
3. Engine Coolant Temperature Sensor (ECTS) 15. Main Relay
4. Throttle Position Sensor (TPS) 16. Ignition Coil
5. Camshaft Position Sensor (CMPS) 17. DLC (Diagnostic Link Connector)
6. Crankshaft Position Sensor (CKPS) 18. Heated Oxygen Sensor (Bank1, Sensor1)
7. Injector 19. Heated Oxygen seneor (Bank1, Sensor2)
8. Idle Speed Control Actuator (ISCA) 20. Heated Oxygen seneor (Bank2, Sensor1)
9. Vehicle Speed Sensor (VSS) 21. Heated Oxygen seneor (Bank2, Sensor2)
10. Knock Sensor
11. VIS Control solenoid valve
1. Mass Air Flow Sensor (MAFS) 2. Intake Air Temperature Sensor (IATS)
3. Engine Coolant Temperature Sensor 4. Throttle Position Sensor (TPS)

(ECTS) 8. Idle Speed Contorl Actuator (ISCA)
5. Camshaft Position Sensor (CMPS) 6. Crankshaft Position Sensor (CKPS)

Page 20 of 670
7.Injector 10. Knock Sensor
11. VIS Control Solenoid Valve
14. Purge Control Solenoid Valve (PCSV) 15. Main Relay

Page 21 of 670
16. Ignition Coil 18. Heated Oxygen Sensor (Bank 1, Sensor 1)
19. Heated Oxygen Sensor (Bank 1, Sensor 2) 20. Heated Oxygen Sensor (Bank 2, Sensor 1)
21. Heated Oxygen Sensor (Bank 2, Sensor 2)
Fuel System > Engine Control System > Engine Control Module (ECM) > Schematic Diagrams
Circuit Diagram
Page 22 of 670
Page 23 of 670
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1. ECM Harness Connector

Page 25 of 670
2. ECM Terminal Function

[Connector C30-1]
PIN
Description Connected to Remark
NO.
1 Ignition key switch signal Ignition key
2 Not connected -
3 Diagnostic data line Data Link Connector (DLC)
4 ECM ground Chassis ground
5 Power stages 1 ground Chassis ground
6 Power stages 2 ground Chassis ground
7 Battery voltage Battery
8 Battery voltage after main relay Main relay
9 Battery voltage after main relay Main relay
[Connector C30-2]
PIN
NO.
1 HO2S heater (B1/S1) HO2S (B1/S1)
2 Not connected -
3 Not connected -
4 Not connected -
5 Not connected -
6 Not connected -
8 HO2S shield (B1/S1) HO2S (B1/S1)
12 Not connected -
Page 26 of 670
HO2S signal input
14 HO2S (B1/S1)
(B1/S1)
HO2S signal input
15 HO2S (B2/S1)
(B2/S1)
HO2S signal input
16 HO2S (B1/S2)
(B1/S2)
17 Fuel consumption signal TRIP COMPUTER
HO2S signal input
18 HO2S (B2/S2)
(B2/S2)
20 HO2S ground (B1/S1) HO2S (B1/S1)
23 Main relay Main relay
[Connector C30-3]
PIN
NO.
1 MAFS signal input MAFS
2 Not connected -
3 Not connected -
4 Not connected -
5 Not connected -
6 Not connected -
7 Not connected -
8 CKPS signal input CKPS
9 Not connected -
10 TPS supply TPS
11 Not connected -
12 Not connected -
13 Not connected -
14 Not connected -
15 Not connected -
16 Not connected -
17 MAFS ground MAFS ground
18 Not connected -
19 TPS signal input TPS
Page 27 of 670
20 TPS ground TPS
21 CKPS ground CKPS
22 IATS signal input IATS
23 IATS ground IATS
24 ECTS signal input ECTS
25 ECTS ground ECTS
26 Power steer'g load input Power steering switch
27 Not connected -
28 Not connected -
29 Knock sensor1, input A (CYL 1/3/5) Knock sensor1(CYL 1/3/5)
30 Knock sensor1, input B (CYL 1/3/5) Knock sensor1(CYL 1/3/5)
31 Knock sensor2, input A (CYL 2/4/6) Knock sensor2(CYL 2/4/6)
32 Knock sensor2, input B (CYL 2/4/6) Knock sensor2(CYL 2/4/6)
33 Injector output (CYL.1) Injector (CYL.1)
39 Not connected -
40 Not connected -
41 Not connected -
42 Canister purge sol. Valve control Canister purge sol. Valve
43 Not connected -
44 Not connected -
45 VIS sol 1. Output Variable Intake control System sol. 1
46 ISCA PWM output 2 ISCA
47 ISCA PWM output 1 ISCA
48 Knock sensor shield Knock sensor
49 Not connected -
50 Not connected -
51 Not connected -
52 VIS sol2. Output Variable Intake control System sol. 2
[Connector C30-4]
PIN
NO.
Page 28 of 670
1 Not connected MAFS
2 Not connected -
3 Not connected -
4 Fuel tank pressure sensor supply Fuel tank pressure sensor
5 Fuel level sender signal Fuel level sender
6 Not connected -
7 CMPS signal CMPS
8 CMPS ground CMPS
9 Not connected -
10 Fuel pump relay control Fuel pump relay
11 Not connected -
12 Not connected -
13 TPS PWM output EPS, ECS
14 Fuel tank pressure sensor ground Fuel tank pressure sensor
15 Fuel level sender ground Fuel level sender
16 Not connected -
17 Engine speed signal Tachometer(Cluster)
18 Fan low Fan low relay
19 Not connected -
20 MIL MIL(Cluster)
21 Not connected -
Wheel( or Vehicle) speed sensor
22 Wheel( or Vehicle) speed sensor
signal
23 A/C comp. input(Low/High sw) A/C comp
24 A/C switch input A/C switch
25 A/C comp. input(middle sw) A/C middle sw
26 Not connected -
27 Not connected -
28 Not connected -
29 A/C comp. relay control A/C comp. relay
30 Canister close valve Canister close valve
31 Not connected -
32 Not connected -
33 Not connected -
34 Fuel tank pressure sensor signal Fuel tank pressure sensor
35 Not connected -
Page 29 of 670
36 CAN(High) TCM, ESP, ABS, 4WD ECM
37 CAN(Low) TCM, ESP, ABS, 4WD ECM
38 Wheel speed sensor ground Wheel speed sensor
39 Wheel speed sensor signal Wheel speed sensor
40 Fan high Fan high relay
[Connector C30-5]
PIN
NO.
Ignition coil 3 output (CYL.
1 Ignition coil 3 (CYL. 3, 6)
3, 6)
2, 5)
1, 4)
4 Not connected -
5 Ignition power stages ground Chassis ground
6 Not connected -
7 Not connected -
8 Not connected -
9 Not connected -
3. ECM Terminal Input/output Signal

[Connector C30-1]
PIN Vehicle Input, output value
NO. Description Remark
State Type Range
1 Ignition switch IG ON DC Vbatt
IG OFF 0 ~ 0.5 Volt
2 Not connected
3 Diagnosis line IG ON PULSE
(K-line)
4 ECM ground ALWAYS Static signal 0 ~ 0.5 Volt

5 Power stage1 ground ALWAYS Static signal 0 ~ 0.5 Volt
6 Power stage2 ground ALWAYS Static signal 0 ~ 0.5 Volt
7 Battery voltage ALWAYS DC Battery Voltage
8 Battery voltage after main IG ON DC Battery Voltage
relay IG OFF 0 ~ 0.5 Voltage
Page 30 of 670
9 Battery voltage after main IG ON DC Battery Voltage
relay IG OFF 0 ~ 0.5 Voltage
[Connector C30-2]
State Type Range
1 HO2S heater (B1/S1) Engine PWM
RUN
2 Not connected
3 Not connected
4 Not connected
5 Not connected
6 Not connected
RUN
Freq : 10 Hz
8 HO2S shield (B1/S1) Static signal 0 Volt
12 Not connected
RUN
Freq : 10Hz
14 HO2S input (B1/S1) 3000rpm PULSE
after warm-up
Freq:1.1 Hz
15 HO2S input (B2/S1) 3000 rpm PULSE
after
warm-up
Freq : 1.1 Hz
16 HO2S input (B1/S2) Racing PULSE
Page 31 of 670
Freq: 1.1 Hz
17 Fuel consumption signal Engine RUN PULSE
Freq : depend on
Fuel Consumption
Freq : 1.1 Hz
RUN
Freq : 10HZ
3000 rpm
20 HO2S ground (B1/S1) after PULSE 0 ~ 0.4 Volt
warm-up
3000 rpm
warm-up
3000 rpm
warm-up
23 Main relay IG OFF after DC 0 ~ 1 Volt
warm-up Vbatt
24 3000 rpm
HO2S ground (B2/S2) after PLUSE 0 ~ 0.4 Volt
warm-up
[Connecter C30-3]
PIN Input, output value
NO. Description Vehicle State Remark
Type Range
1 MAFs signal input IDLE Analog 0.5 Volt
2000 rpm 1 Volt
2 Not connected
3 Not connected
4 Not connected
Page 32 of 670
5 Not connected
6 Not connected
7 Not connected
8 CKPS signal input IDLE Frequency
3000 rpm
600 ~ 900 Hz
2700 ~ 3300 Hz
9 Not connected
10 TPS Supply After IG ON DC VCC
11 Not connected
12 Not connected
13 Not connected
14 Not connected
15 Not connected
16 Not connected
17 MAFS ground Static signal 0 ~ 0.5 Volt
18 Not connected
IDLE 0.25 ~ 0.8 Volt
19 TPS signal input Analog
Wide open 4.25 ~ 4.7 Volt
20 TPS ground Static signal 0 ~ 0.5 Volt
21 CKPS ground Static signal 0 ~ 0.5 Volt
0°C 4.3 Volt
22 Signal input Analog
20°C 3.44 Volt
23 IATS ground Static signal 0 ~ 0.5 Volt
24 ECTS signal input COLD(20°C) Analog 3.44 Volt
WARM(80°C) 1.25 Volt
25 ECTS ground Static signal 0 ~ 0.5 Volt
POWER STEER'G ON 0 ~ 0.5 Volt
26 DC
LOAD INPUT OFF Vbatt
27 Not connected
28 Not connected
29 Knock sensor1, input A Knocking Frequency -0.3 ~ 0.3 Volt
(CYL 2/4/6) Normal 0 Volt
Knock sensor2, input B
30
(CYL 1/3/5)
Knock sensor2, input B Knocking -0.3 ~ 0.3 Volt
31 Frequency
(CYL 2/4/6) Normal 0 Volt
Page 33 of 670
Knock sensor2, input B
32
(CYL 2/4/6)
33 Injector output(CYL.1) IG ON DC
3000 rpm (PWM)
Freq : 20 ~ 30Hz
3000 rpm (PWM)
Freq : 20 ~ 30Hz
3000 rpm (PWM)
Freq : 20 ~ 30Hz
3000 rpm (PWM)
Freq : 20 ~ 30Hz
37 Injector output(CYL.5) DC
(PWM)
Freq : 20 ~ 30Hz
38 Injector output(CYL.6) DC
(PWM)
Freq : 20 ~ 30Hz
39 Not connected
40 Not connected
41 Not connected
42 Canister purge sol. v/v contorl Inactive Active PULSE
(After warm up PWM
& racing)
Freq:20Hz
43 Not connected
44 Not connected
45 VIS solenoid output 0 ~ 0.5 Volt
14 Volt
Page 34 of 670
46 ISCA PWM output2
Idle(close) PWM
Freq:100Hz
47 ISCA PWM output1 Idle(open) PWM
Freq:100Hz
48 Knock sensor shield GND 0 ~ 0.5 Volt
49 Not connected
50 Not connected
51 Not connected
52 VIS solenoid2 output ON DC 0 ~ 0.5 Volt
OFF 14 Volt
[Connector C30-4]
PIN Input, output value
NO. Description Vehicle State Remark
Type Range
1 Not connected
2 Not connected
3 Not connected
Fuel tank pressure sensor IG ON 5V

4 Static signal
supply IG OFF 0 ~ 0.5V
5 Fuel level sender signal DC 0~Vcc
6 Not connected
7 CMPS signal input IDLE Frequency
(after
cranking)
8 CMPS ground Static signlal 0~0.5 Volt

9 Not connected
IG SW ON Vbatt
10 Fuel pump relay DC
IDLE 0~0.5 Volt
11 Not connected
12 Not connected
13 TPS PWM output to EPS/ECS C.T Engine run
W.O.T 5% DUTY
(C.T)
91% DUTY
(W.O.T)
Page 35 of 670
(W.O.T) Freq:100Hz
Fuel tank pressure sensor
14 GND 0 ~ 0.5Volt
ground
15 Fuel level sender ground GND 0~0.5 Volt
16 Not connected
17 ENGINE ENGINE Frequency
SPEED RUN
SIGNAL
18 FAN LOW RELAY FAN ON DC 0~0.5 Volt

FAN OFF Vbatt
19 Not connected
During IG ON DC 0~0.5 Volt
20 MIL
after START Vbatt
21 Not connected
22 Vehicle speed Sensor signal/ Vehicle PULSE
Wheel speed Sensor RUN
signal(ABS) (80km/h)
250Hz from ABS

25Hz from VSP
23 A/C COMP. SW OFF DC 0~0.5 Volt
SW(HI/LOW) SW ON Vbatt
24 A/C SW SW OFF DC 0~0.5 Volt
SW ON Vbatt
25 A/C COMP. SW OFF DC 0~0.5 Volt
SW(MID) SW ON Vbatt
26 Not connected
27 Not connected
28 Not connected
29 A/CON COMP RESSOR A/C ON DC 0~0.5 Volt
RELAY A/C OFF Vbatt
CLOSE Vbatt
30 CCV control DC
OPEN 0~0.5 Volt
31 Not connected
32 Not connected
33 FTPS input Engine run ANALOG
34 Not connected
35 Not connected
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36 CAN(HIGH) Recessive DC 2.0~3.0Volt
Dominant 2.75~4.5Volt
37 CAN(LOW) Recessive DC 2.0~3.0Volt
Dominant 0.5~2.25Volt
38 Wheel speed sensor ground Static signal 0V
39 Wheel speed sensor signal Run Vehicle
40 Ran relay(high) FAN OFF DC V batt
[Connector C30-5]
State Type Range
1 Ignition Coil3(CYL.3/6) ENGINE PULSE
RUN

RUN

RUN
4 Not connected
Ignition power stages Static
5 0Volt
ground ground
6 Not connected
7 Not connected
8 Not connected
9 Not connected
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.
Between terminal 4 of C30-1 connector and chassis ground : 1Ω or less
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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, TUCSON 2.0L L4).
2. Select "VIN WRITING".

Page 38 of 670
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 39 of 670
6. Turn the ignition switch OFF, and then turn ON.
7. Verify the programmed VIN in the ECM memory.
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)
2. If the resistance is not within specification, replace the injector.
Fuel System > Engine Control System > Troubleshooting

Inspection Chart For Diagnostic Trouble Codes(DTC)
DTC Description MIL
P0030 O2 Sensor Heater - Heater Control Circuit (Bank 1/Sensor 1) ●
P0031 O2 Sensor Heater Circuit low (Bank 1 / Sensor 1) ●
P0032 O2 Sensor Heater Circuit high (Bank 1 / Sensor 1) ●
P0036 O2 Sensor Heater - Heater Control Circuit (Bank 1 / Sensor 2) ●
Page 40 of 670
P0101 Mass or Volume Air Flow Circuit Range / Performance Problem ●
P0102 Mass or Volume Air Flow Circuit Low Input ●
P0103 Mass or Volume Air Flow Circuit high Input ●
P0111 Intake Air Temperature Circuit Range/performance ●
P0112 Intake Air Temperature Circuit Low Input ●
P0113 Intake Air Temperature 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 ●
P0121 Throttle / Pedal Position Circuit Range / Per formance Proble ●
P0122 Throttle / Pedal Position Circuit Low Input ●
P0123 Throttle / Pedal Position Circuit High Input ●
P0125 Insufficient Coolant Temperature for Colsed Loop Fuel Control ●
P0128 Coolant Thermostat (Coolant Temp. below Thermostat Regulating Temp.) ●
P0130 O2 sensor Circuit Malfunction(Bank 1 / Sensor 1) ●
P0131 O2 Sensor Circuit Low Input(Bank 1 / Sensor 1) ●
P0132 O2 Sensor Circuit High Input(Bank 1 / Sensor 1) ●
P0133 O2 Sensor Circuit Slow Response (Bank 1 / Sensor 1) ●
P0134 O2 Sensor Circuit No Activity Detected (Bank 1 / Sensor 1) ●
P0136 O2 Sensor Circuit Malfunction (Bank 1 / Sensor 2) ●
P0137 O2 Sensor Circuit Low Input (Bank 1 / Sensor 2) ●
P0138 O2 Sensor Circuit High Input (Bank 1 / Sensor 2) ●
P0139 O2 SEnsor CIrcuit Slow Response (Bank 1 / Sensor 2) ●
P0150 O2 sensor Circuit Malfunction(Bank 2 / Sensor 1) ●
P0153 O2-Sensor Circuit Slow Response (Bank 2 / Sensor 1) ●
P0156 O2 Sensor Circuit Malfunction (Bank 2 / Sensor 2) ●
P0159 O2 Sensor Circuit Slow Response (Bank 2 / Sensor 2) ●
Page 41 of 670
P0170 Fuel Trim (Bank 1) ●
P0171 Fuel Trim Malfunction - System Too Lean (Bank 1) ●
P0172 Fuel Trim Malfunction - System Too Rich (Bank 1) ●
P0173 O2 Sensor System - Lambda Controller at the Limit (Bank 2) ●
P0174 Fuel Trim Malfunction - System Too Lean (Bank 2) ●
P0175 Fuel Trim Malfunction - System Too Rich (Bank 2) ●
P0230 Fuel Pump Circuit Malfunction ▲
P0261 Cylinder 1 - Injector Circuit Low ●
P0262 Cylinder 1 - Injector Circuit High ●
P0300 Multiple Cylinder Misfire Detected ●
P0301 Cylinder 1 - Misfire detected ●
P0315 Segment Time Acquisition Incorrect ▲
P0325 Knock Sensor 1 Circuit Malfunction ▲
P0330 Knock Sensor 2 Circuit Malfunction ▲
P0335 Crankshaft Position Sensor Circuit Malfunction ●
P0340 Camshaft Position Sensor Circuit Malfunction ●
P0350 Ignition Coil Primary / Secondary Circuit Malfunction ▲
P0351 Ignition Coil 'A' Primary / Secondary Circuit Malfunction ▲
P0352 Ignition Coil 'B' Primary / Secondary Circuit Malfunction ▲
P0353 Ignition Coil 'C' Primary / Secondary Circuit Malfunction ▲
Page 42 of 670
P0354 Ignition Coil 'D' Primary / Secondary Circuit Malfunction ▲
P0355 Ignition Coil 'E' Primary / Secondary Circuit Malfunction ▲
P0356 Ignition Coil 'F' Primary / Secondary Circuit Malfunction ▲
P0420 Catalyst System Efficiency below Threshold (Bank 1) ●
P0430 Catalyst System Efficiency below Threshold (Bank 2) ●
P0441 Evap. Emission Ctrl. System Incorrect Purge Flow ●
P0442 Evap. Emission Ctrl. System - Small Leak detected (1.0 mm) ●
P0444 Evap. Emission Ctrl. System - Purge Ctrl. Valve Circuit Open ●
P0445 Evap. Emission Ctrl. System - Purge Ctrl. Valve Circuit Shorted ●
P0447 Evap. Emission Ctrl. System - Vent Circuit Open (SOV) ●
P0448 Evap. Emission Ctrl. System - Vent Circuit Shorted (SOV) ●
P0449 Evap. Emission Ctrl. System - Vent Valve / Solenoid circuit ●
Evap. Emission Ctrl. System - Pressure Sensor Range / Performance
P0451 ●
(DTP_CON)
P0452 Evap. Emission Ctrl. System - Pressure Sensor Low Input ●
P0453 Evap. Emission Ctrl. System - Pressure Sensor High Input ●
P0454 Evap. Emission Ctrl. System - Pressure Sensor Intermittent (DTP_NOISE) ●
P0455 Evap. Emission Ctrl. System - Large Leak detected (or tank cap loose/off) ●
P0456 Evap. Emission Ctrl. System - Small Leak detected (0.5 mm) ●
P0461 Fuel Level Sensor Circuit Range/Performance ▲
P0462 Fuel Level Sensor Circuit Low Input ▲
P0463 Fuel Level Sensor Circuit High Input ▲
P0464 Fuel Level Sensor Circuit Intermittent ▲
P0501 Vehicle Speed Sensor Range / Performance ●
P0505 Idle Air Control System ●
P0506 Idle Control System - RPM lower than expected ●
P0507 Idle Control System - RPM higher than expected ●
P0551 Power Steering Switch Circuit Malfunction ▲
P0560 System Voltage Malfunction ▲
P0562 System Voltage Low ●
P0563 System Voltage High ●
P0605 Internal Control Module Read Only Memory(ROM) Error ●
P0630 VIN not Programmed or Incompactible - ECM/PCM ●
P0650 Malfunction Indicator Lamp(MIL) Control Circuit Malfunction ▲
P0661 Intake manifold tuning valve #1(IV) control circuit low ▲
P0662 Intake manifold tuning valve #1(IV) control circuit high ▲
Page 43 of 670
P0664 Intake manifold tuning valve #2(MV) control circuit low ▲
P0665 Intake manifold tuning valve #2(MV) control circuit high ▲
P0700 TCU Request for MIL On / Freeze Frame to ECU via CAN ●
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 ●
U0101 Lost Communication With TCM ●
● : MIL ON & FAULT CODE MEMORY

▲ : MIL OFF & FAULT CODE MEMORY
Fuel System > Engine Control System > P0030 HO2S Heater Control Circuit (Bank 1 / Sensor 1)
Component Location
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.
Page 44 of 670
• Evaluate O2 sensor element temperature via
DTC Strategy
measuring element resistance
• Sensor preheating and full heating phases finished
• Time after start elapsed:240 sec. • Related fuse blown or missing
Enable Conditions • 11V<Battery voltage<16V • Heater control circuit open or
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 [Element • Contact resistance in
Temperature < 480°C(896°F)] connectors
Diagnostic Time • 5 min. • Faulty HO2S
Fail Safe • Heater open loop control

MIL On Condition • 2 Driving Cycles
Specification
Normal Parameter
HO2S Heater
20°C (68°F)
Heater
Approx. 3~4Ω
Resistance
Schematic Diagram
Page 45 of 670
Signal Waveform
Fig 1) The HO2S requires a minimum temperature to provide a closed loop fuel control system. SO the HO2S
contains a heater element to reduce its warm-up time and ensure its performance during all driving conditions. The
HO2S heater should always be ON after engine start. The ECM controls this heater element by duty cycle. The
main relay supplies vlltage to the heater and the ECM provides a ground circuit for activating the heater. The
illustration is the signal waveform at idle after HO2S heater completes warm-up
Monitor DTC Status

2. Press F4(DTAL) 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.
5. Is parameter displayed "History(Not Present) fault"?
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 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.
Page 46 of 670

1. Many malfunctions in the electrical system are caused by poor harness(es) and terminals. Faults can also be
caused by interference from other electrical systems, and mechanical or chemical damage.
or damage.
Repair as necessary and go to "Verification of Vehicle Repair"
procedure.
Go to "Power Supply Circuit Inspection" procedure

1. Ignition "OFF".
2. Disconnect HO2S connector.
4. Measure voltage between terminal 3 of the HO2S heater harness connector and chassis ground.
5. Is voltage within the specification?

Go to "Control Circuit Inspection" procedure.
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.
Repair as necessary and go to "Verification of Vehicle Repair" procedure.

Page 47 of 670
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.
(4) Is resistance within the specification?

2. Check for short to ground in control circuit.

(1) Measure resistance between terminal 4 of the HO2S heater harness connector and chassis ground.
Specification : infinite

Page 48 of 670
3. Check for short to power in control circuit.
(2) Measure voltage between terminal 4 of the HO2S heater harness connector and chassis ground
(3) Is voltage within the specification?

Go to "Component Inspection" procedure
1. Measure resistance between terminals 3 and 4 of the sensor connector (Component side).
Specification : 3~4Ω[at 20°C(68°F)]
2. Is resistance within the specification?

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
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

Page 49 of 670
2. Press F4(DTAL) 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.
Go to the applicable troubleshooting procedure.
Fuel System > Engine Control System > P0031 HO2S Heater Control Circuit Low (Bank 1 / Sensor 1)
Component Location
General Description
DTC Description
ECM sets DTC P0031 if the ECM detects that the front HO2S heater control circuit is short to ground.

Page 50 of 670
• 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
• Contact resistance in
Diagnostic Time • 20 sec connectors
Fail Safe • Heater open loop control • Faulty HO2S
Specification
Normal Parameter
HO2S Heater
20°C (68°F)
Heater
Approx. 3~4Ω
Resistance
Schematic Diagram
Signal Waveform
Page 51 of 670
Monitor DTC Status


Page 52 of 670
or damage.
procedure.
Go to "Power Supply Circuit Inspection" procedure.

1. Ignition "OFF".

Injector.
Repair as necessary and go to "Verification of Vehicle Repair" procedure

Page 53 of 670
(1) Ignition "OFF".
connector.



Page 54 of 670


DTC..
Go to the applicable troubleshooting procedure
Fuel System > Engine Control System > P0032 HO2S Heater Control Circuit High (Bank 1 / Sensor 1)
Component Location
Page 55 of 670
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
Specification
Normal Parameter
HO2S Heater
20°C (68°F)
Heater
Approx. 3~4Ω
Resistance
Page 56 of 670
Schematic Diagram
Signal Waveform
Monitor DTC Status

Page 57 of 670

or damage.
procedure.

Page 58 of 670
(1) Ignition "OFF".
(2) Disconnect HO2S and ECM connectors.
connector.

2. Check for short to battery in control circuit.

(1) Reconnect the ECM connector.
(2) Ignition "ON" & Engine "OFF".
(3) Measure voltage between terminal 4 of the HO2S heater harness connector and chassis ground.

Page 59 of 670
1. Ignition "OFF".


DTC.
Component Location
Page 60 of 670
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.

DTC Strategy
Enable Conditions • 11V< Battery voltage<16V • Heater control circuit open or
short
• 1%< Heater power< 99%
short

Specification
Page 61 of 670
Normal Parameter
HO2S Heater
20°C (68°F)
Heater
Approx. 3~4Ω
Resistance
Schematic Diagram
Signal Waveform
Monitor DTC Status

Page 62 of 670

or damage.
procedure.

1. Ignition "OFF".
Page 63 of 670

Go to "Control Circuit Inspection" procedure..
HO2S.
.Especially check for "10A O2 Sensor fuse" is installed and not blown.

(1) Ignition "OFF".
connector.

Page 64 of 670



Page 65 of 670


DTC.
Component Location
Page 66 of 670
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
Enable Conditions
• 1%<Heater power<99% power supply or control
Diagnostic Time • 20 sec. connectors
Specification
Normal Parameter
HO2S Heater
20°C (68°F)
Heater
Approx. 3~4Ω
Resistance
Schematic Diagram
Page 67 of 670
Signal Waveform
Monitor DTC Status

Page 68 of 670

or damage.
procedure.

1. Ignition "OFF".
Page 69 of 670

Injector.

(1) Ignition "OFF".
connector.

Page 70 of 670



Page 71 of 670
DTC.
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.

Page 72 of 670
DTC Strategy
HO2S heater line
Enable Conditions
Threshold Value • Open or short to Battery • Contact resistance in
connectors
Specification
Normal Parameter
HO2S Heater
20°C (68°F)
Heater
Approx. 3~4Ω
Resistance
Schematic Diagram
Signal Waveform
Page 73 of 670
Monitor DTC Status


Page 74 of 670
or damage.
procedure.

(1) Ignition "OFF".
connector.

Page 75 of 670

1. Ignition "OFF".

Page 76 of 670

DTC.
Component Location
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.

Page 77 of 670
DTC Strategy
short
short

Specification
Normal Parameter
HO2S Heater
20°C (68°F)
Heater
Approx. 3~4Ω
Resistance
Schematic Diagram
Page 78 of 670
Signal Waveform
Monitor DTC Status

Page 79 of 670
or damage.
procedure .
Go to "Power Supply Circuit Inspection" procedure..

1. Ignition "OFF".
Specification : B+

HO2S.

Page 80 of 670
1. Check for open in control harness.
(1) Ignition "OFF".
(2) Disconnect ECM connectors.
connector.

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.
Page 81 of 670

Repair" procedure

Page 82 of 670
conditions noted in the freeze frame data or enable conditions .
DTC.
Component Location
General Description
DTC Description
ECM sets DTC P0051 if the ECM detects that the front HO2S heater control line is short to ground.

Page 83 of 670
DTC Strategy
line
Enable Conditions
• 1%<Heater power<99% power supply or control
Specification
Normal Parameter
HO2S Heater
20°C (68°F)
Heater
Approx. 3~4Ω
Resistance
Schematic Diagram
Signal Waveform
Page 84 of 670
Monitor DTC Status


Page 85 of 670
or damage.
procedure ..

1. Ignition "OFF".
Specification : B+

HO2S.
.Especially check for "10A O2 Sensor fuse" is installed and not blown.

Page 86 of 670
(1) Ignition "OFF".
(2) Disconnect ECM and HO2S connectors.
connector.



Repair" procedure
Page 87 of 670


DTC.
Component Location
Page 88 of 670
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.
Enable Conditions
Threshold Value • Short to Battery or line break • Contact resistance in
connectors
Specification
Normal Parameter
HO2S Heater
20°C (68°F)
Heater
Approx. 3~4Ω
Resistance
Schematic Diagram
Page 89 of 670
Signal Waveform
Monitor DTC Status

Page 90 of 670

or damage.
procedure .

Page 91 of 670
(1) Ignition "OFF".
connector.

2. Check for short to power in control circuit


Repair" procedure.
Page 92 of 670
1. Ignition "OFF".


DTC.
Component Location
Page 93 of 670
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.

DTC Strategy
short
short

Specification
Page 94 of 670
Normal Parameter
HO2S Heater
20°C (68°F)
Heater
Approx. 3~4Ω
Resistance
Schematic Diagram
Signal Waveform
Monitor DTC Status

Page 95 of 670

or damage.
procedure .

1. Ignition "OFF".
Page 96 of 670
Specification : B+

HO2S.

(1) Ignition "OFF".
connector.

Page 97 of 670

Repair" procedure.


Repair" procedure
Page 98 of 670


DTC.
Component Location
Page 99 of 670
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
Specification
Normal Parameter
HO2S Heater
20°C (68°F)
Heater
Approx. 3~4Ω
Resistance
Schematic Diagram
Page 100 of 670
Signal Waveform
Monitor DTC Status

Page 101 of 670

or damage.
procedure .

1. Ignition "OFF".
Page 102 of 670
Specification : B+

HO2S.

(1) Ignition "OFF".
(2) Disconnect ECM connector.
connector.

Page 103 of 670

Repair" procedure.


Page 104 of 670
DTC.
Component Location
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.

Page 105 of 670
• 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
Specification
Normal Parameter
HO2S Heater
20°C (68°F)
Heater
Approx. 3~4Ω
Resistance
Schematic Diagram
Signal Waveform
Page 106 of 670
Monitor DTC Status


Page 107 of 670
or damage.
procedure
Go to "Control Circuit Inspection" procedure..

(1) Ignition "OFF".
connector.

Page 108 of 670
2. Check for short to power in control circuit

Repair" procedure.
1. Ignition "OFF".

Page 109 of 670

DTC.
Fuel System > Engine Control System > P0101 Mass or Volume Air Flow \'A\' Circuit Range /
Performance
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.
Page 110 of 670
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.

DTC Strategy • Compare calculated MAF with MAF signal
• 1500< Engine speed(RPM)< 3500 • Dirty air cleaner.
Enable Conditions • 450< Measured Mass Air Flow(mg/rev.) <1050 • Oil Cap or Dipstick missing
• Coolant temperature > 60°C(140°F) or not installed correctly.
• Measured MAF/Calculated MAF <0.5 or >1.3 • Air leak in intake system
Threshold Value • Contact resistance in
• Lambda Controller Limit +/- 20% connectors.
Diagnostic Time • 120 sec. • Faulty MAFS or TPS
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 - - 4.0~4.4 0.2~3.4
Schematic Diagram
Page 111 of 670
Signal Waveform
Fig 1) Normal value with ldle after warm up ; approx_0.7~1.0V

Fig 2) Normal value with ldle after warm up and "ON" : Signal increases proportionally with engine load
Fig 3) Normal value with accelerating and deceleration : The MAFS and TPS signals increase at the same time with
accelerating and decrease with releasing accelerator pedal
Monitor DTC Status

Page 112 of 670
System Inspection
■ 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.
■ 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
Page 113 of 670
2. Connect Scantool and monitor the "THROTTLE P. SENSOR(V)" parameter on the Scantool data list.
Specification : Approx. 0.25~0.80V(Closed throttle Valve) / Approx 4.0~4.4V(Wide Open

Throttle)
3. Is "THROTTLE P. SENSOR(V)" within specification?

Inspect TP sensor and W/harness and repair or replace as necessary. Go to "Verification of

or damage.
procedure .
Go to "Conponent Inspection" 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"
Fig 1) Test Condition : Idle after warm up

Specification : The MAFS is between 0.6~1.0V(11~20kg/h)
Fig 2) Test Condition : Idle after warm up & A/C "ON"
Specification : The MAFS increase proportionally with engine load
Page 114 of 670
4. Is MAF sensor voltage within the specification?
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

DTC.
Fuel System > Engine Control System > P0102 Mass or Volume Air Flow \'A\' Circuit Low Input
Component Location
General Description
Page 115 of 670
DTC Description
ECM sets DTC P0102 if the ECM detects signal voltage lower than the possible range of a properly operating
MAF sensor.

DTC Strategy • Voltage range check
• 1500< Engine speed(RPM)< 3500 • Open or short to ground in
Enable Conditions • 450< Measured Mass Air Flow(mg/rev.) <1050 signal circuit
• Coolant temperature > 60°C(140°F) • Open in power supply circuit.
Threshold Value • Measured MAF < 1.7g/sec.
connections.
Diagnostic Time • 0.6sec. • Faulty MAF sensor
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 - - 4.0~4.4 0.2~3.4
Schematic Diagram
Page 116 of 670
Signal Waveform
Fig 1) Normal value with ignition ON and engine OFF : Approx. 0.6~0.7V
Fig 2) Open in signal or power supply circuit/short to ground in signal or power supply circuit : Approx OV
Monitor DTC Status


Page 117 of 670
or damage.
procedure .

1. Ignition "OFF".
2. Disconnect MAF connector.
4. Measure voltage between terminal 3 of the MAF sensor heater harness connector and chassis ground.
Specification : B+

Go to "Signal Circuit Inspection" procedure..
Check for an open or short to ground in the power supply circuit between the MAF sensor
and main relay

Page 118 of 670
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.

Check for an open in signal harness. Repair as necessary and go to "Verification of
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.
Page 119 of 670
1. Engine "ON".


Specification : The MAFS is between 0.6~1.0V(11~20kg/h)

DTC.
Fuel System > Engine Control System > P0103 Mass or Volume Air Flow \'A\' Circuit High Input
Page 120 of 670
Component Location
General Description
DTC Description
ECM sets DTC P0103 if the ECM detects signal voltage higher than the possible range of a properly operating
MAF sensor.

• 1500< Engine speed(RPM)< 3500 • Open in ground harness
Enable Conditions • 450< Measured Mass Air Flow(mg/stk) <1050 • Short to battery in signal
• Coolant temperature > 60°C(140°F) harness
Threshold Value • Measured MAF > 202g/sec.
connections.
Diagnostic Time • 0.6sec. • Faulty MAF sensor
Specification
Page 121 of 670
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 - - 4.0~4.4 0.2~3.4
Schematic Diagram
Signal Waveform
Page 122 of 670
Fig 1) Normal value with ignition ONand engine OFF : Approx.0.6~0.7V

Fig 2) Open in ground circuit with ingition ON and engine OFF : Approx 5V
Fig 3) Shot to battery in signal circuit with ignition ON and ingine OFF : Approx. 5V
Monitor DTC Status


Page 123 of 670
or damage.
procedure .

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

2. Measure voltage between terminal 2 of the MAF sensor harness connector and chassis ground.
Page 124 of 670
Repair short to battery in harness and go to "Verification of Vehicle Repair"
procedure.
1. Engine "ON".


Specification : The MAFS is between 0.6~1.0V (11~20kg/h)

Page 125 of 670
DTC
Fuel System > Engine Control System > P0111 Intake Air Temperature Sensor 1 Circuit Range /
Performance
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.

Page 126 of 670
• Time after Start > 500 sec.
Enable Conditions
• Coolant temperature increase after Start > • Contact resistance in
40°C(104°F) connections.
• Maximum air temp. - Minimum air temp. < • Faulty IAT sensor
Threshold Value
1.5~5.3°C(34.7~41.5°F)
Diagnostic Time • 5 sec.
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
Signal Waveform
Page 127 of 670
Fig 1) Signal decreases with increasing sensor temperature and increases with decreasing sensor
temperature : Approx.2.59 V at 48°C(118°F)
Fig 2) Short to ground in signal circuit : Approx OV
Monitor DTC Status


1. Ignition "OFF".
Page 128 of 670
2. Disconnect IATS connector.
or damage.
procedure .
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?

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 Vehicle Repair" procedure.

Page 129 of 670
DTC.
Fuel System > Engine Control System > P0112 Intake Air Temperature Sensor 1 Circuit Low Input
Component Location
General Description
DTC Description
IATS.

• Time after start in case of short circuit B+ or line
Enable Conditions • Short to ground in signal
break: 250sec. harness
• Measured intake air temperature > • Contact resistance in
Threshold Value
117.75°C(243.95°F) connections.
Diagnostic Time • Faulty IAT sensor
• 5 sec.
Page 130 of 670
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 2.35~2.54 80 176 0.31~0.32
Schematic Diagram
Signal Waveform
Page 131 of 670
Monitor DTC Status

connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as
Go to "Monitor Scantool Data" procedure.

2. Disconnect IAT sensor connector.
Page 132 of 670
3. Connect Scantool and monitor the "INT.AIR TEMP. SNSR(V)" parameter on the Scantool data list.
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".
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 133 of 670
procedure .
Go to "Component Inspection" procedur
-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


DTC
Page 134 of 670
Fuel System > Engine Control System > P0113 Intake Air Temperature Sensor 1 Circuit High Input
Component Location
General Description
DTC Description
IATS.

DTC Strategy • Voltage range check • Short to battery in signal
• me after start in case of short circuit B+ or line break: harness
Enable Conditions
250sec. • Open in signal or ground
circuit
Threshold Value • Measured intake air temperature > -38°C(-36°F)
Diagnostic Time • 5 sec. connections.
MIL On Condition • 2 Driving Cycles • Faulty IAT sensor
Specification
Page 135 of 670
(°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
Signal Waveform
Page 136 of 670
Monitor DTC Status

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 137 of 670
5. Is IAT data within the specification?
Possibility of sensor malfunction. Go to "Component Inspection"
procedure.
6. Jumper the terminal 1 of the IAT sensor harness connector to chassis ground.
7. Observe the "IAT SENSOR" parameter on the Scantool.

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".
2. Disconnect ECM connector.
3. Measure resistance between terminal 2 of the IATsensor harness connector and 23 of the ECM harness
connector.

Go to "Terminal and Connetor Inspection" procedure.
Repair open circuit and go to "Verification of Vehicle Repair"
procedure

Page 138 of 670
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.

Go to next step as below..
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.

Repair open circuit and go to "Verification of Vehicle Repair" procedure..

or damage.
Page 139 of 670
procedure .
-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


DTC.
Page 140 of 670
Fuel System > Engine Control System > P0116 Engine Coolant Temperature Circuit Range /
Performance
Component Location
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.

Page 141 of 670
ITEM DETECTING CONDITION POSSIBLE CAUSE
DTC Case 1) • Check coolant temperature signal stuck.

Strategy Case 2) • Signal Unplausible High with Long Soaking Condion
• Time after start if intake air temperature is below -
Case 1)
30°C (-22°F): 250sec
• No Relevant Failure
• Engine run Elapse of Previous DC > 500s or ECT at
Engine Stop of Prev. DC > 85°C(185°F)
Enable • During model coolant temperature increase
Conditions • IAT Signal Decrease Energy < 50J by Air Flow
after Start
• Cumulative Time for IAT Signal > 70s decrease
Check (Air Flow > 60 kg/h) • Contact resistance in
• Cumulative Time for IAT Signal > 100s decrease connections.
Check [VS > 71km/h(44 mph)] • Faulty ECT sensor
• Model coolant temperature increase > Threshold

But Measured coolant temperature increase <
Case 1)
Threshold (Threshold depends on Coolant start
Threshold temperature)
Value
• Measured coolant temperature at IAT start >
Case 2) 54°C(129°F) with IAT last DC - IAT start >
12°C(54°F) and IAT at Start
Diagnostic Case 1) • 0.5 sec..
Time
Case 2) • Immediate if Enable Conditions Fullfilled
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
Page 142 of 670
Signal Waveform
Fig 1) Signal decreases with increasing sensor temperature and increases with decreasing sensor temperature
Monitor DTC Status

Page 143 of 670

or damage.
procedure .
1. Ignition "OFF"
2. Disconnect ECTS connector
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
Page 144 of 670
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

DTC.
Fuel System > Engine Control System > P0117 Engine Coolant Temperature Circuit Low Input
Component Location
General Description
Page 145 of 670
DTC Description
ECTS.

• Time after start if intake air temperature is below - • Short to ground in signal
Enable Conditions harness
30°C (-22°F): 250sec.
Threshold Value • Measured coolant temperature > 138°C(280°F).
connections.
Diagnostic Time • 5 sec. • Faulty ECT sensor
Specification
(°C) (°F) (°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
Signal Waveform
Page 146 of 670
Monitor DTC Status


Page 147 of 670
3. Connect Scantool and monitor the "INT.AIR TEMP. SNSR(V)" parameter on the Scantool data list.
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. 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 148 of 670
procedure .
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


Page 149 of 670
DTC.
Fuel System > Engine Control System > P0118 Engine Coolant Temperature Circuit High Input
Component Location
General Description
DTC Description
ECTS.

DTC Strategy • Voltage range check • Short to battery in signal
• Time after start if intake air temperature is below - harness
Enable Conditions
30°C (-22°F): 250sec. • Open in signal or ground
circuit
Threshold Value • Measured coolant temperature < -38°C(-36°F).
Diagnostic Time • 5 sec. connections.
MIL On Condition • 2 Driving Cycles • Faulty ECT sensor
Page 150 of 670
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
Signal Waveform
Page 151 of 670
Monitor DTC Status

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 152 of 670
Possibility of sensor malfunction. Go to "Component Inspection"
procedure.
6. Jumper the terminal 1 of the IAT sensor harness connector to chassis ground.
7. Observe the "IAT SENSOR" parameter on the Scantool.

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 terminals 1 of the ECT sensor harness connector and 25 of the ECM harness
connector.

Go to "Terminal and connector Inspection" procedure.
Repair open circuit and go to "Verification of Vehicle Repair"
procedure.

Page 153 of 670
1. Check for open in signal circuit.
(1) Measure resistance between terminals 3 of the ECT sensor harness connector and 24 of the ECM harness
connector.

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.

Go to "Terminal and Connector Inspection" procedure

or damage.
Page 154 of 670
procedure .
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


Page 155 of 670
DTC.
Fuel System > Engine Control System > P0119 Engine Coolant Temperature Circuit Intermittent
Component Location
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
• Time after start if intake air temperature is below -
Enable Conditions
30°C (-22°F): 250sec
• Coolant temperature gradient < 10°C(50°F) / 0.5 connections.
Threshold Value
sec. • Faulty ECT sensor
Page 156 of 670
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
Signal Waveform
Page 157 of 670
Monitor DTC Status

or damage.
procedure .
1. Ignition "OFF"
Page 158 of 670
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


DTC.
Fuel System > Engine Control System > P0121 Throttle/Pedal Position Sensor/Switch \'A\' Circuit
Range/Performance
Component Location
Page 159 of 670
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 signal
• 1500< Engine speed(RPM) < 3500
Enable Conditions • 450< Measured mass air flow(mg/rev.) <1050
• Coolant temp. >60°C(140°F) connectors
Threshold Value • Measured MAF/Calculated MAF < 0.5 or > 1.3 • Faulty TP Sensor(TPS)
Specification
Page 160 of 670
Normal parameter
TPS
C.T (Idle) W.O.T
Throttle Angle (°) 0~0.5° Approx. 85°
Signal Voltage (V) 0.2~0.8V 4.3~4.8V
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
Signal Waveform
Fig 1) Normal value with accelerating and decelerating : The MAFS and TPS signals increase at the same time with
accelerating and decrease with releasing accelerator pedal
Fig 2) Signal increases proportionally with throttle opening angle
Page 161 of 670
Monitor DTC Status
System Inspection
1. Visually/physically inspect the following items:
Vacuum hoses for splits, kinks and improper connections.
EVAP system for leakage.
PCV hose for proper installation.
2. Was a problem found in any of the above areas?
procedure.

or damage.
Page 162 of 670
procedure .
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
Page 163 of 670
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

DTC.
Fuel System > Engine Control System > P0122 Throttle/Pedal Position Sensor/Switch \'A\' Circuit Low
Input
Component Location
General Description
throttle.
Page 164 of 670
DTC Description
TPS.

DTC Strategy • Voltage range check • Open in power supply
harness
Enable Conditions • 6 ≤ Battery voltage ≤ 16V
• Short to ground in power
Threshold Value • Voltage <0.14V supply or signal harness
connectors
MIL On Condition • 2 Driving Cycles • Faulty TP sensor
Specification
Normal parameter
TPS
C.T (Idle) W.O.T
0.71~1.38 kΩ at all
Schematic Diagram
Page 165 of 670
Signal Waveform
Fig 1) Signal increases proportionally with throttle opening angle

Fig 2) Short to ground in signal circult/Open in power supply circuit : Appox.OV
Fig 3) Short to ground in power supply circuit : Approx.OV
Monitor DTC Status

Page 166 of 670

or damage.
procedure .

1. Ignition "OFF".
Page 167 of 670
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.

Check the short to ground in signal circuit.
procedure.
1. Ignition "OFF".
Page 168 of 670


Page 169 of 670
DTC.
Fuel System > Engine Control System > P0123 Throttle/Pedal Position Sensor/Switch \'A\' Circuit High
Input
Component Location
General Description
throttle.
DTC Description
TPS.

Page 170 of 670
• Open in signal or
Enable • 6 ≤ Battery voltage ≤ 16V ground circuit
Conditions
• Short to battery in
Threshold Value • Voltage > 4.86V signal circuit
connectors
MIL On • 2 Driving Cycles • Faulty TP sensor
Condition
Specification
Normal parameter
TPS
C.T (Idle) W.O.T
0.71~1.38 kΩ at all
Schematic Diagram
Signal Waveform
Page 171 of 670
Fig 1) Signal increases proportinally with throttle opening angle

Fig 2) Open in signal or ground circult : Approx.5V
Monitor DTC Status


Page 172 of 670
or damage.
procedure .

1. Ignition "OFF".

Go to step "Signal Circuit Inspection" procedure.
Check the ground circuit for an open.
procedure.

Page 173 of 670
1. With sensor connector still disconnected, measure voltage between terminal 3 of the sensor harness connector
and chassis ground.

Possibility of open or short to power in signal circuit.
procedure.
1. Ignition "OFF".
Page 174 of 670


DTC.
Fuel System > Engine Control System > P0125 Insufficient Coolant Temperature for Closed Loop Fuel
Control
Component Location
Page 175 of 670
General Description
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.

• Check time to closed loop control start with coolant
DTC Strategy
temperature model.
• Coolant temperature at Start < close loop enable
ECT
Enable Conditions
• Modeled coolant temperature > 20°C(68°F)
• After 100~1000 seconds from engine start
• Measured coolant temperature< threshold When connectors.
Threshold Value
modeled coolant temperature > threshold • Faulty cooling system.
Diagnostic Time • 0.5 sec. • Faulty thermostat.
• Faulty ECT sensor.
• Calculated engine coolant temperature is used for
engine control.
Fall Safe • Cooling/Condenser fan is active with MAX speed.
• EVAP. emission control function is controlled in
minimum operation mode.
Page 176 of 670
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
[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
Signal Waveform
Page 177 of 670
Monitor DTC Status

System Inspection
■ 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.
Page 178 of 670
3. Remove the thermostat and check the following items:
Stuck or damaged
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?
procedure.

or damage.
procedure.
1. Ignition "OFF" .
2. Disconnect ECTS connector.
Specification
-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 179 of 670
Check for poor connection between PCM and component: backed out terminal, improper
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

conditions noted in the freeze frame data or enable conditions
3. Read "DTC Status" parameter
DTC
Fuel System > Engine Control System > P0128 Coolant Thermostat (Coolant Temperature below
Thermostat Regulating Temperature)
Component Location
General Description
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 same 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.
Page 180 of 670
DTC Description
An open stuck thermostat means an increase of the engine warm up time and can cause emission increase as well.
To detect open stuck thermostat, the ECM checks measured coolant temperature as soon as calculated coolant
temperature reaches threshold ( 85°C ) and sets DTC P0128 when measured coolant temperature is lower than
threshold. If same code is set again in the next driving cycle, MIL is illuminated.

DTC Strategy • Coolant temperature not reached warm up state
• Percentage of fuel-cut off phase<20%
• Percentage of low load phase <50%
• Intake air temperature decreases compared to start
Intake air temp. > -9°C(16°F)
Enable Conditions
• Percentage of low vehicle speed <78%
• Percentage of high vehicle speed <90%
• Coolant temperature at start >-9°C(16°F)
connectors
• Intake air temperature at start >-9°C(16°F)
• Faulty cooling system
• Measured coolant temp.< 75°C(167°F) When • Faulty thermostat
Threshold Value
modelled coolant temp. > 85°C(185°F)
• 7~30 min. depending on coolant temperature at start
Diagnostic Time
and driving pattern
• Catalyst monitoring is inhibited
Fall Safe
• Post catalyst fuel trim system monitoring is inhibited
Specification
[ECTS]
-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
[THERMOSTAT]
Page 181 of 670
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
Signal Waveform
Monitor DTC Status

Page 182 of 670
System Inspection
■ 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:
Stuck or damaged
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?
procedure

or damage.
Page 183 of 670

conditions noted in the freeze frame data or enable conditions
3. Read "DTC Status" parameter
DTC
Fuel System > Engine Control System > P0130 O2 Sensor Circuit(Bank 1 / Sensor 1)
Component Location
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.
Page 184 of 670
DTC Description
ECM sets DTC P0130 if the ECM detects that the front HO2S signal circuit is open.

Case 1) • Circuit malfunction
DTC
Strategy • Check time to closed loop control start with O2
Case 2)
sensor voltage
Enable Case 1) • Battery voltage > 10V
Condition • Lambda control active • Open in signal harness
• Open in ground harness
Case 2) • Battery voltage > 10V
Case 1) • 0.37V < Sensor voltage < 0.54V (during 10 sec.) connectors
Threshold • Faulty Heated O2
• Time to closed loop control not activated when O2
Value Sensor(HO2S)
Case 2) sensor voltage blocked between 0.37 ~ 0.54V
(depends on coolant temperature at start)
Diagnostic Case 1) • 1 Sec.

Time Case 2) • Immediate
Schematic Diagram
Signal Waveform
Page 185 of 670
Fig 1) Normal value with idle after warm up: Signal is switching from rich(above 0.45V) to lean(below 0.45V)
a minimum of 3 times in 10 seconds
Fig 2) Open in signal circuit with ignition ON: Approx. 0.4~0.5V
Monitor DTC Status


Page 186 of 670
or damage.
procedure.

1. Ignition "OFF"
3. Measure resistance between terminals 2 of the HO2S harness connector and 20 of the ECM harness connector.

Repair open in the ground circuit and go to "Verification of Vehicle Repair"
procedure

Page 187 of 670
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:
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.
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).
Fig 1) Normal value with idle after warm up : Signal is switching from rich(above 0.45V) to lean(below 0.45V)
Fig 2) Open in signal circuit with ignition ON : Approx. 0.4~0.5V
Page 188 of 670
4. Is sensor switching properly?

DTC
Fuel System > Engine Control System > P0131 O2 Sensor Circuit Low Voltage(Bank 1 / Sensor 1)
Component Location
General Description
Page 189 of 670
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.

DTC Strategy • Sensor voltage low
• Sensor preheating and full heating phases finished • Short to ground in signal
Enable Conditions
• Battery voltage >10V harness
• Sensor voltage <0.02V and element resistance
Threshold Value connectors
<10Ω
• Faulty Heated O2
Diagnostic Time • 16 sec. Sensor.(HO2S)
Schematic Diagram
Signal Waveform
Page 190 of 670
Monitor DTC Status


Page 191 of 670
or damage.
procedure.

1. Ignition "OFF"
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.
Page 192 of 670

DTC.
Fuel System > Engine Control System > P0132 O2 Sensor Circuit High Voltage(Bank 1 / Sensor 1)
Component Location
Page 193 of 670
General 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 P0132 with short circuit to battery.

DTC Strategy • Sensor voltage high
• Short to ground in signal
• Battery voltage >10V
Threshold Value • Sensor voltage > 1.2V connectors
Diagnostic Time • Faulty Heated O2
• 1 sec.
Sensor.(HO2S)
MIL On Condition • 2 Driving
Schematic Diagram
Page 194 of 670
Signal Waveform
Monitor DTC Status

Page 195 of 670

or damage.
procedure.

1. Ignition "OFF"
Page 196 of 670
4. Measure voltage between terminal 1 of the HO2S harness connector and chassis ground.

procedure.
Page 197 of 670

DTC.
Fuel System > Engine Control System > P0133 O2 Sensor Circuit Slow Response (Bank 1 / Sensor 1)
Component Location
General Description
Page 198 of 670
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
<900°C(1652°F)
• Coolant temp. >70°C(158°F)
• 1200 <Engine speed(RPM) <3000
• Leak in intake or exhaust
• 300<Mass air flow(mg/rev.) <840
system
• No misfire detected
Enable Conditions • Faulty fuel system.
• Not transient condition as below • Front and rear HO2S
1. Current Eng Speed - Mean of Eng Speed | < connections reversed.
400rpm • Contact resistance in
2. Current Mass A/Flow-Mean of Mass A/Flow| < connectors
270mg/rev.
• HO2S contamination
3. Current λCorr. Value-Mean of λCorr. Value| <5%
• Sum of O2 sensor lean/rich period > calculated
Threshold Value
period
Diagnostic Time • 70 lambda controller cycles.
Schematic Diagram
Page 199 of 670
Signal Waveform
Monitor DTC Status
If any misfire, Purge Solenoid Valve, Mass Air Flow Sensor or O2 Sensor heater codes are present, DO ALL
REPAIRS associated with those codes before proceeding with this troubleshooting tree.
Page 200 of 670
System Inspection
■ Visual / Physical Inspection
Ensure that the HO2S is securely installed.
Check for corrosion on terminals.
Check for terminal tension ( at the HO2S and at the ECM).
Check for damaged wiring.
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.
procedure
Go to "Air Leakage Inspection" procedure

Exhaust system between HO2S and Three way catalyst for air leakage.
Page 201 of 670
procedure
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 : 330~350kPa(3.30~3.50 kg/cm², 47~50 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.
■ Fuel Injector Inspection

1. Ignition "OFF"
2. Check the fuel injectors for clogging or any restrictions.
Specification : No clogging and restriction
3. Is the fuel injector OK?

procedure
Page 202 of 670

DTC.
Fuel System > Engine Control System > P0134 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor
1)
Page 203 of 670
Component Location
General Description
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.

Page 204 of 670
DTC Case 1) • Signal plausibility during fuel cut off

Strategy Case 2) • Sensor voltage excursion
• Fuel cut-off phase
Case 1)
• Integrated Mass Air Flow since begin fuel cut-off >
20g
Enable
Condition • Sensor preheating and full heating phases finished
• 5 Cycles of A/F Closed Loop passed after lambda • Related fuse blown or missing
Case 2) control active. • Contact resistance in
• Lambda controller is not on the limit connectors
• Battery voltage > 10V • HO2S contamination
Case 1) • Voltage with fuel cut off > 0.2V
Threshold
Value • Mean value of Maximum voltage - Mean value of
Case 2)
Minimum voltage < 0.25V
Diagnostic Case 1) • 5 sec.

Time Case 2) • 120 sec.
Schematic Diagram
Signal Waveform
Page 205 of 670
Monitor DTC Status


Page 206 of 670
or damage.
procedure
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 207 of 670

DTC.
Fuel System > Engine Control System > P0136 O2 Sensor Circuit(Bank 1 / Sensor 2)
Component Location
General Description
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
Page 208 of 670
ECM sets DTC P0136 if the ECM detects that the rear HO2S signal circuit is open.

DTC Strategy • Check open circuit on rear HO2S
• Open in signal harness
Enable Conditions • Open in ground harness
• Battery voltage > 10V
Threshold Value • Sensor element resistance > 60kΩ connectors
Diagnostic Time • 11 sec. • Faulty Heated O2
Sensor(HO2S)
Schematic Diagram
Signal Waveform
Page 209 of 670
Fig 1) - Normal value with idle after warm up: Above 0.8V
- Open in signal circuit: Approx. 0V
Monitor DTC Status


or damage.
procedure.

1. Ignition "OFF"
2. Disconnect HO2S and ECM connectors.
Page 210 of 670

procedure


procedure.
Page 211 of 670
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
Fig 1) Normal value with idle after warm up : Above 0.6V

Open in signal circuit : Approx.0V
3. Is "RR OXYGEN SNSR-B1" sensor data near the specification?

DTC
Fuel System > Engine Control System > P0137 O2 Sensor Circuit Low Voltage (Bank 1 / Sensor 2)
Component Location
Page 212 of 670
General Description
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).

Enable Conditions
<10Ω
Diagnostic Time • 1 sec. Sensor.(HO2S)
Schematic Diagram
Page 213 of 670
Signal Waveform
Monitor DTC Status

Page 214 of 670

or damage.
procedure.

1. Ignition "OFF"
Page 215 of 670

Repair open or short to ground in the signal circuit and go to "Verification of Vehicle Repair"
procedure.


3. Is "RR OXYGEN SNSR-B1" sensor data near the specification?
Page 216 of 670

DTC.
Go to the applicable troubleshooting procedure..
Fuel System > Engine Control System > P0138 O2 Sensor Circuit High Voltage (Bank 1 / Sensor 2)
Component Location
General Description
DTC Description
ECM sets DTC P0138 if the ECM detects signal voltage higher than the possible range of a properly operating rear

Page 217 of 670
Enable • Battery voltage >10V • Short to Battery in
Conditions signal harness
Threshold • Sensor voltage > 1.2V • Contact resistance in
Value connectors
Diagnostic Time • 1 sec. • Faulty Heated O2
Sensor.(HO2S)
MIL On • 2 Driving Cycles
Condition
Schematic Diagram
Signal Waveform
Page 218 of 670
Monitor DTC Status


or damage.
procedure.

1. Ignition "OFF"
Page 219 of 670

procedure.


3. Is sensor display within the specification?
Page 220 of 670

DTC.
Fuel System > Engine Control System > P0139 O2 Sensor Circuit Slow Response(Bank 1 / Sensor 2)
Component Location
General Description
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 221 of 670
• Slow response(Switching time check at entry in fuel
DTC Strategy
cut off)
• Sensor preheating and full phase finished
system
• Catalyst temp.model >350°C(662°F)
• Coolant temp>70°C(158°F) • Front and rear HO2S
• Down O2 Sensor Signal at Entry in Fuel Cut Off > connections reversed.
0.55V
• Average ratio(between measured and maximum connectors
Threshold Value
allowed switching time at entry in fuel cut-off) > 1 • HO2S contamination
Diagnostic Time • 3 fuel cut-off phases
Schematic Diagram
Signal Waveform
Page 222 of 670
Monitor DTC Status

System Inspection
Page 223 of 670
Check for corrosion on terminals
Check for terminal tension ( at the HO2S and at the PCM)
Check for damaged wiring
Check the HO2S ground circuit for a good connection
properly.
procedure
Go to "Exhaust System Inspection" procedure.
■ Exhaust System Inspection

1. Check the exhaust system for an exhaust leak near the engine.
2. Was an exhaust leak found?
procedure.
Go to "Air Leakage Inspection " procedure.

Exhaust system between HO2S and Three way catalyst for air leakage
EVAP system for leakage
PCV hose for proper installation
procedure

2. Install a fuel pressure gage
Test Condition : Ignition "ON" & Engine "ON" & Vacuum hose disconnected at IdleSpecification :
250~350kPa(2.50~3.50 kg/cm², 36~50 psi)
Page 224 of 670
Go to "Fuel Injector Inspection" procedure as below.
Repair" procedure.

clogging.
2. If fuel pressure is lower than specification : Check for fuel line pressure while pinching fuel return hose.

1. Ignition "OFF

procedure.
Ensure that the sensor is securely installed.
Repair as necessary and go to next step.
Page 225 of 670
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")conditionSpecification :
Above 0.6V

4. Is sensor data near the specified value?

DTC
Fuel System > Engine Control System > P0140 O2 Sensor Circuit No Activity Detected (Bank 1 /
Sensor 2)
Component Location
Page 226 of 670
General Description
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.
If same error code is set in the next driving cycle, the ECM illuminates the MIL.

Page 227 of 670
Case 1) • Sensor voltage excursion for Lean and Rich mixture
DTC
Strategy • Signal Plausibility with Rich Mixture (During Catalyst
Case 2)
Purge after Fuel Cut Off)
• Fuel Cut-Off Phase
Case 1)
• Integrated mass air flow since begin fuel cut-off >
20g
• Coolant Temperature > 70°C(158°F)
Enable • Sensor preheating and full heating phases finished
Condition • Integrated mass air flow in last fuel cut-off > 18g • Related fuse blown or missing
• Sensor signal at end of last fuel cut-off < 0.2V • Contact resistance in
Case 2) connectors
• Integrated mass air flow after fuel cut-off > 300g
• Maximum upstream O2 sensor voltage during • HO2S contamination
catalyst purge > 0.55V
• Catalyst Temperature Model > 350°C(662°F)
Case 1) • Voltage too high with fuel cut off > 0.2V
Threshold
Value • Max downstream O2 sensor voltage during Catalyst
Case 2)
purge after fuel cut-off < 0.55V

Time Case 2) • 3 valid fuel cut-off followed by catalyst enrichment
Schematic Diagram
Page 228 of 670
Signal Waveform
Monitor DTC Status


Page 229 of 670
or damage.
procedure.
Go to "HO2S Fuse Inspection" procedure.

Above 0.6V

3. Is sensor display within the specification?

Page 230 of 670
DTC
Fuel System > Engine Control System > P0150 O2 sensor Circuit Malfunction(Bank 2 / Sensor 1)
Component Location
General Description
DTC Description
ECM sets DTC P0150 if the ECM detects that the front HO2S signal circuit is open.

Page 231 of 670
Case 1) • Circuit malfunction
DTC
Strategy • Check time to closed loop control start with O2
Case 2)
sensor voltage
Enable Case 1) • Battery voltage > 10V
• Lambda control active • Open in signal harness
Condition
• Open in ground harness
Case 2) • Battery voltage > 10V
Case 1) • 0.37V < Sensor voltage < 0.54V (during 10 sec.) connectors
Threshold • Faulty Heated O2
• Time to closed loop control not activated when O2
Value Sensor(HO2S)
Case 2) sensor voltage blocked between 0.37 ~ 0.54V
(depends on coolant temperature at start)

Time Case 2) • Immediate
Schematic Diagram
Signal Waveform
Page 232 of 670
a minimum if 3 times in 10 seconds
Monitor DTC Status


Page 233 of 670
or damage.
procedure

1. Ignition "OFF"
3. Measure resistance between terminal 2 of the HO2S harness connector and 21 of the ECM harness connector.

procedure.

Page 234 of 670
procedure.
Fig 1) Normal value with idle after warm up : Signal is switching from rich(above 0.45V) to lean(below 0.45V) a
minimum of 3 times in 10 seconds.

Page 235 of 670
DTC
Component Location
General Description
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.

Page 236 of 670
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. • Faulty Heated O2
• Front HO2S heater is controlled in open loop Sensor.(HO2S)
Fail Safe control.
• EVAP. Emission control function is controlled in
minimum operation mode.
Schematic Diagram
Signal Waveform
Page 237 of 670
Monitor DTC Status


Page 238 of 670
or damage.
procedure.

1. Ignition "OFF"

procedure
Page 239 of 670

DTC.
Component Location
Page 240 of 670
General Description
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.

• Short to battery in signal
Threshold Value • Sensor voltage > 1.2V connectors
Sensor.(HO2S)
Schematic Diagram
Page 241 of 670
Signal Waveform
Monitor DTC Status

Page 242 of 670

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

1. Ignition "OFF"
Page 243 of 670

Go to "Component Circuit Inspection" procedure.
procedure.
Page 244 of 670

DTC.
Component Location
General Description
Page 245 of 670
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
<900°C(1652°F)
• Coolant temp. >70°C(158°F)
• 1200 <Engine speed(RPM) <3000
• 300<Mass air flow(mg/rev.) <840
system
• No misfire detected
• Not transient condition as below • Front and rear HO2S
1. Current Eng Speed - Mean of Eng Speed | < connections reversed.
400rpm • Contact resistance in
2. Current Mass A/Flow-Mean of Mass A/Flow| < connectors
270mg/rev.
• HO2S contamination
3. Current λCorr. Value-Mean of λCorr. Value| <5%
• Sum of O2 sensor lean/rich period > calculated
Threshold Value
period
Diagnostic Time • 70 lambda controller cycles
Schematic Diagram
Page 246 of 670
Signal Waveform
Monitor DTC Status
Page 247 of 670
System Inspection
Check for terminal tension ( at the HO2S and at the ECM).
Check the HO2S ground circuit for a good connection.
properly.
procedure

Page 248 of 670
procedure.

procedure
Go to "Fuel Pressure Inspection" procedure

Test Condition : Engine "ON" & Vacuum hose disconnected at Idle.


Repair" procedure.

clogging.

1. Ignition "OFF"
Page 249 of 670

procedure
3. Install Scantool and monitor the "FR OXYGEN SNSR-B2" parameter on the Scantool data list.
Test Condition : Ignition "ON" & Engine "ON"

HO2S and check for proper operation.
If the problem is corrected, replace HO2S and then go to "Verification of Vehicle Repair"
procedure.
Page 250 of 670
DTC.
Sensor 1)
Component Location
General Description
DTC Description

Page 251 of 670
DTC Case 1) • Signal plausibility during fuel cut off

Strategy Case 2) • Sensor voltage excursion
Case 1)
• Integrated Mass Air Flow since begin fuel cut-off >
20g
Enable
Condition • Sensor preheating and full heating phases finished
• 5 Cycles of A/F Closed Loop passed after lambda • Related fuse blown or missing
Case 2) control active. • Contact resistance in
• Lambda controller is not on the limit connectors
• Battery voltage > 10V • HO2S contamination
Case 1) • Voltage with fuel cut off > 0.2V
Threshold
Value • Mean value of Maximum voltage - Mean value of
Case 2)
Minimum voltage < 0.25V
Diagnostic Case 1) • 5 sec..

Time Case 2) • 120 sec.
Schematic Diagram
Signal Waveform
Page 252 of 670
Monitor DTC Status
Page 253 of 670

or damage.
procedure
Go to "HO2S Fuse Inspection" procedure

Page 254 of 670
3. Install Scantool and monitor the "FR OXYGEN SNSR-B2" parameter on the Scantool data list.
Test Condition : Ignition "ON" & Engine "ON"

HO2S and check for proper operation.
If the problem is corrected, replace HO2S and then go to "Verification of Vehicle Repair"
procedure.

DTC.
Fuel System > Engine Control System > P0156 O2 Sensor Circuit Malfunction (Bank 2 / Sensor 2)
Component Location
Page 255 of 670
General Description
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.

DTC Strategy • Check open circuit on rear HO2S
• Open in signal harness
Enable Conditions • Open in ground harness
• Battery voltage > 10V
Threshold Value • Sensor element resistance > 60 kΩ connectors
Diagnostic Time • Faulty Heated O2
• 11 sec.
Sensor(HO2S)
Schematic Diagram
Page 256 of 670
Signal Waveform
-Open in signal circuit: Approx. 0V
Monitor DTC Status

Page 257 of 670

or damage.
procedure.

1. Ignition "OFF"
Page 258 of 670
3. Measure resistance between terminal 2 of the sensor harness connector and 24 of the ECM harness connector.

procedure.


procedure.
Page 259 of 670
Test Condition : Engine "ON" & In Idle("Closed Loop")condition.

Specification : Above 0.6V.
3. Is sensor data within the specification?

DTC
Component Location
Page 260 of 670
General Description
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
Enable Conditions
<10Ω
Diagnostic Time • 1 sec Sensor(HO2S)
Schematic Diagram
Page 261 of 670
Signal Waveform
Monitor DTC Status

Page 262 of 670

or damage.
procedure.

1. Ignition "OFF"
Page 263 of 670
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.

Page 264 of 670

DTC.
Component Location
General Description
or in the rear exhaust pipe, which is able to detect the catalyst efficiency. The rear heated oxygen sensor (HO2S)
DTC Description

Page 265 of 670
DTC Strategy • Sensor Voltage High
Enable • Battery voltage >10V • Short to battery in
Conditions signal harness
Threshold • Sensor voltage > 1.2V • Contact resistance in
Value connectors
Diagnostic Time • 1 sec • Faulty Heated O2
Sensor(HO2S)
Condition
Schematic Diagram
Signal Waveform
Page 266 of 670
Monitor DTC Status


or damage.
procedure.

1. Ignition "OFF".
Page 267 of 670

procedure.

Page 268 of 670

DTC.
Component Location
General Description
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.

Page 269 of 670
• Slow response(Switching time check at entry in fuel
DTC Strategy
cut off)
• Sensor preheating and full phase finished
system
• Catalyst temp.model >350°C(662°F)
• Coolant temp >70°C(158°F) • Front and rear HO2S
• Down O2 Sensor Signal at Entry in Fuel Cut Off > connections reversed.
0.55V
• Average ratio(between measured and maximum connectors
Threshold Value
allowed switching time at entry in fuel cut-off) > 1 • HO2S contamination
Diagnostic Time • 3 fuel cut-off phases
Schematic Diagram
Signal Waveform
Page 270 of 670
Monitor DTC Status

Fault is intermittent caused by poor contact in the sensor`s and/or ECM`s connector or was
System Inspection
Page 271 of 670
Check for corrosion on terminals
Check for terminal tension ( at the HO2S and at the PCM)
Check for damaged wiring
Check the HO2S ground circuit for a good connection
properly.
procedure.

procedure.
■ Air Leakage Inpection

EVAP system for leakage
PCV hose for proper installation
procedure

2. Install a fuel pressure gage
Test Condition : Ignition "ON" & Engine "ON" & Vacuum hose disconnected at IdleSpecification
: 330~350kPa(3.30~3.50 kg/cm², 47~50 psi)
Page 272 of 670
Repair" procedure.

clogging.
- If it is, replace it.

1. Ignition "OFF"

procedure.
Page 273 of 670
Above 0.6V

DTC.
Sensor 2)
Component Location
Page 274 of 670
General Description
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.

Page 275 of 670
Case 1) • Sensor voltage excursion for Lean and Rich mixture
DTC
Strategy • Signal Plausibility with Rich Mixture (During Catalyst
Case 2)
Purge after Fuel Cut Off)
• Fuel Cut-Off Phase
Case 1)
• Integrated mass air flow since begin fuel cut-off >
20g
• Coolant Temperature > 70°C(158°F)
Enable • Sensor preheating and full heating phases finished
Condition • Integrated mass air flow in last fuel cut-off > 18g • Related fuse blown or missing
• Sensor signal at end of last fuel cut-off < 0.2V • Contact resistance in
Case 2) connectors
• Integrated mass air flow after fuel cut-off > 300g
• Maximum upstream O2 sensor voltage during • HO2S contamination
catalyst purge > 0.55V
• Catalyst Temperature Model > 350°C(662°F)
Case 1) • Voltage too high with fuel cut off > 0.2V
Threshold
Value • Max downstream O2 sensor voltage during Catalyst
Case 2)
purge after fuel cut-off < 0.55V

Time Case 2) • 3 valid fuel cut-off followed by catalyst enrichment
Schematic Diagram
Page 276 of 670
Signal Waveform
Monitor DTC Status
Page 277 of 670

or damage.
procedure.
Go to "HO2S Fuse Inspection" procedure.

Above 0.6V
Page 278 of 670

DTC.
Fuel System > Engine Control System > P0170 Fuel Trim (Bank 1)
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
Page 279 of 670
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
Enable Conditions • Dirty engine oil or oil level too
• Coolant temperature>60°C(140°F)
high
Threshold Value • Lambda controller = +/-32% • Front HO2S or MAFS
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
with this troubleshooting tree.
Page 280 of 670
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.
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 cylinders.
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.
Page 281 of 670
System Inspection
■ Check intake/exhaust system for restriction or leakage
1. Visually/physically inspect the air leakage in intake/exhaust system as following items.
Throttle body gasket.
Gasket between intake manifold and cylinder head.
Seals between intake manifold and fuel injectors.
2. Visually/physically inspect the restriction in intake/exhaust system as following items.
Air cleaner filter element for excessive dirt or for any foreign objects.
Throttle body inlet for damage or for any foreign objects.
Throttle bore, throttle plate and the IAC passages for chocking and for any foreign objects.
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.
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. Change the oil and oil filter and go to "Verification of
Vehicle Repair"
■ Sensor Contamination Inspection

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
Check MAFS for contamination, deterioration, or damage.
If contamination is evident on the HO2S or MAFS, replace contaminated sensor and go to next step.
■ Check for Leakage in EVAP System
Page 282 of 670
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

3. Start engine and let it idle. With the vacuum hose from the fuel pressure regulator disconnected, inspect fuel
pressure.
4. Is fuel pressure within the specification?

Repair" procedure.(Inspection Note)

clogging
- If pressure quickly increases, check pressure regulator

Test Condition : Ignition "OFF".Specification : No clogging and restriction.

Visually/physically inspect the engine mechanical problem. Repair as necessary and go to
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
Page 283 of 670
DTC.
Fuel System > Engine Control System > P0171 System too Lean (Bank 1)
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 >-15%
• Estimated altitude < 8000ft
Enable Conditions • Air leakage
• Coolant temp.>60°C (140°F)
• Fueling adaptation >14.5% • Leaking EVAP system
• Low fuel pressure
• Lambda controller +Trim value > 24% more than
Threshold Value • Faulty sensor signals
60sec. within 400sec.
Page 284 of 670
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.
Page 285 of 670

Go to "Air Leakage Inspection" procedure
System Inspection
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.
Throttle body gasket
Gasket between intake manifold and cylinder head
Seals between intake manifold and fuel injectors
2. Check for air leakage in EVAP. Purge control valve.
Go to "Fuel System Inspection" procedure.

2. Install a fuel pressure gauge.
Page 286 of 670
pressure.


clogging

Test Condition : Ignition "OFF".

Specification : No clogging and restriction.


Page 287 of 670
DTC.
Fuel System > Engine Control System > P0172 System too Rich (Bank 1)
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.

DTC Strategy • Monitoring deviation of lambda fuel control • Restricted intake or exhaust
• Estimated canister loading >-15% system
• Estimated altitude < 8000ft • Dirty engine oil or oil level too
Enable Conditions high
• Fueling adaptation >14.5% • Front HO2S or MAFS
contamination
• Lambda controller +Trim value < -27% more than • Over purging of the EVAP
Threshold Value
60sec. within 400sec. system
Diagnostic Time • 400 sec. • High fuel pressure
• Faulty sensor signals
Monitor DTC Status
Page 288 of 670
Page 289 of 670

Go to " Check intake/exhaust system for restriction or leakage " procedure.
System Inspection
■ CHECK FOR RESTRICTED INTAKE OR EXHAUST SYSTEM
Air cleaner filter element for excessive dirt or for any foreign objects
Throttle body inlet for damage or for any foreign objects
Throttle bore, throttle plate and the ICA passages for chocking and for any foreign objects
Restricted exhaust system
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

Page 290 of 670
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
■ SENSOR CONTAMINATION INSPECTION

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
■ FUEL SYSTEM INSPECTION

pressure.


clogging
Page 291 of 670
■ FUEL INJECTOR INSPECTION


DTC.
Fuel System > Engine Control System > P0173 O2 Sensor System - Lambda Controller at the Limit
(Bank 2)
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.
Page 292 of 670
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.

DTC Strategy • Monitoring deviation of lambda controller • Air leakage or restriction in
intake or exhaust system
• Canister purge solenoid closed
Enable Conditions • Dirty engine oil or oil level too
high
Threshold Value • Lambda controller = +/-32% • Front HO2S or MAFS
contamination
Diagnostic Time • 2 min
• Fuel system
• EVAP system
MIL On Condition
• 2 Driving Cycles • Faulty sensor signals
Monitor DTC Status
Page 293 of 670

If the RPM loss between cylinders is quite large200RPM or more) and engine has high mileage, there is
Page 294 of 670
System Inspection
■ 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.
Air cleaner filter element for excessive dirt or for any foreign objects.
Throttle body inlet for damage or for any foreign objects.
Throttle bore, throttle plate and the IAC passages for chocking and for any foreign objects.
Restricted exhaust system.
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

Remove and inspect the HO2S(B1S1) for any silicon contamination. This contamination will be indicated by a
■ Check for Leakage in EVAP System
Page 295 of 670

pressure.


clogging


Page 296 of 670
DTC.
Fuel System > Engine Control System > P0174 System too Lean (Bank 2)
General Description
DTC Description
negative deviation.

DTC Strategy • Monitoring deviation of fuel centrol
• Estimated canister loading >-15%
• Estimated altitude < 8000ft
Enable Conditions
• Fueling adaptation >14.5% • Air leakage
• Leaking EVAP system
• Lambda controller +Trim value > 24% more than
Threshold Value • Low fuel pressure
60sec. within 400sec.
Diagnostic Time • 400 sec
• EVAP. Emission control function is controlled in
Fail Safe
minimum operation mode
Page 297 of 670
Monitor DTC Status
Mass Air Flow Sensor are stored, do ALL REPAIRS associated with those codes before proceeding with further
troubleshooting.
Page 298 of 670

System Inspection
2. Check for air leakage in EVAP. Purge control valve.

2. Install a fuel pressure gauge.
Page 299 of 670
pressure.


clogging

Test Condition : Ignition "OFF"

Specification : On clogging and restriction.


Page 300 of 670
DTC.
Fuel System > Engine Control System > P0175 System too Rich (Bank 2)
General Description
DTC Description
negative deviation.

DTC Strategy • Monitoring deviation of fuel control • Restricted intake or exhaust
• Estimated canister loading >-15% system
• Estimated altitude < 8000ft • Dirty engine oil or oil level too
Enable Conditions high
• Fueling adaptation >14.5% • Front HO2S or MAFS
contamination
• Lambda controller +Trim value < -27% more than • Over purging of the EVAP
Threshold Value
60sec. within 400sec. system
Diagnostic Time • 400 sec • High fuel pressure
Monitor DTC Status
Page 301 of 670
Page 302 of 670

System Inspection
■ Check for Restricted Intake or Exhaust System
Air cleaner filter element for excessive dirt or for any foreign objects
Throttle body inlet for damage or for any foreign objects
Throttle bore, throttle plate and the ICA passages for chocking and for any foreign objects
Restricted exhaust system
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.

Page 303 of 670
Go to "Sensor Contamination Inspection" procedure
The engine oil is diluted with fuel. Chang the oil and oil filter and go to "Verification of

Remove and inspect the front HO2S for any silicon contamination. This contamination will be indicated by a
■ Over Purging of the EVAP System

pressure.
Specification : 330~350kPa(3.30~3.50 kg/mm², 47~50 psi)

Repair" procedure.

clogging
Page 304 of 670
Test Condition : Ignition "OFF"Specification : No clogging and restriction.


DTC.
Fuel System > Engine Control System > P0230 Fuel Pump Primary Circuit
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.
Page 305 of 670
DTC Description
ECM sets DTC P0230 if the ECM detects the fuel pump relay control circuit is open, shorted to ground or battery.

• 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
Diagnostic Time • Faulty relay
• 1.5 sec
MIL On Condition •-
Schematic Diagram
Monitor DTC Status

Page 306 of 670
1. Ignition "OFF".
2. Remove the fuel pump relay.
3. Apply 12V and a ground to 5 and 3 terminals of the fuel pump relay
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.)
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

or damage.
Page 307 of 670
procedure.

1. Remove the fuel pump relay.
3. Measure the voltage between terminal 1 of the fuel pump relay harness connector and chassis ground.
4. Measure the voltage between terminal 5 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

(1) Ignition "OFF" & Relay connector : Disconnected.
(2) Measure resistance between terminal 3 of the relay harness connector and chassis ground.
Page 308 of 670

(2) Ignition "ON" and Engine "OFF".
(3) Measure voltage between terminal 3 of the relay harness connector and chassis ground.
Specification : Approx 0V

Go to next step as below

(1) Measure resistance between terminals 3 of the relay harness connector and 10 of the ECM harness
connector.
Specification : Approx 0Ω
Page 309 of 670
Thoroughly check connectors for loose or poor connections, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and go to

DTC.
Fuel System > Engine Control System > P0261 Cylinder 1 Injector Circuit Low
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 310 of 670
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
Diagnostic Time • 1.5 sec
connectors
MIL On • 2 Driving Cycles • Faulty injector
Condition
Specification
Temperature
Resistance (Ω)
(°F) (°F)
20 68 13~16
Schematic Diagram
Page 311 of 670
Monitor DTC Status

freeze frame data or enable conditions..
4. Read "DTC Status" parameter..
Page 312 of 670
1. Ignition "OFF".
2. Disconnect injector connector
3. Measure resistance between terminals 1 and 2 of the injector connector(Component side).
Specification : Approx. 13~16Ω 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

or damage.
Page 313 of 670
procedure.

1. Ignition "ON" & Engine "OFF"
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.

(1) Ignition "OFF"
Page 314 of 670
Repair open or short to ground in control harness and go to "Verification of Vehicle Repair"
procedure.

DTC.
Fuel System > Engine Control System > P0262 Cylinder 1 Injector Circuit High
Component Location
General Description
momentarily peak.
DTC Description
ECM sets DTC P0262 if the ECM detects that injector (Cylinder #1) control circuit is open or shorted to battery
Page 315 of 670
voltage.

• 10< Battery voltage (V)<16 • Open or short to battery
Enable Conditions
• Engine speed (rpm)>30 in control harness.
Threshold Value • Open or short to battery
connectors
Diagnostic Time • 1.5 sec • Faulty injector
Specification
Temperature
Resistance (Ω)
(°F) (°F)
20 68 13~16
Schematic Diagram
Page 316 of 670
Monitor DTC Status

Page 317 of 670
1. Ignition "OFF".




or damage.
Page 318 of 670
procedure.


Injector.

(1) Ignition "OFF"
Page 319 of 670
(4) Measure voltage between terminal 2 of the injector harness connector and chassis ground.

Repair as necessary and go to "Verification of Vehicle Repair" procedure.Repair open
or short to
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.

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 320 of 670
DTC.
Component Location
General Description
momentarily peak.
DTC Description

Page 321 of 670
Enable • 10< Battery voltage (V)<16 harness
connectors
Condition
Specification
Temperature
Resistance (Ω)
(°F) (°F)
20 68 13~16
Schematic Diagram
Page 322 of 670
Monitor DTC Status

Page 323 of 670
1. Ignition "OFF".




or damage.
Page 324 of 670
procedure.


Injector.

(1) Ignition "OFF"
(2) Measure resistance between terminal 2 of the injector harness connector and chassis ground.
Page 325 of 670

DTC.
Component Location
General Description
momentarily peak.
DTC Description
ECM sets DTC P0265 if the ECM detects that injector (Cylinder #2) control circuit is open or shorted to baattery
voltage.
Page 326 of 670

• 10≤ Battery voltage (V)≤16 • Open or short to battery
Enable Conditions
connectors
Specification
Temperature
Resistance (Ω)
(°F) (°F)
20 68 13~16
Schematic Diagram
Page 327 of 670
Monitor DTC Status

Page 328 of 670
1. Ignition "OFF".




or damage.
Page 329 of 670
procedure.


Injector.

(1) Ignition "OFF"
Page 330 of 670

or short to
2. Repair open or short to ground in control harness and go to "Verification of Vehicle Repair" procedure.
(1) Ignition "OFF".
connector.


Page 331 of 670
DTC.
Component Location
General Description
momentarily peak.
DTC Description

Page 332 of 670
Enable • 10≤ Battery voltage (V)≤16 harness
connectors
Condition
Specification
Temperature
Resistance (Ω)
(°F) (°F)
20 68 13~16
Schematic Diagram
Page 333 of 670
Monitor DTC Status

Page 334 of 670
1. Ignition "OFF".




or damage.
Page 335 of 670
procedure.


Injector.

(1) Ignition "OFF"
Page 336 of 670

DTC.
Component Location
General Description
momentarily peak.
DTC Description
voltage.
Page 337 of 670

Enable Conditions
connectors
Specification
Temperature
Resistance (Ω)
(°F) (°F)
20 68 13~16
Schematic Diagram
Page 338 of 670
Monitor DTC Status

Page 339 of 670
1. Ignition "OFF".




or damage.
Page 340 of 670
procedure.


Injector.

(1) Ignition "OFF"
Page 341 of 670

or short to
2. Check for open in control circuit.

(1) Ignition "OFF".
connector.


Page 342 of 670
DTC.
Component Location
General Description
momentarily peak.
DTC Description

Page 343 of 670
connectors
Condition
Specification
Temperature
Resistance (Ω)
(°F) (°F)
20 68 13~16
Schematic Diagram
Page 344 of 670
Monitor DTC Status

Page 345 of 670
1. Ignition "OFF".




or damage.
Page 346 of 670
procedure.


Injector.

(1) Ignition "OFF"
Page 347 of 670

DTC.
Component Location
General Description
momentarily peak.
DTC Description
voltage.
Page 348 of 670

• 10≤Battery voltage (V)≤16 • Open or short to battery
Enable Conditions
connectors
Specification
Temperature
Resistance (Ω)
(°F) (°F)
20 68 13~16
Schematic Diagram
Page 349 of 670
Monitor DTC Status

Page 350 of 670
1. Ignition "OFF".




or damage.
Page 351 of 670
procedure.


Injector.

(1) Ignition "OFF"
Page 352 of 670

or short to

(1) Ignition "OFF".
connector.


Page 353 of 670
DTC.
Component Location
General Description
momentarily peak.
DTC Description

Page 354 of 670
connectors
Condition
Specification
Temperature
Resistance (Ω)
(°F) (°F)
20 68 13~16
Schematic Diagram
Page 355 of 670
Monitor DTC Status

Page 356 of 670
1. Ignition "OFF".




or damage.
Page 357 of 670
procedure.


Injector.

(1) Ignition "OFF"
(2) Measure resistance between terminal 2 of the injector harness connector and chassis ground..
Page 358 of 670

DTC.
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.
Page 359 of 670

Enable Conditions
connectors
Specification
Temperature
Resistance (Ω)
(°F) (°F)
20 68 13~16
Schematic Diagram
Page 360 of 670
Monitor DTC Status

Page 361 of 670
1. Ignition "OFF".




or damage.
Page 362 of 670
procedure.


Injector.

(1) Ignition "OFF"
Page 363 of 670

or short to

(1) Ignition "OFF".
connector.


Page 364 of 670
DTC.
Component Location
General Description
momentarily peak.
DTC Description

Page 365 of 670
connectors
Condition
Specification
Temperature
Resistance (Ω)
(°F) (°F)
20 68 13~16
Schematic Diagram
Page 366 of 670
Monitor DTC Status

Page 367 of 670
1. Ignition "OFF".




or damage.
Page 368 of 670
procedure.


Injector.

(1) Ignition "OFF"
Page 369 of 670

DTC.
Component Location
General Description
momentarily peak.
DTC Description
voltage.
Page 370 of 670

Enable Conditions
connectors
Specification
Temperature
Resistance (Ω)
(°F) (°F)
20 68 13~16
Schematic Diagram
Page 371 of 670
Monitor DTC Status

Page 372 of 670
1. Ignition "OFF".




or damage.
Page 373 of 670
procedure.


Injector.

(1) Ignition "OFF"
Page 374 of 670

or short to

(1) Ignition "OFF".
connector.


Page 375 of 670
DTC.
Fuel System > Engine Control System > P0300 Random/Multiple Cylinder Misfire Detected
Component Location
General Description
The Misfire monitor diagnostic is based on crankshaft rotation velocity variation. The ECM determines crankshaft
rotational velocity using the crankshaft position sensor and camshaft position sensor. When a cylinder misfires the
crankshaft slows down momentarily. By monitoring the crankshaft and camshaft position sensor signals, the ECM
can calculate when a misfire occurs. For a non-catalyst damaging misfire, the diagnostic will be required to report a
misfire present within 1000-3200 engine revolutions. For catalyst damaging misfire, the diagnostic will respond to
monitor 200 engine revolutions. Rough roads may cause false misfire detection. The rough road(acceleration)sensor
consists of a piezoelectric vibration pick up which detects vertical acceleration of the vehicle. The sensor signal is
used by the ECM to determine the degree of vertical movement of the car, for example, on a bumpy road. Since this
may also cause uneven engine running, the ECM uses the signal to distinguish the phenomenon from actual misfiring.
DTC Description
The ECM must monitor the engine for misfiring possibly caused by ignition coil defects or injector fails. If misfiring is
detected, the ECM will identify the cylinder(s) that has(have) misfired and then calculate misfiring rate for a given
duration. The DTC for Misfire (P0301 to 0306) is set as soon as the misfiring rate exceeds the limit which may
result in damage to the catalyst or increase emissions. The ECM stores the individual DTC for a cylinder which has
more than a 10% total misfire rate. With a more than two cylinder misfire detection, the ECM sets P0300.

Page 376 of 670
DTC Strategy • Misfire is detected on 2 or more cylinder
• 480 < Engine speed(RPM) < 6500
• Mass Air Flow above zero load : 216 ~ 564 mg/rev • Faulty spark plugs,
Enable Conditions (depending on rpm) hightension lead, or Ignition
• No injector shut off coil
• No rough road • Incorrect valve timing
• Uneven compression
Case 1) • Misfire = 2.8~17% within 200 rev.
Threshold • Air leakage
Value • First 1000 rev.: Misfire > 2.0% • Improper Fuel pressure or
Case 2)
• After first 1000 rev.: Misfire > 2.0% dirty fuel.
Case 1) • 3*200 rev. in FTP Area Else 200 rev. • Blocked/Leaking injectors
Diagnosis
Time • Leakage between cooling
Case 2) • 1000 rev. or 4*1000 rev. system and cylinder
MIL On Case 1) • Immediate
Condition Case 2) • 2 Driving Cycles
Schematic Diagram
Monitor DTC Status
troubleshooting tree
Page 377 of 670
freeze frame data or enable conditions
Page 378 of 670

Go to "Timing Inspection" procedure
to "Spark plug cable Inspection" procedure.
System Inspection
■ Spark Plug Cable Inspection
1. Remove suspect cylinder`s spark plug cable.
Damage, crack and flashover
3. Measure the resistance of the spark plug cable referring to specification.
Specification :
Spark Plug Inspection
No.1 4.39~6.59
No.2 2.28~3.43
No.3 3.49~5.24
No.4 1.9~2.86
No.5 3.25~4.87
No.6 1.3~1.95
Resistance should not be higher than 10,000Ω per foot of cable. If resistance is higher than specification,
replace the cable.
Page 379 of 670
Go to "Spark Plug Inspection " procedure.
procedure.
■ Spark Plug Inspection

1. Remove suspect cylinder`s spark plugs.
Damaged insulation, Worn electrodes, Oil or fuel fouled, Loose terminals and cracks.
Check for plug gap : 1.0 - 1.1 mm (0.039 - 0.043 in.).
Check if the spark plug for the relevant cylinder is lighter in color than the other plugs.
procedure.
Go to "Fuel Injector Inspection" procedure.

Test Condition : Ignition "OFF"Specification : No clogging and restriction

Visually/physically inspect the engine mechanical problem as below:
Bent push rods
Leaky or sticky valves or rings
Excessive valve deposits
Weak valve spring
Leaking head gasket
If NG, repair as necessary and go to "Verification of Vehicle Repair"
procedure.
If OK, go to "Ignition Coil Inspection" procedure
procedure.
■ Ignition Coil Inspection

1. Ignition "OFF"
2. Disconnect ignition coil connector
Damage, cracks and flashover.
Page 380 of 670
4. Measure the resistance in each primary coil, referring to specification.(Component side).
Specification : Approx. 0.96 ± 10% (Ω) at 20°C(68°C)No.1 & 4 cyl. : terminals 3& 2No.2 & 5
cyl. : terminals 3& 1No.3 & 6 cyl. : terminals 3& 4

Go to "Timing Inspection" procedure.
Test with a new ignition coil and check for proper operation. If problem is corrected,
replace ignition coil and go to "Verification of Vehicle Repair" procedure.
■ Timing Inspection
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 381 of 670
4. Are "CKP T/WHEELS-LO CMP" & "CKP T/WHEELS-HI CMP" parameters within the specification?
Go to " Air Leakage Inspection " procedure.
Remove Crankshaft Position Sensor(CKPS) 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 housing to teeth on flywheel/torque
converter (measurement "A") and from mounting surface on sensor to sensor tip (measurement "B")
subtract "B" from "A"
If fail to synchronize CKPS with CMPS, check that the crankshaft and camshaft are correctly aligned the
matching marks of the pulleys. Repair or readjust as necessary and go to "Verification of Vehicle Repair"
procedure.

If OK, go to next step
Repair air leakage and go to "Verification of Vehicle Repair"
procedure.

3. Start engine and let it idle. Inspect fuel pressure with vacuum hose disconnected.
Test Condition : Engine "ON" at IdleSpecification : 330~350kPa(3.30~3.50 kg/cm², 47~50 psi)

Repair as necessary refer to inspection noted as below and go to "Verification of Vehicle
Repair" procedure

clogging.

1.
Page 383 of 670
General Description
DTC Description
more than a 10% total misfire rate.

DTC Strategy • Calculation of engine roughness
Case 2)
Diagnosis
Page 384 of 670
system and cylinder
Schematic Diagram
Monitor DTC Status
troubleshooting tree
Page 385 of 670
steady an rpm reading as possible.Caution! Before beginning tests; set the parking brake, place gear selector in P
or N and block drive wheels for safety.

Page 386 of 670
System Inspection
Specification :
No.1 4.39~6.59
No.2 2.28~3.43
No.3 3.49~5.24
No.4 1.9~2.86
No.5 3.25~4.87
No.6 1.3~1.95
replace the cable.

procedure.

Page 387 of 670
procedure.


Bent push rods
Weak valve spring
Leaking head gasket
procedure
If OK, go to "Ignition Coil Inspection" procedure.
procedure.

1. Ignition "OFF"
4. Measure the resistance between terminals 2 and 3 of the primary ignition coil. (Component side)
Specification : Approx. 0.96 ± 10% (Ω) at 20°C(68°C)

Page 388 of 670

+/- 4 tooth
procedure.

procedure.

Page 389 of 670

Repair" procedure

clogging.

DTC.
Fuel System > Engine Control System > P0302 Cylinder 2-Misfire detected
Component Location
Page 390 of 670
General Description
DTC Description

Case 2)
Diagnosis
Page 391 of 670
system and cylinder
Schematic Diagram
Monitor DTC Status
Page 392 of 670
Page 393 of 670

System Inspection
Specification :
No.1 4.39~6.59
No.2 2.28~3.43
No.3 3.49~5.24
No.4 1.9~2.86
No.5 3.25~4.87
No.6 1.3~1.95
replace the cable.
Page 394 of 670
procedure.

procedure.


Bent push rods
Weak valve spring
Leaking head gasket
procedure.
procedure.

1. Ignition "OFF"
Page 395 of 670
Specification : Approx. 0.96 ± 10%Ω at 20°C(68°C)


+/- 4 tooth
Page 396 of 670
subtract "B" from "A".
procedure.

procedure.


Page 397 of 670
Repair" procedure

clogging.

DTC.
Component Location
Page 398 of 670
General Description
DTC Description

Case 2)
Diagnosis
Page 399 of 670
system and cylinder
Schematic Diagram
Monitor DTC Status
Page 400 of 670

Page 401 of 670
System Inspection
Specification :
No.1 4.39~6.59
No.2 2.28~3.43
No.3 3.49~5.24
No.4 1.9~2.86
No.5 3.25~4.87
No.6 1.3~1.95
replace the cable.

Go to "Spark Plug Inspection " procedure..
procedure.

Page 402 of 670
procedure.


Bent push rods
Weak valve spring
Leaking head gasket
procedure.
procedure.

1. Ignition "OFF"

Page 403 of 670

+/- 4 tooth
subtract "B" from "A".
procedure.

procedure.

Page 404 of 670

Repair" procedure

clogging.

DTC.
Component Location
Page 405 of 670
General Description
DTC Description

Case 2)
Diagnosis
Page 406 of 670
system and cylinder
Schematic Diagram
Monitor DTC Status
Page 407 of 670
Present fault : DTC is occurring at present time

Page 408 of 670
System Inspection
Specification :
No.1 4.39~6.59
No.2 2.28~3.43
No.3 3.49~5.24
No.4 1.9~2.86
No.5 3.25~4.87
No.6 1.3~1.95
replace the cable.

procedure.

Page 409 of 670
procedure.

Test Condition : Ignition "OFF" Specification : No clogging and restriction

Bent push rods
Weak valve spring
Leaking head gasket
procedure.
procedure.

1. Ignition "OFF"
4. Measure the resistance between terminals 2 and 3 of the primary ignition coil (Component side).

Page 410 of 670

+/- 4 tooth
subtract "B" from "A"..
procedure.

procedure.

Page 411 of 670
Test Condition : Engine "ON" at Idle Specification : 330~350kPa(3.30~3.50 kg/cm², 47~50 psi)

Repair" procedure

clogging.

DTC.
Component Location
Page 412 of 670
General Description
DTC Description

Case 2)
Diagnosis
Page 413 of 670
system and cylinder
Schematic Diagram
Monitor DTC Status
Page 414 of 670

Page 415 of 670
System Inspection
Specification :
No.1 4.39~6.59
No.2 2.28~3.43
No.3 3.49~5.24
No.4 1.9~2.86
No.5 3.25~4.87
No.6 1.3~1.95
replace the cable.

procedure.

Page 416 of 670
procedure.


Bent push rods
Weak valve spring
Leaking head gasket
procedure.
procedure.

1. Ignition "OFF"

Page 417 of 670

+/- 4 tooth
procedure.

1. isually/physically inspect the air leakage in intake/exhaust system as following items,
procedure.

Page 418 of 670

Repair" procedure

clogging.

DTC.
Component Location
Page 419 of 670
General Description
DTC Description

Case 2)
Diagnosis
Page 420 of 670
system and cylinder
Schematic Diagram
Monitor DTC Status
Page 421 of 670

Page 422 of 670
System Inspection
Specification :
No.1 4.39~6.59
No.2 2.28~3.43
No.3 3.49~5.24
No.4 1.9~2.86
No.5 3.25~4.87
No.6 1.3~1.95
replace the cable.

procedure

Page 423 of 670
procedure.


Bent push rods
Weak valve spring
Leaking head gasket
procedure.
procedure.

1. Ignition "OFF"
4. Measure the resistance between terminals 4 and 3 of the primary ignition coil. (Component side).

Page 424 of 670

+/- 4 tooth
procedure.

procedure.

Page 425 of 670

Repair" procedure

clogging.

DTC.
Fuel System > Engine Control System > P0315 Crankshaft Position System Variation Not Learned
Component Location
Page 426 of 670
General Description
A Misfire induces a decrease in the engine speed and causes a variation in the segment period. Therefore, misfiring
detection is based on the observation of this variation of the segment period.
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.

DTC Strategy • Monitor segment time adaptation
• Mass Air Flow above zero load : 216 ~ 564 mg/rev • Improperly installed target
Enable Conditions (depending on rpm) wheel
• No injection shut off. • Contact resistance in
• No rough road. connectors
Threshold Value • Segment adaptation value is at the limit = 5/1000
Signal Waveform
Page 427 of 670
Fig 1) Normal wave form with idle : The square wave signal should be smooth and without any distortion.
Fig 2) Normal wave form with engine running : The CMP falling(rising) edge is coincided with 38+/-4 tooth of the
CKP from one longer signal(missing tooth)
Monitor DTC Status
If any codes relating to CKPs are stored, do ALL REPAIRS associated with those codes before proceeding with
troubleshooting.
Page 428 of 670
2. Connect scantool and select "Current Data" mode.
Specification :
"CKP T/WHEELS-LO CMP" : 38 +/- 4 tooth
"CKP T/WHEELS-HI CMP" : 98 +/- 4 tooth
Thoroughly check connectors between CKPS and ECM for loose or poor connections,
bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary
Remove CKP and calculate air gap between sensor and flywheel/torque converter.
Readjust as necessary and go to next step.
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
Page 429 of 670

DTC.
Fuel System > Engine Control System > P0325 Knock Sensor 1 Circuit (Bank 1 or Single Sensor)
Component Location
General Description
The knock sensor is attached to the cylinder block and senses engine knocking. The sensor contains a piezoelectric
element that converts vibration (or noise) into voltage signal and sends this signal to ECM. With input signals from
camshaft position and crankshaft position sensor, ECM can identify which cylinder is knocking. ECM filters
vibrations and determines if the vibrations are knocking signal. The Engine Control Module (ECM) uses this signal to
suppress knocking by retarding ignition timing. The ECM will set a code (Malfunction Indicator Lamp will Not turn
on) if during two driving cycles the Knock sensor’s output voltage falls below minimum threshold. This code
indicates an unexpected vibration is being read by the Knock sensor or ECM under normal engine operation.
DTC Description
The ECM monitors the range of the analog input signal from knock sensor to check sensor failure that is short circuit
or open circuit. If the difference between knock signal and noise level is smaller than the threshold during defined
time period, the DTC P0325 is set. In case the noise level is higher than the upper threshold or lower than the lower
threshold, the DTC P0325 is set too.

Page 430 of 670
DTC Strategy • Voltage Range Check
• Knock control enabled • Open/short in signal or
Enable Conditions ground circuit
Threshold Value • Mean value of sensor signal < 0.1V
connectors
Diagnostic Time • 20 revolutions • Faulty knock sensor
Schematic Diagram
Monitor DTC Status

Page 431 of 670

or damage.
procedure.

1. Ignition "OFF".
2. Disconnect Knock sensor connector.
3. Measure resistance between terminals 1 of the sensor harness connector and 30 of the ECM harness connector.

Check for an open in the ground circuit. Repair as necessary and go to "Verification of

Page 432 of 670
(1) Ignition "OFF".
(2) Measure resistance between terminals 2 of the sensor harness connector and 29 of the ECM harness
connector.


(1) Ignition "OFF"
(2) Measure resistance between terminal 2 of the sensor harness connector and chassis ground

Page 433 of 670
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

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)

Page 434 of 670
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 : Approx. 16 ~ 28 N.m (160 ~ 250 kg.cm, 11.8 ~ 18.4 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 Vehicle Repair" procedure.

DTC.
Fuel System > Engine Control System > P0330 Knock Sensor 2 Circuit (Bank 2)
Component Location
Page 435 of 670
General Description
The knock sensor is attached to the cylinder block and senses engine knocking. The sensor contains a piezoelectric
element that converts vibration (or noise) into voltage signal and sends this signal to ECM. With input signals from
camshaft position and crankshaft position sensor, ECM can identify which cylinder is knocking. ECM filters
vibrations and determines if the vibrations are knocking signal. The Engine Control Module (ECM) uses this signal to
suppress knocking by retarding ignition timing. The ECM will set a code (Malfunction Indicator Lamp will Not turn
on) if during two driving cycles the Knock sensor’s output voltage falls below minimum threshold. This code
indicates an unexpected vibration is being read by the Knock sensor or ECM under normal engine operation.
DTC Description
The ECM monitors the range of the analog input signal from knock sensor to check sensor failure that is short circuit
or open circuit. If the difference between knock signal and noise level is smaller than the threshold during defined
time period, the DTC P0325 is set. In case the noise level is higher than the upper threshold or lower than the lower
threshold, the DTC P0330 is set too.

DTC Strategy • Voltage Range Check
• Knock control enabled • Open/short in signal or
Enable Conditions ground circuit
Threshold Value • Mean value of sensor signal < 0.1V
connectors
Diagnostic Time • 20 revolutions • Faulty knock sensor
Schematic Diagram
Page 436 of 670
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 437 of 670

or damage.
procedure.

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.


Page 438 of 670
(1) Ignition "OFF".
connector.


(1) Ignition "OFF"

Page 439 of 670
(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)

Page 440 of 670
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 : Approx. 16 ~ 28N.m (160 ~ 250 kg.cm, 11.8 ~ 18.4 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 Vehicle Repair" procedure.

DTC.
Fuel System > Engine Control System > P0335 Crankshaft Position Sensor \'A\' Circuit
Component Location
Page 441 of 670
General Description
The Crankshaft Position Sensor (CKPS) is a hall effect type sensor that generates voltage using a sensor and a
target wheel mounted on the crankshaft; there are 58 slots in the target wheel where one is longer than the others.
When the slot in the wheel aligns with the sensor, the sensor voltage outputs low. When the metal (tooth) in the
wheel aligns with the sensor, the sensor voltage outputs high. During one crankshaft rotation there are 58 rectangular
signals and one longer signal. The ECM calculates engine RPM by using the sensor’ s signal and controls the
injection duration and the ignition timing. Using the signal differences caused by the longer slot, the ECM identifies
which cylinder is at top dead center.
DTC Description
The ECM sets DTC P0335 when the number of crankshaft teeth during one revolution is incorrect or crankshaft
signal is missing while camshaft signal is detected.

Item Detecting Condtion Possible Cause
DTC Strategy • Check Crankshaft Signal Switching
Enable Case 1) • Before Synchronization

• Open or short in signal,
Conditions Case 2) • After Synchronization ground or power supply
circuit
• Valid Crankshaft Teeth not yet detected with
Camshaft Signal • Contact resistance in
Threshold Case 1) connectors
• Can not detect TDC with valid Crankshaft Teeth
Value and Camshaft Signal • Damage to the connecting
flange/flywheel
Case 2) • Number of Crankshaft Teeth is not correct • Misadjust crankshaft and
camshaft pulley position
Diagnostic Case 1) • 4 revolutions
Time • Faulty CKP sensor
Case 2) • 5 revolutions
Schematic Diagram
Page 442 of 670
Signal Waveform
Monitor DTC Status

Page 443 of 670

or damage.
procedure.

1. Ignition "OFF".
2. Disconnect CKP sensor connector.
Page 444 of 670

Go to "Ground Circuit Inspection" procedure
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 445 of 670
connector.



Page 446 of 670

Specification :
Page 447 of 670
"Verification Vehicle Repair" procedure .
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
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

DTC.
Fuel System > Engine Control System > P0340 Camshaft Position Sensor \'A\' Circuit (Single Sensor)
Component Location
Page 448 of 670
General Description
The Camshaft Position Sensor (CMPS) is a sensor that detects the compression TDC of the NO. 1 cylinder. The
CMPS consists of a hall type sensor and a target on the end of the intake camshaft. When the target triggers the
sensor, the sensor voltage is 5V. If not, the sensor voltage is 0V. These CMPS signal is sent to the ECM and the
ECM uses the CMPS signal for synchronizing the firing of sequential fuel injectors.
DTC Description
The ECM monitors the camshaft sensor signal transition position which must change only once per crankshaft
revolution. If no camshaft signal is detected while crankshaft signal is detected, the ECM sets DTC P0340.

DTC Strategy • Check camshaft signal switching
• Open or short in signal,
Enable Conditions • No Crankshaft Position Sensor signal error ground or power supply
circuit
• No signal switching
Threshold Value • Rising/falling camshaft edge not within defined
connectors
window : -5 ~ +5 teeth
• Misadjust crankshaft and
Diagnostic Time • 80 revolutions camshaft pulley position
• Faulty CMP sensor
Schematic Diagram
Signal Waveform
Page 449 of 670
Monitor DTC Status

Page 450 of 670

or damage.
procedure.

1. Ignition "OFF".
2. Disconnect CMP sensor connector.
Page 451 of 670
Go to "Ground Circuit Inspection" procedure
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.

Check for an open or short to battery in the ground circuit.
procedure

Page 452 of 670
connector.



Page 453 of 670

Specification :
Page 454 of 670
"Verification Vehicle Repair" procedure .
Remove CKP and calculate air gap.
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

DTC.
Fuel System > Engine Control System > P0350 Ignition Coil Primary / Secondary Circuit Malfunction
Component Location
General Description
With the ignition switch in the ON or START position, voltage is applied to the ignition coil. Each ignition coil
consists of two coils. High tension leads go to each cylinder from the ignition coils. The ignition coils fire two spark
plugs on every power stroke (the cylinder under compression and the cylinder on the exhaust stroke). The Engine
Control Module (ECM) provides a switching circuit to ground for energizing the primary ignition coils. The ECM
uses the crankshaft position sensor and camshaft position sensor signal to time the energizing of the coil. When a
primary ignition coil is energized and de-energized, the secondary coil produces a high voltage spike to the attached
spark plugs.
Page 455 of 670
DTC Description
The ECM monitors the peak voltage duration of the ignition primary circuit. If abnormal signal is detected on three
cylinders or more, the ECM sets DTC P0350

DTC Strategy • Monitoring ignition coil primary voltage • Open or short in power
supply circuit
Enable Conditions • Coolant temperature >75°C(167°F)
• Open or short in control
Threshold Value • Failure on 3 cylinder or more circuit
Diagnostic Time • Contact resistance in
• 85 revolutions
connectors
MIL On Condition •- • Faulty ignition coil
Specification
Normal Parameter at 20°C
Ignition Coil
(68°F)
Resistance (Primary) Approx. 0.96 ± 10% (Ω)
Resistance (Secondary) Approx. 12.5 ± 15% (kΩ)
Schematic Diagram
Monitor DTC Status

Page 456 of 670
Go to next step as below..

or damage.
procedure.

1. Ignition "OFF".
2. Disconnect ignition coil connector.
Page 457 of 670
4. Measure voltage between terminal 3 of the coil harness connector and chassis ground.

Go to "Control Circuit Inspection" procedure
procedure.

(1) Ignition "OFF".
(2) Measure resistance from each ignition coil control circuit to ECM.

Page 458 of 670
(1) Measure resistance from each ignition coil control circuit (4/C14, 1/C14, 2/C14) to chassis ground.

3. Check for short to battery in signal harness.

(3) Measure voltage from each ignition coil control circuit (4/C14, 1/C14, 2/C14) to chassis ground.

■ Ignition System Inspection
1. Ignition "OFF".
Page 459 of 670
4. Measure the resistance in each primary coil, referring to specification.(Component side)
Specification : Approx. 0.96 ± 10% (Ω) at 20°C(68°F)

No.1 & 4 cyl. : terminals 3 & 2
5. Measure the secondary coil resistance.

Measure the resistance between the high-voltage terminal for the No. 3 and No. 6 cylinders, between the high-
voltage terminals for the No. 1 and No. 4 cylinders and between the high-voltage terminals for the No.2 and
No.5 cylinders.
Be sure, when measuring the resistance of the secondary coil, to disconnect the connector of the ignition
coil.
Specification : Approx. 12.5 ± 15% (kΩ) at 20°C(68°F)

Check ignition coil for contamination, deterioration, or damage. Substitute with a known-
good ignition coil and check for proper operation. If the problem is corrected, replace ignition
coil and then go to "Verification of Vehicle Repair" procedure.
Page 460 of 670

DTC.
Fuel System > Engine Control System > P0351 Ignition Coil 'A' Primary / Secondary Circuit
Component Location
General Description
spark plugs.
DTC Description
The ECM monitors the peak voltage duration of the ignition primary circuit. If abnormal signal is detected, the ECM
sets DTC P0351.

Page 461 of 670
DTC Strategy • Monitoring ignition coil primary voltage
• Over voltage duration depending on engine speed
Enable Conditions • Open or short in power
and air mass flow
supply circuit
• Over voltage duration = 0 • Open or short in control
• Over voltage duration < α circuit
Threshold Value
• Over voltage duration of each ignition output • Contact resistance in
overlapping below 4500 rpm connectors
• Faulty ignition coil
Diagnostic Time • 85 revolutions
Specification
Ignition Coil
(68°F)
Schematic Diagram
Monitor DTC Status

Page 462 of 670
Go to nest step as below.

or damage.
procedure.

1. Ignition "OFF".
Page 463 of 670

procedure.

(1) Ignition "OFF".
(2) Measure resistance between terminals 2 of the coil harness connector and 3 of the ECM harness connector.

Page 464 of 670
(1) Measure resistance between terminal 2 of the coil harness connector and chassis ground.


(3) Measure voltage between terminal 2 of the coil harness connector and chassis ground.

1. Ignition "OFF".
Page 465 of 670

Measure the resistance between the high-voltage terminal to following diagram.
coil.
Specification : Approx. 13.3 ± 1.9 (kΩ) at 20°C(68°F)


Page 466 of 670
DTC.
Fuel System > Engine Control System > P0352 Ignition Coil 'B' Primary / Secondary Circuit
Component Location
General Description
spark plugs.
DTC Description
sets DTC P0352.

Page 467 of 670
and air mass flow
supply circuit
Threshold Value
Specification
Ignition Coil
(68°F)
Resistance (Secondary) Approx.12.5 ± 15% (kΩ)
Schematic Diagram
Monitor DTC Status

Page 468 of 670

or damage.
procedure.

1. Ignition "OFF".
Page 469 of 670

procedure.

(1) Ignition "OFF".

Page 470 of 670



1. Ignition "OFF".
Page 471 of 670
4. Measure the resistance between terminals 1 and 3 of the primary ignition coil.(Component side)

coil.


Page 472 of 670
DTC.
Fuel System > Engine Control System > P0353 Ignition Coil 'C' Primary / Secondary Circuit
Component Location
General Description
spark plugs.
DTC Description
sets DTC P0353.

Page 473 of 670
and air mass flow
supply circuit
Threshold Value
Specification
Ignition Coil
(68°F)
Schematic Diagram
Monitor DTC Status

Page 474 of 670

or damage.
procedure.

1. Ignition "OFF".
Page 475 of 670

procedure.

(1) Ignition "OFF".

Page 476 of 670



1. Ignition "OFF".
Page 477 of 670

coil.


Page 478 of 670
DTC.
Fuel System > Engine Control System > P0354 Ignition Coil 'D' Primary / Secondary Circuit
Component Location
General Description
spark plugs.
DTC Description
sets DTC P0354.

Page 479 of 670
and air mass flow
supply circuit
Threshold Value
Specification
Ignition Coil
(68°F)
Schematic Diagram
Monitor DTC Status

Page 480 of 670

or damage.
procedure.

1. Ignition "OFF".
Page 481 of 670

procedure.

(1) Ignition "OFF".

Page 482 of 670



1. Ignition "OFF".
Page 483 of 670

coil.


Page 484 of 670
DTC.
Fuel System > Engine Control System > P0355 Ignition Coil 'E' Primary / Secondary Circuit
Component Location
General Description
spark plugs.
DTC Description
sets DTC P0355.

Page 485 of 670
and air mass flow
supply circuit
Threshold Value
Specification
Ignition Coil
(68°F)
Schematic Diagram
Monitor DTC Status

Page 486 of 670

or damage.
procedure.

1. Ignition "OFF".
Page 487 of 670

procedure.

(1) Ignition "OFF".

Page 488 of 670



1. Ignition "OFF".
Page 489 of 670

coil.


Page 490 of 670
DTC.
Fuel System > Engine Control System > P0356 Ignition Coil 'F' Primary / Secondary Circuit
Component Location
General Description
spark plugs.
DTC Description
sets DTC P0356.

Page 491 of 670
and air mass flow
supply circuit
Threshold Value
Specification
Ignition Coil
(68°F)
Schematic Diagram
Monitor DTC Status

Page 492 of 670

or damage.
procedure.

1. Ignition "OFF".
Page 493 of 670

procedure.

(1) Ignition "OFF".

Page 494 of 670



1. Ignition "OFF".
Page 495 of 670

coil.


Page 496 of 670
DTC.
Fuel System > Engine Control System > P0420 Catalyst System Efficiency below Threshold (Bank 1)
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 P0420 if the average of calculated oscillation size of rear HO2S signal during predetermined duration is
higher than the predetermined threshold.

Page 497 of 670
• 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
<900°C(1652°F)
• Coolant temperature >70°C(158)
• Lambda control within limit
• 1200rpm< Engine speed < 3000rpm
• Exhaust gas leaks
Enable Conditions • 300<Air mass flow(mg/rev.) <840
• Rear HO2S malfunction
• No misfire is detected
• Three way catalyst converter
• Not transient condition as below
malfunction
1. Engine Speed | Current - Mean | < 400rpm
2. Air Flow | Current - Mean | < 270mg/rev.
3. Lambda Correction | Current - Mean | <5%
Threshold Value • Averaged malfunction index > 3
Monitor DTC Status
Page 498 of 670
System Inspection
1. Visually/physically inspect the rear HO2S for the following conditions:
Damage, and for loose or missing hardware.
procedure.
Go to "Rear HO2S Inspection " procedure.
■ Rear HO2S Inspection

Ensure that the HO2S is securely installed.(Pigtail and wiring harness not making contact with the exhaust pipe)
Check for terminal tension. ( at the HO2S and at the ECM)
Any road damage.
procedure
Go to "TWC Inspection " procedure
■ TWC Inspection
1. Visually/physically inspect the three-way catalyst(TWC) converter for the following damage:
Severe discoloration caused by excessive temperature.
Dents and holes.
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.
Page 499 of 670

DTC.
Fuel System > Engine Control System > P0430 Catalyst System Efficiency Below Threshold (Bank 2)
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 500 of 670
• 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
<900°C(1652°F)
• Coolant temperature >70°C(158)
• Lambda control within limit
• 1200rpm< Engine speed < 3000rpm
• Exhaust gas leaks
Enable Conditions • 300<Air mass flow(mg/rev.) <840
• Rear HO2S malfunction
• No misfire is detected
• Three way catalyst converter
• Not transient condition as below
malfunction
1. Engine Speed | Current - Mean | < 400rpm
2. Air Flow | Current - Mean | < 270mg/rev.
3. Lambda Correction | Current - Mean | <5%
Threshold Value • Averaged malfunction index > 3
Monitor DTC Status
Page 501 of 670
System Inspection
Damage, and for loose or missing hardware.
procedure.
Go to "Rear HO2S Inspection " procedure.
■ Rear HO2S Inspection

Ensure that the HO2S is securely installed.(Pigtail and wiring harness not making contact with the exhaust pipe)
Check for terminal tension. ( at the HO2S and at the ECM)
Any road damage.
procedure
Go to "TWC Inspection " procedure
■ TWC Inspection
1. Visually/physically inspect the three-way catalyst(TWC) converter for the following damage:
Severe discoloration caused by excessive temperature.
Dents and holes.
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.
Page 502 of 670

DTC.
Fuel System > Engine Control System > P0441 Evaporative Emission System Incorrect Purge Flow
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 503 of 670
• 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 504 of 670
Monitor DTC Status
If any DTCs (or pending codes) are present, do ALL REPAIRS associated with those codes before proceeding
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.
1. EVAP. Leakage Test enable conditions

2. 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
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 Vehicle Repair" procedure.

Page 505 of 670
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?

System Inspection
■ 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

1. Return vehicle to original condition.
Page 506 of 670
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?

procedure.
Fuel System > Engine Control System > P0442 Evaporative Emission System-Leak detected (small
leak)
Component Location
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
Page 507 of 670
generated within a monitoring period increases above a defined threshold.

• Monitoring the tank pressure sensor(DTP)
DTC Strategy
signal with underpressure
• Idle state
• Minimum modeled ambient temperature
>-10°C(14°F) • Fuel filler cap damage or missing
• Coolant temperature >75°C(167°F) • Faulty or damaged fuel filler pipe
Enable • Vehicle speed< 5km/h(3mph) • Leaking, disconnected or plugged fuel vapor
Conditions • Estimated altitude< 2.4km(8000ft) lines.
• Differential fuel tank pressure: -11 ~ • Fuel in lines due to faulty Rollover Valve
5.5hPa • On-Board Refueling Vapor Recovery Valve
• Limited canister saturation >-10% (ORVR valve) or stuck closed CCV.
• Minimum purge time:100sec. • Improperly installed or stuck Purge Control
Solenoid Valve (PCSV).
Threshold • Pressure fluctuation in fuel tank < -2hPa • Faulty Fuel Tank Pressure Sensor (FTPS).
Value during vapor generation period
• Leaking canister
Diagnostic • 26 sec. In idle
Time
MIL On
Condition • 2 Driving Cycles
Schematic Diagram
Page 508 of 670
Monitor DTC Status
If any codes relating to Fuel tank pressure sensor, Canister closing valve or PCSV circuits are present, do ALL


2) No relevant DTC
Page 509 of 670
4. Is DTC P0442set again?
Go to "PCSV Line Inspection" procedure
System Inspection
■ 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
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.
■ Canister Closing Valve(CCV) Line Inspection

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
Check for cracks or damage in hose connecting CCV and canister. Repair or replace as
necessary.
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.
Page 510 of 670
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
Approx. 0~2 mmHg(2.5V) at Ig. On

Approx. 0 mmHg at 1400rpm
Approx. -2 mmHg at 4000rpm
3. Is signal value within specification?
Go to "Purge Control Solenoid Valve(PCSV) Inspection" procedure
Check for cracks or damage in hose connecting canister and fuel pump. Repair or replace
as necessary.
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 to "Verification of Vehicle Repair" procedure.
■ 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 go to "Verification of Vehicle Repair" procedure.
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:
Canister and fuel filler neck
Canister and CCV
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.
Page 511 of 670
(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



2) No relevant DTC
Page 512 of 670
procedure.
Fuel System > Engine Control System > P0444 Evaporative Emission System-Purge Control Valve
Circuit Open
Component Location
General Description
to the engine for combustion. This valve is actuated by the purge control signal from the ECM and controls fuel
vapor flow from the canister to the intake manifold.
DTC Description
ECM sets DTC P0444 if the ECM detects that the PCSV control circuit is open.

DTC Strategy • Driver stage check
Enable • 10V< Battery voltage
Conditions • Open in PCSV
Threshold • Open circuit harness
Value • Contact resistance in
connectors
Diagnostic • 3 sec.
Time • Faulty PCSV
MIL On
• 2 Driving Cycles
Condition
Page 513 of 670
Specification
Temperature CCV
(°C) (°F) Resistance(Ω)
20 68 24.5~27.5
Schematic Diagram
Monitor DTC Status
Page 514 of 670
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

or damage.
procedure.
Page 515 of 670
2. Measure voltage between terminal 1 of the PCSV harness connector and chassis ground.

Check for a open in the power supply circuit. Repair as necessary and go to "Verification of

1. Ignition "OFF".
3. Measure resistance between terminals 2 of the PCSV harness connector and 42 of the ECM harness connector.


Page 516 of 670
DTC.
Fuel System > Engine Control System > P0445 Evaporative Emission System-Purge Control Valve
Circuit Shorted
Component Location
General Description
to the engine for combustion. This valve is actuated by the purge control signal from the ECM and controls fuel
DTC Description
ECM sets DTC P0445 if the ECM detects that the PCSV control circuit is short to ground or short to battery
voltage.

Page 517 of 670
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 CCV
20 68 24.5~27.5
Schematic Diagram
Monitor DTC Status

Page 518 of 670
Go to "Component Inspection" 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 519 of 670
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

or damage.
procedure.

2. Measure voltage between terminal 1 of the PCSV harness connector and chassis ground.


Page 520 of 670
(1) Ignition "OFF".
(3) Measure resistance between terminals 2 of the PCSV harness connector and 42 of the ECM harness
connector.

2. Check for short to battery in control circuit.

(2) Measure voltage between terminal 2 of the PCSV harness connector and chassis ground.

Page 521 of 670
DTC.
Fuel System > Engine Control System > P0447 Evaporative Emission System-Vent Control Circuit
Open
Component Location
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.

Page 522 of 670
Enable • Battery voltage > 10V
Conditions • Open in CCV
Threshold • Line break harness
connectors
Diagnostic • 3 sec..
Time • Faulty CCV.
MIL On
Condition
Specification
Temp.(°F) CCV
20 68 23~26
Schematic Diagram
Monitor DTC Status

Page 523 of 670
Fault is intermittent, caused by poor contact in the sensor’s and/or PCM’s connector or was
repaired and PCM memory was not cleared. Thoroughly check connectors for looseness,
1. Ignition "OFF".
2. Disconnect CCV connector.
3. Measure resistance between terminals 1 and 2 of the CCV connector(Component side).

Page 524 of 670
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

or damage.
procedure.

2. Measure voltage between terminal 1 of the CCV harness connector and chassis ground.


1. Ignition "OFF".
Page 525 of 670
3. Measure resistance between terminals 2 of the CCV harness connector and 30 of the ECM harness connector.


DTC.
Fuel System > Engine Control System > P0448 Evaporative Emission System - Vent Control Circuit
Shorted
Component Location
Page 526 of 670
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 527 of 670
Monitor DTC Status

Page 528 of 670
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

or damage.
procedure.

Page 529 of 670
2. Measure voltage between terminal 1 of the CCV harness connector and chassis ground.


(1) Ignition "OFF".
(3) Measure resistance between terminals 2 of the CCV harness connector and 30 of the ECM harness
connector.

Page 530 of 670
2. Check for short to battery in control circuit
(2) Measure voltage between terminal 2 of the CCV harness connector and chassis ground

and go to "Verification of Vehicle Repair" procedure

DTC.
Fuel System > Engine Control System > P0449 Evaporative Emission System-Vent Valve / Solenoid
Circuit
Component Location
Page 531 of 670
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.

• Monitoring the tank pressure sensor(DTP) signal
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
Page 532 of 670
Specification
Temp.(°F) CCV
20 68 23~26
Schematic Diagram
Monitor DTC Status

Page 533 of 670
System Inspection
■ 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.
■ Canister Closing Valve(CCV) inspection

2. Ignition "OFF"
click)
If hose was pinched or restricted:

Fueling would be difficult if not impossible.
Restriction or blockage could cause pressure to accumulate in tank triggering a P0451.
Replace CCV. If CCV was stuck closed, inspect all lines and canister for liquid fuel.
Replace any contaminated components and blow out lines.

Page 534 of 670
DTC.
Fuel System > Engine Control System > P0451 Evaporative Emission System-Pressure Sensor Range /
Performance
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
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.

Page 535 of 670
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
Monitor DTC Status
Page 536 of 670

2) No relevant DTC


or damage.
procedure
Go to "Fuel Tank Pressure Sensor(FTPS) inspection" procedure
System Inspection
engine speed

Page 537 of 670
as necessary.
replace FTPS and go to "Verification of Vehicle Repair" procedure


2) No relevant DTC

procedure.
Fuel System > Engine Control System > P0452 Evaporative Emission System-Pressure Sensor Low
Input
Component Location
Page 538 of 670
General Description
DTC Description
FTPS.

Enable • Battery voltage > 11V • Short to ground in
Conditions FTPS harness
• Open in FTPS
Threshold • Signal voltage <0.35V
harness
Value
MIL On • Faulty FTPS.
Condition
Schematic Diagram
Page 539 of 670
Monitor DTC Status

Page 540 of 670

or damage.
procedure.

1. Ignition "OFF".
2. Disconnect FTPS connector.
3. Ignition "ON" & Fngine "OFF".
4. Measure voltage between terminal 3 of the FTPS harness connector and chassis ground.

Page 541 of 670
(1) Ignition "OFF".
(3) Measure resistance between terminals 1 of the FTPS harness connector and 34 of the ECM harness
connector.

2. Check for short to ground in signal circuit

(1) Measure resistance between terminal 1 of the FTPS harness connector and chassis ground
Specification :Infinite

System Inspection
Page 542 of 670
engine speed

as necessary.

DTC.
Fuel System > Engine Control System > P0453 Evaporative Emission System-Pressure Sensor High
Input
Component Location
Page 543 of 670
General Description
DTC Description
FTPS.

Enable • Battery voltage > 11V
Conditions • Short to battery in
FTPS harness
Threshold • Signal voltage > 4.78V
Value
connectors
Diagnostic Time • 5 sec. • Faulty FTPS
MIL On
Condition
Schematic Diagram
Page 544 of 670
Monitor DTC Status


or damage.
procedure.

1. Ignition "OFF".
2. Disconnect FTPS connector.
Page 545 of 670


1. Ignition "OFF".
3. Measure resistance between terminals 2 of the FTPS harness connector and 14 of the ECM harness connector.

Go to "Signal Circuit Inspection" procedure
Check for a open/short circuit. Repair as necessary and go to "Verification of Vehicle
Repair" procedure

Page 546 of 670

procedure.
System Inspection
engine speed

as necessary.

Page 547 of 670
DTC.
Fuel System > Engine Control System > P0454 Evaporative Emission System-Pressure Sensor
Intermittent
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 548 of 670
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
• 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 549 of 670

2) No relevant DTC


or damage.
procedure
Go to "Fuel Tank Pressure Sensor(FTPS) inspection" procedure
System Inspection
Page 550 of 670
engine speed

as necessary.



2) No relevant DTC

procedure.
Fuel System > Engine Control System > P0455 Evaporative Emission System-Leak detected(Large
leak)
Component Location
Page 551 of 670
General Description
The PCM controls the Purge Control Solenoid Valve (PCSV) to purge any collected vapors from the canister back
to the engine for combustion. This valve is actuated by the purge control signal from the PCM and controls fuel
DTC Description
Checking output signals from fuel tank pressure sensor under evap.system test, if fuel tank's vacuum is lower than
prescribed threshold, PCM sets P0455 and then MIL(Malfunction Indication Lamp) turns on.

DTC Strategy • Monitor the fuel tank's vacuum
• 10 V < Battery voltage < 16 V
• Barometric pressure > 72 kPa (0.72 bar)
• Engine coolant temperature at startup - Intake air • Fuel Filler Cap missing
temperature at startup < 6.7°C(12 °F) • Leakage in each hose/fuel
Enable Conditions • Engine coolant temperature at startup: 4.5 ~ filler pipe
35°C(40 ~ 95 °F) • Leakage in CCV/ Canister/
• Intake air temperature at startup: 4.5 ~ 35°C(40 ~ Fuel tank
95 °F) • Stuck in each purge hose/pipe
• Fuel level: 15 ~ 85 % between fuel tank and intake
manifold
Threshold value • Fuel tank's vacuum < a prescribed threshold
Diagnosis Time • One time during Evaporative system diagnosis
MIL On Condition • 1 driving cycle
Schematic Diagram
Page 552 of 670

■ Check DTC Status
2. IG "ON".
3. Select "DTC" button, and then Press "DTC Status" to check DTC's information from the DTCs menu.
5. Is parameter displayed "Present fault"?
Check the Fuel Filler Cap is installed. If not, after closing it, go to "Evap.Leakage Test" as
below with scan tool.
Go to "Evap.Leakage Test" as below with scan tool.
■ Evap. Leakage Test

1. Cool the vehicle down for about two hours to prevent misdiagnosis.
2. Install scan tool and IG "ON" and then clear DTC.
3. Select and press "EVAP.LEAKAGE TEST" mode in the scan tool.
4. Check if the vehicle is under test conditions as below [Fig 1].
5. If OK, Start engine and restart Evap.Leakage Test again[Fig 2].
Page 553 of 670
6. Is the same DTC set after the Evap.leakage test with scan tool ?
Go to "System Inspection" procedure.
Fault is intermittent caused by the fuel cap missing and go to "Verification of vehicle Repair"
procedure.
■ Check CCV for leakage
1. Disconnect the hose leading from the CCV to Canister at CCV.
2. Visually Check any tear of the hose leading from the CCV to Canister.
3. When the CCV operates, apply a vacuum at the nipple and verify that the CCV holds vacuum.
4. Does a leak exist?
Repair or replace as necessary and then go to "Verification of Vehicle Repair"
procedure.
Go to "Check Canister for leakage" as below.
■ Check Canister for leakage

1. Disconnect the hose leading from the CCV to Canister at Canister.
2. When the other nipples are plugged, apply a vacuum at the vent nipple and verify that the Canister holds vacuum.
procedure.
Go to "Check fuel tank for leakage" as below.
■ Check fuel tank for leakage

1. Check fuel tank for crack or leakage.
procedure.
Carefully perform this troubleshooting procedures all over again from the
beginning.
System Inspection
■ Check Fuel Filler Cap
1. Check the Fuel Filler Cap is installed and properly tightened.
2. Check if the Fuel Filler Cap seal is missing or damaged.
3. Is the Fuel Filler Cap OK?
Go to "Check vapor hoses for leakage in fuel system" as below.
Replace the Fuel Filler Cap and go to "Verification of Vehicle Repair"
procedure.
■ Check vapor hoses for leakage in fuel system

Page 554 of 670
1. Check vapor hoses between the following components for leakage:
- Intake manifold ~ Purge control solenoid valve (PCSV)
- Purge control solenoid valve (PCSV) ~ Canister
- Canister ~ Canister close valve (CCV)
- Canister ~ fuel tank
Repair or replace as necessary and then, go to "Verification of Vehicle Repair"
procedure.
Go to "Check vapor hoses for stuck in fuel system" as below.
■ Check vapor hoses for stuck in fuel system

1. Check vapor hoses between the following components for stuck:
- Intake manifold ~ Purge control solenoid valve (PCSV)
- Purge control solenoid valve (PCSV) ~ Canister
- Canister ~ fuel tank
2. Does a stick exist?
procedure.
Go to "Check fuel filler pipe for crack or leakage" as below.
■ Check fuel filler pipe for crack or leakage

1. Check that there is crack or leakage in fuel filler pipe
2. Is there any crack or leakage ?
procedure.

1. Connect scantool and select "DTC" button.
2. Press "DTC Status" button and confirm that "DTC Readiness Flag" indicates "Completed". If not, drive the
vehicle within conditions noted in the freeze frame data or enable conditions.
DTC
Fuel System > Engine Control System > P0456 Evaporative Emission System-Leak detected (very
small leak)
Component Location
Page 555 of 670
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.

• Monitoring the tank pressure sensor (DTP) signal
DTC Strategy
with underpressure
• Idle state
10°C(14°F)
• Leakage in EVAP system line
• Defective CCV,PCSV or
• Differential fuel tank pressure: -11 ~ 5.5hPa
FTPS
• 0.4 mm(0.016 inch) < leak. diameter < 0.8
Threshold value
mm(0.032 inch)
Page 556 of 670
Diagnosis Time • 39 sec. in idle
Schematic Diagram
Monitor DTC Status
If any codes relating to Fuel tank pressure sensor, Canister closing valve or PCSV circuits are present, do ALL
Page 557 of 670

2) No relevant DTC

Go to "Purge Control Solenoid Valve (PCSV) Line Inspection" procedure
System Inspection
■ PCSV to Intake Manifold 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 to "Verification of Vehicle Repair" procedure
■ Canister Closing Valve(CCV) Line Inspection

2. Ignition "OFF"
click)
Page 558 of 670
Go to "Fuel Tank Pressure Sensor Inspection" procedure
Check for cracks or damage in hose connecting CCV and canister. Repair or replace as
necessary.
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 .

engine speed

Go to "PCSV to Canister Line Inspection" procedure
Go to "Evap.Leakage Test" as below with scan tool.
■ 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
Page 559 of 670
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:
Canister and fuel filler neck
Canister and CCV
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

Page 560 of 670

2) No relevant DTC

procedure.
Fuel System > Engine Control System > P0461 Fuel Level Sensor \'A\' Circuit Range/Performance
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 561 of 670
DTC Strategy • Check signal stuck
Enable Conditions • Minimum mileage:322km(200 mile)
Threshold Value • Difference between filtered max./min.value and initial
connectors
value < 5%
• Faulty FLS
Diagnostic Time • Immediate
Specification
Fuel
Resistance (Ω)
Level
E (Empty) Approx. 94~96
1/2 Approx. 89~91
F (Full) Approx. 3~4
Schematic Diagram
Monitor DTC Status
If any codes relating to system voltage (P0560) is stored, do ALL REPAIRS associated with those codes before
proceeding with troubleshooting.
Page 562 of 670
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, contamination, deterioration, or damage. Repair or
replace as necessary and go to "Verification of Vehicle Repair" procedure

or damage.
procedure.
■ Fuel Level Sensor(FLS) Inspection
1. Ignition "OFF"
2. Disconnect FLS harness connector
Page 563 of 670
3. Measure resistance between terminals 1 and 2 of the FLS connector(Component side).
Specification :
Fuel Level Resistance (Ω)
1/2 Approx. 89~91
4. Is resistance within specification?

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


2) No relevant DTC
Page 564 of 670
YES
NO
Fuel System > Engine Control System > P0462 Fuel Level Sensor \'A\' Circuit Low Input
Component Location
General Description
DTC Description
threshold value

DTC Strategy • Voltage range check • Short to ground in signal
Enable Conditions
• Minimum time counter > 200 sec. • Open in power supply
harness
Threshold Value • Short to ground or Line Break(Voltage < 0.02)
MIL On Condition • Faulty FLS
•-
Specification
Page 565 of 670
Fuel
Resistance (Ω)
Level
1/2 Approx. 89~91
Schematic Diagram
Monitor DTC Status

Page 566 of 670

or damage.
procedure.

1. Ignition "OFF".
2. Disconnect Fuel Sender connector.

Check for a open/short in the power supply circuit. Repair as necessary and go to
Page 567 of 670
(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.

2. Check for short to ground in signal circuit

(1) Measure resistance between terminal 2 of the FTPS harness connector and chassis ground

Page 568 of 670
Specification :
1/2 Approx. 89~91


DTC.
Fuel System > Engine Control System > P0463 Fuel Level Sensor \'A\' Circuit High Input
Component Location
Page 569 of 670
General Description
DTC Description
threshold value

• Short to battery in signal
Enable Conditions
• Minimum time counter > 200 sec. • Open in power
supply/ground harness
Threshold Value • Signal voltage >4.95V
Diagnostic Time • 10 sec.. connectors
MIL On Condition • Faulty FLS
•-
Specification
Fuel
Resistance (Ω)
Level
E (Empty) Approx. 94 ~ 96
1/2 Approx. 89 ~ 91
F (Full) Approx. 3 ~ 4
Schematic Diagram
Page 570 of 670
Monitor DTC Status

Fault is intermittent, caused by poor contact in the sensor’s and/or ECM’s connector or was

or damage.
procedure
Page 571 of 670
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

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.

procedure.
Specification :
1/2 Approx. 89~91


Page 572 of 670
DTC.
Fuel System > Engine Control System > P0464 Fuel Level Sensor \'A\' Circuit Intermittent
Component Location
General Description
DTC Description
The ECM sets DTC P0464 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
Page 573 of 670
Fuel
Resistance (Ω)
Level
E (Empty) Approx. 94 ~ 96
1/2 Approx. 89 ~ 91
F (Full) Approx. 3 ~ 4
Schematic Diagram
Monitor DTC Status

Page 574 of 670
or damage.
procedure
1. Ignition "OFF"
2. Disconnect FLS harness connector
Specification :
1/2 Approx. 89~91


DTC.
Fuel System > Engine Control System > P0501 Vehicle Speed Sensor \'A\' Range/Performance
Page 575 of 670
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
• Mass air flow > 654mg/rev.
Enable Conditions • Open or short in harness
• No fuel shut-off • Contact resistance in
connectors
Threshold Value • Vehicle speed = 0 with high engine speed and high
• Faulty wheel speed sensor
load
Schematic Diagram
Page 576 of 670
Monitor DTC Status

1. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)".
Page 577 of 670
Fault is intermittent, caused by poor contact in the sensor’s and/or ECM’s connector or was
[With ABS] Go to "Monitor Scan tool Data" procedure.
[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. Connect Scantool and select ABS system.
3. Monitor the "WHEEL SPD SENSOR-FR" parameter on the current data list.
Specification : 10km/h or more(6mph or more)
Fig 1) Normal value with vehicle on lift and transaxle in gear

Fig 2) Open in input circuit with vehicle in motion : Approx. 0km/h
4. Is value within the specification?
Wheel speed sensor is OK. Go to "Signal Circuit Inspection" procedure.
Check the following conditions:
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.

[With ABS]
Page 578 of 670
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).

Page 579 of 670
2. Check for short to ground in circuit.
(1) Measure resistance between terminal 22 of the ECM harness connector and chassis ground

[Without ABS system]

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]
Terminal 1(sensor) & Terminal 38(ECM)
[With 4WD]
Page 580 of 670

2. Check for short to ground in circuit.

(1) Measure resistance between terminal 38 of the ECM harness connector and chassis ground.
(2) Measure resistance between terminal 39 of the ECM harness connector and chassis ground.

Check wheel speed sensor(FR) as follow:
Gap between ABS sensor and trigger wheel (Air gap : 0.3~1.1 mm(0.011 ~ 0.043
in))
Trigger wheel condition
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.

Page 581 of 670
DTC.
Fuel System > Engine Control System > P0505 Idle Air Control System
Component Location
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.

Page 582 of 670
• 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 • Carbon or foreign objects
• Under normal engine running conditions • Contact resistance in
connectors
Threshold Value • Integral of deviation between setpoint RPM and
• Faulty ISC valve
actual speed RPM is out of the threshold value.
Diagnostic Time • 10~20 sec.
Schematic Diagram
Monitor DTC Status
Page 583 of 670
System Inspection
- Air cleaner filter element for excessive dirt or for any foreign objects
- Throttle body inlet for damage or for any foreign objects
- Restricted exhaust system
procedure.

or damage.
Page 584 of 670
procedure.
Go to "Componment Inspection" procedure.
1. Ignition "OFF"
2. Remove ICA from Throttle body and Check for throttle bore, throttle plate and the ICA 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 ICA by pressing "STAT" key.
6. Check the ICA for clicking sound and visually verifying valve closes and opens.
Repeat numerous times to ensure valve reliability

7. Is ICA OK?
Check ICA valve for contamination, deterioration, or damage. Substitute with a known-
good ICA valve and check for proper operation. If the problem is corrected, replace ICA
valve and then go to "Verification of Vehicle Repair" procedure.

DTC.
Fuel System > Engine Control System > P0506 Idle Air Control System-RPM Lower than Expected
Component Location
Page 585 of 670
General Description
When the TP sensor’s signal indicates closed throttle position and the engine is idling, the ECM adjusts the idle
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.

• Compare engine speed and nominal idle speed in idle
DTC Strategy
state
• Vehicle speed =0
• Engine load <840 mg/rev. • Restriction in intake or
Enable Conditions exhaust system
• Throttle angle:closed
• Carbonustment of the
• Minimum time after start:10sec.
accelerator cable
• Canister purge control < 70%
Threshold Value • Target idle speed - Engine speed > 100rpm (Engine connectors
speed too low) • Faulty ISCA valve
Diagnostic Time • 18.5 sec.
Fail Safe • Evaporative System monitoring is inhibited
Schematic Diagram
Page 586 of 670
Monitor DTC Status
Page 587 of 670
System Inspection
- Air cleaner filter element for excessive dirt or for any foreign objects
- Throttle body inlet for damage or for any foreign objects
- Restricted exhaust system
procedure.

or damage.
procedure.
1. Ignition "OFF"
and for any foreign objects. Repair or clean as necessary.
5. Activates ICA by pressing "STAT" key.
Page 588 of 670
6. Check the ICA for clicking sound and visually verifying valve closes and opens.

7. Is ICA OK?

DTC.
Fuel System > Engine Control System > P0507 Idle Air Control System-RPM Higher than Expected
Component Location
General Description
When the TP sensor’s signal indicates closed throttle position and the engine is idling, the ECM adjusts the idle
Page 589 of 670
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
• Coolant temperature>75°C(167°F) • A stuck or binding throttle
• Engine load <840 mg/rev. plate
Enable Conditions
• Throttle angle:closed • Misadjustment of the
• Minimum time after start:10sec. accelerator cable
• Canister purge control < 70% • Contact resistance in
connectors
Threshold Value • Engine speed - Target idle speed > 200rpm (Engine • Faulty ISCA valve
speed too high)
Schematic Diagram
Monitor DTC Status

Page 590 of 670
System Inspection
■ Accelerator Cable & Throttle plate Inspection
1. Visually/physically inspect the following items. Repair or adjust as necessary and go to next step
Check that the Accelerator Cable is not sticking or moving sluggishly.
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?
procedure.

Page 591 of 670
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

or damage.
procedure.
1. Ignition "OFF"
and for any foreign objects. Repair or clean as necessary
5. Activates ICA by pressing "STAT" key
6. Check the ICA for clicking sound and visually verifying valve closes and opens

Page 592 of 670
7. Is ICA OK?

DTC.
Fuel System > Engine Control System > P0551 Power Steering Pressure Sensor/Switch Circuit
Range/Performance
Component Location

Page 593 of 670
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
Threshold Value • Power steering is ON with vehicle speed >97km/h connectors
(60 mph) & time > 25.5 sec. • Faulty power steering switch
Schematic Diagram
Monitor DTC Status

Page 594 of 670

or damage.
procedure.

1. Ignition "OFF".
2. Disconnect P/S switch connector.
Page 595 of 670
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

Repair open or short in harness and go to "Verification of Vehicle Repair"
procedure.
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

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 Vehicle Repair" procedure.

Page 596 of 670
DTC.
Fuel System > Engine Control System > P0560 System Voltage
Component Location
General Description
The ECM provides ground to one side of the coil of the main relay and the other side is connected to the battery.
The ECM monitors battery voltage and the voltage after the main relay.
DTC Description
The ECM measures the voltage from ignition key and from main relay respectively and compares two voltages. This
comparison will watch if the Main Relay has switched and remains on after ignition Key-On and if it has switched off
after the ignition Key-Off. The ECM sets DTC P0560 if the voltage after Main Relay is lower than a predetermined
threshold after ignition key-on or higher than a predetermined threshold after ignition key-off.

Page 597 of 670
DTC Strategy • Comparison of battery voltage and voltage after
Enable Conditions • Ignition ON
• Ignition OFF • Open or short circuit
Threshold Value • Voltage after main relay when ON < 6V
connectors
• Voltage after main relay when OFF > 6V
Schematic Diagram
Monitor DTC Status

Page 598 of 670
1. Ignition "OFF".
2. Remove the main relay.
3. Apply 12V and a ground to 2 and 4 terminals of the main relay.
4. Check if the main relay works well when it is energized. (If the main relay works normally, a clicking sound can
be heard.)
5. Does the main relay operate normally?
Replace as necessary and go to "Verification of Vehicle Repair"
procedure.

or damage.
procedure.
Page 599 of 670
1. Remove the main relay.
3. Measure the voltage between terminal 2 of the main relay harness connector(E07) and chassis ground.
4. Measure the voltage between terminal 5 of the main relay harness connector(E07) and chassis ground.

Go to "Control Circuit Inspection"
Check for an open or short to ground in the power supply circuit. Repair as necessary and

(1) Ignition "OFF".
(2) Disconnect Relay harness connector.

Page 600 of 670
(1) Ignition "OFF".
(2) Disconnect relay and ECM connectors.
(3) Ignition "ON" and Engine "OFF".
(4) Measure voltage between terminal 4 of the relay harness connector and chassis ground.
Specification : Approx 0V


(1) Ignition "OFF".
(2) Disconnect relay and ECM connectors.
(3) Measure resistance between terminals 4 of the relay harness connector and 23 of the ECM harness
connector.
Specification : Approx 0Ω
Page 601 of 670

DTC.
Fuel System > Engine Control System > P0562 System Voltage Low
Component Location
General Description
DTC Description
ECM sets DTC P0562 if the ECM detects system voltage lower than the possible range of battery voltage.

Page 602 of 670
DTC Strategy • Check system voltage
Enable Conditions • Vehicle speed > 19km/h(12mph)
Threshold Value • Voltage after main relay too low when ON < 5.99V connectors
Diagnostic Time • Faulty charging system
• 240 sec.
Schematic Diagram
Monitor DTC Status
Page 603 of 670

or damage.
procedure.
Go to "Charging System Inspection" procedure.
Charging System Inspection

1. Check battery condition and Generator output
2. Are battery conditions and Generator output both okay?

Page 604 of 670
DTC.
Fuel System > Engine Control System > P0563 System Voltage High
Component Location
General Description
DTC Description
ECM sets DTC P0563 if the ECM detects system voltage lower than the possible range of battery voltage.

DTC Strategy • Check system voltage
Enable Conditions • Vehicle speed > 19km/h(12mph)
Threshold Value • Voltage after main relay too high when ON >
connectors
16.05V
• Faulty charging system
Page 605 of 670
Schematic Diagram
Monitor DTC Status
Page 606 of 670

or damage.
procedure.

1. Check battery condition and Generator output
2. Are battery conditions and Generator output both okay?

DTC.
Page 607 of 670
Fuel System > Engine Control System > P0605 Internal Control Module Read Only Memory(ROM)
Error
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.

DTC Strategy • Check RAM Area / Communication connections
Enable Conditions • Ignition ON
Threshold Value • Internal check connectors
• Faulty ECM
Monitor DTC Status

Page 608 of 670
Voltage Inspection
Back Voltage Inspcetion
1. Ignition "OFF".
3. Turn ignition "ON" and measure voltage between terminal 7 of the ECM harness connector 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 "Verification of Vehicle Repair" procedure.
If voltage fluctuates, check circuit Thoroughly for loose, bent or corroded terminals, Repair

Page 609 of 670
DTC.
Fuel System > Engine Control System > P0630 VIN Not Programmed or Incompatible-ECM/PCM
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 • VIN not exist in boot area
Enable • Ignition ON
Conditions
• ECM is Virgin(not
Threshold Value • Internal check
programmed) status
Diagnostic Time • Immediate
MIL On • Immediate
Condition
Monitor DTC Status

Page 610 of 670
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.

DTC.
Page 611 of 670
Fuel System > Engine Control System > P0650 Malfunction Indicator Lamp (MIL) Control Circuit
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
Diagnostic Time • 20sec.
• Burned out MIL bulb
Schematic Diagram
Page 612 of 670
Monitor DTC Status

Page 613 of 670

1. Ignition "OFF".
2. Disconnect ECM connector
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.
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 "Verification of Vehicle Repair" procedure.

DTC.
Fuel System > Engine Control System > P0661 Intake Manifold Tuning Valve Control Circuit Low
(Bank 1)
Component Location
Page 614 of 670
General Description
Intake manifold tuning valve is used to increase torque at lower rpm and increase horsepower at higher rpm. Delta
2.7ℓ 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 • Short to ground in
Threshold Value • Short to ground or line break control harness
connectors
MIL On •- • Faulty valve
Condition
Specification
Temperature
Resistance(Ω)
(°C) (°F)
20 68 29~35
Page 615 of 670
Schematic Diagram
Monitor DTC Status

Page 616 of 670
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

or damage.
procedure..
Page 617 of 670
2. Measure voltage between terminal 1 of the valve harness connector and chassis ground.

Check for open or blown SNSR Fuse(2).
procedure.

(1) Ignition "OFF".
(2) Measure resistance between terminal 2 of the valve harness connector and chassis ground

procedure.
Page 618 of 670

DTC.
Fuel System > Engine Control System > P0662 Intake Manifold Tuning Valve Control Circuit High
(Bank 1)
Component Location
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.

Page 619 of 670
• Open or short to battery
Enable Conditions • 10 < Battery voltage(V) <16 in control harness
Threshold Value • Short to battery • Contact resistance in
connectors
• Faulty valve
Specification
Temperature
Resistance(Ω)
(°C) (°F)
20 68 29~35
Schematic Diagram
Monitor DTC Status

Page 620 of 670
1. Ignition "OFF".

Page 621 of 670

or damage.
procedure..


procedure.

Page 622 of 670
(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.

Page 623 of 670

DTC.
Fuel System > Engine Control System > P0664 Intake manifold tuning valve #2(MV) control circuit low
Component Location
General Description
DTC Description
ECM sets DTC P0664 if the ECM detects that intake manifold tuning valve control circuit is shorted to ground.

Page 624 of 670
Enable • 10 < Battery voltage(V) <16 harness
Conditions
• Short to ground in
Threshold Value • Short to ground or line break control harness
connectors
MIL On •- • Faulty valve
Condition
Specification
Temperature
Resistance(Ω)
(°C) (°F)
20 68 29~35
Schematic Diagram
Monitor DTC Status

Page 625 of 670
1. Ignition "OFF".

Page 626 of 670

or damage.
procedure..


procedure.

Page 627 of 670
(1) Ignition "OFF".
(2) Measure resistance between terminal 2 of the valve harness connector and chassis ground

procedure.

DTC.
Fuel System > Engine Control System > P0665 Intake Manifold Tuning Valve Control Circuit High
(Bank 2)
Component Location
Page 628 of 670
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.

• Open or short to battery
Enable Conditions • 10 < Battery voltage(V) <16
in control harness
Threshold Value • Short to battery • Contact resistance in
connectors
• Faulty valve
Specification
Temperature
Resistance(Ω)
(°C) (°F)
20 68 29~35
Schematic Diagram
Page 629 of 670
Monitor DTC Status

Page 630 of 670
1. Ignition "OFF".


or damage.
procedure..
Page 631 of 670

procedure.

(1) Ignition "OFF".
(4) Measure voltage between terminal 2 of the valve harness connector and chassis ground.

Page 632 of 670
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.


DTC.
Fuel System > Engine Control System > P0700 Transmission Control System (MIL Request)
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 633 of 670
DTC Strategy • Freeze frame request via CAN
Enable • Battery voltage >10V
Conditions • Engine speed >256 rpm
Threshold • Transaxle system
• MIL is requested by TCM
Value
Diagnostic
• Immediate
Time
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.
Fuel System > Engine Control System > P1505 Idle Speed Control Actuator Signal Low of Coil #1
Component Location
General Description
The Idle Charge Actuator (ISCA) vlave 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.
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.

Page 634 of 670
Enable • Open or short to
Conditions ground in harness
Threshold Value • Open or short to ground • Contact resistance in
connectors
• Faulty ISCA valve
Condition
Specification
Specification
Opening
Closing Coil
Coil
15~16.2Ω 17~18.2 Ω
Schematic Diagram
Signal Waveform
Page 635 of 670
The above waveforms are the voltage signals generated when the ISCA operates. This ISCA is a duty type and the
time opened determines the duty amount. The left side is the waveform of the ISCA Opening coil during idle.
The right side id the waveform of the ISCA Closing coil during idle.
Monitor DTC Status

1. Ignition "OFF".
Page 636 of 670
2. Disconnect ISCA connector.
3. Measure resistance between terminals 1 and 2 of the actuator connector(Component side).
Specification : 15~16.2Ω

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

or damage.
procedure.

1. Ignition "OFF".
Page 637 of 670
4. Measure voltage between terminal 2 of the ISCA harness connector and chassis ground.
5. Is voltage display near the specified value?

Check for an open or short to ground in the power supply circuit between the ISCA and
fuel pump relex. Repair as necessary and go to "Verification of Vehicle Repair" procedure.

2. Measure voltage between terminal 1 of the ICA harness connector and chassis ground.
Specification : Approx. 3~4V

Page 638 of 670
4. Check for open in signal harness
(1) Ignition "OFF".
(2) Measure resistance between terminals 1 of the ICA harness connector and 46 of the ECM harness
connector.


(1) Ignition "OFF".
(2) Measure resistance between terminal 1 of the ICA harness connector and chassis ground.

Repair open or short in harness and go to "Verification of Vehicle Repair" procedure.

Page 639 of 670
DTC.
Fuel System > Engine Control System > P1506 Idle Speed Control Actuator Signal High of Coil #1
Component Location
General Description
DTC Description
ECM sets DTC P1506 if the ECM detects that the ISCA(OPEN) control circuit is short to battery.

Page 640 of 670
Enable
Threshold harness
• Short to battery
connectors
Diagnostic
• 0.5 sec. • Faulty ISCA valve
Time
Condition
Specification
Specification
Opening
Closing Coil
Coil
15~16.2Ω 17~18.2 Ω
Schematic Diagram
Signal Waveform
Page 641 of 670
Monitor DTC Status

1. Ignition "OFF".
Page 642 of 670


or damage.
procedure.

1. Ignition "OFF".
Page 643 of 670

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

Page 644 of 670
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

Repair short in harness and go to "Verification of Vehicle Repair" procedure.

DTC.
Fuel System > Engine Control System > P1507 Idle Speed Control Actuator Signal Low of Coil #2
Component Location
Page 645 of 670
General Description
DTC Description
ECM sets DTC P1507 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
Condition
Specification
Specification
Opening
Closing Coil
Coil
15~16.2Ω 17~18.2 Ω
Schematic Diagram
Page 646 of 670
Signal Waveform
Monitor DTC Status

Page 647 of 670
1. Ignition "OFF".
Page 648 of 670

or damage.
procedure.

1. Ignition "OFF".
5. Is voltage display near the specified value?

Check for an open or short to ground in the power supply circuit between the ISCA and
fuel pump relex. Repair as necessary and go to "Verification of Vehicle Repair" procedure.

Page 649 of 670
Specification : Approx. 0.5~0.6V

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.

Page 650 of 670
(1) Ignition "OFF".
(2) Measure resistance between terminal 3 of the ISCA harness connector and chassis ground.

Repair open or short in harness and go to "Verification of Vehicle Repair" procedure.

DTC.
Fuel System > Engine Control System > P1508 Idle Speed Control Actuator Signal High of Coil #2
Component Location
Page 651 of 670
General Description
DTC Description
ECM sets DTC P1508 if the ECM detects that the ISCA(CLOSE) control circuit is short to battery.

Enable
Threshold harness
• Short to battery
connectors
Diagnostic
• 0.5 sec. • Faulty ISCA valve
Time
Condition
Specification
Specification
Opening
Closing Coil
Coil
15~16.2Ω 17~18.2 Ω
Page 652 of 670
Schematic Diagram
Signal Waveform
Monitor DTC Status

Page 653 of 670
1. Ignition "OFF".
Page 654 of 670

or damage.
procedure.

1. Ignition "OFF".

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.

Page 655 of 670
Specification : Approx. 0.5~0.6V

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

Repair short in harness and go to "Verification of Vehicle Repair" procedure.

Page 656 of 670
DTC.
Fuel System > Engine Control System > U0101 Lost Communication With TCM
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.

DTC Strategy • Missing messages TCU
Enable Conditions • Battery voltage >10V
• Engine speed > 256rpm • Open or short in CAN line
Threshold Value • Time exceeded without message = 0.5 sec.
connectors
Signal Waveform
Fig 1) Normal wave Form with ignition ON

Page 657 of 670
Monitor DTC Status


or damage.
Check for continuity in wiring related to the CAN communication line. Repair as necessary
and then go to "Verification of Vehicle Repair" procedure.
■ Check CAN Communication Line for Open

1. Ignition "OFF".
2. Disconnect ECM harness connector.
Page 658 of 670
3. Measure resistance between terminals 36 and 37 of the ECM harness connector.
Specification : Approx. 110~130Ω

Check for open in wiring related to the CAN communication. Repair as necessary and then
■ Check CAN Communication Line for Short to Ground

1. Measure resistance between terminal 36 of the ECM harness connector and chassis ground.
2. Measure resistance between terminal 37 of the ECM harness connector and chassis ground.
Specification : Infinite(above 10kΩ)

Repair CAN communication line for a short to ground. And then go to "Verification of
■ Check CAN Communication Line for Short to Battery

1. Disconnect the connectors related to the CAN communication.
3. Measure voltage between terminal 36 of the ECM harness connector and chassis ground.
Page 659 of 670
4. Measure voltage between terminal 37 of the ECM harness connector and chassis ground.

Repair CAN communication line for a short to battery. And then go to "Verification of
1. Ignition "OFF"
2. Measure resistance between terminals 36 and 37 of the ECM connector(ECM side)
Specification : Approx. 110~130Ω

Check ECM for contamination, deterioration, or damage. Substitute with a known-good
ECM and check for proper operation. If the problem is corrected, replace ECM and then go

Page 660 of 670
DTC.
Fuel System > Fuel Delivery System > Components and Components Location
Component Location
Page 661 of 670
1. Fuel Tank 6. Leveling Pipe
2. Fuel Pump (Including Fuel Filter) 7. Vapor Hose (Fuel Tank ↔ Canister)
3. Fuel Pressure Regulator 8. Vapor Pipe (Canister ↔ Fuel Tank Air
4. Sub Fuel Sender Filter)
5. Fuel Filler Pipe 9. Fuel Tank Air Filter
10. Fuel Tank Band
Fuel System > Fuel Delivery System > Repair procedures

Fuel Pressure Test
Page 662 of 670
Page 663 of 670
Page 664 of 670
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.
Page 665 of 670
1. Preparation
(1) Remove the rear seat cushion (Refer to "Seat" in BD group).
(2) Open the service cover (A).
(3) Disconnect the fuel pump connector (A).
(4) Start the engine and wait until fuel in fuel line is exhausted.
(5) After engine stalls, turn the ignition switch to OFF position.
2. Disconnect the fuel feed quick-connector (A).
3. Disconnect the sub fuel sender connector (A).

Page 666 of 670
4. Lift the vehicle and support the fuel tank with a jack.
5. Remove the front and main muffler (Refer to "Intake And Exhaust System" in EM group).
6. Remove the propeller shaft (Refer to "Propeller Shaft Assembly" in DS group) [For 4WD].
7. Disconnect the fuel filler hose (A), the leveling hose (B) and the vapor hose (C).
8. Remove the four parking brake installation bolts (A).
9. Remove the fuel tank band (A), and then remove the fuel tank.
Installation
Installation is reverse of removal.
Fuel tank band installation bolt: 44.1 ~ 58.8 N.m (4.5 ~ 6.0 kgf.m, 32.5 ~ 43.4 lb-ft)
Fuel System > Fuel Delivery System > Fuel Pump > Repair procedures
Removal
Page 667 of 670
damaged.
1. Preparation
Page 668 of 670
2. Disconnect the fuel feed tube quick-connector (A), and the suction tube quick-connector (B).
3. Remove the fuel pump installation bolts (C) and remove the fuel pump assembly.
Installation
Fuel pump installation bolts:

2.0 ~ 2.9 N.m (0.2 ~ 0.3 kgf.m, 1.4 ~ 2.2 lb-ft)
When installing the fuel pump module, be careful not to get the seal-ring entangled.
Fuel System > Fuel Delivery System > Sub Fuel Sender > Repair procedures
Removal
damaged.
Page 669 of 670
1. Preparation
2. Disconnect the sub fuel sender connector (A) and the suction tube quick-connector (B).
Page 670 of 670
3. Remove the sub fuel sender installation bolts (C) and remove the sub fuel sender.
Installation
Sub fuel sender installation bolts:

2.0 ~ 2.9 N.m (0.2 ~ 0.3 kgf.m, 1.4 ~ 2.2 lb-ft)
When installing the Sub fuel sender, be careful not to get the seal-ring entangled.
Page 1 of 140
TUCSON(JM) > 2009 > G 2.7 DOHC > Heating,Ventilation, Air Conditioning
Heating,Ventilation, Air Conditioning > General Information > Specifications

Specifications
Item Specification
Heating Heater Type Air mix type
Capacity (Kcal/h) 4,500 ± 5%
Air Cooling capacity 4,500 ± 10%
Evaporator
conditioning (Kcal/h)
Refrigerant Type R-134a
Capacity (g) 510 ± 25
Compressor Engine BETA ENG. DELTA ENG.
Model 10PA15C 10PA17C
Type Swash plate ←
Displacement (cm³/rev) 155.3 177.7
Lubricating oil ND-OIL8 ←
Oil capacity (cc) 120 ~ 135 200 ~ 215
Pressure relief valve Working pressure : 35.2 ~ 42.2
(Kg/cm²) Resealed pressure : Min. 28.1
Magnetic clutch Type L50 ←
Rated voltage (V) DC 12 ←
Consumed current (W) 40 Max. 48
Operating voltage Min. Max. 2.2 Max. 2.66
(A)
Torque (N·m) Min. 53 ←
Pulley pitch dia. ø123 ø125
Condenser Heat rejection (Kcal/h) 13,500 ± 5%
Thermistor ON 2.5 ± 0.5°C
(manual) OFF 0.5 ± 0.5°C
Triple pressure High pressure (kg/cm²) ON 32.0 ± 2.0
switch OFF 26.0 ± 2.0
Middle pressure ON 18.0 ± 0.8
(kg/cm²) OFF 14.0 ± 1.2
Low pressure (kg/cm²) ON 2.3+0.25, -0.29
OFF 2.0 ± 0.2
Heater control assembly MANUAL type, AUTOMATIC type
Page 2 of 140
Heating,Ventilation, Air Conditioning > General Information > Special Service Tools
09977-29000 Removal and installation of pressure
Pressure plate bolt remover plate
Heating,Ventilation, Air Conditioning > General Information > Description and Operation
Air Flow Description
Manual Air Condition Control Panel
Automatic Air Condition Control Panel

Page 3 of 140
AIR FLOW DISTRIBUTION OF MODE (%)
COMPONENT SCHEMATIC
Page 4 of 140
Item Description Item Description

1 Recirculating air port 8 Defrost airflow door
2 Outside air port 9 Panel airflow door
3 Defrost air vent 10 Floor airflow door
4 Panel air vent 11 Air filter
5 Floor air vent 12 Blower unit
6 Air inlet blend door 13 Evaporator core
Air temperature
7 14 Heater core
control door
SYSTEM AIR FLOW DESCRIPTION

MAX A/C
- Air inlet blend door : Recirc

- Air temperature control door : Enable to select
- Defrost airflow door : Close
- Panel airflow door : Open
- Floor airflow door : Close
- A/C compressor : ON
- Blower motor : ON
Page 5 of 140
A/C
- Air inlet blend door : Enable to select

- Defrost airflow door : Enable to select
- Panel airflow door : Enable to select
- Floor airflow door : Enable to select
- Blower motor : ON
PANEL

- A/C compressor : Enable to select
- Blower motor : ON
OFF
Page 6 of 140
- Air inlet blend door : Fresh

- Defrost airflow door : Open
- Panel airflow door : Close
- A/C compressor : OFF
- Blower motor : OFF
PANEL/FLOOR

- Floor airflow door : Open
- Blower motor : ON
FLOOR

- Panel airflow door : Close (Except for side panel air flow)
- Blower motor : ON
FLOOR/DEFROST
Page 7 of 140

- Panel airflow door : Close (Except for side panel air flow)
- Blower motor : ON
DEFROST

- Panel airflow door : Close
- Blower motor : ON
Heating,Ventilation, Air Conditioning > General Information > Troubleshooting

Troubleshooting
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause
of the problem. Check each part in order. If necessary, replace these parts.
Standard:
Symptom Suspect Area
No blower operation 1. HTR Fuse
Page 8 of 140
2. Blower relay
3. Blower motor
4. Blower resistor
5. Blower speed control switch
6. Wire harness
No air temperature 1. Engine coolant capacity
control 2. Heater control assembly
No compressor 1. Refrigerant capacity
operation 2. A/C Fuse
3. Magnetic clutch
4. Compressor
5. Triple pressure switch
6. A/C switch
7. Thermistor, evaporator temp.sensor
8. Wire harness
No cool air comes out 1. Refrigerant capacity
2. Refrigerant pressure
3. Drive belt
4. Magnetic clutch
5. Compressor
7. Thermistor, evaporator temp. sensor
8. A/C switch
9. Heater control assembly
10. Wire harness
Insufficient cooling 1. Refrigerant capacity
2. Drive belt
3. Magnetic clutch
4. Compressor
5. Condenser
6. Expansion valve
7. Evaporator
8. Refrigerant lines
10. Heater control assembly
No engine idle-up when 1. Engine (and ECT) ECU
A/C switch ON 2. Wire harness
No air inlet control Heater control assembly
No mode control Heater control assembly
No condenser fan 1. ECU-IG Fuse
operation 2. Fan motor
3. Engine (and ECT) ECU
4. Wire harness
Page 9 of 140
Heating,Ventilation, Air Conditioning > Air conditioning System > Components and Components
Location
Component Location Index
Engine Room
Interior
Heating,Ventilation, Air Conditioning > Air conditioning System > Troubleshooting

Self-diagnosis
The Full Automatic Temperature Control (F.A.T.C) module self test feature will detect electrical malfunctions and
provide error code for system components with suspected failures.
Control Panel
Self-diagnosis Method
Page 10 of 140
How To Read Self-diagnostic Code

1. After the display panel flickers three times every 0.5 second, the corresponding error code flickers on the setup
temperature display panel every 0.5 second and will show two figures.
2. If error code is more than two, each code flickers 2 times in sequence.
Fault Code Display

1. Normal
Page 11 of 140
2. One error code
3. More error codes than two
4. Checking each error code
DTC Chart
If malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below.
Page 12 of 140
DTC code Detection item Trouble area
00 Normal -
Open INCAR Sensor circuit • Incar sensor
11
• Harness or connector between incar sensor and A/C
Shorted INCAR Sensor circuit control assembly
12
• A/C control assembly
Open Ambient sensor circuit • Ambient sensor
13
• Harness or connector between ambient sensor and
Shorted Ambient sensor circuit A/C control assembly
14
Open water temp. sensor • Water temp. sensor
15
• Harness or connector between water temp. sensor
Shorted water temp. sensor and A/C control assembly
16
Open evap. sensor • Evap. sensor
17
• Harness or connector between evap. sensor and
Shorted evap. sensor A/C control assembly
18
Open or shorted temp. door • Harness or connector between temp. door
19
potentiometer potentiometer and A/C control assembly
20 Defective temp. door potentiometer • Temp. door potentiometer
Open or shorted mode door • Harness or connector between mode door
21
potentiometer potentiometer and A/C control assembly
22 Defective mode door potentiometer • Mode door potentiometer
Open Humidity sensor circuit • Humidity sensor
23
• Harness or connector between humidity sensor and
Shorted Humidity sensor circuit A/C control assembly
24
Fail Safe Function

No. Item Failure FAIL SAFE Function
1 IN-CAR temperature sensor Open/Short 23°C alternate value control
2 Ambient temperature sensor Open/Short 20°C alternate value control
3 Evaporator sensor Open/Short -2°C alternate value control
4 Water temperature sensor Open/Short 10°C alternate value control
Temperature door potentiometer Open/Short setup For 17°C to 24.5°C, set to maximum
temperature cooling position.
5
For 25°C to 32°C, set to maximum heating
position.
Mode door potentiometer Open/Short setup Vent mode, at vent mode
6
mode Def mode, at except vent mode
Page 13 of 140
Heating,Ventilation, Air Conditioning > Air conditioning System > General Safety Information and
Caution
INSPECT FOR LEAKAGE OF REFRIGERANT
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 of connection fittings.
In order to use the leak detector properly, read the manual supplied by the manufacturer.
1. Check the torque on the connection fittings and, if too loose, tighten to the proper torque. Check for gas leakage
with a leak detector.
2. If leakage continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect
the fittings, and check their seating faces for damage. Always replace, even if the damage is slight.
3. Check the compressor oil and add oil if required.
4. Charge the system and recheck for gas leaks. If no leaks are found, evacuate and charge the system again.
A/C SYSTEM TESTS
• 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.
• Compressed air mixed with R-134a forms a combustible vapor.

• The vapor can burn or explode causing serious injury.
• Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning systems.
1. Connect a R-134a refrigerant recover/recycling/charging station to the high-pressure service port and the low-
pressure service port, following the equipment manufacturer's instructions.
Page 14 of 140
2. Insert a thermometer in the center vent.
Determine the relative humidity and air temperature.
3. Test conditions :
A. Avoid direct sunlight.
B. Open the hood.
C. Open the front doors.
D. Set the temperature control dial on MAX COOL, the mode control switch on VENT and the recirculation
control switch on RECIRCULATE.
E. Turn the A/C switch on and the fan switch on MAX.
F. Run the engine at 1,500 rpm.
G. No driver or passengers in vehicle.
4. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature
from the thermometer in the dash vent, the intake temperature near the blower unit behind the glove box and the
high and low system pressure from the A/C gauges.
REFRIGERANT RECOVERY
1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and
the low-pressure service port (C), as shown, following the equipment manufacturer's instruction.
Page 15 of 140
2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be
sure to put the same amount of new refrigerant oil back into the A/C system before charging.
SYSTEM EVACUATION
1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be
evacuated using a R-134a refrigerant recover/recycling/charging station (If the system has been open for several
days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.)
2. Connect a R-134a refrigerant recovery/recycling/charging station(A) to the high-pressure service port(B) and the
low-pressure service port(C), as shown, following the equipment manufacturer's instruction. Evacuate the system.
3. If the low-pressure does not reach more than 93.3 kPa(700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably
a leak in the system. Partially charge the system (see page HA-24), and check for leaks (see page HA-22).
SYSTEM CHARGING
1. Connect a R-134a refrigerant recover/recycling/charging station (A) to the high-pressure service port (B) and the
low-pressure service port (C), as shown, following the equipment manufacturers instructions.
Page 16 of 140
2. Add the same amount of new refrigerant oil to the system that was removed during recovery. Use only ND-OIL8
refrigerant oil.
3. Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the
compressor will be damaged.
Refrigerant capacity : 510 ± 25g
Heating,Ventilation, Air Conditioning > Air conditioning System > Description and Operation
REFRIGERATION CYCLE
Page 17 of 140
Heating,Ventilation, Air Conditioning > Air conditioning System > Drive belt > Repair procedures
Inspection
Only BETA ENG. Apply a force of 98N(10kgf, 22lbf), and measure the deflection at the mid point(A) between the
air condition compressor and crankshaft pulley.
Page 18 of 140
Deflection
Used belt : 6.0~7.0mm (0.24~0.28 in.)
New belt : 5.0~5.5mm (0.20~0.22 in.)
These items when adjusting belt tension :

• If there are cracks or any damage evident on the belt, replace it with a new one.
• "Used belt" means a belt which has been used for five minutes or more.
• "New belt" means a belt which has been used for less than five minutes.
Adjustment
1. Loosen the tension mounting bolt(B).
2. Turn the adjusting bolt to obtain the proper belt tension, then retighten the mounting bolt.
3. Recheck the deflection of the drive belt.
Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line > Components and
Components Location
Component Location
Page 19 of 140
Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line > Repair procedures
Replacement
1. Discharge refrigerant from refrigeration system.
2. Replace faulty tube or hose.
Cap the open fittings immediately to keep moisture or dirt out of the
system.
Page 20 of 140
3. Tighten joint of bolt or nut to specified torque
Connections should not be torqued tighter than the specified

torque.
4. Evacuate air in refrigeration system and charge system with refrigerant.
Specified amount : 510 ± 25g (17.9 ± 0.88 oz.)
5. Inspect for leakage of refrigerant.

Using a gas leak detector, check for leakage of refrigerant.
6. Inspect A/C operation.
Part tightened N·m kgf·cm lbf·ft
Condenser -
5~7 50 ~ 70 3.7 ~ 5.2
Discharge hose
Condenser - Liquid
5~7 50 ~ 70 3.7 ~ 5.2
tube
Compressor -
5~7 50 ~ 70 3.7 ~ 5.2
Discharge hose
Compressor -
5~7 50 ~ 70 3.7 ~ 5.2
Suction hose
Expansion valve -
5~7 50 ~ 70 3.7 ~ 5.2
Evaporator
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Components and
Components Location
Component Location
Page 21 of 140
Components
Page 22 of 140
1. Compressor & clutch assembly 8. Bolt 15. Relief valve
2. Compressor assembly 9. Screw 16. O-ring
3. Field coil 10. Connector bracket 17. Pin knurling
4. Pulley 11. Manifold assembly 18. Flange head bolt
5. Disc & hub 12. Manifold 19. Bolt wrench
6. Retainer ring 13. Suction cap 20. Gasket
7. Shim 14. Discharge cap
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Repair procedures
Replacement
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.
3. Recover the refrigerant with a recovery/charging station (see page HA-23).
4. Loosen the drive belt (see page HA-26).
5. Remove the nuts, then disconnect the suction line (A) and discharge (B) line from the compressor. Plug or cap
the lines immediately after disconnecting them to avoid moisture and dust contamination.
6. Disconnect the compressor clutch connector (A), then remove the mounting bolts and the compressor (B).
Page 23 of 140
7. Using a hexagon wrench (6mm) remove the bolts, the manifold assembly (A) and the gasket (B) from the
compressor.
8. 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 200ml 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-26).
G. Charge the system (see page HA-24), and test its performance (see page HA-22).
Inspection
1. Check the plated parts of the pressure plate for color changes, peeling or other damage. If there is damage,
replace the clutch set.
Page 24 of 140
2. Check the pulley bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it
is noisy or has excessive play/drag.
3. Measure the clearance between the pulley (A) and the pressure plate (B) all the way around. If the clearance is
not within specified limits, remove the pressure plate (see page HA-34) 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.
Page 25 of 140
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
1. Remove the center bolt (A) while holding the pressure plate with a commercially available pressure plate bolt
remover; Special tool number 09977-29000.
Page 26 of 140
2. Remove the pressure plate (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 pressure plate, and
recheck its clearance (see page HA-33).
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 27 of 140
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 > Condenser > Components and
Components Location
Components
Page 28 of 140
Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser > Repair procedures
Replacement
1. Recover the refrigerant with a recovery/recycling/charging station (see page HA-23).
2. Remove the coolant reservoir, but do not disconnect the reservoir hose from the coolant reservoir and the
radiator.
Page 29 of 140
3. Remove the bolt(A), then remove the radiator bracket(B) from the radiator.
4. Remove the bolts(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.
Page 30 of 140
6. Install in the reverse order of removal, and note these items :
A. If you're installing a new condenser, add refrigerant oil.
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. 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 > Triple pressure switch > Components
and Components Location
Component Location
Page 31 of 140
Heating,Ventilation, Air Conditioning > Air conditioning System > Triple pressure switch > Description
and Operation
Descrip4tion
- Rating load : Inductive load DC 12V, 10~250mA
- Applicable voltage range : DC 8V ~ DC 16V
- Applicable temperature range : -30°C ~ 120°C
Page 32 of 140
- Applicable refrigerant : R-134a
- Insulation resistance : Min. 100MΩ at DC 500V
Pressure ON OFF
High 32.0 ± 2.0 26.0 ± 2.0
2.3 + 0.25 / -
Low 2.0 ± 0.2
0.29
Medium 18.0 ± 0.8 14.0 ± 1.2
Low & High
Medium
Heating,Ventilation, Air Conditioning > Air conditioning System > Triple pressure switch > Schematic
Diagrams
Connector
Page 33 of 140
Pin No. 1 2 3 4
Circuit High & High & Medium Medium
Low Low
Circuit Diagram
Heating,Ventilation, Air Conditioning > Air conditioning System > Thermistor > Components and
Components Location
Component Location
Page 34 of 140
Heating,Ventilation, Air Conditioning > Air conditioning System > Thermistor > Description and
Operation
Description
The thermistor will detect the core temperature and interrupt the compressor relay power to prevent evaporator
freezing by excessive cooling.
The thermistor will use the thermal negative characteristic.
- Rated voltage : DC 12V
- Operating voltage : 9V ~ 16V
- Reserved temp. range : -40 ~ 90°C
- Using temp. range : -30 ~ 85°C
- Electric load : ECU
Electric Characteristics According To Temp
Operating
Mode
temperature
A/C ON 2.5 ± 0.5°C
A/C OFF 0.5 ± 0.5°C
Heating,Ventilation, Air Conditioning > Air conditioning System > Thermistor > Schematic Diagrams
Connector
Circuit Diagram
Page 35 of 140
Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Components and
Components Location
Component Location
Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Description and
Operation
Description
The photo sensor is located in the center of defrost nozzle. In response to the photo intensity level in the vehicle, the
sensor will send signals to control module to control the blower level and discharge temperature.
Characteristics
Page 36 of 140
Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Schematic Diagrams
Connector
Pin No. 1 7 8
Circuit Photo Photo
GND
(+) (-)
Circuit Diagram
Page 37 of 140
Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Repair procedures
Inspection
Install the lamp and the photo sensor in the dark room.
Then measure the output current.
LUX 10000 20000 30000
Voltage
26 46 70
(mV)
1. Photo sensor
2. Lamp
3. Dark room
Heating,Ventilation, Air Conditioning > Air conditioning System > Water temperature sensor >
Components and Components Location
Component Location
Page 38 of 140
Description
1. The water sensor, located at the heater core.
2. It will detect water temperature, the sensor will send signal to control module.
Schematic Diagrams
Connector
Page 39 of 140
Heating,Ventilation, Air Conditioning > Air conditioning System > Water temperature sensor > Repair
procedures
Inspection
Measure The Resistance
Resistance
Temp [°C] Voltage [V]
[KΩ]
-40 327.2 4.88
-30 176.3 4.78
-30 97.75 4.62
-10 55.85 4.37
0 32.91 4.02
10 19.99 3.56
20 12.51 3.04
30 8.047 2.50
40 5.311 1.99
50 3.588 1.54
60 2.476 1.18
70 1.742 0.89
80 1.246 0.67
Heating,Ventilation, Air Conditioning > Air conditioning System > Air Quality Sensor(AQS) >
Component Location
Page 40 of 140
Description
1. The A.Q.S. sensor, located at the center support in front of the engine radiator, detects hazardous elements in
ambient air and provides output signals to the control module.
2. Detectable cases
A. Diesel engine exhaust gases : NO, NO , SO
B. Gasoline/LPG engine exhaust gases : CxHy, CO
3. Electrical specification
A. Operating voltage : DC 9 ~ 16V
B. Rated voltage : DC 12V
C. Consumed current : less than 200mA
D. Operating temperature : -30 ~ 105°C
E. Storage temperature : -40 ~ 125°C
Sensor Output
Condition Voltage
Normal condition 5V
Hazardous gas
0V (GND)
detection
Schematic Diagrams
Connector
Page 41 of 140
Pin No. 1 2 3
Circuit DC 12V GND SIGNAL
(IGN) OUTPUT
Heating,Ventilation, Air Conditioning > Air conditioning System > Air Quality Sensor(AQS) > Repair
procedures
Inspection
Checking Method Of Gas Detecting Bench
1. Put the sensor part of AQS(A) toward the air inflow (intake) direction.
2. Connect all of the power supply line and output line to AQS(A).
3. Close the chamber(B) lid after putting the lines in order.
4. Connect the air outlet part of vacuum pump(C) with the air inlet door of chamber(B) by using air hose.
5. Turn on the power of vacuum pump(B).

6. Supply the power to the AQS(A). (DC 12V)
7. LED of AQS(A) is kept "ON" for the first 35 ± 2 seconds after supplying the power.
8. Wait until all of the LEDs are "OFF". Put the diesel engine exhaust gas into the chamber. Then check the LEDs of
number 1 to 10 are "ON".
9. After check LEDs are "ON". Put the clean air into the chamber. Then check LEDs are "OFF".
10. Wait until all of the LEDs are "OFF".
Page 42 of 140
11. And then put the gasoline engine exhaust gas into the chamber, then check the LEDs of number 1 to 10 are
"ON".
12. After check LEDs are "ON". Put the clean air into the chamber. Then check LEDs are "OFF".
- Sensitivity at NO 0.3ppm : More than 2.8
- Sensitivity at Gasoline 10ppm : Less than 0.45
- ON TIME (T on) : 5 sec.
- OFF TIME (T off) : 0 sec.
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Components and
Components Location
Component Location
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Description and
Operation
Description
1. The air temperature sensor, located at the front of the engine radiator, detects ambient air temperature. It is a
negative type thermistor; resistance will increase with lower temperatures, and decrease with higher temperatures.
2. The sensor output will be used for discharge temperature sensor, sensor fail-safe, temperature regulation door
control, blower motor level control, mix mode control and in-car humidity control.
A. R25°C : 30KΩ ± 3%
B. B(0/25) : 3754K ± 2%
C. Operation Temp. range : -30°C ~ 80°C
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Schematic
Diagrams
Page 43 of 140
Connector
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Repair procedures
Inspection
Measure the resistance.
Resistance-temp. Characterisic Table
Temp
R (kΩ)
(°C)
-20 284.5
0 97.5
25 30.000
50 10.83
70 5.27
Characteristics
Page 44 of 140
Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Components and
Components Location
Component Location
Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Description and
Operation
Description
1. The in car sensor, located at the heater control module.
Page 45 of 140
2. It will detect interior temperature, the sensor will send signal to control module.
Pin No. B1 B9
Circuit Sensor IN Sensor OUT
Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Schematic Diagrams
Connector
Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator temperature sensor >
Component Location
Page 46 of 140
Description
1. The evaporator temp. sensor, located at the evaporator core.
2. It will detect evaporator temperature, the sensor will send signal to control module.
Schematic Diagrams
Connector
Repair procedures
Inspection
Measure The Resistance
Resistance
Temp [°C] Voltage [V]
[KΩ]
-10 13.56 3.14
-5 10.37 2.81
0 8.000 2.49
5 6.222 2.18
10 4.877 1.88
15 3.851 1.62
20 3.063 1.38
25 2.453 1.17
30 1.978 0.99
35 1.605 0.83
40 1.310 0.70
Page 47 of 140
45 1.075 0.59
50 0.888 0.50
Heating,Ventilation, Air Conditioning > Heater > Heater Unit > Components and Components Location
Component Location
Page 48 of 140
Components
1. Heater & evaporator 6. Bracket7. Seal 11. Vent door 16. Mode actuator
case 8. Heater & evaporator 12. Floor door 17. Heater core side
2. Heater core upper case 13. Cam bracket
3. Drain hose 9. Upper case seal 14. Temp. actuator 18. Thermistor (Manual)
4. Temp. door 10. Defrost door 15. Water temp. sensor 19. Evaporator temp.
5. Evaporator core (Full auto) sensor (Full auto)
20. Insulation
Page 49 of 140
Heating,Ventilation, Air Conditioning > Heater > Heater Unit > Repair procedures
Replacement
1. Recover the refrigerant with a recovery/recycling/charging station.
2. When the engine is cool, drain the engine coolant from the radiator.
4. 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.
5. Disconnect the inlet(C) and outlet(D) 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.
6. Remove the crash pad (see BD group - crash pad).
7. Remove the cross member.
8. Remove the mounting nut(A), the mounting bolts(B) and heater & evaporator unit(C).
Page 50 of 140
9. Remove the self-tapping screws(A) and the cover(B).
10. Remove the side bracket(C).

11. Remove the clip and lower cover.
Be careful not to bend the inlet and outlet pipes during heater core and evaporator core removal.
12. Install the heater core and evaporator core in the reverse order of removal.
13. Install in the reverse order of removal, and note these items :
A. If you're installing a new evaporator, add refrigerant oil.
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 > Components and
Components Location
Component Location
Page 51 of 140
Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Description and
Operation
Description
- Rate voltage : DC 12V
- Rate load : 1.5 kgf·cm
- Operating time : 4 + 1.0 sec.
- Rate current : Max. 0.1A
- Lock current : Max. 0.55A
- Locked torque : Max. 6kgf·cm
- Noise : Max. 43dB
- Use voltage : DC 10 ~ 15V
- Use temp. : -40 ~ 80°C
Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Schematic Diagrams
Connector
Page 52 of 140
Circuit Diagram
Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Repair procedures
Replacement
1. Disconnect the 7P connector(A) from the temp. actuator(C). Remove the self-tapping screws(B) and the temp.
actuator(C) from the heater unit.
Page 53 of 140
2. Install in the reverse order of removal. After installation, make sure temp. actuator(C) runs smoothly.
Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Components and
Components Location
Component Location
Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Description and Operation
Discription
- Rate load : 1.5 kgf·cm
- Operating time : 4 + 1.0 sec.
- Noise : Max. 43dB
- Use temp. : -40 ~ 80°C
Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Schematic Diagrams
Connector
Page 54 of 140
Circuit Diagram
Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Repair procedures
Replacement
1. Remove the 7P connector(A) from the mode actuator(C). Remove the self-tapping screw(B) and the mode
actuator(C) from the heater unit.
Page 55 of 140
2. Install in the reverse order of removal. After installation, make sure the mode actuator(C) runs smoothly.
Heating,Ventilation, Air Conditioning > Blower > Blower Unit > Components and Components Location
Component Location
Components
Page 56 of 140
1. Outlet duct seal 6. Air filter housing 11. High blower relay (Type full auto)
2. Inlet duct case 7. Blower upper case 12. Blower relay
3. Inlet door 8. Blower lower case 13. Register (Type manual)
4. Fresh and recirculation actuator 9. Blower seal 14. Power TR (Type full auto)
5. Air filter 10. Blower motor
Heating,Ventilation, Air Conditioning > Blower > Blower Unit > Repair procedures
Replacement
3. Disconnect the connectors from the blower relay the blower motor, the blower resistor (or power transistor) and
the fresh and recirculation actuator.
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.
4. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Components and Components
Location
Component Location
Page 57 of 140
Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Description and Operation
Description
Moter : Magnet ø68.2
Item Specifications
Time rating Continuous
Rated voltage DC 12V
3,000 ± 10%
Speed in rated load
RPM
Power in rated 250W grade
Rotation direction CCW
Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Schematic Diagrams
Connector
Page 58 of 140
Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Repair procedures
Inspection
Connect the battery voltage and check the blower motor rotation.
Heating,Ventilation, Air Conditioning > Blower > Blower Relay > Components and Components
Location
Component Location
Page 59 of 140
Heating,Ventilation, Air Conditioning > Blower > Blower Relay > Description and Operation
Description
There should be continuity between No.3 and No.4 terminals when power and ground are connected to the No.1
and No.2 terminals, and there should be no continuity when power is disconnected.
- Rated load current : DC 12V, 25A (Motor load)
Heating,Ventilation, Air Conditioning > Blower > Blower Relay > Schematic Diagrams
Connector
Circuit Diagram
Page 60 of 140
Heating,Ventilation, Air Conditioning > Blower > Power Transistor > Components and Components
Location
Component Location
Heating,Ventilation, Air Conditioning > Blower > Power Transistor > Description and Operation
Description
- Working voltage range : DC 9 ~ 16V
- Working temp. range : -30 ~ 60°C
- Resistance temp. range : -40 ~ 85°C
Page 61 of 140
Heating,Ventilation, Air Conditioning > Blower > Power Transistor > Schematic Diagrams
Connector
Heating,Ventilation, Air Conditioning > Blower > Blower Resistor > Components and Components
Location
Component Location
Heating,Ventilation, Air Conditioning > Blower > Blower Resistor > Description and Operation
Description
Page 62 of 140
- Rated load : Blower motor
- Standard test Temp. : 20°C
- Operation Temp. : -30 ~ +70°C
Heating,Ventilation, Air Conditioning > Blower > Blower Resistor > Schematic Diagrams
Connector
Circuit Diagram
Heating,Ventilation, Air Conditioning > Blower > Blower Resistor > Repair procedures
Inspection
Measure terminal-to-terminal resistance of the blower resistor.
If measured resistance is not within specification, the blower resistor must be replaced. (After removing the resistor)
Page 63 of 140
Heating,Ventilation, Air Conditioning > Blower > Climate control air filtar > Repair procedures
Replacement
1. Open the glove box, remove the glove box stopper(A) in the lower crash pad(assist seat side), and completely
lower the glove box.
2. Remove the A/C air filter assembly(A).

Page 64 of 140
3. Remove the A/C air filter(B) from the filter housing(A).
Replace the A/C air filter according to the maintenance schedule in the owner's manual.
4. Install in the reverse order of removal.

Make sure that there is no air leaking out of the blower unit.
Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Components and Components
Location
Component Location
Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Description and Operation
Description
General performance
Page 65 of 140
- Rate load : 1.5kgf·cm
- Operating time : 3.5 + 1.0 sec.
- Noise : Max. 43dB
- Use temp. : -40 ~ 80°C
Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Schematic Diagrams
Connector
Circuit Diagram
Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Repair procedures
Replacement
Page 66 of 140
1. Disconnect the 7P connector(A) from the inlet actuator(C). Remove the self-tapping screws(B) and the inlet
actuator(C) from the blower unit(D).
2. Install in the reverse order of removal. After installation, make sure the inlet actuator(C) runs smoothly.
Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Manual) >
Components
1. Panel 4. Temperature select knob & A/C

2. Mode select knob & intake switch switch
3. Blower speed knob 5. Inlet panel
6. Housing
Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Manual) > Description
and Operation
Description
1. Blower Switch
The blower switch controls the blowing level of the air conditioning system by controlling blower motor speed.
The switch has an electrical circuit containing a resister that will regulate blower motor input voltage to control the
motor speed.
2. Mode Switch
The mode switch controls air conditioning system discharge location. The switch contains an electrical circuit to
control an actuator that is connected to the mode door for discharge control.
3. Temperature Switch
The temperature switch controls the temperature door position that will be used to regulate the air conditioning
system's discharge air temperature.
4. Intake Switch
The intake switch controls the intake door used to regulate the intake air flow of the air conditioning system. The
switch contains an electrical circuit used to control the actuator that is connected to the intake door.
Page 67 of 140
5. Air Conditioning Switch
The air conditioning switch controls the on/off position of the air conditioning system compressor. The switch
contains an electrical circuit that will switch on/off the power supply to the relay that is connected to the
compressor.
Switch Operation And FeaTURES
Switch Feature Switch selection Function
A/C switch A/C switch pushed • Indicator ON
• A/C operate
A/C switch pushed with • Indicator OFF
A/C ON • A/C non-operate
Fresh and recirculation Switch pushed • Indicator ON
switch • Shift to recirculation
mode
Switch pushed with • Indicator OFF
switch ON • Shift to fresh mode
Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Manual) > Repair
procedures
Check Point By Type
Blower Check
When the blower is turned ON, blower relay becomes turned ON and battery voltage is supplied to the blower
motor upper part. The current determined by the supplied battery voltage, blower motor, and register ground runs to
GND through the blower motor and the selected blower single resister.
Troubleshooting
Page 68 of 140
Symptoms Possible causes How to check
Blower malfunction Short wire of register
Blower wind is discharged Open circuit of blower switch With switch OFF, check the connection
despite switching OFF between each terminal and
GND/COMMON terminal
A/C Check
For A/CON output, blower must be basically operated. When blower speed 1 is selected, blower relay is turned
ON and voltage is supplied to point "A".
When the supplied voltage at point "A" is entered into control connector C15 and at this moment when A/CON
switch is turned ON, voltage is supplied to connector C5 at 9V or more.
Thermistor value determines whether the input power at point "B" is supplied to point "C".
The state of ON/OFF of triple switch determines whether the input power at point "C" is supplied to point "D".
Finally when the voltage is supplied to point "D", engine ECU determines whether A/CON and CONDENSER
FAN turned ON/OFF.
Troubleshooting
Symptoms Possible causes How to check
Wind of A/CON isn't discharged Signal output error of A/CON With switch OFF of A/CON, and measure
into in-car despite switching OFF voltage of connector C5 as shown in the
of A/CON above figure. If the voltage is 9V or more,
check the triple switch, ENG ECU, and
wires.
Mode Check
Page 69 of 140
As shown in the above figure, in adjusting mode switch from VENT to DEF, 0V is outputted from connector B4,
12V is supplied for B5 and mode motor works in direction of DEF. In adjusting mode switch from DEF to VENT,
0V is outputted from connector B5, 12V is supplied for B4 and mode motor works in direction of VENT. When
mode actuator has to move to a certain location for its automatic control, mode feedback signal terminal moves
equally in mode actuator and informs controller of location of mode actuator through mode connector B6.
Comparing original value with the inputted value, it works until they are same.
Troubleshooting
Symptoms Causes How to check
Mode actuator running error Power supply error in mode After altering VENT to DEF, measure
actuator voltage of connector B4, and after altering
DEF to VENT, measure voltage of
connector B5.
If both of them are 9V and more, check
mode actuator and peripheral wiring state
and if one or both of them are 9V and less,
its cause is internal failure of control.
Intake Check
Page 70 of 140
In turning on IG and selecting indoor mode with indoor switch, 0V is outputted from connector B12, 12V is
supplied for C1 and motor works in direction of indoor. In selecting outdoor mode with indoor switch, 0V is
outputted from connector C1, 12V is supplied for B12 and motor works in direction of outdoor.
Troubleshooting
Indoor mode running error Power supply error in actuator Separate connector linked with actuator,
select indoor mode with indoor switch and
measure voltage of connector C1. If 9V and
more, check actuator or wiring state and if
9V and less, check the inside of controller.
Outdoor mode running error Power supply error in actuator Select outdoor mode in the above method
and measure voltage of connector B12. If
9V and more, check actuator or wiring state
and if 9V and less, check the inside of
controller.
Temp.check
Page 71 of 140
As shown in the above figure, in adjusting temp. switch from WARM to COOL, 0V is outputted from temp.
connector B7, 12V is supplied for B8 and temp. motor works in direction of COOL. In adjusting temp. switch from
COOL to WARM, 0V is outputted from temp. connector B8, 12V is supplied for B7 and temp. motor works in
direction of WARM. When temp. actuator has to move to a certain location for its automatic control, temp.
feedback signal terminal moves equally in temp. actuator and informs controller of location of temp. actuator through
temp. connector B9. Comparing original value with the inputted value, it works until they are same
Troubleshooting
Temp actuator running error Power supply error in temp After altering COOL to WARM, measure
actuator voltage of B8, and after altering WARM to
COOL, measure voltage of B7. If Both of
them are 9V and more, check temp actuator
and peripheral wiring state and if one or both
of them are 9V and less, its cause is internal
failure of control.
Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Manual) > Schematic
Diagrams
Connector
Page 72 of 140
Connector Pin No. Circuit Connector Pin NO. Circuit

1 MIDDLE HIGH 1 REC
2 MIDDLE LOW 2 ILL +
3 LOW 3 ILL -
A 4 HIGH 4 BLOWER ON (+)
5 GND 5 A/C OUTPUT
BLOWER COMMON
6 6 -
OUT
1 IGN 7 -
2 BAT + 8 -
3 GND 9 PTC ON SIGNAL
C
MODE ACTUATOR
4 10 BLOWER RELAY ON
(VENT)
MODE ACTUATOR
5 11 PTC RELAY 2
(DEF)
6 MODE F/BACK 12 PTC RELAY 3
B
TEMP ACTUATOR
7 13 -
(WARM)
TEMP ACTUATOR
8 14 -
(COOL)
9 TEMP F/BACK 15 -
10 VCC 16 BLOWER COMMON IN
11 SENSOR GND
12 FRE
Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Full Automatic) >
Components
Page 73 of 140
1. Front panel 4. Incar sensor
2. Inlet panel 5. Incar/humidity
3. Case sensor
Description
Switch Operation And Features

Switch Feature Switch selection Function
Temp switch Push DOWN button at set Select at intervals of 0.5°C from 17°C
temperature of 25°C while to 25°C
operating
Indication screen
Push UP button at set Select at intervals of 0.5°C from 32°C

temperature of 25°C while to 25°C
operating
Indication screen
AUTO switch Push AUTO switch under Control automatically all outlet by input
system OFF or manual value of each sensor
operation
Page 74 of 140
Indication screen
Push AUTO switch under Unchanged

automatic operation
Indication screen
MODE switch Push MODE switch while Indicate the following repeatedly
operating whenever pushing the switch under set
condition. Vent → Bi level → Floor →
Mix → Vent
Indication screen
Push MODE switch under Release AUTO mode and keep

system OFF system OFF
OFF switch Push OFF switch while System OFF (keep TEMP and
operating MODE intake in original condition and
turn OFF blower and compressor)
Indication screen
A/C switch When air conditioner is Turn ON air conditioner outlet

OFF, push A/C switch
under system OFF or
operating
Push A/C switch under air Turn OFF air conditioner outlet
conditioner ON
Air intake When system is OFF, push Keep system OFF and intake door
switch intake switch under air turn to air intake mode
outlet condition
Page 75 of 140
When system OFF, push Keep system OFF and intake door
intake switch under air turn to air outlet mode
intake condition
Push intake switch under Air intake mode
air outlet when operating
When operating, push Air outlet mode
intake switch under air
intake condition
Air outlet mode indicator
condition
Air intake mode indicator

condition
DEF switch Push DEF switch when Mode door : to DEF mode
operating DEF mode or A/C : ON
system OFF Intake : Outlet mode
Others : Condition before OFF
Indicator and indication
screen
Push DEF switch when Return to the condition before DEF

operating DEF mode mode
AQS switch Push AQS switch under Control intake door by AQS signal
AQS stopped while turning on AQS indicator
Push AQS switch when Return to the state before selecting
operating AQS AQS while turning off AQS indicator
Push OFF switch when Turn off indication screen and AQS
operating indicator, and intake door fixes to air
intake mode
Able to select AQS, air intake, and air
outlet when system OFF
Indicator condition while
operating AQS
Indicator condition under

AQS stopped
Blower switch Push blower switch ▼ Voltage between both edges of blower
while operating motor goes down to 3.8V
Page 76 of 140
Indication screen
Push blower switch ▲ Votage between both edges of blower

while operating motor goes up to Max high
Indication screen
Push blower switch under Operate with 3.8V between both

system OFF edges of blower motor
Indication screen
Control Specification
Control item Control features Remarks
Required discharge Required temperature determined by the set temperature
temperature and the inputted sensor value.
Auto control Required discharge temperature is determined by the set
temperature and the inputted sensor value. The feature
will use the required discharge temperature to perform
the auto control of temp. actuator, mode actuator, intake
actuator, blower motor and compressor, and maintain
the set temperature stably.
IN-CAR temperature Upon detecting rapid changes of temperature from the - 0.5°C UP/sec.
correction INCAR sensor, it will gradually correct the incar
temperature value. - 0.5°C DOWN/sec.
AMB temperature Upon detecting rapid changes of temperature from the Logic of the correction
correction AMB sensor, it will gradually correct the ambient speed sensor
temperature value.
Photo correction Upon detecting rapid changes of photo intensity from the - 0→1000(W/m²)/1min
PHOTO sensor, it will gradually correct the photo delay
intensity value.
- 1000→0(W/m²)/5min
delay
TEMP door control It does the automatic control to maintain the optimum The set temperature range
TEMP door opening (0%-100%). It will be computed
LO → HI, 0.5°C step
by the temperature set and the input signal from each
sensor. (LO → HI, 1°F step)
Blower speed Automatic control of the blower speed. The target value - Auto mode blower low
will be computed by the set temperature and the input voltage (Manual low
signal from each sensor. (8 levels may be selected in voltage: 3.8)
case of manual selection.)
Page 77 of 140
case of manual selection.)
- Auto mode heater blower
HI speed: 10.6V
Electro-motive mode During auto control, it will raise the permitted voltage of 12 seconds for shifting
control blower motor gradually in order to improve LO→MAX HI
comfortability.
Photo compensation During auto control, it will compensate the blower level
and the discharge temperature according to the photo
intensity detected from the PHOTO sensor. PHOTO
compensation will begin after 5 seconds when ignition
on.
Mode door control Automatic control of air discharge based on the required - At OFF, MODE door
discharge temperature. It will be computed by the will fix the current
temperature setting and the input signal from each condition.
sensor.
(VENT ↔ B/L ↔ FLOOR) - At OFF in manual mode,
MODE door will maintain
the manual control
condition.
In case of manual selection
(VENT → B/L → FLOOR → MIX → VENT)
INTAKE door control Auto control of intake mode based on the required - Shift to REC when
discharge temperature that will be computed by the selecting REC button at
temperature setting and the input signal from each FRE condition (LED on).
sensor.
- Shift to FRE when
selecting FRE button at
REC condition (LED off).
INTAKE control at OFF The intake door will fix to the FRE. position when - FRE./REC. manual
switching the system off. selection will be enabled at
OFF
- REC indicator will come
out at OFF.
Compressor auto control Control automatically the compressor on/off state - When selecting the
corresponding to the set temperature and the input signal AUTO SW, the
from each sensor. compressor is controlled to
ON/OFF.
- When selecting the DEF
SW, the compressor is
controlled to "ON".
Compressor clutch on/off If EVAP sensor temperature is below 0.5°C, the
control based on refrigerant compressor will be ON and the temperature is 2.5°C,
temperature or higher, with the compressor OFF.
MAX HOT When selecting the set temperature HI at AUTO mode, - TEMP door: MAX HOT
MAX HOT will be performed. It will prevail over MIX - MODE door: FLOOR
mode control.
mode
Page 78 of 140
- INTAKE door: FRE
mode
- Compressor: OFF
- Blower speed: AUTO
HI(10.6V)
MAX COOL When selecting the set temperature LO at AUTO mode, - TEMP door: MAX
MAX COOL will be performed. COOL
- MODE door: FLOOR
mode
- INTAKE door: REC
mode
- Compressor: ON
- Blower speed: MAX HI
Electromotive heating If the water temperature is 40°C or more at B/L or - Blower speed: Controlled
control FLOOR in AUTO mode, it will effect the electromotive at AUTO LOW (4.5V)
heating control to prevent outside cold air from flowing
toward the feet of passengers.
As the coolant temperature rises, the MODE door will Operation release
shift to DEF → MIX → AUTO.
• Water temp.≥60°C
• Max cool
MODE: Manual selection is enabled. • In pressing MODE
switch.
INTAKE door: At AUTO control or at manual selection • In pressing DEF switch.
mode.
Blower speed: Manual selection is enabled (No re-
entry).
Electromotive cooling In order to prevent hot air from the VENT or B/L in
control AUTO mode (A/C on mode blower auto ), the blower
speed will be operated at LOW for approx. 12 seconds
before entering the AUTO control if the EVAP sensor
detection is temperature 30°C or higher.
MAX HOT If the above condition is satisfied, electromotive cooling
control will operate at any time.
Air Quality System (AQS) The AQS system will detect the hazardous elements and - When the initial battery
odors contained in the air. If the harmful element connection and ignition is
concentration is higher than standard, the system will ON, it will operate at
output a LOW signal (1.0V or less) to the FATC. AUTO mode. (AQS will
not operate.)
If the concentration is within the standard value, the - When IGN 2 ON, the
system will output a HI signal (4V) to the FATC. AQS assembly will be
preheated for
34.5±5seconds.
Corresponding to the signal from the AQS, it will control - IGN2 ON: It will check
Page 79 of 140
the INTAKE door as follows to prevent the inflow of circuit break on the AQS
harmful gas in FATC: assembly's signal line for
approx. 7 seconds during
the preheating, irrespective
to the AQS switch
condition.
Condition INTAKE door position - When AQS is selected
prior to IGN2 OFF and
IGN2 is turned
OFF→ON: AQS indicator
will come on, and the
system will operate at AQS
mode. (Store the previous
condition before IGN 2
OFF)
LOW REC
HI FRE
Initialization Upon battery- When supplying the initial power, it will operate in the - When the initial ignition
on initial condition. ON after battery
connection, the system will
operate at the set
temperature 23°C(73°F)
and at AUTO mode.
Memory When removing ignition key, it will store FATC'S - When IGN ON after
operating condition. IGN OFF during FATC
operation, the system will
operate at the previous
before the ignition off.
Repair procedures
Check Point By Type
Page 80 of 140
1. Power supply check

2. Back light check
3. Blower check
4. Air conditioner check
5. Intake check and AQS check
6. Mode check
7. Temp check
8. Sensor check
Power Supply Check
Page 81 of 140
In turning off IGN, battery supplies power for ordinary power, FATC connector A3 through battery fuse. FATC
performs memory function by means of battery power supplied as described above. In turning on IGN, alternator is
driven. At this time, IG2 power generated in alternator FATC connector A12 and A25 terminal through IG2 fuse
and air conditioner fuse 10A. FAT carried out actual system operation by means of IG2 power supplied as
described above.
ERROR DIAGNOSTICS
When IG is ON, memory Battery power supply error Check voltage of battery after turning off IG.
function error occurs If 10V and more, check FATC connector
and if no problem, check the inside of
controller. If 10V and less, check fuse or
wiring state of battery power source.
When IG is ON, system running IG2 power supply error Check voltage of IG2 after turning on IG. If
error occurs 10V and more, check FATC connector and
if no problem, check the inside of controller.
If 10V and less, check fuse or wiring state of
IG2 power source.
Back Light Check
In turning on IG and then light switch, battery power is supplied for FATC connector A2 terminal through wiring.
The supplied power passes connector A1 terminal through light LED in FATC and flows into rheostat as shown in
the above figure. The brightness is adjusted according to rheostat value of reostart.
Error Diagnostics
Page 82 of 140
When light switch is ON, partial Light LED lighting error in FATC
error occurs in back light
When light switch is ON, entire Light power supply error Measure voltage of tail light shown in the
error occurs in back light above figure after switching on light. If 10V
and more, check FATC connector and if no
problem, measure signal voltage of rheostat
shown in the above figure. If 8V and more,
check rheostat wiring and rheostat.
If tail light is below 1V, check tail light
wiring.
Blower Check
Perform the blower check in manual blower running state because it is difficult to check blower at automatic control.
Blower is controlled from level l to level 8 equally as in button operation and running logic. In turning on IG, blower
relay is ON and voltage of 0.1 to 1.4V is transferred from FATC connector A4 terminal to base source of power
TR according to FATC control (selectable from level 1 to level 8). At this time, voltage of blower motor's both ends
is determined according to collector voltage of FATC connector A5 terminal. If FATC is controlled in level 8,
GND(0V) is supplied for FATC connector A18 terminal and high blower relay is driven.
Error Diagnostics
Page 83 of 140
Amount of wind is wrong at Power TR error Check voltage of blower motor's both ends.
manual selection of blower (Level 1: 3.8V, Level 2: 5.2V, Level 3:
6.5V, Level 4: 7.9V, Level 5: 9.2V, Level 6:
10.6V, Level 7: 12.0V, Level 8: 13.5V
[high-relay operation])
Measure voltage of each terminal and if there
is difference more than ±0.6V, check power
TR.
Blower wind is discharged Power TR error Power TR change
despite pressing OFF switch
Air Conditioner Check
11V is outputted from connector A17 terminal in turning on INSULATING and pressing air conditioner switch.
However, although 11V is outputted from FATC connector A17 terminal, compressor clutch isn't driven. Wind of
air conditioner is discharged if only compressor clutch works. Output signal from air conditioner is inputted in engine
computer through triple switch. Then, the engine computer considers several conditions and when output of air
conditioner is judged to be practical, it gives GND to signal terminal of air conditioner relay. Accordingly, relay of air
conditioner is ON and compressor clutch works. Triple switch checks pressure of refrigerant flowing through pipe
and turns on/off switches in it according to standard. So, it controls that output signal of air conditioner outputted
from FATC is inputted into engine computer, and also speed of condenser fan according to pressure level. (For high
pressure, high-speed and for low pressure, low-speed.)
Error Diagnostics
Page 84 of 140
Wind of air conditioner isn't Signal output error of air Switch on air conditioner and measure
discharged into vehicle despite conditioner voltage of FATC connector A17 terminal as
switching on air conditioner. shown in the above figure. If 9V and more,
check triple switch,air conditioner relay and
ECM.
Switch on air conditioner and measure
voltage of FATC connector A17 terminal as
shown in the above figure. If 1V and less,
check input value of evaporator sensor.
Input error of evaporator sensor If evaporator sensor is disconnected or short
or voltage of its input source is more than
3.0V (below 0.5°C), output of air
conditioner isn't made.
Intake And Aqs Check
In turning on IG and selecting indoor mode with indoor switch, 0V is outputted from FATC connector A23 terminal,
12V is supplied for A10 terminal and motor works in direction of outdoor. In selecting outdoor mode with
indoorswitch, 0V is outputted from FATC connector A10 terminal, 12V is supplied for A23 terminal and motor
works in direction of indoor.
Error Diagnostics
Page 85 of 140
Indoor mode running error Power supply error in actuator Separate connector linked with actuator,
select indoor mode with indoor switch and
measure voltage of FATC connector A23
terminal. If 8V and more, check actuator or
wiring state and if 9V and less, check the
inside of controller.
Outdoor mode running error Power supply error in actuator Select outdoor mode in the above method
and measure voltage of FATC connector
A10 terminal. If 8V and more, check
actuator or wiring state and if 9V and less,
check the inside of controller
Fixed in outdoor or indoor mode AQS signal terminal output error Select AQS switch and measure AQS signal
at AQS selection terminal as shown in the above figure. If
there is no change of voltage over 10 min,
check AQS.
Mode Check
In turning on IG and selecting mode switch, sequential operation begins in order of Vent → Bi-level → Blower →
Mix. DIP mode works regardless of order at selecting it. As shown in the above figure, in adjusting mode switch
from VENT to DEF, 12V is outputted from connector B4, 0V is supplied for B5 and mode motor works in
direction of DEF. In adjusting mode switch from DEF to VENT, 12V is outputted from connector B5, 0V is
supplied for B4 and mode motor works in direction of VENT. When mode actuator has to move to a certain
location for its automatic control, mode feedback signal terminal moves equally in mode actuator and informs
controller of location of mode actuator through mode connector B6. Comparing original value with the inputted
value, it works until they are same.
Error Diagnostics
Page 86 of 140
Mode actuator running error Power supply error in mode After altering VENT to DEF, measure
actuator voltage of connector A15, and after altering
DEF to VENT, measure voltage of
connector A14.
It both of them are 9V and move, check
mode actuator an peripheral wiring state and
if one or both of them are 9V and less, its
cause is internal failure of control.
Sensor(+5) power supply error If automatic control isn't operated smoothly,
measure voltage of FATC connector B8
terminal,
If under 4.8V or over 5.2V, its cause is
internal failure of FATC.
Driver error of mode actuator If NO.22 is outputted as result of self-
diagnostic, check mode actuator driver.
Temp Check
In adjusting temp switch from 32°C to 17°C, 0V is outputted from FATC connector A22 terminal, 12V is supplied
for A9 terminal and temp motor works in direction of COOL. In adjusting temp switch from 17°C to 32°C, 0V is
outputted from FATC connector A9 terminal, 12V is supplied for A22 terminal and temp motor works in direction
of WARM. When temp actuator has to move to a certain location for its automatic control, temp feedback signal
terminal moves equally in temp actuator and informs controller of location of temp actuator through FATC
connector B10 terminal. Comparing original value with inputted value, it works until they are same. If 4.9V and
more is inputted in B10 terminal, it is regarded as disconnection. If 0.1V and less is inputted in B10 terminal, it is
regarded as short-circuit. In the case of disconnection or short-circuit as a result of self-diagnostic, substitute control
is carried out as follows.
• If setup temperature is 17°C to 24.5°C, set to MAX COOL.
• If setup temperature is 25°C to 32.0°C, set to MAX WARM.
Page 87 of 140
Error Diagnostics
Temp actuator running error Power supply error in temp After altering 17°C to 32°C and adversely,
actuator measure voltage of A9 and after altering
32°C to 17°C and adversely, measure
voltage of A22. If Both of them are 9V and
more, check temp actuator and peripheral
wiring state and if one or both of them are
5V and less, its cause is internal failure of
FATC.
Sensor (+5) power supply error If automatic control isn't operated smoothly,
measure voltage of FATC connector B8
terminal. If under 4.8V or over 5.2V, its
cause is internal failure of FATC.
Driver error of temp actuator If No. 20 is outputted as a result of self-
diagnostic, check temp actuator driver.
Sensor Check
Resistance value set according to temperature of each part is inputted in FATC controller.
Internal temperature of vehicle is automatically controlled by operating the inputted values.
It is recommended to refer to resistance value and voltage value corresponding to each temperature and the
following explains essential functions of each sensor required for repair and self-diagnostics and substitute functions
at disconnection or short-circuit.
• If 4.9V and more is inputted in connectors B1, B3, B4, B7, B12 terminal, it is regarded as disconnection.
• If 0.1V and less is inputted in connectors B1, B3, B4, B7, B12 terminal, it is regarded as short-circuit.
Schematic Diagrams
Page 88 of 140
Connector
Connector Pin No. Circuit Connector Pin No. Circuit

1 RHEOSTAT 1 INCAR SENSOR IN
2 TAIL LAMP (+) 2 A/C SELECT SIGNAL
3 BATT (+) 3 AMB SENSOR (+)
4 P/TR (BASE) 4 EVA SENSOR (+)
5 P/TR (COLLECTOR) 5 SPEED SENSOR
6 - 6 HI SCAN
WATER TEMP
7 - 7
SENSOR(+)
8 AQS 8 SENSOR REF. (+5V)
B
9 TEMP ACT'R (CCW) 9 INCAR SENSOR OUT
10 INTAKE ACT'R (CCW) 10 TEMP F/B SIGNAL
11 - 11 MODE F/B SIGNAL
12 IGN2 12 PHOTO SENSOR (+)
PHOTO SENSOR
13 GND 13
A (Ground)
14 MODE ACT'R (CW) 14 -
15 MODE ACT'R (CCW) 15 -
16 - 16 SENSOR GND
17 A/C OUTPUT
18 HIGH SPEED RELAY
19 -
20 -
21 -
22 TEMP ACT'R (CW)
23 INTAKE ACT'R (CW)
BLOWER SELECT
24
SIGNAL
Page 89 of 140
25 IGN2
26 GND
Heating,Ventilation, Air Conditioning > Controller > B1200 Humidity Sensor Open(High)
Component Location
General Description
Humidity sensor located at heater control unit 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
incar fogging. Air conditioner operation depends on ambient temperature and humidity
DTC Description
The ECM 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 6,950Hz)

DTC Strategy • Frequency check
Threshold • Open Circuit in
• > 4.9V harness
value
• Fault Humidity
Detecting time • 0.3sec Sensor
FAIL SAFE • Control with the valaue of 10%
Specification
Relative Relative
Frequency(Hz) Frequency(Hz)
humidity(%) humidity(%)
20 6950 60 6540
30 6855 70 6410
40 6750 80 6275
50 6645 90 6100

2. Engine "ON"
Page 90 of 140
3. Monitor the "Humidity Sensor" Parameter on the Scantool.
Fig.1) The current data in abnormal state.

Fig.2) DTC B1200.
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
replace as necessary and then go to "Verification of Vehicle Repair" procedure.

or damage.
procedure.

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.
Check for open in harness. Repair as necessary and go to "Verification Vehicle Repair"
procedure.

Check for open in ground harness
1. Ignition "OFF"
Page 91 of 140
3. Measure resistance between terminal "5" of Humidity Sensor and terminal "14" of A/C Control Unit

Go to "Component Inspection " procedure.
Check for open in ground harness. Repair as necessary and go to "Verification Vehicle
Repair" procedure.
Check Humidity Sensor
1. Engine "ON"
2. Connect Humidity Sensor.
3. Measure Frequency between terminal "3" and "5" of Humidity sensor
Specification : Refer the specifications in fig3)
Fig.3) Siganl wavem of Humidity sensor

Fig.4) Frequency of Humidity sensor Measured by scantool
Fig.5) Specifications : Frequency value as a function of Relative humidity.
4. Is the measured frequency within specifications in (fig5)? (tolerance limits ±5%)
Check if frequency value is inversely proportional to humidity while increasing humidity.
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.

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
Page 92 of 140
procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B1201 Humidity Sensor Short(Low)
Component Location
General Description
Humidity sensor located at heater control unit 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
incar fogging. Air conditioner operation depends on ambient temperature and humidity
DTC Description
The ECM 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
Threshold • Short circuit in
• < 0.1V harness
value
• Fault Humidity
Detecting time • 0.3sec Sensor
FAIL SAFE • Control with the valaue of 10%
Specification
Relative Relative
Frequency(Hz) Frequency(Hz)
humidity(%) humidity(%)
20 6950 60 6540
30 6855 70 6410
40 6750 80 6275
50 6645 90 6100

2. Engine "ON"
Page 93 of 140
3. Monitor the "Humidity Sensor" Parameter on the Scantool.
Fig.1) The current data in abnormal state.

Fig.2) DTC B1201.
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

or damage.
procedure.

Check for short to ground in harness
1. Ignition "OFF"
3. Measure resistance between terminal "3" of Humidity sensor and chassis ground.
Specification : Approx. ∞ Ω

Check for short to ground in harness. Repair as necessary and go to "Verification Vehicle
Repair" procedure.
Check Humidity Sensor
1. Engine "ON"
2. Connect Humidity Sensor.
Page 94 of 140
3. Measure Frequency between terminal "3" and "5" of Humidity sensor
Fig.3) Siganl wavem of Humidity sensor

Fig.4) Frequency of Humidity sensor Measured by scantool
Fig.5) Specifications : Frequency value as a function of Relative humidity.
4. Is the measured frequency within specifications in (fig5)? (tolerance limits ±5%)
Check if frequency value is inversely proportional to humidity while increasing humidity.
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.

procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B1202 Heater Water Temperature Sensor
Open(High)
Component Location
General Description
Water temp sensor located at heater unit detects coolant temperature. Its signal is used for cold engine lookout
control. When the driver operates heater to warm before the engine is warmed up, the signal from sensor is
delivered to the heater control unit and according to this signal, heater control unit reduces blow motor speed untill
coolant temperature is up to threshold value
DTC Description
The ECM sets DTC B1202 if there is an open circuit in water temp sensor signal harness or the measured resistance
Page 95 of 140
value of sensor is more than threshold value(about 176.3kΩ)

DTC Strategy • Voltage check • Open Circuit in
Threshold harness
• > 4.9V • Fault water temp.
value
Sensor
Detecting time • 0.3sec
• Fault A/C Control
FAIL SAFE • Control with the valaue of 20°C Unit
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"
3. Monitor the "WATER TEMP SENSOR" Parameter on the Scantool.
Fig.1) The current data in abnormal state

Fig.2) DTC B1202
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 96 of 140
procedure.

1. Ignition "OFF"
2. Disconnect water temp. sensor.
3. Measure resistance between terminal "1" of water temp. sensor and terminal "7" of A/C Control Unit

procedure.

1. Ignition "OFF"
3. Measure resistance between terminal "2" of water temp. sensor and chasis ground

Repair" procedure.
Check WATER TEMP Sensor
1. Ignition "OFF"
Page 97 of 140
3. Measure resistance between terminal "1" and "2" of water temp. sensor.
Fig.3) Specifications : Resistance value as a function of temperature.

4. Is the measured resistance within specifications in fig3)? (tolerance limits ±3%)
Go to "Check A/C Control Unit" procedure.
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.
Check A/C Control Unit

1. Engine "ON"
3. Measure Voltage between terminal "7" of A/C Control Unit and chasis ground
4. Is the measured voltage within specifications?

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.

procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B1203 Heater Water Temperature Sensor
Short(Low)
Component Location
Page 98 of 140
General Description
Water temp sensor located at heater unit detects coolant temperature. Its signal is used for cold engine lookout
control. When the driver operates heater to warm before the engine is warmed up, the signal from sensor is
delivered to the heater control unit and according to this signal, heater control unit reduces blow motor speed untill
coolant temperature is up to threshold value
DTC Description
The ECM 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
Threshold harness
• < 0.1V • Fault water temp.
value
Sensor
FAIL SAFE • Control with the valaue of 20°C Unit
Specification
Temperature Temperature
Resistance(kΩ) Resistance(kΩ)
(°C(°F) (°C(°F)
-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"
3. Monitor the "WATER TEMP SENSOR" Parameter on the Scantool.

Fig.2) DTC B1203
Page 99 of 140
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.
procedure.

1. Ignition "OFF"
3. Measure resistance between terminal "1" of water temp. sensor and chassis ground.

Repair" procedure.
Check WATER TEMP Sensor
1. Ignition "OFF"
Page 100 of 140
3. Measure resistance between terminal "1" and "2" of water temp. sensor.

Repair" procedure.

1. Engine "ON"
3. Measure Voltage between terminal "7" of A/C Control Unit and chasis ground

procedure.

procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B1233 In-Car Temperature Sensor Short (Low)
Component Location
Page 101 of 140
General Description
The incar temperature sensor located at heater 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 ECM sets DTC B1233 if there is a short circuit in incar temp sensor signal harness or the measured resistance

DTC Strategy • Voltage check • Short circuit in
harness
Threshold value • < 0.1V • Fault incar
Detecting time • 0.3sec temp.sensor
FAIL SAFE • Control with the vlaue of 23°C(73°F) Unit
Specification
(°C(°F) (°C(°F)
-30 (-22) 144.79 25 (77) 10
-15 (5) 63.59 35 (95) 6.73
0 (32) 30.03 60 (140) 2.72
15 (59) 15.21 80 (176) 1.43

2. Engine "ON"
3. Monitor the "INCAR TEMP.SENSOR" Parameter on the Scantool.

Fig.2) DTC B1233
Page 102 of 140
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
SENSOR

or damage.
procedure.

1. Ignition "OFF"
2. Disconnect incar sensor.
3. Measure resistance between terminal "4" of incar sensor and chassis ground

Repair" procedure.
Check Incar Temp. sensor
1. Ignition "OFF"
Page 103 of 140
3. Measure resistance between terminal "4" and "5" of incar sensor

Repair" procedure.

1. Engine : "ON"
3. Measure voltage between terminal "1" of A/C Control Unit and chasis ground

procedure.

procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B1234 In-Car Temperature Sensor Open (High)
Component Location
Page 104 of 140
General Description
The incar temperature sensor located at heater 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 ECM sets DTC B1234 if there is an open circuit in incar temp sensor signal harness or the measured resistance

harness
Threshold value • > 4.9V • Fault incar
FAIL SAFE • Control with the valaue of 23°C(73°F) Unit
Specification
(°C(°F) (°C(°F)
-30 (-22) 144.79 25 (77) 10
-15 (5) 63.59 35 (95) 6.73
0 (32) 30.03 60 (140) 2.72
15 (59) 15.21 80 (176) 1.43

2. Engine "ON"
3. Monitor the "INCAR TEMP.SENSOR" Parameter on the Scantool.

Fig.2) DTC B1234
Page 105 of 140
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
SENSOR

or damage.
procedure.

1. Ignition "OFF"
3. Measure resistance between terminal "4" of incar temp.sensor and terminal "1" of A/C Control Unit

procedure.

1. Ignition "OFF"
2. Disconnect incar temp.sensor.
3. Measure resistance between terminal "5" of incar temp.sensor and terminal "9" of A/C Control Unit
Page 106 of 140
Repair" procedure.
Check Incar Temp. sensor
1. Ignition "OFF"
3. Measure resistance between terminal "4" and "5" of incar sensor

Repair" procedure.

1. Engine : "ON"

procedure.

Page 107 of 140
procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B1237 Ambient Temperature Sensor Short (Low)
Component Location
General Description
The ambient temperature senor located at the center stay of the condensor 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 ECM sets DTC B1237 if there is a short circuit in ambient temp sensor signal harness or the measured
resistance value of sensor is less than threshold value(about 10.8kΩ)

DTC Strategy • Voltage check
• Short circuit in harness
Threshold value • < 0.1V • Fault ambient
• Fault A/C Control Unit
FAIL SAFE • Control with the valaue of 20°C(67°F)
Specification
(°C(°F) (°C(°F)
-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 108 of 140
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.

Fig.2) DTC B1237.
4. Are the DTC B1237 present and is parameter of "AMBIENT TEMP.SENSOR" fixed ?

or damage.
procedure.

1. Ignition "OFF"
2. Disconnect ambient sensor.
3. Measure resistance between terminal "2" of ambient sensor and chassis ground

Repair" procedure.
Check Ambient sensor
1. Ignition "OFF"
Page 109 of 140
3. Measure resistance between terminal "1" and "2" of ambient sensor

Repair" procedure.

1. Engine : "ON"

procedure.

procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B1238 Ambient Temperature Sensor Open (High)
Component Location
Page 110 of 140
General Description
The ambient temperature senor located at the center stay of the condensor 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 ECM 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)

Threshold value • > 4.9V harness
• Fault ambient
FAIL SAFE • Control with the valaue of 20°C(67°F) • Fault A/C Control Unit
Specification
(°C(°F) (°C(°F)
-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.

Fig.2) DTC B1238
Page 111 of 140
4. Are the DTC B1238 present and is parameter of "AMBIENT TEMP.SENSOR" fixed ?

or damage.
procedure.

1. Ignition "OFF"
3. Measure resistance between terminal "2" of ambient temp.sensor and terminal "3" of A/C Control Unit

procedure.

1. Ignition "OFF"
2. Disconnect ambient temp.sensor.
3. Measure resistance between terminal "1" of ambient temp.sensor and chassis ground.
Page 112 of 140
Repair" procedure.
Check Ambient sensor
1. Ignition "OFF"
3. Measure resistance between terminal "1" and "2" of ambient sensor

Repair" procedure.

1. Engine : "ON"

procedure.

Page 113 of 140
procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B1241 Evaporator Sensor Short (Low)
Component Location
General Description
The Evaporator sensor located at 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 ECM sets DTC B1241 if there is a short circuit in evaporator sensor signal harness or the measured resistance

DTC Strategy • Voltage check • Short circuit in harness
Threshold value • < 0.1V • Fault Evaporator
sensor
Detecting time • 0.3sec • Fault A/C Control
FAIL SAFE • Control with the valaue of -20°C (-4°F) Unit
Specification
(°C(°F) (°C(°F)
-10 (5) 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 114 of 140
3. Monitor the "EVAPORATIVE SENSOR" Parameter on the Scantool.

Fig.2) DTC B1241
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.
procedure.

1. Ignition "OFF"
2. Disconnect evaporator sensor.
3. Measure resistance between terminal "1" of evaporator sensor and chassis ground

Repair" procedure.
Check evaporator sensor
1. Ignition "OFF"
Page 115 of 140
3. Measure resistance between terminal "1" and "2" of evaporator sensor

Repair" procedure.

1. Engine "ON"

procedure.

procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B1242 Evaporator Sensor Open (High)
Component Location
Page 116 of 140
General Description
The Evaporator sensor located at 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 ECM sets DTC B1242 if there is an open circuit in evaporator sensor signal harness or the measured resistance

harness
Threshold value • > 4.9V • Fault Evaporator
Detecting time • 0.3sec sensor
FAIL SAFE • Control with the valaue of -20°C (-4°F) Unit
Specification
(°C(°F) (°C(°F)
-10 (5) 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.

Fig.2) DTC B1242
Page 117 of 140
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.
procedure.

1. Ignition "OFF"
3. Measure resistance between terminal "1" of evaporator sensor and terminal "4" of A/C Control Unit

procedure.

1. Ignition "OFF"
3. Measure resistance between terminal "2" of evaporator sensor and chassis ground.
Page 118 of 140
Repair" procedure.
Check evaporator sensor
1. Ignition "OFF"
3. Measure resistance between terminal "1" and "2" of evaporator sensor

Repair" procedure.

1. Engine "ON"

procedure.

Page 119 of 140
procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B1245 Air Mix Potentiometer Open (Low)-Driver
Component Location
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. then temperature will be regulated by the
hot/cold air ratio decided by position of temp door
DTC Description
The ECM sets DTC B1245 if there is an open circuit or poor connection of connected part in the air mix
potentiometer.

Monitor Strategy
• Voltage check
Description
• Poor connection of connected
Threshold value • <0.1V part
Detecting time • 0.3sec • Open circuit in harness
• If temperature setting 17°C - 24.5°C (62-76°F) fix
• Faulty DR Air Mix
at max. cooling position
FAIL SAFE potentiometer
• If temperature setting 25°C - 32°C (77-90°F) fix at
max. heaing position
Specification

2. Engine "ON"
Page 120 of 140
3. Monitor the "DR AIR MIX Potentiometor" Parameter on the Scantool.

Fig.2) DTC B1245
4. Are the DTC B1245 present and is parameter of "DR AIR MIX Potentiometor" fixed ?
Parameter of "DR AIR MIX Potentiometor" will be fixed at 100%(or any value above 90%), or 0% (or any
value below 10%), if there is any fault in DR AIR MIX potentiometer.

or damage.
procedure.

1. Ignition "OFF"
2. Disconnect DR Air Mix Actuator
3. Measure resistance between terminal "4" of DR Air Mix Potentiometor 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 Vehicle
Repair" procedure.

1. Ignition "OFF"
Page 121 of 140
3. Measure resistance between terminal "4" of DR Air Mix Potentiometor and chasis ground

Go to "Power circuit Inspection" procedure.
Check for short to ground in signal harness. Repair as necessary and go to "Verification

1. Ignition "ON"
2. Connect DR Air Mix Potentiometor.
3. Measure voltage between terminal "5" of DR Air Mix Potentiometor and chasis ground
Specification : Approx.5V

Go to "Ground circuit Inspection" procedure.
Check for short or open in power harness. Repair as necessary and go to "Verification

1. Ignition "OFF"
2. Disconnect DR Air Mix Potentiometor.
3. Measure resistance between terminal "3" of DR Air Mix Potentiometor and chasis ground

Repair" procedure.
Check actuator
1. Ignition "OFF"
3. Verify that the temperature actuator operates to the hot position when connecting 12V to the terminal 1 and
grounding terminal 2.
Page 122 of 140
4. Verify that the temperature actuator operates to the cool position when connecting in the reverse.
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 and then go to "Verification of Vehicle Repair" procedure.
Check potentiometer
1. Ignition "ON"
2. Connect DR Air Mix Actuator
3. Measure voltage between terminal "3" and "4" of DR AIR MIX potentiometer while operating the temp switch.
Door position Voltasge (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
Fig.3) Specifications : Voltage value of Air Mix potentiometer as a function of position of temperature door.
4. Is the measured voltage within specifications in fig3)?

procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B1246 Air Mix Potentiometer Short (High)-Driver
Component Location
Page 123 of 140
General Description
DTC Description
The ECM sets DTC B1246 if there is a short to power harness in the air mix potentiometer.

Monitor Strategy
• Voltage check
Description
Threshold value • >4.9V
• Faulty DR Air Mix
• If temperature setting 17°C - 24.5°C (62-76°F) fix potentiometer
at max. cooling position
FAIL SAFE
• If temperature setting 25°C - 32°C (77-90°F) fix at
max. heaing position
Specification

2. Engine "ON"

Fig.2) DTC B1246
4. Are the DTC B1246 present and is parameter of "DR AIR MIX Potentiometor" fixed ?
Parameter of "DR AIR MIX Potentiometor" will be fixed at 100%(or any value above 90%), or 0% (or any
value below 10%), if there is any fault in DR AIR MIX potentiometer.
Page 124 of 140
or damage.
procedure.

Check for short in harness
1. Ignition "OFF"
3. Measure resistance between terminal "5" and "4" of DR AIR MIX potentiometer

Check for short to power harness in signal harness. Repair as necessary and go to
Check actuator
1. Ignition "OFF"

Check potentiometer
1. Ignition "ON"
Page 125 of 140


procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B1249 Direction Potentiometer Open (Low)-
Driver
Component Location
General Description
The mode control actuator mounted on heater unit adjusts position of mode door by generating 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 ECM sets DTC B1249 if there is an open circuit or poor connection of connected part in the Direction
potentiometer.
Page 126 of 140

Monitor Strategy
• Voltage check • Poor connection of
Description
connected part
Threshold value • <0.1V • Open circuit in harness
Detecting time • 0.3sec • Short circuit in harness
• Faulty DR Direction
• fix vent position
FAIL SAFE potentiometer
• fix in defrost mode
Specification

2. Engine "ON"
3. Monitor the "DR DIRECTION POTENTIO" parameter on the scantool.

Fig.2) DTC B1249
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 DR direction Potentiometor

or damage.
procedure.

Page 127 of 140
1. Ignition "OFF"
2. Disconnect DR Direction Actuator
3. Measure resistance between terminal "4" of DR Direction Potentiometor and terminal "11" of A/C control unit.

Repair" procedure.

1. Ignition "OFF"
3. Measure resistance between terminal "4" of DR Direction Potentiometor and chasis ground

Go to "Power circuit Inspection" procedure.

1. Ignition "ON"
2. Connect DR Direction Potentiometor.
3. Measure voltage between terminal "3" of DR Direction Potentiometor and chasis ground
Specification : Approx.5V

Go to "Ground circuit Inspection" procedure.
Check for short or open in power harness. Repair as necessary and go to "Verification

1. Ignition "OFF"
2. Disconnect DR Direction Potentiometor.
Page 128 of 140
3. Measure resistance between terminal "5" of DR Direction Potentiometor and chasis ground

Repair" procedure.
Check actuator
1. Ignition "OFF"
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 connecting in the reverse.

Check potentiometer
1. Ignition "ON"
3. Measure voltage between terminal "4" and "5" of DR Direction Potentiometor as the mode switch is operated

VENT 0.3±0.15V
BI-LEVEL(1) 1.35±0.4V
BI-LEVEL(2) 2.25±0.4V Undervoltage : 0.08V or less
FLOOR 3.0±0.4V Overvoltage : 4.92V or more
MIX 3.6±0.4V
DEF 4.7±0.15V
Page 129 of 140

procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B1250 Direction Potentiometer Short (High)-
Driver
Component Location
General Description
DTC Description
The ECM sets DTC B1250 if there is a short to power harness in the Direction potentiometer.

Monitor Strategy
• Voltage check
Description
Threshold value • >4.9V • Faulty DR Direction
Detecting time • 0.3sec potentiometer
FAIL SAFE • fix vent position
Specification
Page 130 of 140

2. Engine "ON"

Fig.2) DTC B1250
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 DR direction Potentiometor

or damage.
procedure.

Check for short in harness
1. Ignition "OFF"
3. Measure resistance between terminal "3" and "4"of DR Direction Potentiometor

Check for short to power harness in signal harness. Repair as necessary and go to
Page 131 of 140
Check actuator
1. Ignition "OFF"
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 connecting in the reverse.

Check potentiometer
1. Ignition "ON"
3. Measure voltage between terminal "4" and "5" of DR Direction Potentiometor while operating the mode switch.

VENT 0.3±0.15V
BI-LEVEL(1) 1.35±0.4V
MIX 3.6±0.4V
DEF 4.7±0.15V

Page 132 of 140
procedure.
time.
Heating,Ventilation, Air Conditioning > Controller > B2406 Air Mix Motor-Driver
Component Location
General Description
DTC Description
The ECM sets DTC B2406 if the air mix actuator dosen’t move to intended position within 40sec (In this case,
ECM try to move temp door for 2sec. 3 times, every 20 sec. before setting DTC)

Monitor Strategy • Poor connection of
• Voltage check
Description connected part
• Open circuit in harness
Threshold value • <0.1V
Detecting time • 0.3sec • Faulty DR Air Mix
potentiometer
FAIL SAFE •- • Fault A/C Control Unit
Specification

2. Engine "ON"

Fig.2) DTC B2406
Page 133 of 140
4. Are the DTC B2406 present and is parameter of "DR AIR MIX Potentiometor" fixed?
There is any fault in DR 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.
procedure.

1. Ignition "OFF"
3. Measure resistance between terminal "1,2" of DR Air Mix Motor and terminal "9,22" of A/C control unit.

Repair" procedure.

1. Ignition "OFF"
3. Measure resistance between terminal "1,2" of DR Air Mix Motor and chasis ground
Page 134 of 140
Go to "Visual/Physical Inspection " procedure.

Check actuator
Check if DR Air Mix Actuator works properly through ACTUATION TEST.
1. Ignition : ON
2. Connect Scantool and select " ACTUATION TEST" mode and press [F1]
Fig.3) DR Air Mix Actuator.

Fig.4) Selecting "ACTUATION TEST" mode.
3. Dose DR Air Mix Actuator work properly?
Check actuator
1. Ignition "OFF"

Check potentiometer
1. Ignition "ON"
Page 135 of 140


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.

procedure.

procedure.
time.
Page 136 of 140
Heating,Ventilation, Air Conditioning > Controller > B2409 Direction Control Motor-Driver
Component Location
General Description
DTC Description
The ECM sets DTC B2409 if the direction motor dosen’t move to intended position within 40sec (In this case,
ECM try to move mode door for 2sec. 3 times, every 20 sec. before setting DTC)

Monitor Strategy • Poor connection of
• Voltage check
Description connected part
• Open circuit in harness
Threshold value • <0.1V
Detecting time • 0.3sec • Faulty DR Direction
potentiometer
FAIL SAFE •- • Fault A/C Control Unit
Specification

2. Engine "ON"

Fig.2) DTC B2409
Page 137 of 140
4. Are the DTC B2409 present and is parameter of "DR DIRECTION POTENTIO" fixed?
There is any fault in DR Direction Motor. If the parameter of "DR DIRECTION POTENTIO" is 10% or less
on "VENT" mode, or If the parameter is 90% or more on "DEF" mode.
Terminal7 and Connector Inspection

or damage.
procedure.

1. Ignition "OFF"
2. Disconnect DR Direction Actuator.
3. Measure resistance between terminal "1,2" of DR Direction Motor and terminal "14,15" of A/C control unit.

Repair" procedure.

1. Ignition "OFF"
2. Disconnect DR Direction Actuator.
3. Measure resistance between terminal "1,2" of DR Direction Motor and chasis ground
Page 138 of 140
Go to "Visual/Physical Inspection " procedure.

Check actuator
Check if DR Direction Actuator works properly through ACTUATION TEST.
1. Ignition : ON
2. Connect Scantool and select " ACTUATION TEST" mode and press [F1]
Fig.3) DR Direction Actuator.

Fig.4) Selecting "ACTUATION TEST" mode.
3. Dose DR Direction Actuator work properly?
Check actuator
1. Ignition "OFF"
3. Verify that the temperature actuator operates to vent mode when connecting 12V to the terminal 1 and grounding
terminal 2.

Check potentiometer
1. Ignition "ON"
Page 139 of 140
3. Measure voltage between terminal "4" and "5" of DR Direction Potentiometor while operating the mode switch.

VENT 0.3±0.15V
BI-LEVEL(1) 1.35±0.4V
MIX 3.6±0.4V
DEF 4.7±0.15V

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.

procedure.

Page 140 of 140
procedure.
time.
Page 1 of 297
TUCSON(JM) > 2009 > G 2.7 DOHC > Restraint
Restraint > General Information > General Information

General
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 contains the 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 Detecting System (PODS) 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 , it input to ACU if the seat
track position is full forward. SRSCM located on the floor under the heater core which monitors the system, an
accelerometer which senses the vehicle deceleration, a spring interconnection (clock spring) located within the
steering column ; system wiring and wiring connector; and a knee bolster located under the steering column. 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 circuity to the
microprocessor.
SRSCM (SRS Control Module)
The SRS airbag system consists of electrical and electronic. Be cautious in the airbag parts.
SRSCM will detect front impact with inside sensor, and side impact with side impact sensor, detect airbag
deployment request signal, 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 inside operation voltage. If inside operation voltage is below
critical value setting, it will perform re-setting.
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 during
vehicle power supply is on, system failure may be checked with trouble codes using scan too. (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 be turned on for about
six seconds and then go off to indicate operation.
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.
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 seat crash pad.
8. Once airbag is deployed, SRSCM should not be used again but replaced.
9. SRSCM will determine whether passenger has put on seat belt using built-in switch signal in seat belt buckle, and
deploy front seat airbag at each set crash speed.
Page 2 of 297
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

0957A-34100A Airbag deployment tool
Deployment tool DAB, PAB: 0957A-38510
CAB, BPT: 0957A-38500
SAB: 0957A-3F100
0957A-38200 Simulator to check the resistance of

Dummy each wiring harness
Dummy adapter
DAB, PAB, CAB, BPT: 0957A-2G000
SAB: 0957A-3F000
0957A-38510 Use with deployment tool
Deployment adapter(DAB, PAB)
0957A-38500 Use with deployment tool.

Deployment adapter(CAB,BPT)
0957A-3F100 Use with deployment tool.

Deployment adapter(SAB)
0957A-2G000 Use with dummy.

Dummy adapter
(DAB, PAB, CAB, BPT)
Page 3 of 297
0957A-3F000 Use with dummy.
Dummy adapter(SAB)
* DAB : Driver Airbag

* PAB : Prassenger Airbag
* SAB : Side Airbag
* BPT : Belt Pretensioner
* CAB : Curtain Airbag
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
disconnected from 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.
Page 4 of 297
• Store the removed airbag with the pad surface up.
• 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 200°F/93°C).
• 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, the front impact sensor 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, the front impact sensor 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 5 of 297
• 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 6 of 297
• 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
Disconnecting
To release the lock, pull the spring-loaded sleeve (A) toward the stop (B) while holding the opposite half of the
connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half.
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.
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2. When the connector halves are completely connected, the pawl is released, and the spring-loaded sleeve locks
the connector.
Airbag Connector
Disconnecting
To release the lock, pull the spring-loaded sleeve (A) and the slider (B), while holding the opposite half of the
connector. Pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half.
Connecting
Hold both connector halves and press firmly until the projection (C) of the sleeve-side connector clicks to lock.
Page 8 of 297
Restraint > General Information > Description and Operation

SRS Harness
The SRS haress is wrapped in yellow tube to be discriminated from other system harness. And the shorting bar is
included inside the wiring connectors of DAB, PAB, SAB, CAB and BPT module circuit when the connectors are
disconnected. The circuits to the inflator module are shorted in this way to help prevent unwanted deployment of the
airbag when serving the airbag module.
SRSCM Independent Lamp Activation
There are certain fault conditions in which the SRSCM (SRS Control Module) cannot function and thus cannot
control the operation of the lamp. In these cases, the lamp is directly activated by appropriate circuitry that operates
independently of the SRSCM, as follow.
1. Loss of ignition voltage supply to the SRSCM : Lamp turned on continuously.
2. Loss of internal operating voltage : Lamp turned on continuously.
3. SRSCM malfunctioning : Lamp turned on continuously.
4. SRSCM not connected : Lamp turned on through shorting bar in wiring harness connector.
Warning lamp operation condition and status operation condition Lamp
Restraint > General Information > Components and Components Location

Components
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Page 10 of 297
Restraint > SRSCM > SRS Control Module (SRSCM) > Repair procedures
Removal
1. Disconnect the battery negative cable, and wait at least three minutes before beginning work.
2. Disconnect the airbag connectors.
3. Disconnect the side airbag connectors.
4. Remove the center consol(See BD- console group)
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5. Disconnect SRS harness(A) from the SRSCM (B).
6. Disconnect the bolts (C), then remove the SRSCM (B).
Installation
1. Install the new SRSCM unit with the three bolts, then connect the connectors to the SRSCM unit.
2. Install the console.
3. Reconnect the airbag connectors.
4. Reconnect the side airbag connectors.
5. Reconnect the battery negative cable.
6. After installing the SRSCM unit, 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 > SRSCM > Front Impact Sensor (FIS) > 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 (see BD group-exterior).
3. Remove the bolt then remove the front impact sensor.
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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.
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 turned on for
about six seconds and then go off.
Restraint > SRSCM > Side Impact Sensor (SIS) > 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 (see BD group - seat).
3. Remove the front door sill trim (see BD group - interior).
4. Remove the center pillar trim (see BD group - interior).
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5. Remove the two bolts then remove the side impact sensor (A).
6. Disconnect the SRS harness connector from the side impact sensor.
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.
3. After installing the side 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 > SRSCM > Seat Track Position Sensor (STPS) > Description and Operation
Description
STPS function : Input to ACU if the seat track position is full forward.
Restraint > SRSCM > Passenger Occupant Detecting Sensor (PODS) > Description and Operation
PODS Description
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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 Airbag Control Unit 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.
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 > SRSCM > Passenger Occupant Detecting Sensor (PODS) > Components and Components
Location
PODS Component
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1. Bladder : Sense occupant weight and provide fluid pressure input to Pressure Sensor.
2. Push pins : Use to secure the Bladder assembly on the seat pan and maintain the correct Bladder position during
seat assembly.
3. Backer Board : Provide stable and smooth reaction surface for Bladder, together with Felt Pad.
4. Felt Pad : Provide stable reaction surface for Bladder, together with Backer Board, and protect Bladder
Assembly from the seat frame environment.
5. ECU : Utilizing data from the Pressure Sensor, BTS (Belt Tension sensor), and Compensation Tables,
determine if PAB (Passenger Airbag) will be suppressed.
6. Pressure Sensor : Sense pressure input from Bladder and convert the pressure input to a voltage signal for
ECU.
Restraint > SRSCM > Schematic Diagrams

Circuit Diagram (1)
Circuit Diagram (2)

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SRSCM Connector Terminal
PIN NO. FUNCTION INPUT/OUTPUT

1 1st stage Driver airbag, High (+) Output
2 1st stage Driver airbag, Low (-) Output
3 1st stage Passenger airbag, Low (-) Output
4 1st stage Passenger airbag, High (+) Output
5 - -
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6 - -
7 - -
8 - -
9 Driver side airbag, High (+) Output
10 Driver side airbag, Low (-) Output
11 Passenger side airbag, Low (-) Output
12 Passenger side airbag, High (+) Output
13 Driver curtain airbag, High (+) Output
14 Driver curtain airbag, Low (-) Output
15 Passenger curtain airbag, Low (-) Output
16 Passenger curtain airbag, High (+) Output
17 2nd stage Driver airbag, High(+) Output
18 2nd stage Driver airbag, Low(-) Output
19 2nd stage Passenger airbag, Low(-) Output
20 2nd stage Passenger airbag, High(+) Output
21 Driver belt pretensioner, High (+) Output
22 Driver belt pretensioner, Low (-) Output
23 Ignition Input
24 ~ 25 Shorting bar -
26 Telltale warning lamp Output
27 Crash output Output
28 Driver front impact sensor, High (+) Output
29 Driver front impact sensor, Low (-) Output
30 Passenger front impact sensor, Low (-) Output
31 Passenger front impact sensor, High (+) Output
32 PODS CAN, High (+) Output
33 PODS CAN, Low (-) Output
34 Driver side impact sensor, High (+) Output
35 Driver side impact sensor, Low (-) Output
36 Passenger side impact sensor, Low (-) Output
37 Passenger side impact sensor, High (+) Output
38 STPS Driver, High (+) Output
39 STPS Driver, Low(-) Output
40 STPS Passenger, Low (-) Output
41 STPS Passenger, High (+) Output
42 Driver buckle switch, High (+) Output
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43 Driver buckle switch, Low (-) Output
44 Passenger buckle switch, Low (-) Output
45 Passenger buckle switch, High (+) Output
46 Passenger belt pretensioner, High (+) Output
47 Passenger belt pretensioner, Low (-) Output
48 K-diagnostic line Input/Output
49 Ground Input
50 Warning lamp Output
Restraint > SRSCM > Troubleshooting

Diagnostic Trouble Codes(DTC)
DTC
Fault Description Remark
code
B1100 Battery voltage
B1101 Battery voltage high
B1326 FIS(Front Impact Sensor)-Driver short to Ground
B1327 FIS(Front Impact Sensor)-Driver short to Battery
B1328 FIS(Front Impact Sensor)-Driver defect
B1329 FIS(Front Impact Sensor)-Driver communication error
B1330 FIS(Front Impact Sensor)-Driver Wrong ID
B1331 FIS(Front Impact Sensor)-Passenger short to Ground
B1332 FIS(Front Impact Sensor)-Passenger short to Battery
B1333 FIS(Front Impact Sensor)-Passenger defect
B1334 FIS(Front Impact Sensor)-Passenger communication error
B1335 FIS(Front Impact Sensor)-Passenger Wrong ID
B1346 Driver airbag resistance too High (1st stage)
B1347 Driver airbag resistance too Low (1st stage)
B1348 Driver airbag resistance circuit short to Ground (1st stage)
B1349 Driver airbag resistance circuit short to Battery (1st stage)
B1352 Passenger airbag resistance too High (1st stage)
B1353 Passenger airbag resistance too Low (1st stage)
B1354 Passenger airbag resistance circuit short to Ground (1st stage)
B1355 Passenger airbag resistance circuit short to Battery (1st stage)
B1361 Pretensioner front-Driver resistance too High
B1362 Pretensioner front-Driver resistance too Low
B1363 Pretensioner front-Driver resistance circuit short to Ground
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B1364 Pretensioner front-Driver resistance circuit short to Battery
B1367 Pretensioner front-Passenger resistance too High
B1368 Pretensioner front-Passenger resistance too Low
B1369 Pretensioner front-Passenger resistance circuit short to Ground
B1370 Pretensioner front-Passenger resistance 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 resistance circuit short to Ground
B1381 Side airbag front-Driver resistance 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 resistance circuit short to Ground
B1385 Side airbag front-Passenger resistance circuit short to Battery
B1396 STPS(Seat Track Position Sensor)-Driver open or short to Ground
B1397 STPS(Seat Track Position Sensor)-Driver short or short to Battery
B1398 STPS(Seat Track Position Sensor)-Passenger open or short to Ground
B1399 STPS(Seat Track Position Sensor)-Passenger short or short to Battery
B1400 SIS(Side Impact Sensor)front-Driver defect
B1401 SIS(Side Impact Sensor)front-Driver circuit short to Ground
B1402 SIS(Side Impact Sensor)front-Driver circuit short to Battery
B1403 SIS(Side Impact Sensor)front-Passenger defect
B1404 SIS(Side Impact Sensor)front-Passenger circuit short to Ground
B1405 SIS(Side Impact Sensor)front-Passenger circuit short to Battery
B1409 SIS(Side Impact Sensor)front-Driver communication error
B1410 SIS(Side Impact Sensor)front-Passenger communication error
B1414 SIS(Side Impact Sensor)front-Driver Wrong ID
B1415 SIS(Side Impact Sensor)front-Passenger Wrong ID
B1473 Inflatable curtain airbag front-Driver resistance too High
B1474 Inflatable curtain airbag front-Driver resistance too Low
B1475 Inflatable curtain airbag front-Driver resistance circuit short to Ground
B1476 Inflatable curtain airbag front-Driver resistance circuit short to Battery
B1477 Inflatable curtain airbag front-Passenger resistance too High
B1478 Inflatable curtain airbag front-Passenger resistance too Low
B1479 Inflatable curtain airbag front-Passenger resistance circuit short to Ground
B1480 Inflatable curtain airbag front-Passenger resistance circuit short to Battery
B1481 Driver airbag resistance too High(2nd stage)
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B1482 Driver airbag resistance too Low(2nd stage)
B1483 Driver airbag resistance circuit short to Ground(2nd stage)
B1484 Driver airbag resistance circuit short to Battery(2nd stage)
B1485 Passenger airbag resistance too High(2nd stage)
B1486 Passenger airbag resistance too Low(2nd stage)
B1487 Passenger airbag resistance circuit short to Ground(2nd stage)
B1488 Passenger airbag resistance circuit short to Battery(2nd stage)
B1489 PODS(Passenger Occupant Detecting System)ECU Defect
B1490 PODS(Passenger Occupant Detecting System)Sensor(Bladder) Defect
B1491 PODS(Passenger Occupant Detecting System)ECU supply voltage too Low
B1492 PODS(Passenger Occupant Detecting System)short to Battery
B1493 PODS(Passenger Occupant Detecting System)Communication error
B1494 PODS(Passenger Occupant Detecting System)Wrong ID
B1495 BTS(Belt-Tension Sensor) Defect
B1521 Buckle Switch Driver short or short to Battery
B1522 Buckle Switch Driver open or short to Ground
B1523 Buckle Switch Passenger short or short to Battery
B1524 Buckle Switch Passenger open or short to Ground
B1620 Internal fault - Replace SRSCM
B1650 Crash recorded in 1st stage only(Frontal - Replace SRSCM)
B1651 Crash recorded in front-Driver side airbag(Replace SRSCM)
B1652 Crash recorded in front-Passenger side airbag(Replace SRSCM)
B1657 Crash recorded in Belt pretensioner only
B1658 Belt pretensioner 6 times deployment
B1670 Crash recorded in full stage(Frontal - Replace SRSCM)
B2500 Warning lamp Failure
B2502 Passenger airbag Telltale lamp Failure
Restraint > SRSCM > B1101 Battery Voltage High

General Description
RSCM (Supplemental Restraints System Control Module) checks input voltage when "IG ON" to make air bag
system work properly.
If input voltage is out of normal range, there can be malfunction in system operation. In this case, Check battery and
charging system.
DTC Description
The SRSCM sets DTC B1101 and turns warning light on if voltage above threshold value is detected for more than
4 sec. (If voltage within threshold value is detected for 4 sec. SRSCM regards DTC as being cleared and turns
Page 21 of 297
warning light off).

DTC Strategy • Check voltage • Poor connection of
connected part.
Enable Conditions • Ignition "ON"
• Open/Short circuit in
Threshold Value • 16.5V < Vbat power harness.
Qualification • More than 10 sec
Diagnostic ground harness.
Time De- • Faulty charging system.
• More than 10 sec
Qualification • Faulty SRSCM.
Specification
Test Condition Voltage
Approx. 10.6≤
Idle & WOT
Vbatt≤ 16.5
Schematic Diagram

1. Ignition "OFF", connect scantool.
2. Ignition "ON"& Engine "OFF", select "Diagnostic Trouble Codes(DTC)" mode.
3. Monitor diagnostic trouble code and present of trouble code.
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4. Using a scan tool, clear the DTC.
- H : Historical fault
- P : Present fault
5. Is DTC present problem ?

Displaying nothing(no DTC) or DTC with label "H"(historical) shows that Fault is
intermittent caused by poor contact in the part's and/or SRSCM connector or was repaired
and SRSCM memory was not cleared.
Thoroughly check connectors for l ooseness, poor connection, bending, corrosion,

Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
or damage.
procedure.

1. Engine "ON", headight and heatwire "ON".
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2. Measure voltage between the battery terminal (+) and (-) maintaining ENG. RPM 2,500RPM (idle) over 2
minutes.
Specification : Approx. 10.6V ~16.5V

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

1. Ignition "OFF'.
2. Disconnect the battery (-) terminal cable from the battery, and wait at least one minutes.
3. Disconnect the SRSCM connector.
4. Connect the battery (-) terminal cable and start engine.
5. Measure voltage between terminal "23" of the SRSCM harness connector and chassis ground.
Specification : Approx.10.6V ~ 16.5V

Thoroughly check all connectors (and connections) for looseness, bending, corrosion,
contamination, deterioration, and/or damage.

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1. Ignition "OFF".
4. Measure resistance between terminal "49" of the SRSCM harness connector and chassis ground.
Specification : Approx. 1 Ω below.

Substitute a known-good SRSCM, and check for proper operation.
If the problem is corrected, replace SRSCM and then go to "Verification of Vehicle Repair"
procedure.
Substitute the SRSCM main harness and check for proper operation.
If the problem is corrected, replace SRSCM main harness and then go to "Verification of

1. Connect scan tool and select "Diagnostic Trouble Codes(DTC)" mode.
4. Are any DTC present ?
procedure.
time.
Restraint > SRSCM > B1102 Battery Voltage Low

General Description
SRSCM (Supplemental Restraints System Control Module) checks input voltage when "IG ON" to make air bag
system work properly.
If input voltage is out of normal range, there can be malfunction in system operation. In this case, Check battery and
charging system.
DTC Description
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The SRSCM sets DTC B1102 and turns warning light on if voltage above threshold value is detected for more than
4 sec. (If voltage within threshold value is detected for 4 sec. SRSCM regards DTC as being cleared and turns
warning light off).

DTC Strategy • Check voltage • Poor connection of
connected part.
Threshold Value • Vbat < 9.0V power harness.
Qualification • More than 10 sec ground harness.
Diagnostic
Time De- • Faulty charging system.
• More than 10 sec
Specification
Approx. 10.6≤
Idle & WOT
Vbatt≤ 16.5
Schematic Diagram

Page 26 of 297
- P : Present fault


or damage.
procedure.

1. Engine "ON", headight and heatwire "ON".
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2. Measure voltage between the battery terminal (+) and (-) maintaining ENG. RPM 2,500RPM (idle) over 2
minutes.
Specification : Approx. 10.6V ~16.5V

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

1. Ignition "OFF'.
4. Connect the battery (-) terminal cable and start engine.
5. Measure voltage between terminal "23" of the SRSCM harness connector and chassis ground.
Specification : Approx.10.6V ~ 16.5V

Thoroughly check all connectors (and connections) for looseness, bending, corrosion,
contamination, deterioration, and/or damage.

Page 28 of 297
1. Ignition "OFF".
4. Measure resistance between terminal "49" of the SRSCM harness connector and chassis ground.
Specification : Approx. 1 Ω below.

procedure.

1. Connect scan tool and select "Diagnostic Trouble Codes(DTC)" mode
procedure.
time.
Restraint > SRSCM > B1326 FIS(Front Impact Sensor)-Driver Short to Ground
General Description
Front Impact Sensor(FIS)located at both sides of the front of engine room detects head-on collision. When FIS
delivers collision signal to SRSCM, SRSCM checks if safing sensor located in SRSCM detects collusion.
and if both FIS and safing sensor detects collision simultaneously, SRSCM operates front air bag.
DTC Description
The SRSCM sets DTC B1326 if there is short to ground in DFIS harness.
Page 29 of 297

DTC Strategy • Check current(PWM type)
Enable Conditions • Ignition "ON" • Short to ground in
Threshold Value • Rs < 60Ω harness.
• Faulty DFIS.
Diagnostic • Faulty SRSCM.
Time De-
• More than 4 sec
Qualification
Specification
Test
Resistance
Condition
Ignition OFF Rs > 1kΩ
Schematic Diagram

Page 30 of 297
- P : Present fault


2. Thoroughly check all connectors (and connections) for looseness, bending, corrosion, contamination,
deterioration, and/or damage.
procedure.
Go to "Main harness circuit inspection" procedure.
Main harness Circuit Inspection

1. Ignition "OFF".
3. Disconnect DFIS connector and SRSCM main harness connector.
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4. Measure resistance between terminal "1" or "2" of the DFIS harness connector and chassis ground.
Specification : ∞
5. Is the measured resistance within specification?

1. Ignition "ON" & Engine "OFF" and Using a scan tool, clear the DTC.
2. Ignition "OFF".
4. Disconnect DFIS connector.
5. Substitute the DFIS and check for proper operation.
procedure.
Substitute a known-good DFIS, and check for proper operation.
If the problem is corrected, replace DFIS and then go to "Verification of Vehicle Repair"
procedure.

Page 32 of 297
procedure.
time.
Restraint > SRSCM > B1327 FIS(Front Impact Sensor)-Driver Short to Battery
General Description
Front Impact Sensor(FIS)located at both sides of the front of engine room detects head-on collision.
When FIS delivers collision signal to SRSCM, SRSCM checks if safing sensor located in SRSCM detects
collusion.
DTC Description
The SRSCM sets DTC B1327 if there is short to power harness in DFIS harness.

• Short to power in
Threshold Value • Rs < 50Ω
harness.
Qualification • More than 2 sec • Faulty DFIS.
Diagnostic
Time De-
• More than 4 sec
Qualification
Specification
Test
Resistance
Condition
Schematic Diagram
Page 33 of 297

- P : Present fault
intermittent caused by poor contact in the part’s and/or SRSCM connector or was repaired
Page 34 of 297
procedure.

1. Ignition "OFF".
3. Disconnect DFIS connector and SRSCM main harness connector.
5. Measure voltage between terminal "1" or "2" of the DFIS harness connector and chassis ground.
Specification : 0V
6. Is the measured Voltage within specifications?

2. Ignition "OFF".
4. Disconnect DFIS connector.
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procedure.
procedure.

procedure.
time.
Restraint > SRSCM > B1328 FIS(Front Impact Sensor)-Driver Defect

General Description
collusion.
DTC Description
The SRSCM sets DTC B1328 if there is any fault in Driver side front impact sensor.

• FIS sends "Sensor Defect" message to the ACU
Threshold Value • Poor connection of
(7Dhex) continuosly connected part.
• Less than 2 sec during the Normal diagnosis. And • Faulty DFIS.
Qualification
less than 5 secs during the initial diagnosis. • Faulty SRSCM.
Diagnostic
Time • On the Next Power on reset of the SIS/FIS, which
De-
occurs in every 25.5 secs after the Fault
Qualification
qualification.
Page 36 of 297
Schematic Diagram

- P : Present fault
Page 37 of 297

or damage.
procedure.
2. Ignition "OFF".
4. Disconnect DFIS connector .
procedure.
procedure.

procedure.
time.
Restraint > SRSCM > B1329 FIS(Front Impact Sensor)-Driver Communication error
General Description
Page 38 of 297
collusion.
DTC Description
The SRSCM sets DTC B1329 if there is any error in communication between DFIS and SRSCM

Enable Conditions • Ignition "ON". • Poor connection of
Threshold Value • No communication or Parity or Manchester error connected part.
• Faulty DFIS.
Time De-
• More than 4 sec
Qualification
Schematic Diagram

Page 39 of 297
- P : Present fault


or damage.
procedure.
2. Ignition "OFF".
Page 40 of 297
procedure.
procedure.

procedure.
time.
Restraint > SRSCM > B1330 FIS(Front Impact Sensor)-Driver Wrong ID

General Description
collusion.
DTC Description
The SRSCM sets DTC B1330 if DFIS with wrong ID is detected.

Enable Conditions • Ignition "ON".
Threshold Value • DFIS sends the "Wrong ID" continously • Faulty DFIS with wrong ID.
• Faulty SRSCM.
Qualification • Less than 1 sec after SIS/FIS power on.
Diagnostic
Time De-
• On the Next ACU Ignition cycle.
Qualification
Page 41 of 297
Schematic Diagram

2. Ignition "ON"& Engine "OFF", select "Diagnostic Trouble Codes(DTCs)" mode.
4. Using a scan tool, clear the DTCs.
- P : Present fault
intermittent caused by poor contact in the part`s and/or SRSCM connector or was repaired
Page 42 of 297

or damage.
procedure.
2. Ignition "OFF".
procedure.
procedure.

procedure.
time.
Restraint > SRSCM > B1331 FIS(Front Impact Sensor)-Passenger Short to Ground
General Description
delivers collision signal to SRSCM, SRSCM checks if safing sensor located in SRSCM detects collusion. and if
Page 43 of 297
both FIS and safing sensor detects collision simultaneously, SRSCM operates front air bag.
DTC Description
The SRSCM sets DTC B1331 if there is short to ground in PFIS harness.

Enable Conditions • Ignition "ON". • Short to ground in
• Faulty PFIS.
Time De-
• More than 4 sec
Qualification
Specification
Test
Resistance
Condition
Schematic Diagram

Page 44 of 297
- P : Present fault


or damage.
procedure

1. Ignition "OFF".
3. Disconnect PFIS connector and SRSCM main harness connector.
Page 45 of 297
4. Measure resistance between terminal "1" or "2" of the PFIS harness connector and chassis ground.
Specification : ∞

2. Ignition "OFF".
4. Disconnect PFIS connector .
5. Substitute the PFIS and check for proper operation.
procedure.
Substitute a known-good PFIS, and check for proper operation.
If the problem is corrected, replace PFIS and then go to "Verification of Vehicle Repair"
procedure.

procedure.
time.
Page 46 of 297
Restraint > SRSCM > B1332 FIS(Front Impact Sensor)-Passenger Short to Battery
General Description
DTC Description
The SRSCM sets DTC B1332 if there is short to power harness in PFIS harness.

Enable Conditions • Ignition "ON". • Short to power in
• Faulty PFIS.
Qualification • More than 2.2 sec
Time De-
• More than 1 time
Qualification
Specification
Test
Resistance
Condition
Schematic Diagram
Page 47 of 297

- P : Present fault

or damage.
procedure

1. Ignition "OFF".
3. Disconnect PFIS connector and SRSCM main harness connector.
Page 48 of 297
5. Measure voltage between terminal "1" or "2" of the PFIS harness connector and chassis ground.
Specification : 0V

2. Ignition "OFF".
procedure.
procedure.

procedure.
time.
Page 49 of 297
Restraint > SRSCM > B1333 FIS(Front Impact Sensor)-Passenger Defect

General Description
DTC Description
The SRSCM sets DTC B1333 if there is any fault in Passenger side front impact sensor

• FIS sends "Sensor Defect" message to the ACU
Threshold Value • Poor connection of
(7Dhex) continuosly
connected part
• Less than 2 sec during the Normal diagnosis. And • Faulty PFIS.
Qualification
less than 5 secs during the initial diagnosis. • Faulty SRSCM.
Diagnostic
De-
occurs in every 25.5secs after the Fault
Qualification
qualification.
Schematic Diagram

Page 50 of 297
- P : Present fault

or damage.
procedure
2. Ignition "OFF".
Page 51 of 297
procedure.
procedure.

procedure.
time.
Restraint > SRSCM > B1334 FIS(Front Impact Sensor)-Passenger Communication error
General Description
DTC Description
The SRSCM sets DTC B1334 if there is any error in communication between PFIS and SRSCM

Enable Conditions • Ignition "ON". • Poor connection of
Threshold Value • No communication or Parity or Manchester error connected part.
• Faulty PFIS.
Time De-
• More than 4 sec
Qualification
Schematic Diagram
Page 52 of 297

- P : Present fault
Page 53 of 297
or damage.
procedure
2. Ignition "OFF".
procedure.
procedure.

procedure.
time.
Restraint > SRSCM > B1335 FIS(Front Impact Sensor)-Passenger Wrong ID

General Description
Page 54 of 297
DTC Description
The SRSCM sets DTC B1335 if PFIS with wrong ID is detected.

Threshold Value • PFIS sends the "Wrong ID" continously • PFIS with wrong ID.
• Faulty SRSCM.
Qualification • Less than 1 sec after SIS/FIS power on.
Diagnostic
Time De-
• Less than 1 sec after SIS/FIS power on.
Qualification
Schematic Diagram

Page 55 of 297
- P : Present fault


or damage.
procedure
2. Ignition "OFF".
Page 56 of 297
procedure.
procedure.

procedure.
time.
Restraint > SRSCM > B1346 Driver Airbag Resistance too High (1st stage)
General Description
Driver Air bag module (hereinafter referred to DAB) located at center of steering wheel protects driver by reducing
impact of collision. DAB is consist of air bag, pat cover and inflator. There are power,circuit for ignition, gas
generator and diffuser screen in inflator. Air bag reduces impact of collision by fillied up gas. In collision, pat cover
splits and through this crack, air bag emerges and deploys. Inflator generates gas that expands air bag. Clock spring
is located between steering wheel and column. It connects SCSRM to DAB.
Never measure resistance of DAB directly, Current of measuring device may cause unexpected air bag deploy.
DTC Description
The SRSCM sets DTC B1346 if the measured resistance value of DAB circuit is more than the threshold value.
*In this case, SRSCM checks if there’s any fault in circuit by sending current for a while.

Page 57 of 297
DTC Strategy • Check Resistance • Poor connection of
Enable Conditions • Ignition "ON". connected part.
• Poor connection between
Threshold Value • DAB resistance > 5.7 Ω shorting bar and release pin.
Qualification • More than 2 sec • Faulty DAB.
Diagnostic • Faulty Clock spring.
Time De-
• More than 4 sec • Faulty SRSCM.
Qualification
Specification
Test Condition Resistance
1.7Ω < DAB resistance <
2.3Ω
Ignition OFF
0.2Ω < Clock spring
resistance < 0.6Ω
Schematic Diagram

Page 58 of 297
- P : Present fault

Thoroughly check shorting bar/shorting bar release pin and connectors for looseness, poor
connection, bending, corrosion, contamination, deterioration, or damage.

2. Thoroughly check shorting bar/shorting bar release pin and connectors for looseness, poor connection, bending,
corrosion, contamination, deterioration, or damage.
procedure
Go to "Squib Circuit Inspection" procedure.
Squib Circuit Inspection

1. Ignition "OFF".
2. Disconnect (-) terminal cable from battery and wait for 1 minutes or more.
3. Remove the DAB module and connect the dummy (0957A-38200) and dummy adapter (0957A-2G000) to
DAB connector of the clock spring harness connector.
If dummy and dummy adaptor are not able to be prepared, use a known-good DAB or 2Ω resistor.
Lay Removed DAB facing upward for unexpected air bag deploy .
Page 59 of 297
4. Connect (-) terminal cable to battery and Ignition "ON" & Engine "OFF" and wait for 30 seconds or more.
5. Connect scantool to Data Link Connector(DLC) and clear DTC with scantool and diagnose again.

Go to "Clock Spring Circuit Inspection" procedure.
Substitute a known-good DAB assembly, and check for proper operation.
If the problem is corrected, replace DAB and then go to "Verification of Vehicle Repair"
procedure.
Clock Spring Circuit Inspection

1. Ignition "OFF".
2. Disconnect the battery (-) terminal cable from the battery and wait at least one minutes.
3. Remove DAB module and disconnect SRSCM connector of the clock spring harness.
4. Measure resistance between terminal "Low.1" and "High.1" of the Clock Spring harness connector.
Specification : approx. 1 Ω below

Page 60 of 297
Substitute the Clock spring and check for proper operation.
If the problem is corrected, replace Clock spring and then go to "Verification of Vehicle
Repair" procedure.

1. Ignition "OFF".
1. Measure resistance between terminal "Low.1" and "High.1" of the DAB harness connector.

procedure.

procedure.
time.
Page 61 of 297
Restraint > SRSCM > B1347 Driver Airbag Resistance too Low (1st stage)
General Description
DTC Description
The SRSCM sets DTC B1347 if the measured resistance value of DAB circuit is less than the threshold value

Threshold Value • DAB resistance < 1.5Ω shorting bar and release pin.
Time De-
Qualification
Specification
2.3Ω
Ignition OFF
resistance < 0.6Ω
Schematic Diagram
Page 62 of 297

- P : Present fault

Page 63 of 297
procedure

1. Ignition "OFF".
2. Disconnect (-) terminal cable from battery and wait for 1 minutes or more

procedure.

1. Ignition "OFF".
Page 64 of 297
4. Measure resistance between terminal "Low.1" and "High.1" of the Clock Spring harness connector.

Repair" procedure.

1. Ignition "OFF"

Page 65 of 297
procedure.

procedure.
time.
Restraint > SRSCM > B1348 Driver Airbag resistance circuit short to Ground (1st stage)
General Description
DTC Description
The SRSCM sets DTC B1348 if there is a short to ground in DAB harness

DTC Strategy • Check Voltage • Short to ground in DAB
Enable Conditions • Ignition "ON". harness.
• Poor connection of
Threshold Value • Squib circuit voltage < 1.3 V connected part.
Time De-
Qualification
Page 66 of 297
Specification
Squib circuit voltage :
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram

- P : Present fault
Page 67 of 297

procedure

1. Ignition "OFF".
Page 68 of 297
procedure.

1. Ignition "OFF"
4. Measure resistance between terminal "Low.1" and "High.1"of the clock spring harness connector and chassis ground.
Specification : ∞

Repair" procedure.

1. Ignition "OFF"
Page 69 of 297
Specification : ∞

procedure.

procedure.
time.
Restraint > SRSCM > B1349 Driver Airbag resistance circuit short to Battery (1st stage)
General Description
Page 70 of 297
DTC Description
The SRSCM sets DTC B1349 if there is a short to power in DAB harness

DTC Strategy • Check Voltage • Short to power in DAB
Threshold Value • Squib circuit voltage > 4.1 V connected part.
Time De-
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram

Page 71 of 297
- P : Present fault


procedure

1. Ignition "OFF".
Page 72 of 297

procedure.

1. Ignition "OFF".
5. Measure Voltage between terminal "Low.1" and "High.1" of the clock spring harness connector and chassis ground.
Specification : 0V
Page 73 of 297
Repair" procedure.

1. Ignition "OFF" and wait at least one minutes.
2. Remove DAB module and disconnect SRSCM connector of the main harness.
Lay Removed DAB facing upward for unexpected air bag

deploy .
Specification : approx. 0V

procedure.

Page 74 of 297
procedure.
time.
Restraint > SRSCM > B1352 Passenger Airbag Resistance too High (1st Stage)
General Description
Passenger Air bag module (hereinafter referred to PAB) located at passenger side crush pad protects passenger by
reducing impact of collision. PAB is consist of air bag, pat cover and inflator. Air bag reduces impact of collision by
fillied up gas. Inflator keeps gas and uses it to deploy air bag on collision.
Never measure resistance of PAB directly, Current of measuring device may cause unexpected air bag deploy.
DTC Description
The SRSCM sets DTC B1352 if the measured resistance value of PAB circuit is more than the threshold value.
*In this case, SRSCM checks if there’s any fault in circuit by sending current for a while

DTC Strategy • Check Resistance
Threshold Value • PAB resistance > 5.7Ω • Poor connection between
shorting bar and release pin.
Diagnostic • Faulty PAB.
Time De- • Faulty SRSCM.
• More than 4 sec
Qualification
Specification
1.6Ω < PAB resistance
Ignition OFF
< 2.4Ω
Schematic Diagram
Page 75 of 297

- P : Present fault

Page 76 of 297
procedure

1. Ignition "OFF".
3. Remove the PAB module and connect the dummy (0957A-38200) and dummy adapter (0957A-2G000) to
PAB harness connector.
If dummy and dummy adaptor are not able to be prepared, use a known-good PAB or 2Ω resistor.
Lay Removed PAB facing upward for unexpected air bag deploy

Substitute a known-good PAB assembly, and check for proper operation.
If the problem is corrected, replace PAB and then go to "Verification of Vehicle Repair"
procedure.

1. Ignition "OFF".
3. Disconnect PAB connector and SRSCM main harness connector.
Lay Removed PAB facing upward for unexpected air bag

deploy .
Page 77 of 297
4. Measure resistance between terminal "Low.1" and "High.1" of the PAB harness connector.

procedure.

procedure.
time.
Restraint > SRSCM > B1353 Passenger Airbag Resistance too Low (1st stage)
General Description
DTC Description
The SRSCM sets DTC B1353 if the measured resistance value of PAB circuit is less than the threshold value.
Page 78 of 297

Threshold Value • PAB resistance < 1.5Ω • Poor connection between
• More than 4 sec
Qualification
Specification
Ignition OFF
< 2.4Ω
Schematic Diagram

Page 79 of 297
- P : Present fault


procedure

1. Ignition "OFF".
Lay Removed PAB facing upward for unexpected air bag deploy .
Page 80 of 297

procedure.

1. Ignition "OFF".

deploy .
4. Measure resistance between terminal "Low.1" and "High.1" of the PAB harness connector.

procedure.
Page 81 of 297
procedure.
time.
Restraint > SRSCM > B1354 Passenger Airbag Resistance Circuit Short to Ground (1st Stage)
General Description
DTC Description
The SRSCM sets DTC B1354 if there is a short to ground in PAB harness

• Short to ground in PAB
Threshold Value • Squib circuit voltage < 1.3 V • Poor connection of
connected part.
• More than 4 sec
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram
Page 82 of 297

- P : Present fault

Page 83 of 297
procedure

1. Ignition "OFF".

procedure.

1. Ignition "OFF".

deploy .
Page 84 of 297
4. Measure resistance between terminal "Low.1" and "High.1" of the PAB harness connector and chassis ground.
Specification : ∞

procedure.

procedure.
time.
Restraint > SRSCM > B1355 Passenger Airbag Resistance Circuit Short to Battery (1st Stage)
General Description
DTC Description
The SRSCM sets DTC B1355 if there is a short to power in PAB harness.
Page 85 of 297

DTC Strategy • Check Voltage
• Short to power in PAB
Threshold Value • Squib circuit voltage > 4.1 V • Poor connection of
connected part.
• More than 4 sec
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram

Page 86 of 297
- P : Present fault


procedure

1. Ignition "OFF".
Page 87 of 297

procedure.

1. Ignition "OFF"

deploy .
4. Connect the battery (-) terminal cable to the battery and Ignition "ON" & Engine "OFF".
5. Measure voltage between terminal "Low.1" and "High.1" of the PAB harness connector and chassis ground.
Page 88 of 297
procedure.

procedure.
time.
Restraint > SRSCM > B1361 Pretensioner Front-Driver Resistance too High
General Description
Seat Belt Pretensioner(hereinafter referred to BPT) is located at both side of center pillar. BPT tightens seat belt
before air bag deploys to protect passenger from bumping against crush pad, steering wheel and front window. In
BPT, there are a ignition circuit and cylinder for rewinding belt. Cylinder has piston that can rewind seat belt in it.
Gas chamber generates expansive force of gases to push piston in cylinder.
Never measure resistance of BPT directly, Current of measuring device may cause unexpected BPT depoy.
DTC Description
The SRSCM sets DTC B1361 if the measured resistance value of DBPT circuit is more than the threshold value.

Threshold Value • DBPT resistance > 5.7Ω • Poor connection between
Diagnostic • Faulty DBPT.
• More than 4 sec
Qualification
Page 89 of 297
Specification
1.8Ω < DBPT
Ignition OFF
resistance < 2.5Ω
Schematic Diagram

- P : Present fault
Page 90 of 297

procedure

1. Ignition "OFF".
3. Disconnect DBPT module and connect the dummy (0957A-38200) and dummy adapter (0957A-2G000) to
main harness connector.
If dummy and dummy adaptor are not able to be prepared, use a known-good DBPT or 2Ω resistor.

Substitute a known-good DBPT assembly, and check for proper operation.
If the problem is corrected, replace DBPT and then go to "Verification of Vehicle Repair"
procedure.

1. Ignition "OFF".
Page 91 of 297
3. Disconnect DBPT connector and SRSCM main harness connector.
4. Measure resistance between terminal "2" and "1" of the DBPT harness connector.

procedure.

procedure.
time.
Restraint > SRSCM > B1362 Pretensioner Front-Driver Resistance too Low
General Description
DTC Description
Page 92 of 297
The SRSCM sets DTC B1362 if the measured resistance value of DBPT circuit is less than the threshold value.

Threshold Value • DBPT resistance < 1.5Ω • Poor connection between
• More than 4 sec
Qualification
Specification
1.8Ω < DBPT
Ignition OFF
resistance < 2.5Ω
Schematic Diagram

Page 93 of 297
- P : Present fault


procedure

1. Ignition "OFF".
Page 94 of 297

procedure.

1. Ignition "OFF".
4. Measure resistance between terminal "2" and "1" of the DBPT harness connector.

procedure.

Page 95 of 297
procedure.
time.
Restraint > SRSCM > B1363 Pretensioner front-Driver resistance circuit short to Ground
General Description
DTC Description
The SRSCM sets DTC B1363 if there is a short to ground in DBPT harness.

• Short to ground in DBPT
connected part.
• More than 4 sec
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram
Page 96 of 297

- P : Present fault

Page 97 of 297

procedure

1. Ignition "OFF".

procedure.

1. Ignition "OFF".
Page 98 of 297
4. Measure resistance between terminal "1" or "2" of the DBPT harness connector and chassis ground
Specification : ∞

procedure.

procedure.
time.
Restraint > SRSCM > B1364 Pretensioner front-Driver resistance circuit short to Battery
General Description
DTC Description
The SRSCM sets DTC B1364 if there is a short to power in DBPT harness.
Page 99 of 297

• Short to power in DBPT
connected part
• More than 4 sec
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram

Page 100 of 297
- P : Present fault


procedure

1. Ignition "OFF".
Page 101 of 297

procedure.

1. Ignition "OFF".
3. Disconnect DBPT connector and SRSCM main harness connector
5. Measure voltage between terminal "1 or 2" of the DBPT harness connector and chassis ground.
6. Is the measured voltage within specification?

procedure.

Page 102 of 297
procedure.
time.
Restraint > SRSCM > B1367 Pretensioner Front-Passenger Resistance too High
General Description
DTC Description
The SRSCM sets DTC B1367 if the measured resistance value of PBPT circuit is more than the threshold value.

Threshold Value • PBPT resistance > 5.7Ω • Poor connection between
Diagnostic • Faulty PBPT.
• More than 4 sec
Qualification
Specification
1.8Ω < PBPT
Ignition OFF
resistance < 2.5Ω
Schematic Diagram
Page 103 of 297

- P : Present fault

Page 104 of 297

procedure

1. Ignition "OFF".
3. Disconnect PBPT module and connect the dummy (0957A-38200) and dummy adapter (0957A-2G000) to
If dummy and dummy adaptor are not able to be prepared, use a known-good PBPT or 2Ω resistor.

Substitute a known-good PBPT assembly, and check for proper operation.
If the problem is corrected, replace PBPT and then go to "Verification of Vehicle Repair"
procedure.

1. Ignition "OFF".
3. Disconnect PBPT connector and SRSCM main harness connector.
Page 105 of 297
4. Measure resistance between terminal "2" and "1" of the PBPT harness connector.

procedure.

procedure.
time.
Restraint > SRSCM > B1368 Pretensioner Front-Passenger Resistance too Low
General Description
DTC Description
The SRSCM sets DTC B1368 if the measured resistance value of PBPT circuit is less than the threshold value.
Page 106 of 297

Threshold Value • DBPT resistance < 1.5Ω • Poor connection between
• More than 4 sec
Qualification
Specification
1.8Ω < PBPT
Ignition OFF
resistance < 2.8Ω
Schematic Diagram

Page 107 of 297
- P : Present fault


procedure

1. Ignition "OFF".
Page 108 of 297

procedure.

1. Ignition "OFF".
4. Measure resistance between terminal "2" and "1" of the PBPT harness connector.

procedure.

Page 109 of 297
procedure.
time.
Restraint > SRSCM > B1369 Pretensioner Front-Passenger Resistance Circuit Short to Ground
General Description
DTC Description
The SRSCM sets DTC B1369 if there is a short to ground in PBPT harness.

• Short to ground in PBPT
connected part.
• More than 4 sec
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram
Page 110 of 297

- P : Present fault

Page 111 of 297

procedure

1. Ignition "OFF".

procedure.

1. Ignition "OFF".
Page 112 of 297
4. Measure resistance between terminal "1" or "2" of the PBPT harness connector and chassis ground.
Specification : ∞

procedure.

procedure.
time.
Restraint > SRSCM > B1370 Pretensioner Front-Passenger Resistance Circuit Short to Battery
General Description
DTC Description
The SRSCM sets DTC B1370 if there is a short to power in PBPT harness.
Page 113 of 297

• Short to power in PBPT
connected part.
• More than 4 sec
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram

Page 114 of 297
- P : Present fault


procedure

1. Ignition "OFF".
Page 115 of 297

procedure.

1. Ignition "OFF".
5. Measure voltage between terminal "1 or 2" of the PBPT harness connector and chassis ground.

procedure.

Page 116 of 297
procedure.
time.
Restraint > SRSCM > B1378 Side Airbag Front-Driver Resistance too High
General Description
Side Airbag (hereinafter referred to SAB) located in driver and passenger seat protects passenger’s head and
shoulder. SAB is consist of air bag and inflator. Air bag reduces impact of collision by fillied up gas. Inflator keeps
gas and uses it to deploy air bag on collision.
Never measure resistance of SAB directly, Current of measuring device may cause unexpected air bag deploy.
DTC Description
The SRSCM sets DTC B1378 if the measured resistance value of DSAB circuit is more than the threshold value.

DTC Strategy • Check resistance
Threshold Value • DSAB resistance > 5.7Ω • Poor connection between
Diagnostic • Faulty DSAB.
• More than 4 sec
Qualification
Specification
1.7Ω < DSAB
Ignition OFF
resistance < 2.3Ω
Schematic Diagram
Page 118 of 297
procedure

1. Ignition "OFF".
3. Disconnect DSAB module and connect the dummy (0957A-38200) and dummy adapter (0957A-3F000) to
If dummy and dummy adaptor are not able to be prepared, use a known-good DSAB or 2Ω resistor.

Substitute a known-good DSAB assembly, and check for proper operation.
If the problem is corrected, replace DSAB and then go to "Verification of Vehicle Repair"
procedure.

1. Ignition "OFF".
3. Disconnect DSAB connector and SRSCM main harness connector.
Page 119 of 297
4. Measure resistance between terminal "2" and "1" of the DSAB harness connector.

procedure.

procedure.
time.
Restraint > SRSCM > B1379 Side Airbag Front-Driver Resistance too Low
General Description
DTC Description
The SRSCM sets DTC B1379 if the measured resistance value of DAB circuit is less than the threshold value.
Page 120 of 297

DTC Strategy • Check resistance
Enable Conditions • Ignition "ON" connected part.
Threshold Value • DSAB resistance < 1.5Ω • Poor connection between
• More than 4 sec
Qualification
Specification
1.7Ω < DSAB
Ignition OFF
resistance < 2.3Ω
Schematic Diagram

Page 121 of 297
- P : Present fault


procedure

1. Ignition "OFF".
Page 122 of 297

procedure.

1. Ignition "OFF".
4. Measure resistance between terminal "2" and "1" of the DSAB harness connector.

procedure.

1. Connect scan tool and select "Diagnostic Trouble Codes(DTC)" mode/
Page 123 of 297
procedure.
time.
Restraint > SRSCM > B1380 Side Airbag Front-Driver Resistance Circuit Short to Ground
General Description
DTC Description
The SRSCM sets DTC B1380 if there is a short to ground in DSAB harness.

• Short to ground in DSAB
Enable Conditions • Ignition "ON" harness.
connected part.
• More than 4 sec
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram
Page 124 of 297

- P : Present fault

Page 125 of 297
procedure

1. Ignition "OFF".

procedure.

1. Ignition "OFF".
Page 126 of 297
4. Measure resistance between terminal "1" or "2" of the DSAB harness connector and chassis ground.
Specification : ∞

procedure.

procedure.
time.
Restraint > SRSCM > B1381 Side Airbag Front-Driver Resistance Circuit Short to Battery
General Description
DTC Description
The SRSCM sets DTC B1381 if there is a short to power in DSAB harness.
Page 127 of 297

• Short to power in DSAB
connected part.
• More than 4 sec
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram

Page 128 of 297
- P : Present fault


procedure

1. Ignition "OFF".
Page 129 of 297

procedure.

1. Ignition "OFF".
5. Measure voltage between terminal "1 or 2" of the DSAB harness connector and chassis ground.

procedure.

Page 130 of 297
procedure.
time.
Restraint > SRSCM > B1382 Side Airbag Front-Passenger Resistance too High
General Description
DTC Description
The SRSCM sets DTC B1382 if the measured resistance value of PSAB circuit is more than the threshold value.

Threshold Value • PSAB resistance > 5.7Ω • Poor connection between
Diagnostic • Faulty PSAB.
• More than 4 sec
Qualification
Specification
1.7Ω < PSAB
Ignition OFF
resistance < 2.3Ω
Schematic Diagram
Page 131 of 297

- P : Present fault

Page 132 of 297
procedure.

1. Ignition "OFF".
3. Disconnect PSAB module and connect the dummy (0957A-38200) and dummy adapter (0957A-3F000) to
If dummy and dummy adaptor are not able to be prepared, use a known-good PSAB or 2Ω resistor.

Substitute a known-good PSAB assembly, and check for proper operation.
If the problem is corrected, replace PSAB and then go to "Verification of Vehicle Repair"
procedure.

1. Ignition "OFF".
3. Disconnect PSAB connector and SRSCM main harness connector.
Page 133 of 297
4. Measure resistance between terminal "2" and "1" of the PSAB harness connector.

procedure.

procedure.
time.
Restraint > SRSCM > B1383 Side Airbag Front-Passenger Resistance too Low
General Description
DTC Description
The SRSCM sets DTC B1383 if the measured resistance value of PSAB circuit is less than the threshold value.
Page 134 of 297

Threshold Value • PSAB resistance < 1.5Ω • Poor connection between
• More than 4 sec
Qualification
Specification
1.7Ω < PSAB
Ignition OFF
resistance < 2.3Ω
Schematic Diagram

Page 135 of 297
- P : Present fault


procedure.

1. Ignition "OFF".
Page 136 of 297

procedure.

1. Ignition "OFF".
4. Measure resistance between terminal "2" and "1" of the PSAB harness connector.

procedure.

Page 137 of 297
procedure.
time.
Restraint > SRSCM > B1384 Side Airbag Front-Passenger Resistance Circuit Short to Ground
General Description
DTC Description
The SRSCM sets DTC B1384 if there is a short to ground in PSAB harness.

• Short to ground in PSAB
connected part.
• More than 4 sec
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram
Page 138 of 297

- P : Present fault

Page 139 of 297
procedure.

1. Ignition "OFF".

procedure.

1. Ignition "OFF".
Page 140 of 297
4. Measure resistance between terminal "1" or "2" of the PSAB harness connector and chassis ground.
Specification : ∞

procedure.

procedure.
time.
Restraint > SRSCM > B1385 Side Airbag Front-Passenger Resistance Circuit Short to Battery
General Description
DTC Description
The SRSCM sets DTC B1385 if there is a short to power in PSAB harness.
Page 141 of 297

• Short to power in PSAB
connected part.
• More than 4 sec
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram

Page 142 of 297
- P : Present fault


procedure.

1. Ignition "OFF".
Page 143 of 297

procedure.

1. Ignition "OFF".
5. Measure voltage between terminal "1 or 2" of the PSAB harness connector and chassis ground.

procedure.

Page 144 of 297
procedure.
time.
Restraint > SRSCM > B1396 STPS(Seat Track Position Sensor)-Driver Open or Short to Ground
General Description
STPS located underneath passenger seat detects horizental position of passenger seat and delivers it to SRSCM.
Signal of STPS is the one of major parameters that determine the way dual output type airbag deploys.
DTC Description
The SRSCM sets DTC B1396 if there is a short to ground in Driver STPS harness.

• Short to ground in STPS
Threshold Value • Current < 2 mA • Poor connection of
connected part.
Diagnostic • Faulty STPS
• More than 4 sec
Qualification
Specification
Test
Current (mA)
Condition
Ignition OFF
Schematic Diagram
Page 145 of 297

- P : Present fault

Page 146 of 297
procedure.

1. Ignition OFF.
3. Disconnect STPS connector and SRSCM main harness connector.
4. Measure resistance between terminal "1" and "2" of the STPS harness connector and chassis ground.
Specification : ∞

2. Ignition "OFF".
4. Disconnect STPS connector.
5. Substitute the STPS and check for proper operation.
Page 147 of 297
procedure.
Substitute a known-good STPS, and check for proper operation.
If the problem is corrected, replace STPS and then go to "Verification of Vehicle Repair"
procedure.

procedure.
time.
Restraint > SRSCM > B1397 STPS(Seat Track Position Sensor)-Driver Short or Short to Battery
General Description
DTC Description
The SRSCM sets DTC B1397 if there is a short to power in Driver STPS harness.

• Short to power in STPS
Threshold Value • Current > 20 mA • Poor connection of
connected part.
• More than 4 sec
Qualification
Specification
Page 148 of 297
Test
Current (mA)
Condition
Ignition OFF
Schematic Diagram

- P : Present fault
Page 149 of 297

procedure.

1. Ignition OFF.
5. Measure voltage between terminal "1" and "2" of the STPS harness connector and chassis ground.

Page 150 of 297
2. Ignition "OFF".
procedure. Substitute the SRSCM main harness and check for proper operation.
procedure.

procedure.
time.
Restraint > SRSCM > B1398 STPS(Seat Track Position Sensor)-Passenger Open or Short to Ground
General Description
DTC Description
The SRSCM sets DTC B1398 if there is a short to ground in Passenger STPS harness.

Page 151 of 297
• Short to ground in STPS
Threshold Value • Current < 2 mA • Poor connection of
connected part.
• More than 4 sec
Qualification
Specification
Test
Current (mA)
Condition
Ignition OFF
Schematic Diagram

Page 152 of 297
- P : Present fault


procedure.

1. Ignition OFF.
Page 153 of 297
4. Measure resistance between terminal "1" and "6" of the STPS harness connector and chassis ground.
Specification : ∞

2. Ignition "OFF".
procedure.
procedure.

Page 154 of 297
procedure.
time.
Restraint > SRSCM > B1399 STPS(Seat Track Position Sensor)-Passenger Short or Short to Battery
General Description
DTC Description
The SRSCM sets DTC B1399 if there is a short to power in Passenger STPS harness.

DTC Strategy • Current > 20 mA
• Short to power in
Enable Conditions • Ignition "ON" STPS harness.
Threshold Value • Current > 20 mA • Poor connection of
connected part.
• More than 4 sec
Qualification
Specification
Test
Current (mA)
Condition
Ignition OFF
Schematic Diagram
Page 155 of 297

- P : Present fault

Page 156 of 297
procedure.

1. Ignition OFF.
5. Measure voltage between terminal "1" and "6" of the STPS harness connector and chassis ground.

2. Ignition "OFF".
Page 157 of 297
procedure.
procedure.

procedure.
time.
Restraint > SRSCM > B1400 SIS(Side Impact Sensor) Front-Driver defect
General Description
Side Impact Sensor(SIS) is located in both side of center pillar detects broad collision. When SIS delivers collision
signal to SRSCM, SRSCM checks if safing sensor located in SRSCM detects collusion. and if both SIS and safing
sensor detects collision simultaneously, SRSCM operates side air bag.
DTC Description
The SRSCM sets DTC B1400 if there is any fault in DSIS circuit.

• Less than 2 sec during the Normal diagnosis. And • Faulty DSIS circuit.
Qualification • Faulty DSIS.
less than 5 secs during the initial diagnosis.
De-
occurs in every 25.5 secs after the Fault
Qualification
qualification.
Page 158 of 297
Schematic Diagram

- P : Present fault

Page 159 of 297

or damage.
procedure.
2. Ignition "OFF".
4. Disconnect DSIS connector .
5. Substitute the DSIS and check for proper operation.
procedure.
Substitute a known-good DSIS, and check for proper operation.
If the problem is corrected, replace DSIS and then go to "Verification of Vehicle Repair"
procedure.

procedure.
time.
Restraint > SRSCM > B1401 SIS(Side Impact Sensor)Front-Driver Circuit Short to Ground
General Description
Page 160 of 297
DTC Description
The SRSCM sets DTC B1401 if there is a short to ground in DSIS harness.

Enable Conditions • Ignition "ON" • Short to ground in DSIS
• Faulty DSIS.
Time De-
• More than 4 sec
Qualification
Specification
Test
Resistance
Condition
Ignition OFF Rs > 1 kΩ
Schematic Diagram

Page 161 of 297
- P : Present fault


procedure.

1. Ignition "OFF".
3. Disconnect DSIS connector and SRSCM main harness connector.
Page 162 of 297
4. Measure resistance between terminal "1" or "2" of the DSIS harness connector and chassis ground.
Specification : ∞

2. Ignition "OFF".
4. Disconnect DSIS connector.
procedure.
procedure.

Page 163 of 297
procedure.
time.
Restraint > SRSCM > B1402 SIS(Side Impact Sensor)Front-Driver Circuit Short to Battery
General Description
DTC Description
The SRSCM sets DTC B1402 if there is short to power harness in DSIS harness.

Enable Conditions • Ignition "ON" • Short to power in DSIS
• Faulty DSIS.
Time De-
• More than 4 sec
Qualification
Specification
Test
Resistance
Condition
Schematic Diagram
Page 164 of 297

- P : Present fault

Page 165 of 297
procedure.

1. Ignition "OFF".
3. Disconnect DSIS connector and SRSCM main harness connector.
5. Measure voltage between terminal "1" or "2" of the DSIS harness connector and chassis ground.
Specification : 0V

2. Ignition "OFF".
4. Disconnect DSIS connector.
Page 166 of 297
procedure.
procedure.

procedure.
time.
Restraint > SRSCM > B1403 SIS(Side Impact Sensor)Front-Passenger Defect

General Description
DTC Description
The SRSCM sets DTC B1403 if there is any fault in PSIS circuit.

• PSIS sends "Sensor Defect" message to the ACU
Threshold Value
(7Dhex) continuosly • Faulty PSIS circuit.
• Faulty PSIS.
• Less than 2 sec during the Normal diagnosis. And
less than 5 secs during the initial diagnosis.
Diagnostic
De-
occurs in every 25.5secs after the Fault
Qualification
qualification.
Schematic Diagram
Page 167 of 297

- P : Present fault
Page 168 of 297
or damage.
procedure.
2. Ignition "OFF".
4. Disconnect PSIS connector .
5. Substitute the PSIS and check for proper operation.
procedure.
Substitute a known-good PSIS, and check for proper operation.
If the problem is corrected, replace PSIS and then go to "Verification of Vehicle Repair"
procedure.

procedure.
time.
Restraint > SRSCM > B1404 SIS(Side Impact Sensor)Front-Passenger Circuit Short to Ground
General Description
Page 169 of 297
DTC Description
The SRSCM sets DTC B1404 if there is a short to ground in PSIS harness.

Enable Conditions • Ignition "ON" • Short to ground in PSIS
• Faulty PSIS.
Time De-
• More than 4 sec
Qualification
Specification
Test
Resistance
Condition
Schematic Diagram

Page 170 of 297
- P : Present fault


procedure.

1. Ignition "OFF".
3. Disconnect PSIS connector and SRSCM main harness connector.
Page 171 of 297
4. Measure resistance between terminal "1" or "2" of the PSIS harness connector and chassis ground.
Specification : ∞

2. Ignition "OFF".
procedure.
procedure.

Page 172 of 297
procedure.
time.
Restraint > SRSCM > B1405 SIS(Side Impact Sensor)Front-Passenger Circuit Short to Battery
General Description
DTC Description
The SRSCM sets DTC B1405 if there is short to power harness in PSIS harness.

Enable Conditions • Ignition "ON" • Short to power in PSIS
• Faulty PSIS.
Time De-
• More than 4 sec
Qualification
Specification
Test
Resistance
Condition
Schematic Diagram
Page 173 of 297

- P : Present fault

Page 174 of 297
procedure.

1. Ignition "OFF".
3. Disconnect PSIS connector and SRSCM main harness connector.
5. Measure voltage between terminal "1" or "2" of the PSIS harness connector and chassis ground.
Specification : 0V

2. Ignition "OFF".
Page 175 of 297
procedure.
procedure.

procedure.
time.
Restraint > SRSCM > B1409 SIS(Side Impact Sensor) Front-Driver Communication Error
General Description
DTC Description
The SRSCM sets DTC B1409 if there is any error in communication between DSIS and SRSCM.

• Faulty DSIS circuit.
Threshold Value • No communication or Parity or Manchester error
• Faulty DSIS.
Qualification • More than 2 sec • Faulty SRSCM.
Diagnostic
Time De-
• More than 4 sec
Qualification
Schematic Diagram
Page 176 of 297

- P : Present fault

Page 177 of 297
or damage.
procedure.
2. Ignition "OFF".
procedure.
procedure.

procedure.
time.
Restraint > SRSCM > B1410 SIS(Side Impact Sensor) Front-Passenger Communication Error
General Description
Page 178 of 297
DTC Description
The SRSCM sets DTC B1410 if there is any error in communication between PSIS and SRSCM.

• Faulty PSIS circuit.
Threshold Value • No communication or Parity or Manchester error
• Faulty PSIS.
Qualification • More than 2 sec • Faulty SRSCM.
Diagnostic
Time De-
• More than 4 sec
Qualification
Schematic Diagram

Page 179 of 297
- P : Present fault


or damage.
procedure.
2. Ignition "OFF".
Page 180 of 297
procedure.
procedure.

procedure.
time.
Restraint > SRSCM > B1414 SIS(Side Impact Sensor) Front-Driver Wrong ID
General Description
DTC Description
DTC B1414 is recorded when occurrence of a communication error between Side Impact Sensor and SRSCM due
to invalid signals if you try to use incorrect parts for the system.

• When use incorrect Side Impact Sensor for the
DTC Strategy
system.
Enable Conditions • Ignition "ON" • Poor connection of
connected part.
Threshold Value • SIS sends the "Wrong ID" continously
• Faulty DSIS.
Qualification • Less than 1 sec after SIS/FIS power on. • Faulty SRSCM.
Diagnostic
Time De-
Qualification
Page 181 of 297
Schematic Diagram

- P : Present fault
Page 182 of 297

or damage.
procedure.
2. Ignition "OFF".
procedure.
procedure.

Page 183 of 297
procedure.
time.
Restraint > SRSCM > B1415 SIS(Side Impact Sensor) Front-Passenger Wrong ID
General Description
DTC Description
DTC B1415 is recorded when occurrence of a communication error between Side Impact Sensor and SRSCM due
to invalid signals if you try to use incorrect parts for the system.

• When use incorrect Side Impact Sensor for the
DTC Strategy
system.
Enable Conditions • Ignition "ON" • Poor connection of
connected part.
Threshold Value • SIS sends the "Wrong ID" continously
• Faulty PSIS
Qualification • Less than 1 sec after SIS/FIS power on. • Faulty SRSCM.
Diagnostic
Time De-
Qualification
Schematic Diagram
Page 184 of 297

- P : Present fault

Page 185 of 297
or damage.
procedure.
2. Ignition "OFF".
procedure.
procedure.

procedure.
time.
Restraint > SRSCM > B1473 Inflatable Curtain Airbag Front-Driver Resistance too High
General Description
Curtain Airbag (hereinafter referred to CAB)is located at driver and passenger side of headliner It protects
passenger’s head and shoulder from fragments of glass or something sharpen caused by overturn. CAB is consist of
air bag and inflator. Air bag reduces impact of collision by fillied up gas. Inflator keeps gas and uses it to deploy air
bag on collision.
Page 186 of 297
Never measure resistance of CAB directly, Current of measuring device may cause unexpected air bag deploy.
DTC Description
The SRSCM sets DTC B1473 if the measured resistance value of DCAB circuit is more than the threshold value.

Threshold Value • DCAB resistance > 5.7Ω • Poor connection between
Diagnostic • Faulty DCAB.
• More than 4 sec
Qualification
Specification
Ignition OFF 1.8Ω < DCAB
resistance < 2.2Ω
Schematic Diagram
Page 187 of 297
- P : Present fault

procedure.
Go to " Squib Circuit Inspection" procedure.

1. Ignition "OFF".
Page 188 of 297
3. Disconnect DCAB module and connect the dummy (0957A-38200) and dummy adapter (0957A-2G000) to
If dummy and dummy adaptor are not able to be prepared, use a known-good DCAB or 2Ω resistor.

Substitute a known-good DCAB assembly, and check for proper operation.
If the problem is corrected, replace DCAB and then go to "Verification of Vehicle Repair"
procedure.

1. Ignition "OFF".
3. Disconnect DCAB connector and SRSCM main harness connector.
4. Measure resistance between terminal "2" and "1" of the DCAB harness connector.

procedure.
Page 189 of 297

procedure.
time.
Restraint > SRSCM > B1474 Inflatable Curtain Airbag Front-Driver Resistance too Low
General Description
bag on collision.
DTC Description
The SRSCM sets DTC B1474 if the measured resistance value of DCAB circuit is less than the threshold value.

Threshold Value • DCAB resistance < 1.5Ω • Poor connection between
Diagnostic • Faulty DCAB.
• More than 4 sec
Qualification
Specification
Ignition OFF 1.8Ω < DCAB
resistance < 2.2Ω
Schematic Diagram
Page 190 of 297

- P : Present fault

Page 191 of 297

procedure.

1. Ignition "OFF".

procedure.

1. Ignition "OFF".
Page 192 of 297
4. Measure resistance between terminal "2" and "1" of the DCAB harness connector.

procedure.

procedure.
time.
Restraint > SRSCM > B1475 Inflatable Curtain Airbag Front-Driver Resistance Circuit Short to
Ground
General Description
bag on collision.
DTC Description
The SRSCM sets DTC B1475 if there is a short to ground in DCAB harness.
Page 193 of 297

DTC Strategy • Check Voltage • Short to ground in DCAB
harness.
Qualification • More than 2 sec shorting bar and release pin.
Diagnostic
Time De- • Faulty DCAB.
• More than 4 sec
Specification
Ignition ON Squib circuit voltage :
approx. 2.5 ~ 3V
Schematic Diagram

Page 194 of 297
- P : Present fault


procedure.

1. Ignition "OFF".
Page 195 of 297

procedure.

1. Ignition "OFF".
4. Measure resistance between terminal "1" or "2" of the DCAB harness connector and chassis ground.
Specification : ∞

procedure.

Page 196 of 297
procedure.
time.
Restraint > SRSCM > B1476 Inflatable Curtain Airbag Front-Driver Resistance Circuit Short to
Battery
General Description
bag on collision.
DTC Description
The SRSCM sets DTC B1476 if there is a short to power in DCAB harness.

DTC Strategy • Check Voltage • Short to power in DCAB
harness.
Diagnostic
Time De- • Faulty DCAB.
• More than 4 sec
Specification
approx. 2.5 ~ 3V
Schematic Diagram
Page 197 of 297

- P : Present fault
Page 198 of 297
procedure.

1. Ignition "OFF".

procedure.

1. Ignition "OFF".
Page 199 of 297
5. Measure voltage between terminal "1 or 2" of the DCAB harness connector and chassis ground.

procedure.

procedure.
time.
Restraint > SRSCM > B1477 Inflatable Curtain Airbag Front-Passenger Resistance too High
General Description
Curtain Airbag (hereinafter referred to CAB)is located at driver and passenger side of headliner. It protects
bag on collision.
DTC Description
The SRSCM sets DTC B1477 if the measured resistance value of PCAB circuit is more than the threshold value.
Page 200 of 297

Threshold Value • PCAB resistance > 5.7Ω • Poor connection between
Diagnostic • Faulty PCAB.
• More than 4 sec
Qualification
Specification
Ignition OFF 1.8Ω < PCAB
resistance < 2.2Ω
Schematic Diagram

Page 201 of 297
- P : Present fault


procedure.

1. Ignition "OFF".
3. Disconnect PCAB module and connect the dummy (0957A-38200) and dummy adapter (0957A-2G000) to
If dummy and dummy adaptor are not able to be prepared, use a known-good PCAB or 2Ω resistor.
Page 202 of 297

Substitute a known-good PCAB assembly, and check for proper operation.
If the problem is corrected, replace PCAB and then go to "Verification of Vehicle Repair"
procedure.

1. Ignition "OFF".
3. Disconnect PCAB connector and SRSCM main harness connector.
4. Measure resistance between terminal "2" and "1" of the PCAB harness connector.

procedure.

Page 203 of 297
procedure.
time.
Restraint > SRSCM > B1478 Inflatable Curtain Airbag Front-Passenger Resistance too Low
General Description
bag on collision.
DTC Description
The SRSCM sets DTC B1478 if the measured resistance value of PCAB circuit is less than the threshold value.

Threshold Value • PCAB resistance < 1.5Ω • Poor connection between
Diagnostic • Faulty PCAB.
• More than 4 sec
Qualification
Specification
Ignition OFF 1.8Ω < PCAB
resistance < 2.2Ω
Schematic Diagram
Page 204 of 297

- P : Present fault
Page 205 of 297
procedure.

1. Ignition "OFF".

procedure.

1. Ignition "OFF".
Page 206 of 297
4. Measure resistance between terminal "2" and "1" of the PCAB harness connector.

procedure.

procedure.
time.
Restraint > SRSCM > B1479 Inflatable Curtain Airbag Front-Passenger Resistance Circuit Short to
Ground
General Description
bag on collision.
DTC Description
Page 207 of 297
The SRSCM sets DTC B1479 if there is a short to ground in PCAB harness.

DTC Strategy • Check Voltage • Short to ground in PCAB
harness.
Diagnostic
Time De- • Faulty PCAB.
• More than 4 sec
Specification
approx. 2.5 ~ 3V
Schematic Diagram

Page 208 of 297
- P : Present fault


procedure.

1. Ignition "OFF".
Page 209 of 297

procedure.

1. Ignition "OFF".
4. Measure resistance between terminal "1" or "2" of the PCAB harness connector and chassis ground.
Specification : ∞

procedure.

Page 210 of 297
procedure.
time.
Restraint > SRSCM > B1480 Inflatable Curtain Airbag Front-Passenger Resistance Circuit Short to
Battery
General Description
bag on collision.
DTC Description
The SRSCM sets DTC B1480 if there is a short to power in PCAB harness.

DTC Strategy • Check Voltage • Short to power in PCAB
harness.
Diagnostic
Time De- • Faulty PCAB.
• More than 4 sec
Specification
approx. 2.5 ~ 3V
Schematic Diagram
Page 211 of 297

- P : Present fault
connection, bending, corrosion, contamination, deterioration, or damage
Page 212 of 297
procedure.

1. Ignition "OFF".

procedure.

1. Ignition "OFF".
Page 213 of 297
5. Measure voltage between terminal "1 or 2" of the PCAB harness connector and chassis ground.

procedure.

procedure.
time.
Restraint > SRSCM > B1481 Driver Airbag Resistance too High(2nd stage)
General Description
Dual output type airbag deploys two bags in sequence within specified time difference. It can protect driver with less
Page 214 of 297
impact of gas expention force, that can reduce driver’s injury. Constituent is the same as single output type airbag.
DTC Description
The SRSCM sets DTC B1481 if the measured resistance value of DAB circuit is more than the threshold value.

Threshold Value • DAB resistance > 5.7Ω shorting bar and release pin.
Time De-
Qualification
Specification
2.3Ω
Ignition OFF
resistance < 0.6Ω
Schematic Diagram

Page 215 of 297
- P : Present fault

procedure.

1. Ignition "OFF".
Page 216 of 297

procedure.

1. Ignition "OFF".
Page 217 of 297
4. Measure resistance between terminal "1" and "2" of the Clock Spring harness connector.

Repair" procedure.

1. Ignition "OFF".
4. Measure resistance between terminal "3" and "4" of the DAB harness connector.
Page 218 of 297
procedure.

procedure.
time.
Restraint > SRSCM > B1482 Driver Airbag Resistance too Low(2nd stage)
General Description
DTC Description
The SRSCM sets DTC B1482 if the measured resistance value of DAB circuit is less than the threshold
value(1.0Ω)

Page 219 of 297
Threshold Value • DAB resistance < 1.5Ω shorting bar and release pin.
Time De-
Qualification
Specification
2.3Ω
Ignition OFF
resistance <0.6Ω
Schematic Diagram

Page 220 of 297
- P : Present fault


procedure.

1. Ignition "OFF".
Page 221 of 297

procedure.

1. Ignition "OFF".
4. Measure resistance between terminal "1" and "2" of the Clock Spring harness connector.

Page 222 of 297
Repair" procedure.

1. Ignition "OFF".
Lay Removed DAB facing upward for unexpected air bag deploy
4. Measure resistance between terminal "3" and "4" of the DAB harness connector.

procedure.

procedure.
time.
Page 223 of 297
Restraint > SRSCM > B1483 Driver Airbag Resistance Circuit Short to Ground(2nd stage)
General Description
DTC Description
The SRSCM sets DTC B1483 if there is a short to ground in DAB harness.

DTC Strategy • Check Voltage • Short to ground in DAB
Time De-
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram
Page 224 of 297

- P : Present fault

Page 225 of 297
procedure.

1. Ignition "OFF".

procedure.

1. Ignition "OFF".
Page 226 of 297
4. Measure resistance between terminal "1" or "2 "of the clock spring harness connector and chassis ground.
Specification : ∞

Repair" procedure.

1. Ignition "OFF"
4. Measure resistance between terminal "3" or "4" of the DAB harness connector and chassis ground.
Specification : ∞
Page 227 of 297
procedure.

procedure.
time.
Restraint > SRSCM > B1484 Driver Airbag Resistance Circuit Short to Battery(2nd stage)
General Description
DTC Description
The SRSCM sets DTC B1484 if there is a short to power in DAB harness.

Page 228 of 297
DTC Strategy • Check Voltage • Short to power in DAB
Time De-
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram

Page 229 of 297
- P : Present fault


procedure.

1. Ignition "OFF".
Page 230 of 297

procedure.

1. Ignition "OFF".
5. Measure Voltage between terminal "1" or "2 "of the clock spring harness connector and chassis ground.
Specification : 0V
Page 231 of 297
Repair" procedure.

1. Ignition "OFF" and wait at least one minutes.
2. Remove DAB module and disconnect SRSCM connector of the main harness.
Lay Removed DAB facing upward for unexpected air bag

deploy.
4. Measure voltage between terminal "3 or 4" of the DAB harness connector and chassis ground.

procedure.

Page 232 of 297
procedure.
time.
Restraint > SRSCM > B1485 Passenger Airbag Resistance too High(2nd stage)
General Description
DTC Description
The SRSCM sets DTC B1485 if the measured resistance value of PAB circuit is more than the threshold value.

Threshold Value • PAB resistance > 5.7Ω • Poor connection between
• More than 4 sec
Qualification
Specification
Ignition OFF
< 2.4Ω
Schematic Diagram
Page 233 of 297

- P : Present fault

Page 234 of 297
procedure.

1. Ignition "OFF".

procedure.

1. Ignition "OFF"

deploy .
Page 235 of 297
4. Measure resistance between terminal "1" and "2" of the PAB harness connector.

procedure.

procedure.
time.
Restraint > SRSCM > B1486 Passenger Airbag Resistance too Low(2nd stage)
General Description
DTC Description
Page 236 of 297
The SRSCM sets DTC B1486 if the measured resistance value of PAB circuit is less than the threshold value.

Threshold Value • PAB resistance < 1.5Ω • Poor connection between
• More than 4 sec
Qualification
Specification
Ignition OFF
< 2.4Ω
Schematic Diagram

Page 237 of 297
- P : Present fault


procedure.

1. Ignition "OFF".
Page 238 of 297

procedure.

1. Ignition "OFF".

deploy .
4. Measure resistance between terminal "1" and "2" of the PAB harness connector.

procedure.
Page 239 of 297
procedure.
time.
Restraint > SRSCM > B1487 Passenger Airbag Resistance Circuit Short to Ground(2nd stage)
General Description
DTC Description
The SRSCM sets DTC B1487 if there is a short to ground in PAB harness

• Short to ground in PAB
connected part.
• More than 4 sec
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram
Page 240 of 297

- P : Present fault

Page 241 of 297
procedure

1. Ignition "OFF".

procedure.

1. Ignition "OFF"

deploy .
Page 242 of 297
4. Measure resistance between terminal "1" or "2" of the PAB harness connector and chassis ground.
Specification : ∞

procedure.

procedure.
time.
Restraint > SRSCM > B1488 Passenger Airbag Resistance Circuit Short to Battery(2nd stage)
General Description
Page 243 of 297
DTC Description
The SRSCM sets DTC B1488 if there is a short to power in PAB harness.

• Short to power in PAB
connected part.
• More than 4 sec
Qualification
Specification
Ignition ON
approx. 2.5 ~ 3V
Schematic Diagram

Page 244 of 297
- P : Present fault


procedure

1. Ignition "OFF".
Page 245 of 297

procedure.

1. Ignition "OFF".

deploy .
5. Measure voltage between terminal "1 or 2" of the PAB harness connector and chassis ground.
Page 246 of 297
procedure.

procedure.
time.
Restraint > SRSCM > B1489 PODS(Passenger Occupant Detecting System) ECU Defect
General Description
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.
sensor.
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.
*Especially, do not forget to initialize PODS using "PODS RESET FUNCTION" of scantool when replacing
cushion assembly or PODS ECU.
DTC Description
When unable to control SRS system due to internal fault in PODS module assembly.

Page 247 of 297
DTC Strategy • Internal fault in PODS module
Threshold Value • PODS sends this message for 2 times • PODS Faulty.
• SRSCM Faulty.
Diagnostic
Time De-
• More than 4 sec
Qualification
Schematic Diagram

- P : Present fault
Page 248 of 297
Substitute with a PODS ECU and check for proper operation.
If the problem is corrected, replace PODS ECU and then go to "Verification of Vehicle
Repair" procedure.

1. Initialize PODS using scantool when replacing PODS ECU.
3. Using a scan tool, clear the DTCs
procedure.
time.
Restraint > SRSCM > B1490 PODS(Passenger Occupant Detecting System) Sensor(Bladder) Defect
General Description
sensor.
airbag suppression.
DTC Description
DTCs B1490 are recorded when a malfunction in the PODS sensor is detected.

Page 249 of 297
DTC Strategy • Sensor(Bladder) failure
Threshold Value • PODS sends this message for 2 times • Sensor(Bladder) failure.
• SRSCM Faulty.
Diagnostic
Time De-
• More than 4 sec
Qualification
Schematic Diagram

- P : Present fault
Page 250 of 297
Substitute with a PODS ECU and check for proper operation. If the problem is corrected,
replace PODS ECU and then go to "Verification of Vehicle Repair" procedure.

procedure.
time.
Restraint > SRSCM > B1493 PODS(Passenger Occupant Detecting System) Communication error
General Description
sensor.
airbag suppression.
DTC Description
DTCs B1493 are recorded when a malfunction in the PODS ECU CAN Communication error is detected.

Page 251 of 297
DTC Strategy • Communication error
Enable Conditions • Ignition "ON" • CAN communication line
Threshold Value • No communication or CAN communication Error failure.
• PODS ECU failure.
Diagnostic • SRSCM Faulty.
Time De-
• More than 5 sec
Qualification
Schematic Diagram

- P : Present fault
Page 252 of 297
Repair" procedure.

procedure
Go to "CAN COMMUNICATION LINE Inspection" procedure.
Can Communication Line Inspection

2. Ignition "OFF".
3. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least one minutes.
4. Disconnect the PODS MODULE from the PODS wiring harness.
5. Disconnect the SRSCM from the PODS wiring harness.
6. Measure resistance between terminal 4 or 5 of the CAN COMM wiring connector and chassis ground.

Substitute a known-good PODS Module, and check for proper operation.
If the problem is corrected, replace PODS Module and then go to "Verification of Vehicle
Repair" procedure.

Page 253 of 297
procedure.
time.
Restraint > SRSCM > B1494 PODS(Passenger Occupant Detecting System) Wrong ID
General Description
sensor.
airbag suppression.
DTC Description
The SRSCM sets DTC B1449 if there is any error in communication between OC Passenger Sensor and SRSCM.

DTC Strategy • Wrong ID(mismatch)
Threshold Value • PODS sends Wrong ID for 2 times • PODS Faulty.
• SRSCM Faulty.
Diagnostic
Time De-
• More than 4 sec
Qualification
Schematic Diagram
Page 254 of 297

- P : Present fault
Repair" procedure.

Page 255 of 297
procedure.
time.
Restraint > SRSCM > B1495 BTS(Belt-Tension Sensor) Defect

General Description
Sensing seat belt tension, belt tension sensor sends signals to PODS ECU. Sensing the intensity of pressure from
pressure sensor and tension from belt tensioner, PODS ECU decide a passenger as an adult or a child.
DTC Description
The SRSCM sets DTC B1450 if OC Passenger Sensor with wrong ID is detected

DTC Strategy • Belt-Tension Sensor failure.
Enable Conditions • Ignition "ON" • Belt-Tension Sensor
Threshold Value • Belt-Tension Sensor failure. failure.
• PODS ECU failure.
Diagnostic • SRSCM Faulty.
Time De-
• More than 4 sec
Qualification
Schematic Diagram

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- P : Present fault
Repair" procedure.

procedure

1. Engine "OFF".
3. Disconnect Belt tension sensor connector.
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5. Measure voltage between terminal 1 of the Belt tension sensor connector and chassis ground.

After reparing open in power circuit or short circuit of belt tension sensor, go to "Verification
vehicle Repair" procedure.
Substitute a known-good Belt tension sensor, and check for proper operation.
If the problem is corrected, replace the Belt tension sensor and then go to "Verification of

1. Engine "OFF".
2. Disconnect Belt tension sensor connector.
3. Measure resistance between terminal 2 of the Belt tension sensor connector and chassis ground.
Specification : approx. 1Ω below.

After reparing open in ground circuit or short circuit of belt tension sensor, go to
"Verification vehicle Repair" procedure.
Substitute a known-good Belt tension sensor, and check for proper operation.If the
problem is corrected, replace the Belt tension sensor and then go to "Verification of Vehicle
Repair" procedure.
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1. Connect Belt tension sensor connector & PODS ECU.
3. When mounting seat belt , check belt tension signals for change for various belt tension.
4. Measure voltage between terminal 3 of the Belt tension sensor connector and chassis ground.
Specification : approx. 0 ~ 5V

Check Belt tension sensor for contamination, deterioration, or damage. Substitute with a
known-good Belt tension sensor and check for proper operation.
If the problem is corrected, replace Belt tension sensor and then go to "Verification of Vehicle
Repair" procedure.
Substitute a known-good Belt tension sensor, and check for proper operation.
If the problem is corrected, replace the Belt tension sensor and then go to "Verification of
Substitute a known-good PODS ECU, and check for proper operation.
If the problem is corrected, replace the PODS ECU and then go to "Verification of Vehicle
Repair" procedure.

procedure.
time.
Restraint > SRSCM > B1521 Buckle Switch Driver Short or Short to Battery
General Description
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Seat-belt Buckle Switch(SBBS) is located in driver and passenger side seat.
SRSCM checks if seatbelt is buckled by signal of SBBS.
SRSCM controls air bag module and BPT differently in accordance with vehicle speed at the moment of collision
and signal from SBBS.
DTC Description
The SRSCM sets DTC B1521 if there is a open circuit or short to power in DSBBS harness.

DTC Strategy • Check current(PWM type) • Short to power in DSBBS
• Short circuit in DSBBS
Threshold Value • Current > 20mA
harness.
Qualification • More than 2 sec • Poor connection of
Diagnostic connected part.
Time De-
Qualification
Specification
● Unbuckled = 400Ω
± 5%
Ignition OFF
● Buckled = 700Ω ±
5%
Schematic Diagram
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- P : Present fault


procedure
Go to "Main harness circuit inspection 1" procedure.
Main harness Circuit Inspection 1

1. Ignition "OFF".
3. Disconnect Seat-belt Buckle Switch connector and SRSCM main harness connector.
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4. Measure resistance value between terminal "42" and "43" of main harness of SRSCM(I01) and "7" and "2" of
harness of SBBS(I05).
Specification : ∞

Main harness Circuit Inspection 2

1. Ignition "OFF".
5. Measure voltage between terminal "7" or "2" of the Seat-belt Buckle Switch harness connector and chassis ground.
Specification : 0V
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procedure.
time.
Restraint > SRSCM > B1522 Buckle Switch Driver Open or Short to Ground
General Description
DTC Description
The SRSCM sets DTC B1522 if there is a short or short to ground in DSBBS harness.

DTC Strategy • Check current(PWM type) • Short to ground in DSBBS
harness.
• Open circuit in DSBBS
Threshold Value • Current < 2mA harness.
Qualification • More than 2 sec connected part.
Diagnostic
Time De- • Faulty DSBBS.
• More than 4 sec
Specification
Page 263 of 297
± 5%
Ignition OFF
5%
Schematic Diagram

- P : Present fault
Page 264 of 297

procedure
Go to "Main harness circuit inspection " procedure.

1. Ignition "OFF".
4. Measure resistance between terminal "7" or "2" of the Seat-belt Buckle Switch harness connector and chassis
ground.
Specification : ∞

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2. Ignition "OFF".
4. Disconnect Seat-belt Buckle Switch connector.
5. Substitute the Seat-belt Buckle Switch and check for proper operation.
procedure.
Substitute a known-good Seat-belt Buckle Switch, and check for proper operation.
If the problem is corrected, replace Seat-belt Buckle Switch and then go to "Verification of

procedure.
time.
Restraint > SRSCM > B1523 Buckle Switch Passenger short or short to Battery
General Description
DTC Description
The SRSCM sets DTC B1523 if there is a open circuit or short to power in PSBBS harness.

Page 266 of 297
DTC Strategy • Check current(PWM type) • Short to power in PSBBS
harness.
• Short circuit in PSBBS
Threshold Value • Current > 20mA harness.
Diagnostic
Time De- • Faulty PSBBS.
• More than 4 sec
Specification
± 5%
Ignition OFF
5%
Schematic Diagram

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- P : Present fault


procedure.

1. Ignition "OFF".
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4. Measure resistance value between terminal "44" and "45" of main harness of SRSCM(I01) and "7" and "2" of
harness of SBBS(I06).
Specification : ∞

2. Ignition "OFF".
procedure.

Page 269 of 297
procedure.
time.
Restraint > SRSCM > B1524 Buckle Switch Passenger Open or Short to Ground
General Description
DTC Description
The SRSCM sets DTC B1524 if there is a short or short to ground in PSBBS harness.

DTC Strategy • Check current(PWM type) • Short to ground in PSBBS
harness.
• Short circuit in PSBBS
Threshold Value • Current < 2mA harness.
Diagnostic
Time De- • Faulty PSBBS.
• More than 4 sec
Specification
± 5%
Ignition OFF
5%
Schematic Diagram
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- P : Present fault

Page 271 of 297
procedure.

1. Ignition "OFF".
4. Measure resistance between terminal "7" or "2" of the Seat-belt Buckle Switch harness connector and chassis
ground.
Specification : ∞

2. Ignition "OFF".
Page 272 of 297
procedure.

procedure.
time.
Restraint > SRSCM > B1620 Internal fault-Replace SRSCM

General Description
In collision, SRSCM sends current to pertinent air bag for deployment.
Besides SRSCM performs diagnosis of overall air bag system and light warning lamp if there’s any fault in it. Main
functions of SRSCM are as follows.
1. Collision and Passenger presence Detection.
2. Determination of BPT, and air bag deployment in accordane with given condition.
3. Internal and external diagnosis of air bag system.
4. Warning by warning lamp if there’s any fault in airbag system.
5. Proffering data for scantool diagnosis.
DTC Description
The SRSCM sets DTC B1620 if there is any fault in SRSCM.

DTC Strategy • Check SRSCM
Qualification • 2 sec • SRSCM.
Diagnostic
Time De-
• ∞(infinite-DTC cannot be erased)
Qualification
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- P : Present fault
Internal fault of SRSCM. Substitute with a SRSCM and check for proper operation.
procedure.

procedure.
time.
Restraint > SRSCM > B1650 Crash Recorded in 1st Stage Only(Frontal-Replace SRSCM)
General Description
Page 274 of 297
DTC Description
The SRSCM sets DTC B1650 if DAB or PAB deploys.

DTC Strategy • Check DAB or PAB deployment
Diagnostic
Time De-
Qualification

- P : Present fault
DTC caused by deployment of front air bag. Substitute with a SRSCM and check for
proper operation.
procedure.

Page 275 of 297
procedure.
time.
Restraint > SRSCM > B1651 Crash Recorded in Front-Driver Side Airbag(Replace SRSCM)
General Description
DTC Description
The SRSCM sets DTC B1651 if DSAB deploys.

DTC Strategy • Check DSAB deployment
Diagnostic
Time De-
Qualification

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- P : Present fault

DTC caused by deployment of front driver side air bag. Substitute with a SRSCM and
procedure.

procedure.
time.
Restraint > SRSCM > B1652 Crash Recorded in Front-Passenger Side Airbag(Replace SRSCM)
General Description
DTC Description
The SRSCM sets DTC B1652 if PSAB deploys.
Page 277 of 297

DTC Strategy • Check PSAB deployment
Diagnostic
Time De-
Qualification

- P : Present fault

DTC caused by deployment of front passenger side air bag. Substitute with a SRSCM and
procedure.

Page 278 of 297
procedure.
time.
Restraint > SRSCM > B1657 Crash Recorded in Belt Pretensioner only
General Description
DTC Description
The SRSCM sets DTC B1657 if any BPT deploys.

DTC Strategy • Check BPT deployment
Diagnostic
Time De-
•-
Qualification

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- P : Present fault

DTC caused by deployment of BPT. Substitute with a SRSCM and check for proper
operation.
procedure.

procedure.
time.
Restraint > SRSCM > B1658 Belt Pretensioner 6 times Deployment

General Description
DTC Description
When the Crash (Belt pretensioner 6 times deployment) recorded in the SRSCM.
Page 280 of 297

DTC Strategy • Check BPT deployment
Diagnostic
Time De-
Qualification

- P : Present fault

DTC caused by 6th deployment of BPT. Substitute with a SRSCM and check for proper
operation.
procedure.

Page 281 of 297
procedure.
time.
Restraint > SRSCM > B1670 Crash recorded in full stage(Frontal-Replace SRSCM)
General Description
DTC Description
When the frontal Crash recorded in the SRS Control module .

DTC Strategy • Crash recorded in Full stage.
Diagnostic
Time De-
Qualification

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- P : Present fault

Crash recorded Replace SRSCM.
Go to "Verification of Vehicle Repair"
procedure.

procedure.
time.
Restraint > SRSCM > B2500 Warning lamp Failure

General Description
Air bag warning lamp is located at cluster. When key is in ‘ignition on’ position, SRSCM performs diagnosis of
overall air bag system.If there’s no fault, air bag. Warning lamp in cluster flickers for a whlie and then goes out.
SRSCM measures voltage of out terminal of warning lamp to check if warnning lamp is operated in accordance with
signal SRSCM sends.
DTC Description
The SRSCM sets DTC B2500 if there is any fault in air bag warning light circuit.

Page 283 of 297
Enable Conditions • Ignition "ON" • Burnt-out fuse.
• Battery Short : If the voltage at the TL Driver is • Burnt-out warning lamp.
more than 1 Vol when TL is ON. • Open circuit in warning lamp
Threshold Value
• Ground Short : If the voltage at the WL Driver is harness.
less than 1 Vol when WL is OFF. • Short circuit in warning lamp
harness.
Time De-
• More than 4 sec
Qualification
Specification
Warning Lamp
VWL ≤ 6V
"ON"
Warning Lamp
VWL ≥ 4V
"OFF"
Schematic Diagram

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- P : Present fault


2. Thoroughly check shorting connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage.
procedure
Go to "Warning lamp Circuit Inspection" procedure.
Warning lamp Circuit Inspection

1. Ignition "OFF".
2. Disconnect SRSCM main harness connector.
3. Release the shorting bar.
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5. Measure voltage between terminal "50" of the SRSCM main harness connector and chassis ground.
Specification : Batt Voltage

Check warning lamp and connectors for looseness, poor connection, bending, corrosion,
Check airbag fuse, passenger compartment junction block, harness between junction block
and SRS . Repair as necessary and go to "Verification of Vehicle Repair" procedure.

procedure.
time.
Restraint > SRSCM > B2502 Passenger Airbag Telltale Lamp Failure
General Description
The SRS Telltale Lamp is located on the center of crash pad consists with the Digital Clock. When the passenger
sest are unoccupied, the Telltale Lamp lights up for the notice, and if passenger are occupied under seat,Telltale
Lamp are goes off automatically.
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DTC Description
DTC B2502 is recorded when occurrence of a malfunction in the Telltale indicator Lamp system.

Enable Conditions • Ignition "ON" • Burnt-out fuse.
• Battery Short : If the voltage at the TL Driver is • Burnt-out Telltale lamp.
more than 1 Vol when TL is ON. • Open circuit in Telltale lamp
Threshold Value
• Ground Short : If the voltage at the TL Driver is harness.
less than 0.7 Vol when TL is OFF. • Short circuit in Telltale lamp
harness.
Time De-
• More than 4 sec
Qualification
Specification
Telltale Lamp
VWL ≤ 6V
"ON"
Telltale Lamp
VWL ≥ 4V
"OFF"
Schematic Diagram
Page 287 of 297

- P : Present fault

2. Thoroughly check shorting connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage.
procedure
Go to "Telltale lamp Circuit Inspection" procedure.
Telltale lamp Circuit Inspection

1. Ignition "OFF".
2. Remove the Instrument center facia assembly.
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4. Measure voltage between terminal "26" of the SRSCM main harness connector and chassis ground.
Specification : Batt Voltage

Check telltale lamp and connectors for looseness, poor connection, bending, corrosion,
Repair or replace as necessary and then go to "Verification of Vehicle Repair" procedure
Check airbag fuse, passenger compartment junction block, harness between junction block
and SRS .

procedure.
time.
Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring > Description and
Operation
Airbag module (DAB, PAB, CAB, SAB)
The driver airbag (DAB), the passenger airbag (PAB), the side airbag (SAB), and the curtain airbag (CAB)
modules that consist of the inflator (ignitor) and the cushion, the ignition unit (cracker, ignitor charger, gas) is
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integrated into the inflator.
Upon front or side crash of intensity enabling SRSCM sensor operation, current will flow through the ignitor circuit.
Current will flow into the inflator and activate the ignition material in the inflator to deploy the airbag.
Clock spring
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1. The clock spring (coil spring) consists of two current carrying coils. It is attached between the steering column
and the steering wheel. It allows rotation of the steering wheel while maintaining continuous contact of the
deployment loop through the inflator module.
The steering wheel must be fitted correctly to the steering column with the clock spring at the neutral position,
otherwise cable disconnection and other troubles may result.
2. The system includes ring gear (90 teeth) located at upper case, transparent cover installed at rotor with screw,
and gear (80 teeth) interlocked with ring gear and driven by prominent part of the cover. Upper case is installed
on the steering column at fixed position. Rotor is connected with steering column and always rotate with steering
wheel. Gear is always interlocked with ring gear by prominent part of the cover. Rotor and prominent part of the
cover will rotate together.
Therefore, gear will rotate in reverse direction to rotor by 10 teeth difference with the ring gear. On the gear, R2,
R1 NEUTRAL, L1 and L2 marks are embedded on every tenth teeth. Matching marks are on the upper case.
Clock spring mark should match with gear's NEUTRAL mark when the vehicle is in straight forward position.
Gear's R mark indicates rotor rotation clockwise and L counterclockwise. In order to center again, turn the
steering wheel clockwise to the end, and thereafter turn counterclockwise about 3 revolution to match the mark.
Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring > Repair procedures
Removal
1. Disconnect the battery negative cable and wait at least three minutes before beginning work.
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2. After removing the cover (A), then loosen the two Torx bolt (B).
3. Remove the driver's airbag from the steering wheel, then disconnect the driver's airbag connectors.
Installation
1. Connect the driver's airbag connectors, then install the driver's airbag on the steering wheel.
Be sure to fully seat the locking tabs.

2. Secure the airbag with the new Torx bolts.
3. Connect the battery negative cable.
4. After installing the airbag, 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.
B. Make sure both horn buttons work.
5. Enter the customer's preset radio stations.
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Clock Spring Replacement
1. Disconnect the negative battery cable, and wait at least 30 seconds before beginning work.
2. Remove the DAB.
3. Remove the steering wheel (See ST- Steering wheel group).
4. After disconnecting the lock pins (A), disconnect the connectors (B).
5. Loosen the mounting screw (C), then remove the clock spring (D).
6. Installation : verify steering wheel is straight ahead and tires are straight ahead.
7. Center clock spring.
8. Install Clock spring, turn wheel to check for binding.
Complete installation in reverse order of removal.
Rotate the steering wheel from lock to lock and recheck.
After installing the clock spring, confirm proper system operation; Turn the ignition switch ON: the SRS
indicator light should be turnde on for about 6 seconds and then go off.
Restraint > Airbag Module > Passenger Airbag (PAB) Module > Repair procedures
Removal
1. Disconnect the battery negative cable and wait at least three minutes before beginning work.
2. Remove the glove box (see BD group - glove box) , then disconnect the connector between the SRS main
harness connector (A) and front passenger's airbag connector (B).
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4. Remove the mounting nuts (A) from the crash pad. Then remove the passenger's airbag (B).
Replace the crash pad which is damaged while PAB is deployed.
Installation
1. Place the new front passenger's airbag on the dashboard. Tighten the front passenger's airbag mounting nuts.
2. Install the dashboard.
3. Connect the front passenger's airbag connector to the SRS main harness connector.
Attach the front passenger's airbag connector to the connector holder, then reinstall the glove box.
4. Reconnect the battery negative cable.
5. After installing the airbag, 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.
6. Enter the customer's preset radio stations.
Restraint > Airbag Module > Side Airbag (SAB) Module > Repair procedures
Side Airbag Replacement
Review the seats replacement procedure in the body section of the manual before performing repair or service
1. Replace complete seat back(See BD-Front seat).
Restraint > Airbag Module > Curtain Airbag (CAB) Module > Repair procedures
Replacement
1. Disconnect the battery negative cable and wait of least 30 second before beginning work.
2. Remove the follows parts (See BD-group).
A. Front and rear seat
B. Interior side trim
C. Trunk trim
D. Headlining
3. Disconnect the connector (A).
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4. After lossening the mounting bolts, remove the curtain airbag(B).
5. Installation is the reverse of removal
After installing the curtain airbag, 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.
Restraint > Airbag Module > Air Disposal > 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 an 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
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 is securely mounted.
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3. Confirm that the special tool is functioning properly by following the check procedure.
(1) Driver's Airbag :
A. Remove the driver's airbag and install the SST(0957A-38510).
B. Install the driver's airbag on the steering wheel.
(2) Front Passenger's Airbag :
A. Remove the glove box, then disconnect the 2P connector between the front passenger's airbag and SRS
main harness.
A. Install the SST(0957A-38510).
(3) Side Airbag :
A. Disconnect the 2P connector between the side airbag and side wire harness.
A. Install the SST (0957A-3F100).
(4) Curtain Airbag :
A. Disconnect the 2P connector between the curtain airbag and wire harness.
(5) Seat Belt Pretensioner :
A. Disconnect the 2P connector from the seat belt pretensioner.
4. Place the deployment tool at least thirty feet (10 meters) away from the airbag.
5. Connect a 12 volt battery to the tool.
6. Push the tool's deployment switch. The airbag should deploy (deployment is both highly audible and visible: a
loud noise and rapid inflation of the bag, followed by slow deflection)
7. 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 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 > Seat Belt Pretensioner (BPT) > Description and Operation
Pre-tensioner seat belt
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1. This system is designed to protect the occupants from moving forward by transmitting a signal from SRSCM to
the ignition system (gas generator) which in built is the pre-tensioner belt. When the ignition system explodes, then
the spindle will turn in reverse direction to keep the belt from waving and hold the passengers.
2. The Load Limiter is designed to restrain the passenger by the seat belt from moving forward in case of an
accident. In order to protect the passenger from injury, the torsion bar installed in the seat belt will be deformed
when pressure between chest and the belt reaches 7KN or more, so that it reduces the impact by releasing the
seat belt.
Restraint > 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 (see BD group - seat)
3. Remove the front door scuff trim (see BD group - interior)
4. Remove the center pillar trim (see BD group - interior)
5. Remove the lower anchor bolt (see BD group - belt)
6. Remove the upper anchor bolt (see BD group - belt)
7. Disconnect the connector (A).
8. After loosening the mounting bolt (B).
Remove the pretensioner (C).
Installation
1. Install the new belt pretensioner with bolt.
2. Install the upper anchor bolt.
3. Install the center pillar trim.
4. Install the lower anchor bolt.
5. Install the front door scuff trim.
6. Install the seat assembly.
8. After installing the belt pretensioner, 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.
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Page 1 of 47
TUCSON(JM) > 2009 > G 2.7 DOHC > Steering System
Steering System > General Information > Specifications

Specifications
Cross joint, tilt column with pop-
up weight
Shaft and joint type Rack and pinion
Steering gear type 140 ± 1 mm (lock to lock : 3.06
Rack stroke turns)
Power steering pump type Vane type
Oil pump displacement
2.0(I4) 9.6cc/rev. MAX. (0.59 in³/rev.
2.7(V6) MAX.)
10.5cc/rev. MAX. (0.64 in³/rev.
MAX.)
Service Standard
0~30mm (0~1.1 in.)
Steering wheel free play
Steering angle 36°77´ ± 1°30´
Inner wheel 31°74´
Outer wheel 2° or less
Difference between LH and RH 29N (3.0kg, 6.5lbs) or less
Stationary steering effort
Belt deflection [under 98N (10kg, 22lb) force] 8.8~11.0mm
New belt 12.5~14.3mm
Use belt
Oil pump relief pressure 8.6~9.1 MPa (88~93 kg/cm², 1251~1322
2.0 (I4), 2.7 (V6) psi)
2.0 (D-ENG) 9.1~9.6 MPa (93~98 kg/cm², 1322~1393
Total pinion preload psi)
Tie rod swing resistance 0.6~1.3 Nm (6~13 kgf·cm, 5.2~11.3 lbf·in.)
2~5 Nm (20~50 kgf·cm, 1.4~3.6 lbf·ft)
Tightening Torques
Page 2 of 47
Item N.m kgf.cm lbf.ft
Power steering column and shaft
Steering column and shaft mounting bolt 13 ~ 18 130 ~ 180
9.6 ~ 13.3
Power steering wheel lock nut 40 ~ 50 400 ~ 500
28.9 ~ 37
Pinion gear and joint assembly 15 ~ 20 150 ~ 200
10.8 ~ 14.8
Steering column shaft and universal joint 15 ~ 20 150 ~ 200
10.8 ~ 14.8
assembly 4~6 40 ~ 60
3.0 ~ 4.0
Dust cover mounting bolt
Power steering gear box
Gear box mounting bolt
60 ~ 80 600 ~ 800 44 ~ 59
Tie rod end ball joint and knuckle arm
45 ~ 60 450 ~ 600 32.5 ~ 43.4
mounting nut
10 ~ 16 100 ~ 160 7.4 ~ 11.8
Feed tube to gear box
20 ~ 30 200 ~ 300 14.8 ~ 21.7
Gear box to valve body
50 ~ 70 500 ~ 700 37 ~ 50
Yoke plug lock nut
Power steering oil pump
Pressure hose to oil pump 65 ~ 75 650 ~ 750 47.9 ~ 54.2
Oil pump adjusting bolt 35 ~ 50 350 ~ 500 25.3 ~ 37
Oil pump mounting bolt 35 ~ 50 350 ~ 500 25.8 ~ 37
Oil pump bracket mounting bolt 35 ~ 50 350 ~ 500 25.8 ~ 37
Power steering hose
Power steering reservoir mounting bolt 17 ~ 26 170 ~ 260 12.3 ~ 18.8
Power steering hose mounting bolt 4~6 40 ~ 60 3.0 ~ 4.0
Power steering tube mounting bolt 4~6 40 ~ 60 3.0 ~ 4.0
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 As required
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 & SILICON GREASE
As required
tie rod (SPEC NO : MS511-41)
0.75~0.8 liter
Power steering fluid PSF-3
(0.79~0.84 qts.)
Steering System > General Information > Special Service Tools

Page 3 of 47
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 Measuring the mainshaft preload.

Preload 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)
Page 4 of 47
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 5 of 47
Symptom Probable cause Remedy (see page)
Excessive play in steering Loose yoke plug
Loose steering gear mounting bolts Retighten
Loose or worn tie rod end Retighten
Steering wheel operation is not V-belt slippage Readjust

smooth (Insufficient power Damaged V-belt Replace
assist) Low fluid level Replenish
Air in the fluid Bleed air
Twisted or damaged hoses Correct the routing or replace
Insufficient oil pump pressure Repair or replace the oil pump
Sticky flow control valve Replace
Excessive internal oil pump leakage Replace the damaged parts
Excessive oil leaks from rack and pinion in Replace the damaged parts
gear box
Distorted or damaged gear box or valve body Replace
seals
Steering wheel does not return Excessive 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 > General Information

General
Checking Steering Wheel Free Play
Page 6 of 47
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°74'
2. If the measured value is not within the standard value, adjust the linkage.
Checking The Tie Rod End Ball Joint Starting Torque
1. Disconnect the tie rod(A) and knuckle(B) by using the special tool (09568-34000).
Page 7 of 47
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 (5~25 kgf·cm, 0.36~1.78 lbf·ft)
4. If the starting torque exceeds the upper limit of the standard value, replace the tie rod end.
5. Even if the starting torque is below the lower limit of the standard value, check the play of the ball joint and
replace if necessary.
Checking Stationary Steering Effort
1. 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).
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.
Page 8 of 47
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

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 (0.04~0.43in)
Used belt : 12.5 ~ 14.3 mm (0.49~0.56in)
Page 9 of 47
2. If the belt deflection is beyond the standard value, adjust the belt tension as follows.
(1) Loosen the bolt adjusting(A) the power steering "V"belt tension.
(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 bolt adjusting the power steering "V"belt tension.
(4) Check the belt deflection and adjust it again if necessary.
After turning the V belt in the normal rotation direction more than once, recheck the belt deflection.
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.
Page 10 of 47
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 clip.
6. Fill the power steering fluid reservoir with the specified fluid.
PSF-3 : 0.75~0.8 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.
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. If air bleeding is done while the vehicle is idling, the air will be broken up and absorbed into the fluid.
Be sure to do the bleeding only while cranking.
4. Connect the high tension cable, and then start the engine (idling).
Page 11 of 47
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 :
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.
5. Remove the special tools, and tighten the pressure hose(B) against the oil pump (A) using the specified torque.
Tightening torque
65~75 Nm (650~750 kgf.cm, 47.9~54.2 lbf·ft)
Page 12 of 47
6. Air bleed the system.
Steering System > Steering Column & Shaft > Steering Column-Shaft > Components and Components
Location
Components
Page 13 of 47
1. Universal joint assembly 6. Steering column shaft mounting 11. Tilt lever
2. Steering column shaft assembly bolt 12. Multifunction switch
3. Steering wheel 7. Steering column upper shroud 13. Steering column lower shoud
4. Universal joint assembly 8. Universal joint mounting bolt 14. Steering column lower
5. Steering column shaft assembly 9. Steering column shaft mounting shroud
bolt mounting bolt
10. Steering column shaft mounting
nut
Steering System > Steering Column & Shaft > Steering Column-Shaft > Repair procedures
Page 14 of 47
Removal
1. Disconnect the negative (-) terminal(A) from the battery.
2. Take away the bolts (A) in the illustration, and then remove the driver airbag module(B).
3. Remove the steering wheel lock nut(A).

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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.
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).

Page 16 of 47
8. After removing three bolts(A) in the illustration, remove the multifunction switch assembly(B).
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).
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.
Disassembly And Reassembly

Key Lock Assembly
Page 17 of 47
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 screwdriver to remove the key lock assembly mounting bracket(C).
2. Disassemble the key lock assembly(A) from the steering column and shaft assembly(B).

Universal Joint Assembly
1. Remove the bolt(A) connecting the universal joint assembly(B) and the steering column and shaft assembly(C).
2. Remove the universal joint assembly(A) from the steering column and shaft assembly(B).

Page 18 of 47
Installation
installation is the reverse of removal.
When installing the clock spring, refer the RT group to prevent the damage of clock spring inner cable.
Steering System > Hydraulic Power Steering System > Power Steering Gear Box > Components and
Components Location
Components
Page 19 of 47
1. Tie rod end assembly 5. Rack housing 9. Tie rod end assembly
2. Tie rod assembly 6. Joint assembly 10. Tie rod end assembly
3. Bellows 7. Valve body assembly 11. Slotted nut
4. Feed tube 8. Tie rod assembly 12. Split pin
1. Power steering gear box mounting clamp 8. Yoke plug 15. Lock nut
2. Feed tube 9. Rack support yoke 16. Bellows clip
3. Valve body housing 10. Rack support spring 17. Bellows
4. Bolt 11. Lock nut 18. Bellows band
5. Rack housing 12. Rack 19. Tie rod
6. Pinion valve assembly 13. Tie rod end 20. Circlip
7. Oil seal 14. Dust cover 21. Rack stopper
Steering System > Hydraulic Power Steering System > Power Steering Gear Box > Repair procedures
Page 20 of 47
Removal
1. Disconnect the cover fixing clip(A) on the universial joint indoor driver side, loosen the noise covers(B).
2. Loosen the universal joint and the gear box mounting bolt and disconnect the universial joint from the gear box.
Keep the neutral-range to prevent the damage of the clock spring inner cable when you handlethe steering
wheel.
3. Lift up the vehicle.

4. Remove the front tires (RH/LH).
5. After removing the split pin, disconnect the tie rod(A) from the knuckle(B) by using the special tool (09568-
34000).
6. Drain the power steering fluid.

Page 21 of 47
7. Remove the engine under cover(A).
8. Remove the front muffler assembly(A).
9. Disconnect the end tube of the pressure hose(A) and the end hose of the return hose(B) from the gear box.
10. Remove the bracket(A) holding the end tubes of the pressure tube and the return tube.
Page 22 of 47
11. Remove the mounting clamp of power steering gear box, and also remove the clamp holding the pressure tube
and the return tube.
12. Remove the mounting bolt(A) from the power steering gear box.
13. Pull the power steering gear box assembly(A) toward the right side of the vehicle.
When removing the gear box, pull it out carefully and slowly so as not to cause damage to the
Bellows(B).
Inspection And Adjustment Before Disassembly

Page 23 of 47
When mounting the gear box in a vise, only fix the mounting section in the jaws. If other section is fixed the gear
box may be damaged.
Total Pinion Preload

1. Rotate the pinion gear for approximately 4 to 6 seconds for one rotation to measure the total pinion preload.
Standard value
Total pinion preload :
0.6~1.3 N.m (6~13 kgf.cm, 0.4~1.0 lbf.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.
Page 24 of 47
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 N.m (20~50 kgf.cm, 17~43 lbf.in)]
3. If the measured value exceeds the standard value, replace the tie rod assembly.
Even if the measured value is below the standard value, the tie rod that swings smoothly without excessive
play may be used. If the measured value is below 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.
3. If the bellows are defective, replace them with new ones.
Inspection
1. Rack
A. Check for rack tooth face damage or wear
B. Check for oil seal contact surface damage
C. Check for rack bending or twisting
D. Check for oil seal ring damage or wear
E. Check for oil seal damage or wear
Page 25 of 47
2. Pinion valve
A. Check for pinion gear tooth face damage or wear
B. Check for oil seal contact surface damage
C. Check for seal ring damage or wear
D. Check for oil seal damage or wear
3. Bearing
A. Check for seizure or abnormal noise during rotation
B. Check for excessive play
C. Check for missing needle bearing rollers
4. Others
A. Check for damage of the rack housing cylinder bore
B. Check for boot damage, cracking or aging
Disassembly
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.
Page 26 of 47
3. Remove the bellows band(A).
4. Remove the bellows clip(A).
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(A) which fixes the tie rod(B) and rack(C) with a chisel.
Page 27 of 47
9. Remove the tie rod(A) from the rack(B).
Remove the tie rod(A) from the rack(B), taking care not to twist the
rack.
10. Remove the yoke plug locking nut(A), and then remove the yoke plug.
11. Remove the lock nut(A), yoke plug(B), rack support spring(C), rack support yoke(D) and bushing(E) from the
gear box.
Page 28 of 47
12. Remove the valve body housing(A) by loosening the two bolts(B).
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(A) from the rack bushing(B).
16. Remove the pinion valve assembly(A) from the valve body housing(B) with a soft hammer(C).
17. Using the special tool, remove the oil seal and ball bearing from the valve body housing.
Page 29 of 47
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(A) from the rack housing.
Be careful not to damage the rack cylinder inside of the rack housing.
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

Page 30 of 47
4. Install the oil seal(A) in the rack bushing(B).
5. Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.
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.
Page 31 of 47
10. After applying the specified fluid to the oil seal, install it in the rack housing, and fix the valve body assembly(A)
and O-ring in the gear box(B).
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 plug before installation.
Page 32 of 47
13. With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to
15 Nm (150 kg.cm, 11 lb.ft). Loosen the yoke plug approximately from 30° to60° and tighten the locking nut to
the specified torque.
Tightening torque
50~70 N.m (500~700 kgf.cm, 37~52 lbf.ft)
14. Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.
15. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
Recommended grease : Silicone grease
16. Install the new attaching band to the bellows.
When the bellows are installed, a new band must be

used.
17. Install the bellows in position, taking care not to twist it.
Page 33 of 47
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
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 : 112.2mm
20. Check for total pinion preload.
Installation
1. Push in the power steering gear box assembly(A) on the right side of the vehicle.
2. Install the dust cover mounting plate.

3. Connect the dust cover to its mounting plate with a new strap.
Page 34 of 47
4. Connect the steering gear box assembly to the universal joint assembly(A) by using the bolt(B).

6. After installation, air bleed the system. (Refer to ST group - 'Air Bleeding')
Steering System > Hydraulic Power Steering System > Power Steering Hoses > Components and
Components Location
Components
Page 35 of 47
1. Power steering oil reservoir 7. Feed tube

2. Suction hose 8. Return hose
3. Power steering oil pump assembly 9. Pressure tube
4. Tie rod end 10. Tie rod end
5. Pressure hose and tube assembly 11. Power steering gear box
6. Power steering cooler tube assembly
Steering System > Hydraulic Power Steering System > Power Steering Hoses > Repair procedures
Removal
Page 36 of 47
1. Support the specified point of the vehicle with a lift.
2. Drain the power steering fluid.

3. Lift up the vehicle and remove the mounting clamp which is holding both the pressure tube and the return tube(A).
4. Disconnect the pressure tube fitting(A) at the gear box side. (when removing the pressure tube)
5. Remove the return hose(A) in the gear box. (when removing return hose)
Page 37 of 47
6. Lower the vehicle.
7. Remove the clamp of the return tube and hose. (when removing return tube and hose)
8. Remove the return tube and hose. (when removing return hose)
9. Disconnect the pressure hose (A) connector from the oil pump. (when removing the pressure hose)
10. Disconnect the pressure hose assembly. (when removing the pressure hose)
11. Remove the color tube mounting clip bolt. (when removing the color tube)
12. Disconnect then remove the color tube from the power steering oil reservoir tank side hose. (when working on
the color tube)
Installation
Page 38 of 47
1. Support the specified portion of the vehicle with a lift.
2. Insert the color tube from the front pump upper part to the lower part and install mounting bolts. (when installing
the color tube)
3. Connect the color tube to the power steering oil reservoir tank side hose, return tube and hose side and fix it with
clips. (when installing the color tube)
4. Place the pressure hose and tube assembly in position and connect it to the oil pump. (when installing the pressure
hose and tube)
5. Raise the vehicle with a lift.
6. Fix the return hose(A) and pressure tube(B) fitting to the power steering gear box.
Page 39 of 47
7. Fix the power steering pressure tube and return tube mounting clamp(A) with a bolt.
8. Lower the vehicle.
9. Add power steering fluid(PSF-3).

Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Components and
Components Location
Components
Page 40 of 47
1. Pulley & driveshaft assembly 9. Rotor 17. Oil seal

2. Connector 10. Cam ring 18. Bush
3. O-ring 11. Cam ring 19. Front housing
4. Spring 12. Bush 20. O-ring
5. O-ring (Inner) 13. O-ring 21. Suction pipe
6. O-ring (Outer) 14. Mounting bolt 22. Mounting bolt
7. Oil pump side plate 15. Oil pump cover assembly
8. Vane 16. Side plate spring
Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Repair procedures
Removal
Page 41 of 47
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.
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 42 of 47
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).
Disassembly
1. Remove two 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 assembly.
3. Remove the cam ring.
4. Remove the rotor and vanes.
Page 43 of 47
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 44 of 47
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 45 of 47
2. Install the oil seal in the pump body by using the special tool(09222-32100).
3. Install the pump pulley(A).
4. Assemble 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 46 of 47
7. Install vanes(A) to the rotor(B).
8. Install the O-ring and the oil pump cover assembly.

9. Install the suction pipe(A) and O-ring.
Installation
1. Install the oil pump(A) to the oil pump bracket.
Page 47 of 47
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.

6. Check the oil pump pressure.
Page 1 of 53
TUCSON(JM) > 2009 > G 2.7 DOHC > Suspension System
Suspension System > General Information > Specifications

Specifications
Specifications
Items
BETA M/T BETA, DELTA A/T
Front Model Macpherson strut type
suspension
Shock absorber
Type Gas type
Stroke mm(in.) 160.7(6.33)
Identification color GREEN
Coil spring-2WD
Inside dia. mm(in.) Ø137.8(5.43) Ø137.8(5.42)
Outside dia. mm(in.) Ø164.7~167.7(6.48~6.60) Ø164.7~167.7(6.48~6.60)
Load rate Kgf/mm 2.8±0.14 2.8±0.14
Free height mm(in.) 339.7(13.37) 346.8(13.65)
Identification color WHITE BLUE
Coil spring-4WD
Inside dia. mm(in.) Ø137.7(5.42) Ø137.6(5.42)
Outside dia. mm(in.) Ø164.8~167.8(6.49~6.61) Ø164.9~167.9(6.49~6.61)
Load rate Kgf/mm 2.9±0.15 2.9±0.15
Free height mm(in.) 341.6(13.45) 348.5(13.72)
Identification color WHITE-WHITE BLUE-BLUE
Rear Model Dual link
suspension
Shock absorber
Type Gas type
Stroke mm(in.) 191.0(7.52)
Identification color YELLOW
Coil spring 2WD 4WD
Min. dia. mm(in.) Ø100(3.94) Ø100(3.94)
Max. dia. mm(in.) Ø170(6.69) Ø170(6.69)
Load rate Kgf/mm 2.5±0.13 2.6±0.13
Measurement range of 142.1~303.2(5.60~11.94) 147.8~307.0(5.82~12.09)
rate mm(in.)
Free height mm(in.) 355.9(14.01) 360.1(14.18)
Identification color BLUE GREEN
Page 2 of 53
Wheel & Tire Wheel alignment Front Rear
Dimension P215/65R16 P235/60R16 P215/65R16 P235/60R16
Toe-in 0°±0.2° 0°±0.2° 0.37° ~ 0.41° 0.37° ~ 0.41°
Camber 0°±0.5° 0°±0.5° -0.92°±0.5° -0.92°±0.5°
Caster angle(to ground)) 3.53°±0.5° 3.53°±0.5° ─ ─
King pin angle 12.77°±0.5° 12.77°´±0.5° ─ ─
King pin offset mm(in.) -9.73(0.383) -10.41(0.410) ─ ─
Side slip mm(in.) ±3(0.118) ±3(0.118) ±3 ±3
Wheel AL wheel
Size 6.5JX16
Run out mm(in.) Radial : 0.3(0.01), Lateral : 0.3(0.01)
Tire
P215/65R16, P235/60R16
Size
2.1±0.07(30+1.0)
Inflation pressure kg/cm² (psi)
Tightening Torques
Items N.m Kgf.cm Ibf.ft
Front suspension
Wheel nut 90~110 900~1100 66.4~81.2
Strut upper mounting nut 45~60 450~600 33.2~44.3
Strut lower mounting nut 140~160 1400~1600 103.3~118.0
Strut mounting self-locking nut 60~70 600~700 44.3~51.6
Speed sensor cable mounting bolt 7~11 70~110 5.2~8.1
Lower arm mounting nut 80~90 800~900 59.0~66.4
Lower arm bush(A) mounting bolt 100~120 1000~1200 73.8~88.5
Lower arm bush(G) mounting bolt 140~160 1400~1600 103.3~118.0
Stabilizer bracket mounting bolt 50~65 500~650 36.9~48.0
Stabilizer link mounting nut 100~120 1000~1200 73.8~88.5
Tie rod end ball joint mounting nut 45~60 450~600 33.2~44.3
Tie rod toe adjustment nut 50~60 500~600 36.9~44.3
Rear suspension
Wheel nut 90~100 900~1100 66.4~81.2
Strut upper mounting nut 30~40 300~400 22.1~29.5
Strut lower mounting nut 140~160 1400~1600 103.3~118.0
Strut mounting self-locking nut 40~55 400~550 29.5~40.6
Speed sensor cable mounting bolt 7~11 70~110 5.2~8.1
Stabilizer bracket mounting bolt 50~65 500~650 36.9~48.0
Stabilizer link mounting nut 100~120 1000~1200 73.8~88.5
Tie rod toe adjustment nut 50~60 500~600 36.9~44.3
Suspension arm mounting bolt[2WD] 160~180 1600~1800 118.0~132.8
Suspension arm mounting bolt[4WD] 140~160 1400~1600 103.3~118.0
Cross member mounting bolt 100~120 1000~1200 73.8~88.5
Trailing arm bracket mounting bolt 100~120 1000~1200 73.8~88.5
Trailing arm to carrier mounting bolt 100~120 1000~1200 73.8~88.5
Differential mounting bolt 90~120 900~1200 59.0~88.5
Page 3 of 53
Replace the self-locking nuts with new ones after removal.
Lubricants
Item Quantity
In insulator of
As required
strut
Suspension System > General Information > Special Service Tools

Tool(Number and Name) Illustration Use
09216-21100 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 bushing
remover
installer
09546-26000 Compression of the coil spring

Strut spring compressor
Suspension System > General Information > Troubleshooting

Troubleshooting
Page 4 of 53
Trouble symptom Probable cause
Hard steering Improper front wheel alignment
Excessive turning resistance of lower arm ball joint
Flat tire
No power assist
Poor return of steering
Improper front wheel alignment
wheel to center
Poor ride quality Improper front wheel alignment
Damaged shock absorber
Varied or damaged stabilizer
Varied or damaged coil spring
Worn lower arm bushing
Abnormal tire wear Improper front wheel alignment
Worn of shock absorber
Wandering Improper front wheel alignment
Poor turning resistance of lower arm ball joint
Loose or worn lower arm bushing
Vehicle pulls to one side Improper front wheel alignment
Bent lower arm
Improper tire inflation pressure
Steering wheel shimmy Improper front wheel alignment
Varied or damaged stabilizer
Worn lower arm bushing
Worn of shock absorber
Improper front wheel alignment
Bottoming Broken or worn spring
Malfunction of shock absorber
Page 5 of 53
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
• Worn suspension specification
excessive 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 Feather edges wheels Wear pattern
• Caused by out-of-round brake • Toe adjustment out of • Excessive toe on non-drive

drums. specification wheels
• Damaged or worn tie rods • Lack of rotation
• Damaged knuckle
Suspension System > Front Suspension System > Front Strut Assembly > Components and
Components Location
Component Location
Page 6 of 53
1. Strut insulator dust 5. Stabilizer bar link

cover 6. Stabilizer bar
2. Front strut 7. Sub-frame
3. Knuckle
4. Lower arm
Components
Page 7 of 53
1. Insulator dust cover 6. Spring upper seat 10. Spring lower pad
2. Upper mounting nuts 7. Spring upper pad 11. Piston rod
3. Self-locking nut 8. Strut dust cover & bumper rubber 12. Strut assembly
4. Spacer 9. Coil spring 13. Spring lower seat
5. Insulator
Suspension System > Front Suspension System > Front Strut Assembly > Repair procedures
Removal
Page 8 of 53
Be careful not to damage the hub bolts(C) when removing the front wheel and
tire(A).
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).
Page 9 of 53
5. Remove the nut(B) from the stabilizer bar link(A).
6. Remove the strut upper mounting nuts(A).
7. Remove the strut lower mounting bolts(A) and then remove the strut assembly(B).
Disassembly
1. Remove the dust cover(A) with a flat-tipped (-) screw driver.
Page 10 of 53
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 spring tension 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.
3. Compress and extend the piston rod(A) and check that there is no abnormal resistance or unusual sound during
operation.
Disposal
1. Fully extend the piston rod.
Page 11 of 53
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.
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) Two identification color marks are indicated 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 idemtification 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.
Page 12 of 53
5. Remove the special tool(09546-26000).
6. Tighten the self-locking nut to the specified torque.
Tightening torque
60~70 N.m(600~700 kgf.cm, 44.3~51.6 Ibf.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.
Installation
1. Install the strut assembly(B) and then install the strut lower mounting bolts(A).
Tightening torque
140~160 N.m (1400~1600 kgf.cm, 103.3~118.0 Ibf.ft)
2. Install the strut upper mounting nuts(A).
Tightening torque
45~60 N.m (450~600 kgf.cm, 33.2~44.3 Ibf.ft)
Page 13 of 53
3. Install the nut(B) on the stabilizer bar link(A).
Tightening torque
100~120 N.m (1000~1200 kgf.cm, 73.8~88.5 Ibf.ft)
4. Install the speed sensor cable mounting bolt(B) and speed sensor(A).
Tightening torque
7~11 N.m (70~110 kgf.cm, 5.2~8.1 Ibf.ft)
5. Install the brake hose bracket(B) and speed sensor cable mounting bolt(C) on the strut assembly(A).
Tightening torque
7~11 N.m (70~110 kgf.cm, 5.2~8.1 Ibf.ft)
Page 14 of 53
Tightening torque
90~110 N.m (900~1100 kgf.cm, 66.4~81.2 Ibf.ft)
Be careful not to damage the hub bolts(C) when installing the front wheel and tire(A).
Suspension System > Front Suspension System > Front Lower Arm > Components and Components
Location
Components
Page 15 of 53
1. Lower 3. A bushing
arm 4. Connector
2. G bushing
Suspension System > Front Suspension System > Front Lower Arm > Repair procedures
Removal
Page 16 of 53
tire(A).
4. Remove the lower arm mounting bolts(A).
Replacement
Page 17 of 53
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 bushing on the lower arm.
Insert bush in the orientation shown.
Separation force is over 800Kg
Installation
Page 18 of 53
1. Install the lower arm mounting bolts(A).
Tightening torque
A bushing :
100~120 N.m (1000~1200 kgf.cm, 73.8~88.5 Ibf.ft)
G bushing :
140~160 N.m (1400~1600 kgf.cm, 103.3~118.0 Ibf.ft)
2. Install the lower arm ball joint mounting bolts(A).
Tightening torque
100~120 N.m (1000~1200 kgf.cm, 73.8~88.5 Ibf.ft)
Tightening torque
90~110 N.m (900~1100 kgf.cm, 66.4~81.2 Ib.ft)
Page 19 of 53
Suspension System > Front Suspension System > Front Stabilizer Bar > Components and Components
Location
Components
Page 20 of 53
1. Stabilizer bar 4. Sub-frame

2. Stabilizer bar 5. Knuckle
link 6. Strut assembly
3. Lower arm
Suspension System > Front Suspension System > Front Stabilizer Bar > Repair procedures
Removal
Page 21 of 53
tire(A).
3. Remove the stabilizer bar link(A).

A. Remove the nut(B) and stabilizer bar link(A).
B. Remove the stabilizer bar link on the opposite side in the same way.
4. Remove the rear mounting bolts of subframe.
5. Remove the stabilizer bracket(A) and bushing(B).
A. After loosen the bolts(C), then remove the bracket(A) and bushing(B).
B. Remove the stabilizer bracket and bushing on the opposite side in the same way.
Page 22 of 53
6. Remove the stabilizer bar.
Be careful not to damage the power steering pressure

tube.
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.
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
50~65 N.m (500~650 kgf.cm, 36.9~48.0 Ibf.ft)
4. Install the rear mounting bolts of sub-frame.

Page 23 of 53
5. Install the nut(B) on the stabilizer bar link(A).
Tightening torque
100~120 N.m (1000~1200 kgf.cm, 73.8~88.5 Ibf.ft)
Tightening torque
90~110 N.m (900~1100 kgf.cm, 66.4~81.2 Ibf.ft)
Suspension System > Front Suspension System > Sub Frame > Repair procedures
Replacement
1. Remove the under cover.
Page 24 of 53
2. Remove the front pipe (A).
3. Loosen the mount nuts (A, B).
4. Remove the sub frame bracket.

5. Remove the mount nuts.
6. Installation is the reverse of the removal.

Bush
Page 25 of 53
1. Installation the main nut (A).
2. Installation the support (A).
3. the main bolt (A) through the support and bush then fasten a main bolt with a nut.
4. Remove the bush after turning the main bolt clockwise.

5. Installation is the reverse of the removal.
Suspension System > Rear Suspension System > Rear Strut Assembly > Components and Components
Location
Component Location
Page 26 of 53
1. Strut assembly 4. Cross member

2. Trailing arm 5. Carrier
3. Suspension arm 6. Disc brake
assembly
Page 27 of 53
1. Strut assembly 5. Drive shaft

2. Trailing arm 6. Carrier
3. Suspension arm 7. Disc brake
4. Cross member assembly
Components
Page 28 of 53
1. Self-locking nut 6. Strut dust cover & bumper

2. Spacer rubber
3. Upper mounting nut 7. Spring lower pad
4. Insulator 8. Piston rod
5. Coil spring 9. Strut assembly
10. Spring lower seat
Suspension System > Rear Suspension System > Rear Strut Assembly > Repair procedures
Removal
Page 29 of 53
Be careful not to damage the hub bolts(C) when removing the rear wheel and
tire(A).
3. Remove the speed sensor cable mounting bolt(A) and speed sensor(C).
4. Remove the stabilizer bar link nut(B).

5. Remove the strut upper mounting nut(A).
Page 30 of 53
6. Remove the strut lower mounting bolts(A) and then remove the strut assembly(B).
Disassembly
1. Using the special tool(09546-26000), compress the coil spring(A) until there is only a little tension on the
strut(B).
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.
Disposal
1. Fully extend the piston rod.
Page 31 of 53
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.
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) Two idenitification color marks are indicated on the coil spring; one follows model option (see page
SS-2) the other follows load classification according to the below.
Pay attention to distinguish between the two marks and then install them.
2) Install the coil spring with the identification mark directed toward the knuckle.
3. After fully extending the piston rod, install insulator assembly.

4. After seating the upper and lower ends of the coil spring(A) in lower spring seat grooves(B) correctly, tighten
new self-locking nut temporarily.
Page 32 of 53
5. Remove the special tool(09546-26000).
6. Tighten the self-locking nut to the specified torque.
Tightening torque
40~55 N.m (400~550 Kgf·cm, 29.5~40.6 Ibf·ft)
Installation
1. Install the strut assembly(B) and then install the strut lower mounting bolts(A).
Tightening torque
140~160 N.m (1400~1600 kgf.cm, 103.3~118.0 Ibf.ft)
2. Install the strut upper mounting nuts(A).
Tightening torque
30~40 N.m (300~400 kgf.cm, 22.1~29.5 Ibf.ft)
Page 33 of 53
3. Install stabilizer bar link nut(B).
Tightening torque
100~120 N.m (1000~1200 kgf.cm, 73.8~88.5 Ibf.ft)
4. Install the speed sensor cable mounting bolt(A).
Tightening torque
7~11 N.m (70~110 kgf.cm, 5.2~8.1 Ibf.ft)
Tightening torque
90~110 N.m (900~1100 kgf.cm, 66.4~81.2 Ibf.ft)
Be careful not to damage the hub bolts(C) when installing the rear wheel and tire(A).
Suspension System > Rear Suspension System > Rear Suspension Arm > Components and
Components Location
Components
Page 34 of 53
1. Suspension arm
2. Suspension arm bracket mounting bolt
3. Cross member
Page 35 of 53
1. Suspension arm
2. Cross member
Suspension System > Rear Suspension System > Rear Suspension Arm > Repair procedures
Replacement
[2WD]
Page 36 of 53
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 37 of 53
6. Install the suspension arm bracket mounting bolts(A).
Tightening torque
160~180 N.m (1600~1800 kgf.cm, 118.0~132.8 Ibf.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 N.m (1600~1800 kgf.cm, 118.0~132.8 Ibf.ft)
[4WD]
1. Remove the muffler(A).
Page 38 of 53
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 39 of 53
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 N.m (1400~1600 kgf.cm, 103.3~118.0 Ibf.ft)
11. Install the rear differential(A) on the cross member(B).
Tightening torque
90~120 N.m (900~1200 kgf.cm, 59.0~88.5 Ibf.ft)
12. Install the propeller shaft. (Refer to DS Group - 'Propeller Shaft')

Page 40 of 53
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 N.m (1000~1200 kgf.cm, 73.8~88.5 Ibf.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 N.m (1400~1600 kgf.cm, 103.3~118.0 Ibf.ft)
16. Install the rear wheel & tire.

17. Check the alignment. (Refer to 'Tires/Wheels - alingment')
Suspension System > Rear Suspension System > Trailing Arm > Components and Components
Location
Page 41 of 53
Components
1. Trailing arm 5. Cross member

2. Stabilizer bar 6. Tire
3. Strut assembly 7. Drive shaft
4. Suspension
arm
Suspension System > Rear Suspension System > Trailing Arm > Repair procedures
Removal
Page 42 of 53
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 300Kg
Insert bush with the arrow pointed toward trailing arm length.
Installation
1) Install the trailing arm mounting bolt(A).
Tightening torque
100~120 N.m (1000~1200 kgf.cm, 73.8~88.5 Ib.ft)
Page 43 of 53
2) Install the trailing arm bracket mounting bolt, nut.
Tightening torque
100~120 N.m (1000~1200 kgf.cm, 73.8~88.5 Ibf.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 44 of 53
1. Stabilizer 3. Bushing
bar 4. Bracket
2. Stabilizer
bar link
Suspension System > Rear Suspension System > Rear Stabilizer Bar > Repair procedures
Removal
Page 45 of 53
Be careful not to damage the hub bolts(C) when removing the rear wheel and
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. Use the same method described in steps 3 and 4 to the other side.
6. Remove the stabilizer bar.
Inspection
1. If there is a crack and damage in the dust cover, replace the stabilizer bar link.
Page 46 of 53
2. Mount the self-locking nut on the ball joint, and then measure the ball joint rotating torque.
Tightening torque
0.7~2 N.m (7~20 kgf.cm, 5.2 ~14.5 Ibf.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.
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 stabilizer bracket(B) and then install the stabilizer bar mounting bolts(A).
Page 47 of 53
3. One side bracket should be temporarily tightened, and then install the bushing on the opposite side.
Tightening torque
50~65 N.m (500~650 kgf.cm, 36.9~48.0 Ibf.ft)
4. Install the stabilizer bar link mounting nut(A).
Tightening torque
100~120 N.m (1000~1200 kgf.cm, 73.8~88.5 Ibf.ft)
5. Employ the same manner described above step 3 and 4 to the other side.
Tightening torque
90~110 N.m (900~1100 kgf.cm, 66.4~81.2 Ibf.ft)
Be careful not to damage the hub bolts(C) when installing the rear wheel and tire(A).
Suspension System > Tires/Wheels > Front Wheel Alignment > Description and Operation
Description
Wheel Alignment
Toe
Page 48 of 53
ITEM Description
Positive (+) toe
A-B<0
(toe in)
Negative (-) toe
A-B>0
(toe out)
Standard value
Toe-in (B-A) : 0°±0.2°(0 ±0.079in)
• Toe-in adjustment should be made by turning the right and left tie rods by the same amount.
• When adjusting toe-in, loosen the outer bellows clip to prevent twisting the bellows.
• After the adjustment, tighten the tie rod end lock nuts firmly and reinstall the bellows clip.
• Adjust each toe-in to be the range of ±1°.
Tie rod end lock nuts(A) tightening torque

50~60 N.m (500~600 kgf.cm, 36.9~44.3 Ibf.ft)
Camber
Page 49 of 53
ITEM Description
Camber
A
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 steering 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.
Camber : 0°±0.5°
Caster
Caster : 3.53°±0.5°
• 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°.
Suspension System > Tires/Wheels > Rear Wheel Alignment > Description and Operation
Description
Toe-in
Standard value : 0.37°~0.41°
Suspension System > Tires/Wheels > Wheel Runout > Description and Operation
Description
Page 50 of 53
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 N.m (900~1100 kgf.cm, 66.4~81.2 Ibf.ft)
When using an impact gun, final tightening torque should be checked using a torque wrench.
Page 51 of 53
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.
Tire Rotation
Discription
Lead/pull Correction Chart
Page 52 of 53
Rotation
Page 53 of 53
Page 1 of 93
TUCSON(JM) > 2009 > G 2.7 DOHC > Suspension System
Suspension System > Tire Pressure Monitoring System > Components and Components Location
Components
Suspension System > Tire Pressure Monitoring System > Description and Operation
Page 2 of 93
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
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.
D. When the receiver connector is not connected (Only applicable to the vehicle with active circuit applied to the
instrument cluster)
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
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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.
5) TREAD or DTC telltale open circuits ; requires observation of lamps at Ignition ON to diagnose.
6) Second speed input implemented receiver can detect a speed signal failure.
Suspension System > Tire Pressure Monitoring System > Schematic Diagrams
Schematic Diagram
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
Page 4 of 93
NO Pin-out assignment NO Pin-out assignment
1 Battery 11 -
Ground(TPMS
2 12 -
receiver)
3 - 13 -
4 - 14 -
5 - 15 -
6 Speed signal 2 16 TREAD lamp
Diagnostic lamp
7 - 17
(TPMS)
8 - 18 Speed signal 1
9 K-LINE 19 Ignition 1(+)
10 - 20 -
Circuit Diagram
Page 5 of 93
Suspension System > Tire Pressure Monitoring System > TPMS Sensor > Description and Operation
Description
1. MODE
(1) Normal Fixed Base State
2. Storage Auto 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.
3. 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.
Sensor mode is used to configure sensor between high line and low line system. TPM sensor of JM should
be set to low line.
Suspension System > Tire Pressure Monitoring System > TPMS Sensor > Repair procedures
Removal
Tire Removal
Page 6 of 93
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.
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.
Page 7 of 93
Installation
Sensor Fit
• Handle the sensor with care.

• Avoid lubricant contact if possible.
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 8 of 93
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).

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1. Change the newly installed sensor mode to Normal Fixed Base(Low Line) with the 'TPMS exciter'.
Mode(Status/option) of the sensor installed to the vehicle should be Normal Fixed Base
(Low)
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.
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3. Connect 'TPMS exciter' to the diagnostic connector.
4. Register the four sensor's ids to the receiver.

Page 11 of 93
5. Cycle Ignition, (wait 15 seconds before turn Ignition back on) then related DTC should be erased from the
receiver.
In order for the system to correctly monitor tires for under-inflation, there should be a total of exactly 4
sensors fitted to each of the four driven wheel positions. There should be no other sensors in the vehicle
since this could cause the system to monitor the wrong sensors.
Ensure that there are only 4 sensors in the vehicle.
Suspension System > Tire Pressure Monitoring System > TPMS Receiver > Description and
Operation
Description
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.
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(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.
(3) Test State

This state is only used in manufacturing plant to check RF transmission between sensor and receiver.
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 continuously over 12.4 mph(20 kph) to learn a new sensor is up to 20 minutes.
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 time which vehicle is driven at speed greater than or equal to 12.4
mph(12 kph).
Suspension System > Tire Pressure Monitoring System > TPMS Receiver > Repair procedures
Replacement
Page 13 of 93
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 and
not High Line 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.
6. Connect 'TPMS exciter' to the diagnostic connector.
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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')
9. Register sensor's ids to receiver.
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10. Register VIN number of the vehicle.(17 digits)
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.
Suspension System > Tire Pressure Monitoring System > Troubleshooting

Troubleshooting
Page 16 of 93
- the lamp check should occur and then all lamps / LED's should turn off.
- If the lamp test does not occur:
• Check connector is pushed all the way into the receiver connector slot.
• 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:
• 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 and check the pressure by
reading the sensor state with TPMS exciter.
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 & learning procedure).
- If the problem still exists, replace sensor.
- Ensure that all tires are inflated to their correct Placard pressures.
- Re-enter Sensor IDs.
- 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.
Diagnostic Trouble Code Chart

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DTC Trouble description
C1121 Sensor 1BatteryLow
C1126 TPMS ECUBatteryVoltage Low.
C1127 TPMS ECUBatteryVoltage High.
C1212 First Speed Input Fault
C1240 Second Speed In put Fault
C1660 Receiver Radio Frequency Circuit Failure
C1661 Receiver EEPROM Failure
C1300 LF / RF External Interference Failure
C1306 RF InternalInterference Failure
C1312 Sensor 1 Radio Frequency Channel Failure
C1322 Sensor 1 Over Temperature
C1332 Sensor 1 Fault
C2510 TRED LAMP open / short circuit
Diagnostic(TPMS) Lamp Short Circuit to
C2511
12V
Suspension System > Tire Pressure Monitoring System > C1121 Sensor 1 Battery Voltage Low
Component Location
Page 18 of 93
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 simultaneous 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
status is ‘Storage State’ or the sensor battery runs out. The transmitter should transmit data at vehicle speeds
between 0mph (0kph) and 186mph (300kph). 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 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.
[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 20s
nominally independent of vehicle operation. Monitoring shall be every 20s. If sensor detects rapid deflation, then RF
messages will be transmitted every 4s for 1 minute duration. Communication from wheel sensors shall be via RF at a
frequency of 315 MHz, 5kBaud.
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 to ±41°F(±5°C) from -40 to 248°F(-40 to 120°C).
Page 19 of 93
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
• Latest Lowest sensor Temp. > -4°F(-20°C)
Enable conditions • Sensor temperature low
• Distance travelled during 12 min. > 2.5 Mile (4
km) • Sensor battery low
• Faulty TPMS sensor
Threshold value • Sensor voltage < 2.2 V
Diagnosis time • 12 ~13 minutes

1. Park the vehicle on a level surface.
2. Connect ‘TPMS exciter’ or scantool to Data Link Connector(DLC).
3. Select "TPMS DIAGNOSIS" mode.
4. Select the "FULL" mode 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’.
Fig.1) Sensor current data (normal)

Fig.2) Connect the DLC for 'TPMS exciter'
6. Is parameter within specifications?
Fault is intermittent. It has been repaired and TPMS receiver module memory is not
cleared yet.
Page 20 of 93
1. Turn ON ‘TPMS exciter’.
2. Select "TIRE SNSR CONFIG(EXCITER)" mode.
3. Execute "SET SENSOR STATUS" of each wheel.
Specification : ‘Sensor battery value’ is ‘Normal’ and ‘Sensor Temp.’ is more than -68°F(-20°C).
Fig.1) Sensor status (normal)

Fig.2) Executing "SET SENSOR STATUS"
4. Is any sensor data outside specification?
Check wheel / tire where abnormal sensor data was detected.
Check for sensor if unable to retrieve data with ‘TPMS exciter’.
Repair or replace if necessary and go to "Verification of Vehicle Repair"
procedure.
Replace TPMS sensor if necessary and register sensor ID with ‘TPMS
exciter’.

1. Connect TPMS exciter or scantool and select "Diagnostic Trouble Codes(DTCs)" mode
2. Using a TPMS exciter or scantool, Clear DTC.
procedure.
Component Location
Page 21 of 93
General Description
Page 22 of 93
DTC Description


‘Normal’.

cleared yet.
Page 23 of 93
Specification : ‘Sensor battery value’ is ‘Normal’ and ‘Sensor Temp.’ is more than -68°F( -
20°C).

procedure.
exciter’.

procedure.
Component Location
Page 24 of 93
General Description
Page 25 of 93
DTC Description


‘Normal’.

cleared yet.
Page 26 of 93
‘Normal’.

procedure.
exciter’.

procedure.
Component Location
Page 27 of 93
General Description
Page 28 of 93
DTC Description


‘Normal’.

cleared yet.
Page 29 of 93
Specification : ‘Sensor battery value’ is ‘Normal’ and ‘Sensor Temp.’ is more than -68°F( -
20°C).

procedure.
exciter’.

procedure.
Suspension System > Tire Pressure Monitoring System > C1126 TPMS ECU Battery Voltage Low
Component Location
Page 30 of 93
General Description
TPMS Receiver is located under the paking brake lever in the center console. The operating battery of TPMS
module is supplied from the vehicle battery. Data such as Tire pressure, Tire Temperature, TPMS sensor battery
status and TPMS sensor valve ID from TPMS sensors are transmitted to TPMS receiver in the form of RF signal.
TPMS 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 strategy • Battery level check
• Faulty charging
Enable
• Battery voltage level low system
conditions
• Vehicle battery
Threshold low
• Battery voltage < 9 V
value • Faulty TPMS
Diagnosis Receiver
• 2 sec.
time

1. Start engine and turn headight and rear defroster on.
5. Maintaining ENG. RPM at 2,500RPM(idle) over 2 minutes.
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6. Monitor the parameter of BATT. VOLT on the ‘TPMS exciter’ or scantool.
Specification : ‘BATT. VOLT’ is more than 10 V

Fig.2) BATT. VOLT low
cleared yet.
Go to "Inspection/Repair" procedure.

1. Many malfunctions in the electrical system are caused by poor harness and terminal condition.
Repair if necessary and then go to "Verification of Vehicle Repair"
procedure.
Page 32 of 93

1. Engine "ON"
2. Headight and rear defroster "ON".
3. Measure voltage between terminal (+) and (-) of battery maintaining ENG. RPM at 2,500RPM(idle) over 2
minutes.
Specification : more than 10 V

Substitute with a known-good TPMS receiver and check for proper operation.
If the problem is corrected, replace TPMS 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.
Repair if necessary and then go to "Verification of Vehicle Repair" procedure.

procedure.
Suspension System > Tire Pressure Monitoring System > C1127 TPMS ECU Battery Voltage High
Component Location
Page 33 of 93
General Description
TPMS Receiver is integrated with the TPMS module installed at the bottom of the steering column. The operating
battery of TPMS module is supplied from the vehicle battery. Data such as Tire pressure, Tire Temperature, TPMS
sensor battery status and TPMS sensor valve ID from TPMS sensors are transmitted to TPMS receiver in the form
of RF signal. TPMS module accomplishes Tire Monitoring and Warning Logic with received data.
DTC Description
This indicates that the receiver battery level is High. The most likely cause is receiver input / A-D failure.

DTC strategy • Battery level check
• Faulty charging
Enable
• Battery voltage level high system
conditions
• Vehicle battery
Threshold high
• Battery voltage > 17.5 V
value • Faulty TPMS
Diagnosis Receiver
• 2 sec.
time

1. Start engine and turn headight and rear defroster on.
5. Maintaining ENG. RPM at 2,500RPM(idle) over 2 minutes.
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6. Monitor the parameter of BATT. VOLT on the ‘TPMS exciter’ or scantool.
Specification : ‘BATT. VOLT’ is less than 16.5 V

Fig.2) BATT. VOLT high
cleared yet.
Go to "Inspection/Repair" procedure.

procedure.
Page 35 of 93

1. Engine "ON"
2. Headight and rear defroster "ON".
3. Measure voltage between terminal (+) and (-) of battery maintaining ENG. RPM at 2,500RPM(idle) over 2
minutes.
Specification : less than 16.5 V

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.
Repair or replace if necessary and then go to "Verification of Vehicle Repair" procedure.

procedure.
Suspension System > Tire Pressure Monitoring System > C1212 First Speed Input Fault
General Description
Page 36 of 93
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 conditions • Vehicle is driving under more than 20 km/h.
• Speed Sensor input 2 speed > 20 km/h while Speed • Open in speed signal line
Threshold value Sensor input 1 speed < 10 km/h. • Faulty Speed sensor
• Invalid Speed Sensor input 1 is measured.
Diagnosis time • 20 seconds
Page 37 of 93

procedure.

Chcek Open
1. Ignition "OFF"
2. Disconnect Vehicle speed sensor connector and TPMS receiver connector.
3. Measure resistance between terminal "3" of Vehicle speed sensor harness connector and terminal "18" 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
Repair as necessary in speed signal circuit and then go to "Verification of Vehicle Repair"
procedure.

Page 38 of 93
procedure.
Suspension System > Tire Pressure Monitoring System > C1240 Second Speed Input Fault
General Description
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.
Page 39 of 93
DTC strategy • Check speed signal
Enable conditions • Vehicle is driving under more than 20 km/h.
• Speed Sensor input 1 speed > 20 km/h while Speed • Open in speed signal line
Threshold value Sensor input 2 speed < 10 km/h. • Faulty Speed sensor
• Invalid Speed Sensor input 2 is measured.
Diagnosis time • 20 seconds

procedure.

Chcek Open
1. Ignition "OFF"
2. Disconnect Vehicle speed sensor connector and TPMS receiver connector.
3. Measure resistance between terminal "22(39)" of ECM harness connector and terminal "6" of TPMS receiver
harness connector.
Page 40 of 93

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
Repair as necessary in speed signal circuit and then go to "Verification of Vehicle Repair"
procedure.

procedure.
Suspension System > Tire Pressure Monitoring System > C1660 Receiver Radio Frequency Circuit
Failure
Component Location
Page 41 of 93
General Description
DTC Description
This DTC occurs 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 other RF
• No valid RF data for 12 min from any sensor transmissions received
Enable conditions
• RF messages and the signal levels are unexpected • Low Line - receiver RF
Threshold value • Internal RF circuit fault shielding
• Faulty TPMS Receiver
Diagnosis time • 12 ~13 minutes module
[Check status of all TPM sensor]

Page 42 of 93
4. Are status of all sensors "normal"?
Check TPMS receiver RF shielding.
If it is OK, go to "Check TPMS receiver" as follows.
Repair if necessary and go to "Verification of Vehicle Repair"
procedure.
Change status of all TPMS sensors into "normal" status with ‘TPMS
exciter’.
[Check TPMS receiver]

2. Clear DTC.
3. IG OFF & IG ON. Wait 4 minutes.
4. Execute "Diagnostic Trouble Codes(DTCs)" mode.
5. Is ‘C1660’ present ?
Substitute with a known-good TPMS Receiver module and check for proper operation.
If the problem is corrected, replace TPMS Receiver module and go to "Verification of
TPMS receiver complete successful Auto-Learn.
System is OK.

procedure.
Suspension System > Tire Pressure Monitoring System > C1661 Receiver EEPROM Failure
Page 43 of 93
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
• Transient over voltage due to
Enable conditions • Reading or writing problem to EEPROM vehicle fault (fault would
Threshold value • EEPROM in the receiver module fault typically recover)
Diagnosis time • < 10 sec.

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2. Clear DTC.
System is OK.

procedure.
Suspension System > Tire Pressure Monitoring System > C1668 Internal failure detection
Component Location
General Description
DTC Description
This DTC indicates that the receiver has detected an internal error.
Page 45 of 93
DTC strategy • Receiver module check
• Transient over voltage due to
Enable conditions • An Internal error vehicle fault (fault would
Threshold value • TPMS Receiver module fault typically recover)
Diagnosis time • < 3 sec. - Carried out once at Ignition ON

2. Clear DTC.
System is OK.

procedure.
Page 46 of 93
Suspension System > Tire Pressure Monitoring System > C1300 LF/RF External Interference Failure
Component Location
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
• System not functioning due to High RF interference • LF/RF Interference from
Enable conditions external sources(unless
levels
C1306 also exists as historic.
• No valid RF data for 8 min from any sensor If this is the case then
Threshold value • Distance travelled during 8 minutes ≤ 1.7 Mile (2.7 interference source is likely to
km) be internal to the vehicle)
Diagnosis time • 8 ~ 9 minutes

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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

Fault is intermittent. It has been repaired and TPMS receiver module memory is not cleared
yet.
Substitute with a known-good TPMS receiver module and check for proper operation.
If the problem is corrected, replace TPMS receiver module and then go to "Verification of

procedure.
Suspension System > Tire Pressure Monitoring System > C1306 RF Internal Interference Failure
Component Location
Page 48 of 93
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
• System not functioning due to High RF interference
Enable conditions
(Internal) levels
• No valid RF data for 8 min from any sensor • Internal vehicle noise source
Threshold value • Distance travelled during 8 minutes ≤ 1.7 Mile (2.7
km)
Diagnosis time • 8 ~ 9 minutes

Page 49 of 93
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

Fault is intermittent. It has been repaired and TPMS receiver module memory is not cleared
yet.

procedure.
Suspension System > Tire Pressure Monitoring System > C1312 Sensor 1 Radio Frequency Channel
Failure
Component Location
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General Description
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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.

• Incorrectly configured TPMS
DTC strategy • RF message from sensor1 check sensor e.g.Low Line vehicle
with High Line sensors.
• Low Line vehicle sensors in
storage state.
• 2.5 Mile (4 km) < Distance travelled during 12 min. • Wrong receiver type fitted
Enable conditions
< 25 Mile (40 km) e.g. Low Line receiver to a
High Line vehicle.
• Shielding in vehicle.
• Failure to Learn Sensors1 Correctly. • Un-approved wheels/tires i.e.
Threshold value a vehicle set up that has not
• No RF message received from sensor1 over 12 min.
been approved for good RF
performance.
• Incorrectly fitted sensor /
Diagnosis time • 12 ~ 20 minutes. receiver.

Page 52 of 93

Fig.2) Sensor current data (failure)
5. Is parameter normal?
cleared yet.

4. Is data unable to be retrieved for any sensor?
Replace affected TPMS sensor and register sensor ID with ‘TPMS exciter’.

Page 53 of 93
procedure.
Failure
Component Location
General Description
Page 54 of 93
DTC Description

storage state.
Enable conditions
High Line vehicle.
performance.

Page 55 of 93

cleared yet.
Page 56 of 93


procedure.
Failure
Component Location
Page 57 of 93
General Description
Page 58 of 93
DTC Description

storage state.
Enable conditions
High Line vehicle.
performance.

Page 59 of 93

cleared yet.


Page 60 of 93
procedure.
Failure
Component Location
General Description
Page 61 of 93
DTC Description

DTC strategy • RF message from sensor1 check sensor e.g.Low Line vehicle with
High Line sensors.
• Low Line vehicle sensors in storage
Enable conditions • 2.5 Mile (4 km) state.
• 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 • Un-approved wheels/tires i.e. a
12 min. vehicle set up that has not been
approved for good RF
performance.
Diagnosis time • 12 ~ 20 minutes. • Incorrectly fitted sensor / receiver.

Page 62 of 93

cleared yet.
Page 63 of 93


procedure.
Suspension System > Tire Pressure Monitoring System > C1322 Sensor 1 Over Temperature
Component Location
Page 64 of 93
General Description
Page 65 of 93
DTC Description
This DTC indicates that the sensor has seen a temperature in excess of 230°F(110°C). At 257°F(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
• 2 consecutive Alert State temperature > 230°F • Damaged tire
Enable conditions • Excessive braking
(110°C)
• Driving while the parking
Threshold value • Sensor temperature > 230°F(110°C) brake is on.

5. Monitor SENSOR 1’s temperature parameter on the ‘TPMS exciter’ or scantool after 4 minutes.
Specification : Less than 230°F(110°C)

cleared yet.
Page 66 of 93
[Check TPM SENSOR 1]
4. Monitor the parameter of each sensor temperature on the ‘TPMS exciter’.

The sensor which displays data outside specification is SENSOR 1.
Check wheel / tire of SENSOR 1 if Damaged tire, Excessive braking, Driving while the
parking brake is on is detected.
Repair or replace if necessary and go to "Verification of Vehicle Repair" procedure.
If it is OK, go to "Check wheel / tire" as follows.
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
[Check wheel / tire]

1. Cool the heat of the SENSOR 1 wheel / tire.
2. IG OFF & IG ON.
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’.

Page 67 of 93
procedure.
Component Location
General Description
Page 68 of 93
DTC Description

(110°C)

Page 69 of 93

cleared yet.

Page 70 of 93

2. IG OFF & IG ON.


procedure.
Component Location
Page 71 of 93
General Description
Page 72 of 93
DTC Description

(110°C)


cleared yet.
Page 73 of 93


2. IG OFF & IG ON.


Page 74 of 93
procedure.
Component Location
General Description
Page 75 of 93
DTC Description

(110°C)

Page 76 of 93

cleared yet.


2. IG OFF & IG ON.
Page 77 of 93


procedure.
Suspension System > Tire Pressure Monitoring System > C1332 Sensor 1 Fault
Component Location
General Description
Page 78 of 93
DTC Description
This DTC indicates that the sensor has detected that it has an internal fault. The most likely cause is sensor failure.

DTC strategy • Sensor check
Enable
• An internal fault in the TPMS sensor • Damage to sensor
conditions
Threshold value • TPMS sensor fault
Diagnosis time • < 9 minutes
Page 79 of 93

cleared yet.
2. Select "TIRE SNSR CONFIG (EXCITER)" mode.
Page 80 of 93

Check for damaged of TPMS sensor on affected wheel.
Replace TPMS sensor if necessary and register sensor ID with ‘TPMS exciter’.

procedure.
Component Location
Page 81 of 93
General Description
Page 82 of 93
DTC Description

Enable
conditions


Page 83 of 93
cleared yet.


procedure.
Page 84 of 93
Component Location
General Description
Page 85 of 93
DTC Description

Enable
conditions


Page 86 of 93
cleared yet.


procedure.
Page 87 of 93
Component Location
General Description
Page 88 of 93
DTC Description

Enable
conditions


Page 89 of 93
cleared yet.


procedure.
Suspension System > Tire Pressure Monitoring System > C2510 TREAD LAMP open/short circuit
Page 90 of 93
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]
When tire pressure is below allowed threshold.
When rapid leak is detected by the sensor.
Indicates that tire needs to be re-inflated to placard pressure / repaired.
[Turn the TREAD indicator lamp off]
Under-inflation : When tire pressure is above (warning threshold + hysteresis).
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) lamp is short circuit to 12 V 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 conditions • TREAD lamp circuit short to 12 V
• Short circuit to 12V between
• TREAD lamp - 200mA allowed each (after in rush lamp and TPMS receiver
Threshold value
time). 50mA margin built in.
Diagnosis time • < 3s

Page 91 of 93
procedure.

1. Engine "OFF".
2. Disconnect instrument cluster connector and TPMS receiver connector.
3. Engine "ON".
4. Measure voltage between terminal "16" of TPMS receiver harness connector and chassis ground.
Specification : 0 V

Repair" procedure.
Check for short to power in control harness.

procedure.
Suspension System > Tire Pressure Monitoring System > C2511 Diagnostic(TPMS) Lamp Short
Circuit to 12V
Component Location
Page 92 of 93
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]
When the system detects a fault that is external to the receiver / sensor.
When the system detects a receiver fault.
When the system detects a sensor fault.
[Turn the TPMS DTC Warning indicator lamp off]
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.
‘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 DTC Warning lamp is short circuit to 12 V 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 conditions • TREAD lamp circuit short to 12 V
• Short circuit to 12V between
• TREAD lamp - 200mA allowed each (after in rush lamp and TPMS receiver
Threshold value
time). 50mA margin built in.
Diagnosis time • < 3s

Page 93 of 93
procedure.

1. Engine "OFF".
2. Disconnect instrument cluster connector and TPMS receiver connector.
3. Engine "ON".
4. Measure voltage between terminal "17" of TPMS receiver harness connector and chassis ground.
Specification : 0 V

Repair" procedure.
Check for short to power in control harness.

procedure.

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Page 1 of 24

TUCSON(JM) > 2009 > G 2.7 DOHC > General Information

General Information > General Information > General Information

Identification Number Description

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

M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

Always use Genuine Hyundai parts and recommedended fluid.

Selection Of Engine Oil

3. Cleaning parts for reuse

Depending on their location.

Ruber Parts And Tubes

Measuring Body Dimensiongs

Measuring Actual Dimensions

Checking Cables And Wires

Serivicing The Electrical System

Precautions For Catalytic Converter

Automatic Transaxle System > General Information > Specifications (F4A42-2)

09432 - 33200 Removal of 4WD coupling flange oil seal

1. Reverse clutch 10. Torque converter

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.

Electric Control Location

Operating Components And Functions

Clutch To Clutch Shift Control

Skip Shift Control

Feedback Shift Control

Damper Clutch Control

Communication Speed: 15.625Kbit/sec

Input signals to TCM through 'CAN communication'

Terminal Number Wire Color Description

TCM Input/output Signal Voltage Check Sheet

Auto transaxle fluid:

Running conditions : "N" range with engine idling.

5. Pour the new fluid in through the oil filler tube.

Stop pouring if the full volume of fluid cannot be poured

How To Select Vehicle And System

2. Select "VEHICLE NAME"

8 3RD SHIFT INDICATOR LAMP

Torque Converter Stall Test

Hydraulic Pressure Test

Standard Hydraulic Pressure Test