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http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
BODY DIMENSION INDICATION
PROJECTED DIMENSIONS
The projected dimension indicates a dimension from a reference point on the body. (Height may be different in some cases)
STRAIGHT-LINE DIMENSIONS (ACTUAL MEASURED DIMENSIONS)
The straight-line dimension indicates an actual measured dimension between the measurement reference points.
UPPER BODY (FRONT BODY)
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Ebay User ID: reveleus1
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
No.
1
2
3
4
5
6
7
Email: suzlever@gmail.com
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8
9
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Dimensions
(mm)
No.
Dimensions
(mm)
Ebay User ID: reveleus1
1312
566
1330
566
1437
1053
10
11
12
13
14
15
1048
724
330
876
910
330
774
SIDE FRAME PANEL (4 DOOR)
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1042
1270
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Ebay User ID: reveleus1
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
No.
Dimensions
(mm)
No.
Dimensions
(mm)
1
2
3
4
5
6
7
8
9
1060
988
375
1026
1084
1095
1026
356
874
10
11
12
13
1357
921
1345
501
INTERIOR A (5 DOOR)
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Ebay User ID: reveleus1
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
No.
Dimensions
(mm)
1
2
3
4
5
6
7
8
9
1086
1354
1340
1212
1352
1202
1090
974
951
INTERIOR-A (4DOOR)
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
No.
1
2
3
4
5
Email: suzlever@gmail.com
6
7
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8
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Dimensions
(mm)
1086
1354
1340
Ebay User ID: reveleus1
1212
1352
1094
1362
INTERIOR-B (5 DOOR)
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?ve...2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (10 of 25)14/04/2009 9:23:08 AM
1090
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Ebay User ID: reveleus1
No.
1
2
3
4
5
6
7
Email: suzlever@gmail.com
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8
9
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Dimensions
(mm)
Ebay User ID: reveleus1
1052
960
1065
1065
1052
No.
10
11
12
13
14
Dimensions
(mm)
757
1644
1644
1186
1186
960
1097
INTERIOR-B (4 DOOR)
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?ve...2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (12 of 25)14/04/2009 9:23:08 AM
1097
757
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Ebay User ID: reveleus1
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
No.
1
2
3
4
5
6
7
8
9
1065
1065
1052
1052
960
960
1097
1097
757
No.
10
11
12
13
14
Dimensions
(mm)
757
1542
1542
1564
1564
Dimensions
(mm)
INTERIOR-C (5 DOOR)
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?ve...2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (14 of 25)14/04/2009 9:23:08 AM
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Ebay User ID: reveleus1
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
No.
1
2
3
4
5
6
7
8
9
1211
1211
1143
1143
883
883
585
585
966
No.
10
11
12
Dimensions
(mm)
966
991
991
Dimensions
(mm)
INTERIOR-C (4 DOOR)
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?ve...2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (16 of 25)14/04/2009 9:23:08 AM
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Ebay User ID: reveleus1
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
No.
Dimensions
(mm)
No.
Dimensions
(mm)
1
2
3
4
5
6
7
8
9
1643
1643
2064
2064
2034
2034
1211
1211
1143
10
11
12
13
14
1143
925
925
778
778
REAR BODY (5 DOOR)
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?ve...2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (18 of 25)14/04/2009 9:23:08 AM
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Ebay User ID: reveleus1
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
No.
Dimensions
(mm)
1
2
3
4
5
6
7
8
9
566
1074
677
1189
668
1189
644
644
930
REAR BODY (4 DOOR)
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?ve...2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (20 of 25)14/04/2009 9:23:08 AM
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Ebay User ID: reveleus1
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?ve...2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (21 of 25)14/04/2009 9:23:08 AM
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Ebay User ID: reveleus1
No.
1
2
3
4
5
6
7
8
9
Dimensions
(mm)
900
723
716
944
497
486
1028
1028
422
No.
10
11
Dimensions
(mm)
422
930
UNDER BODY (PROJECTED DIMENSIONS)
Measurement Points
Description
Size of hole
A
Tension rod mounting hole of No. 1 Crossmember
Ø 12 mm
B
Tension rod mounting hole of front sub frame
Ø 12 mm
C
Front lower frame hole
Ø 20 mm
D
Front lower frame hole
Ø 16 mm
E
Front frame B hole
Ø 15 mm
F
Spring seat mounting hole of rear side frame
Ø 14 mm
G
Rear side frame B hole
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Ø 18×20 mm
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Ebay User ID: reveleus1
UNDER BODY (STRAIGHT-LINE DIMENSIONS)
Measurement Points
Description
Email: suzlever@gmail.com
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Size of hole
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A
Ebay
User
Tension rod mounting
hole
of ID:
No.reveleus1
1 Crossmember
Ø 12 mm
B
Tension rod mounting hole of front sub frame
Ø 12 mm
C
Front lower frame hole
Ø 20 mm
D
Front lower frame hole
Ø 16 mm
E
Front frame B hole
Ø 15 mm
F
Spring seat mounting hole of rear side frame
Ø 14 mm
G
Rear side frame B hole
Email: suzlever@gmail.com
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Ø 18×20 mm
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
COMPONENTS
CRASH PAD
DUCTS
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (1 of 2)14/04/2009 9:28:01 AM
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Ebay User ID: reveleus1
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (2 of 2)14/04/2009 9:28:01 AM
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Ebay User ID: reveleus1
REMOVAL
ASHTRAY
1. Remove ashtray from center panel trim.
2. Install ashtray in center panel trim.
CENTER PANEL TRIM
1. Remove ash tray.
2. Remove one screw from center panel trim.
3. Disconnect harness connector from rear of center panel trim.
4. Pull out center panel trim.
REMOVAL
FRONT CONSOLE
1. Remove cover and mounting bolt from rear console.
2. Remove rear console.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (1 of 7)14/04/2009 9:28:20 AM
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3. Remove center panel trim. Refer to "Center panel
trim"ID:
in reveleus1
this section.
Ebay User
4. Remove two mounting screws and two fasteners from left side of front console.
5. Repeat for right side.
6. Remove front console.
REMOVAL
INSTRUMENT PANEL
1.
2.
3.
4.
Remove center panel trim. Refer to center panel trim in this section.
Remove console. Refer to "Console" in this section.
Remove driver air bag module. Refer to "Driver Air Bag Module" in this section.
Remove steering wheel, turn signal assembly, and upper/lower column covers. Refer to Group ST, Steering
System.
5. Remove hood release handle lock nut, hood release handle and cable assembly nut.
6. Remove two mounting bolts and side cover from left side of T-bar.
7. Remove two mounting bolts from left side of instrument panel as shown.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (2 of 7)14/04/2009 9:28:20 AM
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8. Remove four mounting screws from radio. Ebay User ID: reveleus1
9. Disconnect electrical connector for rear of radio.
10. Remove antenna cable for rear of radio.
11. Remove radio.
12. Remove ventilation control panel. Refer to "Ventilation Control Panel" in this section.
13. Remove glove box.
14. Remove passenger air bag module. Refer to "Passenger Air Bag Module" in this section.
15. Remove two mounting bolts and side cover on right side of T-bar as shown.
16. Remove two mounting bolts from right of instrument panel assembly as shown.
17. Remove one mounting bolt and cover at middle of top of instrument panel.
18. Remove two mounting bolts on either side of steering column, which hold instrument panel and steering
column together. Lower steering column to floor level.
19. Disconnect all connectors between instrument panel and vehicle bulkhead electrical wire harness.
20. Remove instrument panel.
REMOVAL
VENTILATION CONTROL PANEL
1. Remove center panel trim. Refer to "Center panel Trim" in this section.
2. Remove four mounting screws.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (3 of 7)14/04/2009 9:28:20 AM
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3. Remove ventilation control panel from mounting
Ebayspace.
User ID: reveleus1
4. Disconnect harness connector from rear of unit.
5. Remove glove box.
6. Remove temperature cable and mode cable from heater unit by carefully depressing plastic retaining tab and
remove cable from retaining clip. Refer to Group HA, Heating, Ventilation and Air conditioning.
7. Remove ventilation control panel from instrument panel.
REMOVAL
DUCTS
1.
2.
3.
4.
5.
Remove mounting screws holding duct parts to instrument panel.
Remove LH side defroster duct and LH defrost grille.
Remove RH side defroster duct and RH defrost grille.
Remove LH air duct.
Remove RH air duct.
REMOVAL
HOOD RELEASE CABLE
1.
2.
3.
4.
5.
6.
7.
Remove hood release handle. Refer to "Hood Release Handle" in this section.
Remove nut holding hood release cable in place at LH side of instrument panel.
Feed hood release cable through bulkhead.
Release clips holding hood release cable in place along top portion of engine compartment.
Remove hood release cable from position along left top portion of engine compartment.
Remove end of hood release cable from hood release on front portion of engine compartment.
Repair or replace hood release cable as necessary.
REMOVAL
HOOD RELEASE HANDLE
1. Remove hood release handle locknut.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (4 of 7)14/04/2009 9:28:20 AM
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2. Remove hood release handle.
Ebay User ID: reveleus1
INSTALLATION
CENTER PANEL TRIM
1.
2.
3.
4.
Connect harness connector to rear of center panel trim.
Mount trim in position.
Install one screw to center panel trim.
Install ashtray.
INSTALLATION
FRONT CONSOLE
1. Position front console and install two mounting screws and two fasteners.
2. Position rear console.
3. Install one mounting bolt and cover to rear coÓsole.
4. Install center panel trim. Refer to "Center panel trim" in this section.
INSTALLATION
INSTRUMENT PANEL
1. Mount instrument panel into position.
Make sure steering column is mounted correctly through T-bar with electrical wire harness in position before
attempting to position instrument panel in place. If this is not done, column cannot be positioned correctly.
2. Connect linking connectors between vehicle electrical wire harness and instrument panel.
Each connector is keyed so an electrical harness connector mates with correct instrument panel connector.
3. Install two mounting bolts, one on either side of steering column, which hold instrument panel and steering
column together.
Tighten bolts to 13~19 lb·ft (18~26 N·m, 1.8~2.7 kg·m)
Email: suzlever@gmail.com
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4. Install one mounting bolt and cover.
Ebay User ID: reveleus1
5. Install three mounting bolts to right side of instrument panel as shown.
Tighten bolts to 13~19 lb·ft (18~26 N·m, 1.8~2.7 kg·m)
6. Install two mounting bolts on right side of instrument panel as shown.
Tighten bolts to 13~19 lb·ft (18~26 N·m, 1.8~2.7 kg·m)
7. Install passenger air bag module. Refer to "Passenger Air Bag Module" in this section.
Tighten bolts to 13~19 lb·ft (18~26 N·m, 1.8~2.7 kg·m)
8. Install glove box.
9. Install ventilation control panel. Refer to "Ventilation Control Panel" in this section.
10. Install antenna cable to rear of radio.
11. Connet electrical connector to rear of radio.
12. Install four mounting screws to radio.
13. Install two mounting bolts to left side of instrument panel.
Tighten bolts to 13~19 lb·ft (18~26 N·m, 1.8~2.7 kg·m)
14. Install two bolts and side cover on left side of T-bar.
Tighten bolts to 13~19 lb·ft (18~26 N·m, 1.8~2.7 kg·m)
15. Install retaining nut holding hood release cable in position.
16. Install hood release handle. Refer to "Hood Release Handle" in this section.
17. Install steering wheel, turn signal assembly and upper/lower column covers. Refer to group ST, Steering
System.
18. Install driver air bag module. Refer to "Driver Air Bag Module" in this section.
19. Install console. Refer to "Console" in this section.
20. Install center panel trim. Refer to "Center panel trim" in this section.
21. Install negative cable onto battery terminal.
INSTALLATION
VENTILATION CONTROL PANEL
1. Mount ventilation control panel in position in instrument panel.
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2.
3.
4.
5.
6.
Depress plastic tab on heater assembly and Ebay
connect
cable and mode cable in place in retaining clip.
Usertemperature
ID: reveleus1
Install glove box.
Connect harness connector to rear of ventilation control panel.
Mount ventilation control panel into position and install four mounting screws.
Install center panel trim. Refer to "Center Panel Trim" in this section.
INSTALLATION
DUCTS
1.
2.
3.
4.
5.
Install RH air duct.
Install LH air duct.
Install RH side defroster duct and RH defrost grille.
Install LH side defroster duct and LH defrost grille.
Install mounting screws holding duct parts to instrument panel.
INSTALLATION
HOOD RELEASE CABLE
1.
2.
3.
4.
5.
Install hood release cable to hood release on front portion of engine compartment.
Route and clip hood release cable along pathway from hood release to bulkhead.
Feed hood release cable through bulkhead into interior of vehicle.
Install mounting nut to secure hood release cable to instrument panel.
Install hood release handle. Refer to "Hood Release Handle" in this section.
INSTALLATION
HOOD RELEASE HANDLE
1. Install hood release handle.
2. Install hood release handle locknut.
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COMPONENTS
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
DESCRIPTION AND OPERATION
Front and rear bumpers consist of three parts; bumper face, energy absorbing foam, and bumper reinforcement.
The bumperface is made of polypropylene and the absorption medium is styrofoam. Reinforcement is constructed
of metal with energy absorbing foam placed between bumper face and the reinforcement.
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REMOVAL
1. Remove two nuts and four fasteners from top of the bumper.
2. Remove three bolt and four fasteners from air guide.
3. Remove air guide.
4. Remove three fasteners from right mud guard.
5. While pulling right mud guard, remove one screw from side of bumper.
6. Repeat for left side.
7. Remove two bolts from the left-hand bumper support bracket.
8. Repeat for the right side.
9. Remove bumper assembly.
INSTALLATION
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Install front bumper in reverse order of removal.Ebay User ID: reveleus1
Tighten bumper mounting bolts to 23~34 lb·ft (32~47 N·m, 3.2~4.7 kg·m)
REMOVAL AND REPLACEMENT PROCEDURE
1.
2.
3.
4.
5.
6.
7.
Remove fasteners from face and reinforcement while bumper is on work bench.
Remove reinforcement and inspect bumper face for damage. Replace as required.
Remove foam and inspect foam for damage or deterioration. Replace as required.
Inspect reinforcement for damage. Replace as required.
Install foam.
Install reinforcement.
Install fasteners that secure reinforcement to bumper face.
INSPECTION
1. Inspect front bumper face for damage and check that front bumper is securely mounted.
2. Inspect front bumper for missing attaching hardware.
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COMPONENTS
FRONT DOOR
WINDOW SYSTEM
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Ebay User ID: reveleus1
Email: suzlever@gmail.com
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DESCRIPTION AND OPERATION
Vehicle door is attached to vehicle body by two hinges and a door checker. Door checker limits amount of swing of
the vehicle door. A hollow rubber weatherstrip is installed on the door opening flange to prevents leaks between
vehicle door and inside of vehicle body. The door lock assembly is linked with outside and inside door handle.
The window system is comprised of a window regulator assembly (on which glass is fastened) and a front glass
guide (which guides movement of the window).
A plastic door screen covers door frame, protecting all components. The door striker may be adjusted for proper
operation and easy door closure.
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REMOVAL
FRONT DOOR
1. Disconnect negative battery cable.
2. Remove door trim. Refer to "Trim" in this section.
3. Remove one screw on pull handle bracket.
4. Remove pull handle bracket.
5. Remove door speaker.
A.emove three screws on door speaker.
B.Unfasten harness connector from door frame.
C.Pull out speaker and disconnect connectors.
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6. Remove inside door handle.
Ebay User ID: reveleus1
A.Remove one screw from inside door handle.
B.Disconnect one control rod.
C.Remove inside door handle.
7. Peel off plastic door screen carefully by pulling it away gradually from door frame.
8. Remove window glass.
A.Remove two glass mounting bolts from window regulator.
B.Remove glass carefully; hold glass from both its inner and outer surfaces. While tilting it toward hinge side of
door, pull it out from outside door frame.
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9. Remove regulator assembly.
Ebay User ID: reveleus1
A.Remove seven nuts on door frame.
B.Remove regulator assembly from out of access hole.
10. Remove run channel.
11. Remove door lock assembly.
A.Disconnect two remote control rods from door lock assembly.
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Ebay User
reveleus1
B.Remove three screws from door lock assembly
andID:
remove
assembly from access hole.
C.Remove two mounting nuts from outside door handle.
D.Remove outside door handle.
12. Remove rearview mirror from door.
A.Disconnect electrical connector.
B.Remove three mounting bolts and rearview mirror.
13. Remove wiring harness.
A.Disconnect harness connectors from inner door frame.
B.Pull out wiring harness from access hole.
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14. Remove door checker installation bolt from Ebay
body.User ID: reveleus1
15. Remove door by removing bolts on both hinges.
REMOVAL
DOOR OPENING WEATHERSTRIP
1. Remove front door scuff plate, and A pillar trim. Refer to "Trim" in this section.
2. Remove door opening weatherstrip from door opening flange.
REMOVAL
WINDOW REGULATOR
1. Disconnect negative battery cable.
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2. Remove door trim. Refer to "Trim" in this section.
Ebay User ID: reveleus1
3. Remove one screw on pull handle bracket.
4. Remove pull handle bracket.
5. Remove speaker.
A.Remove three screws on door speaker.
B.Unfasten harness connector from door frame.
C.Pull out speaker and disconnect connectors.
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6. Peel off plastic moisture barrier carefully by pulling
it away
gradually from door frame.
Ebay User
ID: reveleus1
7. Remove window glass.
A.Remove two glass mounting bolts from window regulator.
B.Remove glass carefully. Hold glass from both its inner and outer surfaces while tilting it toward hinge side of
door, pull it out from outside door frame.
8. Remove window regulator assembly.
A.Remove seven nuts on door frame.
B.Remove window regulator assembly from out of access hole.
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Ebay User ID: reveleus1
9. Remove run channel.
REMOVAL
WINDOW GLASS
1. Disconnect negative battery cable.
2. Remove door trim. Refer to "Trim" in this section.
3. Remove one screw on pull handle bracket.
4. Remove pull handle bracket.
5. Remove speaker:
A.Remove three screws on door speaker.
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
B.Unfasten harness connector from door frame.
C.Pull out speaker and disconnect connectors.
6. Peel off plastic door screen carefully by pulling it away gradually from door frame.
7. Remove window glass:
A.Remove two glass mounting bolts from window regulator.
B.Remove glass carefully. Hold glass from both its inner and outer surfaces. While tilting it toward hinge side of
door, pull it out from outside door frame.
REMOVAL
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Ebay User ID: reveleus1
FRONT DOOR (TRUNK SIDE : 5 DOOR (INTERIOR))
1.
2.
3.
4.
5.
6.
7.
Remove two fasteners on trunk end trim.
Remove trunk end trim.
Remove two screws and one fastener from trunk side trim.
Remove one screw from striker.
Remove two mounting screws from holder.
Disconnect electrical connector.
Remove trunk side trim.
REMOVAL
TRUNK END TRIM (INTERIOR)
1. Remove two fasteners.
2. Unfasten trunk end trim.
3. Remove trunk end trim.
INSTALLATION
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FRONT DOOR
Ebay User ID: reveleus1
1. Install door.
A.Position door on vehicle properly.
B.Install bolts on both hinges.
Tighten door hinge bolts to 13~22 Ib·ft (18~30 N·m, 1.8~3.0 kg·m)
2. Install dust weatherstrip.
3. Install one bolt on door checker pin assembly.
4. Install wiring harness.
A.Position wiring harness in access hole.
B.Fasten harness connectors onto door frame.
5. Install rearview mirror on door.
A.Position rearview mirror on door as originally positioned.
B.Install three mounting bolts.
C.Connect electrical connector.
6. Install door lock assembly.
A.Position it as originally positioned through access hole.
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B.Install three mounting screws.
Ebay User ID: reveleus1
7. Install outside door handle.
A.Connect two control rods of door lock assembly.
B.Install two mounting nuts.
8. Install run channel. Use soap and water for lubrication.
9. Install regulator assembly.
A.Position regulator assembly through access hole.
B.Install seven mounting nuts.
Tighten mounting nuts to 78~113 Ib·in (9~13 N·m, 90~130 kg·cm)
Email: suzlever@gmail.com
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10. Install window glass.
Ebay User ID: reveleus1
A.Position glass carefully:
Hold glass from both its inner and outer surfaces. While tilting it towards hinge side of door, place it on small
bracket on window regulator assembly.
B.Loosely install two glass mounting bolts on window regulator assembly.
C.Tighten two glass mounting bolts on window regulator assembly.
Tighten two bolts to 17~26 Ib·in (2~3 N·m, 20~30 kg·cm)
D.Position window all way down.
11. Install plastic door screen.
A.Fasten plastic door screen.
B.Pull out electrical harness connector from plastic door screen.
C.Pull out remote control rod for inside door handle from plastic door screen.
12. Install inside door handle.
A.Connect one control rod of door lock assembly.
B.Install one mounting screw.
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Ebay User ID: reveleus1
13. Install door speaker with three mounting screws.
14. Install pull handle bracket with one mounting screw.
15. Install door trim.
16. Install inner door handle assembly.
17. Fasten door trim. Refer to "Trim" in this section.
18. Install inner weatherstrip.
19. Connect negative battery cable.
INSTALLATION
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DOOR OPENING WEATHERSTRIP
Ebay User ID: reveleus1
1. Position weatherstrip on door opening flange and press it in.
2. Start at one corner and work around entire edge of door opening.
3. Install front door scuff plate, and A-pillar trim. Refer to "Trim" in this section.
INSTALLATION
WINDOW REGULATOR
1. Install run channel.
2. Install glass guide.
A.Position glass guide as originally installed through access hole.
B.Install one bolt loosely.
3. Install window regulator assembly.
A.Position window regulator assembly as originally installed throughaccess hole.
B.Install seven mounting nuts.
Tighten mounting nuts to 78~113 lb·in (9~13 N·m, 90~130 kg·cm)
4. Install window glass.
A.Position glass carefully. Hold glass from both its inner and outersurfaces, and while tilting it toward hinge side
of door, place it on smallbracket on window regulator assembly.
Email: suzlever@gmail.com
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Ebay
User ID:
reveleus1
B.Install two glass mounting bolts on window
regulator
assemblyloosely.
C.Tighten two glass mounting bolts on window regulator assembly.
Tighten two mounting bolts to 17~26 lb·in (2~3 N·m, 20~30 kg·cm)
5. Install plastic moisture barrier.
A.Fasten plastic moisture barrier as originally installed.
B.Pull out electrical harness connector from plastic moisture barrier.
C.Pull out two control rods for inside door handle from plasticmoisture barrier.
6. Install speaker with three mounting screws.
Email: suzlever@gmail.com
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7. Install pull handle bracket with one mountingEbay
screws.
User ID: reveleus1
8. Install door trim. Refer to "Trim" in this section.
INSTALLATION
WINDOW GLASS
1. Install window glass:
A.Position glass carefully. Hold glass from both its inner and outer surfaces. While tilting it toward hinge side of
door, place it on small bracket on window regulator assembly.
Email: suzlever@gmail.com
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B.Install two glass mounting bolts on window
regulator
assembly
loosely.
Ebay
User ID:
reveleus1
C.Tighten two glass mounting bolts on window regulator assembly.
Tighten two bolts to 17~26 Ib·in (2~3 N·m, 20~30 kg·cm)
2. Install plastic moisture barrier.
A.Fasten plastic moisture barrier as originally installed.
B.Pull out electrical harness connector from plastic moisture barrier.
C.Pull out two control rods for inside door handle from plastic moisture barrier.
3. Install speaker with three mounting screws.
4. Install pull handle bracket with one mounting screw.
Email: suzlever@gmail.com
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5. Install door trim. Refer to "Trim" in this section.
Ebay User ID: reveleus1
INSTALLATION
FRONT DOOR (TRUNK SIDE : 5 DOOR (INTERIOR))
1.
2.
3.
4.
Position trunk side trim.
Connect electrical connector.
Install holder and, striker to trunk side trim.
Install trunk end trim.
INSTALLATION
TRUNK END TRIM (INTERIOR)
1. Position trunk end trim.
2. Install two fastener to trunk end trim.
ADJUSTMENT
DOOR HINGE AND DOOR LOCK STRIKER
1. Check that door can be closed easily and properly. If door is loose, tighten door hinge installation bolts.
2. To adjust door-to-body offset, loosen door hinge installation bolts and make adjustment.
3. Check that door can be closed easily and properly. If there is a problem, loosen striker installation bolts and
adjust door by moving striker vertically and horizontally.
4. Adjust rear offset of door to body by moving door lock striker horizontally.
Email: suzlever@gmail.com
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COMPONENTS
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:36:39 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
DESCRIPTION
Safety belt system consists of five restraints. Outboard passengers(front and rear) have both shoulder and lap
safety belts. Inboard passenger(rear) has only a lap safety belt. Driver's safety belt is equipped with awarning light
on the instrument panel and an audible chime to remind driverto fasten safety belt. Warning ceases after
approximately 60 seconds. Thereare no warnings on other passengers' belts. Retractors are securely mountedto
body. Buckles are also securely mounted to floor.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:36:22 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
REMOVAL
FRONT BUCKLE ASSEMBLY
1. Remove screw cover near bottom of assembly.
2. Remove one bolt from mounting bracket.
REMOVAL
FRONT LAP/SHOULDER BELT
1. Remove one bolt from mounting bracket and remove bracket.
2. Retract belt slowly as far as it will go.
3. Unsnap captive shoulder belt anchor bolt cover from bottom and lift up.
4. Remove one anchor bolt.
5. Remove B-pillar lower trim panel.
Email: suzlever@gmail.com
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6. Remove one bolt and one sheet metal screwEbay
to remove
retractor
assembly.
User ID:
reveleus1
INSTALLATION
FRONT BUCKLE ASSEMBLY
1. Install one bolt through mounting bracket.
Tighten mounting bolt to 29~58 Ib·ft (38~78 N·m, 3.9~8.0 kg·m)
2. Install screw cover.
INSTALLATION
FRONT LAP/SHOULDER BELT
1. Install one bolt and one sheet metal screw to attach retractor assembly.
Tighten mounting bolt to 29~58 Ib·ft (38~78 N·m, 3.9~8.0 kg·m)
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
EXERCISE CARE TO INSTALL BELT SO THERE ARE NO TWISTS IN IT. A TWISTED BELT MAY BE
HARMFUL TO A PASSENGER IN A SERIOUS ACCIDENT. A TWISTED BELT ALTERS DISTRIBUTION
OF FORCE RESULTING FROM SUDDEN DECELERATION.
2. Install belt guide.
3. Install B-pillar upper trim.
4. Install B-pillar lower trim.
5. Install anchor bolt.
Tighten anchor bolt to 29~58 Ib·ft (38~78 N·m, 3.9~8.0 kg·m)
6. Install anchor bolt cover.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (3 of 4)14/04/2009 9:36:57 AM
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7. Install one bolt through lap belt mounting bracket.
Ebay User ID: reveleus1
Tighten bolt to 29~58 Ib·ft (38~78 N·m, 3.9~8.0 k·m)
INSPECTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
Inspect buckle assembly mounting to ensure that it is secure.
Inspect anchor assembly mounting to ensure that it is secure.
Remove B-pillar lower trim. Refer to "Trim" in this section.
Inspect retractor assembly mounting to ensure that it is secure.
Install B-pillar lower trim.
Extend safety belt fully to ensure its motion is smooth and easy.
Retract safety belt fully to ensure its motion is smooth and easy.
Buckle safety belt. Pull firmly on each side of buckle to ensure that it is secure.
Press buckle release button to ensure that it releases correctly and returns to its original position.
Do not disassemble either buckle or retractor assemblies. They are not repairable.
10. Inspect safety belt reminder system with driver's safety belt retracted. Turn ignition key to "ON" position. Safety
belticon on warning and indicator panel will light up and a chime will be heard. Lighted icon and chime indicate
that driver's safety belt is not buckled. Chime will not be heard after 5~6 seconds. Turn ignition key to "LOCK"
position. Safety belt icon and chime will extinguish. Turn key to "ON" position. Just as before, safety belt icon
will light up andchime will be heard. Buckle driver's safety belt. Safety belt icon and chime will extinguish. Turn
key to "LOCK" position and remove key.
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
COMPONENTS
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:34:41 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
DESCRIPTION AND OPERATION
Front seat consists of a seat back and a cushion. Both items are replaceable or serviceable. Both seats can be
reclinedor adjusted front-to-rear by two levers, reclining lever and adjusting lever. Head restraint can also be
adjusted or removed.
Seat adjuster lever is under right or left front corner of front seats. Pulling up this lever unlocks seat, allowing it to
slide forward or backward on a track attached to vehicle floor. Track assembly and seat adjuster lock are
replaceable items.
Reclining lever is placed on door side of either seat. If this lever is pulled up and pressure is placed on seatback,
seatback will recline. If no pressure is applied, seat will spring forward past vertical driving position. If pressure is
applied to seatback, it will recline to actual driving position and then lock. Reclining adjuster is a replaceable items.
Driver's seat is also equipped with lifter levers. This is controlled by levers on left side of driver's side seat cushion.
Lifter control levers are replaceable items.
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
REMOVAL
FRONT SEAT
1. Pull reclining lever and let seatback spring forward.
2. Pull seat adjuster and push seat all of the way back.
3. Remove front two mounting bolts.
4. Move seat forward.
5. Remove rear mounting bolt and nut.
6. Remove seat.
REMOVAL
FRONT SEATBACK COVER
1. Remove seat from vehicle.
2. Remove reclining lever knob.
3. From under seat, push in tabs holding screw caps and then remove caps.
4. Remove two screws on seat side cover.
Email: suzlever@gmail.com
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5. For driver's seat, remove lift knob cover, unscrew
one mounting
screw and remove lift knob.
Ebay User
ID: reveleus1
6. Remove side cover.
7. Remove headrest and pull off holding catches. Replace catches.
8. Remove hog rings on seatback cover.
9. Slide seat trim up and off seatback.
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
10. Reverse removal procedure.
FRONT SEAT CUSHION COVER
1. Remove reclining lever.
2. Remove hog rings on underside of seat cushion.
3. Pull cover off of foam cushion.
REMOVAL
HARDREST
1. Pull headrest up until it locks.
2. Release tab lock and pull headrest off seat.
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
REMOVAL
RECLINING KNUCKLE
1. Follow seatback cover removal steps 1-8.
2. Pull up trim until upper two knuckle mounting bolts are exposed.
3. Remove upper two hex head bolts and remove seatback.
4.
5.
6.
7.
Pull knuckle lever and push seat into reclining position.
Remove two lower knuckle hex head bolts.
Remove reclining knuckle.
Reverse removal procedures.
Tighten knuckle bolts to 25~41 Ib·ft (34~56 N·m, 3.5~5.7 kg·m)
INSTALLATION
FRONT SEAT
Email: suzlever@gmail.com
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Reverse removal procedures.
Ebay User ID: reveleus1
Tighten bolts to 28~38 Ib·ft (39~51 N·m, 3.9~5.2 kg·cm)
INSTALLATON
FRONT SEAT CUSHION COVER
1. Place cover over foam cushion.
2. Install hog rings.
3. Install reclining lever and seatback.
INSTALLATION
HEADREST
1. Insert headrest in holes and push down until it locks.
2. Release lock and adjust position for comfort.
INSPECTION
FRONT SEAT
1. Check that seat adjuster and reclining lever move smoothly.
2. Look under seat and visually check seat adjuster for wear or damage.
Email: suzlever@gmail.com
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3. Apply grease to all exposed moving parts. Ebay User ID: reveleus1
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
COMPONENTS
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:23:46 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
DESCRIPTION AND OPERATION
The vehicle hood is a front-opening type secured by a standard double-release latch. The hood release T-handle is
located below and to left of steering column. When the hood is opened, it pivots on two hinges and is held open by
a hood prop. The two hinges are secured to body with two bolts and to hood with two bolts on each hinge. The
hood alignment canbe adjusted fore-and-aft and side-to-side by loosening hood bolts and moving the hood as
necessary. The hood latch can be adjusted in both axes to match position of the permanently attached striker.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:23:26 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
REMOVAL
1. Raise hood and support with prop.
2. Support hood so it will not fall when hinges are removed.
Have an assistant help remove hood.
3. Remove hinges from hood by removing four bolts.
4. Remove prop from hood.
5. Remove hood.
INSTALLATION
Have an assistant help install hood.
1.
2.
3.
4.
Install in reverse order of removal.
Tighten four hinge bolts to just over finger-tight.
Lower and lock hood.
Check fit and adjust as required in accordance with illustrated specifications.
Tighten bolts to 14~19 lb·ft (19~26 N·m, 1.9~2.6 kg·m)
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (1 of 2)14/04/2009 9:24:04 AM
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5. Check alignment of locking mechanism and Ebay
hood User
striker
align as required.
ID:and
reveleus1
Tighten lock assembly bolts to 70~96 lb·in (8~11 N·m, 80~110 kg·cm)
Tighten lock assembly nuts to 70~96 lb·in (8~11 N·m, 80~110 kg·cm)
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (2 of 2)14/04/2009 9:24:04 AM
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Ebay User ID: reveleus1
COMPONENTS
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:29:41 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
REMOVAL
A-PILLAR TRIM
1. Unfasten A-pillar trim with a trim removal tool.
2. Remove A-pillar trim.
REMOVAL
B-PILLAR LOWER TRIM
1.
2.
3.
4.
Remove lower mounting bolt from safety belt anchor.
Remove front and Rear scuff plate. Refer to "Front, Rear scuff plate" in this section.
Unfasten B-pillar lower trim with a trim removal tool.
Remove B-pillar lower trim.
REMOVAL
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?ve...2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (1 of 12)14/04/2009 9:30:01 AM
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B-PILLAR UPPER TRIM
Ebay User ID: reveleus1
1. Removal lower maunting bolt from safety belt anchor.
2. Remove front and rear scuff plate. Refer to "Front, Rear scuff plate" in this section.
3.
4.
5.
6.
Unfasten B-pillar lower trim with a trim removal tool.
Remove B-pillar lower trim.
Remove upper mounting bolt from safety belt anchor.
Remove B-pillar upper trim with a trim removal tool.
REMOVAL
C-PILLAR TRIM : 4 DOOR
1.
2.
3.
4.
Remove rear seat cushion and seat back. Refer to "Seat" in this section.
Remove Package trim. Refer to "Package trim" in this section.
Remove tire house trim. Refer to "Tire house trim" in this section.
Unfasten C-pillat trim.
Email: suzlever@gmail.com
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5. Remove C-pillar trim.
Ebay User ID: reveleus1
REMOVAL
C-PILLAR : 5 DOOR
1.
2.
3.
4.
Remove trunk end trim.
Remove trunk side trim.
Remove tire house trim.
Remove upper anchor bolt from seat belt.
5. Remove two screws from C-pillar trim.
6. Unfasten C-pillar trim.
7. Remove C-pillar trim.
REMOVAL
FOOTREST TRIM
1. Remove upper nut and rubber cap of footrest trim.
2. Remove lower rubber cap.
3. Remove one lower nut.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?ve...2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (3 of 12)14/04/2009 9:30:01 AM
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4. Remove footrest trim.
Ebay User ID: reveleus1
REMOVAL
FRONT DOOR TRIM
1. Remove inner garnish.
2. Remove one screw on inside door handle.
3. Remove one screw on door pull handle .
Email: suzlever@gmail.com
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4. Remove door pull handle .
Ebay User ID: reveleus1
5. Remove three screws from front door trim.
6. Remove one screw on right side of front trim.
7. Remove snap ring and regulator handle from front door trim.
8. Unfasten front door trim with a trim removal tool.
9. Remove front door trim by lifting front door trim up.
REMOVAL
FRONT SCUFF PLATE
1. Remove four fasteners on front scuff plate.
2. Unfasten front scuff plate with trim removal tool.
3. Remove front scuff plate.
REMOVAL
REAR DOOR TRIM
Email: suzlever@gmail.com
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1. Remove one screw on inside door handle. Ebay User ID: reveleus1
2.
3.
4.
5.
6.
7.
Remove one screw on door pull handle.
Remove door handle pull.
Remove snap ring and regulator handle from rear door trim.
Remove regulator handle.
Remove three screws from right side and bottom side of rear door trim.
Unfasten rear door trim with trim removal tool.
REMOVAL
REAR HATCH TRIM
1. Remove hi-mounting brake light assembly. Refer to "Exterior right" in this section.
2. Remove two mounting screws and cover from assist handle.
3. Remove assist handle.
Email: suzlever@gmail.com
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Ebay User ID: reveleus1
4. Unfasten rear hatch trim.
5. Remove rear hatch trim.
REMOVAL
REAR SCUFF PLATE
1. Remove two fasteners from rear scuff plate.
2. Unfasten rear scuff plate.
3. Remove rear scuff plate.
REMOVAL
PACKAGE TRIM
1.
2.
3.
4.
5.
6.
Remove high-mounted brake light assembly.
Remove tire house trim. Refer to "Tire house trim" in this section.
Remove two child restraint anchorage.
Remove four screws on Package trim.
Unfasten Package trim.
Remove Package trim.
REMOVAL
TIRE HOUSE TRIM : 4 DOOR
1.
2.
3.
4.
Remove rear seat cushion and seatback. Refer to "Seat" in this section.
Remove two fasteners on rear scuff plate.
Remove rear scuff plate.
Remove three fasteners.
Email: suzlever@gmail.com
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5. Remove tire house trim.
Ebay User ID: reveleus1
REMOVAL
TIRE HOUSE TRIM : 5 DOOR
1.
2.
3.
4.
Remove trunk end trim, trunk side trim and Rear scuff plate. Refer to "Trim" in this section.
Remove cover from tire house trim.
Remove one screw.
Remove tire house trim.
INSTALLATION
A-PILLAR TRIM
1. Position A-pillar trim.
2. Press A-pillar trim into fasten clips.
INSTALLATION
Email: suzlever@gmail.com
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B-PILLAR LOWER TRIM
1.
2.
3.
4.
Ebay User ID: reveleus1
Position B-pillar lower trim.
Press B-pillar lower trim in to fasten clips.
Install lower mounting bolt to seat belt anchor.
Install front and rear scuff plate.
INSTALLATION
B-PILLAR UPPER TRIM
1. Position B-pillar upper trim
2. Install safety belt anchor:
A.Install one bolt on seat belt anchor.
Tighten mounting bracket bolt to 29~58 Ib·ft (38~78 N·m, 3.9~8.0 kg·m)
B.Fasten safety belt.
3. Position B-pillar lower trim.
4. Press B-pillar lower trim.
5. Install safety belt anchor.
Tighten mounting bracket bolt to 29~58 Ib·ft (38~78 N·m, 3.9~8.0 kg·m)
INSTALLATION
C-PILLAR TRIM : 4 DOOR
1. Position C-pillar trim and press in.
Email: suzlever@gmail.com
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2. Install tire house trim. Refer to "Tire house trim"
this ID:
section.
EbayinUser
reveleus1
3. Install Package trim. Refer to "Package trim" in this section.
4. Install rear seat back and seat cushion. Refer to "Seat" in this section.
INSTALLATION
C-PILLAR : 5 DOOR
1.
2.
3.
4.
5.
6.
Position C-pillar trim and press in.
Install to screws to C-pillar trim.
Install upper anchor bolt to seat belt.
Install tire house trim.
Install trunk side trim.
Install trunk end trim.
INSTALLATION
FOOTREST TRIM
1.
2.
3.
4.
Position footrest trim.
Install one lower nut.
Install lower rubber cap.
Install one upper nut and rubber cap.
INSTALLATION
FRONT DOOR TRIM
1. Place front door trim.
2.
3.
4.
5.
6.
7.
Install regulator handle to front door trim.
Install one screw to right side of front trim.
Install three screws to front trim.
Install one screw to door pull handle.
Install one screw to inside door handle.
Install inner garnish.
INSTALLATION
FRONT SCUFF PLATE
1. Position front scuff plate.
2. Press in front scuff plate in to fasten clips.
3. Install four fasteners to front scuff plate.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?ve...2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (10 of 12)14/04/2009 9:30:01 AM
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INSTALLATION
Ebay User ID: reveleus1
REAR DOOR TRIM
1. Install rear door trim.
2. Install inside door handle.
3. Install one screw on inside door handle.
4. Install door pull handle.
5. Install one screw on door pull handle.
6. Install three screws at right side and bottom side of rear door trim.
INSTALLATION
REAR HATCH TRIM
1. Position rear hatch trim.
2. Install assist handle
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?ve...2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (11 of 12)14/04/2009 9:30:01 AM
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3. Install high-mounted brake light assembly. Ebay User ID: reveleus1
INSTALLATION
REAR SCUFF PLATE
1. Position rear scuff plate.
2. Press in rear scuff plate.
3. Install two fasteners to rear scuff plate.
INSTALLATION
PACKAGE TRIM
1.
2.
3.
4.
Position Package trim.
Install four screws and two child restraint anchorage.
Install tire house trim.
Install hi-mounted brake light assembly.
INSTALLATION
TIRE HOUSE TRIM : 4 DOOR
1.
2.
3.
4.
Position tire house trim.
Install three fasteners.
Install rear scuff plate.
Install rear seat cushion and seatback. Refer to "Seat" in this section.
INSTALLATION
TIRE HOUSE TRIM : 5 DOOR
1. Position tire house trim.
2. Install onescrew and cover to tire house trim.
3. Install rear scuff plate, trunk side trim and trunk end trim. Refer to "Trim" in this section.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?ve...2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (12 of 12)14/04/2009 9:30:01 AM
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Ebay User ID: reveleus1
COMPONENTS
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:27:23 AM
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Ebay User ID: reveleus1
DESCRIPTION AND OPERATION
Outside rearview mirror assembly is comprised of mirror glass, a mirror frame (which holds mirror glass), a motor,
a wire harness, and garnish. Each outside rearview mirror can be adjusted in four directions from inside vehicle.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:27:09 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
REMOVAL
1. Disconnect negative battery cable.
2. Remove garnish.
3. Remove three rearview mirror assembly retaining bolts.
4. Pull out outside rearview mirror assembly and disconnect harness connector.
5. Remove outside rearview mirror assembly.
INSTALLATION
1. Position outside rearview mirror assembly on door.
2. Install three retaining bolts.
3. Connect harness connector.
4. Install garnish.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (1 of 2)14/04/2009 9:27:37 AM
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5. Connect negative battery cable.
Ebay User ID: reveleus1
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (2 of 2)14/04/2009 9:27:37 AM
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Ebay User ID: reveleus1
COMPONENTS(4 DOOR)
COMPONENTS(5 DOOR)
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (1 of 2)14/04/2009 9:33:49 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (2 of 2)14/04/2009 9:33:49 AM
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Ebay User ID: reveleus1
DESCRIPTION AND OPERATION
Front and rear bumpers consist of three parts; bumper face, energy absorbing foam, and bumper reinforcement.
The bumperface is made of polypropylene and the absorption medium is styrofoam. Reinforcement is constructed
of metal with energy absorbing foam placed between bumper face and the reinforcement.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:33:31 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
REMOVAL
1.
2.
3.
4.
5.
Remove three screws that secure left rear mud flap to mud guard.
Remove right mud flap.
Remove three screws that secure right rear mud flap to mud guard.
Remove one screw from right side of bumper.
Repeat for left side.
6. Remove two nuts from left side in trunk.
7. Repeat for right side.
8. Remove eight fasteners from top of bumper.
9. Remove two bolts from left rear bumper stay.
10. Repeat for right side.
11. Remove rear bumper.
INSTALLATION
Install in reverse order of removal.
Tighten bumper mounting bolts to 23~34 lb·ft (32~47 N·m, 3.2~4.7 kg·m)
REMOVAL AND REPLACEMENT PROCEDURE
1.
2.
3.
4.
Remove fasteners on face and reinforcement.
Inspect bumper face for damage. Replace as required.
Inspect energy absorbing foam for damage or deterioration. Replace as required.
Inspect reinforcement for damage. Replace as required.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (1 of 2)14/04/2009 9:34:03 AM
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5. Install fasteners on face and reinforcement. Ebay User ID: reveleus1
INSPECTION
1. Inspect rear bumper face for damage and check that it is securely mounted.
2. Inspect rear bumper for missing attaching hardware.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (2 of 2)14/04/2009 9:34:03 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
COMPONENTS
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:26:30 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
DESCRIPTION AND OPERATON
Vehicle door is attached to vehicle body by two hinges and a door checker. Door checker limits amount of swing of
the vehicle door. A hollow rubber weatherstrip is installed on the door opening flange to prevents leaks between
vehicle door and inside of vehicle body. The door lock assembly is linked with outside and inside door handle.
The window system is comprised of a window regulator assembly (on which glass is fastened) and a front glass
guide (which guides movement of the window).
A plastic door screen covers door frame, protecting all components. The door striker may be adjusted for proper
operation and easy door closure.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:26:14 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
REMOVAL
1.
2.
3.
4.
5.
Remove one screw on outside belt weatherstrip.
Remove outside belt weatherstrip.
Remove door trim. Refer to "Trim" in this section.
Remove one screw on pull handle bracket.
Remove pull handle bracket.
6. Remove inside door handle assembly.
A.Remove one screw from inside door handle.
B.Disconnect two control rods.
C.Remove inside door handle assembly.
7. Peel off plastic door screen carefully by pulling it away gradually from door frame.
8. Remove glass run channel.
9. Remove one screw and one bolt from center channel.
10. Remove center channel.
11. Remove quarter glass
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (1 of 7)14/04/2009 9:26:46 AM
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12. Remove window glass :
Ebay User ID: reveleus1
A.Remove two glass retaining bolts on regulator assembly
B.Remove door glass carefully. Hold glass from both its inner and outer surfaces. While tilting it toward hinge
side of door, pull it out from outside door frame.
13. Remove two nuts on outside door handle from access hole.
14. Remove outside door handle.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (2 of 7)14/04/2009 9:26:46 AM
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15. Remove three screws on door lock assembly.
Ebay User ID: reveleus1
16. Remove door lock assembly from access hole.
17. Remove six nuts on window regulator assembly.
18. Remove window regulator assembly from access hole.
19. Remove wire harness from access hole towards hinge side of door.
20. Remove outside molding around window opening.
21. Remove door checker assembly.
A.Remove one bolt on checker pin assembly.
B.Remove checker pin assembly from access hole.
22. Remove door:
A.Remove bolts on both hinges.
B.Remove door.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (3 of 7)14/04/2009 9:26:46 AM
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Ebay User ID: reveleus1
INSTALLATION
1. Install door.
A.Position door on vehicle properly.
B.Install bolts on both hinges.
Tighten door hinge bolts to 13~22 lb·ft (18~30 N·m, 1.8~3.0 kg·m)
2. Install door checker pin assembly.
A.Position checker pin assembly through access hole.
B.Install one bolt.
3.
4.
5.
6.
Install outside molding around window opening.
Position wire harness from hinge side of door.
Position regulator assembly.
Install six nuts on window regulator assembly.
Tighten six nuts to 78~113 lb·in (9~13 N·m, 90~130 kg·cm)
7. Position door lock assembly from access hole.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (4 of 7)14/04/2009 9:26:46 AM
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8. Install three screws on door lock assembly. Ebay User ID: reveleus1
9. Position outside door handle.
10. Install two nuts on outside door handle from access hole.
11. Connect outside door handle rod of door lock assembly to outside door handle.
12. Install glass piece carefully.
A.Use lubricant around window opening edges.
B.Hold glass from both its inner and outer surfaces. While tilting it towards hinge side of door, push it in from
outside door frame and place on glass mounting bracket of regulator assembly.
Make sure that glass edges are properly fitted into window edges.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (5 of 7)14/04/2009 9:26:46 AM
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Ebay User ID: reveleus1
13. Install two glass mounting bolts on window regulator.
Tighten two bolts to 17~26 lb·in (2~3 N·m, 20~30 kg·cm)
14. Make glass adjustments as necessary.
15. Install quarter glass.
16. Install center channel.
17. Install glass run channel.
18. Install plastic screen on door frame, make sure to pull out door lock knob rod and inside door handle rod of
door lock assembly from plastic screen.
19. Install inside door handle.
A.Connect two control rods of door lock assembly.
20. Install pull handle bracket.
A.Position pull handle bracket.
B.Install one mounting screw.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (6 of 7)14/04/2009 9:26:46 AM
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21. Install trim. Refer to "Trim" in this section. Ebay User ID: reveleus1
22. Install outside belt weatherstrip.
23. Move window glass to maximum upper position.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (7 of 7)14/04/2009 9:26:46 AM
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Ebay User ID: reveleus1
COMPONENTS
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:37:35 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
DESCRIPTION
Safety belt system consists of five restraints. Outboard passengers(front and rear) have both shoulder and lap
safety belts. Inboard passenger(rear) has only a lap safety belt. Driver's safety belt is equipped with awarning light
on the instrument panel and an audible chime to remind driverto fasten safety belt. Warning ceases after
approximately 60 seconds.There are no warnings on other passengers' belts. Retractors are securely mountedto
body. Buckles are also securely mounted to floor.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:37:19 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
REMOVAL
REAR BUCKLE
1. Pull safety belts to rear through seats.
2. Fold seat forward and secure.
3. Remove one bolt from rear buckle assembly mounting bracket.
REMOVAL
REAR LAP/SHOULDER BELT
1. Remove rear seat cushion.
2. Remove one bolt from lap belt mounting bracket.
3. Retract belt slowly as far as belt will go.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (1 of 4)14/04/2009 9:37:52 AM
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4. Remove high-mounted brake light assembly.Ebay
Refer
to "Exterior
lights" in this section.
User
ID: reveleus1
5. Remove three mounting bolts from rear seat back.
6. Remove seat back.
7. Remove package trim. Refer to "Trim" in this section
8. Remove C-pillar trim. Refer to "Trim" in this section.
9. Remove two mounting bolt from belt retractor.
10. Remove seat belts retractor.
INSTALLATION
REAR BUCKLE
1. Install mounting bolt through bracket.
Tighten mounting bolt to 29~58 Ib·ft (38~78 N·m, 3.9~8.0 kg·m)
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (2 of 4)14/04/2009 9:37:52 AM
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Ebay User ID: reveleus1
2. Feed buckle between seatback and cushion without any twists.
INSTALLATION
REAR LAP/SHOULDER BELT
1. Install retractor mounting bolt and sheet metal screw.
Tighten mounting bolt to 29~58 Ib·ft (38~78 N·m, 3.9~8.0 kg·m)
2.
3.
4.
5.
Install C-pillar trim.
Install package trim.
Install high-mounted brake light assembly.
Install rear seat back.
6. Install one bolt through lap belt mounting bracket.
Tighten mounting bracket bolt to 29~58 Ib·ft (38~78 N·m, 3.9~8.0 kg·m)
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (3 of 4)14/04/2009 9:37:52 AM
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7. Install rear seat cushion.
Ebay User ID: reveleus1
INSPECTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
Inspect three buckle assembly mountings to ensure that they are secure. (This is done from rear of vehicle.)
Inspect remaining belt's mounting to ensure that it is secure. (This is done from rear of vehicle.)
Pull safety belts to rear between seatback and cushion.
Remove seat cushion.
Inspect outboard lap belt mountings to ensure that they are secure.
Disconnect fasteners of C-pillar trim from body and pull C-pillar trim down completely.
Fold rear seatback forward for front side of seat cushion.
Remove package tray.
Inspect retractor assembly mountings to ensure that they are secure
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?veh...E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24 (4 of 4)14/04/2009 9:37:52 AM
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Ebay User ID: reveleus1
COMPONENTS
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:35:40 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
DESCRIPTION AND OPERATION
5 DOOR
The rear seat consist of two separate seatbacks and a seat cushion.
Seat cushion is mounted on vehicle frame by two bolts.
Two seatbacks are attached to vehicle frame by mounted hinge bushing and brackets.
Seatbacks of rear seat are locked to vehicle frame by seatback strikers.
4 Door
The rear seat consist of seatback and seat cushion.
The seatback is mounted on vehicle frame by three bolts.
The seat cushion is mounted on vehicle frame by three bolts.
Email: suzlever@gmail.com
http://www.kiatechinfo.com/viewer/content.asp?vehicl...3%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%2414/04/2009 9:35:22 AM
http://www.kiatechinfo.com/viewer/content.asp?vehicletype=PAS...EKM%5EBC13%5E2002%5Eall%5E0%5Enone%5Enone%5Enone%5Eshop%5E%24
Ebay User ID: reveleus1
REMOVAL
1. Remove two mounting bolts as shown in figure to release cushion, then pull seat cushion out.
2. Remove three mounting bolt from bottom of seatback.
3. Remove seatback.
INSTALLATION
1. Reverse removal procedures.
Tighten seat mounting bolts to 16~22 Ib·ft (22~31 N·m, 2.2~3.1 kg·m)
Tighten seat hinge bracket bolts to 16~22 Ib·ft (22~31 N·m, 2.2~3.1 kg·m)
Email: suzlever@gmail.com
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COMPONENTS
Email: suzlever@gmail.com
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DESCRIPTION AND OPERATION
Headliner is a cloth cushion that serves as a buffer between passengers and top of vehicle. It also covers thermal
and acoustic insulation in top of vehicle and wiring for dome light. Both headliner and insulation are replaceable.
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Ebay User ID: reveleus1
REMOVAL
1.
2.
3.
4.
Unscrew two mounting screws from sunvisors.
Remove sunvisors and sunvisors retaining clips.
Remove assist handle covers, unscrew mounting screws.
Remove three assist handles.
5.
6.
7.
8.
Gently remove lens assembly on interior and map light.
Remove light bulb.
Remove two mounting screws.
Disconnect power connector and remove interior and map light.
9. Remove A, B and C pillar trims. Refer to "Trim" in this section.
10. Remove seven fasteners.
Email: suzlever@gmail.com
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11. Remove geadliner.
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12. Reverse remove procedure.
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TIGHTENING SPECIFICATIONS
Description
Item
Tightening torque
Front bumper mounting bolts
23-34 lb·ft (32-47 N·m)
Rear bumper mounting bolts
23-34 lb·ft (32-47 N·m)
Bumper
Door checker bolts (Door side)
7-10 lb·ft (9-13 N·m)
Door hinge bolts
13-22 lb·ft (18-30 N·m)
Door hinge setting bolts
13-22 lb·ft (18-30 N·m)
Door striker mounting screws.
13-20 lb·ft (18-27 N·m)
Doors
Glass mounting bolts
17-26 lb·in (200-300 N·cm)
Regulator assembly mounting nuts/bolts
78-113 lb·in (9-13 N·m)
Hood hinge bolts
14-19 lb·ft (19-26 N·m)
Hood lock assembly bolt/nut
70-96 lb·in (8-11 N·m)
Hood
Front seat mounting bolts
Seats
Rear seat mounting bolt
Rear seat striker mounting bolts
Safety belts
Trunk lid
128-137 lb·ft (39-52 N·m)
16-22 lb·ft (22-31 N·m)
7-10 lb·ft (9-13 N·m)
Anchor bolt
28-58 lb·ft (39-80 N·m)
Lap belt bracket mounting bolt
28-58 lb·ft (39-80 N·m)
Rear buckle assembly bracket mounting
bolt
28-58 lb·ft (39-80 N·m)
Rear tongue assembly mounting bolt
28-58 lb·ft (39-80 N·m)
Retractor assembly mounting bolt
28-58 lb·ft (39-80 N·m)
Trunk lid hinge assembly bolt
7-9 lb·ft (9-13 N·m)
Trunk lid striker assembly bolt
5-7 lb·ft (7-10 N·m)
Trunk hatch assembly bolt
5-7 lb·ft (7-10 N·m)
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Ebay User ID: reveleus1
GENERAL
BUMPER
Problem
Possible cause
Front face damaged
Action
Accident
Replace
Energy absorbing foam damaged or deteriorated Accident or exposure
Replace
Reinforcement damaged
Accident
Replace
Brackets or stays damaged
Accident
Repair or replace
Missing attaching hardware
Accident or vibration
Replace
POWER MIRROR
If power mirror does not operate, refer to Rio Electrical troubleshooting Manual.
SAFETY BELTS
Problem
Possible cause
Action
Buckle release does not release
reliably
Faulty spring or dirt in mechanism
Replace buckle assembly
Buckle release does not depress
Jammed mechanism
Replace buckle assembly
Buckle release button does not
return to normal position
Jammed mechanism
Replace buckle assembly
Webbing is frayed
Caught in door
Replace retractor assembly
Stitching is loose
Wear or accident
Replace retractor assembly
Belt retracts part-way
Faulty spring
Replace retractor assembly
Belt does not extend completely
Faulty mechanism
Replace retractor assembly
Belt does not retract
Wear or accident
Replace retractor assembly
Belt does not extend
Faulty mechanism
Replace retractor assembly
Buckle assembly is loose
Vibration or accident
Tighten to specified torque
Retractor assembly is loose
Vibration or accident
Tighten to specified torque
Anchor assembly is loose
Vibration or accident
Tighten to specified torque
Driver's safety belt is fastened but
reminder lamp and chime either
do not actuate or fail to deactivate
Cable harness, computer module, or
indicator light
Isolate fault with continuity tester. If
test fails, repair or replace cable. If
test fails, repair or replace faulty
component.
Email: suzlever@gmail.com
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COMPONENTS
TRUNK LID
REAR HATCH
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Email: suzlever@gmail.com
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DESCRIPTION AND OPERATION
TRUNK LID
Trunk lid is attached to body by two hinges connected to each other by two balance springs to provide an assist in
raising trunk lid and fully supports it when it is open.
The trunk lid is fully adjustable.
A striker at center-top of the body and a latch attached to the center-bottom of the trunk lid secures trunk lid in the
closed position.
Weatherstripping on trunk lid jamb flange prevents leakage between trunk and body.
REAR HATCH
The rear hatch is attched to the body by two pin-type hinges riveted to the body and bolted to the hatch.
A damper stay on either side of the hatch provides an assist in raising the hatch and fully supports it when it is
open.
A latch at the center-bottom of the opening secures the hatch in the closed position.
Weatherstripping on the hatch jamb flange prevents leaks between the door and the body. The hatch is fully
adjustable.
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REMOVAL
TRUNK LID
1. Raise the trunk lid.
Have an assistant help remove trunk lid.
2. Support trunk lid so trunk lid will not fall when trunk lid installation bolts are removed.
3. Remove four trunk lid installation bolts and then remove trunk lid.
4. Remove trunk lid rubber cushion.
REMOVAL
TRUNK LID HINGE ASSEMBLY
1. Remove trunk lid, Refer to "Trunk lid" in this section.
2. Remove the trunk lid balance spring.
3. Remove rear seat cushion and rear seatback.
Refer to "Seat" in this section.
4. Remove high-mounted brake light assembly.
Refer to "Exterior lights" in this section.
5. Remove package trim and C-pillar trim .
Refer to "Trim" in this section.
Email: suzlever@gmail.com
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6. Remove six trunk lid hinge installation nuts, and
trunk lid hinge assembly.
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REMOVAL
REAR HATCH
1.
2.
3.
4.
Disconnect battery.
Raise the rear hatch.
Remove the center grommet from the hatch to expose the rear window washer tubing.
Remove the rear window washer nozzle and remove the tybing from the nozzle.
5. Compress the boot to expose the hose coupling. Secure the coupling outside the boot to make installation of the
nozzle hose easier.
6. Remove the nozzle hose from the coupling.
7. Remove the nozzle hose.
8. Remove trunk end trim. Refer to "Trim" in this section.
9. Remove trunk side trim
10. Remove seat belt anchor mounting bolt and one screw from C-pillar trim
11. While pulling C-pillar trim, disconnect electrical connector.
12. Pull the cable harness carefully through the acces hole and through the cable harness boot and grommet
Removal of the damper stay assemblies requires that the rear hatch be well supported to permit it to remain
in the openposition so there is access to the hatch hinges. Have an assistant help in rear hatch removal.
13. Support the rear hatch in the open position.
Email: suzlever@gmail.com
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14. Remove two mounting bolts from damper stay
assembly.
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15. Remove one bolt from the left and right-head hinges.
The last step in the removal of the rear hatch is a two-man job. Have an assistant help remove the hatch.
16. Remove the last two bolts from the hatch
17. Remove the rear hatch.
REMOVAL
REAR HATCH DAMPER STAY
1. Open the rear hatch.
2. Remove two upper mounting nuts from the left and right damper stay.
3. Remove trunk end trim and trunk corner trim. Refer to "Trim" in this section.
4. Remove safety belts anchor mounting bolt and then remove safety belt anchor.
5. Remove one screw on C-pillar trim.
Email: suzlever@gmail.com
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6. While pulling C-pillar trim, remove two lower Ebay
retaining
from the damper stay.
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7. Remove damper stay.
REMOVAL
REAR HATCH LOCK
1.
2.
3.
4.
5.
Disconnect negative battery cable.
Swing spare tire carrier aside.
Open rear hatch.
Remove high-mounted brake light assembly. Refer to"Exterior lights" in this section.
Remove the rear hatch trim. Refer to "Trim" in this section.
6. Unfasten cylinder rod clip, outer handle rod clip and actuator rod clip.
Email: suzlever@gmail.com
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7. Disconnect electrical connector on the lock assembly.
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8. Remove two bolts on the lock assembly.
9. Remove lock assembly.
REMOVAL
OUTSIDE HANDLE
1.
2.
3.
4.
5.
Remove rear hatch trim. Refer to "Trim" in this section.
Licence plate light assembly. Refer to "Exterior lights" in this section.
Disconnect remote control rod from outside handle assembly.
Remove two mounting bolts from outside handle assembly.
Remove outside handle.
INSTALLATION
TRUNK LID
Have an assistant help install trunk lid.
1.
2.
3.
4.
Install in reverse order of removal.
Tighten four trunk lid installations bolts to just over finger-tight.
Lower and lock trunk lid.
Check fit and adjust the clearance on all sides before tightening bolts.
Tighten trunk lid hinge bolts to 78~113 Ib·ft (9~13 N·m, 90~130 kg·m)
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5. Check alignment of the locking mechanism and
and align as required.
Ebaytrunk
Userlid
ID:striker
reveleus1
Tighten striker bolts to 61~87 Ib·ft (7~10 N·m, 70~100 kg·m)
INSTALLATION
TRUNK LID HINGE ASSEMBLY
Have an assistant help install trunk lid hinge.
1. Install in reverse order of removal.
2. Tighten trunk lid hinge installation nut.
Tighten trunk lid hinge nuts to 78~113 Ib·ft (9~13 N·m, 90~130 kg·m)
3. Install trunk lid.
INSTALLATION
REAR HATCH
1. Install in reverse order of removal.
Tighten the hinge bolts to 12~17 lb·ft (16~24 N·m 1.6~2.4 kg·m)
INSTALLATION
REAR HATCH DAMPER STAY
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1. Install in revere order of removal.
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2. Position the damper stay.
3. Install two lower retaining bolts on the damper stay.
Tighten two lower retaining bolts to12~16 lb·ft (16~24 N·m, 1.6~2.4 kg·m)
4. Install two upper mounting nuts of the damper stay.
Tighten two mounting nuts to12~16 lb·ft (16~24 N·m, 1.6~2.4 kg·m)
5. Close rear hatch.
INSTALLATION
REAR HATCH LOCK
1. Position lock assembly.
2. Connect one connector on the lock assembly.
3. Install two bolts on the lock assembly.
Tighten two bolts to12~16 lb·ft (16~22 N·m, 1.6~2.2 kg·m)
4. Fasten cylinder rod, outer handle rod and actuator rod clip.
Email: suzlever@gmail.com
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5.
6.
7.
8.
Install rear hatch trim. Refer to "Trim" in this Ebay
section.
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Install high-maunted brake light assembly. Refer to "Trim" in this section.
Close rear hatch.
Connect negative battery cable.
INSTALLATION
OUTSIDE HANDLE
1.
2.
3.
4.
5.
Install out side handle.
Install two mounting bolts to outside handle assembly.
Connect remote control rod to outside handle assembly.
Install license plate light assembly. Refer to "Exterior light" in this section.
Install rear hatch trim. Refer to "Trim" in this section.
ADJUSTMENT
REAR HATCH
1. Measure the distances for views A,B and B to determine whether or not the fit is within specifications. If they are
acceptable, tighten the ball studs and the hinge bolts as specified below. If not, make the appropriate
adjustments at the hinges. The options are:
A.Move the hatch forward or backward
B.Move the hatch left or right
C.Rotate the hatch colckwise or counterclockwise.
D.Or any combination of the three.
Tighten the hinge bolts to 14 lb·ft (20N·m) after adjustments are complete. Check each dimension once more to
make certain the hatch did not move in the process.
2. Measure the dimension in view B. The position of the wedges on either side of the hatch opening controls the
degree of hatch closure in view B. If the dimension is too large, move the wedges away from each other. If the
dimension is too small, move the wedges toward each other.
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REMOVAL
1. Disconnect the negative battery cable from the battery.
2. Pull up the locker to remove the unit connector.
3. Disconnect the six brake lines (2 inlet and 4 outlet) using a flare nut wrench.
Temporarily seal open brake lines with plastic caps or equivalent.
4. Remove the hydraulic control unit bracket bolt and nut on the vehicle.
5. Store the hydraulic control unit in a protective container while it is being serviced.
INSTALLATION
1. Install hydraulic control unit into position and tighten the bolt and nut.
Tightening torque: 18~27 N·m (1.8~2.7 kg·m, 12~20 lb·ft)
2. Reconnect six brake lines. Be certain that the four lower outlet lines have been connected to the correct ports.
Tighten the nuts to specification
Tightening torque: 12~22 N·m (1.3~2.2 kg·m, 9~16 lb·ft)
3. Connect the hydraulic control unit connector to the hydraulic control unit. Be certain connectors are fully mated.
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4. Bleed the brake system using ABS procedure
described
brake system bleeding, refer to service Adjustment
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procedure.
Email: suzlever@gmail.com
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COMPONENTS
Email: suzlever@gmail.com
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DESCRIPTION AND OPERATION
ABS (ANTI-LOCK BRAKE SYSTEM)
The purpose of the antilock brake system is to prevent wheel lockup during periods of high wheel slip. Preventing
lockuphelps maintain vehicle braking action and steering control. The ABS controller activates the system whenever
sensor signals indicate high wheel slip. High wheel slip is a condition where the wheel rotation approaches 20 to 30
percentof actual vehicle speed during braking. This usually occurs when braking involves high pedal pressure and rate of
vehicle deceleration. The antilock system prevents lockup during high slip conditions by modulating fluid apply pressure
to the brakes. The apply pressure is modulated according to wheel speed, degree of slip and rate of deceleration. A
sensor at each wheel converts wheel speed into electrical signals.
The antilock brake system on the Rio is a 4-sensor, 4-channel system. In this configuration, the front wheels are
controlled independently and rear wheels are controlled in tandem by a select low system (controlling hydraulic pressure
onside on which slip is first occurred).
HYDRAULIC CONTROL UNIT (HCU)
1. The HCU consists of a motor pump assembly in which motor sensor is built, and valve block for controlling ABS
pressure.
Reference
Diameter of front brake pipe holepitch: FL, RL: 0.47 in (12 mm)
Diameter of rear brake pipe holepitch: FR, RR: 0.39 in (10 mm)
The motor pump is a reciprocal 2-line pump and transmits enough pressure to the wheel system, and the valve block
controls fluid pressure to each wheel cylinder.
ABS MODULE
The ABS module illuminates the ABS warning lamp when an ABS failure occurs.
ABS CONTROL UNIT
The ABS control unit performs the following functions.
• Controls the ABS
• Calculates vehicle speed
• Self-diagnostics: Stores malfunction codes, performs ABS control unit self-diagnostic and fail-safe functions with two
separated microprocessors.
The ABS control unit continuously checks locking of each wheel and controls each valve to adjust brake fluid pressure
ifrequired. The ABS control unit also checks that components are working properly and stops ABS if a malfunction is
detected.
Then, it is operated as a standard brake system.
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ABS SENSOR (ABS STRUCTURE)
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1. The speed sensor detects wheel rotation and consists of a permanentmagnet and pickup coil. Sensors for the front
wheels are attached to driveshaft and rear hub spindle for the rear wheel.
ABS WARNING LAMP
The ABS warning lamp in the instrument panel illuminates for 3 secondsafter ignition key is turned ON. If the warning
lamp does not turned off,or turns on intermittently, there is a malfunction in ABS. When a malfunctionof ABS is occurs,
the ABS will not operate and the brakes will operate asa standard brake system.
TYPE OF OPERATION
Under normal conditions, the standard brake system performs until locking of a wheel is detected by the ABS control unit.
During standard braking, inlet valves are normally opened and outlet valves are normally closed.
When the ABS control unit detects a wheel lock, the hydraulic unit controls each valve to maintain, increase or decrease
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pressure.
The ABS control unit detects the speed and the deceleration rate of each wheel with wheel speed sensors. When braking
the wheel speed is decreased and difference between wheel speed and vehicle speed is generated. If deceleration rate
ofsome wheels exceeds expected value (Point A), ABS control unit determines wheel lock has occurred and opens the
corresponding outlet solenoid valves to reduce brake fluid pressure. If locking pressure on the wheels is exceeded (Point
B)and wheel speed reaches point C, then the ABS control unit closes outlet valve of the corresponding wheels to
increasefluid pressure.
For vehicles with ABS, the following symptoms can occur, but indicate normal operation of the ABS.
Symptom
Descriptions
Motor noise
Noise can be heard when ABS hydraulic unit is operated.
Noise from suspension system
Since braking is done in 3 steps during operation of ABS, noise from suspension
system can be heard.
Oscillation of brake pedal
Slight oscillation (kickback) on brake pedal occurs during operation of ABS.
PRINCIPLE OF OPERATION
Standard braking (Non-ABS braking)
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When the brake pedal is depressed, the power brake unit closes the central valve of the master cylinder and generates
pressure on the brake hydraulic pressure line. This opens the solenoid inlet valve and closes the outlet valve and
transmits hydraulic pressure from the master cylinder to the wheel cylinders.
ABS braking (2.1 Maintaining pressure)
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After the ABS control unit detects wheel lock due to excessively increased pressure, the ABS control unit closes the inlet
valve to avoid further increase in hydraulic pressure.
ABS braking (2.2 Decreasing pressure)
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If wheel lock continues, the ABS control unit opens the corresponding outlet valve so that brake fluids flow to the
pressure accumulator. This reduces pressure only for wheels that are locked.
ABS braking (2.3 Increasing pressure)
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When wheels have been returned to normal speed from locking, the ABS control unit stops operating the solenoid valve
and returns to standard braking operation.
Hydraulic circuits
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OEPRATION
ABS WARNING LAMP
Since teeth of sensor rotor change magnetic field of sensor, it generatesalternative voltage. This voltage is proportional to
rotating speed and itsperiod can be changed. It can sense speed of wheel by detecting period.
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O-01 ABS CONTROL UNIT CONNECTOR
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TROUBLESHOOTING GUIDE
SELF-DIAGNOSIS
The ABS control unit starts self-diagnostic functions after the ignition is switched ON. The ABS control unit detects failure
for each circuit andcomponent by comparing condition of the system with limited condition set inside the ABS control unit.
The ABS control unit stores the failurecode and then outputs the two-digit malfunction code to the diagnostic scan tool (Hi/
Scan pro) when the ABS data link connector is connected.
SELF-DIAGNOSIS PROCEDURES
1. With the ignition switch OFF, connect the diagnostic scan tool (Hi/Scan pro) to the data link connector in the engine
compartment.
2. Turn the ignition switch ON, then check diagnostic trouble code(s).
3. If a diagnostic trouble code(s) is displayed, check for cause by using number on diagnostic trouble code. Repair as
necessary.
4. After repair, perform after-repair procedure to verify that there are no remaining diagnostic trouble codes.
If Hi/Scan pro is not available, check the blinking code by the ABS warning lamp.
• Ground the pin "i" and "r" of data link connector in the engine compartment with the ignition switch OFF.
• Turn ignition switch ON.
• DTC's will be displayed beginning will the lowest DTC number first.
• After all stored DTC's have been displayed, the process will repeat and display the lowest DTC number first.
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A: 0.1 Seconds
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The ABS warning lamp illuminates for 0.1 second after the ignition switch is turned ON. This does not indicate an
error code.
B: 4 Seconds
C: 0.5 Seconds
D: 1.5 Seconds
E: 2.5 Seconds or 4 Seconds
• The OFF state between DTC display cycles is 4 seconds.
• When several DTC's are displayed, the OFF state between codes is 2.5 seconds.
F: All Clear Code - 0.25 Seconds
If the system is operating normally (no malfunction) the warning lamp ill blink once every 0.25 second. This is the
“All Clear” code.
AFTER-REPAIR PROCEDURES
1. After repair, erase all diagnostic trouble codes stored in the ABS controlunit with Hi scan pro. (Refer to Hi-scan pro
operatingmanual)
1. Verify that no diagnostic trouble codes are displayed.
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2. Remove Hi-scan pro from the data link connector.
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If Hi scan pro is not available, to erase the diagnostic trouble codefrom ABS control unit, perform the following
instructions.
• With the ignition switch OFF, ground pin “i” and “r”at the underhood data link connector.
• Turn ignition switch ON.
• Rapidly depress and release the brake pedal six times in three secondsto erase any stored DTC's. The ABS
warning lamp will flash the all clear code.
• Turn the ignition key OFF and remove the jumper wire at the underhoodDLC.
• After DTC's are erased, if there is still problem in the system, ABSwarning lamp will stay remain ON. If this
occurs, repeat the previous procedureto retrieve trouble codes.
How to use diagnosis and troubleshooting
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Basic inspection Visual observation
Step
1
Inspection
Actions
Yes
Go to next step.
No
- Repair or replace lever/cable.
- Inspect parking brake switch
- Check operation.
Yes
Go to next step.
No
Fill up brake fluids.
Yes
Replace corresponding part.
No
Go to next step.
Yes
Go to next step.
No
Replace it.
Yes
Check functions.
No
Connect it again.
Repair or replace it.
Check if parking brake is working properly.
Check if brake fluid level in the reservoir tank
is between "Max" and "Min".
2
Check if brake fluid leak on all hydraulic lines.
3
4
5
Check if each "ABS" (30A) fuse is properly
connected.
- Opened or shorted
- Connection
Check if following component is properly
connected.
- Wheel speed sensor
- Hydraulic control unit (Include ECU)
- Brake fluids reserve tank
- Stop lamp switch
- ABS warning module
Checking functionality
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Inspection Ebay User ID: reveleus1
Step
Verify if ABS warning lamp turns on for two to
four seconds when ignition is switched ON.
1
Verify if brake warning lamp turns off when
parking brake is released.
2
Check for malfunction code using diagnostic
tool(Hi/Scan pro).
3
Go to step 3 again after driving vehicle, and
check for a malfunction code.
4
Actions
Yes
Go to next step.
No
Go to detail inspection.
Yes
Go to next step.
No
- Check level of brake fluids.
- Inspect brake pipes, hoses, wheel cylinder,
seal and leak at master cylinder.
Yes
Go to corresponding detail inspection.
No
Go to next step.
Yes
Go to corresponding detail inspection.
No
- Check each connector and connections.
- System OK.
-If brake warning lamp and ABS Warning lamp turn on at the same time, Go to detail inspection after checking error code
of ABS unit. Because of EBD fail.
Diagnostic trouble codes
DTC
Failed part
Possible cause
00
No error
-
11
Valve relay circuit open
● Open between Fuse Box and ABS control unit.
12
Valve relay circuit short
● Short between Fuse Box and ABS control unit.
13
Motor relay circuit open
● Open between Fuse Box and ABS control unit.
14
Motor relay circuit open
● Short between Fuse Box and ABS control unit.
21
Valve (IFR)
22
Valve (OFR)
● Open or short between Fuse Box and ABS control
unit.
23
Valve (IFL)
24
Valve (OFL)
25
Valve (IRR)
26
Valve (ORR)
27
Valve (IRL)
28
Valve (ORL)
31
Wheel speed sensor (FR)
● Open or short between wheel speed sensor and
ABS control unit.
32
Wheel speed sensor (FL)
33
Wheel speed sensor (RR)
● Missing sensor signal because of loosen wheel
speed sensor (Sensor notinserted, shorted sensor
coil).
- Air gap too large.
● Valve malfunction.
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- Tooth wheel not installed.
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34
Wheel speed sensor (RL)
35
Wheel speed sensor noise (FR)
36
Wheel speed sensor noise (FL)
37
Wheel speed sensor noise (RR)
38
Wheel speed sensor noise (RL)
41
Power supply over voltage
● Over voltage or Low voltage.
49
ECU Internal error
● Internal circuit or connected failed.
51
Motor harness open or Motor lock
● Open between Fuse Box and ABS control unit
● Pump motor failed.
● Unusual sensor output signal noise.
ABS CU INSPECTION TERMINAL VOLTAGE TABLE
Terminal
Signal
Connected to
O-01-1
Wheel speed sensor (FL)
Wheel speed sensor (+)
O-01-2
Wheel speed sensor (FL)
Wheel speed sensor (-)
O-01-3
Not used
-
O-01-4
Power supply
Ignition switch
Test condition
Measure value
Ignition switch OFF
1.3~1.5 kΩ
-
-
Ignition switch ON
B+
Ignition switch OFF
0V
Ignition switch OFF
1.3~1.5 kΩ
O-01-5
Wheel speed sensor (RL)
Wheel speed sensor (+)
O-01-6
Wheel speed sensor (RL)
Wheel speed sensor (-)
O-01-7
K-Line
Data link connector (H
Ignition switch ON
B+
O-01-8
Ground
Ground
Constant
0V
O-01-9
Power supply (Solenoid
valve)
Battery
Constant
B+
O-01-10
Not used
-
-
-
O-01-11
Not used
-
-
-
Warning lamp OFF
-
O-01-12
EBD Warning lamp
Brake Warning lamp
Warning lamp ON
0V
O-01-13
Not used
-
-
-
O-01-14
L-Line
Data link connector (I)
Ignition switch ON
B+
O-01-15
Not used
-
-
-
Warning lamp OFF
-
O-01-16
ABS Warning lamp
ABS warning lamp
Warning lamp ON
0V
-
-
O-01-17
Not used
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O-01-18
Brake
Brake switch
0V
Brake pedal
depressed
B+
Ignition switch OFF
1.3~1.5 kΩ
-
-
Ignition switch OFF
1.3~1.5 kΩ
O-01-19
Wheel speed sensor (FR)
Wheel speed sensor (+)
O-01-20
Wheel speed sensor (FR)
Wheel speed sensor (-)
O-01-21
Not used
-
O-01-22
Wheel speed sensor (RR)
Wheel speed sensor (+)
O-01-23
Wheel speed sensor (RR)
Wheel speed sensor (-)
O-01-24
Ground
Ground
Constant
0V
O-01-25
Power supply (ABS
Motor)
Battery
Constant
B+
* B+ : Battery Voltage
VALVE RELAY CIRCUIT
● Valve relay circuit open
● Valve relay circuit short
Diagnostic trouble code 11/12
Check
point
Step
1
2
3
4
5
● ABS fuse (30A)
● Open or short in wiring from fuse box to ABS control unit
Inspection
Actions
Are all connections at connector and
connector pins OK?
Yes
Go to next step
No
Repair or replace connector (s)
Measure terminal voltage of ABS control unit
at terminal O-01-9.
Standard voltage : Battery voltage
Yes
Go to step 5
No
Go to next step
Yes
Go to next step
No
Repair or replace connectors and wiring
Yes
Go to next step
No
Repair or replace connectors and wiring.
Yes
Temporarily install known good ABS control
unit. Go to step 6. If problemis corrected,
replace ABS control unit.
No
The problem is a temporarily poor connection
of harness or connectors,and should be
investigated further.
- Disconnect negative battery cable.
- Disconnect ABS control unit connector.
- Check for continuity at O-01-24 or O-01-8
and ground.
Are connectors and wiring between fuse box
and ABS control unit OK?
After diagnostic trouble code has been
cleared, does reinspection diagnostictrouble
code appear?
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Return vehicle to original condition. Clear
DTC's.
Verify repairsby driving vehicle with scan tool
connected and monitor for pending codes.
MOTOR
● Motor relay circuit open
● Motor relay circuit short
● Motor harness open or Motor lock
Diagnostic trouble code 13/14/51
Check
point
● ABS fuse (30A)
● Open or short in wiring from fuse box to ABS control unit
● Motor lock
Step
1
2
3
4
5
6
Inspection
Actions
Are all connections at connector and
connector pins OK?
Yes
Go to next step
No
Repair or replace connector (s)
Measure terminal voltage of ABS control unit
at terminal O-01-25.
Standard voltage : Battery voltage
Yes
Go to step 5
No
Go to next step
Yes
Go to next step
No
Repair or replace connectors and wiring
Yes
Go to next step
No
Repair or replace connectors and wiring.
Yes
Temporarily install known good ABS control
unit. Go to step 6. If problemis corrected,
replace ABS control unit.
No
The problem is a temporarily poor connection
of harness or connectors,and should be
investigated further.
- Disconnect negative battery cable.
- Disconnect ABS control unit connector.
- Check for continuity at O-01-24 or O-01-8
and ground.
Are connectors and wiring between fuse box
and ABS control unit OK?
After diagnostic trouble code has been
cleared, does reinspection diagnostictrouble
code appear?
Return vehicle to original condition. Clear all DTC's. Verify repairsby driving vehicle with scan tool
connected and monitor for pending codes.
MOTOR
Diagnostic trouble code 51
Check
point
Step
1
● Motor harness open or Motor lock
● Hydraulic control unit
Inspection
Are all connections at connector and
connector pins OK?
Actions
Yes
Go to next step
No
Repair or replace connector (s)
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Replace Hydraulic control unit.
VALVE
Diagnostic trouble code 21/22/23/24/25/26/27/28
Check
point
● ABS fuse (30A)
● Open or short in wiring from fuse box to ABS control unit
Step
1
2
3
4
5
6
● Valve (IFR/OFR/IFL/OFL/IRR/ORR/IRL/ORL)
Inspection
Actions
Are all connections at connector and
connector pins OK?
Yes
Go to next step
No
Repair or replace connector (s)
Measure terminal voltage of ABS control unit
at terminal O-01-9.
Standard voltage : Battery voltage
Yes
Go to step 5
No
Go to next step
Yes
Go to next step
No
Repair or replace connectors and wiring
Yes
Go to next step
No
Repair or replace connectors and wiring.
Yes
Temporarily install known good ABS control
unit. Go to step 6. If problemis corrected,
replace ABS control unit.
No
The problem is a temporarily poor connection
of harness or connectors,and should be
investigated further.
- Disconnect negative battery cable.
- Disconnect ABS control unit connector.
- Check for continuity at O-01-24 or O-01-8
and ground.
Are connectors and wiring between fuse box
and ABS control unit OK?
After diagnostic trouble code has been
cleared, does reinspection diagnostictrouble
code appear?
Return vehicle to original condition. Clear all DTC's. Verify repairsby driving vehicle with scan tool
connected and monitor for pending codes.
WHEEL SPEED SENSOR
Diagnostic trouble code 31/32/33/34/35/36/37/38
Check
point
Step
1
● Wheel speed sensor (FR) 31, 35
● Wheel speed sensor (FL) 32, 36
● Wheel speed sensor (RR) 33, 37
● Wheel speed sensor (RL) 34, 38
● Open or short in wiring from fuse box to ABS control unit
● Wheel speed sensor malfunction
● Damaged speed sensor and rotor
Inspection
Are all connections at connector and
connector pins OK?
Actions
Yes
Go to next step
No
Repair or replace connector (s)
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Inspect the following items:
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● Gap between speed sensor and rotor Air
gap:
Front : 0.0118~0.0433 in (0.3 ~ 1.1 mm)
Rear : 0.0118~0.0433 in (0.3 ~ 1.1 mm)
Yes
Go to step 5
No
Go to next step
Yes
Go to next step
No
Repair or replace connectors and wiring
Yes
Go to next step
No
1.3 KΩ or more : Repair or replace open
circuit wiring.
2
● Damage of rotor teeth
● Damage of wheel speed sensor
● Connection, rust and deformation of wheel
wpeed sensor connector.
- Disconnect wheel speed sensor connector
with ignition switch OFF.
- Measure resistance
3
It resistance within standard?
- Disconnect ABS control unit connector with
ignition switch OFF
-Measure resistance
4
Below 1KΩ : Repair or replace shorted wiring.
It resistance within standard?
5
Yes
Temporarily install known good ABS control
unit. Go to step 6. If problemis corrected,
replace ABS control unit.
No
The problem is a temporarily poor connection
of harness or connectors,and should be
investigated further.
After diagnostic trouble code has been
cleared, does reinspection diagnostictrouble
code appear?
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Return vehicle to original condition. Clear
DTC's.
Verify repairsby driving vehicle with scan tool
connected and monitor for pending codes.
POWER SUPPLY OVER VOLTAGE
Diagnostic trouble code 41
Check
point
● Generator malfunction
● Battery malfunction
● Short in wiring from fuse box to ABS control unit
Step
1
2
● Power supply over voltage
Inspection
Actions
Yes
Go to next step
No
Repair or replace connector.
Refer to section EE, Charging System.
Yes
Go to next step
No
Repair or replace connector (s)
Yes
Go to next step
No
Repair or replace connectors and wiring
Yes
Go to next step
No
Replace or replace connectors and wiring.
Yes
Temporarily install known good ABS control
unit. Go to step 6. If problemis corrected,
replace ABS control unit.
No
The problem is a temporarily poor connection
of harness or connectors,and should be
investigated further.
Inspect generator and battery.
Are all connections of connector and
connector pins OK?
Measure terminal voltage of ABS control unit
at terminal O-01-9, O-01-25 and O-01-4.
3
It voltage within standard?
4
5
6
● Disconnect negative battery cable.
● Disconnect ABS control unit connector.
● Check for continuity at O-01-24 or O-01-8
and ground.
After diagnostic trouble code has been
cleared, does reinspection diagnostictrouble
code appear?
Return vehicle to original condition. Clear all DTC's. Verify repairsby driving vehicle with scan tool
connected and monitor for pending codes.
ABS CONTROL UNIT
Diagnostic trouble code 49
● ABS Control unit internal error
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Check
point
Step
1
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● ABS Control unit
Inspection
Actions
Replace ABS Control unit.
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COMPONENTS
Take the following steps after the installation:
• Add a fluid and bleed the air.
• Check all parts for the fluid leakage.
• Adjust and check the brake pedal operation.
• Make an on-vehicle check of the unit.
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REMOVAL
1.
2.
3.
4.
Disconnect the fluid level warning connector.
Remove the brake pipes.
Remove the master cylinder
Disconnect the vacuum supply hose from the power brake unit.
5. From inside the vehicle, remove the cotter pin securing the clevis pin.
6. Remove the clevis pin from the clevis.
7. Have a second technician support the brake booster in the engine compartment.
8. Remove the four brake booster mounting nuts securing the brake booster to the bulkhead.
9. Remove the brake booster.
10. Remove the gasket between the brake booster and the bulkhead.
INSTALLATION
Lubricate the clevis pin with white lithium grease.
To install, reverse the removal procedure.
Tighten the four brake booster mounting nuts.
Tightening torque : 18.6~25.5 N·m (1.9~2.6 kg·m, 13.7~18.8 lb·ft)
INSPECTION
Power brake unit function check (Simple method)
1. Step 1
(1) With the engine stopped, depress the pedal a few times.
(2) With the pedal depressed, start the engine.
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(3) If immediately after the engine starts the pedal
moves
slightly, the unit is operating.
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2. Step 2
(1) Start the engine.
(2) Stop the engine after it has run for 1 or 2 minutes.
(3) Depress the pedal with the usual force.
(4) If the first pedal stroke is long and becomes shorter with subsequent strokes, the unit is operating.
(5) If a problem is found, inspect for damage of the check valve or vacuum hose and examine the installation.
Repair if necessary, and inspect it once again.
3. Step 3
(1) Start the engine.
(2) Depress the pedal with the usual force.
(3) Stop the engine with the pedal held depressed.
(4) Hold the pedal down for about 30 seconds.
(5) If the pedal height does not change, the unit is operating.
(6) If there is a problem, check for damage to the check valve or vacuum hose, and check the connection.
Repair if necessary and check once again.
If the nature of the problem is still not clear after the 3 steps above, follow the more detailed check described
in the "Method-using tester" below.
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(Method-using tester)
Connect the SST, vacuum gauge A, and pedal depression force gauge B as shown in the figure. After bleeding the
air from the SST, conduct the test as described in the 3 steps below.
Use a commercially available vacuum gauge and pedal depression force gauge.
a) Checking for vacuum loss Unloaded condition
1. Start the engine.
2. Stop the engine when the vacuum gauge reading reaches 66.7 kPa (500 mmHg, 19.7 inHg).
3. Observe the vacuum gauge for 15 seconds. If the gauge shows 63.3~66.7 kPa (475~500 mmHg, 18.7~19.7
inHg), the unit is operating.
Loaded condition
1. Start the engine.
2. Depress the brake pedal with a force of 196 N (20 kg, 44 lb).
3. With the brake pedal depressed, stop the engine when the vacuum gauge reading reaches 66.7 kPa (500
mmHg, 19.7 inHg).
4. Observe the vacuum gauge for 15 seconds. If the gauge shows 63.3~66.7 kPa (475~500 mmHg, 18.7~19.7
inHg), the unit is operating.
b) Checking for hydraulic pressure
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1. If with the engine stopped (vacuum 0 kPa (0Ebay
mmHg,
0 ID:
inHg))
the fluid pressure is within the specification, the
unit is operating.
Pedal force
N (kg, lb)
Fluid pressure
196 (20,44)
kPa (kg/cm2, psi)
1,177 (12,171)
2. Start the engine. Depress the brake pedal when the vacuum reaches 66.7 kPa (500 mmHg, 19.7 inHg). If the
fluid pressure is within the specification, the unit will operate.
Pedal force
N (kg, lb)
Fluid pressure
196 (20,44)
kPa (kg/cm2, psi)
8,040 (82,1,165)
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REMOVAL
FLEXIBLE HOSE
1. Remove the brake pipe with the SST.
2. Disconnect the clip and remove the flexible hose from the bracket.
INSTALLATION
FLEXIBLE HOSE
1. Fix the flexible hose in the bracket and install the clip.
2. Connect the flexible hose to the brake pipe and tighten the flare nut with the SST.
Verify that the hose is not twisted.
Verify that the hose does not contact other parts when the vehicle bounces or when the steering wheel is
turned fully right or left.
Tightening torque : 13~22 N·m (1.3~2.2 kg·m, 9~16 lb·ft)
ADJUSTMENT
AIR BLEEDING
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1. Jack up the vehicle and support it with a safety
stands.
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The brake fluid reservoir must be kept 3/4 full during air bleeding.
2.
3.
4.
5.
Remove the bleeder cap and attach a vinyl hose to the bleeder plug.
Place the other end of the vinyl tube in a clear container.
One person should depress the brake pedal a few times, and then hold it in the depressed position.
A second person should loosen the bleeder screw, drain out the fluid, and retighten the screw with the SST.
Be sure the pedal remains depressed until the bleed screw is tightened.
6. Repeat Steps 4 and 5 until no air bubbles are seen.
7. Check for the correct brake operation.
8. Verify that there is no fluid leakage. Clean away any spilled fluid with rags.
9. After bleeding the air, add a brake fluid to the reservoir up to the specified level.
Tightening torque : 5.9~8.8 N·m (60~90 kg·cm, 52~78 lb·in)
Air bleeding must be started from the bleeder screw furthest from the master cylinder.
INSPECTION
BRAKE PIPE
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1. Check for cracks, damage, and corrosion of Ebay
the brake
FLEXIBLE HOSE
Check for scars, cracks, and swelling of the flexible hose. Replace the hose if necessary.
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COMPONENTS
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REMOVAL
1.
2.
3.
4.
5.
6.
7.
Disconnect the negative battery cable.
Remove the split pin from the brake pedal clevis pin and remove the pin.
Remove the pivot bolt attaching nut, lockwasher, and spring washer.
Remove the spacer from the pivot bolt.
Slide the pivot bolt to the right and remove.
Remove the brake pedal, brake pedal return spring, and spacers.
If necessary, remove the brake pedal bushings, foot pad, and stop bumper.
INSTALLATION
1.
2.
3.
4.
5.
6.
7.
8.
If necessary, install the brake pedal stop bumper, foot pad, and bushings.
Position the brake pedal spacer and slide the pivot bolt through to hold it in position.
Position the return spring on the brake pedal.
Position the clutch pedal, if equipped, and slide the pivot bolt through to hold it in position.
Install the clutch pedal spacer, if equipped.
Install the pivot bolt attaching washers and nut.
Install the brake pedal clevis pin and split pin.
Connect the negative battery cable.
INSPECTION
BRAKE PEDAL HEIGHT
1. Verify that the distance from the center on the pedal pad to the dash lower panel mat is as specified.
Specification : 6.69~6.93 in (170~176mm)
INSPECTION
PEDAL PLAY
1. Depress the pedal a few times to eliminate the vacuum in the system.
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2. Gently depress the pedal by hand and checkEbay
the free
(until resistance is felt).
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Free play : 0.16~0.28 in (4~7 mm)
INSPECTION
PEDAL-TO-FLOOR CLEARANCE
1. Verify that the distance from the floor panel to the center of the pedal pad is as specified when the pedal is
depressed with a force of 490.33 N (50 kg) MIN.
Pedal-to-floor clearance : 2.76in (70mm)
If the distance is less than specified, check for the following problems:
(1) Air in brake system
(2) Malfunction of automatic adjuster (rear drum brakes)
(3) Worn shoes or pads
ADJUSTMENT
BRAKE PEDAL HEIGHT
1. Disconnect the stoplight switch connector.
2. Loosen the locknut B and turn the switch A until it does not contact the pedal.
3. Loosen the locknut D and turn the rod C to adjust the height of the brake pedal.
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4. Tighten the stoplight switch until it contacts the
pedal
turn it an additional 1/2 turn. Tighten the locknuts B
and D.
Tightening torque : 23.5~34.3 N·m (2.4~3.5 kg·m, 17.4~25.3 lb·ft)
5. Verify the operation of the stoplights.
ADJUSTMENT
PEDAL PLAY
1. Loosen the locknut D and turn the rod C to adjust the free play.
2. Verify the pedal height and the stoplight operation.
3. Tighten a lock nut D.
Tightening torque : 23.5~34.3 N·m (2.4~3.5 kg·m, 17.4~25.3 lb·ft)
4. Check the height of pedal and the lightening of stop lamp after the adjustment.
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COMPONENTS
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OPERATION
ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD)
The EBD system (Electrinic Brake Force Distribution) is a part of the ABS system and is designed to control the brake
force applied to the rear wheels.
The EBD System enhances the effciency of the ABS system by controlling the slip of the rear wheels in partial braking
situations. By doing this, the brake force is moved closer to the optimum range and is still controlled electronically.As a
result, threr is no need for a proportioning valve on the Rio equipped with ABS.
The reason for this is that the proportioning valve, being a mechanical device, has limitations in achieving ideal
brakeforce distribution to the rear wheels. Additionally, a proportioning valve cannot utilize flexible brake force distribution
when there are changes in vehicle load or increased vehicle weight.
The EBD System is controlled by the ABS Control Module. The ABS Control Module calculates the slip ratio of each
wheels.If the EBD fails, the EBD warning lamp (Parking Brake Lamp) will illuminate.
BRAKE FORCE DISTRIBUTION OF FRONT & REAR
The proportioning valve operates by allowing full hydraulic pressure to the rear wheels up to a set point called the valves
split point. Beyond this split point, the proportioning valve reduces the amount hudraulic pressure to the rear brakes
according to a certain ratio. Therefore, on light brake pedal applications, the proportioning valve allows about the same
hydraulic pressure to be applied to both the front and rear brakes. On heavier brake pedal stops, the proportioningvalve
will control hydraulic pressure to the rear brakes, so that hydraulic pressure at the rear brakes will be lower than that at
the front brakes. However, this kind of a mechanical valve does not consider the load condition or weight ofthe vehicle.
The EBD System on the other hand, detects and compares the wheel speed of front and rear, and controls therear wheel
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brake pressure electronically according to the braking
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PRINCIPLE OF EBD OPERATION
EBD OPERATING (NON-ABS BRAKING)
If a rear wheel slip ratio exceeds a front wheel slip ratio, EBD system begins to operate to stop increasing the brake
pressure of the rear wheel. During EBD operation, inlet valve(NO) of the rear wheel is closed (Hold mode) to stop the
pressure increase. If closing the inlet valve is not enough, then outlet valve(NC) is open to release the pressure. This
time, ABS motor does not operate.
EBD FAILURE
Failure cause
None
System
Warning lamp
ABS
EBD
ABS
EBD
ON
ON
OFF
OFF
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1 wheel speed sensor failure
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OFFID: reveleus1 ON
ON
OFF
Pump malfunction
OFF
ON
ON
OFF
Low voltage
OFF
ON
ON
OFF
2 or more wheel speed sensor failure
OFF
OFF
ON
ON
Solenoid valve failure
ABS control module malfunction
Other failure
*EBD warning lamp : Parking brake lamp
ABS AND EBD WARNING LAMP
1. The ABS and EBD warning lamp in the instrument panel illuminates for 2 seconds after ignition key is turned ON.
If the warning lamp does not turn off, or turns on intermittently, there is a malfunction in ABS or EBD. When a
malfunction of ABD or EBD occurs, the ABS or EBD will not operate and the brakes will operate as a standard brake
system.
Location : Inside left right wheel cover
CLUSTER
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COMPONENTS
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DESCRIPTION AND OPERATION
The front disc brake system consists of a full-floating caliper and ventilated rotor. The caliper is attached to the steering
knuckle with two attaching bolts that also serve as the caliper slide pins.
The single piston caliper applies brake pads that are held in position by a wire clip and two pins. The brake shoes
areprevented from rattling against the caliper and pins by an M-shaped anti-rattle spring that maintains a constant
pressureon the shoes.
A flexible hose is used to connect the caliper to the hydraulic system. Leakage at the hose connection is prevented by the
copper washers installed on either side of the hydraulic fitting.
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REPLACEMENT
DISC PAD
1. Raise and support the vehicle.
2. Remove the wheel.
Do not use a screwdriver or similar tool to pry the piston away from the rotor.
3. Remove the brake pad pin retainer.
4. Disengage the anti-rattle spring from the brake pads.
5. Remove the brake pad pins and the-rattle spring.
Do not discard the shims found behind the brake pads.
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6. Remove the brake pads and shims.
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7. Remove the connector bolt.
Discard the seal washer.
8. Loosen the sleeve bolt and remove the caliper from the steering knuckle
INSTALLATION
DISC PAD
1. Push the piston back into the caliper bore by using SST.
2. Apply the grease supplied with the brake pad set to both surfaces of the inner shim and to the back of the brake
pad.
Ensure the shims are installed with the inner and outer pads.
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3.
4.
5.
6.
7.
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Install the brake pads and shims.
Install the brake pad pins.
Install the anti-rattle spring.
Install the brake pad pin retainer.
Install the wheel and tire assembly. Tighten the wheel attaching bolts.
Tightening torque : 88~118 N·m (9.0~12.0 kg·m, 65~87 lb·ft)
8. Lower the vehicle.
9. Check the master cylinder fluid level. Add a fluid as necessary.
DISC PLATE
1. Install the anti-squeak caps.
2. Position the caliper on the steering knuckle and install the caliper bolts and tighten.
Tightening torque : 39~49 N·m (4.0~5.0 kg·m, 29~36 lb·ft)
3. Connect the caliper brake hose. Be sure to use new seal washers. Tighten the caliper brake hose bolt.
Tightening torque : 22~29 N·m (2.2~3.0 kg·m, 16~22 lb·ft)
4. Install the brake pads.
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5. Bleed the brakes. Refer to the procedure in this
REMOVAL
CALIPER
1. Remove the brake pads.
2. Remove the caliper brake hose bolt. Discard the seal washers.
3. Remove the caliper bolts and the caliper.
4. Remove the anti-squeak caps.
INSPECTION
DISC PAD
1. Check for the oil or grease on the facing, abnormal wear or cracks, and deterioration or damage from heat.
2. Measure the thickness of the lining.
Specified thickness : 0.39 in (10 mm)
Minimum : 0.08 in (2.0 mm)
3. Check visually for the damage or wear of the guide plate.
DISC PLATE
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1. Measure the thickness of the disc plate.
Standard 0.86 in (22 mm)
Minimum 0.78 in (20 mm)
2. Measure the runout at the outer edge of the contact surface of the disc pad.
Runout : 0.003 in (0.08 mm) max.
There must be no wheel bearing looseness.
DISASSEMBLY
CALIPER
1. Loosen the bleeder screw and drain the brake fluid out of the caliper. Install the bleeder screw.
2. Remove the dust boot retaining ring.
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3. Position a block of wood or a roll of shop towels
piston and the caliper.
DO NOT USE AN EXCESSIVE AMOUNT OF AIR PRESSURE TO REMOVE THE PISTON. EXCESSIVE
PRESSURE CAN FORCE THE PISTON OUT OF THECALIPER BORE WITH ENOUGH FORCE TO
CAUSE PERSONAL INJURY. NEVER ATTEMPT TO CATCH THE PISTON BY HAND AS IT COMES OUT
OFTHE CALIPER BORE.
A compressed air can be used as an alternative to removing the caliper piston.
Apply the air pressure through the fluid inlet port. Apply only enough pressure to ease the piston out of the
bore.
4. Remove the piston
5. Remove the dust boot from the piston and discard.
Do not use a screwdriver or other metal tool. A metal tool can scratch or nick the seal groove resulting in a
possible leak.
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6. Remove the piston seal from the caliper bore.
UseUser
a plastic
or wooden stick to remove the seal.
7. Remove the bleeder screw.
8. Remove the caliper bushings and the bushing seals.
Do not use petroleum based solvent, kerosene, or gasoline for cleaning caliper parts. Their use as a
cleaning agent can leave residues which can damage the rubber seals.
9. Wash the parts in clean denatured alcohol and dry with a compressed air.
REASSEMBLY
CALIPER
1. Install the piston seal.
Lubricate the piston seal with the pink grease and install it in the caliper.
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2. Lubricate the piston with brake fluid and partially install the piston. The dust boot groove must remain above the
caliper bore.
3. Lubricate the dust boot with the pink grease then install it on the piston.
4. Press the piston into the caliper until it bottoms in the bore.
5.
6.
7.
8.
Install a new dust boot retaining ring.
Install the bleeder screw.
Install the caliper bushings and new bushing seals.
Lubricate the inside surface of the bushings with the pink grease contained in the overhaul kit. Do not allow the
grease to enter the bushing bore.
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REMOVAL
1. Disconnect the negative battery cable from the battery.
2. Remove the ABS sensor from the knuckle assembly.
3. Remove the ABS sensor wire from the attaching clip.
4. After removeing trim, remove the ABS sensor and connector in the engine room.
REPLACEMENTt
1. Install ABS sensor and connector.
Tightening torque: 6~8 lb·ft (8~12N·m, 0.8~1.2 kg·m)
2.
3.
4.
5.
Install trim.
Install the ABS sensor to the attaching clip.
Install the ABS sensor to the knuckle assembly.
Connect the negative battery cable to the battery.
A shield wire is used to prevent interruption of the input signal from the ABS sensor. Return the wire to its
original position after repair.
INSPECTION
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1. Measure the resistance of the ABS sensor. Ebay User ID: reveleus1
Resistance: 1.3~1.5 KΩ
2. Replace ABS sensor if necessary.
INSPECTION
1. Check rotor for damage.
2. Check if gap between rotor and sensor meets the specified value.
Gap: 0.012~0.043 in (0.3~1.1 mm)
3. Replace the sensor rotor if necessary.
DISASSEMBLY/REASSEMBLY
1. Remove the drive shaft assembly from the vehicle.
2. Remove the sensor rotor by using the SST (0K670 990 AA0)
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3. Install the sensor rotor by using suitable tool.Ebay User ID: reveleus1
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COMPONENTS
• Secure the master cylinder flange in a vise when necessary.
• Replace the piston assembly, if necessary.
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REMOVAL
MASTER CYLINDER
1. Disconnect the low fluid level sensor wiring connector.
2. Disconnect the brake pipes from the master cylinder and ABS control unit by using SST(0K130 430 019). Cap
the tubes andplug the master cylinder ports and ABS control unit ports to prevent the entry of contaminants.
3. Remove the two master cylinder attaching nuts and washers.
4. Remove the master cylinder from the mounting studs on the brake booster.
REPLACEMENT
LEAKAGE CHECK
1. Follow the procedure outlined in "Air Bleeding".
2. Continue bleeding and replacing the brake fluid until only clean fluid is expelled.
3. Fill the reservoir to the MAX level.
INSTALLATION
MASTER CYLINDER
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1. Position the master cylinder on the brake booster.
Refer
check push rod length.
Ebay User
ID:toreveleus1
Piston to push rod clearance Standard type
A.Place the SST on the master cylinder. Turn the adjusting bolt until it bottoms in the push rod hole in the piston
B.Apply 19.7 inHg (500 mmHg) vacuum to the power brake unit with a vacuum pump.
C.Invert the adjustment gauge used in Step 1 and place it on the power brake unit.
D.Measure the clearance between the end of the gauge and the push rod of the power brake unit. If it is not 0
in (0 mm), loosen the push rod locknut and turn the push rod to make the adjustment.
By making the above adjustment, the clearance between the push rod and piston (after installation of the
brake master cylinder to the power brake unit) will be as shown in the table below.
Vacuum applied to unit
Push rod-to-piston clearance
0 inHg (0 mmHg)
0.016~0.024 in (0.4~0.6 mm)
Approx. 19.7 inHg (500 mmHg)
0.004~0.016 in (0.1~0.4 mm)
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2. Install the master cylinder attaching washers and nuts. Tighten the master cylinder attaching nuts.
Tightening torque : 9.81~15.7 N·m (1.0~1.6 kg·m, 7~12 lb·ft)
3. Tighten the brake pipe flare nut with the SST.
Tightening torque : 13~22 N·m (1.3~2.2 kg·m, 10~16 lb·ft)
4. Connect the low fluid level sensor wiring.
5. Bleed the brakes.
DISASSEMBLY
1. Remove the cap and drain the master cylinder reservoir. Remove the master cylinder.
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2. Remove the level sensor with screwdriver. Ebay User ID: reveleus1
3. Remove the reservoir attaching screw.
4. Carefully pry the reservoir out of the master cylinder.
5. Remove the reservoir seals from the master cylinder.
6. Push the primary piston into the master cylinder bore to ease the snap ring removal. Remove the primary piston
snap ring and the primary piston.
7. Push the secondary piston into the master cylinder bore before removing the stop screw. Remove the
secondary piston stop screw.
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8. Remove the secondary piston assembly by gradually
the compressed air into the cylinder.
Use a rag to stop the secondary piston assembly. Do not use a petroleum based solvent, kerosene, or
gasoline for cleaning the master cylinder parts. Their use as a cleaning agent can leave residues which can
damage the rubber seals.
REASSEMBLY
As the master cylinder parts are assembled, they must be lubricated with a clean brake fluid.
1. Install new seals on the primary and secondary pistons.
2. Lubricate the secondary piston with a brake fluid and install.
3. Install the secondary piston stop screw and O-ring such like below.
Stopper screw and O-ring
A.Push the secondary piston assembly in fully.
B.Install and tighten a new O-ring and stop screw.
C.Push and release the piston to verify that it is held by the stop screw.
4. Install the primary piston.
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5. Install the primary piston snap ring. Push theEbay
piston
intoID:the
master cylinder bore to ease snap ring installation.
6. Install new reservoir seals.
7. Install the reservoir.
8. Install the master cylinder in the vehicle and bleed the system.
BRAKE FLUID
LEAKAGE INSPECTION
1. Depress the brake pedal several times, and inspect for leakage of the brake lines and system.
LEAKAGE CHECK (BRAKE FLUID LEVER)
1. Verify that the fluid level in the reservoir is between the MAX and MIN lines on the reservoir.
Add fluid if it is below MAX.
CHECK VALVE
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The check valve is pressed into the vacuum hose. The arrow on the hose indicates the direction of hose
installation (toward engine).
1. Remove the clamps and remove the hose (with the internal check valve).
2. Apply a suction and pressure to the hose from the engine side. Verify that air flows only toward the engine. If the
airpasses in both directions or not at all, replace the vacuum hose (along with the check valve).
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COMPONENTS
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REMOVAL
1. Remove the parking brake console after loosening console bolt.
2. Disconnect the indicator lamp switch connector.
3. Loosen the cable adjust nut.
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4. Remove the parking brake lever after loosening
nuts
a bolt.
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5. Disconnect the front cable from the rear cable by loosening attaching pin.
6. Remove the rear cable attaching bracket.
7. Remove the two rear seat hinge attaching bolts.
8. Remove the rear seat.
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9. Remove the side-door trim push reatiners. Ebay User ID: reveleus1
10. Remove the rear carpet push retainers and carefully pull the carpeting forward to expose the parking brake
cable cover.
11. Remove the parking brake cable cover attaching nut.
12. Remove the parking brake cable cover.
13. Raise and support vehicle.
14. Remove the rear wheel and tire assemblies.
15. Remove the rear brake drum and shoe assemblies.
(refer to rear drum brake)
16. Remove the parking brake cable from the brake shoe assembly.
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17. Loosen the parking brake cable attaching nut
andUser
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18. Pull the end of the cable through the body hole and romove from the vehicle.
19. Remove the parking brake cable from the back plate.
Installation
1.
2.
3.
4.
5.
Position the end of the cable through the body hole.
Put the parking brake cable into the back plate.
Install the parking brake cable on the brake shoe assembly.
Install the drum assembly (refer to rear drum brake)
Install the parking brake cable attaching nut and bolt.
Tightening torque: 19~26 N·m (19~26 kg·m, 14~19 lb·ft))
6. Install the wheel and tire assemblies.
7. Lower the vehicle.
8. Install the parking brake cable cover.
Tightening torque: 19~26 N·m (19~26 kg·m, 14~19 lb·ft))
9. Install the rear cable attaching bracket.
Tightening torque: 19~26 N·m (19~26 kg·m, 14~19 lb·ft))
10. Install the rear cable attaching bracket.
11. Install the rear carpet and rear side-door trim.
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12. Install the rear seat.
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Tightening torque: 19~26 N·m (19~26 kg·m, 14~19 lb·ft))
13. Secure the cable with the pin after connecting the front cable with the rear cable.
14. Install the parking brake lever.
Tightening torque: 19~26 N·m (19~26 kg·m, 14~19 lb·ft))
15. Route the end of the cable through the parking brake lever and then properly tighten the cable adjuster nut.
16. Install the parking brake indicator lamp switch.
17. Install the parking brake console.
Check that the stroke is within specification.
Check that the parking brake warning lamp illuminates when pulling the brake lever back one notch.
ADJUSTMENT
Parking brake cable
1. Ensure the parking brake lever is in the fully released position.
2. Raise the vehicle and ensure the rear wheels are free to turn.
3. Adjust the cable length with adjuster nut so that the number of sector notch is 5~7 when pulling force of 10kg.
The rear brakes should lock when the parking brake lever is pulled upward 5~7 notches.
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4. Do not attach parking cable with 90° or moreEbay
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5. Check the operation of the parking brake.
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REMOVAL AND INSTALLATION
1.
2.
3.
4.
5.
Remove the brake pipe shown in the figure.
Remove the bolt.
Remove the proportioning valve.
Install in the reverse order of removal.
After the installation, add a brake fluid, bleed air and check for the fluid leakage.
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INSPECTION
PROPORTIONING VALVE
1. Connect the SST to the brake pipes with adapters as shown in the figure.
Adapter and flare nut tightening torque : 12.8~21.5 N·m (130~220 kg·cm, 113~190 lb·in)
Disconnect and connect the brake pipes with SST.
2. Bleed the air from the brake system.
3. Depress the brake pedal until the master cylinder pressure equals to A; then record the rear brake pressure A'.
4. Depress the brake pedal again, apply the additional pressure until the pressure equals to B; then record the
pressure B'.
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FLUID PRESSURE
Master Cylinder Pressure
Rear Wheel Cylinder Pressure
A
2943 (30,427)
A'
2943 (30,427)
B
9810 (100,1422)
B'
5003 (51,725)
• Do not attempt to adjust the dual proportioning valve.
• After the inspection, bleed the air from the brake system and check for the fluid leakage.
• If the measurements are not within the specification, replace the valve assembly.
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COMPONENTS
Email: suzlever@gmail.com
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Email: suzlever@gmail.com
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REMOVAL
1.
2.
3.
4.
Raise and support the vehicle after releasing the parking brake
Remove the wheel and tire.
Remove the hub cap.
Use a small cape chisel to raise the staked edge of the lock nut.
Use carefully not to damage the groove and threads of spindle.
5. Remove the drum, washer and bearings as an assembly from the spindle.
6. Remove the brake shoe hold-down springs and pins.
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7. Remove the brake shoe assembly.
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8. Remove the parking brake cable from the brake shoe assembly.
9. Remove the wheel cylinder brake pipe.
10. Remove the wheel cylinder attaching bolt.
11. Remove the anti-rattle spring from brake shoe assembly.
12. Remove the operating lever after removing the return spring.
13. Remove the parking brake operating lever retainer.
DISASSEMBLY
1.
2.
3.
4.
Remove the dust boots and discard.
Remove the pistons and the return spring.
Remove the piston seals and discard.
Remove the bleeder screw and the ball seal.
Do not use petroleum based solvent, kerosene, or gasoline for cleaning wheel cylinder parts. Their use as a
cleaning agent can leave residues which can damage the rubber seals.
5. Wash the parts in clean denatured alcohol and dry with compressed air.
REASSEMBLY
1.
2.
3.
4.
Install the seals on the pistons.
Lubricate the wheel cylinder bore and pistons with the specified brake fluid.
Install the return spring, pistons, and dust boots.
Install the ball seal and the bleeder screw.
INSPECTION
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1. Inspect the inside of the brake drum for scratches and uneven or abnormal wear.
2. Repair minor damage or replace if damage is excessive.
3. Measure the inside diameter of the brake drum using Brake Drum Micrometer or equivalent.
4. The standard inner drum diameter is 7.87 inches (200 mm).
The maximum diameter is 7.91 in (201 mm).
Be sure to check the drum-to-shoe contact after repairing or replacing the brake drum.
5. Check the brake linings for peeling, cracks, or extremely uneven wear.
6. If the brake lining thickness is less than 0.04 inch (1.0 mm), replace the brake shoes.
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REMOVAL
ABS SENSOR (REAR)
1. Disconnect the negative battery cable from the battery.
2. Loosen the rear shock absorber attaching bolt.
3. Remove the ABS sensor from the back plate.
4. Remove the ABS sensor wire from the attaching clip.
5. After removing the rear seat and rear side door-trim, remove the ABS sensor and connector.
INSTALLATION
ABS SENSOR (REAR)
1. Install the ABS sensor and connect.
2. Install the rear seat and rear side door trim.
3. Install the ABS sensor wire attaching trim.
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4. Put the ABS sensor into the back plate and install
the ABS
sensor.
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Tightening torque: 8~12 N·m (0.8~1.2 kg·m, 6~8 lb·ft)
5. Install the rear shock absober attaching bolt.
Tightening torque: 78~98 N·m (8.0~10.0 kg·m, 58~72 lb·ft)
6. Connect the negative battery cable from the battery.
INSPECTION
1. Check rotor for damage.
2. Check if gap between rotor and sensor meets the specified value.
Gap : 0.012~0.043in (0.3~1.1 mm)
3. Remove the sensor rotor if necessary.
DISASSEMBLY/REASSEMBLY
1. Remove the rear brake drum from the vehicle.
2. Remove the sensor rotor by using the SST (0K670 990 AA0)
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3. Install the sensor rotor by using suitable tool.Ebay User ID: reveleus1
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SPECIAL SERVICE TOOLS
Tool
(Number and
Name)
Illustration
Use
0K130 430 019
Flare nut wrench
Used to remove
and install brake
pipe.
0KK30 430 017
Disc brake
expander
Used to assemble
disc pad.
0K670 990 AA0
Bearing puller set
Used to remove
sensor rotor.
0K370 430 018
Brake adjust
gauge
Used to adjust
push rod gap.
K2CA 089 HSP
Hi/scan pro
Used to diagnose
anti-lock brake
system.
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0KK30 140 001
Oil pressure
gauge & adapter
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Used to measure
brake fluid
pressure.
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SPECIFICATIONS
Model
Specifications
Item
Brake pedal
Type
Suspended
Pedal lever ratio
4.15 : 1
Max. stroke (in(mm))
5.0 (127)
Type
Tandem (with level sensor)
Cylinder bore diameter (in(mm))
0.87 (22.22)
Type
Ventilated disc
Cylinder bore (in(mm))
2.01 (51.1)
Master cylinder
Front disc
brake
Rear drum
brake
Braking force
control device
Pad dimensions (area × thickness) (in² (mm²) × in
5.89 (3800) × 0.39 (10)
(mm))
Disc plate dimensions (in(mm))(outer diameter ×
thickness)
9.25 × 0.87 (2.35 × 22)
Type
Leading-trailing
Wheel cylinder inner diameter (in(mm))
17.46 (0.6874)
Lining dimensions (in(mm)) (width × thickness)
0.98 × 0.19
(25 × 5)
Drum inner diameter (in(mm))
7.87 (200)
Shoe clearance adjustment
Automatic adjuster
Type
Proportioning valve (Without ABS)
Brake fluid
SAE J1703 or FMVSS 116, DOT-3, DOT-4
Type
Mechanical two-rear-wheel control
Operation system
Center lever
Parking brake
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TROUBLESHOOTING GUIDE
Condition
• Brake Warning Lamp in
Instrument Cluster ON
• Low Pedal
• Pedal Goes to Floor
(Excessive Pedal Travel)
• Brakes Grab
Possible source
Action
• Low fluid level
• FILL system. CHECK for leaks.
• Leaking master cylinder primary
piston cup.
• OVERHAUL or REPLACE master
cylinder.
• Parking brake not fully released.
• FREE up and ADJUST parking
brake. REPLACE defective parts.
• Parking brake wiring grounded.
• REPAIR parking brake wiring.
• Parking brake switch grounded.
• REPLACE parking brake switch.
• Rear brake self-adjuster not
operating properly.
• CHECK self-adjusting mechanism.
REPAIR or REPLACE defective parts.
• Caliper piston or slide pins
sticking.
• REPAIR or REPLACE caliper or slide
pins.
• Loose wheel bearings.
• DISASSEMBLE front spindles,
INSPECT bearings and ADJUST.
• Leak in hydraulic system.
• REPAIR leak. CHECK entire
hydraulic system. REFILL and
BLEED.
• Improper adjustment of pedal
play.
• ADJUST pedal.
• Air in system.
• BLEED brakes. CHECK for leaks.
• Worn master cylinder piston cups
or scored cylinder bore.
• OVERHAUL or REPLACE master
cylinder.
• Disc brake "knock back" (Pads
push caliper piston back into
caliper. Caused by excessive
rotor lateral runout or loose wheel
bearings.).
• CHECK rotor runout, MACHINE or
REPLACE rotor. ADJUST front wheel
bearings.
• Worn brake pads.
• REPLACE brake pads.
• Linings contaminated by grease
or brake fluid.
• REPLACE linings. REPAIR cause of
contamination.
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• Brake shoes
bent,
cracked or loose on platform.
• Brakes Drag
• Poor Braking
• REPLACE brake linings.
• Loose backing plate.
• TIGHTEN rear bearing hub attaching
bolts. REPLACE if worn or bent.
• Loose caliper slide pins or anchor
bolts.
• TIGHTEN slide pins or bolts. CHECK
for hole elongation.
• Hot spotted drums or rotors.
• REPLACE drums or rotors. CHECK
pads/shoes.
• Binding wheel cylinders or caliper
pistons.
• OVERHAUL or REPLACE wheel
cylinders or calipers.
• Frozen or incorrectly adjusted
parking brake components.
• REPAIR or REPLACE frozen
components.
• Frozen or incorrectly adjusted
parking brake components.
• REPAIR or REPLACE frozen
components.
• Broken or weak rear brake return
springs.
• REPLACE springs.
• Caliper or wheel cylinder pistons
frozen.
• OVERHAUL or REPLACE calipers or
wheel cylinders.
• Brake pedal binding at pivot
points.
• REPAIR or REPLACE brake pedal
bushings or pedal assembly.
• Brake On/Off(BOO) switch
incorrectly adjusted, not letting
pedal return.
• ADJUST Brake On/Off(BOO) switch.
• Power booster binding push rod
adjustment or binding assist unit.
• REPLACE binding power booster.
• Master cylinder compensating
ports plugged.
• UNPLUG compensating ports using
compressed air. REPLACE if
obstruction cannot be removed.
• Leak in hydraulic system.
• REPAIR leak. CHECK entire
hydraulic system. REFILL and
BLEED.
• Air in system.
• BLEED brakes. CHECK for leaks.
• Worn / damaged brake pad.
• REPLACE brake pad.
• Foreign material on brake pad.
• CLEAN or REPLACE brake pad.
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• Caliper piston
• Brake(s) Pull to One Side
• Brakes Do Not Release
• REPLACE caliper piston.
• Master cylinder malfunction.
• REPAIR or REPLACE master
cylinder.
• Power brake booster malfunction.
• REPLACE power brake booster.
• Check valve (vacuum hose)
malfunction.
• REPLACE check valve and vacuum
valve.
• Dual proportioning valve
malfunction.
• REPLACE dual proportioning valve.
• Damaged vacuum hose.
• REPLACE vacuum hose.
• Damaged flexible hose.
• REPLACE flexible hose.
• Worn/damaged brake pad.
• REPLACE brake pad.
• Foreign material on brake pad.
• CLEAN or REPLACE brake pad.
• Abnormal wear or distortion of
rotor.
• REPAIR or REPLACE rotor.
• Caliper piston malfunction.
• REPLACE caliper piston.
• Improper wheel alignment
adjustment.
• PERFORM wheel alignment
adjustment. REFER to Section 54.
• Improper tire air pressure.
• INFLATE tire to proper air pressure.
• Loose or damaged dust cover
mounting bolt.
• TIGHTEN or REPLACE dust cover
mounting bolt.
• Improper wheel bearing preload
adjustment.
• ADJUST preload or REPLACE wheel
bearing.
• No brake pedal play.
• ADJUST brake pedal play.
• Improper push rod clearance
adjustment.
• ADJUST push rod for proper
clearance.
• Master cylinder return port
clogged.
• CLEAN return port on the master
cylinder.
• Caliper piston malfunction
• REPLACE caliper piston.
• Excessive rotor runout.
• REPLACE rotor.
• Brake pad not returning properly.
• CHECK and REPLACE brake pad if
necessary.
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• Improper wheel
bearing
preload
adjustment.
• ADJUST preload or REPLACE wheel
bearing.
• Worn / damaged brake pad.
• REPLACE brake pad.
• Loose caliper mounting bolt.
• TIGHTEN caliper mounting bolt.
• Insufficient grease on sliding
parts.
• APPLY grease where necessary.
• Foreign material or scratches on
rotor contact surface.
• CLEAN rotor contact surface.
• Damaged rotor contact surface.
• REPLACE rotor.
• Lack of vacuum to the power
booster.
• REPAIR vacuum supply to power
booster.
• Vacuum check valve restricted.
• TEST and REPLACE check valve as
necessary.
• Restricted vacuum hose.
• REPAIR or REPLACE hose as
necessary.
• Groaning Noise
• Dry or rough brake cable holders.
• LUBRICATE cable and cable holders.
• Brake Pedal Pulsates
• Brake drums out-of-round.
• REPLACE drums.
• Disc rotors have excessive lateral
runout.
• MACHINE rotors, REPLACE if
necessary.
• Loose wheel bearings.
• INSPECT and ADJUST wheel
bearings.
• Bent front / rear spindles.
• REPLACE spindle.
• Bent or distorted hub mounting
flange.
• REPLACE hub.
• Worn brake linings.
• REPLACE linings.
• Bent, cracked brake lining
platforms on backing plate.
• REPLACE linings. REPLACE
backing plate.
• Foreign objects in linings.
• REPLACE linings, CHECK drums for
scoring.
• Cracked or heat checked drums
or rotors.
• REPLACE drums or rotors. CHECK
pads / shoes.
• Broken or loose rear brake holddown or return springs.
• REPLACE hold-down or return
springs.
• Abnormal Noise or
Vibration During Braking
• Low or Hard Pedal
• Brake Noise
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• Dry or rough
backing
plate
slide
pads.
• SAND and LUBRICATE slide pads.
• Loose or missing disc brake antirattle springs.
• REPAIR or REPLACE anti-rattle
springs.
• Loose caliper mounting bolts.
• TIGHTEN mounting bolts, CHECK for
hole elongation.
TROUBLESHOOTING GUIDE
Problem
Possible cause
Action
Brakes do not release
Improper return of parking brake cable or
improper adjustment
Repair or adjust
Parking brake does not hold well
Excessive lever stroke
Adjust
Brake cable stuck or damaged
Repair or replace
Brake fluid or oil on lining
Clean or replace
Hardening of lining surface or poor contact
Grind or replace
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REMOVAL(PRESSURE PLATE AND CLUTCH DISC)
Do not allow oil or grease to contaminate the clutch disc facing. Even a trace of oil or grease may cause clutch
grabbing or slipping. Handle the disc by its edges and do not touch the facing.
1. Remove the transaxle. Refer to Section MT.
2. If the pressure plate will be reused, paint or scribe the alignment marks on the pressure plate and flywheel for
assembly reference.
Loosen the pressure plate bolts one turn at a time to release the pressure plate spring tension evenly. A
failure to release the tension evenly could cause distortion of the pressure plate.
3. Remove the pressure plate bolts, the pressure plate, and the clutch disc. While loosening the bolts, use SST to
prevent turning of the flywheel.
INSTALLATION
1. Position the clutch disc on the flywheel and hold it in position with SST.
Use the marks which were made during removal for the alignment reference.
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2. Position the pressure plate on the flywheel and
install
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Tighten the bolts evenly and alternately to prevent distortion of the pressure plate.
3. Tighten the pressure plate bolts.
Tightening torque : 13~20 lb·ft (18~26 N·m, 1.8~2.7 kg·m)
4. Remove the clutch alignment tool.
Before installing the transaxle, clean the clutch disc splines on the input shaft and coat them with a light film
of a Clutch Grease, or equivalent.
5. Install the transaxle. Refer to Section MT.
INSPECTION
PRESSURE PLATE AND CLUTCH DISC
1. Check the following parts, and repair or replace those if necessary.
CLUTCH COVER
1. Check the contact surface of the clutch disc for scorings, cracks, or discoloration.
Minor scoring or discoloration should be removed with a sandpaper.
2. Inspect the diaphragm spring for damage, or damage to the cover.
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CLUTCH DISC
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1. Check the facing surface for hardening or oil contamination.
Use sandpaper if the contamination is minor.
2. Inspect for looseness of the facing rivets.
3. To inspect for a worn clutch disc, measure the depth to the rivet heads with a slide caliper.
Depth : 0.012 in (0.3 mm) min
4. Inspect the run-out of the clutch disc.
Lateral run-out : 0.027 in (0.7 mm) max.
Vertical run-out : 0.039 in (1.0 mm) max.
5. Inspect for wear or rust on the splines. Remove any minor rust.
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CLUTCH PEDAL REMOVAL
1.
2.
3.
4.
5.
6.
Loosen the cable adjuster nut at the transaxle release lever until the cable can be disengaged from the lever.
Remove the clip securing the cable case to the pedal support bracket.
Pull upward on the cable and disengage it from the hook on the pedal.
Remove the attaching nut, lockwasher, and flatwasher from the end of the pivot bolt.
Slide off the clutch pedal and return spring from the pivot bolt.
If necessary, remove the pedal pad, stop bumper, and bushings from the pedal.
Apply a grease (lithium base, NGLI No.2) to the bushings and pivot points.
CLUTCH CABLE REMOVAL
1.
2.
3.
4.
Loosen the cable adjuster nut at the transaxle release lever until the cable can be disengaged from the lever.
Remove the bolts attaching the cable routing bracket to the transaxle.
Remove the clip which is securing the cable case to the pedal support bracket.
Pull upward on the cable and disengage it from the hook on the pedal.
5. If necessary, loosen the attaching nut and remove the routing bracket.
6. Remove the cable through the hole in the bulkhead.
CLUTCH PEDAL INSTALLATION
To install, rverse the removal proedure.
CLUTCH CABLE INSTALLATION
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To install, reverse the removal procedure. Adjust
theUser
clutch
free play. Refer to the procedures in this section.
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INSPECTION
Check the following parts and replace if necessary.
1. Worn or damaged bushings.
2. Twisted or bent clutch pedal.
3. Worn or damaged pedal pad.
4. Damage to the inner or outer cable.
5. Function of the cable.
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REMOVAL
1. Remove the transaxle. Refer to Section MT.
2. Remove the release fork attaching bolt.
3. Remove the release bearing.
RELEASE FORK / LEVER REMOVAL
1. Remove th transaxle. Refer to Secton MT.
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2. Remove the release fork attaching bolt (Reamer
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3. Remove the release bearing.
4. Remove eh release lever return spring.
5. Slide the release lever upward out of the release fork and remove the fork.
6. Slide the release lever out of the transaxle clutch housing.
7. Remove the release lever bushings from the transaxle clutch housing.
CLUTCH RELEASE BEARING INSTALLATION
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1. Apply a light film of Lubricant XG-1-C, or equivalent,
onID:
the
following areas :
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A.The sliding surface on the transaxle bearing support
B.The release fork where it contacts the bearing
C.The front of the bearing where the pressure plate release spring contacts
Fill only the groove and remove all the excess grease from the bearing hub. If the excess grease remains in
the hub, it can be forced onto the clutch disc splines where it may contaminate the clutch friction surfaces.
2. Fill the groove in the release bearing hub with a Lubricant XG-1-C, or equivalent. Also, apply a light film of
lubricanton the release fork contact area. The lubricant areas are shown in the right illustration.
3. Install the release bearing.
4. Install the release fork attaching bolt. Tighten the attaching bolt.
Tightening torque : 26~30lb·ft(35~41 N·m, 3.6~4.2 kg·m)
5. Install the transaxle. Refer to Section MT.
RELEASE FORK / LEVER (INSTALLATION)
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Apply a light film of Lubricant XG-1-C, or equivalent, to the inside of the bushing before installing.
1. Install therelease lever bushings.
2. Install the release bearing. Refer to the Release Bearing installation procedure for the proper lubrication of the
bearing.
3. position the release fork and install the release lever.
4. Install the release lever ruturn spring.
5. Align the bolt holes in the release fork and lever shaft.
6. Install the release fork attaching bolt and tighten.
Tightening torqu : 26~30 lb·ft(36~41N·m, 3.6~4.2 kg·m)
7. Install the transaxle. Refer toSection MT.
INSPECTION
The clutch release bearing is sealed, and should not be washed in solvent.
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1. Turn bearing while applying force in axial direction.
If bearing
sticks or has excessive resistance, replace it.
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SERVICE ADJUSTEMEN PROCEDURE (PEDAL FREEPLAY)
1. Depress the pedal lightly by hand and measure the freeplay, and ensure that it is within the specification.
Pedal freeplay : 0.35~0.59 in (9~15 mm)
2. Depress the release lever and pull the pin away from the lever, then adjust the clearance A by turning the adjust
nut B.
Standard clearnace : 0.06~0.10 in (1.5~2.5 mm)
3. After the adjustment ensure that when the clutch is disengaged, the distance between the dash lower panel and
the upper center of the pedal pad is within the specification.
Disengagement height : (ithout carpet) 3.28 in (83.2 mm) min.
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SERVICE ADJUSTMENT PROCEDURE (PEDAL HEIGHT)
1. Disconnect the clutch cable at the transaxle release lever to eliminate the possibility that the clutch cable is
affecting pedal height.
2. Measure the distance from the upper center of the pedal pad to the dash lower panel and ensure the distance is
within the specification.
Pedal height : (Without Carpet) 7.677in (195mm)
3. Inspect the clutch pedal mounting for damaged, worn, or missing parts.
4. To adjust the pedal height, loosen the lock nut A and turn the clutch switch until the lower pedal is at the
specified height.
5. Tighten the lock nut A.
Tightening torque : 0~13 lb·ft (14~18 N·m, 1.4~1.8 kg·m
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COMPONENTS
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DESCRIPTION AND OPERATION
The transaxle input shaft is linked to the engine through a mechanical clutch consisting of a Belleville spring-type pressure
plate, and a 7.87 in(200mm) friction disc for A3 and A5 engines. After it has passed through the clutch disc splines, the input
shaft is support in the flywheel on a small, fully sealed ball bearing.
The holding force switch is exerted by the pressure plate against the clutch disc is released by a pedal-operated cable linked
to a release lever, release fork, and release bearing.
The clutch pedal is suspended with the brake pedal, from a support racket welded to the body. Both pedals hang from the
support bracket on a common pivot bolt secured in position by a nut and two washers.
From the top lf the clutch pedal, the cable extends to a release lever at the transaxle. The clutch system operates as follows :
• When the clutch pedal is pressed, the cable and release lever rotate a shaft that enters the transaxle clutch housing and
connects to the clutch release fork.
• As the shaft rotates, the fork slides the release bearing support until it contacts and releases the pressure plate.
• When the pedal is released, springs attached to the support bracket an release lever return the clutch release
components to the normal applied position.
Clutch pedalfree play is adjusted where the clable passes through the release lever. A nut on the threaded end of the cable
is used to reposition the pin that engages the release lever. Repositioning the pin adjusts pedal free play by lengthening or
shortening the cable.
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SPECIAL SERVICE TOOLS
Tool(Number and Name)
Illustration
Use
0K 130 111 002
Ring gear brake
To prevent the flywheel from
turning
0K 130 171 013
Bearing puller
To remove he pilot bearing
0K 130 160 010
Clutch disc centering
Used to fix clutch disc centering
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SPECIFICATION
Engine Type
Item
A5D
Clutch control type
Cable type
Type
Diapgragm spring
Clutch cover
Set load N(kgf, lb)
4248(433,953)
Outer diameter (in(mm))
7.87(200)
Inner diameter (in(mm))
2.12(130)
Clutch disc
Pressure plate side
(in(mm))
0.138(3.5)
Flywheel sode (in
(mm))
0.138 (3.5)
Tehickness
Type
Clutch pedal
Suppended
Full stroke (in(mm))
5.091 (129.3)
Height (in(mm))
7.677 (195)
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TROUBLESHOOTING GUIDE
Trouble
Possible cause
Remedy
Slippage
Facing worn excessively
Facing surface hardened or contaminated with oil
Clutch cove deformed
Diaphragm sprign damaged or fatigued
Excessive clutch pedal play
Clutch pedal not functioning smoothrly
Flywheel warped
Clutch cable not functioning smoothly
Replace
Repair or replace
Repair or replace
Repalace
Adjust
Repair or repalce
Repair or replace
Repalce
Poor disengagement
Excessive deflection and diformity of clutch disc
Clutch disc spline worn or rusted
Oil on the facing surfacd
Diaphragm spring fatigued
Excessive clutch pedal play
Replace
Replace or remove he rust
Clean or replace
Replace
Adjust
Clutch judders when
engaging
Oil on facing surface
Torsion spring fatigued
Facing surface hardened or deformed
Facing rivets loose
Diaphragm spring fatigued
Clutch cover excessively warped
Flywheel surface hardened or warped
Engine mount loose or fatigued
Clean or replace
Replace
Repair or replace
Replace
Replace
Replace
Repair or replace
Refer to Section EM
Clutch pedal does not
funcion smoothly
Pedal shaft not properly lubricated
Cable not properly lubricated
Cale kinked
Lubricate or replace
Lubricate or repalce
Repair or replace
Noise
Release bearing damaged
Poor lubication of release bearing sleeve
Worn sliding part of release fork
Torsion spring fatigued
Pedal freeplay insufficient
Excessive crankshaft end play
Replace
Lubricate or replace
Realce
Realce
Adjust
Refer to Section EM
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DESCRIPTION AND OPERATION
The halfshafts are the mechanical link that transfer the engine torquefrom the transaxle and differential to the front
wheels. At the transaxleend, the halfshafts are splined to the differential side gears. Disengagementof the shaft
from the gear is prevented by an expanding spring steel circlip.During the installation, the clip compresses around
the shaft as it entersthe gear. Once through the differential gear, the clip expands into a counterboremachined into
the back side of the gear.
The wheel end of the halfshafts are splined to the wheel hubs whichare supported on the opposed tapered wheel
bearings. Disengagement of theshaft from the wheel hub is prevented by a washer and an attaching nut.
A backlash between the wheel hub and halfshaft is eliminated by thesplines. The wheel hub splines are machined
straight while the halfshaft splinesare machined with a slight helical cut.
Constant Velocity (CV) joints are installed at both ends of the halfshafts.
Two different types of CV joints are used. The inboard CV joints arerepairable tripod CV joints. The outboard CV
joints are non-repairable BirfieldCV joints.
Tripod CV joints are used to prevent the transfer of engine vibrationthrough the halfshafts to the vehicle body.
Additional reduction of vibrationis provided by a dynamic damper installed approximately in the middle of theright
halfshaft.
CV joints are necessary because the halfshaft is required to transmittorque while compensating for front
suspension movement. As the suspensionmoves, the CV joints allow the halfshaft to change length and operate
smoothlythrough varying angles.
For the necessary flexibility, Birfield CV joints use ball bearingspositioned by a cage. The tripod CV joint uses three
balls mounted on needlebearings and a spider. In both types of joints, the outer race is machinedinto the CV joint
housing.
The tripod CV joints can be disassembled and serviced. Other than theCV joint boot, the outboard Birfield CV joint
is serviced only as an assemblywith the shaft.
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COMPONENTS
• Clamp the shaft in a vice. Use protectors in the vice to avoid damage.
• Do not allow dust or foreign material to enter the joint during disassembly or assembly.
• Do not disassemble the ball-joint at the wheel side. Do not wipe off the grease if there is no problem.
• Do not remove the clip used to secure the tripod joint to the differential side gear if there is no problem. If the clip is
removed, replace it with a new one.
COMPONENTS
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DISASSEMBLY
1. Clamp the halfshaft in a vise. Do not allow the vise to contact the boot or its clamps.
2. Remove the large boot clamp. Side cutters can be used to cut the clamp. After removing the clamp, roll the boot
back over the shaft.
3. Remove the wire ring bearing retainer.
4. Mark the matching marks on the spider and tripod housing
Mark with a paint, do not use a punch.
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5. Remove the outer race.
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6. Make the matching marks on the drive shaft end and spider.
7. Remove the tripod joint snap ring.
8. Tap the boss with a hammer and rod to remove the spider assembly.
Do not tap on the rollers.
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If the boot is to be reused, wrap the halfshaft splines with a tape before removing it from the shaft.
If necessary, remove the small boot clamp and the CV joint boot from the halfshaft.
INSPECTION
Check the following parts:
1. Twisted or cracked driveshaft.
2. Worn splines.
3. Excessively loose joint.
4. Cracked or damaged boots.
REASSEMBLY
1. Install the tripod assembly on the halfshaft.
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2. Tap the assembly onto the shaft by using a hammer
and
drift.
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3. Install the tripod assembly retaining ring.
4. Fill the CV joint outer race with 3.5 oz (100 mg) of the specified grease.
5. Install the outer race over the tripod joint and install the wire ring bearing retainer.
6. Position the CV joint boot. Make sure the boot is fully seated in the grooves in the shaft and outer race.
7. Extend or compress the joint as necessary until the distance between the CV joint boot clamp grooves
measures 2.66 in (67.5 mm).
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8. Insert a dulled screwdriver blade between the
bootUser
andID:
thereveleus1
outer bearing race to allow trapped air to escape
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from the boot.
9. Install new boot clamp(s). wrap the clamps around the boots in a clockwise direction, pull tight with pliers, and
bend the locking tabs to secure in position.
• Always use new bands.
• Bands should install so that their pointed ends initially point in forward direction of rotation.
10. Using a boot band tool, place pincer jaws in closing hooks of boot band.
11. Secure clamp by drawing closing hooks together.
12. After assembling the driveshaft, check to make sure the joint parts move smoothly in the directions indicated by
the arrows. Check the boots for grease leaks or damage.
REMOVAL
1. Jack up the front of the chassis and support it with a safety stands.
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2. Drain the transaxle oil.
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3. Remove the front wheel and tire assemblies.
4. Raise the nut tab and loosen the driveshaft lock nut, but do not remove it.
When loosening the nut, lock the hub by applying brakes.
5. Remove the tension rod mounting nuts.
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6. Remove the ball joint clamp bolt and nut from
the User
lowerID:
arm.
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7. Pry down the lower arm and disconnect the ball-joint.
Be careful not to damage the ball-joint dust boot.
8. Remove the stabilizer bar from the control link after loosening the control link nut.
(Refer to section SS-Suspension system)
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9. Separate the driveshaft from the transaxle. Ebay User ID: reveleus1
Separate the shaft by pulling the hub outward. Do not use too much force at once, increase the force
gradually. (If the shaft is pulled out too quickly, the oil seal may be damaged.)
10. Remove the driveshaft lock nut and discard.
11. Pull the driveshaft out of the wheel hub.
Be especially careful not to damage the oil seal at this time.
12. Pull the driveshaft out of the transaxle. Discard the circlip.
13. Install the differential side gear holder into the transaxle to fix the side gear.
INSTALLATION
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1. Check the driveshaft length.
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When measuring the length the ball-joint must be fully pushed toward the driveshaft.
A5 (in (mm))
Right shaft
Left shaft
Dynamic damper
M/T
A/T
14.54
14.93
(369.2)
(379.2)
25.67
25.67
(652)
(652)
L
L
A
19.13 0± 0.138 (486 ± 3.5)
2. Install a new circlip on the inboard halfshaft end.
3. Lubricate the inboard end of the halfshaft with grease.
4. Install the inboard end of the halfshaft into the differential side gear.
Insert the halfshaft carefully so as not to damage the oil seal.
5. Lubricate the outboard end of the halfshaft with grease.
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6. Insert the outboard end of the halfshaft into the
wheel
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Insert the halfshaft carefully so as not to damage the oil seal.
7. Install a new halfshaft attaching nut onto the halfshaft and finger-tighten.
8. Push up the lower arm and reconnect the ball joint.
Use caution to avoid damaging the ball joint dust boot.
9. Install the clamp nut and bolt on the lower arm.
10. Install a new driveshaft lock nut. Tighten to the specified torque and stake the lock nut, ensuring that it seats
into the groove in the driveshaft.
Driveshaft lock nut : 116~174 lb·ft (157~235 N·m, 16~24 kg·m)
Knuckle to lower arm ball-joint : 40~50 lb·ft (54~68 N·m, 5.5~6.9 kg·m)
11. Install the stabilizer bar to the control link.
Tightening torque : 32~45 lb·ft (43~60.8 N·m, 14.4~6.2 kg·m)
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12. Install the tension rod mounting bracket nuts
andUser
tighten.
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ID: reveleus1
Tightening torque : 87~108 lb·ft (118~147 N·m, 12~15 kg·m)
13. Install the front wheel.
1)After installation, pull the front hub outward to check that the driveshaft does not come out.
2)Do not stake the lock nut with a pointed tool.
3)Check that the wheel hub can be turned smoothly by hand.
14. Refill the transaxle with the specified grade and quantity of transaxle oil.
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COMPONENTS
Email: suzlever@gmail.com
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Email: suzlever@gmail.com
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DESCRIPTION
The front wheel mounting area on each side of the vehicle is located at the junction of various drive, steering,
braking, and suspension components. The outboard length of the halfshaft is the front wheel drive member. The
steering knuckle is the steering, suspension, and support member for the wheels. As a steering member, the
knuckle is connected to the steering gear tie rod end. As a suspension member, the knuckle is connected to the
control arm and MacPherson strut. As a support member, the knuckle contains the wheel hub bearings. The brake
components associated with the front hubsinclude the disc brake caliper, which is mounted on the steering
knuckle, and the disc brake rotor.
The wheel hub is supported in the steering knuckle on opposed tapered roller bearings. A press fit secures the
bearing inner races to the hub and the outer races in the steering knuckle. Bearing preload is set using a selective
spacer that is installed in the steering knuckle between the inner and outer bearings and the races.
The halfshaft, which is splined to the hub, is secured to the hub with a staked nut and a large flat washer.
Whenever the nut is loosened, it must be replaced with a new nut.
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REMOVAL
1. Raise the front of the vehicle and support it with a safety stands.
2. Remove the wheel.
3. Raise the nut tab and remove the driveshaft locknut. Discard the locknut, regardless of condition.
Use care not to damage the groove and threads in the driveshaft end.
When loosening the nut, lock the hub by applying the brakes.
4. Remove the cotter pin and the tie rod end attaching nut. Discard the cotter pin, regardless of condition.
5. Separate the tie-rod end from the knuckle with the SST.
If it is difficult to separate, hit the knuckle with a hammer.
6. Remove the caliper assembly from the knuckle. Do not allow the caliper to hang freely by its flexible hose. Suspend the
assembly by rope or wire from the Macpherson strut.
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7. Remove the ABS speed sensor and the wheel speed sensor #(RH side).
8. Remove the disc rotor.
9. Remove the clamp bolt and nut. Push the lower arm downward to separate the knuckle and the ball-joint.
10. Remove the bolts and nuts which couple the knuckle and the shock absorber.
11. Separate the front hub and the knuckle from the driveshaft.
INSTALLATION
1. Mount the front hub and knuckle to the driveshaft.
2. Mount the knuckle to the lower arm ball-joint and to the shock absorber.
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3. Tighten the mounting bolts and nuts.
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Tightening torque :
Knuckle to shock absorber 76~90 lb·ft (103~122 N·m, 10.5~12.5 kg·m)
knuckle to lower arm ball-joint 40~50 lb·ft (54~68 N·m, 5.5~6.9 kg·m)
4. Install the disc rotor.
Tightening torque : 7.2~10.8 lb·ft (9.8~14.7 N·m, 1.0~1.5 kg·m)
5. Install the disc brake caliper assembly.
Tightening torque : 29~36 lb·ft (39~49 N·m, 4.0~5.0 kg·m)
6. Position the caliper hose in the strut routing bracket and install the retaining clip.
7. Use a new driveshaft lock nut, tighten it to the specified torque and stake it securely into the groove.
Tightening torque : 116~174 lb·ft (157~235 N·m, 16.0~24.0 kg·m)
• Do not use a sharp edge tool for staking. If the nut cracks even slightly during staking, replace it with another new
one.
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• Check that the wheel hub turns freely by hand.
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8. Install the tie-rod end to the knuckle and tighten the nut.
Tightening torque : 32~41 lb·-ft (47~52 N·m, 3.8~5.3 kg·m)
Use a new cotter pin.
9. Install a new cotter pin through the tie rod end attaching nut and the tie rod ball stud.
If the openings in the nut and the hole in the tie rod ball stud fail to line up, tighten the nut slightly just to the point of
alignment. Never loosen the nut.
Tightening torque : 65~87 lb·ft (88~118 N·m, 9.0~12.0 kg·m)
10. Install the ABS speed sensor and the wheel speed sensor.
Tightening torque : 6~8 lb·ft (8~12 N·m, 0.8~1.2 kg·m)
11. Install the wheel and tighten the wheel lug bolts.
REASSEMBLY
FRONT HUB/KNUCKLE
• Do not remove the dust cover unless necessary for repairs.
• Do not confuse the inner bearing with the outer bearing.
COMPONENT
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REASSEMBLY
WHEEL BEARING PRELOAD
If the bearings or knuckle have been replaced, the bearing preload must be checked before assembly. If necessary, refer
to the procedure in this Section.
1. If the dust shield was removed, install a new one by using the Dust Shield Replacer or equivalent.
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2. Install the bearing races in the steering knuckle. Ebay User ID: reveleus1
3. Pack the bearings with the Lubricant lithium grease. Pack the hub area as shown in the figure.
4. Place the inner bearing into the steering knuckle bore so that it rests in a level position.
5. Lubricate the lip of the new inner oil seal. Apply a sufficient amount of lubricate to the cutting parts along the edge of seal
lip.
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6. Install the new inner oil seal in the bore.
Ebay User ID: reveleus1
7. Place the original bearing preload spacer, or the spacer selected from the bearing preload check procedure in the steering
knuckle bore.
8. Position the outer bearing in the steering knuckle bore.
9. Lubricate the lip of a new outer oil seal.
10. Install the new outer oil seal in the steering knuckle bore.
11. Install the knuckle assembly.
12. Use the SST and position the wheel hub assembly in the steering knuckle bore.
DISASSEMBLY
FRONT HUB/KNUCKLE
1. Remove the knuckle assembly.
2. Remove the wheel hub assembly by using the SST.
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3. Remove the outer bearing, outer oil seal, outer bearing
raceID:
and
spacer from the wheel hub by using the SST.
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reveleus1
Hold the hub to prevent it from falling.
4. Discard the oil seal, regardless of condition.
5. Disassemble the knuckle assembly.
Remove the race gradually and carefully.
6. Remove the oil seal (inner) with a screwdriver.
7. Remove the wheel bearing (inner).
8. Remove the bearing race (inner) with the SST and a hammer.
Tap on the bearing race (inner) only.
Do not remove the dust cover if it is not necessary.
Do not reuse the dust cover if it is removed once.
9. Mark the dust cover and knuckle for the proper reassembly.
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10. Remove the dust cover with a chisel.
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INSPECTION
FRONT HUB/KNUCKLE
1. Wash the disassembled parts before inspecting. Replace any damaged parts. Minor rust should be removed with a fine
sandpaper.
Inspect for :
1. Abnormal wear, damage or seizure of bearing.
Replace the bearing as a set (inner and outer races).
2. Cracks or damage of the knuckle. Scoring or rust of the bearing bore.
3. Damaged dust cover or poor fit with knuckle.
4. Cracks or damage of the hub. Scoring or rust of the bearing bore. Wear at the oil seal contact surface.
ADJUSTMENT
WHEEL BEARING PRELOAD
1. Insert the two wheel bearings and removed spacer into the steering knuckle and attach the SST.
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2. Secure the bottom of the SST.
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3. Tighten the nut of the SST to the specified torque.
Tightening torque : 116~173 lb·ft (157~235 N·m, 16~24 kg·m)
When tightening, tighten it with 49 N·m (5 kg-m, 36 lb-ft) step by step to prevent applying the excessive preload.
4. Rotate the steering knuckle to seat the wheel bearings.
5. Measure the wheel bearing preload with the SST and a pull scale.
Wheel bearing preload : 2.17~10.41 lb·in (0.25~1.17 N·m, 2.5~12 kg·cm)
0.55~2.64 lb (2.5~11.7 N, 0.25~1.2kg)
(pull scale reading)
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6. If the preload is not within the specification, select
the User
proper
from the table to adjust it.
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ID:spacer
reveleus1
Increase the spacer thickness to reduce the preload and decrease it to increase the preload.When a spacer is
changed by 1 rank, the preload changes 0.2 to 0.4 N.m (2.0~4.0 kg·cm, 1.7~3.5 lb·in)The rank marking is stamped on
the outer periphery of the spacer.
Mark
Thickness (in (mm))
Mark
Thickness (in (mm))
1
0.2474 (6.285)
12
0.2648 (6.725)
2
0.2490 (6.325)
13
0.2663 (6.765)
3
0.2506 (6.365)
14
0.2679 (6.805)
4
0.2522 (6.405)
15
0.2695 (6.845)
5
0.2538 (6.445)
16
0.2711 (6.885)
6
0.2554 (6.485)
17
0.2726 (6.925)
7
0.2570 (6.525)
18
0.2742 (6.965)
8
0.2585 (6.565)
19
0.2758 (7.005)
9
0.2600 (6.605)
20
0.2774 (7.045)
10
0.2616 (6.645)
21
0.2789 (7.085)
11
0.2631 (6.685)
7. Remove the SST.
Wheel bearing (outer & inner), oil seal (outer), and spacer
Completely fill the shaded area shown in the figure with a lithium grease.
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COMPONENTS
Email: suzlever@gmail.com
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DESCRIPTION
The rear wheels and brake drums are supported on the opposed tapered roller bearings. The bearing inner races
ride on a spindle attached to the torsion beam.
The outer bearing races are pressed into a hub that is an integral part of the brake drum. Contamination of the
bearing lubricant is prevented by a seal on the inboard side and a grease cap on the outboard side.
The brake drum/hub bearing assembly is attached to the spindle with a nut.
The nut and washer are used to hold the bearings and hub in position on the spindle and set the bearing preload.
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REMOVAL
REAR HUB/AXLE
1.
2.
3.
4.
Raise the rear of the vehicle and support it with a safety stands.
Remove the wheel and tire.
Remove the hub cap.
Use a small cape chisel to raise the staked edge of the lock nut.
Use care not to damage the groove and threads of spindle.
5. Remove the drum, washer and bearings as an assembly from the spindle.
If it is difficult to remove the brake drum, increase the shoe clearance.
6. Remove the rear brake shoe assembly and brake pipe.
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7. Remove the sensor rotor by using SST(for ABS).
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8. Remove the bearing oil seal. Discard the seal.
9. Remove the inner bearings from the bearing hub.
If the bearings are to be reused, they should be tagged so that they can be installed in their orignal positions.
10. Remove the inner and outer bearing outer races by using SST.
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11. Remove the wheel speed sensor (for ABS).Ebay User ID: reveleus1
12. Remove the spindle attaching nuts.
13. Remove the backing plate and then support the backing plate with the wire, and remove the spindle.
14. Remove the serration bolt by using a press.
• Do not remove the serration bolt if it is not necessary.
• Do not reuse the serration bolt if it is removed once.
INSTALLATION
REAR HUB/AXLE
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1. Install new serration bolts by using a press. Ebay User ID: reveleus1
2. Install wheel speed sensor (for ABS).
3. Install the backing plate.
4. Install the spindle attaching nuts.
Tightening torque: 32~45 lb·ft (43~61 N·m, 4.4~6.2 kg·m)
5. Tighten the wheel speed sensor (for ABS).
Tightening torque: 13~19 lb·ft (17.6~26.5 N·m, 1.8~2.7 kg·m)
6. Install the rear brake assembly and brake pipe.
(Refer to BR Gr-Brake system)
7. Install the outer bearing race by using a hammer.
Tap in until the outer race is fully seated in the hub.
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8. Position the inner bearing in the bearing hub.
9. Lubricate the oil seal lip with a lithium grease.
10. Install an oil seal.
11. Install the sensor rotor by using a flat plate to press it is (for ABS).
• Use a new oil seal, and coat the lip with grease in the middle of the right halfshaft.
• Do not hit the oil seal directly with a hammer.
12. Completely fill the area shaded in the figure with a lithium grease.
13. Position the brake drum bearings and hub assembly on the spindle.
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14. Keep the drum which is centered on the spindle
prevent
a damage to the oil seal and spindle threads.
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ID: reveleus1
15. Install the outer bearing.
16. Install the washer.
17. Install new lock nut.
18. Adjust the bearing preload.
Bearing Preload: 5.6~8.6 lb·ft (0.63~0.98 N·m, 6.5~10 kg·cm)
19. Fix lock nut to the groove firmly.
Inside loosening of lock nut: more 14.4 lb·ft (19.6 N·m, 2 kg·m)
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20. Install hub cap.
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BEARING PRELOAD
1.
2.
3.
4.
Make sure the parking brake is fully released.
Remove the wheel and tire assembly.
Remove the grease cap.
Rotate the brake drum to make sure there is no brake drag.
5. Seat the bearings by tightening the nut after raising the nut tap.
Tightening torque 18~22 lb·ft :(25~29 N·m, 2.5~2.9 kg·m)
6. Loosen the nut slightly until it can be turned by hand.
Before the bearing preload can be set, the amount of seal drag mustbe measured and added to the required
preload.
7. Use a pull scale and measure the oil seal drag.
8. Pull the scale squarely. Take the oil seal drag value when the wheelhub starts to turn, and record it.
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9. Add the oil seal drag value in the previous step
to User
the specified
valueof 0.6~1.9 lb (2.6~8.5 N, 0.26~0.87 kg).
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ID: reveleus1
This isregarded as the standard bearing preload.
10. Turn the nut slowly to adjust to the standard bearing preload whilechecking with the pull scale.
11. Firmly fix the lock nut to the groove.
12. Install the hub cap.
13. Install the wheel and tire assembly.
Tightening torque : 65~87 lb·ft (88~118 N·m, 9.0~12.0 kg·m)
INSPECTION
BEARING
check the following and replace if necessary.
1. Abnormal wear, damage or seizure of bearing.
Replace the bearing as a set (inner and outer races).
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2. Damaged hub cap.
3. Wear or rust of oil seal? contact surface.
4. Crack or damage of rear hub spindle.
BRAKE DRUM
1. Wear or damage on the brake drum.
Remove the minor rust with a sandpaper.
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SERVICE ADJUSTMENT PROCEDURE
BOOT
1. Check the boots on the driveshaft for cracks, damage, grease leakageor loose boot bands. If any damage is
found, replace the boot.
SPLINE LOOSENESS
1. Turn the driveshaft by hand and check that the spline and joint arenot excessively loose.
If a damage is found or joint is loose, replace or repair.
TWISTED OR CRACKED
1. Check that the driveshaft is not twisted or cracked. Replace if necessary.
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SPECIAL SERVICE TOOLS
Tool
(Number and
Name)
Illustration
Use
0K670 321 019
Ball joint puller
For removal of ball
joint
0K130 331 016
Spacer selector
For adjustment of
wheel bearing
preload
0K201 270 014
Transaxle side
gear holder
For prevention of
transaxle oil leak
0K130 331 AA0A
Wheel hub puller
For removal of
wheel hub.
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0K670 990 AA0
Bearing puller set
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For removal of
sensor rotor.
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SPECIFICATIONS
Engine
Item
A5D
MTX
Driveshaft
ATX
Inside
Tripod
Type of joint
Outside
Length of joint (in
(mm))
Left side
Shaft diameter (Φ(in
(mm)))
Right side
Right side
Left side
Birtield joint
14.54 (369.2)
14.93 (379.2)
25.67 (652)
25.67 (652)
0.94 (24)
0.89 (22.5)
Front axle (in(mm))
Axis direction
bearing play
0 (0)
Rear axle (in(mm))
Axis direction
bearing play
0 (0)
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TROUBLESHOOTING GUIDE
Trouble
Possible cause
Faulty operation of driveshaft
Abnormal noise from driveshaft
Steering wheel pulls. While driving on a straight and level road, the
steering wheel pulls to one side
Remedy
Broken ball-joint
Replace
Broken tri-pod joint
Replace
Worn or seized joint
Replace
Insufficient grease
in ball-joint or spline
Replenish or
replace
Excessive backlash
on spline
Replace
Worn joint
Replace
Incorrect front wheel Adjust or replace
bearing preload
adjustment
Bent steering linkage Refer to Section
ST
Fatigued coil spring
Refer to Section
SS
Lower arm bushing
worn or damaged
Refer to Section
SS
Bent knuckle arm
Replace
Bent lower arm or
loose mounting
Refer to Section
SS
Incorrect toe-in
adjustment
Refer to Section
SS
Improper tire air
pressure
Refer to Section
SS
Unevenly worn tires
(difference in wear
between left and
right tires)
Refer to Section
SS
Brake dragging
Refer to Section
BR
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Unstable handling
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Incorrect wheel
bearing preload
adjustment
Adjust or replace
Bent steering linkage Refer to Section
ST
Excessive steering wheel play
Joint in steering
system worn or
damaged
Refer to Section
ST
Incorrect steering
pinion preload
adjustment
Refer to Section
ST
Fatigued coil spring
Refer to Section
SS
Shock absorber
malfunction or
looseness
Refer to Section
SS
Lower arm bushing
worn or damaged
Refer to Section
SS
Incorrect toe-in
adjustment (front or
rear)
Refer to Section
SS
Improper tire air
pressure
Refer to Section
SS
Wheels bent or
unbalanced
Refer to Section
SS
Incorrect front wheel Adjust
bearing preload
adjustment
Incorrect steering
pinion preload
adjustment
Refer to Section
ST
Rack and pinion
worn
Refer to Section
ST
Joint in steering
system worn or
damaged
Refer to Section
ST
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Tires are excessively worn or worn unevenly
Abnormal noise from axle
Lower arm bushing
worn or damaged
Refer to Section
SS
Incorrect front wheel Adjust
bearing preload
adjustment
(excessively loose)
Incorrect toe-in
adjustment
Refer to Section
SS
Improper tire air
pressure
Refer to Section
SS
Unbalanced wheel
(s)
Refer to Section
SS
Malfunction of
wheel bearing
Replace
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TROUBLESHOOTING (MAIN CATALYST)
P0422: Main catalyst efficiency below threshold
Circuit description
(Blank)
(Blank)
DTC
P0422
Fault type
Fault condition
Catalyst oxygen storage
capacity by evaluating
• Averaged malfunction index is higher
than threshold value
O₂sensor2 fuctuations
• (No limit catalyst available)
• Repair all other malfunction related to
DTC No.P0136, P0139, and P0140.
MAIN CATALYST
Diagnostic trouble code No.
P0422
Related items
Main catalyst efficiency below threshold
• Catalytic converter deteriorated
If any codes relating to HO2S sensor. MAFS, injectors, a P0171 or aP0172
are present, do all repairs associated with them before proceeding with this
troubleshooting procedure.
Step
1
2
Inspection
Connect SCAN TOOL to data link
connector or OBD-II check connector. Turn
ignition to ON and check other DTCs.t
Are DTC P0300~P0304, P0115, P0116,
P0125, P0130, P0133, P0134, P0135,
P0136, P0139, P0140 and/or P141 set?
Release fuel pressure and attach fuel
pressure gauge to service port on fuel rail.
Start an engine and warm up to operating
temperature. Check for fuel pressure at idle.
· Fuel pressure at idle : 46-51 psi (320-350
kPa, 3.2-3.5kg/cm²)
Is fuel pressure within specification?
Action
Yes
Do all repairs associated with those codes
before proceeding this procedure.
No
Go to step 2.
Yes
Go to step 3.
No
Check fuel delivery system.
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3
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Check exhaust system for leaks, cracks,
Yes
Go to step 4.
loose connection (especially exhaust
manifold, catalyst around rear HO2S, etc)
No
Repair or replace as necessary.
Is exhaust system okay?
4
Check for any split, disconnected or
perforated vacuum hoses. Also, check PCV
valve for proper operation.
Are vacuum hoses and PCV okay?
5
6
7
Check for fuel injector operation.
Are fuel injectors working normal and
dispensing proper volume?
Check intake system for leaks, cracks,
loose connection as following items:
· Throttle body gasket
· Gasket between intake manifold and
surge tank
· Seals between intake manifold and fuel
injectors
· Seals between surge tank and PCV valves
Is intake system okay?
Yes
Go to step 5.
No
Replace faulty vacuum hoses or PCV.
Yes
Go to step 6.
No
Repair as necessary.
Yes
Replace catalytic converter as necessary.
No
Repair or replace as necessary.
Return vehicle to original condition. Clear all Diagnostic Trouble Codes. Verify by driving vehicle with
SCAN TOOL connected and monitor for pending codes.
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TROUBLESHOOTING
P0440: Evaporative emission control system malfunction
P0442: Evaporative emission control system leak detected (small leak 1.0mm)
P0455: Evaporative emission control system leak detected (large leak > 0.75mm)
P0456: Evaporative emission control system leak detected
Circuit description
DTC
Fault type
Fault condition
P0440
Purge control valve open stuck
Fuel tank pressure < -2.3 hPa
P0442
Small leak
Leak diameter > 0.75mm
P0455
Large leak/Cap missing
Fuel tank pressure > -15 hPa
P0456
Small leak
0.75mm > Leak diameter > 0.45mm
Diagnostic trouble code No. P0440
EVAP emission control system malfunction
Diagnostic trouble code No. P0442
EVAP emission control system small leak detected (1.0mm)
Diagnostic trouble code No. P0455
EVAP emission control system leak detected (large leak)
Diagnostic trouble code No. P 0456
EVAP emission control system leak detected (small leak 0.5mm)
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Related items
Ebay• Fuel
Userfiller
ID: reveleus1
cap loose or missing
• Fuel filler cap o-ring missing or damaged
• Faulty or damaged fuel filler pipe
• Leaking disconnected or plugged fuel vapor lines
• Fuel in lines due to faulty Rollover Valve (RV), On-Board Refueling
Vapor Recovery Valve (ORVR valve)
• Canister close valve clogged, stuck open or closed
• Improperly installed purge solenoid valve (PSV)
• PSV stuck open or closed
• Faulty fuel tank pressure sensor
• Leaking canister or catch tank
If any codes relating to FTPS, CCV, or PSV circuits are present,
doall repairs associated with those codes before proceeding with
this troubleshootingprocedure.
Step
1
2
3
4
Inspection
Connect SCAN TOOL to data link connector or
OBD-II check connector.
Turn ignition to ON and check any other DTCs.
Is DTC P0440, P0443, P0446, P0450, or
P0451 set?
Using SCAN TOOL proceed EVAP leakage
test.
Is EVAP system okay?
Check fuel filler cap for being tightly installed,
has o-ring seal installed and is in good
condition.
Verify cap releases vacuum at specified values
(approximately 2psi pressure and
approximately 1.5 inches hg vacuum).
Are cap, o-ring and release pressures OK?
Check fuel filler pipe for cracks, damage and oring seat for deformation.
Is fuel filler pipe OK?
Thoroughly check all fuel vapor hoses and
hose clamps between :
Action
Yes
Do all repairs associated with those codes
before proceeding this procedure.
No
Go to step 2.
Yes
Problem is intermittent or was repaired and
engine control module memory was not
cleared. Check terminal conections at ECM
and PSV.
No
Go to step 3.
Yes
Go to step 4.
No
Repair fuel filler cap.
Yes
Go to step 5.
No
Replace fuel filler cap.
Yes
Go to step 6.
1.canister and rollover/ORVR valves
2.canister and CCV
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5
3.canister and PSV
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4.PSV and intake manifold
(At this point, also verify arrow on PSV is
pointing towards intake manifold. If it is not,
reverse towards intake manifold. if is not
preverseinstallation)
6
Turn ignition to OFF and remove FTPS access
plate.
Remove FTPS from tank unit. Turn ignition to
ON (engine OFF) and monitor FTPS output
voltage with SCAN TOOL.
No
Replace all cracked/damaged hoses or loose
clamps.
Yes
Go to step 7.
No
Temporarily install a known good FTPS and
check for proper operation. If problem is
corrected replace FTPS.
Yes
Go to step 8.
No
Temporarily install a known good PSV and
check for proper opertion. If problem is
corrected replace PSV.
Yes
Go to step 9.
No
Temporarily install a known good CCV and
check for proper operation. If problem is
corrected replace CCV.
Yes
Go to step 10.
No
Repair or replace as necessary.
● Specification : 2~3V
Is voltage within specification?
7
8
9
10
Turn ignition OFF and disconnect hose leading
from PSV to intake manifold at PSV. Draw a
vacuum at nipple and verify PSV holds vacuum.
Turn ignition to ON and jumper a wire to
ground at PSV control terminal1 (should hear a
faint click from PSV). Vacuum should bleed off.
Repeat this procedure 4 or 5 times to ensure
PSV reliability.
Is PSV working properly?
Turn ignition OFF and disconnect hose
connecting CCV to canister. Blow air into hose
removed form canister and verify air escapes.
Turn ignition to ON and jumper a wire to
ground at CCV control terminal1. Blow an air
into hose and verify air does not escape form
port. Repeat this procedure 4 or 5 times to
ensure CCV reliablility.
Is CCV working properly?
Thoroughly check fuel gas leaks, cracks,
damages of the following items:
Fuel filler cap
Fuel vent valve (ORVR)
Fuel cut valve (Rollover valve)
FTPS
EVAP hoses
Canister
Are the above items okay?
Return vehicle to original condition.
Clear all Diagnostic Trouble Codes. Verify by driving vehicle with SCAN TOOL connected and monitor for
pending codes.
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TROUBLESHOOTING
P0443 : Evaporative emission control system purge control valve circuit malfunction
P0446 : Evaporative emission control system vent malfunction
Circuit description
The evaporative system prevents hydrocarbon vapors
from the fuel tank escaping into the atmosphere where
they would form photo-chemical smog.
Gasoline vapors are collected in the charcoal canister.
The ECM controls the purge control solenoid valve, to
purge any collected vapors from the canister back to
the engine for burning.
EMS system considers the adaptive function in the
EVAP emission control in the ECM. Any purge of
EVAP canister results in the A/F regulation loop control
deviations.
During purging of EVAP canister (opening of EVAP
purge valve), adaptive valve is maintained to neutral
and adaptive A/F regulation loop control is allowed only
when no purging of EVAP canister (closing of EVAP
purge valve) is feeding the vapors into the intake
manifold.
A check valve is used to control pressures in the fuel
tank and to prevent fuel spillage in the event of a rollover.
DTC
P0443
P0446
Diagnostic trouble code
No. P 0443
Diagnostic trouble code
No. P 0446
Fault type
Fault condition
GND short
Signal below lower limit when ignition
switch is turned ON.
Battery short
Signal above upper limit when ignition
switch is turned ON.
Open
No signal when ignition switch is turned ON.
Evaporative emission control system purge control circuit malfunction
Evaporative emission control system vent malfunction
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Related items
EbayinUser
ID: canister
reveleus1purge control valve wiring
• Open circuit
EVAP
• VAP canister purge valve malfunction
• Short to battery voltage or short to ground in EVAP canister valve circuit
Step
1
2
3
4
5
6
7
Inspection
Ignition OFF, disconnect EVAP purge valve
connector.
Ignition On, engine OFF, measure voltage
between harness connector B21-1(to ECM)
and GND.
Action
Yes
Go to step 2.
No
Open between connector B21-1 and main
relay.
Repair as necessary.
Ignition OFF, measure resistance between
EVAP purge valve harness connector B211 (to ECM) and GND.
Yes
Short to ground in connector B21-1.
Repair as necessary.
Is measured resistance less than 1Ω?
No
Go to step 3.
Disconnect ECM connector.
Check for continuity between harness
connector
B21-2 ECM harness connector B03-42.
Does continuity exist?
Yes
Go to step 4.
No
Open between connector B21-1 and ECM
connector B03-42.
Repair as necessary.
Ignition ON, engine OFF measure voltage
between EVAP purge valve harness
connector B21-1 and GND (B+).
Is voltage within specification?
Yes
Go to step 5.
No
Open or short between connector B21-1
and main relay.
Repair as necessary.
Check for proper connections at connector
B21-1 an main relay.
Are connections correct?
Yes
Go to step 6.
No
Repair connection as necessary.
Measure resistance between EVAP
canister purge valve connector B21
Yes
terminals 1 and 2 (approx, 24~28Ω at 68°F
(20°C)).
Is resistance within specification?
Visually inspect for terminal contact failure
(oxidized, deformed or misplaced, etc).
Repair as necessary.
No
Replace EVAP canister purge valve.
Return vehicle to original condition. Clear all Diagnostic Trouble Codes. Verify by driving vehicle with
SCAN TOOL connected and monitor for pending codes.
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TROUBLESHOOTING
P0450 : Evaporative emission control system pressure sensor malfunction
P0451 : Evaporative emission control system pressure sensor range/performance problem
Step
1
2
3
4
5
6
7
Inspection
Action
Ignition OFF, disconnect CMP sensor
connector, Ignition ON, measure voltage
between CMP sensor harness connector
B19-1 and GND (B+).
Is voltage within specification?
Yes
Go to step 2.
No
Open or short between sensor connector
B19-1 and main relay. Repair as necessary.
Ignition OFF< disconnect ECM connector
B04 and measure resistance between CMP
sensor harness connector B19-3(to ECM)
Yes
Go to step3.
and GND(<1Ω).
Is resistance within specification?
No
Short to graund between sensor connector
B19-3 and ECM connector B04-8. Repair
as necessary.
Ignition OFF, measure resistance between
sensor harness connector B19-2 (to ECM)
and GND (infinite resistance).
Is resistance within specification?
Yes
Go to step 4.
No
Short to GND between sensor connector
B19-2 and ECM connector B04-18.
Repair as necessary.
Measure resistance between CMP sensor
harness connector B19-2(to ECM) and
Yes
Go to step 5.
ECM harness connector B04-18(<1Ω).
Is resistance within specification?
No
Open between sensor connector B19-2 and
ECM connector B04-18.
Repair as necessary.
Ignition ON, measure volage between CMP
sensor harness connector B19-2 (to ECM)
and GND (<0.5V). Is voltage within
specification?
Yes
Go to step 6.
No
Short to battery voltage between sensor
connector B19-2 an ECM connector B04-18.
Repair as necessary.
Yes
Temporarily install a known good CMP
sensor and check for proper operation. If
problem is corrected, replace CMP sensor.
No
Remove camshaft and install half-moon
wheel correctly.
Disconnect CMP sensor installed at
cylinder head and check half-moon
installation. Is half-moon wheel installed
properly?
Return Vehicle to original condition. Clear all Diagnostic Trouble Codes. Verify by driving vehicle with
SCAN TOOL connected and monitor for pending codes.
Circuit description
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(blank)
(blank)
DTC
P0450
P0451
Fault type
Fault condition
GND short
• Pressure sensor signal is lower than
0.14V
Battery short/Open
• Pressure sensor signal is higher than
4.9V
Pressure sensor stuck
• Pressure sensor signal variation is lower
than 15mV
Diagnostic trouble code
No. P0450
Evaporative emission control system pressure sensor malfunction
Diagnostic trouble code
No. P0451
Eaporative emission control system pressure sensor range/perfomance
preoblem
Related items
• Open or short to battery voltage between (FTPS) B25-3 an (ECM) B02-15.
• High resistance or open between (FTPS) B25-2 and (ECM) B02-9.
• Defective FTPS.
• Stuck closed Canister Close Valve(CCV.)
• Blocked vapor passage between Fuel Tank and CCV.
Step
1
2
3
Inspection
With ignition on and FTPS disconnected,
measure voltage at B25-3(approx. 5V).
Is voltage ok?
Ignition off, disconnect (ECM) B02. With
FTPS still disconnected, check resistance
from B25-1 to B02-9(<1 ohm).
Is resistance <1 ohm?
Remove FTPS from tank unit. Reconnect
B02 to ECM and B25 to FTPS. Turn ignition
on (engine off) and measure output voltage
Action
Yes
Go to step 2.
No
If voltage is below specification, thoroughly
check for loose, bent, misplaced or
corroded connector terminals between B253 and B02-15.
If voltage is between 5V and battery
voltage, check for short to battery between
B25-3 and B02-15. Repair as necessary.
Yes
Go to step 3.
No
Thoroughly check for loose, bent,
misplaced or corroded connector terminals
between B02-9 and B 25-1.
Repair as necessary.
Yes
Check for stuck closed CCV of blocked
vapor passage between Fuel Tank and
CCV.
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at B25-3 (2.0~3.0V).
Ebay User ID: reveleus1 Temporarily install a Known good FTPS
Is FTPS output voltage within specs?
No
and Check check for proper operation. If
problem is connected, replace FTPS
Remove CCV from vehicle and blow air into "A" and verify air escapes from "B". Connect battery positive to one
terminal on CCV and battery negative to the other. Verify air does not escape from "B". Replace CCV if it fails
this functional test. (Refer to On-vehicle service)
4
Return vehicle to original condition. Clear all Diagnostic Trouble Codes. Verify by driving vehicle with
SCANTOOL connected and monitor for pending codes.
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DISASSEMBLY
Insert protective material in the jaws of the vise.
1. Remove four cap screws from rear housing.
2. Use a 200-watt soldering iron to heat the rear of bearing box to allow the bearing to be removed from rear
housing.
If bearing box is not heated, bearing cannot be pulled out of rear housing. The rear bearing and rear housing
fit together very tightly.
3. Use a flat-blade screwdriver to separate front housing from stator.
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• Insert protective material in the jaws of the vise.
• Insert protective material in the jaws of the vise.
4. Place rotor in a vise and loosen locknut, then disassemble pulley, rotor, and front housing.
5. If necessary, remove front bearing using a socket and a hand press or vise.
6. Remove rear bearing with a bearing puller.
7. Remove B terminal nut and insulating bushing.
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8. Remove five screws holding the rectifier andEbay
brush
holder.
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9. Separate rear bracket and stator.
10. Use a soldering iron to remove solder from rectifier and stator leads, and then remove IC regulator.
Disconnect quickly. If soldering iron is used for more than 5 seconds, rectifier may be damaged by heat.
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11. Replace brushes. Remove solder from pigtail,
and
then
brush.
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INSPECTION
1. Rotor
(1) Measure resistance between slip rings with a ohmmeter. If it is not within standard resistance, replace rotor.
Standard resistance : 3.5~4.5 Ω
(2) Check for continuity between slip ring and core with a circuit tester. Replace rotor if there is continuity.
(3) If slip ring surface is rough, smooth with a lather or fine sandpaper.
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2. Stator
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(1) Check for continuity between stator coil leads with a circuit tester.
(2) Replace stator if there is no continuity.
(3) Check for continuity between stator coil leads and core with a circuit tester.
(4) Replace stator if there is continuity.
3. Rectifier
(1) Check for continuity between each diode with an ohmmeter.
Negative(Black)
Negative (Black)
Negative (Black)
E
Pn, P₁, P₂, P₃
O
B
Pn, P₁, P₂, P₃
×
T
Pn, P₁, P₂, P₃
×
E
×
B
O
T
O
T
×
Pn, P₁, P₂, P₃
Pn, P₁, P₂, P₃, Pn
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(2) Replace if necessary.
4. Bearing
(1) Check for abnormal noise, looseness, insufficient lubrication, etc.
(2) Replace bearing(s) if there is any abnormality.
REASSEMBLY
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1. Assemble brush, and solder pigtail so that wear
line
brush projects 0.079~0.118 in (2~3 mm) out of brush
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holder.
2. Assemble regulator, and solder with rectifier and stator leads.
Disconnect quickly. If solderings iron is used for more than 5 seconds, rectifier may be damaged by heat.
3. Assemble rear bracket and stator.
4. Tighten screws holding rectifier and brush holder.
Tightening torque : 1.5~4.0 Ib-ft (2.0~5.4 N·m, 0.2~0.55 kg-m)
5. Tighten B terminal nut and insulating bushing.
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6. Assemble rear bearing and stopper spring. Ebay User ID: reveleus1
Make sure groove on bearing rim is facing slip ring side.
7. Assemble front bearing. Using a socket which exactly fits outer race of bearing, carefully push in front bearing.
Use a hand press or a vise.
Insert protective material in the jaws of the vise.
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CIRCUIT DIAGRAM
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BATTERY RECHARGING
Slow Charging
1. It is not necessary to remove vent caps to perform a slow charge.
Battery
Slow charge (A)
Quick chagre
PT48-24GL MF
Under 5
Maximum 20
Quick charging
1. Remove battery from vehicle and remove vent caps to perform a quick charge.
• Before performing maintenance or recharging battery, turn off all accessories and stop engine.
• Negative cable must be removed first and installed last
• Set battery in water when quick charging to prevent overheating battery.
Drive Belt
1. Check drive belt and pulley for wear, cracks, and fraying. Replace if necessary.
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2. Measure drive belt tension with a tension gauge.
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Tension
Drive belt
Generator
A/C and P/S
New lb(N)
Used lb(n)
85.8-130.4 (383-461)
68.2-85.8(304-383)
110-132 (491-589)
95-110 (422-491)
3. Measure deflection by applying moderate pressure (22 Ib [98 N]) midway between pulleys. Adjust if necessary.
Deflection
Drive belt
New in(mm)
Used in(mm)
Generator
0.31-0.35 (8-9)
0.35-0.39(9-10)
A/C and P/S
0.31-0.35 (8-9)
0.35-0.39 (9-10)
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REMOVAL
1.
2.
3.
4.
5.
Remove negative battery cable.
Open B terminal cover cap.
Remove B terminal nut.
Remove B terminal lead.
Disconnect generator connector.
6. Loosen pivot bolt B and tensioner mounting bolt A. Do not remove.
7. Relieve tension on drive belt by rotating adjustment bolt C.
8. Remove drive belt from generator pulley.
9. Remove tensioner mounting bolt and belt tensioner.
10. Remove generator pivot bolt.
11. Loosen bolt at base of adjusting bracket and rotate the bracket up.
12. Lift generator from engine compartment.
REPLACEMENT
1.
2.
3.
4.
5.
6.
Position generator on engine.
Install pivot bolt(leave loose).
Rotate bracket into position on top of generator.
Place belt tensioner into position on adjustment bracket.
Install tensioner mounting bolt (leave loose).
Place drive belt on generator pulley.
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7. Adjust belt tension by rotating adjustment bolt
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Allowable deflection :
New belt: 0.22-0.28 in (5.5-7.0 mm)
Old belt: 0.24-0.28 in (6.0-7.0 mm)
8. Tighten tensioner bolt.
Tighten tensioner bolt to 14-19 Ib-ft (19-26 N·m, 1.9~2.6 Kg-m)
9. Tighten pivot bolt and bracket bolt.
Tighten pivot and bracket bolt to 28-38 Ib-ft (38-51 N·m, 3.8~5.3 Kg-m)
10. Connect generator L and S terminal connectors.
11. Connect B terminal lead.
12. Install and tighten B terminal nut.
13. Close B terminal nut cover.
14. Install air intake inlet pipe and tighten end clamp.
15. Connect top hose to air intake inlet pipe.
16. Install front air intake inlet pipe bolts.
17. Connect negative battery cable.
• Be sure battery connections are not reversed. This will damage rectifier.
• Do not use high voltage testers, such as a megger. They will damage the rectifier.
• Remember that battery voltage is always applied to alternator B terminal.
• Do not ground L terminal while engine is running.
• Do not start engine while L and S terminals are disconnected from generator.
INSPECTION
Generator
Before testing the generator, perform the following checks :
1. Inspect the battery condition.
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2. Inspect condition of battery cable and terminals,
posts,
connections at engine block, starter solenoid and
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relay.
3. Inspect all fuses in both the engine compartment fuse/relay box and the passenger compartment fuse box.
4. Inspect the generator mounting bolts for tightness.
5. Inspect the generator drive belt condition and tension.
6. Inspect connections at generator field, battery output and ground terminals. Check ground connection at engine.
Charging System Resistance Check
This tests will indicate the amount of voltage drop across the generator output wire, from the generator output (B+)
terminal to the battery positive post. They will also show the amount of voltage drop from the ground (-) terminal on
the generator to the negative battery post. Refer to the Rio Electrical Troubleshooting Manual for connector and
terminal information.
1. Engage the parking brake, make sure the transaxle is in PARK (A/T) or NEUTRAL (M/T) and start the engine.
2. Set blower control to the maximum position
3. Turn on headlights and set in high-beam position and turn the vehicle interior lamps on.
4. Bring the engine speed up to 2400 RPM and hold.
5. Touch the DVOM negative lead directly to the positive battery post.
6. Touch the DVOM positive lead to the B+ output terminal stud on the generator (not the terminal mounting nut).
The output voltage should be no higher than 0.6V. If the voltage is higher than 0.6V, touch the DVOM positive
lead to the terminal mounting stud nut and then to the wiring connector. If the voltage is now below 0.6V, look for
dirty, loose or poor connection.
7. Touch the DVOM negative lead directly to the negative battery post.
8. Touch the DVOM positive lead to the ground terminal stud on the generator case (not the terminal mounting
nut). The voltage should be no higher than 0.3V. If the voltage is higher than 0.3V touch the DVOM positive lead
to the terminal mounting stud nut and then to the wiring connector. If the voltage is now below 0.3V, look for
dirty, loose or poor connection.
A voltage drop test can be performed at each (-) connection in this circuit to locate the excessive resistance.
This test can also be performed between the generator case and the engine. If test voltage is higher than
0.3V, check for corrosion at the generator mounting points or loose generator mounting.
Current Output Test
This test will determine if the charging system can deliver its minimum test current (amperage) output. A volt/amp
tester equipped with both a battery load control and an inductive type pickup clamp (ammeter probe) will be used
for this test. Refer to the operating instructions supplied with the tester.
1. Engage the parking brake, make sure the transaxle is in PARK (A/T) or NEUTRAL (M/T) and start the engine.
2. Bring the engine speed up to 2500 RPM and hold.
This load test must be performed within 15 seconds to prevent damage to test equipment.
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3. Slowly adjust the rheostat control (load) on the
tester
obtain
the highest amperage reading. Do not allow the
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voltage to drop below 12V.
On certain brands of test equipment, this load will be applied automatically. Refer to the operating
instructions supplied with the test equipment.
4. The ammeter reading must meet the minimum amps specifications listed on the specifications chart.
5. Turn the load control knob on the tester to the OFF position but continue to hold the engine speed at 2500 RPM.
If all circuitry is okay, the amperage should drop below 15 to 20 amps. This may take several minutes with all
electrical accessories OFF. If amperage does not drop, refer to the Electrical Troubleshooting Manual and check
circuitry.
6. Remove the volt/amp tester. If the minimum amperage requirements could not be met, test the generator. If the
generator tests okay, check the charging system circuitry (refer to the Electrical Troubleshooting Manual).
Inspection
Any of the following conditions can result in abnormal battery discharging :
1. Corroded or loose battery posts and terminal clamps.
2. A loose or worn generator drive belt.
3. Electrical loads that exceed the output of the charging system. This can be due to equipment installed after
manufacture or repeated short trip use.
4. Slow driving speeds (heavy traffic conditions) or prolonged idling with high-amperage draw system in use.
5. A faulty circuit or component causing excessive ignition-off draw or "parasitic" draw.
6. A faulty or incorrect charging system component.
7. A faulty or incorrect battery. Before testing, visually inspect the battery for any damage (a cracked case or cover,
loose posts, etc.) that would cause the battery to be faulty.
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1)If a battery shows signs of freezing, leaking, loose posts or freezing, leaking, loose posts or low
electrolyte level, do not test, assist-boost or charge. The battery may arc internally and explode. Personal
injury or death could occur.
2)Explosive hydrogen gas froms in and around the battery. Do not smoke, use flame, or create sparks near
the battery. Personal injury or death could occur.
3)The battery contains sulfuric which is poisnous and caustic. Acid contact with the skin, eyes or clothing.
In the event of contact, flush with water and contact a physician immediately. Keep out of the reach of
children.
4)If the battery is equipped with removable cell caps, be certain that each of the cell caps in is place and
tight before the battery injury and/or vehicle damage could occur.
Electrolyte Level
1. Check whether or not the electrolyte level lies between "UPPERLEVEL" line and "LOWER LEVEL" line.
2. If low, add distilled water to "UPPER LEVEL" line. Do not overfill.
Hydrometer (Specific-gravity) Test
The hydrometer tests battery state-of-charge by measuring the specific gravity of the electrolyte. This test cannot
be performed on maintenance-free batteries with non-removable cell caps. Specific gravity is a comparison of the
density of the electrolyte to the density of pure water. Pure water has a specific gravity of 1.000, and sulfuric
(battery) acid makes up approsimately 35% of the electrolyte by weight, or 24% of its volume. In a fully charged
battery the electrolyte will have a temperature-corrected specific gravity of 1.260 to 1.290. However, a specific
gravity of 1.235 or above is satisfactory for battery load testing and/or return to service.
1. Measure specific gravity with a hydrometer. Refer to the instructions supplied with the hydrometer for
recommendations on the correct use of the hydrometer.
Battery Open-circuit Voltage Test
A battery open-circuit voltage (no load) test will show the state of charge of a battery. This test can be used in
place of the hydrometer test. Before proceeding with this test, make sure the battery is completely charged.
1. Before measuring the open-circuit voltage, the surface charge must be removed from the battery. Turn on the
headlights for fifteen seconds, then allow up to five minutes for the battery voltage to stabilize.
2. Disconnect and isolate both battery cables, negative cable first.
3. Using a DVOM connected to the battery post, measure the open-circuit voltage. Refer to the Open-Circuit
Voltage table. This voltage will indicate the battery state-of-charge, but will not reveal its cranking capacity. If the
open-circuit voltage reading is 12.4V or greater, perform the load test.
Battery Load Test
1. Disconnect and isolate both battery cables, negative cable first. Make sure the battery top and posts are clean.
2. Connect a suitable VAT Tester to the battery posts. Check the open-circuit (no load) of the battery. Open-circuit
voltage must be 12.4V or greater.
3. Apply a 300 Amp load to the battery for fifteen seconds to remove the surface charge from the battery, then
allow the battery to stabilize for five minutes.
4. Apply a load equal to 50% of the CCA rating of the battery. After approximately fifteen seconds, check the
loaded voltage reading, then remove the load.
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5. The voltage drop will vary with the battery temperature
at the
time of the load test.
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Battery voltage load
Approximate battery temp
Minimum voltage(V)
80°F(27°C)
70°F(21°C)
60°F(15°C)
50°F(10°C)
40°F(4°C)
30°F(-1°C)
20°F(-7°C)
10°F(-12°C)
9.7
9.6
9.5
9.4
9.3
9.1
8.9
8.7
Battery Ignition Off Draw Test
The battery draw test refers to power being drained from the battery with the ignition switch in the OFF position. A
normal electrical system will draw from five to twenty-five milliamps (0.005 to 0.025 ampere) with the ignition OFF
and allnon-ignition controlled circuits working properly. The 0.025 ampere is needed to enable the memory
functions of the vehicle to function.
1. Verify that all electrical accessories are OFF. Turn off all lamps, remove the ignition key and close all doors.
2. Disconnect the negative battery cable.
3. Set a DVOM to its highest amperage scale and connect the DVOM between the disconnected negative battery
cable and the negative battery post.
4. If the amperage reading is higher that 0.025 ampere, remove each fuse until the amperage reading becomes
within specifications, this will isolate each circuit and identify the source of the draw. If the amperage reading
remains high after disconnecting each fuse, unplug the connector from the generator. If the amperage reading
becomes within specifications, check the charging system.
5. After appropriate repairs have been made, retest the system.
Voltage Drop Test
The voltage drop test will determine if there is excessive resistance in the battery terminal connections or the
batterycables. When performing these tests, remember that the voltage drop is giving an indication of the
resistance between the two points at which the DVOM probes are attached. For example, when testing the
resistance of the battery positive cable, connect one of the DVOM leads to the positive battery cable clamp and the
other cable connector at the starter solenoid. If you probe the positive battery terminal post and the cable
connector at the starter solenoid, you are actually reading the combined voltage drop in the positive battery cable
clamp-to-terminal post connection and the positive battery cable.
1. Connect the positive lead of the DVOM to the negative battery terminal post.
2. Connect the negative lead of the DVOM to the negative battery terminal cable clamp.
3. Turn the ignition switch to the start meter and observe the DVOM. If voltage is detected, correct the poor contact
between the cable clamp and the terminal post.
4. Connect the positive lead of the DVOM to the positive battery terminal post.
5. Connect the negative lead of the DVOM to the positive battery terminal cable clamp.
6. Turn the ignition switch to START and observe the DVOM. If voltage is detected, correct the poor contact
between the cable clamp and the terminal post.
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7. Connect the voltmeter to measure between the
positive
battery
terminal post and the starter solenoid battery
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terminal stud.
8. Turn the ignition switch to START and observe the reading on the DVOM. If the reading is above 0.2V, clean
and tighten the battery cable connection at the solenoid and repeat the test. If the reading is still above 0.2V,
replace the faulty positive battery cable.
9. Connect the DVOM to measure between the negative battery terminal post and a good clean ground on the
engine block.
10. Turn the ignition switch to START and observe the DVOM. If the reading is above 0.2V, clean and tighten the
battery cable connection on the engine block and repeat the test. If the reading is still above 0.2V, correct the
faulty negative battery cable.
11. Connect the DVOM positive lead to the starter housing. Connect the DVOM negative lead to the negative
battery terminal post.
12. Turn the ignition switch to START and observe the DVOM. If the reading is above 0.2V, correct the poor starter
to engine block ground contact.
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SYMPTOM-RELATED DIAGNOSTIC PROCEDURE
Generator
Step
1
Inspection
Check battery voltage.
Specification : Above 12.4V
2
Start engine and check if generator warning
light goes out
3
4
Action
Yes
Check charging system
No
Go to next step.
Yes
Repair or replace connection.
No
Check for seized motor armature. Repair
or replace as necessary.
Yes
Check wiring harness between battery
and terminal B.
No
●Check wiring harness.
●Replace generator.
Yes
Charging system normal
No
Go to next step.
Yes
Replace generator.
Check if voltage at generator terminals are
1. Connnect an ammeter (80A minimum)
between terminal B harness connector.
2. Start engine.
3. Turn all electrical loads ON and depress
brake pedal
4. Check if output current is 65A or more at
2,500-3,000 rpm.
Caution
Do not ground terminal B.
5
Check drive belt tension OK?
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No
Adjust drive belt tension.
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GENERAL DESCRIPTION
Ignition System Overview
This vehicle incorporates DLI(Distributorless ignition) system in order to increase the rarge of ignition timing and
distributor voltage and to decrease electric wave noise. The components of this system are :
• Ignition Coil
• Camshaft Position Sensor
• ECM
• Spark Plug Wires and Spark Plugs
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REMOVAL
1.
2.
3.
4.
5.
Disconnect battery cable.
Disconnect high-tension leads.
Disconnect ignition coil connectors.
Remove four ignition coil mounting bolts.
Remove ignition coils.
INSTALLATION
1. Position two coils above No.2 and No.4 spark plugs, and firmly push down to connect.
2. Insert and tighten four ignition coil mounting bolts.
Tightening torque : 11.5~16.6 lb-ft (15.6~22.6 N·m, 1.6~2.3 kg-m)
3. Reconnect ignition coil connectors. .
4. Reattach high tension leads. Leads are marked for correct connection
5. Reconnect battery cable.
INSPECTION
Voltage check
1.
2.
3.
4.
Disconnect negative battery cable.
Disconnect ignition coil connector.
Turn ignition switch to "NO".
Measure voltage between terminal ECU and B+ at ignition coil connector.
Voltage : approximately 12Volts
5. If no voltage, check main fuse, ignition switch and wire harness.
Resistance check
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1. Using an ohmmeter, check resistance of primary
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Connect one lead of ohmmeter to positive (+)terminal and other lead to each negative (-)terminal. If not within
specification, replace coil. Remember that unit has two coil assemblies, so both be checked.
Primary coil resistance : 0.6~0.8Ω @ 68°F (20°C)
2. Using an ohmmeter, check resistance of the secondary coil. If not within specification, replace coil.
Remember that you must check resistance of both top and bottom secondary coil. If one is out of specification
replace the whole unit.
Secondary coil resistance : 11~15kΩ @ 68°F (20°C)
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SYSTEM OPERATION
In a conventional ignition system, the ignition coil produces a high voltage current and the distributor then relays this current,
at the required time, to each spark plug. In the distributorless ignition system, two sensors, the camshaft position sensor and
the crankshaft position sensor, tell the Engine Control Module(ECM) which cylinder is ready to fire. The ECM then sends an
ignition signal to an electronic ignition coil. This ignition coil then produces and sends a high voltage current to the proper
spark plug.
Distributorless ignition is a "wasted-spark" system in which two spark plugs fire simultaneously. One cylinder fires at TDC on
the compression stroke, while the other fires at TDC of the exhaust stroke.
The cylinders are grouped together by firing order. For example, firing order is 1-3-4-2. Cylinders 1 and 4 are in the same
position, while cylinders 2 and 3 are 180 behind. Plugs 1 and 4 fire together, as do the plugs in cylinders 2 and 3.
This means that an ignition spark is fired in one cylinder while at the same time a "waste" spark is fired in the companion
cylinder. Because of dualed plug firing, if an inductive tachometer is connected to a plug wire, it will indicate an engine RPM
that is twice the actual speed (i.e., 1,600 RPM, instead of 800 RPM).
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Electronic Spark Advance System
Ignition Timing is determined and set within the ECM based on signals from various sensors and switches.
Optimum performance is gained with this system. The ECM varies ignition timing according to engine speed,
intake air amount, coolant temperature and other conditions.
• Timing specification at idle is: 8±5° BTDC
• Timing is not adjustable.
Ignition System Components
The mechanical, rotating high-voltage distributor mechanism has been replaced by static electronically controlled
components. These components are described below.
• Ignition coils
Two ignition coils are used in this system. The engine locates them directly above the #2 and #4 spark plugs.
The coil resistance is identical for these two coils, and there is no maintenance required for them. If determined
to be faulty, they must be replaced.
• High-tension leads
The high-tension leads connect the two ignition coils to the spark plugs. Their function is basically the same as
on theprevious system. Because of their shorter length, the DLI high-tension leads enhance the ignition
systems delivered voltage. In addition, they reduce the wave interference from one high tension wire to another.
• Spark plugs
The spark plugs provide the air gap necessary to produce an arc from the electrical energy coming in from the
ignition coil. This arc then ignites the fuel/air mixture in the cylinder, producing power.
Ignition Timing
Ignition timing can be thrown off for two reasons: A problem with a sensor, which will be detected by ECM or a
misalignment of camshaft to crankshaft. This last problem indicates a problem with timing belt, which is covered in
Group EM, Engine. There is no need to adjust engine timing after replacement of a coil.
Check Procedure
1. Warm engine and let idle.
2. Turn all other electrical systems OFF.
3. Connect timing light to high-tension lead number one.
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4. Check that ignition timing mark on crankshaftEbay
pulley
aligns
with timing mark on engine block.
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REMOVAL
Camshaft Position Sensor
1.
2.
3.
4.
Disconnect negative battery cable.
Disconnect two wire harness.
Remove mounting bolts.
Remove sensor from the cylinder head.
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INSPECTION
High-Tension Leads
1.
2.
3.
4.
Disconnect from coil and spark plugs.
Check for breaks in insulation.
Check inside high-tension lead connectors for corrosion or carbon deposits.
Connect high-tension lead to an ohmmeter and check resistance.
Resistance : 16kΩ per 3.28 feet(1m)
5. Replace if defective.
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REMOVAL
Do not attempt any maintenance on spark plugs if engine is hot.
1.
2.
3.
4.
Disconnect negative battery terminal.
Carefully remove high-tension leads.
Use compressed air to blow any dirt or debris from around spark plug hole.
Check that spark plug fits squarely in spark plug socket and remove spark plug.
INSTALLATION
1. Install spark plug into cylinder head.
Tightening torque : 18~22 Ib-ft (25~30 N·m, 2.5~3.0 kg-m)
2. Reconnect high-tension leads.
3. Reconnect negative battery cable.
INSPECTION
1. Reconnect negative battery cable.
2. Connect spark plug to high-tension lead.
3. Hold spark plug with insulated pliers 0.2 to 0.39 inch (5~10 mm) from a ground.
Do not touch vehicle body during following instructions.
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4. While holding spark plug, have a second person
engine.
Verify that a strong blue spark jumps from spark
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plug to ground.
5. If there is no spark or the spark is weak, check for, and implement correction:
A.Carbon deposits. Clean out or replace plug.
B.Oil fouling. Correct oil problem, replace plug.
C.Worrn or burnt electrode. If present, replace plug.
D.Broken or burned ceramic insulator. If present replace plug.
E.Damaged spark plug ring. If so, replace ring.
F.Improper spark plug gap. Regap if possible, otherwise replace plug.
A5D Gap : 0.027~0.031 in (0.7~0.8 mm)
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SPECIFICATION
Item
Torque
Engine idle speed
Ignition coil
750 ± 50rpm
Type
Double-ended
Primary coil resistance
0.6~0.8Ω at 68°F (20°C)
Secondary coil resistance
11~15kΩ at 68°F (20°C)
High-tensioner lead
16kΩ per 3.28 feet (1m)
Spark plug gap
0.027~0.031in(0.7~0.8mm)
Spark plug type
BRK6E
Starter
Engine/Trans
Item
Starter
A5D
Type
Pre-engaged drive
Output
12V - 0.85KW
Generator
Engine
Item
Battery
A5D
Voltage
12V
Type
MF 60
Capacity(20-hour rate)
60A-h
Current draw*
Generator
25 (0.025 ampere)
Type
A/C
Output
12V - 80A
Regulator type
Transistorized (built-in IC regulator)
Regulator voltage
14.1-14.7
FASTENER TIGHTENING SPECIFICATIONS
Item
Torque
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Ignition coil bolt
Spark plugs
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11.5~16.6lb-ft (15.6~22.6N·m, 1.6~2.3kg-m)
18~22lb-ft (25~30N·m, 2.5~3.0kg-m)
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COMPONENT
Email: suzlever@gmail.com
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DISASSEMBLY
1. Remove nut from M terminal.
2. Remove field wire from M terminal.
If pinion depth shims are found between solenoid and drive end housing, remove them and set aside.
3. Remove solenoid screws and magnetic switch.
4. Remove solenoid plunger spring.
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5. Disengage plunger from lever and remove plunger.
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6. Remove bolts from rear cover. Separate motor assembly from drive end housing. Also separate motor assembly
from planetary gear set, if present.
7. Remove lever from drive pinion.
8. Drive stopper from snap ring using a deep well socket or similar tool.
9. Remove snap ring from its groove in pinion shaft.
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10. Remove stopper and drive pinion from pinion
shaft.
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11. Remove two brush plate screws and rear cover.
12. Remove armature from field coil housing.
13. Remove armature washers from the end of the armature.
INSPECTION
1. Solenoid
(1) Check for continuity between S and M terminals with ohmmeter. Replace solenoid if there is no continuity.
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(2) Check for continuity between S terminal and
with ohmmeter. Replace solenoid if there is no
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continuity.
(3) Check continuity between M and B terminal with ohmmeter. Replace solenoid if there is continuity.
2. Brush and brush holder.
(1) Check continuity between each insulated brush and plate with ohmmeter. Replace brush holder if there is
continuity.
(2) Replace spring if there is no continuity.
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3. Field coil
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(1) Check for continuity between M terminal wire and brushes with ohmmeter. Replace yoke assembly if there is
no continuity.
(2) Check continuity between M terminal wire and yoke with ohmmeter. Replace yoke assembly if there is
continuity.
(3) Check if field coil is loose. Replace yoke assembly if necessary.
4. Armature
(1) Check continuity between commutator and core with ohmmeter. Replace armature if there is continuity.
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(2) Check continuity between commutator and
shaft
with
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reveleus1 Replace armature if there is continuity.
REASSEMBLY
1. Reassemble armature washers to the end of armature.
2. Reassemble armature in field coil housing.
3. Reassemble rear cover and tighten two brush plate screws.
Tightening torque : 1.7~3.2 Ib-ft (2.4~4.4 N·m, 0.24~0.44 kg-m)
4. Reassemble drive pinion and stopper on pinion shaft.
5. Place snap ring on its groove in pinion shaft.
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6. Reassemble stopper.
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7. Reassemble lever on drive pinion.
8. If present, reassemble planetary gear set to motor assembly.
9. Reassemble motor assembly in drive end housing.
10. Place bolts in rear cover and tighten.
Tightening torque : 2.8~5.2 Ib-ft (3.8~7.1 N·m, 0.39~0.72 kg-m)
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11. Engage plunger in lever.
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12. Insert solenoid plunger spring.
13. Reassemble magnetic switch and tighten solenoid screws.
Tightening torque : 3.0~5.6 Ib-ft (4.1~7.6 N·m, 0.42~0.77 kg-m)
14. Apply battery power to the S terminal and ground starter motor body. Pinion will eject outward and then stop.
15. Measure clearance (pinion gap) between pinion and stopper.
Pinion gap: 0.079 in (2.0 mm)
Be careful not to let electricity flow continuously for more than 10 seconds. .
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16. If pinion gap is not within specified range, adjust
it by increasing
or decreasing the number of washers used
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between solenoid and drive housing. The gap will become smaller if the number of washers is increased.
Do not use more washers than plates.
17. Connect field wire to M terminal.
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REMOVAL
1.
2.
3.
4.
5.
Disconnect negative battery terminal.
Remove four upper intake manifold support bracket bolts.
Disconnect S terminal connector.
Disconnect B terminal connector.
Remove starter
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SYMPTOM-RELATED DIAGNOSTIC PROCEDURE
Starter
Symptom Guide
No.
1
Will not crank-starter motor does not operate
2
Will not crank-starter motor spins
3
Cranks slowly
4
Generator warning light illuminates with engine running
5
Discharge battery
Symptom Troubleshooting
1
Step
Will not crank-starter motor does not operate
Inspection
Action
1
Yes Check charging system.
Check if engine cranks with fulley charged battery.
No Go to next step.
2
Check if battery votlage is supplied at B terminal.
Yes Go to next step.
No Check wiring harness.
3
Check if battery voltage is supplied at S terminal with clutch
pedal depressed (A/T), car in park (A/T), and ignition switch
in START position.
Yes Replace start unit
No
• Check transmission range switch(A/T)
(Refer to section AT.)
• Check ignition switch.
• Check wiring harness
2
Will not crank-starter spins
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Step
1
Inspection Ebay User ID: reveleus1
Action
Check if drive is pulled out while cranking.
(Click heard pulled out.)
Remove starter and check flywheel ring
Yes gear teeth and starter drive drive pinion
teeth.
No Replace starter unit.
3
Step
Cranks slowly
Inspection
Action
1
Yes
Check if engine cranks normally when fully charged.
Check charging system. (Refer to
Section EE-CH)
No Go to next step.
2
Check starter cable connection for looseness and corrosion
Yes Repair or replace connection.
No
4
Step
Generator warning lamp illuminates with engine running
Inspection
Action
1
Yes
Check wiring harness between generator
L terminal and generator warning lamp.
No
Check charging system (Refer to Section
EE-CH)
Check for correct battery voltage at idle
Specification : 14.1~14.7V
5
Step
Check for seized motor armature. Repair
or replace as necessary.
Discharged battery
Inspection
Action
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1
Check charging system.
(Refer to Section EE-CH)
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Turn ignition switch ON and check dark
current as shown.
Dark current : Below 20mA
(Refer to Section EE-HA)
Yes
No Refer or replace parts as necessary.
Diagnosis and Testing(Cold Cranking Test)
1. Connect a DVOM tester to the battery terminals.
Refer to the operating instructions for the tester being used.
2. Make sure the parking brake is fully engaged. If the vehicle is equipped with an automatic transaxle, place the shift
selector in the PARK position. If the vehicle is equipped with a manual transaxle, place the gearshift lever in the
NEUTRAL position.
3. Make sure that all accessories are turned off.
4. Turn the ignition switch to START and observe the cranking voltage and current draw.
5. If the voltage reading is below 9.6 volts, remove the starter for bench testing. If the starter bench test is okay, refer
to section EM - Engine Mechanical for further diagnosis of the engine. If the starter bench test is not okay, replace
the starter.
6. If the voltage reading is above 9.6V and the current (amperage) draw is below specifications, go to the BATTERY
VOLTAGE DROP TEST in section EE-CH.
7. If the voltage reading is 12.5V or more and the starter doesn´t turn, go to the SOLENOID TEST.
8. If the voltage reading is 12.5V or more and the starter turns very slowly, go to the BATTERY VOLTAGE DROP
TEST in section EE-CH.
A cold engine will increase the starter current (amperage) draw reading and reduce the battery voltage reading
Solenoid Test
1. Remove the starter.
2. Check for continuity between the solenoid terminal and the field coil terminal. If there is continuity, go to next step.
If there is no continuity, repair/replace the faulty components and retest.
3. Check for continuity between the solenoid terminal and the solenoid case. If there is continuity, check the Starter
Relay, Park/Neutral Position Switch, Clutch Pedal Position Switch and Ignition Switch. Refer to the Rio Electrical
Troubleshooting Manual. If there is no continuity, repair/replace the faulty components and retest.
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TROUBLESHOOTING(MISFIRE)
Diagnostic trouble code No.
P0300
Random misfire detected
Diagnostic trouble code No.
P0301
Cylinder 1 misfire detected
Diagnostic trouble code No.
P0302
Cylinder 2 misfire detected
Diagnostic trouble code No.
P0303
Cylinder 3 misfire detected
Diagnostic trouble code No.
P0304
Cylinder 4 misfire detected
Related items
• Vacuum leak in air intake system.
• CKP sensor circuit malfunction.
• Faulty CKP sensor
Low/high fuel pressure due to faulty pressure regulator, restricted fuel lines,
plugged fuel filler or faulty pump.
Fuel injector circuit malfunction.
Faulty fuel injector.
Ignition circuit malfunction.
Low compressing due to blown head gaket, leaking valve(s) or piston(s).
Step
1
2
Inspection
Check for any split, disconnected or
perforated vacuum hoses. Also, check PCV
valve for proper operation.
Are vacuum hoses and PCV okay?
With ignition off, disconnect B07 and B08
packs.
Turn ignition on and measure voltage at
B07-1 and B08-1(B+).
Is battery voltage available?
Ignition off, visually check ignition coils and
plug wires for cracks or carbon tracing.
Check resistance of primary coils (0.6 to
3
Action
Yes
Go to step 2.
No
Replace faulty vacuum hose(s) or PCV.
Yes
Go to step 3.
No
Check for open between B07-1, B08-1 and
X03.
If wiring is okay, check for loose bent,
misplaced or corroded terminals at B07/B08
and X-03.
Repair as necessary.
Yes
Go to step 4.
0.8Ω at 20°C) and secondary coils (11 to
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15kΩ at 20°C) per service manual.Ebay
Check
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resistance of plug wires [16kΩ per 1m).
No
Repair as necessary.
Are ignition coils and plug wires okay?
4
5
6
7
8
9
Disconnect B14 from CKP, Measure
resistance between B14-1 and B14-2 at
CKP pigtail (800 to 900 ohms at 68 degrees
F). Remove CKP sensor from transmission
and calculate air gap between sensor and
flywheel/torque converter (0.012 to
0.067~0.3mm to 1.7mm) [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" =
air gap]. Are air gap and resistance
measurements within specification?
Backprobe front O₂sensor output wire (B161).
· Throttle body gasket
· Gasket between intake manifold and
surge tank
· Seals between intake manifold and fuel
injectors
· Are any air leaks indicated?
Release fuel pressure and attach fuel
pressure gauge to service port on fuel rail.
Start engine and warm up to operating
temperature.
Check fuel pressure at idle
Fuel line pressure : 46~51psi(330~340kPa,
3.3~3.4kg/cm²)
Is fuel pressure within specification?
Check for any injector related DTCs.
Are any injector DTCs present?
Remove compression test [0.027 to 0.031
inches (0.7 to 0.7mm)] and plug condition.
Are spark plugs gapped properly and in
good condition?
Perform compression test [approximately
(184psi, 1275Kpa, 13.0kg/cm²) at 300rpm
Yes
Thoroughly check for loose, bent or
corroded terminals between B14 (CKP
sensor) and B04 (ECM). Measure
resistance between B14-3 and GND (1<
ohm). Repair as necessary. If okay, go to
step 3.
No
Replace CKP sensor or call tech line if air
gap is out of specification.
Yes
Repair as necessary.
No
Go to step 6.
Yes
Go to step 7.
No
Check fuel delivery system
Yes
Refer to diagnostic trouble code
No
Go to step 8.
Yes
Go to step 9.
No
Repair as necessary.
Yes
Go to step 10.
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(no more than 10% between highest
andUser ID: reveleus1 perform leak down test to determine source
Ebay
lowest cylinder)]. Is compression okay?
No
of low compression and repair as
necessary.
10
Return Vehicle to original condition. Clear all Diagnostic Codes. Verify by driving vehicle with SCAN
TOOL connected and monitor for pending codes.
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TROUBLESHOOTING (SYSTEM VOLTAGE)
Diagnostic trouble code No.
P0562
System voltage low
Diagnostic trouble code No
P0563
System voltage high
Related items
• Charging system malfunction
• Poor terminal contact or open at ECM back-up voltage supply circuit
Step
1
2
3
Inspection
Start engine, measure output voltage of
generator (approx. 12~15V)
Is voltage within specification?
Turn engine OFF, ignition ON, measure
voltage at ECM connector B01-7 and GND
(B+).
Is voltage within specification?
Action
Yes
Go to step?
No
Refer to Charging system.
Yes
Poor connection at ECM connector B01
terminals 1, 8 and 9 or intermittently poor
terminal contact.
Repair poor connection or clean oxidization.
No
Open between ECM Connector B01
terminals 1, 8 and 9 and battery. Repair as
necessary.
Return vehicle to original condition. Clear all Diagnostic Trouble Codes. Verify by driving vehicle with
SCAN TOOL connected and monitor for pending codes.
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DIAGNOSIS
Problem
Possible Cause
Action
Engine light "ON"
Engine control module detects fault in
system
Check engine control module. Repair
as required
Engine runs rough
Spark plug failure
Check, clean or replace plugs
High-tension lead arcing to ground
Replace high-tension leads
Ignition coil(s) faulty
Check/replace ignition coil(s)
CMP sensor faulty
Check/replace sensor
CKP sensor faulty
Check/replace sensor
Fuse failure
Check/replace IGN fuse
Low battery cuttent
Check charging system
Ignition coil(s) failure
Check/replace coil(s)
CMP sensor failure
Check/replace sensor
CKP sensor failure
Check/replace sensor
Engine fails to start, starter
turning
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INSTALLATION
1. Lift the air cleaner housing unit and install the air cleaner beneath the housing unit.
2. Lower the housing unit and replace six retaining screws to hold the unit in place.
3. Reattach air intake hose to mass air flow sensor and tighten retaining clamp.
INSPECTION
1. Check the air cleaner element for excessive dirt, damage, or oil, and replace or clean if necessary.
Use a compressed air to clean the element from the internal side to the external side, or from the upper to
the lower.
Inspection
1.
2.
3.
4.
Loosen air intake hose clamp at the mass air flow sensor.
Disconnect air hose from mass air flow sensor.
Remove six screws retaining air cleaner housing and lift housing unit.
Remove air cleaner from beneath air cleaner housing.
Do not use compressed air to clean the air cleaner element.
5. Inspect air cleaner element for excessive dirt, damage or oil.
6. Replace the cleaner element if necessary.
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COMPONENTS (DOHC)
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DISASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
Disconnect the breather hose and the PCV hose.
Remove the coolant pump pulley and crankshaft pulley.
Remove the timing belt cover.
Loosen the timing bolt tensioner pulley and temporarily secure it.
Remove the timing belt from the camshaft sprocket.
Loosen the center cover bolts and then remove the center cover.
Remove the ignition coil assembly.
Loosen the cylinder head cover bolts and then remove it.
Remove the camshaft pulley.
10. Remove the cam carrier assembly and timing belt.
11. Remove the camshaft.
12. Remove the HLA.
REASSEMBLY
1. Install the HLA
2. Check that ?O mark on intake camshaft pulley is aligned with mark on cylinder head cover and ?O mark on
exhaust camshaft pulley is aligned with mark on cylinder head cover.
3. Install the camshaft after lubricating the journal of camshaft with engine oil.
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4. Install the cam carrier assembly.
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5. Tighten the cam carrier bolts to the specified torque in two or three steps.
Tightening torque : 8.31~10.5 Ib-ft (11.2~14.2 N·m, 1.15~1.45 kg-m)
6. Using special tool, camshaft oil seal installer (09221-21000), press the camshaft oil seal. Be sure to apply
engine oil to the external surface of the oil seal. Insert the oil seal along the camshaft front end install by driving
the installer with a hammer until the oil seal is fully seated.
INSPECTION
1. Set front and rear camshaft bearing journals on V-blocks.
2. Position a dial indicator on center bearing journal and zero dial.
3. Rotate camshaft in V-blocks and check runout.
Runout : 0.0012 in (0.03 mm) maximum
4. Check camshaft for uneven wear patterns, cracks, or damage.
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5. Measure cam lobe heights at two points as shown.
Lobe height
Intake - Standard : 1.6848 in (42.87 mm)
Exhaust - minimum : 1.6877 in (42.868 mm)
6. Check camshaft bearing journal diameter (X and Y directions) on both sides (A and B) of journal as shown in
figure.
Standard diameter : 1.324~1326 in (33.961~34.0 mm)
Minimum diameter : 1.0594 in (26.910 mm)
Out-of-round : 0.0012 in (0.03 mm) maximum
7. Replace camshafts if necessary.
8. Measure camshaft journal oil clearance with HLA's removed.
9. Remove all foreign material and oil from journals and bearing surfaces.
10. Set camshafts onto cylinder head.
11. Position Plastigage® on journals in axial direction.
12. Do not rotate camshafts.
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13. Install cam carrier assembly.
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14. Install cam carrier bolts.
Tightening torque : 8.31~10.5 lb-ft (11.2~14.2 N·m, 1.15~1.45 kg-m)
15. Loosen cam carrier assembly bolts.
16. Remove cam carrier assembly.
17. Measure oil clearances.
Oil clearance : 0.0014~0.0031 in (0.035~0.081 mm)
Maximum : 0.006 in (0.15 mm)
18. If oil clearance exceeds specification, replace cylinder head.
19. Install camshafts.
20. Place a dial indicator against end of camshaft.
21. Using a prying tool, move camshaft as far forward as possible.
22. Zero dial.
23. Using prying tool, move camshaft as far rearward as possible.
24. Check gauge to determine how much end play is present.
End play : 0.0003~0.0004 in (0.08~0.10 mm)
Maximum : 0.008 in (0.20 mm)
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REPLACEMENT
• Never open radiator cap while engine is hot.
• Wrap a thick cloth around cap before loosening.
• Use caution when draining hot coolant.
• Do not use alcohol or methanol-based coolant.
• Use only demineralized water in coolant mixture.
1.
2.
3.
4.
5.
Remove radiator cap and loosen drain plug.
Drain coolant into a suitable container.
Flush cooling system with water until all traces of color are gone; then let system drain completely.
Install drain plug.
Fill with proper mixture of ethylene glycolased coolant.
Coolant Capacity: 6.3 gal (6.0L)
6.
7.
8.
9.
Run the engine with the radiator cap removed until the upper radiator hose is hot.
With the engine idling, add coolant to the radiator until it reaches the bottom of the filler neck.
Install the radiator cap.
Allow engine to cool and check coolant level.
INSPECTION
• Never remove radiator cap while engine is hot.
• Wrap a thick cloth around radiator cap before removing.
• When removing radiator cap, loosen slowly to first stop and wait until pressure in radiator is released, then
completely remove.
1. Level (engine cold)
(1) Verify that there is no build-up of rust or scale around radiator cap or radiator filler neck.
(2) Verify that coolant is free of contaminants. Replace coolant if necessary.
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2. Coolant quality
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(1) Verify that there is no build-up of rust or scale around radiator cap or radiator filler neck.
(2) Verify that coolant is free of contaminants. Replace coolant if necessary.
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COMPONENT
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COMPONENT
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REMOVAL
1. Remove the transaxle. Refer to Section MT.
2. Remove the clutch pressure plate and disc. Refer to the procedure in this section.
While loosening the bolts, use SST to prevent the flywheel from turning.
3. Remove the pressure plate bolts and the flywheel.
REMOVAL (PILOT BEARING)
1. Remove the flywheel. Refer to the procedure in this section.
2. Use a suitable driver to remove the pilot bearing from the flywheel.
INSTALLATION
1. Clean the sealant from the flywheel bolts.
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2. Coat the six flywheel bolt threads with a StudEbay
and User
Bearing
Mount Sealer. or equivalent.
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3. Position the flywheel on the cranksaft and install the six flywheel bolts, use SST to prevent the flywheel from
turning.
4. Tighten the six flywheel bolts.
Tightening torque : 71~76 lb·ft (96~103 N·m, 9.6~10.3 kg·m)
5. If the flywheel has been replaced, it will be necessary to install a pilot bearing in the new flywheel. Refer to the
procedure in this section.
INSTALLATION (PILOT BEARING)
Make sure the driver contacts the bearing outer race. Any contact to the inner race will damage the bearing.
1. Insyall the pilot bearin using a suitable driver.
2. Install the flywheel. Refer to the procedures in this section.
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INSPECTION
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1. Check rhe surfae for crack scoring or discoloration of the clutch contact surface.
If the problem is minor, the repairs cna be made by cleaning with a sandpaper.
2. Damaged or worn ring gear teeth.
If necessary, replace the ring gear as follows :
A.Heat the ring gear with a blowtorch, then tap around the gear to emove it from the flywheel.
B.Heat the new ring gear to (480-570°F), 250~300°C, then fit it onto the flywheel..
The bevelled side of the ring gear must face toward the engine side.
3. Run-out of flywheel
A.To measure, position the dial gauge feeler on the clutch disc contact surface, then turn the flywheel.
Runpout : 0.008 in (0.2 mm) max.
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B.If the run-out exceeds the specification, repair by grinding.
Grinding limit : 0.020 in (0.5 mm) max.
DISASSEMBLY
1. Remove the timing belt, front case, flywheel cylinder head assembly and oil pan. For details, refer to respective
chapters,
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.
Mark the main bearing caps to permit reassembly in the original position and direction.
4. Remove the main bearing caps and remove the crankshaft.
Keep the bearings in order by cap number.
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INSPECTION
1. Inspect each valve for following:
A.Damaged or bent valve stem
B.Rough or damaged face
C.Damaged or unevenly worn stem tip
2. Resurface or replace valve as needed.
Margin thickness
Intake: 0.0394 in (1.0mm)
Exhaust: 0.0394 in (1.0mm)
3. Measure length of each valve.
Length
Intake: 3.761 in (96.45 mm)
Exhaust: 3.726 in (95.55 mm)
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4. Measure diameter of each valve stem.
Diameter
Intake: 0.2131~0.21372 in (5.465~5.48 mm)
Exhaust: 0.2117~0.2125 in (5.43~5.45 mm)
5. Measure inside diameter of each valve guide at points shown in figure.
Diameter intake and exhaust valve guide : 0.2165~0.2171 in (5.5~5.515 mm)
6. Calculate valve stem-to-valve guide clearance. Subtract outer diameter of valve stem from inside diameter of
respective valve guide.
Clearance
Intake valve : 0.0007~0.0019 in (0.020~0.050 mm)
Exhaust valve : 0.0019~0.0033 in (0.050~0.085 mm)
Max : 0.008 in (0.20 mm)
7. If clearance exceeds specification, replace valve, and/or valve guide.
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8. Measure protrusion height of each valve guide.
Replace
guide as needed.
Intake: 0.5118~0.5196 in (13.0~13.2 mm)
Exhaust: 0.5118~0.5196 in (13.0~13.2 mm)
Intake and exhaust valve guides are different.
Valve Seat
1. Inspect contact surface of each valve seat and valve face for following:
A.Roughness
B.Damage
C.Pitting
D.Cracks
2. Resurface valve seats with a 45º valve seat cutter. Resurface valve faces as needed.
3. Apply a coat of Dychem blue to valve face and valve seat and allow to dry.
4. Inspect valve seating by pressing valve against seat and rotating valve 360.
A.If Dychem blue is not removed 360¡ around valve face, replace valve.
B.If Dychem blue is not removed 360¡ around valve seat, resurface valve seat.
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5. Measure seat contact width.
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Width:0.037~0.061 in (0.97~1.57 mm)
6. Complete seat-cutting process by lapping valve to seat using valve-lapping compound.
7. Inspect valve seat for sinking.
Intake: 1.0433 in (26.5 mm)
Exhaust: 0.9291 in (23.6 mm)
Clean valves thoroughly before reassembly, and insure that all traces of lapping compound has been
removed.
8. Check for valve sink by measuring protruding length (Dimension L) of valve stem to lower valve spring seat.
Dimension L
Intake : 1.6107 in (41.3 mm)
Exhaust : 1.6068 in (41.2 mm)
Valve spring
1. Inspect each valve spring for cracks and damage.
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2. Measure free length and out-of-square. Replace
springs
as needed.
Free length
Limit : 1.646 in (42.2 mm)
Out-of-square : 0.433 in (1.11 mm)
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COMPONENTS
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REMOVAL
1. Disconnect battery cables.
2. Remove battery and battery tray.
3. Drain engine coolant.
4. Remove fresh air duct.
5. Remove upper and lower radiator hose.
6. Remove accelerator cable.
7. Disconnect fuel hose from fuel injector rail.
8. Remove heater hose.
9. Disconnect brake vacuum hose and purge control vacuum hose from dynamic chamber.
10. Disconnect injector connectors.
11. Disconnect electric connectors.
12. Remove transaxle linkage (A/T).
13. Remove manual transaxle linkage and extension bar (M/T).
14. Remove clutch release cylinder and pipe (M/T).
15. Disconnect transaxle range switch connector (A/T).
16. Disconnect solenoid valve connector (A/T).
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17. Disconnect ATF cooler hose (A/T).
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18. Disconnect power steering pump hose.
19. Disconnect B-terminal and S-terminal connector from starter.
20. Disconnect generator B-terminal connector from generator.
21. Remove four A/C compressor bolts.
22. Remove both front wheels.
23. Disconnect front exhaust pipe and catalytic converter. 25. Remove both right and left tie rod ends from steering
Knuckles by removing one cottor pin and one nut each.
24. Remove both right and left tie rod ends from steering Knuckles by removing one cottor pin and one nut each.
25. Remove bolt and nut from both right and left lower arm and separate low arm from steering knuckles.
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26. Remove 2bolts and nuts from damper and separate
from steering knuckles.
27. Gently pry both driveshafts from transaxle.
28. Support engine with engine hoist.
29. Remove four nuts and four bolts from engine mounting member.
30. Remove two bolts from No.1 engine mounting bracket.
31. Remove one nut from No.2 engine mounting rubber.
32. Remove four bolts from No.2 engine mounting bracket.
33. Remove two nuts from No.3 engine mounting rubber.
34. Lift engine and transaxle out as a unit.
INSTALLATION
1. Install engine and transaxle into engine compartment as a unit.
2. Install two No.3 engine mounting rubber.
Tightening torque : 49~68 Ib-ft (68~93 N·m, 6.8~9.5 kg-m)
3. Install No.2 engine mounting nut bracket bolts and rubber.
Tightening torque
Nut : 49~68 Ib-ft (68~93 N·m , 6.8~9.5 kg-m)
Bolts : 28~38Ib-ft (39~52 N·m, 3.9~5.3 kg-m)
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4. Install four engine mounting member bolts &Ebay
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Tightening torque
Nut : 28~38 Ib-ft (39~52 N·m , 3.9~5.3 kg-m)
Bolts : 47~66Ib-ft (65~91 N·m, 6.5~9.1 kg-m)
5. Remove engine hoist.
6. Install new clips on driveshaft.
7. Push driveshaft and joint shaft into transaxle with opening of clips pointing upward.
8. Install damper to steering knuckles.
9. Install both right and left lower arm to steering knuckles.
10. Install both right and left tie rod ends to steering knuckles.
11. Install front exhaust pipe and catalytic converter.
Tightening torque : 27~38 Ib-ft (37.2~52 N·m , 3.8~5.3 kg-m)
12. Install A/C compressor.
13. Connect B-terminal connector to generator.
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14. Connect B-terminal and S-terminal connector
to starter.
15. Connect power steering pump hose.
16. Connect ATF clooler hose(A/T).
17. Connect solenoid valve connector(A/T).
18. Connect transaxle range switch connector(A/T).
19. Install clutch release cylinder and pipe(M/T).
Tightening torque : 13.7~18.8 Ib-ft (18.6~25.5 N·m , 1.9~2.6 kg-m)
20. Install extension bar and manual transaxle linkage(M/T).
Tightening torque
Extension bar : 27~38 Ib-ft (37.2~52 N·m, 3.8~5.3 kg-m)
Manual transaxle linkage : 12~17 Ib-ft (16~23 N·m )
21. Install transaxle linkage(A/T).
Tightening torque : 24~83Ib-ft (32~46 N·m, 3.2~4.7 kg-m)
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22. Connect electric connectors.
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23. Connect injector connectors to injector rail.
24. Connect brake vacuum hose and purge control vacuum hose to dynamic chamber.
25. Install heater hose.
26. Connect fuel hose to injector rail.
27. Install accelerator cable.
28. Install upper and lower radiator hose.
29. Install fresh air duct.
30. Install battery tray and battery.
Tightening torque : 10~12 Ib-ft (13.5~16 N·m, 1.4~1.6 kg-m)
31. Fill engine coolant with specified type and amount.
32. Connect both battery cables.
33. Check and/or fill all fluids.
34. Test run engine perform an overall check.
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COMPONENT I
COMPONENT II
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COMPONENT III
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REPLACEMENT
Be careful when draining because oil is hot and could cause personal injury.
1.
2.
3.
4.
Warm engine to normal operating temperature and turn engine off. Position a suitable container under oil pan.
Remove oil filler cap and oil pan drain plug.
Allow oil to be fully drained.
Install drain plug with new gasket.
Tightening torque : 22~30 lb-ft (29~41 N·m, 3.0~4.2 kg-m)
5. Refill engine with specified type and amount of engine oil.
6. Run engine and check for leaks.
7. Check oil level and add oil if necessary.
Oil pan capacity : 3.2 U.S. qt (3.0 liters, 2.6 lmp qt)
8. Install oil filler cap.
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COMPRESSION
If the engine exhibits low power, poor fuel economy, or poor idle, check the following :
1. Ignition system
2. Compression
3. Fuel system
Inspection
1.
2.
3.
4.
5.
6.
Check that the battery if fully charged. Recharge it if necessary.
Warm up the engine to normal operating temperature.
Remove the center cover.
Disconnect the high tension lead and ignition coil.
Remove all spark plugs.
Connect a compression gauge to the No.1 spark plug hole.
7. Fully depress the accelerator pedal and crank the engine.
8. Record the maximum gauge reading.
9. Check each cylinder.
Compression(kpa (kg/cm², psi)- Standard
rpm
Difference between cylinders
1275 (13, 184)
90 (1, 14.2)
10. If the compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder and
recheck the compression.
(1) If the compression increases, the piston, piston rings, or cylinder wall may be worn.
(2) If the compression stays low, the valve may be stuck or seating improperly.
(3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be defective or the cylinder
head distorted.
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REMOVAL
Remove components in the order shown in above figure.
INSTALLATION
Install front exhaust as follows:
1.Tighten A temporarily
2.Tighten B temporarily
3.Tighten A fully
4.Check the connection between the pipe of B and bracket
5.Tighten B fully
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COMPONET
Intake system
Ehaust system
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Oil Pressure Check
1.
2.
3.
4.
Disconnect and remove oil pressure switch.
Install oil pressure gauge into oil pressure switch installation hole.
Warm engine to normal operating temperature.
Run engine at 3,000 rpm, and note gauge readings.
Oil pressure : 43~57 psi (294~392 kPa, 3.0~4.0 kg/cm²)
5. If pressure is not within specification, check for cause, and repair.
6. Remove oil pressure gauge and install oil pressure switch.
Tightening torque : 104~156 lb-in (12~18 N·m, 1.2~1.8 kg-m)
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REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
Raise vehicle.
Remove oil filter with oil filter wrench. If rubber seal is stuck to engine, remove it.
Apply a small amount of clean engine oil to rubber seal of new filter.
Install oil filter and turn it by hand until rubber seal contacts base.
Tighten filter 1-1/6 turns with filter wrench.
Start engine and check for leaks.
Turn engine off, and wait 5 minutes. Check oil level and add oil if necessary.
Oil filter capacity : 0.21 U.S. qt (0.20 liter, 0.18 lmp qt)
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COMPONENTS
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COMPONENT
Email: suzlever@gmail.com
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REMOVAL
1.
2.
3.
4.
5.
Disconnect negative battery cable.
Drain engine oil.
Remove Drive belt.
Remove timing belt.
Remove components in the order shown in above figure.
INSPECTION
1. Clean all components and clean off dust from all components.
2. Check all components with specifications and replace as necessary.
Component
Specification
Oil pump
Side clearance
0.0039in (0.10mm)
Tooth tip coearance
0.007in (0.18mm)
Outer roter to pump body clearance
0.0078in (0.20mm)
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COMPONENTS(ROD AND PISTON)
COMPONENTS(ROD AND PISTON)
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DISASSEMBLY
1. Use a numbering stamp and mark rod cap and connecting rod with their corresponding cylinder number.
Mark connecting rods on same side and make a reference mark on block so that rods are installed in correct
position anddirection. Failure to install rods properly with result in oil starvation, spun bearings, or damaged
internal engine components.
2. Rotate crankshaft so that cylinders No.2 and No.3 are at Bottom Dead Center (BDC) and repeat marking
procedure.
3. Remove connecting rod nuts and gently loosen rod caps by tapping cap with a light plastic mallet.
4. Remove rod caps.
Coter connecting rod bolts to protect crankshaft jounals.
5. Push connecting rod and piston as far up into cylinder as possible. Using a wooden dowel, tap gently on piston
to release it from cylinder.
6. Repeat this procedure for each cylinder.
7. Mark tops of pistons with corresponding cylinder numbers they were removed from.
8. Using a piston ring expander, remove piston rings.
9. Hold piston upright and gently move connecting rod.
10. Release connecting rod and observe its movement.
Do not swing connecting rod widely. Constant, hard contact with piston will cause a bell-mouth condition
that will require piston replacement.
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11. If connecting rod does not move freely, check
piston
and connecting rod for straightness and
Ebay
Userpin
ID: bore
reveleus1
deformation.
12. Remove piston pin clip from ends of piston pin bore.
13. Tilt piston and allow piston pin to slide out into your hand. Piston pins may need to be pressed out.
Do not allow pins to drop to the ground.
14. Remove connecting rod from piston. Keep individual piston, piston pin, and piston clips together for reassembly.
DIASSEMBLY
1. Use a numbering stamp and mark rod cap and connecting rod with their corresponding cylinder number.
Mark connecting rods on same side and make a reference mark on block so that rods are installed in correct
position and direction. Failure to install rods properly with result in oil starvation, spun bearings, or damaged
internal engine components.
2. Rotate crankshaft so that cylinders No.2 and No.3 are at Bottom Dead Center (BDC) and repeat marking
procedure.
3. Remove connecting rod nuts and gently loosen rod caps by tapping cap with a light plastic mallet.
4. Remove rod caps.
Coter connecting rod bolts to protect crankshaft jounals
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reveleus1Using a wooden dowel, tap gently on piston
5. Push connecting rod and piston as far up into
cylinder
to release it from cylinder.
6. Repeat this procedure for each cylinder.
7. Mark tops of pistons with corresponding cylinder numbers they were removed from.
8. Using a piston ring expander, remove piston rings.
9. Hold piston upright and gently move connecting rod.
10. Release connecting rod and observe its movement.
Do not swing connecting rod widely. Constant, hard contact with piston will cause a bell-mouth condition
that will require piston replacement.
11. If connecting rod does not move freely, check piston pin bore and connecting rod for straightness and
deformation.
12. Remove piston pin clip from ends of piston pin bore.
13. Tilt piston and allow piston pin to slide out into your hand. Piston pins may need to be pressed out.
Do not allow pins to drop to the ground.
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14. Remove connecting rod from piston. Keep individual
piston pin, and piston clips together for reassembly.
RESSEMBLY
1. Insert connecting rod into piston and slide piston pin through piston and through connecting rod until it makes
contact with the piston pin clip already installed.
Verify that piston and rod are assembled in same direction as they were prior to disassembly.
2. Install second piston pin clip into clip grooves on opposite side of piston.
3. Hold piston upright and move connecting rod back and forth. Check that rod moves freely.
4. Install three piece oil ring onto piston.
A.Apply clean engine oil to the oil ring expander and upper and lower oil rings.
B.Install expander onto piston so that expander ends face upward.
C.Install lower oil ring onto piston. Ring may be installed with either face upward.
D.Install upper oil ring onto piston. Ring may be installed with either face upward.
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5. Check that oil ring expander separates upperEbay
andUser
lowerID:oilreveleus1
rings, and that oil ring assembly spins freely on
piston.
6. Use a ring expander and install second ring.
7. Use a ring expander and install top ring.
Top ring and second ring should be installed with "O" or "Y" mark facing up.
8. Align piston ring gaps as shown.
9. Install a bearing into connecting rod.
10. Place rubber sleeves (rubber fuel line works well) on connecting rod bolts to protect crankshaft from damage.
11. Check piston rings for correct end gap stagger.
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12. Place piston (cylinder number one) with ?OEbay
markUser
facing
of engine block, then slip piston and connecting
rod assembly into a piston ring compressor.
13. Rotate crankshaft so that crank pin journal for specific cylinder is at its lowest point (bottom dead center).
14. Lower piston and connecting rod assembly until piston ring compressor makes contact with deck surface of
engine block.
15. Using butt end of a hammer, tap the top of piston into cylinder and continue tapping until connecting rod makes
contact with crankshaft.
Follow this procedure for remaining piston and connecting rod assemblies.
16. Install a connecting rod bearing in each connecting rod cap.
17. Place a piece of Plastigage¨ on crank pin journals.
18. Install connecting rod caps, aligning marks made previous to disassembly and torque to specification.
Tightening torque : 22~24 lb-ft (29~34 N·m, 3.0~3.5 kg-m)
When installing the connecting rods, match marks made on the connecting rod and cap to reference mark
made on cylinder block to prevent oil starvation to the connecting rod bearings.
19. Loosen and remove connecting rod caps.
20. Check the connecting rod bearing clearance.
Oil clearance : 0.0010 ~ 0.0021 in (0.026 ~ 0.054 mm)
Maximum : 0.004 in (0.10 mm)
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21. If oil clearance exceeds maximum oil clearance
grind the crankshaft and use undersized
connecting rod bearings.
(1) Connecting rod bearing selection table
Connecting rod code
Pin journal shaft
diameterr
39.940~39.956mm
1
2
3
(Green)
(Blue)
(Red)
*Marking colors is coated in the bearing side.
(1) Connecting rod bearing housing bore size
Code
Connecting rod bearing housing bore size (mm)
1
43.000~43.006
2
43.006~43.012
3
43.012~43.016
(2) Connecting rod bearing thickness
Connecting bearing
Standard bearing
Undersize bearing
bearing thickness
(Green)
1.506~1.509
(Blue)
1.509~1.512
(Red)
1.512~1.515
0.25
1.631~1.635
0.50
1.756~1.760
0.75
1.881~1.885
22. Apply a coat of clean engine oil to connecting rod bearing in connecting rod cap.
23. Install connecting rod cap and torque to specification.
Tightening torque : 22 ~ 24 lb-ft (29 ~ 34 N·m, 3.0~3.5 kg-m)
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reveleus1and sheck connecting rod side clearance.
24. Insert a thickness gauge between connecting
rodUser
andID:
crankshaft
Do not measure between connecting rod cap and crankshaft.
Side clearance : 0.0044~0.0103 in (0.110~0.262 mm)
Maximum: 0.012 in (0.30 mm)
25. If side clearance exceeds maximum side clearance specification, replace connecting rod and cap.
RESSEMBLY
1. Insert connecting rod into piston and slide piston pin through piston and through connecting rod until it makes
contact with the piston pin clip already installed.
Verify that piston and rod are assembled in same direction as they were prior to disassembly.
2. Install second piston pin clip into clip grooves on opposite side of piston.
3. Hold piston upright and move connecting rod back and forth. Check that rod moves freely.
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4. Install three piece oil ring onto piston.
A.Apply clean engine oil to the oil ring expander and upper and lower oil rings.
B.Install expander onto piston so that expander ends face upward.
C.Install lower oil ring onto piston. Ring may be installed with either face upward.
D.Install upper oil ring onto piston. Ring may be installed with either face upward.
5. Check that oil ring expander separates upper and lower oil rings, and that oil ring assembly spins freely on
piston.
6. Use a ring expander and install second ring.
7. Use a ring expander and install top ring.
Top ring and second ring should be installed with "O" or "Y" mark facing up.
8. Align piston ring gaps as shown.
9. Install a bearing into connecting rod.
10. Place rubber sleeves (rubber fuel line works well) on connecting rod bolts to protect crankshaft from damage.
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11. Check piston rings for correct end gap stagger.
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12. Place piston (cylinder number one) with O mark facing front of engine block, then slip piston and connecting
rod assembly into a piston ring compressor.
13. Rotate crankshaft so that crank pin journal for specific cylinder is at its lowest point (bottom dead center).
14. Lower piston and connecting rod assembly until piston ring compressor makes contact with deck surface of
engine block.
15. Using butt end of a hammer, tap the top of piston into cylinder and continue tapping until connecting rod makes
contact with crankshaft.
Follow this procedure for remaining piston and connecting rod assemblies.
16. Install a connecting rod bearing in each connecting rod cap.
17. Place a piece of Plastigage on crank pin journals.
18. Install connecting rod caps, aligning marks made previous to disassembly and torque to specification.
Tightening torque : 22~24 lb-ft (29~34 N·m, 3.0~3.5 kg-m)
When installing the connecting rods, match marks made on the connecting rod and cap to reference mark
made on cylinder block to prevent oil starvation to the connecting rod bearings.
19. Loosen and remove connecting rod caps.
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20. Check the connecting rod bearing clearance.
Oil clearance : 0.0010 ~ 0.0021 in (0.026 ~ 0.054 mm)
Maximum: 0.004 in (0.10 mm)
21. If oil clearance exceeds maximum oil clearance specification, grind the crankshaft and use undersized
connecting rod bearings.
(1) Connecting rod bearing selection table
Connecting rod code
Pin journal shaft
diameter
1
39.940~39.956mm
(Green)
2
(Bue)
3
(Red)
*Marking colors is coated in the bearing side.
(2) Connecting rod bearing housing bore size
Code
Connecting rod bearing housing bore size (mm)
1
43.000~43.006
2
43.006~43.012
3
43.012~43.016
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(3) Connecting rod clearance thickness
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Connecting rod bearing
Standard bearing
Undersize bearing
Bearing thickness
(Green)
1.506~1.509
(Blue)
1.509~1.512
(Red)
1.512~1.515
0.25
1.631~1.635
0.50
1.756~1.760
0.75
1.881~1.885
22. Apply a coat of clean engine oil to connecting rod bearing in connecting rod cap.
23. Install connecting rod cap and torque to specification.
Tightening torque : 22 ~ 24 lb-ft (29 ~ 34 N·m, 3.0~3.5 kg-m)
24. Insert a thickness gauge between connecting rod and crankshaft and sheck connecting rod side clearance.
Do not measure between connecting rod cap and crankshaft.
Side clearance : 0.0044~0.0103 in (0.110~0.262 mm)
Maximum : 0.012 in (0.30 mm)
25. If side clearance exceeds maximum side clearance specification, replace connecting rod and cap.
INSPECTION
Piston Ring
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1. Insert a new piston ring into a piston ring groove
clearance between piston ring and ring end.
Clearance between ring and ring end.
Standard : A5D : 0.03~0.07 mm
Maximum: 0.10 mm
2.
3.
4.
5.
6.
7.
If clearance exceeds the maximum, replace piston.
Inspect piston rings for damage, abnormal wear, or breakage.
Replace piston rings if necessary.
Insert piston ring into cylinder by hand.
Square ring in cylinder by inverting a piston into cylinder and pushing ring to the bottom of its travel in cylinder.
Place a feeler gauge in end gap and check end gap clearance.
End gap clearance
Ring
A5D
Top ring
0.006~0.011 in (0.15~0.30mm)
Second ring
0.016~0.021 in (0.40~0.55mm)
Oil rail
0.008~0.027 in (0.20~0.70mm)
Maximum
0.039 in (1.0mm)
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COMPONENTS
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COMPONENTS
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Cooling fan relay
Inspection
Cooling fan motor relay is located in the engine compartment fuse/relay box.
1. Disconnect negative battery cable.
2. Remove cooling fan motor relay from engine compartment fuse/relay box.
3. Check continuity with an ohmmeter.
Terminal
Continuity
38 ~ 87
No
85 ~ 86
Yes
4. Apply 12V to terminal 85 and ground to terminal 86. Check for continuity between terminals 30 and 87.
5. If there is no continuity, replace fan motor relay.
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INSPECTION
Cooling fan motor relay is located in the engine compartment fuse/relay box.
1. Disconnect negative battery cable.
2. Remove cooling fan motor relay from engine compartment fuse/relay box.
3. Check continuity with an ohmmeter.
Terminal
Continuity
38~87
No
85~86
Yes
4. Apply 12V to terminal 85 and ground to terminal 86. Check for continuity between terminals 30 and 87.
5. If there is no continuity, replace fan motor relay.
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REMOVAL
Remove components in the order shown above figure.
INSPECTION
Cooling fan motor relay is located in the engine compartment fuse/relay box.
1. Disconnect negative battery cable.
2. Remove cooling fan motor relay from engine compartment fuse.relay box.
3. Check continuity with an ohmmeter.
Terminal
Continuity
38~87
No
85~86
Yes
4. Apply 12V terminal 85 and ground to terminal 86.
Check for continuity between terminals 30 and 87.
5. If there is no continuity, replace fan motor relay.
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REMOVAL
1.
2.
3.
4.
Disconnect negative battery cable.
Remove fresh air duct.
Drain coolant.
Remove components in the order shown in the above figure.
INSTALLATION
1. Install in the reverse order of removal.
2. After installation, fill engine coolant and check coolant leakage
INSPECTION
Leakage
1. Connect a coolant system pressure tester to the radiator filler neck.
2. Apply 15psi(103kPa) pressure to the system.
3. Verify that the pressure remains steady at 15psi (103kPa).
4. If not, check system for coolant leakage.
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SPECIAL SERVICE TOOLS
Tool (Number and
Name)
Illustration
Use
OK670 321 019
Ball joint puller
Used to remove tie-rod
end.
OK130 111 004
Coupling flange holder
Used to disassemble and
assemble timing belt pulley.
OK130 111 002
Ring gear brake
Used to prevent engine
rotation.
OK130 160 010
Clutch disc centering tool
Used to install clutch disc.
OK130 990 007
Engine stand
Used to disassemble and
assemble engine.
OKK30 101 001
Engine stand hanger
Used to disassembly and
assembly engine.
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OK993 120 001
Valve spring lifter arm
Used to remove and install
valve.
OK993 120 004
Valve spring lifter pivot
Used to remover and
install valve.
OK1993 120 006
Valve seal remover
Used to remove valve seal.
OK12CA 120 AA0
Valve spring compressor
set
Used to replace valve seal
and vlave spring.
OK30 140 001
Oil pressure gauge
Used to measure fuel
pressure.
OK130 120 006
Valve guide remover &
installer
Used to remove and install
valve guide
OK2CA 120 001
Valve spring compressor
hook
Used to replace valve seal
and valve spring
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SPECIFICATION
Engine Type
Item
A5D
Type
Gasoline, 4 cycle
Cylinder arrangement and number
In line, 4 cylinders
Combustion chamber
Pentroof
Valve system
DOHC, belt driven (IN : 2, EX : 2)
Displacement
1.493cc (91.1cu in)
Compression ratio
Valve timing
9.5 : 1
In
EX
Valve clearance mm(in)
Open
6° BTDC
Close
46° BTDC
Open
46° BTDC
Close
6° ATDC
IN
0 : Maintenance-free
EX
0 : Maintenance-free
Idle speed
750 ± 50 rpm
Ignitioin timing
6° ± 5° BTDC
Fring order
1-3-4-2
Lubrication system
Oil pump
Forced-fed type
Type
Trochoid gear
Relief pressure
Oil filter
466~564kPa (4.75~5.75kg/cm², 66~80psi)
Type
Full-flow, paper element
Relief-valve opening pressure
98kPa (1.0kg/cm², 14psi)
Oil pressure switch activation pressure
25kPa (0.25kg/cm², 3.6psi)
Oil capacity
Total (dry engine)
3.4liter (3.6US qt, 3.0lmp qt)
Oil pan
3.0liter (3.2US qt, 2.6lmp qt)
Oil filter
0.20liter (0.21US qt, 0.18lmp qt)
Engine oil
Cooling system
API service SG
Water-cooled, forced circulation
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Coolant capacity(with heater)
Thermostat
Type
6.0liter (6.3US qt, 5.3lmp qt)
Wax type
Opening temperature
86.5~86.9°C (187.7~193.1°F)
Full-open temperature
100°C (212°F)
Full-open lift
8.0mm (0.31in)
Water pump
Type
Centrifugal
Radiator
Type
Corrugted fin type
Cap valve pressure
Cooling fan
74~103liyer (0.75~1.05Us qt, 11~15lmp qt)
Outer diameter
300mm (11.8in)
Number of blades
4
Intake and exhaust system
Air cleaner element type
Dried
Accelerator cable free play
1~3mm (0.039~0.11in)
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COMPONENT
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REMOVAL
Remove components in the order shown in above figure.
INSTALLATION
1. Install thermostat into cylinder head with jiggle pin positioned up.
2. Install in the reverse of removal.
INSPECTION
1. Visually check that thermostat is airtight.
2. Place thermostat and a thermometer in water.
3. Gradually heat water and check following.
Inital opening temperature : 188~193°F (86.5~89.5°C)
Full open temperature : 212°F (100°C)
Full open lift : 0.31in (8.0mm) min
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COMPONENTS
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REMOVAL
1. Disconnect negative battery cable.
2. Loosen power steering lock bolts and nuts accordingly and remove tension from power steering (P/S) and/or air
conditioning (A/C) compressor drive belt.
3. Remove P/S and/or A/C drive belt.
4. Loosen generator mounting bolts and adjusting bolt.
5. Remove generator bolts.
6. Remove water pump pulley.
7. Remove crankshaft pulley and timing belt guide plate.
8. Remove upper and lower timing belt covers.
9. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine.
10. Check that "I" mark on intake camshaft pulley is aligned with mark on cylinder head cover and "E" mark on
exhaust camshaft pulley is aligned with mark on cylinder head cover.
Do not move camshaft or crankshaft once timing marks have been correctly positioned.
11. Loosen tensioner pulley lock bolt.
12. Protect timing belt with a rag.
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13. Remove tensioner pulley.
14. Remove timing belt.
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Mark the direction of timing belt rotation (on the timing belt) for proper reinstallation.
INSTALLATION
1. Install tensioner pulley.
Replace tensioner spring whenever timing belt is replaced.
2. Pull tensioner pulley to its furthest point and tighten lock bolt.
3. Check that timing mark on timing belt pulley is aligned with timing mark on engine.
4. Check that "I" mark on intake camshaft pulley is aligned with mark on cylinder head cover and "E" mark on
exhaust camshaft pulley is aligned with mark on cylinder head cover.
If existing timing belt is being reused, install belt in proper rotation direction marked prior to removal.
5. Install timing belt onto timing belt pulley first, then idler pulley, exhaust camshaft pulley, intake camshaft pulley,
and tensioner pulley in that order.
6. Check that there is no looseness in belt between idler pulley and exhaust camshaft pulley or between intake and
exhaust camshaft pulleys.
7. Loosen tensioner pulley lock bolt and allow tensioner spring to apply tension to timing belt.
Do not add additional tension.
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8. Tighten tensioner pulley lock bolt to specifiedEbay
torque.
Tightening torque : 28~38 lb-ft (38~51 N·m, 3.9~5.2 kg-m)
9. Rotate crankshaft two full revolutions (clockwise only) and align timing mark on timing belt pulley with timing
mark on engine block.
10. Check that "I" mark on intake camshaft pulley "E" mark on exhaust camshaft pulley are aligned with marks on
cylinder head cover.
11. If they are not aligned, remove timing belt and start process from tensioner installation.
12. Measure timing belt deflection by applying moderate pressure midway between camshaft pulleys. If deflection
is not correct, repeat from tensioner installation.
Deflection pressure : 22 Ib. (98 N, 10 kg)
Deflection : 0.39~0.50 in. (11~13 mm)
13. Install lower and upper timing belt covers in that order.
Tightening torque : 70~96 Ib-ft (7.9~10.7 N·m, 0.8~1.1 kg-m)
14. Install timing belt guide plate and crankshaft pulley.
Tightening torque : 9.0~12.6 lb-ft (12.3~17.2 N·m, 1.3~1.8 kg-m)
15. Install water pump pulley.
Tightening torque : 9.0~12.6 lb-ft (12.3~17.2 N·m, 1.3~1.8 kg-m)
16. Install generator belt and adjust the tension.
17. Install P/S and/or A/C drive belt and adjust the tension.
18. Connect negative battery cable.
INSPECTION
Never forcefully twist, turn inside out or bend timing belt. Do not allow oil or grease to come in contact with
timing belt.
1. Replace timing belt if it is contaminated with oil or grease.
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2. Check timing belt for uneven wear, fraying, peeling,
cracking
and hardening. Replace timing belt as necessary.
3. Bend timing belt into a "U" shape as shown in figure. Distance "A" must be at least 1.0 in (25 mm).
4. Inspect both idler pulley and tensioner pulley for uneven wear and smooth bearing operation.
5. Inspect camshaft pulleys and timing belt pulley for broken teeth or damage.
Replace any component that shows damage, excessive wear, or that appears prone to a possible failure.
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THERMOSTAT
Diagnostic trouble code No.
P0128
Related items
Engine coolant thermostat open stuck
• Thermostat stuck opened
• After engine start-up, the elapsed time before feedback operation is
initiated is too long (engine coolant temperature sensor input is insufficient
for closed loop operation)
• Poor connections between ECTS and ECM
• Misplaced, loose or corroded terminals
• Contaminated, deteriorated ECTS
Step
1
2
3
4
5
Inspection
Remove thermostat and check that
thermostat is stuck
Is thermostat okay?
Connect SCAN TOOL to data link
connector or OBD-II check connector and
turn ignition to ON.
Is DTC P0115, P0116, or P0125 set?
Start engine and allow engine to idle until
engine reaches operating temperature.
Using SCAN TOOL and monitor ECT
signals.
· 3.2~3.8V @ 0°C(32°F)
· 2.3~2.9V @ 20°C(68°F)
· 1.5~2.1V @ 40°C(104°F)
· 0.4~1.0V @ 80°C(176°F)
Is signal within specifications?
Check ECTS for contamination,
deterioration or damage.
Is ECTS contaminated, deteriorated or
damaged?
Thoroughly check for loose, bent or
corroded connectors at ECM and ECTS
connectors.
With ignition OFF, disconnect ECM and
ECTS connectors. Measure resistance
Action
Yes
Go to step 2.
No
Temporarily install a known good
thermostat and check for proper operation.
If problem is corrected, replace thermostat.
Yes
Do all repairs associated with those codes
before proceeding this procedure.
No
Go to step 3.
Yes
Problem is intermittent or was repaired and
engine control module memory was not
cleared.
Check terminal connections at ECM and
ECTS.
No
Go to step 4.
Yes
Clean ECTS with cleaner before installing.
If damaged or deteriorated, replace.
No
Go to step 5.
Yes
Go to step 6.
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between ECTS and ECM on all two
circuits.
Is resistance all below 1 ohm?
No
Repair as necessary.
6
Return vehicle to original condition. clear all diagnostic trouble codes. Verify by driving vehicle with
SCAN TOOL connected and monitor for pending codes.
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TROUBLESHOOTING
Engine mechanical system
Problem
Engine will not crank
Engine cranks normall, but does
not start
Poor idle quality
Possible cause
Action
Battery, starting system or other
electrical problems
Refer to starting system, section EE,
charging system, section EE, or
electrical troubleshooting manual
Liquid in combustion chamber
Remove with suction gun, then crank
engine over with spark plugs removed
Seized engine
Repair
Fuel system malfunction
Refer to fuel system, section FL
Ignition system malfunction
Refer to ignition system, section EE
Improper valve clearance
Check HLA's
Restricted exhaust system
Refer to exhaust system
Timing belt and/or related parts
Inspect timing belt and related parts :
replace if necessary
Low compression due to : stuck or
burned valves : worn piston, piston
ring or cylinder : failed cylinder head
gaket
Perform a compression test as
outlined in this section : repair engine
as necessary
Camshaft worn
Replace
Fuel system malfunction
Refer to fuel system section FL
Emission system malfunction
Refer to emission system, section FL
Ignition system malfunction
Refer to ignition system system
section EE
Impeoper valve clearance
Check HLA's
Unven cylinder compression
Perform a compression test, as
outlined in this section : repair engine
as necessary
Poor valve-to-valve seat contact
Repair or replace
Broken valve spring
Repair
Failed cylinder head gasket
Replace
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White exhaust smoke
Black exhaut smoke
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Usually cause
byUser
water
which
is a normal by-product of combustion
on cold days
None repuired
Excessive white smoke with engine
warmed up could be caused by a
failed cylinder head or intake gasket.
Could also be a cracked block,
cylinder head or intake manifold
Repair or replace
Fuel system malfunction
Refer to fuel system. section FL
Emission system malfunction
Blue exhaust smoke
Usually caused by oil buring in the
combustion chambers from : worn
rings, worn valve guides, worn valve
seals or failed cylinder head gasket
Replace
Valve train noise
Worn valve guides
Repair
Low oil pressure
Refer to lubrication system
Improper valve clearance
Check HLA's
Broken valve spring
Replace
Sticking valves
Free valves
Camshaft worn or faulty
Replace
Insufficient compression caused by :
1. Improper valve clearance
2. Leakage from valve seat
3. Seized valve stem
4. Weak or broken valve spring
5. Failed cylinder head gasket
6. Cracked or distorted cylinder head
7. Sticking damaged or worn piston
ring
8. Cracked or worn piston
Check HLA's
Repair or replace
Replace
Replace
Replace
Repair or replace
Replace
Replace
Fuel system malfunction
Refer to fuel system, section FL
Slipping clutch
Refer to clutch, section CL
Dragging brakes
Refer to brake system, section BR
Worng tire size
Refer to wheels and tires, Refer to
exhaust system
Restriced exhaust system
Abnormal combustion
Insufficient power
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Abnormal combustion
Engine knocks at idle when hot
Slight noise at idle, becomes
louder as engine louder as
engine speed is increased
Engine knocks when cold
Engine has heavy knock when
hot and torque us applied
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Improper valve
Check HLA's
Sticking or burned valve
Replace
Weak or broken valve spring
Replace
Carbon accumulation in combustion
chamber
Eliminate carbon
Loose or worn accessory drive belt/
tensioner
Check belts and tensioners Replace if
necessary
A/C compressor generator bearing
Replace
Improper oil viscosity
Install proper oil viscosity for expected
temperatures
Excessive piston pin clearance
Install new piston, pin and/or
connecting rod
Connecting rod clearance
Check and replace rods if necessary
Insufficient pistonto-bore clearance
Hone and replace rods if necessary
Faulty timing belt tensioner or guide
Replace
Loose damper pulley
Tighten or replace if necessary
Valve spring clicking on cap, off
square or broken
Repair or replace
Excessive stem to guide clearance
Repair
Excessive valve seat runout
Repair
Excessive piston to wall clearance
Replace pistons
Loose or broken damper pulley
Tighten or replace
Broken damper pulley
Replace
Accessory belts too tight or damaged
Adjust or replace belt
Belt tensioned damaged
Replace
Flywheel cracked or loose clutch plate Replace flywheel or clutch plate
Excessive main bearing clearance
Repair
Excessive rod bearing clearance
Repair
Engine has light knock when hot Improper timing
and under light load conditions
Piston pin and/or connecting rod
Poor quality fuel
Check timing
Replace piston pin and/or rod
Use recommender or higher grade fuel
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Exhaust leak at manifold
Tighten bolts and/or replace exhaust
manifold gaskets if necessary
Excessive rod bearing clearance
Repair
Improper oil viscosity
Install proper oil viscosity for expected
temperatures
Tooth is broken or cracked
Camshaft jamming
Inspect camshaft by removing
cylinder head cover
Repair or replace if necessary
Back surface is cracked and/or
worn
Tensioner jamming
Remove tensioner and inspect
Replace if necessary
Engine overheating
Inspect cooling system
Refer to engine cooling system
Interference with timing belt cover
Remove timing belt cover and inspect
Replace if necessary
Improper installation of timing belt
Remove timing belt and reinstall
Malfunction of timing belt guide plate
Remove timing belt and inspect guide
plate
Poor belt cover sealing
Remove timing belt and inspect
Replace if necessary
Coolant leak at water pump
Inspect water pump
Replace if necessary
Camshaft malfunction
Inspect camshaft by removing the
cylinder head cover
Repair or replace if necessary
Excessive belt tension
Remove tensioner spring and inspect
Replace if necessary
Poor oil sealing
Inspect front oil seals
Replace if necessary
Coolant leak at water pump
Inspect water pump
Replace if necessary
Poor belt cover sealing
Remove timing belt cover and inspect
Replace if necessary
Engine knocks during intial start
up and lasts only a few seconds
Side surface is worn and/or
frayed
Teeth are worn
Oil or coolant is on the belt
HLA(Hydraulic lash adjuster)
Problem
Possible cause
Action
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1. Noise when engine is started
immediately after oil is changed.
2. Noise when engine is started after
setting approx. one day.
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Oil leakage
in ID: reveleus1
Oil passage
Run engine at 2,000~3,000rpm.
If noise stops after 2 seconds 10minutes*, HLA is normal.
If not, replace HLA
*Time required for engine oil to
circulate within engine includes
tolerance for engine oil condition and
ambient temperature
3. Noise when engine is started after
cranking for 3 seconds or more.
4. Noise when engine is started after
new HLA is installed
Oil leakage in HLA
5. Noise continues more than 10
minutes.
Insufficient oil pressure
Check oil pressure.
If lower than specification, check for
cause.
Oil pressure : 43~57psi
(294~392kPa, 3.0~4.0kg/cm²)3,000rpm
Faulty HLA
Press down HLA by hand.
If it does not move, HLA is normal.
If it moves, replace HLA.
Measure valve clearance.
If more than 0mm (0in), replace HLA.
Incorrect oil amount
Check oil level.
Drain or add oil as necessary.
Deteriorated oil
Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
6. Noise during after high-speed
running
Lubrication system
Problem
Engine hard starting
Excessive oil consumption
Oil pressure drop
Possible cause
Action
Improper engine oil
Replace
Insufficient engine oil
Add oil
Internal engine wear
Refer to EM
Oil leak
Repair
Insufficient oil
Add oil
Oil leakage
Repair
Worn and/or
damaged oil pump
gear
Replace
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Worn plunger(inside
oil pump) or weak
spring
Replace
Clogged oil strainer
Warning lamp illuminates while engine is running
Overheating
Excessive main
bearing or
connecting rod
bearing clearance
Refer to EM
Oil pressure drop
As described above
Malfunction of oil
pressure switch
Refer to Section BE
of electrical
Troubleshooting manual
Refer to Section BE of
electrical
Malfunction of
electrical system
Troubleshooting manual
Coolant level
insufficient
Add
Coolant leakage
Repair
Radiator fins clogged Clean
Corrosion
Radiator cap
malfunction
Replace
Fan motor
malfunction
Replace
Water passage
clogged
Clean
Water pump
malfunction
Replace
Impurities in coolant
Replace
Cooling system
Problem
Overheating
Possible cause
Action
Coolant level insufficient
Add
Coolant leakage
Repair
Radiator fins clogged
Clean
Radiator cap malfunction
Replace
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Corrosion
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Fan motor malfunction
Replace
Thermostat malfunction
Replace
Water passage clogged
Clean
Water pump malfunction
Replace
Impurities in coolant
Replace
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COMPONENT
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DISASSEMBLY
1. Drain the coolant and disconnect the upper radiator hose.
2. Remove the breather hose (beween the air cleaner and the head cover).
3. Remove the air-intake hose.
4. Remove the vacuum hose, fuel hose and coolant hose
5. Remove the cables from the spark plugs. The cables should be removed by hold ing the boot portion.
6. Remove the ignition coil.
7. Remove the power steering oil pump and bracket.
8. Remove the intake manifold.
9. Remove the heat protector and exhaust manifold assembly.
10. Remove the coolant pump pulley and the crankshaft pulley.
11. Remove the timing belt cover.
12. Remove the timing belt tensioner pulley.
13. Remove the timing belt.
14. Remove the head cover and cam carrier assembly.
15. Remove the cylinder head assembly. The cylinder head bolts should be removed by using Special Tool,
Cylinder Head Bolt Wrench, in the sequence as shown in the illustration in two or three steps.
16. Remove the gasket pieces from cylinder block top surface and cylinder head bottom surface.
Make sure that the gasket pieces do not fall in the engine
INSPECTION
• Clean all components.
• Remove gasket fragments, dirt, oil, grease, carbon, moisture, residue, and other foreign materials.
1. Cylinder head
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2. Inspect cylinder head for damage, cracks, and
leakage
of reveleus1
oil and water. Replace cylinder head if necessary.
Ebay
User ID:
3. Measure cylinder head mating surface in six directions as shown in figure.
Distortion : 0.012 in (0.03 mm) maximum
Before resurfacing cylinder head, check following repair or replace cylinder head if necessary
• Sunken valve seats.
• Damage at intake and exhaust manifold mating surfaces.
• Camshaft oil clearances and end play.
4. Grind cylinder head mating surface if distortion exceeds specification.
Distortion : 0. 012 in (0.03 mm) maximum
5. Check cylinder head height by measuring from cylinder deck surface to cylinder head cover gasket surface.
6. If cylinder head height is not within specification, replace cylinder head.
Hight : 5.031~5.039 in (127.8~128 mm)
7. Measure intake and exhaust manifold mating surface distortion at two directions shown in figure.
Distortion : 0.002 in (0.05 mm) maximum
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8. If distortion exceeds specification, resurface Ebay
or replace
cylinder
head.
Distortion : 0.002 in (0.05 mm) maximum
RESSEMBLY
1. Clean all gasket surfaces of the cylinder block and the cylinder head.
2. Install a new cylinder head gasket onto the cylinder head assembly. Apply sealant to the gasket and do not
reuse the old cylinder head gasket.
A.Tighten cylinder head bolts in order shown.
Tightening torque : 36.1 lb-in (49 N·m, 5 kg-m)
B.Loosen bolts in reverse of order shown.
C.Retighten cylinder head bolts in order shown.
Tightening torque : 18 lb-in (25 N·m, 2.5 kg-m)
D.Mark cylinder head bolts for rotational reference.
E.Rotate cylinder head bolts 90° (1/4 Turn) in order shown.
1)Do not rotate crankshaft without timing belt.
2)Make sure that all pistons are positioned in the middle of cylinder before installing sylinder head.
3)Two bolts (No.7 and No.8) are shorter than other bolts. Never install the two bolts in other position. (for
A5D)
4)Do not reuse the old cylinder head bolts.l.
3. Install the timing belt tensioner pulley.
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4. Install the timing belt on the camshaft sprocket,
marking
that the tension side is tightened by turning the
camshaft sprocket in reverse, all timing marks are in alignment.
5. Adjust the timing according to "Timing Belt".
6. Install the rocker cover and tighten the bolts to the specififed torque.
Tightening torque
Rocker cover bolt : 3.6~6.5 lb-ft (5~9 N·m, 0.5~0.9 kg-m)
7. Install the timing belt cover.
8. Install the new intake manifold gasket and the intake manifold. Tighten the nuts and bolts to the specified torque.
9. Install the exhaust manifold gasket and the exhaust manifold. Tighten the exhaust manifold attaching nuts to the
specified torque.
10. Install the surge tank and tighten the nuts and bolts to the specified torque.
Tightening torque
Manifold nuts and bolts (both intake and exhaust) : 11~14 lb-ft (15~20 N·m, 150~200 kg-m)
Surge tank to inlet manifold nuts and bolts : 11~14 lb-ft (15~20 N·m, 150~200 kg-m)
11. Install the power steering oil pump and bracket.
12. Install the ignition coil.
13. Install the air intake hose.
14. Connect the vacuum hose, fuel hose and water hose.
15. Install breather hose.
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COMPONENTS
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REMOVAL
Do not disassemble water pump assembly. If a problem is found, replaed assembly as a unit.
1.
2.
3.
4.
5.
Disconnect negative battery cable.
Remove drive belt.
Remove timing belt.
Remove power steering pump in order to remove water inlet pipe.
Remove components in the order shown in above figure.
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INTAKE SYSTEM
Remove components in the order shown in above figure.
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ACCELERATOR CABLE
1. Depress the accelerator pedal to the floor and check that the throttle valve is fully opened.
Adjust with nut (A) , if necessary.
2. Measure the free play of the accelerator cable.
Free play: 0.16~0.28 in (4~7 mm)
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COMPONENTS (DOHC)
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DISASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
Disconnect the breather hose and the PCV hose.
Remove the coolant pump pulley and crankshaft pulley.
Remove the timing belt cover.
Loosen the timing belt tensioner pulley and temporarily secure it.
Remove the timing belt from the camshaft sprocket.
Loosen the center cover bolts and then remove the center cover.
Remove the ignition coil assembly.
Loosen the cylinder head cover bolts and then remove it.
Remove the camshaft pulley.
10. Remove the cam carrier assembly.
11. Remove the camshaft.
12. Remove the HLA.
INSPECTION
1. Set front and rear camshaft bearing journals on V-blocks.
2. Position a dial indicator on center bearing journal and zero dial.
3. Rotate camshaft in V-blocks and check runout.
Runout:
0.0012 in (0.03 mm) maximum
4. Check camshaft for uneven wear patterns, cracks, or damage.
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5. Measure cam lobe heights at two points as shown.
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Lobe height
Intake, Exhaust
Standard: 1.6878 in (42.870 mm)
Minimum: 1.6877 in (42.868 mm)
6. Check camshaft bearing journal diameter (X and Y directions) on both sides (A and B) of journal as shown in
figure.
Standard diameter:
1.3370-1.3386 in (33.961-34.0 mm)
Minimum diameter:
1.0594 in (26.910 mm)
Out-of-round:
0.0012 in (0.03 mm) maximum
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7. Replace camshafts if necessary.
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8. Measure camshaft journal oil clearance with HLA's removed.
9. Remove all foreign material and oil from journals and bearing surfaces.
10. Set camshafts onto cylinder head.
11. Position Plastigauge on journals in axial direction.
12. Do not rotate camshafts.
13. Install cam carrier assembly.
14. Install cam carrier bolts.
Tightening torque:
8.3~10.5 lb-ft (11.3~14.2 N·m 1.15~1.45 kg-m)
15. Loosen cam carrier assembly bolts.
16. Remove cam carrier assembly.
17. Measure oil clearances.
Oil clearance: 0.0014~0.0032 in (0.035~0.081 mm)
Maximum: 0.006 in (0.15 mm)
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18. If oil clearance exceeds specification, replace cylinder head.
19. Install camshafts.
20. Place a dial indicator against end of camshaft.
21. Using a prying tool, move camshaft as far forward as possible.
22. Zero dial.
23. Using prying tool, move camshaft as far rearward as possible.
24. Check gauge to determine how much end play is present.
End play: 0.0026~0.0054 in (0.067~0.137 mm)
Maximum: 0.0058 in (0.147 mm)
REASSEMBLY
1. Install the HLA.
2. Install the phase sensor target wheel to the intake camshaft.
The knock pin of camshaft and the white paint mark of target wheel must be symmetrical each other
centering around axis of camshaft when installing the target wheel.
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3. Install the camshaft after lubricating the journal of camshaft with engine oil.
4. Apply liquid sealant on the cam carrier as shown illustration.
Sealant type : HYLOGRIP 3000
Bead width : 0.0787 in (2 mm)
• Clean the foreign material from mating surface before applying sealant.
• Assembly procedure must be completed within 15 minutes after applying sealant.
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5. Install the cam carrier assembly. Tighten theEbay
cam User
carrier
as shown illustration.
Tightening torque :
8.3~10.5 lb-ft (11.3~14.2 N-m , 1.15~1.45kg-m)
6. Install the camshaft oil seal. Be sure to apply engine oil to the external surface of the oil seal. Insert the oil seal
along the camshaft front end until the oil seal is fully seated.
7. Install the seal plate.
8. Install the camshaft pulley.
Tightening torque :
55.0~77.4 lb-ft (74.5~104.9 N-m , 7.6~10.7 kg-m)
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9. Check that “I” mark on intake camshaft pulley
is aligned
with
mark on seal plate and “E” mark on exhaust
camshaft pulley is aligned with mark on seal plate.
10. Install the cylinder head cover.
Tightening torque :
3.6~6.5 lb-ft (4.9~8.8 N-m , 0.5~0.9 kg-m)
11. Install the ignition coil.
12. Install the timing belt.
13. Tighten the timing belt tensioner pulley.
Tightening torque :
27.5~38.3 lb-ft (37.3~52.0 N-m , 3.8~5.3 kg-m)
14. Install the timing belt cover.
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INSPECTION
• Never remove radiator cap while engine is hot.
• Wrap a thick cloth around radiator cap before removing.
• When removing radiator cap, loosen slowly to first stop and wait until pressure in radiator is released, then
completely remove.
LEVEL (ENGINE COLD)
1. Verify that there is no build-up of rust or scale around radiator cap or radiator filler neck.
2. Verify that coolant is free of contaminants. Replace coolant if necessary.
COOLANT QUALITY
1. Verify that there is no build-up of rust or scale around radiator cap or radiator filler neck.
2. Verify that coolant is free of contaminants. Replace coolant if necessary.
REPLACEMENT
• Never open radiator cap while engine is hot.
• Wrap a thick cloth around cap before loosening.
• Use caution when draining hot coolant.
• Do not use alcohol or methanol-based coolant.
• Use only demineralized water in coolant mixture.
1.
2.
3.
4.
5.
Remove radiator cap and loosen drain plug.
Drain coolant into a suitable container.
Flush cooling system with water until all traces of color are gone; then let system drain completely.
Install drain plug.
Fill with proper mixture of ethylene glycol-based coolant.
Coolant Capacity: 6.0 liters (6.3 US qt, 5.3 lmp qt)
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6.
7.
8.
9.
Run the engine with the radiator cap removed until the upper radiator hose is hot.
With the engine idling, add coolant to the radiator until it reaches the bottom of the filler neck.
Install the radiator cap.
Allow engine to cool and check coolant level.
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COMPONENT
Remove components in the order shown in figure.
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COMPONENT
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DISASSEMBLY
1. Remove the timing belt, front case, flywheel cylinder head assembly and oil pan. For details, refer to respective
chapters,
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.
Mark the main bearing caps to permit reassembly in the original position and direction.
4. Remove the main bearing caps and remove the crankshaft.
Keep the bearings in order by cap number.
INSPECTION
1.
2.
3.
4.
Check crankshaft bearing and crank pin journals for damage and scoring.
Check oil holes for clogging.
Set crankshaft on V-blocks.
Measure crankshaft run-out at center journal. Replace crankshaft if it is not within specification.
Run-out : 0.0016 in (0.04 mm)
5. Grind crankshaft only if there is visible scoring, or if out-of-round is excessive.
6. Only grind crankshaft amount necessary to correct condition.
7. If a crankshaft must be ground 0.020 in (0.50 mm) or more, heat-treat crankshaft to ensure durability.
MAIN JOURNAL DIAMETER UNDERSIZES:
Bearing size
Journal diameter
0.010 in (0.25 mm)
undersize
1.9562~1.9569 in
(49.688~49.706 mm)
0.020 in (0.50 mm)
undersize
1.9464~1.9471 in
(49.438~49.456 mm)
0.030 in (0.75 mm)
undersize
1.9365~1.9372 in
(49.188~49.206 mm)
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CRANK PIN JOURNAL DIAMETER UNDERSIZES:
Bearing size
Journal diameter
0.010 in (0.25 mm)
undersize
1.5626~1.5632 in
(39.690~39.706 mm)
0.020 in (0.50 mm)
undersize
1.5528~1.5534 in
(39.440~39.456 mm)
0.030 in (0.75 mm)
undersize
1.5429~1.5435 in
(39.190~39.206 mm)
MAIN BEARING AND CONNECTING ROD BEARINGS
1. Check main and connecting rod bearings for peeling, scoring and other damage.
REASSEMBLY
1. Inspect journals and bearings for any foreign material. Clean crankshaft, oil holes, and main bearing journals
thoroughly, and dry components with compressed air.
2. Install grooved main bearings into saddles on engine block.
3. Install thrust bearings with oil groove facing crankshaft.
4.
5.
6.
7.
Set crankshaft on installed bearings.
Install remaining main bearings into main bearing caps.
Position Plastigauge on crankshaft journals.
Install main bearing caps along with lower main bearings according to cap number and ← mark.
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8. Tighten main bearing cap bolts.
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Tightening torque:
40~43 lb-ft (54~59 N·m, 5.5~6.0 kg-m)
Do not rotate crankshaft with Plastigauge on crankshaft journals.
9. Remove main bearing caps and check bearing clearance.
The widest point of Plastigauge is the smallest clearance, and the narrowest point of Plastigauge is the
largest clearance.
10. If oil clearance exceeds specification, grind and polish crankshaft and use undersized main bearings.
Oil Clearance:
0.0007~0.0014 in (0.018~0.036 mm)
MAXIMUM: 0.0031 in (0.08 mm)
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11. Lift crankshaft out of cylinder block and carefully remove Plastigauge from main bearings and crankshaft
journals.
12. Apply a light coat of engine oil on main bearings and install crankshaft by gently lowering it onto bearings.
13. Apply a light coat of oil on crankshaft main bearing journals and on main bearings on main bearing caps.
14. Install main bearing caps along with lower main bearings according to cap number and ← mark.
15. Tighten main bearing cap bolts according to the following procedure:
Tighten bolts in order shown
Tightening torque:
40~43 lb-ft (54~59 N·m, 5.5~6.0kg-m)
16. Rotate crankshaft to ensure it does not bind.
17. Place a dial indicator against front of crankshaft and zero gauge.
18. Using a prying tool, move crankshaft forward and zero dial indicator.
19. Move the crankshaft toward the rear of block with prying tool and check the amount of movement on dial
indicator.
End Play:
0.0032~0.0111 in (0.080~0.282 mm)
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20. If end play exceeds specification, grind crankshaft and install oversized thrust bearings, or replace crankshaft
and thrust bearings.
OVERSIZE THRUST BEARING WIDTH
Thrust bearing size
Specification
Standard
0.0985~0.1003in
(2.500~2.550 mm)
Standard + 0.010 in (0.25 mm)
0.1034~0.1053 in
(2.625~2.675 mm)
Standard + 0.020 in (0.50 mm)
0.1083~0.1102 in
(2.750~2.800 mm)
Standard + 0.030 in (0.75 mm)
0.1132~0.1151 in
(2.875~2.925 mm)
21. Install the oil seal in the crankshaft rear oil seal case. Press fit the oil seal all the way in, being careful not
misalign it.
22. Install the rear plate and tighten the bolts.
23. Install the connecting rod caps. Refer to "Piston and Connecting Rods".
24. Install the flywheel, front case, oil pan and timing belt. For further details, refer to the respective chapters.
MAIN BEARING SELECTION
1. Standard main bearing selection
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2. Main bearing housing bore size
Code
Main bearing housing bore size
A
2.1260-2.1262 in (54.000-54.006 mm)
·
2.1262-2.1265 in (54.006-54.012 mm)
C
2.1265-2.1267 in (54.012-54.018 mm)
3. Main journal shaft diameter
Code
Main journal shaft diameter
A
1.9661-1.9663 in (49.938-49.944 mm)
·
1.9663-1.9665 in (49.944-49.950 mm)
C
1.9665-1.9668 in (49.950-49.956 mm)
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4. Main bearing thickness
Main bearing
Standard bearing
Undersize bearing
Thickness
Yellow
0.0790-0.0791 in
(2.007-2.010 mm)
Green
0.0791-0.0793 in
(2.010-2.013 mm)
Brown
0.0793-0.0794 in
(2.013-2.016 mm)
Black
0.0794-0.0795 in
(2.016-2.019 mm)
Blue
0.0795-0.0796 in
(2.019-2.022 mm)
Red
0.0796-0.0797 in
(2.022-2.025 mm)
0.25
0.0840-0.0841 in
(2.133-2.137 mm)
0.50
0.0889-0.0891 in
(2.258-2.262 mm)
0.75
0.0938-0.0940 in
(2.383-2.387 mm)
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Inspection
VALVE MECHANISM
1. Inspect each valve for following:
A.Damaged or bent valve stem
B.Rough or damaged face
C.Damaged or unevenly worn stem tip
2. Resurface or replace valve as needed.
Margin thickness
Intake: 0.0394 in (1.0mm)
Exhaust: 0.0394 in (1.0mm)
3. Measure length of each valve.
Length
Intake: 3.7815 in (96.05 mm)
Exhaust: 3.7402 in (95.00 mm)
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4. Measure diameter of each valve stem.
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Diameter
Intake: 0.2152~0.2157 in (5.465~5.480 mm)
Exhaust: 0.2138~0.2146 in (5.430~5.450 mm)
5. Measure inside diameter of each valve guide at points shown in figure.
Diameter intake and exhaust valve guide:
0.2165~0.2171 in (5.500~5.515 mm)
6. Calculate valve stem-to-valve guide clearance.
Subtract outer diameter of valve stem from inside diameter of respective valve guide.
Clearance
Intake valve:
0.0008~0.0020 in (0.020~0.050 mm)
Exhaust valve:
0.0020~0.0033 in (0.050~0.085 mm)
Max: 0.008 in (0.20 mm)
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7. If clearance exceeds specification, replace valve, and/or valve guide.
8. Measure protrusion height of each valve guide. Replace valve guide as needed.
Intake: 0.5039~0.5276 in (12.8~13.4 mm)
Exhaust: 0.5039~0.5276 in (12.8~13.4 mm)
Intake and exhaust valve guides are different.
Be sure to use correct valve guide.
VALVE SEAT
1. Inspect contact surface of each valve seat and valve face for following:
A.Roughness
B.Damage
C.Pitting
D.Cracks
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2. Resurface valve seats with a 45° valve seat Ebay
cutter.User
Resurface
valve faces as needed.
3. Apply a coat of Dychem blue to valve face and valve seat and allow to dry.
4. Inspect valve seating by pressing valve against seat and rotating valve 360°.
A.If Dychem blue is not removed 360° around valve face, replace valve.
B.If Dychem blue is not removed 360° around valve seat, resurface valve seat.
5. Measure seat contact width.
Width: 0.0382~0.0618 in (0.97~1.57 mm)
6. Complete seat-cutting process by lapping valve to seat using valve-lapping compound.
Clean valves thoroughly before reassembly, and insure that all traces of lapping compound has been
removed.
VALVE SPRING
1. Inspect each valve spring for cracks and damage.
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2. Measure free length and out-of-square. Replace
springs
as needed.
Free length :
Standard : 1.5354 in (39.0 mm)
Limit : 1.5276 in (38.8 mm)
Out-of-square : 0.0402 in (1.02 mm)
Replacement
Valve seat ring
1. Cut away the inner face of the valve seat to reduce the wall thickness.
2. Enlarge the cylinder head hole so that matches the specified cylinder head hole inner diameter of new valve
seat ring.
3. Heat the cylinder head to about 250°C (480°F) and press-fit an oversize seat ring for the cylinder head hole size.
4. Using lapping compound, lap the valve to the new seat.
Valve seat contact width :
0.0382~0.0618in (0.97~1.57mm)
VALVE SEAT RING OVERSIZE (1600cc)
Item
Over size
(in (mm))
Size
mark
Cylinder head hole
inner diameter (in (mm))
Seat ring
outer diameter (in
(mm))
Seat ring
height (in (mm))
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Intake
valve
seat ring
Exhaust
valve
seat ring
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1.1961-1.1968
(30.38-30.40)
1.2000-1.2008
(30.480-30.500)
0.1858-0.1890
(4.72-4.80)
30
1.2079-1.2087
(30.68-30.70)
1.2118-1.2126
(30.780-30.800)
0.1976-0.2008
(5.02-5.10)
0.024 (0.6) OS
60
1.2197-1.2205
(30.98-31.00)
1.2236-1.2244
(31.080-31.100)
0.2094-0.2126
(5.32-5.40)
STD
-
1.0819-1.0827
(27.48-27.50)
1.0858-1.0866
(27.580-27.600)
0.1858-0.1890
(4.72-4.80)
0.012 (0.3) OS
30
1.0937-1.0945
(27.78-27.80)
1.0976-1.0984
(27.880-27.900)
0.1976-0.2008
(5.02-5.10)
0.024 (0.6) OS
60
1.1055-1.1063
(28.08-28.10)
1.1094-1.1102
(28.180-28.200)
0.2094-0.2126
(5.32-5.40)
STD
-
0.012 (0.3) OS
Valve guide
1. Using the special tool (09221-FD100(A)), withdraw the old valve guide toward the bottom of cylinder head.
2. Recondition the cylinder head hole so that it can match the newly press-fitted oversize valve guide.
3. Using the special tool (09221-FD100(A), (B)), press-fit the valve guide. The valve guide must be press-fitted
from the upper side of the cylinder head.
Do not install a valve guide unless it is oversize.
4. After the valve guide is press-fitted, insert a new valve and check for proper stem-to-guide clearance.
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5. After the valve guide is replaced, check that Ebay
the valve
properly. Recondition the valve seats as
necessary.
VALVE GUIDE OVERSIZE (1600cc)
Item
Valve
guide
Over size
(in (mm))
Size
mark
Cylinder head hole
inner diameter (in
(mm))
Valve guide
outer diameter (in
(mm))
STD
-
0.3740-0.3747
(9.500-9.518)
0.3753-0.3757
(9.533-9.544)
0.002 (0.05)
OS
5
0.3760-0.3767
(9.550-9.568)
0.3773-0.3777
(9.583-9.594)
0.010 (0.25)
OS
25
0.3839-0.3846
(9.750-9.768)
0.3852-0.3856
(9.783-9.794)
0.020 (0.50)
OS
50
0.3937-0.3944
(10.000-10.018)
0.3950-0.3954
(10.033-10.044)
Valve guide protrusion
height (in (mm))
0.5039-0.5276
(12.8-13.4)
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COMPONENT I
COMPONENT II
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COMPONENT III
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COMPONENT IV
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REMOVAL
1. Disconnect battery cables.
2. Remove battery and battery tray.
3. Drain engine coolant.
4. Remove fresh air duct.
5. Remove upper and lower radiator hose.
6. Remove accelerator cable.
7. Disconnect fuel hose from fuel injector rail.
8. Remove heater hose.
9. Disconnect brake vacuum hose and purge control vacuum hose from dynamic chamber.
10. Disconnect injector connectors.
11. Disconnect electric connectors.
12. Remove transaxle linkage (A/T).
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13. Remove manual transaxle linkage and extension
bar (M/T).
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14. Remove clutch release cylinder and pipe (M/T).
15. Disconnect transaxle range switch connector (A/T).
16. Disconnect solenoid valve connector (A/T).
17. Disconnect ATF cooler hose (A/T).
18. Disconnect power steering pump hose.
19. Disconnect B-terminal and S-terminal connector from starter.
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20. Disconnect generator B-terminal connector Ebay
from User
generator.
21. Remove four A/C compressor bolts.
22. Remove both front wheels.
23. Disconnect front exhaust pipe and catalytic converter.
24. Remove both right and left tie rod ends from steering knuckles by removing one cotter pin and one nut each.
25. Remove bolt and nut from both right and left lower arm and separate lower arm from steering knuckles.
26. Remove 2bolts and nuts from damper and separate damper from steering knuckles.
27. Gently pry both driveshafts from transaxle.
28. Support engine with engine hoist.
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29. Remove four nuts and four bolts from engine
mounting
30. Remove two bolts from No.1 engine mounting bracket.
31. Remove one nut from No.2 engine mounting rubber.
32. Remove four bolts from No.2 engine mounting bracket.
33. Remove two nuts from No.3 engine mounting rubber.
34. Lift engine and transaxle out as a unit.
INSTALLATION
1. Install engine and transaxle into engine compartment as a unit.
2. Install two nuts to No.3 engine mounting rubber.
Tightening torque:
49~69 Ib-ft (66~93 N·m, 6.8~9.5 kg-m)
3. Install No.2 engine mounting bracket bolts and install No.2 engine mounting rubber nut.
Tightening torque:
Nut:49~69 Ib-ft (66~93 N·m, 6.8~9.5 kg-m)
Bolts:28~38 Ib-ft (37~52 N·m, 3.8~5.3 kg-m)
4. Install four engine mounting member bolts & nuts.
Tightening torque:
Nut:28~38 Ib-ft (37~52 N·m, 3.8~5.3 kg-m)
Bolts:52~69 Ib-ft (71~93 N·m, 7.2~9.5 kg-m)
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5. Remove engine hoist.
6. Install new clips on driveshaft.
7. Push driveshaft and joint shaft into transaxle with opening of clips pointing upward.
8. Install damper to steering knuckles.
9. Install both right and left lower arm to steering knuckles.
10. Install both right and left tie rod ends to steering knuckles.
11. Install front exhaust pipe and catalytic converter.
Tightening torque:
27~38 Ib-ft (37.2~52 N·m , 3.8~5.3 kg-m)
12. Install A/C compressor.
13. Connect B-terminal connector to generator.
14. Connect B-terminal and S-terminal connector to starter.
15. Connect power steering pump hose.
16. Connect ATF cooler hose(A/T).
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17. Connect solenoid valve connector(A/T).
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18. Connect transaxle range switch connector(A/T).
19. Install clutch release cylinder and pipe(M/T).
Tightening torque:
13.7~18.8 Ib-ft (18.6~25.5 N·m , 1.9~2.6 kg-m)
20. Install extension bar and manual transaxle linkage(M/T).
Tightening torque:
Extension bar: 27~38 Ib-ft
(37.2~52 N·m, 3.8~5.3 kg-m)
Manual transaxle linkage:
12~17 Ib-ft (16~23 N·m , 1.6-2.3 kg-m)
21. Install transaxle linkage(A/T).
Tightening torque:
23.1~34.0 Ib-ft (31.4~46.1 N·m, 3.2~4.7 kg-m)
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22. Connect electric connectors.
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23. Connect injector connectors to injector rail.
24. Connect brake vacuum hose and purge control vacuum hose to dynamic chamber.
25. Install heater hose.
26. Connect fuel hose to injector rail.
27. Install accelerator cable.
28. Install upper and lower radiator hose.
29. Install fresh air duct.
30. Install battery tray and battery.
Tightening torque:
10~12 Ib-ft (13.5~16 N·m, 1.4~1.6 kg-m)
31. Fill engine coolant with specified type and amount.
32. Connect both battery cables.
33. Check and/or fill all fluids.
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REPLACEMENT
Be careful when draining because oil is hot and could cause personal injury.
1.
2.
3.
4.
Warm engine to normal operating temperature and turn engine off. Position a suitable container under oil pan.
Remove oil filler cap and oil pan drain plug.
Allow oil to be fully drained.
Install drain plug with new gasket.
Tightening torque:
22~30 lb-ft (29~41 N·m, 3.0~4.2 kg-m)
5. Refill engine with specified type and amount of engine oil.
6. Run engine and check for leaks.
7. Check oil level and add oil if necessary.
Oil pan capacity:
3.2 U.S. qt (3.0 liters, 2.6 lmp qt)
8. Install oil filler cap.
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COMPONENT
Remove components in the order shown in above figure.
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INSTALLATION
Install front exhaust as follows:
1. Tighten (A) temporarily
2. Tighten (B) temporarily
3. Tighten (A) fully
4. Check the connection between the pipe of (B) and bracket
5. Tighten (B) fully
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COMPRESSION
If the engine exhibits low power, poor fuel economy, or poor idle, check thefollowing :
1. Ignition system
2. Compression
3. Fuel system
INSPECTION
1.
2.
3.
4.
5.
6.
Check that the battery if fully charged. Recharge it if necessary.
Warm up the engine to normal operating temperature.
Remove the center cover.
Disconnect the high tension lead and ignition coil.
Remove all spark plugs.
Connect a compression gauge to the No.1 spark plug hole.
7. Fully depress the accelerator pedal and crank the engine.
8. Record the maximum gauge reading.
9. Check each cylinder.
Compression
(kpa (kg/cm², psi)-rpm)
Standard
Difference between cylinders
1275
(13, 184)
98 (1, 14.2)
10. If the compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder and
recheck the compression.
(1) If the compression increases, the piston, piston rings, or cylinder wall maybe worn.
(2) If the compression stays low, the valve may be stuck or seating improperly.
(3) If the compression in adjacent cylinders stays low, the cylinder head gasketmay be defective or the cylinder
head distorted.
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OIL PRESSURE CHECK
1.
2.
3.
4.
Disconnect and remove oil pressure switch.
Install oil pressure gauge into oil pressure switch installation hole.
Warm engine to normal operating temperature.
Run engine at idle and note gauge readings.
Oil pressure:
12.8 psi (88.26 kPa, 0.9 kg/cm²) above
5. If pressure is not within specification, check for cause, and repair.
6. Remove oil pressure gauge and install oil pressure switch.
Tightening torque:
8.7~13.0 lb-ft (12~18 N·m, 1.2~1.8 kg-m)
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REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
Raise vehicle.
Remove oil filter with oil filter wrench. If rubber seal is stuck to engine, remove it.
Apply a small amount of clean engine oil to rubber seal of new filter.
Install oil filter and turn it by hand until rubber seal contacts base.
Tighten filter 1-1/6 turns with filter wrench.
Start engine and check for leaks.
Turn engine off, and wait 5 minutes. Check oil level and add oil if necessary.
Oil filter capacity:
0.21 U.S. qt (0.20 liter, 0.18 lmp qt)
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COMPONENT
Email: suzlever@gmail.com
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Installation
1. Apply continuous sealant to mating surface as shown illustration.
Sealant type : LOCTITE 5900
Bead width : 0.1575 in (4 mm)
• Clean the foreign material from mating surface before applying sealant.
• Assembly procedure must be completed within 4 minutes after applying sealant.
2. Install the oil pan.
Tightening torque :
A : 7.2~8.7 lb-ft (9.8~11.8 N-m , 1.0~1.2kg-m)
B,C,D : 7.2~9.4 lb-ft (9.8~12.7 N-m , 1.0~1.3kg-m)
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COMPONENT
COMPONENT
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REMOVAL
1.
2.
3.
4.
5.
Disconnect negative battery cable.
Drain engine oil.
Remove Drive belt.
Remove timing belt.
Remove components in the order shown in figure.
Installation
1. Apply continuous sealant to mating surface as shown illustration.
Sealant type : LOCTITE 5900
Bead width : 0.0394~0.0787 in (1~2 mm)
• Clean the foreign material from mating surface before applying sealant.
• Be careful for sealant not to enter the oil hole.
2. Install the oil pump.
Tightening torque :
13.7~18.8 lb-ft (18.6~25.5 N·m, 1.9~2.6 kg-m)
INSPECTION
1. Clean all components and clean off dust from all components.
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2. Check all components with specifications and
replace
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Component
Specification
Oil pump
Side clearance
0.0039 in (0.10 mm)
Tooth tip coearance
0.0071 in (0.18 mm)
Outer roter to pump body clearance
0.0078 in (0.20 mm)
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COMPONENT
Email: suzlever@gmail.com
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DIASSEMBLY
1. Mark corresponding cylinder number on rod cap and connecting rod with a numbering stamp.
Mark connecting rods on same side and make a reference mark on block so that rods are installed in correct
position and direction. Failure to install rods properly with result in oil starvation, spun bearings, or damaged
internal engine components.
2. Rotate crankshaft so that cylinders No.2 and No.3 are at Bottom Dead Center (BDC) and repeat marking
procedure.
3. Remove connecting rod nuts and gently loosen rod caps by tapping cap with a light plastic mallet.
4. Remove rod caps.
Coter connecting rod bolts to protect crankshaft jounals
5. Push connecting rod and piston as far up into cylinder as possible. Using a wooden dowel, tap gently on piston
to release it from cylinder.
6. Repeat this procedure for each cylinder.
7. Mark tops of pistons with corresponding cylinder numbers they were removed from.
8. Using a piston ring expander, remove piston rings.
9. Hold piston upright and gently move connecting rod.
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10. Release connecting rod and observe its movement.
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Do not swing connecting rod widely. Constant, hard contact with piston will cause a bell-mouth condition
that will require piston replacement.
11. If connecting rod does not move freely, check piston pin bore and connecting rod for straightness and
deformation.
12. Remove piston pin clip from ends of piston pin bore.
13. Tilt piston and allow piston pin to slide out into your hand. Piston pins may need to be pressed out.
Do not allow pins to drop to the ground.
14. Remove connecting rod from piston. Keep individual piston and piston pin together for reassembly.
INSPECTION
PISTON RING
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1. Insert a new piston ring into a piston ring groove
clearance between piston ring and ring end.
Clearance between ring and ring end
Standard : 0.0012-0.0028 in (0.03-0.07 mm)
Maximum : 0.0039 in (0.10 mm)
2.
3.
4.
5.
6.
7.
If clearance exceeds the maximum, replace piston.
Inspect piston rings for damage, abnormal wear, or breakage.
Replace piston rings if necessary.
Insert piston ring into cylinder by hand.
Square ring in cylinder by inverting a piston into cylinder and pushing ring to the bottom of its travel in cylinder.
Place a feeler gauge in end gap and check end gap clearance.
End gap clearance
REASSEMBLY
Ring
A6 DOHC
Top ring
0.006~0.011 in
(0.15~0.30 mm)
Second ring
0.016~0.021 in
(0.40~0.55 mm)
Oil rail
0.008~0.027 in
(0.20~0.70 mm)
Maximum
0.039 in (1.0 mm)
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1. Select the piston which has the size mark which is identical with the size mark of the corresponding cylinder.
Piston outer diameter and cylinder bore inner diameter
2. Insert connecting rod into piston and slide piston pin through piston and connecting rod.
Verify that piston and rod are assembled in same direction as they were prior to disassembly.
3. Hold piston upright and move connecting rod back and forth. Check that rod moves freely.
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4. Install three piece oil ring onto piston.
A.Apply clean engine oil to the oil ring expander and upper and lower oil rings.
B.Install expander onto piston so that expander ends face upward.
C.Install lower oil ring onto piston. Ring may be installed with either face upward.
D.Install upper oil ring onto piston. Ring may be installed with either face upward.
5. Check that oil ring expander separates upper and lower oil rings, and that oil ring assembly spins freely on
piston.
6. Use a ring expander and install second ring.
7. Use a ring expander and install top ring.
Top ring and second ring should be installed with "R" or "Y" mark facing up.
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8. Align piston ring gaps as shown.
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9. Install a bearing into connecting rod.
10. Place rubber sleeves on connecting rod bolts to protect crankshaft from damage.
11. Check piston rings for correct end gap stagger.
12. Place piston with "F" mark facing front of engine block, then slip piston and connecting rod assembly into a
piston ring compressor.
13. Rotate crankshaft so that crank pin journal for specific cylinder is at its lowest point (bottom dead center).
14. Lower piston and connecting rod assembly until piston ring compressor makes contact with deck surface of
engine block.
15. Using butt end of a hammer, tap the top of piston into cylinder and continue tapping until connecting rod makes
contact with crankshaft.
Follow this procedure for remaining piston and connecting rod assemblies.
16. Install a connecting rod bearing in each connecting rod cap.
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17. Place a piece of Plastigauge(R) on crank pin
journals.
18. Install connecting rod caps, aligning marks made previous to disassembly and torque to specification.
Tightening torque:
22~24 lb-ft (29~34 N·m, 3.0~3.5 kg-m)
• When installing the connecting rods, match marks made on the connecting rod and cap to reference
mark made on cylinder block to prevent oil starvation to the connecting rod bearings.
• When installing the piston assembly into cylinder bolck, position the piston between TDC and BDC, then
install the cylinder head in order to prevent pistons and valves from contacts which may cause damage.
19. Loosen and remove connecting rod caps.
20. Check the connecting rod bearing clearance.
Oil clearance:
0.0010 ~ 0.0021 in (0.026 ~ 0.054 mm)
Maximum: 0.004 in (0.10 mm)
21. If oil clearance exceeds maximum oil clearance specification, grind the crankshaft and use undersized
connecting rod bearings.
(1) Connecting rod bearing selection table
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(2) Connecting rod bearing housing bore size
Code
Connecting rod bearing housing bore size
1
1.6929-1.6931 in (43.000-43.006 mm)
2
1.6931-1.6934 in (43.006-43.012 mm)
3
1.6934-1.6935 in (43.012-43.016 mm)
(3) Connecting rod bearing thickness
Connecting rod bearing
Standard bearing
Undersize bearing
bearing thickness
Green
0.0593-0.0594 in
(1.506-1.509 mm)
Blue
0.0594-0.0595 in
(1.509-1.512 mm)
Red
0.0595-0.0596 in
(1.512-1.515 mm)
0.25
0.0642-0.0644 in
(1.631-1.635 mm)
0.50
0.0691-0.0693 in
(1.756-1.760 mm)
0.75
0.0741-0.0742 in
(1.881-1.885 mm)
22. Apply a coat of clean engine oil to connecting rod bearing in connecting rod cap.
23. Install connecting rod cap and torque to specification.
Tightening torque:
22~24 lb-ft (29~34 N·m, 3.0~3.5 kg-m)
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reveleus1and check connecting rod side clearance.
24. Insert a thickness gauge between connecting
rodUser
andID:
crankshaft
Do not measure between connecting rod cap and crankshaft.
Side clearance:
0.0044~0.0103 in (0.110~0.262 mm)
Maximum: 0.012 in (0.30 mm)
25. If side clearance exceeds maximum side clearance specification, replace connecting rod and cap.
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COMPONENT
Email: suzlever@gmail.com
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REMOVAL
1.
2.
3.
4.
Disconnect negative battery cable.
Remove fresh air duct.
Drain coolant.
Remove components in the order shown in the figure.
INSTALLATION
1. Install in the reverse order of removal.
2. After installation, fill engine coolant and check coolant leakage
LEAKAGE
1. Connect a coolant system pressure tester to the radiator filler neck.
2. Apply 15 psi (103 kPa, 1.05 kg/cm²) pressure to the system.
3. Verify that the pressure remains steady at 15psi (103 kPa, 1.05 kg/cm²).
4. If not, check system for coolant leakage.
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Special service tools
Tool
(Number and Name)
Illustration
Use
0K670 321 019
Ball joint puller
Used to remove tie-rod end.
0K130 111 004
Coupling flange holder
Used to disassemble and assemble timing
belt pulley.
0K130 111 002
Ring gear Brake
Used to prevent engine rotation.
0K130 160 010
Clutch disc centering tool
Used to install clutch disc.
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0K130 990 007
Engine stand
Ebay User ID: reveleus1 Used to disassemble and assemble engine.
0KK30 101 001
Engine stand hanger
Used to disassemble and assemble engine.
0K993 120 001
Valve spring lifter arm
Used to remove and install valve.
0K993 120 004
Valve spring lifter pivot.
Used to remove and install valve.
0K993 120 006
Valve seal remover
Used to remove valve seal.
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0K2CA 120 AA0
Valve spring compressor
set
Ebay User ID: reveleus1 Used to replace valve seal and valve
spring.
0KK30 140 001
Oil pressure gauge
Used to measure fuel pressure.
09221-FD100(A)
Valve guide remover
09221-FD100(B)
Valve guide installer
Used to remove and install valve guide.
0K2CA 120 001
Valve spring compressor
hook
Used to replace valve seal and valve
spring.
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Specifications
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COMPONENT
Remove components in the order shown in figure.
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INSPECTION
1. Visually check that thermostat is air tight.
2. Place a thermostat and a thermometer in water.
3. Gradually heat water and check following.
Initial opening temperature:
189.5~191.3°F (87.5~88.5°C)
Full open temperature:
212°F (100°C)
Full open lift:
0.31 in (8.0 mm) min
INSTALLATION
1. Install thermostat into cylinder head with jiggle pin positioned up.
2. Install in the reverse of removal.
When installing thermostat gasket, make sure that printing side of gasket is facing toward cylinder head.
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COMPONENT
Email: suzlever@gmail.com
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REMOVAL
1. Disconnect negative battery cable.
2. Loosen power steering lock bolts and nuts accordingly and remove tension from power steering (P/S) and/or air
conditioning (A/C) compressor drive belt.
3. Remove P/S and/or A/C drive belt.
4. Loosen generator mounting bolts and adjusting bolt.
5. Remove generator bolts.
6. Remove water pump pulley.
7. Remove crankshaft pulley.
8. Remove upper and lower timing belt covers.
9. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine.
10. Check that "I" mark on intake camshaft pulley is aligned with mark on seal plate and "E" mark on exhaust
camshaft pulley is aligned with mark on seal plate.
Do not move camshaft or crankshaft once timing marks have been correctly positioned.
11. Loosen tensioner pulley lock bolt.
12. Protect timing belt with a rag.
13. Remove tensioner pulley.
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14. Remove timing belt.
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Mark the direction of timing belt rotation (on the timing belt) for proper reinstallation.
INSTALLATION
1. Install tensioner pulley.
Replace tensioner spring whenever timing belt is replaced.
2. Pull tensioner pulley to its furthest point and tighten lock bolt.
3. Check that timing mark on timing belt pulley is aligned with timing mark on engine.
4. Check that "I" mark on intake camshaft pulley is aligned with mark on seal plate and "E" mark on exhaust
camshaft pulley is aligned with mark on seal plate.
If existing timing belt is being reused, install belt in proper rotation direction marked prior to removal.
5. Install timing belt onto timing belt pulley first, then idler pulley, exhaust camshaft pulley, intake camshaft pulley,
and tensioner pulley in that order.
6. Check that there is no looseness in belt between idler pulley and exhaust camshaft pulley or between intake and
exhaust camshaft pulleys.
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7. Loosen tensioner pulley lock bolt and allow tensioner
to apply tension to timing belt.
Do not add additional tension.
8. Tighten tensioner pulley lock bolt to specified torque.
Tightening torque:
28~38 lb-ft (38~51 N·m, 3.9~5.2 kg-m)
9. Rotate crankshaft two full revolutions (clockwise only) and align timing mark on timing belt pulley with timing
mark on engine block.
10. Check that "I" mark on intake camshaft pulley and "E" mark on exhaust camshaft pulley are aligned with marks
on seal plate.
11. If they are not aligned, remove timing belt and start process from tensioner installation.
12. Measure timing belt deflection by applying moderate pressure midway between camshaft pulleys. If deflection
is not correct, repeat from tensioner installation.
Deflection pressure:
22 Ib. (98 N, 10 kg)
Deflection:
0.39~0.50 in. (11~13 mm)
13. Install lower and upper timing belt covers in that order.
Tightening torque:
5.8~8.0 Ib-ft (7.9~10.7 N·m, 0.8~1.1 kg-m)
14. Install timing belt guide plate and crankshaft pulley.
Tightening torque:
9.0~12.6 lb-ft (12.3~17.2 N·m, 1.3~1.8 kg-m)
15. Install water pump pulley.
Tightening torque:
9.0~12.6 lb-ft (12.3~17.2 N·m, 1.3~1.8 kg-m)
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16. Install generator belt and adjust the tension.Ebay User ID: reveleus1
17. Install P/S and/or A/C drive belt and adjust the tension.
18. Connect negative battery cable.
INSPECTION
Never forcefully twist, turn inside out or bend timing belt. Do not allow oil or grease to come in contact with
timing belt.
1. Replace timing belt if it is contaminated with oil or grease.
2. Check timing belt for uneven wear, fraying, peeling, cracking and hardening. Replace timing belt as necessary.
3. Bend timing belt into a "U" shape as shown in figure. Distance "A" must be at least 1.0 in (25 mm).
4. Inspect both idler pulley and tensioner pulley for uneven wear and smooth bearing operation.
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5. Inspect camshaft pulleys and timing belt pulley
forUser
broken
teeth or damage.
Replace any component that shows damage, excessive wear, or that appears prone to a possible failure.
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TROUBLESHOOTING PROCEDURE FOR DTC
Diagnostic trouble code
No. P0128
[Related items]
Engine coolant thermostat open stuck
• Thermostat stuck opened
• After engine start-up, the elapsed time before feedback operation is
initiated is too long
(engine coolant temperature sensor input is insufficient for closed loop
operation)
• Poor connections between ECTS and ECM
• Misplaced, loose or corroded terminals
• Contaminated, deteriorated ECTS
Step
Inspection
1
Remove thermostat and check that thermostat is
stuck.
Is thermostat okay?
Yes Go to step 2.
Connect SCAN TOOL to data link connector or
OBD-II check connector and turn ignition to ON.
Are any DTC relating ECTS and/or IATS set?
Yes Do all repairs associated with those codes
before proceeding this procedure.
Start engine and allow engine to idle until engine
reaches operating temperature.
Using SCAN TOOL and monitor ECT signals.
Yes Problem is intermittent or was repaired and
engine control. module memory was not cleared.
Check terminal connections at ECM and ECTS.
2
3
Action
No Temporarily install a known good thermostat and
check for proper operation.
If problem is corrected, replace thermostat.
No Go to step 3.
• 3.6~3.8V (2.31~2.59 kΩ) @ 20°C (68°F)
• 1.2~1.5V (0.31~0.33 kΩ) @ 80°C (176°F)
Is signal within specifications?
4
5
No Go to step 4.
Check ECTS for contamination, deterioration or
damage.
Is ECTS contaminated, deteriorated or
damaged?
Yes Clean ECTS with cleaner before installing. If
damaged or deteriorated, replace.
Thoroughly check for loose, bent or corroded
connectors at ECM and ECTS connectors.
With ignition OFF, disconnect ECM and ECTS
connectors. Measure resistance between ECTS
and ECM on all two circuits.
Is resistance all below 1 ohm?
Yes Go to step 6.
No Go to step 5.
No Repair as necessary.
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Return vehicle to original condition. Clear
all User
diagnostic
trouble codes. Verify by driving vehicle with SCAN
TOOL connected and monitor for pending codes.
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TROUBLESHOOTING GUIDE
ENGINE MECHANICAL SYSTEM
Problem
Engine will not crank
Engine cranks normally,
but does not start
Poor idle quality
Possible cause
Action
Battery, starting system or other electrical problems
Refer to Starting system,
Charging system.
Liquid in combustion chamber
Remove with suction gun,
then crank engine over
with spark plugs removed
Seized engine
Repair
Fuel system malfunction
Refer to Fuel system
Ignition system malfunction
Refer to Ignition system
Improper valve clearance
Check HLA's
Restricted exhaust system
Refer to exhaust system
Timing belt and/or related parts
Inspect timing belt and
related parts; replace if
necessary
Low compression due to: stuck or burned valves; worn
piston, piston ring orcylinder; failed cylinder head
gasket
Perform a compression
test, as outlined in this
section; repair engine
asnecessary
Camshaft worn
Replace
Fuel system malfunction
Refer to Fuel system
Emission system malfunction
Refer to Emission control
system
Ignition system malfunction
Refer to Ignition system
Improper valve clearance
Check HLA's
Uneven cylinder compression
Perform a compression
test, as outlined in this
section ; repair engine
asnecessary
Poor valve-to-valve seat contact
Repair or replace
Broken valve spring
Repair
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Failed cylinder head
White exhaust smoke
Replace
Usually caused by water vapor, which is a normal byproduct of combustionon cold days
None required
Excessive white smoke with engine warmed up could
be caused by a failed cylinderahead or intake gasket.
Could also be a cracked block, cylinder head or
intakemanifold
Repair or replace
Fuel system malfunction
Emission system malfunction
Refer to Fuel system
Blue exhaust smoke
Usually caused by oil burning in the combustion
chambers from: worn rings,worn valve guides, worn
valve seals or failed cylinder head gasket
Replace
Valve train noise
Worn valve guides
Repair
Low oil pressure
Refer to Lubrication
system
Improper valve clearance
Check HLA's
Broken valve spring
Replace
Sticking valves
Free valves
Camshaft worn or faulty
Replace
Insufficient compression caused by:
1. Improper valve clearance
2. Leakage from valve seat
3. Seized valve stem
4. Weak or broken valve spring
5. Failed cylinder head gasket
6. Cracked or distorted cylinder head
7. Sticking, damaged or worn piston ring
8. Cracked or worn piston
Check HLA's
Repair or replace
Replace
Replace
Replace
Repair or replace
Replace
Replace
Fuel system malfunction
Refer to Fuel system
Slipping clutch
Refer to Clutch
Dragging brakes
Refer to Brake system
Wrong tire size
Refer to Wheels and tires
Restricted exhaust system
Refer to Exhaust system
Improper valve clearance
Check HLA's
Sticking or burned valve
Replace
Black exhaust smoke
Insufficient power
Abnormal combustion
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Weak or broken valve
spring
Replace
Carbon accumulation in combustion chamber
Eliminate carbon
Loose or worn accessory drive belt/tensioner
Check belts and tensioners
Replace if necessary
A/C compressor or generator bearing
Replace
Improper oil viscosity
Install proper oil viscosity
for expected temperatures
Excessive piston pin clearance
Install new piston, pin and/
or connecting rod
Connecting rod clearance
Check and replace rods if
necessary
Insufficient piston-to-bore clearance
Hone and replace rods if
necessary
Faulty timing belt tensioner or guide
Replace
Loose damper pulley
Tighten or replace if
necessary
Valve spring clicking on cap, off square or broken
Repair or replace
Excessive stem to guide clearance
Repair
Excessive valve seat runout
Repair
Excessive piston to wall clearance
Replace pistons
Loose or broken damper pulley
Tighten or replace
Knock increases with
torque
Excessive piston to bore clearance
Replace piston
Bent connecting rod
Replace
Engine has heavy knock
when hot and torque is
applied
Broken damper pulley
Replace
Accessory belts too tight or damaged
Adjust or replace belt
Belt tensioned damaged
Replace
Flywheel cracked or loose clutch plate
Replace flywheel or clutch
plate
Excessive main bearing clearance
Repair
Excessive rod bearing clearance
Repair
Improper timing
Check timing
Piston pin and/or connecting rod
Replace piston pin and/or
rod
Engine knocks at idle
when hot
Engine knocks at idle
when hot
Slight noise at idle,
becomes louder as engine
speed is increased
Engine knocks when cold
Engine has light knock
when hot and under light
load conditions
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Poor quality fuel Ebay User ID: reveleus1
Engine knocks during
initial start up and lasts
only a few seconds
Use recommended or
higher grade fuel
Exhaust leak at manifold
Tighten bolts and/or
replace exhaust manifold
gaskets if necessary
Excessive rod bearing clearance
Repair
Improper oil viscosity
Install proper oil viscosity
for expected temperatures
TIMING BELT
Problem
Possible cause
Action
Tooth is broken or
cracked
Camshaft jamming
Inspect camshaft by removing cylinder
head cover
Repair or replace if necessary
Back surface is
cracked and/or worn
Tensioner jamming
Remove tensioner and inspect
Replace if necessary
Engine overheating
Inspect cooling system
Refer to engine cooling system
Interference with timing belt cover
Remove timing belt cover and inspect
Replace if necessary
Side surface is worn
and / or frayed
Improper installation of timing belt
Remove timing belt and reinstall
Malfunction of timing belt guide plate
Remove timing belt and inspect guide plate
Teeth are worn
Poor belt cover sealing
Remove timing belt cover and inspect
Replace if necessary
Coolant leak at water pump
Inspect water pump
Replace if necessary
Camshaft malfunction
Inspect camshaft by removing cylinder
head cover
Repair or replace if necessary
Excessive belt tension
Remove tensioner spring and inspect
Replace if necessary
Poor oil sealing
Inspect front oil seals
Replace if necessary
Coolant leak at water pump
Inspect water pump
Replace if necessary
Oil or coolant is on
the belt
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Poor belt cover sealingEbay User ID: reveleus1 Remove timing belt cover and inspect
Replace if necessary
HLA(HYDRAULIC LASH ADJUSTER)
Problem
Possible cause
Action
1. Noise when engine is started
immediately after oil is changed.
2. Noise when engine is started after
setting approx. one day.
Oil leakage in
oil passage
3. Noise when engine is started after
cranking for 3 seconds or more.
4. Noise when engine is started after new
HLA is installed.
Oil leakage in HLA
5. Noise continues more than 10 minutes.
Insufficient oil pressure
Check oil pressure
If lower than specification, check for
cause.
Oil pressure: 12.8 Psi
(88.26 kpa, 0.9 kg/cm²) - at idle
Faulty HLA
Press down HLA by hand
If it does not move, HLA is normal.
If it moves, replace HLA.
Measure valve clearance.
If more than 0 mm (0 in), replace HLA.
Incorrect oil amount
Check oil level.
Drain or add oil as necessary.
Deteriorated oil
Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
6. Noise during idle after high-speed
running.
Run engine at 2,000~3,000 rpm.
If noise stops after 2 seconds - 10
minutes*, HLA is normal.
If not, replace HLA.
* Time required for engine oil to
circulate within engine includes
tolerance for engine oil condition and
ambient temperature.
LUBRICATION SYSTEM
Problem
Possible cause
Action
Engine hard starting
Improper engine oil
Insufficient engine oil
Replace
Add oil
Excessive oil
Consumption
Internal engine wear
Oil leak
Refer to Engine
Mechanical System
Repair
Oil pressure drop
Insufficient oil
Add oil
Oil leakage
Repair
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Warning lamp illuminates
while engine is running
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ID: reveleus1
Worn and/or damaged
oil pump
gear
Replace
Worn plunger (inside oil pump) or weak spring
Replace
Clogged oil strainer
Clean
Excessive main bearing or connecting rod bearing
clearance
Refer to Engine
Mechanical System
Oil pressure drop
As described above
Malfunction of oil pressure switch Refer to Body
Electrical System
Refer to Body Electrical
System
Malfunction of electrical system
Troubleshooting manual
COOLING SYSTEM
Problem
Overheating
Corrosion
Possible cause
Action
Coolant level insufficient
Add
Coolant leakage
Repair
Radiator fins clogged
Clean
Radiator cap malfunction
Replace
Fan motor malfunction
Replace
Thermostat malfunction
Replace
Water passage clogged
Clean
Water pump malfunction
Replace
Impurities in coolant
Replace
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COMPONENT
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Email: suzlever@gmail.com
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DISASSEMBLY
1. Drain the coolant and disconnect the upper radiator hose.
2. Remove the breather hose (beween the air cleaner and the head cover).
3. Remove the air-intake hose.
4. Remove the vacuum hose, fuel hose and coolant hose
5. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion.
6. Remove the ignition coil.
7. Remove the power steering oil pump and bracket.
8. Remove the intake manifold.
9. Remove the heat protector and exhaust manifold assembly.
10. Remove the coolant pump pulley and the crankshaft pulley.
11. Remove the timing belt cover.
12. Remove the timing belt tensioner pulley.
13. Remove the timing belt.
14. Remove the head cover and cam carrier assembly.
15. Remove the cylinder head assembly. The cylinder head bolts should be removed by using Special Tool,
Cylinder Head Bolt Wrench, in the sequence as shown in the illustration in two or three steps.
16. Remove the gasket pieces from cylinder block top surface and cylinder head bottom surface.
Make sure that the gasket pieces do not fall in the engine
INSPECTION
1. Clean all components.
2. Remove gasket fragments, dirt, oil, grease, carbon, moisture, residue, and other foreign materials.
CYLINDER HEAD
1. Inspect cylinder head for damage, cracks, and leakage of oil and water. Replace cylinder head if necessary.
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2. Measure cylinder head mating surface in sixEbay
directions
as reveleus1
shown in figure.
User ID:
Distortion:
0.0012 in (0.03 mm) maximum
Before resurfacing cylinder head, check following repair or replace cylinderhead if necessary
• Sunken valve seats.
• Damage at intake and exhaust manifold mating surfaces.
• Camshaft oil clearances and end play.
3. Grind cylinder head mating surface if distortion exceeds specification.
Distortion:
0.0012 in (0.03 mm) maximum
4. Check cylinder head height by measuring from cylinder deck surface to cylinderhead cover gasket surface.
5. If cylinder head height is not within specification, replace cylinder head.
Height:
5.031~5.039 in (127.8~128 mm)
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Userdistortion
ID: reveleus1
6. Measure intake and exhaust manifold matingEbay
surface
at two directions shown in figure.
Distortion:
0.002 in (0.05 mm) maximum
7. If distortion exceeds specification, resurface or replace cylinder head.
Distortion:
0.002 in (0.05 mm) maximum
REASSEMBLY
1. Clean all gasket surfaces of the cylinder block and the cylinder head.
2. Install a new cylinder head gasket onto the cylinder head assembly.
Apply sealant to the gasket and do not reuse the old cylinder head gasket.
A.Tighten cylinder head bolts in order shown.
Tightening torque:
36.1 lb-ft (49 N·m, 5 kg-m)
B.Loosen bolts in reverse of order shown.
C.Retighten cylinder head bolts in order shown.
Tightening torque:
18 lb-ft (25 N·m, 2.5 kg-m)
D.Mark cylinder head bolts for rotational reference.
E.Rotate cylinder head bolts 90° (1/4 Turn) in order shown.
• Do not rotate crankshaft without timing belt.
• Make sure that all pistons are positioned in the middle of cylinder before installing sylinder head.
• Two bolts (No.7 and No.8) are shorter than other bolts. Never install the two bolts in other position. (for
A6D)
• Do not reuse the old cylinder head bolts.
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3. Install the timing belt tensioner pulley.
4. Install the timing belt on the camshaft sprocket, marking sure that the tension side is tightened by turning the
camshaft sprocket in reverse, all timing marks are in alignment.
5. Adjust the timing according to "Timing Belt".
6. Install the rocker cover and tighten the bolts to the specififed torque.
Tightening torque:
Rocker cover bolt
3.6~6.5 lb-ft (5~9 N·m, 0.5~0.9 kg-m)
7. Install the timing belt cover.
8. Install the new intake manifold gasket and the intake manifold. Tighten the nuts and bolts to the specified torque.
9. Install the exhaust manifold gasket and the exhaust manifold. Tighten the exhaust manifold attaching nuts to the
specified torque.
10. Install the surge tank and tighten the nuts and bolts to the specified torque.
Tightening torque:
Manifold nuts and bolts (both intake and exhaust)
11~14 lb-ft (15~20 N·m, 1.5~2.0 kg-m)
Tightening torque:
Surge tank to inlet manifold nuts and bolts
11~14 lb-ft (15~20 N·m, 1.5~2.0 kg-m)
11. Install the power steering oil pump and bracket.
12. Install the ignition coil.
13. Install the air intake hose.
14. Connect the vacuum hose, fuel hose and water hose.
15. Install breather hose.
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COMPONENT
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Removal
Do not disassemble water pump assembly.
If a problem is found, replace assembly as a unit.
1.
2.
3.
4.
5.
Disconnect negative battery cable.
Remove drive belt.
Remove timing belt.
Remove power steering pump in order to remove water inlet pipe.
Remove components in the order shown in figure.
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CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) Sensor works with the CKP Sensor to provide inputs to the ECM to establish and
maintain correct injector firing order. Refer to section EE-IG for more information.
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CRANKSHAFT POSITION SENSOR
The Crankshaft Position (CKP) Sensor is used to signal the ECM when a spark and/or fuel injection event required.
The output from this sensor, in conjunction with the camshaft position Sensor signal, is used to determine whether
spark or fuel is required in a particular cylinder.
The engine will not start without a CKP Sensor signal to the ECM. Refer to section EE-IG for more information.
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Component description table
Component
Function
Remark
Controls battery power to
compressor magnetic clutch and
condenser fan relay according to
vehicle conditions
Control condenser fan relay and
compressor magnetic clutch.
Controls battery power to A/C
DEF switch and grounds A/C
DEF switch.
Normal open type
A/C switch
Air cleaner
Filters air entering throttle body
Camshaft positin(CMP) sensor
Detects number 1 cylinder TDC
and sends the signal to ECM
Installed at rear of cylinder head
(bank 1)
Check valve
Maintains pressure in the fuel
tank and regulates vapor flow to
the evaporative emissions
canister
Located in the evaporative
system lines next to the fuel tank
Detects crankshaft angle from
flywheel rotation and sends
signal to ECM
SGT signal
Centalized service connector for
on-board diagnosis
For on-board diagnosis and
service/inspection
Supplies battery power to
electrical devices
Normal open type
Controlled by ECM
A/C relay
Crankshaft position (CKP) sensor
Data link connector (DLC)
EGI main relay
Engine control module (ECM)
Detects the following:
1. A/C operation
1. A/C switch
2. Air/fuel ratio (oxygen
concentration)
2. Oxygen sensor
3. Vertical chassis movement
3. Chassis acceleration sensor
4. Ignition ON signal
4. Ignition switch
5. Engine coolant temperature
5. Engine coolant temperature
sensor
6. Engine speed
6. Crankshaft position (CKP)
sensor (SGT signal)
7. In-gear condition (A/T only
7. Transaxle range switch (A/T)
8. Intake air amount
8. Mass air flow sensor
9. Intake air temperature
9. Intake air temperature sensor
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No.
piston TDC
(compression stroke)
10. Camshaft position (CMP)
sensor (SGC signal)
11. Throttle valve opening angle
11. Throttle position sensor
12. Vehicle speed
12. Vehicle speed sensor
13. Fuel tank pressure
13. Fuel tank pressure sensor
14. Engine knocking
14. Knock sensor
Controls operation of following:
1. A/C
1. A/C relay
2. Self-diagnosis function
2. Hi-scan pro & MIL
3. Fuel injection system
3. Injector
4. Ignition control system
4. Ignition coil
5. Idle speed control
5. Idle air control valve
6. Purge control system
6. Evaporative canister purge
valve
7. Fuel pump control
7. Fuel pump relay
8. Cooling fan control
8. Cooling fan control relay
Engine coolant temperature (ECT) sensor
Detects engine coolant
temperature and sends signal to
ECM
-
Evaporative emission canister
Stores fuel tank vapors (engine
stopped) -
-
Fuel filter (high pressure side)
Filters fine dirt particles in fuel
discharged from the fuel pump
-
Fuel filter (low pressure side)
Filters fuel in fuel tank
-
Fuel injector
Injects fuel into intake port
Controlled by signals from ECM
Fuel pressure regulator
Adjusts fuel pressure supply to
injectors
Controlled by intake manifold
vacuum
Fuel pump
Supplies fuel from fuel tank to
fuel under pressure
Actuated by fuel pump relay
installed
Controls battery power to fuel
pump
Actuated by ECM fuel pump
control signal or by jumping data
link connector terminal 1 to
battery
Normal open type
Detects vapor leakage and
monitors purge valve operation
Located on the fuel tank
Fuel pump relay
Fuel tank pressure sensor
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density in
Located in exhaust manifold
exhaust gas and sends signal to
ECM For air/fuel mixture
adjustment
Heated oxygen sensor(front)
Heated oxygen sensor (rear)
Idle air control(ISC) valve
Ignition coils
Ignition control module
Detects oxygen density in
exhaust gas and sends signal to
ECM
TWC converter verification
Supplies intake air to engine,
bypassing throttle valve
For idle speed control
Actuated by ECM idle speed
control signal
Supplies secondary voltage to
spark plugs
Mounted directly above spark
plugs
Controls operation of ignition coils Incorporated into ECM
Ignition switch
Starts engine and controls
battery power to electrical devices
-
Intake manifld
Supplies intake air to all cylinders
-
Knock sensor
Detects detonation in the
combustion (chambers) and
sends signal to ECM
The ECM will retard ignition
timing hased on input signal
Supplies current to output
devices and ECM
-
Mass air flow (MAF) sensor
Detects amount of intake air and
sends signal to ECM
-
Positive crankcase ventilation (PCV) valve
Sends blow-by gas in crankcase
into intake manifold (dynamic
chamber) For blow-by gas recirculation
Actuatedd by intake manifold
vacuum
Evaporative canister purge solenoid valve
Controls fuel vapor from
evaporative emission canister to
intake manifold (dynamic
chamber)
For purge control
Actuated by ECM purge control
signal
Resonance chamber
Reduces intake air suction noise
and increases engine torque
Rollover valve
Restricts fuel from entering the
evaporative system in a vehicle
rollover
Main relay
Starter
Located on the fuel tank
Starts engine by rotating flywheel
ring gear
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HC, CO, and NO in
Three way catalytic converter
exhaust through chemical
reaction
Throttle body
Controls intake air amount
For exhaust gas emissions
reduction
-
Throttle position sensor
Detects throttle valve opening
angle and sends signal to ECM
Installed on throttle body
Transaxle control module
Controls functions of transaxle
for better performance and shift
quality lower trim panel
Located below instrument panel
behind left
Transaxle range switch
Detects shift lever position and
sends to ECM
For idle speed control load/no
load determination
VICS valve
Controls shift lever position and
sends to ECM
On-board refueling vaporrecovery (ORVR) valve
Prevents fuel vapor from fuel
tank leaking to air in event of
refueling
Located on fuel tank
OBD-II overview
The goal of the On Board Diagnostics-II (OBD-II)regulation, which was mandated by the Environmental Protection Agency
(EPA), is to ensure proper emission system operation for the life of the vehicle by providing the vehicle with an "on-board"
diagnostic system which is capable of continuously monitoring the efficiency of the emission control system.
To achieve this goal, OBD-II diagnostics monitors emissions-related components and systems for deterioration and identifies
an emissions-related malfunction before the driver notices a problem with the vehicle. The Engine Control Module (ECM)
monitors many different circuits in the fuel injection, ignition, emission and engine systems. If the ECM senses a problem
with a monitored circuit often enough to indicate an actual problem, it stores a Diagnostic Trouble Code in the ECM memory.
If the code applies to a non-emissions related component or system and the problem is repaired or ceases to the exist, the
ECM cancels the code after a predetermined number of drive cycles.
Certain criteria must be met before the ECM stores a DTC in memory. The criteria may be a specific range of engine RPM,
engine temperature, and/or input voltage to the ECM. Keep in mind though that the ECM might not store a DTC for a
monitored circuit even though a malfunction has occurred. This may happen because one of the DTC criteria for the circuit
has not been met. FOR EXAMPLE, lets say the DTC criteria requires the ECM to monitor the circuit only when the engine
operates between 750 and 2000 RPM. Suppose the sensors output circuit shorts to ground as a result of engine torque
when the engine operates above 2400 RPM (resulting in 0 volt input to the ECM). Since the condition happens at the
enginespeed above the maximum threshold, in this case 2000 RPM, the ECM will not store a DTC.
through the DLC.
The ECM executes the following key monitoring for OBD-II:
• Primary emission control system/components
• Heated oxygen sensors (includes heater)
• Catalyst
• Fuel system
• Evaporative emission system
• Misfire
• Comprehensive components (input and output)
Heated oxygen sensor monitoring
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System description
Effective control of exhaust emission is achieved by an oxygen "feedback system" to the ECM. This "feedback" is
accomplished with the HO2 Sensors. Once the HO2 Sensor reaches operating temperature, the sensor generates a voltage
signal to the ECM that is inversely proportional to the amount of oxygen in the exhaust. This voltage signal is used by the
ECMto calculate the fuel injector pulse width to maintain the ideal 14.7 to 1 Air Fuel (A/F) ratio. This is the ideal mixture
because at this ratio, the catalyst works best to remove hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxide (NOX)
from the exhaust.
Monitoring process
To achieve the requirements of the HO2S Monitoring diagnosis, diagnostic tests have been designed to monitor the following:
• Heater voltage and current.
• Period of front HO2S reaction
• Other parameter (Tv) to monitor sensor aging.
Heater voltage and current
The voltage readings taken from the HO2 Sensor are very temperature sensitive and are not particularly accurate below
300C. For this reason, heating of the HO2 sensor is necessary to allow the engine crontroller to shift to closed loop control
as soon as possible. The heating element used to heat the HO2 Sensor must be tested to ensure that it is heatingthe sensor
properly.
Period of front HO2 reaction
The ECM is supplied with information regarding the oxygen content of the exhaust gases by the front HO2S. The signal
isused to compute the injection period. The front HO2S monitors the contaminated exhaust gases. This, in time, causes
agingof the device and a change in the signal. To monitor the front HO2S responsiveness, the response period of the
upstreamoxygen sensor signal is compared with a lower and upper threshold. This comparison is done in an applicable
range of engine speed and load with the engine at operating temperature. If the actual mean value of the period is outsideof
the lower and upper period thresholds the diagnostic trouble code is set.
Other parameter (Tv) to monitor sensor aging
The sensor aging is monitored by comparing the front and rear HO2S and also using the correction value (Tv) which
determines the mean value of the lean/rich shift necessary for optimal air/fuel ratio-control. With the help of this information,
the ECM can make allowance for aging of the front HO2S in its injection period calculations. When the parameter-Tv is
above or below the specific limits, the ECM will set the diagnostic trouble code HO2S Slow Response by aging.
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MIL illumination
If any fault relating to HO2S is detected, then the MIL is only turned ON if the same fault is again detected during a second
drive cycle.
Three way catalytic converter (TWC) monitoring (System description)
To comply with clean air regulations, vehicles are equipped with catalytic converters. These converters reduce the emissions
of hydrocarbons, oxides of nitrogen and carbon monoxide. Normal vehicle operation or engine misfire can cause a catalyst to
decay. A meltdown of the ceramic core can cause a reduction of the exhaust passage resulting in an increasein vehicle
performance and deteriorate engine performance, driveablity and fuel economy.
The catalyst uses dual oxygen sensor to monitor the efficiency of the converter because as a catalyst deteriorates, itsoxygen
storage capacity and its efficiency are both reduced. By monitoring the oxygen storage capacity of a catalyst,its efficiency
can be indirectly calculated. The upstream (front) HO2 Sensor is used to detect the amount of oxygen inthe exhaust gas
before it enters the catalytic converter. A low voltage indicates a high oxygen content (lean air mixture) A high voltage
indicates a low content of oxygen (rich mixture).
When the front HO2 Sensor detects a lean condition, there is an abundance in the oxygen in the exhaust has. A functioning
converter would store this oxygen so it can use it for the oxidation of HC and CO. As the converter absorbs the oxygen, there
will be a lack of oxygen downstream of the converter. The output of the downstream (rear) HO2 Sensor will indicate limited
activity in this condition. As the converter loses the ability to store oxygen, the condition can be detectedfrom the operation of
the rear HO2 Sensor. When the catalyst efficiency drops, no chemical reaction takes place.This means the concentration of
oxygen will be the same downstream (rear) as upstream (front). The output voltage of the rear HO2 Sensor copies the
voltage of the front HO2 Sensor. The only difference is a time lag (monitored by the ECM) between the switching of the HO2
Sensors.
To monitor the system, the lean-to-rich switches of front to rear HO2 Sensors is counted. The ratio of rear switches tofront
switches is used to determine whether the catalyst is operating properly. An effective catalyst will have fewerrearswitches
than it has front switches, that is, a ratio closer to zero. For a totally ineffective catalyst, this ratio will be one-to-one indicating
that no oxidation occurs in the catalytic converter.
The system must be monitored so that when catalyst efficiency deteriorates and exhaust emissions increase to over the legal
limit, the MIL will illuminate.
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Fuel system monitoring (System description)
The determination of how much fuel to deliver to the engine is the calculation of injector pulse width. Basic injection duration
(injector pulse width) is determined by:
• Engine load (MAF sensor)
• Engine Speed (SGT)
• Short fuel trim correction factor
• Long fuel trim correction factor
Fuel trim is monitored to meet the OBD-II requirements
1. Short fuel trim (FT)
Short FT is a temporary correction to fuel delivery which changes with every cycle of the front Heated Oxygen Sensor.
Under normal conditions, it fluctuates rapidly around its ideal value of 0% correction and is set to 0% during open loop
operation.
Short FT is a parameter of the OBD-II serial data stream and can be displayed by a scan tool. The normal range of
shortFT is ±25%, but under normal operating conditions it rarely goes beyond ±10%. Short FT responds to changes in
front HO2S output. If basic injection duration results in a lean air/fuel ratio, Short FT responds with positive corrections
(+1% to +25%) to add fuel and enrich the mixture. If basic injection is too rich, Short FT responds with negative
corrections (-1% to -25%) to subtract fuel and lean the mixture.
2. Long Fuel Trim
Long FT is a data parameter on the OBD-II data streams. It is a more permanent correction to fuel delivery because it
ispart of the basic injection duration calculation. Long FT changes slowly, in response to Short FT. It's normal rangeis
±25%, positive values indicating rich correction and negative values indicating lean correction.
Unlike Short FT which affects injection duration calculation in closed loop only, the Long FT correction factor affectsthe
basic injection duration calculation in open and closed loop. Because Long FT is stored in a non-volatile RAM andis not
erased when the ignition is switched OFF, the fuel system is able to correct for variances in engine and fuel conditions
even during warm-up and wide open throttle conditions.
Monitoring process
The ECM monitors the averages of long term and short term fuel trim. If these fuel trim values reach and stay at their
maximum limits (±25%) for a defined period of time, a diagnostic trouble code is set.
MIL illumination
When the fuel trim value exceeds the failure thresholds, then the MIL is only turned ON if the same fault is detected during a
second drive cycle.
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Evaporative emission controls (Evaporative
Control
System)
The evaporation control system prevents the emission of fuel tank vapor into the atmosphere. When fuel evaporates in
thefuel tank, the vapors pass through vent hoses or tubes to a charcoal filled evaporative canister. The canister temporarily
holds the vapors. The ECM allows intake manifold vacuum to draw vapors into the combustion chambers during certain
operating conditions.
1. Fuel tank
The fuel tank is located under the rear of the vehicle. The fuel pump, fuel level sending unit and fuel tank pressure sensor
are installed on the upper part of the fuel tank.
2. Fuel filler cap
A ratchet tightening device on the threaded fuel filler cap reduces the chances of incorrect installation, which would
prevent sealing fuel vapors. After the gasket on the fuel filler cap and the fill neck flange contact each other, the ratchet
produces a loud clicking noise indicating the seal has been set
3. Evaporative emissions canister
A maintenance free, EVAP canister is used on the Rio located under the right side of the vehicle near the fuel tank.
TheEVAP canister is filled with granules of an activated carbon mixture. Fuel vapors enter into the EVAP canister are
absorbed by the charcoal granules. Fuel tank pressure vents into the EVAP canister and are temporarily held in the
canister until they can be drawn into the intake manifold.
4. Canister close valve
The Canister Close Valve (CCV) closes off the air inlet to the Evaporative Emissions Canister for the Evaporative
Emissions System leak detection inspection function. The CCV also prevents fuel vapors from escaping from the
Evaporative Emissions Canister when the vehicle is not operating.
5. Purge solenoid valve
This valve is actuated by the purge control signal from the ECM and controls fuel vapor from the EVAP Canister to the
intake manifold.
6. Fuel tank pressure sensor
The Fuel Tank Pressure Sensor (FTPS) is an integral part of the monitoring system. The FTPS checks Purge Solenoid
Valveoperation and leak detection in the Evaporative Emissions System by monitoring pressure and vacuum levels in the
fueltankduring and between Purge Solenoid Valve operating cycles.
EVAP system monitoring: Leakage detection (system description)
The evaporative system is monitored by a pressure test. The canister close valve and fuel tank pressure sensor are usedto
close the system and observe tank pressure respectively.
Monitoring conditions
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The leak test is conducted when the vehicle is stopped
an idle
condition.
Monitoring process
The canister close valve and the EVAP canister purge control valve are closed and an increase in fuel tank pressure caused
by fuel evaporation occurs (compensation gradient). Afterwards, the canister close valve and the purge control valve are
opened. The canister close valve will be shut if the purge control valve reached its final duty cycle.
1. Gross leak detection
A gross leak is assumed if negative pressure is built-up below a certain threshold. In this case, the EVAP canister purge
control valve is closed and the canister close valve is opened. Then, the diagnosis is completed.
2. Small leak detection
The EVAP canister purge control valve is closed as soon as the maximum vacuum level is achieved. The rate of vacuum
losswill be corrected by the above compensation gradient. A small leak is assumed if this corrected rate of vacuum loss is
above a certain threshold. Then, the canister close valve is opened and the diagnosis is completed.
MIL illumination
If either a rough leak or a small leak is detected for two driving cycles, then a defective evaporative system is assumed and
the MIL is illuminated.
Misfire monitoring (System description)
Misfire is monitored by evaluating fluctuations of the angular velocity of the crankshaft position sensor. The crankshaft
position sensor allows the ECM to monitor crankshaft speed variations during each cylinder power stroke. When all cylinders
of an engine are firing evenly, the crankshaft speeds up evenly with each power stroke. During a misfire, crankshaft speed
decreases in that cylinder. Kia OBD-II engines use a 60 minus 2 tooth crankshaft position sensor to measure crankshaft
speed and position. The ECM uses this information to determine if a misfire occurs, which cylinder it is occurring in, and the
degree of misfire. If a significant misfire is detected, a DTC is stored. The MIL in the instrument panelwill illuminate, informing
the driver of a malfunction.
Monitoring conditions
The misfire monitoring begins as soon as 2.9 to 50 ignitions pass after engine start. It is disabled while the ECM detects a
sudden change of engine speed or load. The misfire monitoring covers the full range of engine operation.
Monitoring process
A new function for pre-filtering of sensor wheel segment duration signal is introduced to Sephia in order to enlarge themisfire
monitoring range. The sensor wheel segment duration is pre-filtered by this function and then the filtered valueis used to
calculate the engine roughness which is compared
with the
reference value to detect misfiring. With this function, it is
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reveleus1 on the detection of misfire.These oscillations
possible to eliminate the influence of the crankshaft-synchronous
can be caused by sensor wheel tolerance or crankshaft torsional vibration. The misfire monitoring ofSephia covers nearly the
full range of engine operation in case of random or continuous misfire, and for symmetrical misfire.
MIL illumination
The MIL is illuminated when a misfire is detected which can cause the damage of catalyst or exhaust emission higher than
1.5 times certification standard (I/M failure).
The MIL flashes while a catalyst damaging misfire is being detected.
COMPREHENSIVE COMPONENTS MONITORING
Any input or output components that can affect emissions or any input or output component used to monitor any other
monitored component/system is monitored.
The lack of circuit continuity any rationality, and out-ofrange values to ensure proper operation of the input devices, are
monitored for proper response to ECM commands.
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ENGINE CONTROL MODULE (ECM)
The Engine Control Module (ECM) operates the fuel system. It regulatesignition timing, air fuel ration, emission
control devices, charging system,idle speed control, air conditioning clutch engagement, etc. The ECM has
theability to adapt to changing operating conditions.
The ECM receives input signals from various switches and sensors. Basedon these inputs, the ECM regulates
various engine and vehicle operations throughdifferent system components also known as ECM Outputs. On the
other hand,the sensors and switches that provide inputs to the ECM are ECM Inputs. Forexample, the ECM
adjusts ignition timing based upon inputs it receives fromsensors that react to: engine RPM, engine coolant
temperature, throttle position,transaxle gear, vehicle speed, etc. The ECM adjusts idle speed based on inputsit
receives from sensors that react to: throttle position, vehicle speed,transaxle gear, etc.
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MFI CONTROL
EMISSION CONTROL DIAGRAM
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Diagnostic trouble codes
Diagnostic trouble
code
Condition
P0030
Heated O₂sensor heater malfunction (bank 1, sensor 1)
P0036
Heated O₂sensor heater malfunction (bank 1, sensor 1)
P0100
Mass air flow (MAF) circuit malfunction
P0101
Mass air flow (MAF) circuit range/performance problem
P0115
Intake air temperature (IAT) circuit malfunction
P0116
Engine coolant temperature (ECT) circuit malfunction
P0120
Engine coolant temperature (ECT) circuit range/performance problem
P0121
Throttle position (TP) sensor circuit malfunction
P0125
Throttle position (TP) sensor circuit range/performance problem
P0128
Insufficient coolant temperature for closed loop fuel control
P0130
Coolant thermostat stuck opened
P0133
Heated O₂sensor circuit malfunction (bank 1, sensor 1)
P0134
Heated O₂sensor slow response (bank 1, sensor 1)
P0135
Heated O₂sensor circuit no activity detected (bank 1, sensor 1)
P0136
Heated O₂sensor circuit malfunction (bank 1, sensor 1)
P0110
Heated O₂sensor circuit slow response (bank 1, sensor 2)
P0139
Heated O₂sensor circuit no activity detected (bank 1, sensor 2)
P0140
Heated O₂sensor heater current malfunction (bank 1, sensor 2)
P0141
Heated O₂sensor heater current malfunction (bank 1, sensor 2)
P0170
Fuel system malfunctio (A/F adaptation diagnosis malfunction)
P0171
Fuel system too lean
P0172
Fuel system too rich
P0201
Cylinder 1 injector circuit malfunction
P0202
Cylinder 2 injector circuit malfunction
P0203
Cylinder 3 injector circuit malfunction
P0204
Cylinder 4 injector circuit malfunction
P0300
Random misfire detected
P0301
Cylinder 1 misfire detected
P0302
Cylinder 2 misfire detected
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P0303
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Cylinder 3 misfire detected
P0304
Cylinder 4 misfire detected
P0325
Knock sensor circuit malfunction
P0335
Crankshaft position (CKP) sensor circuit malfunction
P0340
Camshaft position sensor circuit malfunction
P0422
Main catalyst efficiency below threshold
P0440
Evaporative emission control system malfunction
P0442
Evaporative emission control system leak detected (small leak 1.0mm)
P0443
Evaporative emission control system purge control valve circuit malfunction
P0446
Evaporative emission control system vent control malfunction
P0450
Evaporative emission control system pressure sensor malfunction
P0451
Evaporative emission control system pressure sensor rang/performance problem
P0455
Evaporative emission control system leak detected (large leak)
P0466
Evaporative emission control system leak detected (small lesk 0.5mm)
P0501
Vehicle speed sensor circuit range/perfomance malfunction
P0506
Idle speed system rpm lower than expected
P0507
Idle speed system rpm higher than expected
P0562
System voltage low
P0563
System voltage high
P0601
Internal control module memory check sum error
P0650
Malfunction indicator lamp
P1505
Idle control vlave opening coil signal low
P1506
Idle control vlave opening coil signal high
P1507
Idle control vlave closing coil signal low
P1508
Idle control vlave opening coil signal high
P1586
AT/MT condification signal malfunction
P1640
Main relay malfunction
P1693
MIL circuit malfunction
USING THIS SECTION
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1. Introduction
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Most of the fuel and emission control system is electrically controllde, often making it difficult to diagnose problems in the
system, especially intermittent problems. Before undertaking actual checks, take a few minutes to talk with a customer
who approaches with a driveablity complaint. Teh customer is often a good source of information on such problems,
especially intermittent ones. Through talks with the customer, one can find out what the symptoms are and under what
conditions they occur.
2. Work flow
Diagnostic Symptom Index
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Symptom Diagnosis charts
1. Description : Further describes the symptom. Confirm that the chart addresses the actual symptom before beginning
troubleshooting.
2. Troubleshooting Hints : This describes the possible point of malfunction.
3. Step : This shows the order of troubleshooting. Proceed with troubleshooting as indicated.
4. Check : This describes an inspection to determine the malfunction of parts quickly.
5. Remedy : This recommends the appropriate action to take as a resuit (Yes/No) of the check.
DIAGNOSTIC SYMPTOM INDEX
NO.
1
TROUBLESHOOTING ITEM
DESCRIPTION
Will not crank or cranks slowly
Refer Engine Electrical System
No combustion
Engnie cranks at normal speed but shows only partial combustion
and will not continue to run
Partial combustion
Engine cold
Engine cranks at normal speed but shows only partial combustion
and will not continue to run
4
Partial combustion
sfter warm-up
Engine start normally when cold, but will not start after running
and hot soaked
5
Always
Engine cranks at normal speed but requires excessive cranking
time before starting
When engine is cold
Same condition as No.5 after running and cold; restarts normally
after warm-up
2
3
6
7
Cranks normally but
will not start
Cranks normally but
hard to start
After warm-up
Same condition as No.5 after running and hot soaked; starts
normally when cold
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8
9
10
Always
Rough idle
(Low idle speed/
engine stalls at idle)
11
Ebay User
ID:stalls
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Engine
or vibrates excessively at idle.
Before warm-up
Engine stalls or vibrates excessively at idle during warm-up
After warm-up
Engine runs normally at idle during warm-up but vibrates
excessively or stalls after warm-up
When A/C ON
Engine stalls or vibrates excessively at idle when A/C ON
12
Rough idle/engine stalls just after starting
Engine stalls or vibrates excessively only just after starting
(acceleration from idle)
13
High idle speed after warm-up
Idle speed excessive after warm-up
14
Idle moves up and down/idle hunting
Engine speeds up and down periodically at idle
15
Engine stalls on deceleration
Engine unexpectedly stops running while decelerating or after
deceleration
16
Engine stalls suddenly (intermittent)
Engine intermittently stops running
17
Stumbles/hesitates on acceleration
Flat spot occurs just after accelerator depressed or mid jerking
occurs during acceleration
18
Surges while cruising
Unexpected change in engine speed which is usually repetitive
19
Lack of power
Performance poor under load when throttle valve wide open
Maximum speed reduced
20
Poor acceleration
Performance poor while accelerating
21
Runs rough on deceleration/backfire
Engine runs rough while decelerating and abnormal combustion
occurs in exhaust system
22
Knocking
Abnormal combustion accompanied by audible "pinging" noise
23
Fuel odor
Gasoline odor in cabin
24
High oil consumption
Oil consumption excessive
25
MIL always ON
Kia Data Pro Scan Tool does not indicate Diagnostic Trouble
Code but MIL always ON
26
MIL never ON
Kia Data Pro Scan Tool indicates malfunction
27
A/C does not work
Blower fan operates but magnetic clutch does not operate
Driveability Definitions
1. Stumble : Mild jerking during acceleration.
2. Hesitation : Delay in increase in engine speed occurring just after the accelerator pedal is depressed.
3. Surge : Continuous soft jerking during cruise.
Precautions for Symptom Diagnosis
Fuel System Pressure Release
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The fuel system remains under pressure when the engine is not running. Release fuel system pressure before
disconnectingany fuel line to reduce the chance of personal injury or fire damage to vehicle components. any fuel line to
reduce thechance of personal injury or fire damage to vehicle components.
Fuel is explosive. An empty fuel tank can still contain explosive gases.
Supply adequate ventilation to the work area. Do not smoke, and keep sparks and open flames away. Refer to fuel
system for fuel system pressure release procedures.
SYSPTOM DIAGNOSIS CHARTS
2
Cranks normally, but will not start (no combustion)
· Cranks normally, but no combustion
Description · Battery is OK
· Throttle valve closed while cranking
(Troubleshooting hint)
No fuel injection to engine because of fuel shortage or no ignition in all cylinders.
No spark
· Ignition control malfunction
· Malfunction of ignition system component
No fuel injection
· Malfunction of fuel pump
· Malfunction of injector
Low fuel line pressure
Low engine compression pressure
Step
1
2
Check
Action
Check strong blue spark at each spark plug
cord disconnected.
Is blue spark present?
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Does MIL stay on after engine start-up?
Check ignition system. Check resistance of DLI
coils.
3
Primary : Approx. 0.6~0.8Ω
Secondary : 11 -15Ω
Check wiring harness between ECM and DLI
coil.
Is resistance within specification?
Check high tension cords.
4
Resistance : 16kΩ/m
Check for damage to spark plug wires.
Are spark plug wires OK?
Yes
Go to step 5.
No
Go to next step.
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to Troubleshooting
with OBD-II Diagnostic Trouble Codes.
No
Go to next step
Yes
Go to next step.
No
Replace ignition coils or repair wiring harness.
Yes
Go to next step.
No
Replace high tension cord.
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5
6
7
8
9
10
11
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Connect data link connector terminals fuel
Yes
pump and B+ with a jumper wire and check
operational sound of fuel pump.
Does fuel pump operate?
No
Check that engine starts on this condition.
- Check fuel pump relay or wiring harness if
engine starts.
- Go to step 7 if engine does not start.
Go to next step.
Yes
Check continuity of fuel pump (between PNK
and BLK).
- If there is no continuity, replace fuel delivery
module.
- If there is continuity, repair the ground circuit.
No
Repair the related wiring harness.
Crank engine and check operational sound of
injector
Yes
Go to step 10.
No
Go to next step.
Check that battery voltage is applied on injector
connector when ignition switch is ON.
Yes
Go to next step.
No
Check wire between main relay and injector.
Yes
Go to next step.
No
Temporarily install a known good injector and
check for proper operation. If problem is
corrected, replace injector.
Yes
Go to next step.
Check that battery voltage is applied on R/W
wire of fuel pump connector B12 when ignition
switch is ON.
Check that the resistance of injector is
13.5~15.5Ω.
Connect the data link connector terminals
FUEL PUMP and B+ with a jumper wire and
check fuel line pressure while ignition switch is
ON.
Fuel line pressure : 46~51 psi (320~350 kPa,
3.2~3.5 kg/cm²)
Is fuel line pressure within specification?
Check engine compression pressure.
Engine compression pressure : 184 (1275 kPa,
13.0 kg/cm²) at 300 rpm
Is engine compression pressure within
specification?
High pressure :
Disconnect return line from filter side.
Blow through line towards tank.
If line is clear, try with new pressure regulator.
If line is blocked, check for blockage in return
line and clean or replace as necessary.
No
Low pressure :
Block return line and check if pressure rises.
If pressure rises, replace pressure regulator.
If pressure does not rise, check fuel filter at fuel
delivery module.
If it is OK, measure fuel pump max.
Pressure and replace as necessary.
Yes
Go to next step.
No
Check engine condition :
- Wear of pistion, piston rin and cylinder wall
- Defect of cylinder head gasket
- Deformation of cylinder head
- Improper valve clearance
- Valve stuck to guide
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12
Check condition of all spark plugs. Ebay User ID: reveleus1
Yes
Go to next stpe.
Spark plug gap : 0.027~0.031 in (0.7~0.8mm)
Check for excessive carbon deposit and correct
contact with spark plug wires.
No
Clean or replace.
Are spark plugs OK?
13
Check crankshaft position sensor.
Is crankshaft position sensor OK?
14
3
Yes
Go to next step.
No
Check crankshaft position sensor and related
wire harness.
Replace ECM and check for proper operation.
Cranks normally, but will not start (partial combustion)-When engine is cold
· Cranks normally, but partial, not continuous, combustion occurs
Description · Battery is OK
· Fuel present in tank
(Troubleshooting hint)
Overrich air/fuel ratio
· Clogged air cleaner element
· Malfunction of mass air flow sensor
Overlean air/fuel ratio
· Incorrect fuel injection control (correction for engine coolant temperature)
· Low fuel line pressure
· Air leakage at intake system
Low engine compression pressure
Step
1
2
3
Check
Check that malfunction indicator light is
illuminated.
While ignition switch is OK?
Does the MIL remain on after engine start-up?
Disconnect spark plug.
Crank engine and check for spark at plug wire
terminal. Is spark OK?
Action
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to Troubleshooting
with OBD-II Diagnostic Trouble Codes.
No
Go to next step.
Yes
Go to next step.
No
Replace ignition coil or repair wiring harness
No
Replace ignition coils or repair wiring harness.
Yes
Go to next step.
High pressure :
Disconnect return line from filter side.
Blow through line towards tank.
If line is clear, try with new pressure regulator.
If line is blocked, check for blockage in return
line and clean or replace as necessary
Connect the data link connector terminals
FUEL PUMP and B+ with a jumper wire and
check fuel line pressure while ignition switch is
ON.
No
Fuel line pressure : 46~51 psi (320~350 kPa,
3.2~3.5 kg/cm²)
Is fuel line pressure within specification?
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Ebay User ID: reveleus1 Low pressure :
Block return line and check if pressure rises.
If pressure rises, replace pressure regulator.
If pressure does not rise, check fuel filter at fuel
delivery module.
If it is OK, measure fuel pump max.
Pressure and replace as necessary.
4
5
6
7
8
9
10
11
Yes
Go to next step.
No
Check that battery voltage is applied on injector
connector and check wire between main relay
and injector.
Check resistance of injector.
Yes
Go to next step.
Resistance : 13.5~15.5Ω
Is resistance within specification?
No
Replace injector.
Yes
Go to next step.
No
Open circuit or incorrect voltage :
- Repair wiring harness
- Replace IAC valve
Yes
Go to next step.
No
Check for causes.
Yes
Replace MAF sensor.
No
Go to next step.
Yes
Check engine coolant temperature sensor
- If normal : check wiring harness between
engine coolant temperature sensor and ECM
- If not normal : replace engine coolant
temperature sensor.
No
Go to next step.
Yes
Repair or replace.
No
Go to next step.
Yes
Go to next stpe.
Does injector operate while cranking engine?
Chank condition of IAC valve.
Chank for open circuit between IAC valve and
ECM
Check battery voltage is applied to R/Y wire of
ISC valve
Check ISC valve hose connection
Is IAC valve OK?
Check terminal voltage of mass air flow sensor,
throttle position sensor, ignition coils, engine
coolant temperature sensor.
Are sensors functioning properly?
Check MAF sensor and related.
Is MAF sensor OK?
Check that engine starts when engine coolant
temperature sensor connector is disconnected.
Does engine start?
Check air leakage at intake system
components.
Check engine compression pressure.
Engine compression pressure : 184 psi
(1275kPa, 13.0 kg/cm²) at 300 rpm
Is engine compression pressure within
specification?
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Ebay User ID: reveleus1 Check engine condition.
No
12
13
4
Check condition of spark plug.
· Spark plug gap : 0.027~0.031 in (0.7~0.8mm)
· Excessive carbon deposit
· Contact with high tension cord
Are spark plugs OK?
- Wear of piston, piston ring and cylinder wall
- Defect of cylinder head gasket
- Deformation of cylinder head- Improper valve
clearance
- Valve stuck to guide
Yes
Go to next step.
No
Clean or replace.
Replace ECM and check for proper operation.
Cranks, normally, but won't start (partial combustion) - After engine is warmed up
· After engine is left hot after running, cranking speed is OK
Description · Battery is OK
· Engine starts normally when engine is cold
(Troubleshooting hint)
Overrrich air/fuel ratio
· Correction for coolant temperature
· Fuel leakage at injector
Vapor lock occurs
· Fuel pressure is not kept when engine stops
Step
1
2
Check
Action
Warm up engine to normal operating
temperature and stop engine. Connect the data
link connector terminals FUEL PUMP and B+
with a jumper wire for 3 minutes while ignition
swithc is ON. Then check that engine starts.B+
with a jumper wire for3 minutes while ignition
swithc is ON. Then check that engine starts.
Does engine start?
Connect the data link connector terminals
FUEL PUMP and B+ with a jumper wire and
check fuel line pressure while ignition switch is
ON.
Fuel line pressure : 46~51 psi (320~350 kPa,
3.2~3.5 kg/cm²)
Is fuel line pressure within specification?
Yes
Replace fuel with another brand.
No
Go to step 2.
Yes
Go to next step.
High pressure :
Disconnect return line from filter side.
Blow through line towards tank.
If line is clear, try with new pressure regulator.
If line is blocked, check for blockage in return
line and clean or replace as necessary.
No
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Ebay User ID: reveleus1 Low pressure :
Block return line and check if pressure rises.
If pressure rises, replace pressure regulator.
If pressure does not rise, check fuel filter at fuel
delivery module.
If it is OK, measure fuel pump max.
Pressure and replace as necessary.
3
4
5
6
7
5
Plug fuel pressure regulator outlet and check
that fuel pressure is kept while ignition switch is
OFF
Fuel line pressure : 25 psi (180 kPa, 1.8 kg/
cm²) for 15 minutes
Is fuel line pressure retention within
specification?
Check that engine starts when engine coolant
temperature sensor connector is disconnected.
Does engine start?
Check that malfunction indicator light is
illuminated. Is MIL illuminated?
Check terminal voltage of mass air flow sensor,
throttle position sensor, ignition coils, engine
coolant temperature sensor.
Are sensor terminal voltages correct?
Yes
Replace fuel pressure regulator.
No
Check fuel pump pressure is kept.
- If normal : check fuel leakage from injector
- If not normal : replace fuel pump
Yes
Check engine coolant temperature sensor.
- If normal : check wiring harness between
engine coolant temperature snesor and ECM
- If not normal : replace engine coolant
temperature sensor
No
Go to next step.
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to Troubleshooting
with OBD-II Diagnostic Trouble Codes.
No
Go to next step.
Yes
Go to next step.
No
Check for causes.
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
Cranks normally, but hard to start - Always
· Cranks normally, but cranking time up to starting is excessively long
Description · Battery is OK
· Engine is normal while engine is idling (Refer to "Rough ldling" if not in good idling condition)
(Troubleshooting hint)
Overrich air/fuel ratio
· Incorrect fuel injection control (correction for engine coolant temperature_
· Low fuel line pressure
· Air leakage at intake system
Overrich air/fuel ratio
· Clogged air cleaner element
· Malfunction of mass air flow sensor
Spark plugs not in good condition
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Step
1
2
3
4
5
6
7
8
Check
Ebay User ID: reveleus1
Action
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to Troubleshooting
with OBD-II Diagnostic Trouble Codes.
No
Go to next step.
Yes
Go to next step.
No
Check air leakage at intake system.
Check cleanness of air cleaner element.
Is air cleaner element OK?
Yes
Go to next step.
No
Check air leakage at intake system.
Check if engine starts easily when throttle valve
is held quarter open.
Does engine start easily?
Yes
Check carbon deposit on throttle valve and go
to step 6.
No
Go to next step.
Yes
Go to next step.
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Does the MIL remain ON after engine start-up?
Check vacuum in intake manifold while engine
is idling.
Vacuum : more than 18.9 in.Hg (480 mmHg)
Is intake manifold vacuum within specification?
Check that fuel line pressure while engine is
idling.
Fuel line pressure : 46~51 psi (320~350 kPa,
3.2~3.5 kg/cm²)
Is fuel line pressure within specification?
Check dondition of ISC valve. Check for open
circuit between ISC valve & ECM.
Measure Battery voltage is applied to R/Y wire
engine running. Check ISC valve hoe
connection. Is ISC valve OK?
Connect data link connector terminals fuel
pump and B+ with a jumper wire and check
than engine starts.
Does engine start?
High pressure :
Disconnect return line from filter side.
Blow through line towards tank.
If line is clear, try with new pressure regulator.
If line is blocked, check for blockage in return
line and clean or replace as necessary
No
Low pressure :
Block return line and check if pressure rises.
If pressure rises, replace pressure regulator.
If pressure does not rise, check fuel filter at fuel
delivery module.
If it is OK, measure fuel pump max.
Pressure and replace as necessary.
Yes
Go to next step.
No
Check for causes.
Yes
Check fuel pump relay.
- If normal, repair or replace wiring harness.
- If not normal, replace relay.
No
Go to next step.
Yes
Go to next step.
Check MAF sensor and related DTC.
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Ebay User ID: reveleus1 Temporarily install a known good MAF sensor
9
10
11
6
Check engine compression pressure.
Engine compression pressure : 184 psi (1275
kPa, 13.0 kg/cm²) at 300 rpm
Is engine compression pressure within
specification?
Check spark plug condition.
Spark plug gap : 0.027~0.03 in (0.7~0.8mm)
Check for exessive carbon deposit and correct
contact with spark plug wires. Are spark plugs
OK?
No
and check for proper operation. If problem is
corrected, replace MAF sensor
Yes
Go to next step.
No
Check engine condition.
- Wear of piston, piston ring and cylinder wall
- Defect of cylinder head gasket
- Deformation of cylinder head
- Improper valve clearance
- Valve stuck to guide
Yes
Go to next step.
No
Clean or replace.
Replace ECM and check for proper operation.
Cranks normally, but hard to start - When engine is cold
· Cranks normally, but cranking time up to starting is excessively long
· Battery is OK
Description
· Restart is normal after engine warmed up
· Engine is normal while engine is idling (Refer to "Rough Iding" if not in good idling condition)
(Troubleshooting hint)
Overrich air/fuel ratio
· Malfunction of mass air flow sensor
· Overlean air/fuel ratio
· Contaminated air cleaner element
· Malfunction of idle speed control
Overlean air/fuel ratio
· Malfunction of injection control (Correction for engine coolant temperature)
Step
1
2
3
Check
Action
Check if malfunction indicator light is
illuminated while ignition switc in ON.
Is MIL illuminated longer than 3 seconds after
ignition switch is turned ON?
Check terminal voltage of mass air flow sensor,
throttle position sensor, ignition coils, engine
coolant temperature sensor.
Are sensors OK?
Check if engine starts easily when throttle valve
is held one quarter open.
Does engine start easily?
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to troubleshooting with
diagnostic trouble codes.
No
Go to next step.
Yes
Go to next step.
No
Check for causes.
Yes
Check carbon deposit on throttle valve and go
to step 6.
No
Go to next step.
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Check vacuum in intake manifold while
engine
Yes
Go to next step.
is idling.
Check air leakage at intake air system
Vacuum : more than 18.9 in.Hg (480 mmHg)
No
component.
Is intake manifold vacuum within specification?
5
Check cleanness of air cleaner element.
Is air cleaner element OK?
6
Connect the data link connector terminals fuel
pump and B+ with a jumper wire and check fuel
line pressure while ignition switch is ON.
Fuel line pressure : 40~51 psi (320~350 kPa,
3.2~3.5 kg/cm²)
Is fuel line pressure within specification?
Yes
Go to next step.
No
Replace air cleaner element.
Yes
Go to next step.
High pressure :
Disconnect return line from filter side.
Blow through line towards tank.
If line is clear, try with new pressure regulator.
If line is blocked, check for blockage in return
line and clean or replace as necessary
No
Low pressure :
Clamp return line and check if pressure rises.
If pressure rises, replace pressure regulator.
If pressure does not rise, check fuel filter at fuel
delivery module.
If it is OK, measure fuel pump max.
Pressure and replace as necessary.
7
Temporarilly install a known good ECM and check for proper operation. If problem is corrected, replace ECM
7
Cranks normally, but hard do start-After engine is warmed up
Descirtion
· After engine is left hot after running, cranks normally, but cranking time up to starting is excessively long
· Battery is OK
· Starts normally when engine is cold
· Engine is normal while engine is idling (Refer to "Rough ldling" if not in good idling condition)
(Troubleshooting hint)
Overrichair/fuel ration
· Malfunction of fuel ignition control
· Fuel leakage from injector
Vapor lock
· Fuel leakage from injector
Step
1
2
Check
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Is MIL illuminated longer than 3 seconds after
ignition switch is turned ON?
Action
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to troubleshooting with
diagnostic trouble codes.
No
Go to next step.
Check terminal voltage of manifold absolute
Yes
Go to next step.
pressure sensor, throttle position sensor,
ignition coils and engine coolant temperature
sensor.
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No
Check for causes.
Are sensors OK?
3
4
5
8
After engine idling and turn ignition switch OFF.
Check that fuel line pressure is retained.
Fuel line pressure : more than 25 psi (180 kPa,
1.8 kg/cm²) for 15 minutes
Is fuel line pressure retention within
specification?
Warm up engine to normal operating
temperature and stop engine. Connect the data
link connector terminals FUEL PUMP and B+
with a jumper wire for 3 minutes while ignition
switch is ON. Then check that engine starts
easily.
Does engine start easily?
Yes
Go to next step.
No
Plug outlet of fuel pressure regulator and turn
ignition switch OFF. Then check that fuel line
pressure is kept.
- If normal : replace fuel pressure regulator
- If not normal : check fuel pump pressure kept.
If fuel pump is normal, check fuel leakage from
injector.
Yes
Replace fuel with another brand.
No
Go to next step.
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
Rough idling/Engine stops while idling - Always
Description · Engine starts normally, but engine stops or vibrates while idling.
(Troubleshooting hint)
Overrich air/fuel ratio
· Air leakage
· Malfunction of fuel injection control
· Low fuel line pressure
Clogging or malfunction of one or more injector
Malfunction of mass air flow sensor
Malfunction of IAC valve
Malfunction of spark plug
Low engine compression pressure
Malfunction of throttle position sensor or related wiring harness
Step
1
2
3
Check
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Does the MIL illuminated longer than 3
seconds after ignition switch is turned ON?
Check terminal voltage of mass air flow sensor,
throttle position sensor, ignition coils, engien
coolant temperature sensor.
Are sensor OK?
Action
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to Troubleshooting
with diagnostic trouble codes.
No
Go to next step.
Yes
Go to next step.
No
Check for causes.
Check operating sound of injector while engine
Yes
Go to step 5.
idling.
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No
Go to next step.
Are injectors operating?
4
5
6
7
8
9
9
Check that approx. battery voltage is applied
on injector connector while ignition switch is
ON (approx. 12V).
Is voltage within specification?
Yes
Go to next step.
No
Check the wiring harness between ECM and
injector.
Check the resistance of injector.
Yes
Go to next step.
Resistance : 13.5~15.5Ω
Is resistance within specification?
No
Replace injector.
Yes
Go to next step.
No
Temporarily install a known good TP sensor
and check for proper operation. If problem is
corrected, replace TP sesnor.
Yes
Go to next step.
No
Temporarily install a known good MAF sensor
and check for proper operation. If problem is
corrected, replace MAF sensor.
Yes
Go to next step.
No
Check engine condition.
- Wear of piston, piston ring and cylinder wall
- Defect of cylinder head gasket
- Deformation of cylinder head
- Valve stuck to guide
Ignition ON, throttle closed, measure voltage of
throttle position sensor 3 (L/O) (0.2~0.8V).
Is voltage within specification?
Check MAF sensor and related DTC.
Is MAF sensor OK?
Check engine compression pressure.
Engine compression pressure : 184 psi (1275
kPa, 13.0 kg/cm²) - 300 rpm
Is engine compression pressure within
specification?
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
Rough idling / Engine stops while engine is idling - Engine cold
Description · Engine speed is slow, engine stops or vibrates while warming up engine.
(Troubleshooting hint)
Insufficient intake air.
· Malfunction of mass air flow sensor
· Clogged air cleaner element
· Malfunction of IAC valve
Malfunction of fuel injection control.
· Malfunction of fuel injection control devices
(correction for engine coolant temperature)
Step
1
Check
Action
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Is MIL illuminated longer than 3 seconds after
ignition switch is turned ON?
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to troubleshooting with
diagnostic trouble codes.
No
Go to next step.
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Check air leakage at intake system and
Yes
Go to next step.
vacuum of dynamic chamber while engine is
idling.
Vacuum : 18.9 in.Hg (480 mmHg) at idle
No
Check air leakage at intake system component.
Is intake manifold vacuum within specification?
3
Check cleanness of air cleaner element.
Is air cleaner element OK?
4
Check terminal voltage of mass air flow sensor,
throttle position sensor, ignition coils, engine
coolant temperature sensor.
Are sensors OK?
Check resistance of engine coolant
temperature sensor.
5
6
10
· At -4°F(-20°C) : 15.4 (+1.79, -1.80) kΩ
· At 68°F(20°C) : 2.45 (+0.19, -0.18) kΩ
· At 176°F(80°C) : 0.318±0.011 kΩ
Is resistance within specification?
Yes
Go to next step.
No
Replace air cleaner element.
Yes
Go to next step.
No
Check for causes.
Yes
Go to next step.
No
Temporarily install a knowin good ECT sensor
and check for proper operation. If problem is
corrected, replace ECT sensor.
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
Rough idling/Engine stops while engine is idling - After engine is warmed up
Description · Engine operation is normal while warming up engine, but engine stops or vibrates after warming up.
(Troubleshooting hint)
Malfunction of IAC valve
Overlean air/fuel ratio
· Air leakage
· Low fuel line pressure
Malfunction of ignition system
Overrich air/fuel ratio
· Malfunction of fuel injection control
(correction for coolant temperature)
Low engine compression pressure
Step
1
2
3
Check
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Is MIL illuminated longer than 3 seconds after
ignition switch is turned ON?
Check terminal voltage of mass air flow sensor,
throttle position sensor, ignition coils, engine
coolant temperature sensor.
Are sensors OK?
Action
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to troubleshooting with
diagnostic trouble codes.
No
Go to next step.
Yes
Go to next step.
No
Check for causes.
Yes
Go to next step.
Check vacuum of intake manifold.
Vacuum : more than 18.9 in.Hg (480 mmHg) at
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Ebay User ID: reveleus1 Check for air leakage at intake system
No
component.
idle
4
5
6
7
Check cleanness of air cleaner element.
Is air cleaner element OK?
Check fuel line pressure while engine is idling.
Fuel line pressure : 46~51 pai (320~350 kPa,
3.2~3.5 kg/cm²)
Is fuel line pressure within specificaiton?
Disconnect engine coolant temperature snesor
connector and check that engine condition
improves.
Does engine condition improve?
Check operating sound of injector while engine
is idling. Are injectors operating?
Yes
Go to next step.
No
Replace air cleaner.
Yes
Go to next step.
High pressure :
Disconnect return line from filter side.
Blow through line towards tank.
If line is clear, try with new pressure regulator.
If line is blocked, check for blockage in return
line and clean or replace as necessary.
No
Low pressure :
Block return line and check if pressure rises.
If pressure rises, replace pressure regulator.
If pressure does not rise, check fuel filter at fuel
delivery module.
If it is OK, measure fuel pump max.
Pressure and replace as necessary.
Yes
Replace the engine coolant temperature sensor.
No
Go to next step.
Yes
Go to step 10.
No
Go to next step.
Yes
Go step 10.
No
Temporarily install a known good injector and
check for proper operation. If problem is
corrected, replace injector.
Yes
Go to next step.
No
Check the engine
Check resistance of injector
8
9
10
11
Description
Resistance : 13.5~15.5Ω
Is resistance within specification?
Check engine compression pressure.
Engine compression pressure : 184psi (1275
kPa, 13.0 kg/cm²) at 300 rpm
Is engine compression pressure within
specification?
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
Rough idling / Engine stops while engine is idling - When A/C is in operation
· Engine stops or vibrates excessively when A/C is operating.
· Idling condition is normal when A/C is turned OFF.
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(Troubleshooting hint)
Malfunction of ISC control system
Malfunction of A/C operational switch
Malfunction of blower switch
Step
1
2
3
4
12
Check
Action
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to troubleshooting with
diagnostic trouble codes.
No
Go to next step.
Check air conditioner cut relay is ON/OFF
when air conditioner swithc is ON/OFF.
Are A/C cut relay, blower switch and A/C switch
OK?
Yes
Go to next step.
No
Malfunction of air conditioner switch, relay, or
blower switch.
Check for continuity between B04-24, B04-23
and B04-36 of ECM.
Does continuity exist?
Yes
Go to next step.
No
Repair wiring harness.
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Is MIL illuminated longer than 3 seconds after
ignition swtich is turned ON?
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
Abnormal idling / Engine stops immediately after starting
· Starting is normal, but engine vibrates excessively or stops immediately after starting (when accelerating
Description from idling condition)
· Idling condition is normal on other conditions.
(Troubleshooting hint)
Malfunction of ISC system
Air leakage at intake system
Malfunction of mass air flow sensor
Step
1
2
3
Check
Action
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Is MIL illuminated longer than 3 seconds after
ignition switch is turned ON?
Check MAF sensor and related DTC.
Is MAF sensor OK?
Check that voltage of throttle position sensor
terminal is 0.2~0.8V and does not vary.
Is voltage within specification?
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to troubleshooting with
diagnostic trouble codes.
No
Go to next step.
Yes
Go to next step.
No
Temporarily install a known good MAF sensor
and check for proper operation. If problem is
corrected, replace MAF sensor.
Yes
Go to next step.
No
Temporarily install a known good TP sensor
and check for proper operation. If problem is
corrected, replace TP sensor.
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Check for air leakage at intake system
andUser ID: reveleus1
Yes
Go to next step.
vacuum of dynamic chamber while engine is
idling.
Vacuum : more than 18.9 in.Hg (480 mmHg)
No
Check intake system and dynamic chamber.
Is intake manifold vacuum within specification?
5
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
13
High idle speed after engine warmed up
Description · Excessively high idle speed after engine warmed up
(Troubleshooting hint)
Excessive intake air flow
Throttle valve not closed completely
Malfunction of idle speed control
· ISC valve stuck
· ISC valve connector disconnected
· Incorrect input signal from coolant temperature sensor
Step
1
2
3
4
5
6
Check
Remedy
Check that throttle valve is closed completely
when accelerator pedal is released.
Is throttle valve closed?
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Is MIL illuminated longer than 3 seconds after
ignition switch is turned ON?
Disconnect engine coolant temperature sensor
connector and check if engine condition
improves.
Does engine condition improves?
Plug PCV hose connected with dynamic
chamber and check engine speed decrease.
Does engine speed decrease?
Check that voltage of throttle position sensor
terminal is 3(L/O) is 0.2~0.8V and does not
vary.
Check ECM terminal voltage.
· ISC valve control
· A/C switch input
· Park/neutral input
Are voltages correct?
Yes
Go to next step.
No
Check correct installation and free operation of
throttle linkage. If not normal, clean or adjust
linkage.
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to Troubleshooting
with diagnostic trouble codes.
No
Go to next step.
Yes
Temporarily install a known good ECT sensor
and check for proper operation. If problem is
corrected, replace ECT sesnor.
No
Go to next step.
Yes
Check or replace the PCV valve.
No
Go to next step.
Yes
Temporarily install a known good TP sensor
and check for proper operation. If problem is
corrected, replace TP sensor.
No
Go to next step.
Yes
Go to next step.
No
Replace as necessary.
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reveleus1
Temporarily install a known good ECM
andUser
check
proper operation. If problem is corrected, replace ECM
14
Variation of idle speed / Idle hunting
Description · Periodic engine speed increase and decrease while engine is idling
(Troubleshooting hint)
Malfunction of throttle position sensor system
Air leakage
Malfunction of IAC control system
Fuel injection is irregular
Malfunction of ignition system
Step
1
2
3
4
5
6
7
8
9
Check
Remedy
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Is MIL illuminated longer than 3 seconds after
ignition switch is turned ON?
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to troubleshooting with
diagnostic trouble codes.
No
Go to next step.
Yes
Go to next step.
No
Temporaily install a known good TP sensor and
check for proper operation. If problem is
corrected, replace TP sensor
Check air cleaner element.
Is air cleaner element OK?
Yes
Go to next step.
No
Replace air cleaner element.
Disconnect high tension cord and check equal
engine speed decrease in all cylinders.
Yes
Go to next step.
No
Go to step 7.
Yes
Go to next step.
No
Check for causes.
Yes
Go to next step.
No
Temporaily install a known good MAF sensor
and check for proper operation. If problem is
corrected, replace MAF sensor
Check operating sound of injector while engine
is idling.
Are injectors OK?
Yes
Go to step 9.
No
Go to next step.
Check that approx. battery voltage is applied to
injector connector terminals.
Is voltage within specification?
Yes
Go to next step.
No
Check the wiring harness between ECM and
injector.
Check resistance of injector
Yes
Go to next step.
Check that voltage of throttle position sensor
terminal 3(L/O) is 0.2~0.8V and does not vary.
Is voltage within specification?
Check ECM terminal voltage.
· ISC valve control
· A/C switch input
· Park/neutral input
Are voltages correct?
Check MAF sensor and related DTC.
Is MAF sensor OK?
Resistance : 13.5~15.5Ω
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Is resistance within specification?
10
11
12
13
Check spark plugs for proper operation.
Are spark plugs OK?
Check engine compression pressure.
Engine compression pressure : 184 psi (1275
kPa, 13 kg/cm²) at 300 rpm
Is engine compression pressure within
specification?
Check for fuel leakage from injectors.
Do injecors leak?
Yes
Go to next step.
No
Clean or replace.
Yes
Go to next step.
No
Check for cause.
Yes
Temporaily install a known good injector sensor
and check for proper operation. If problem is
corrected, replace injector
No
Go to next step.
Temporaily install a known good ECM sensor and check for proper operation. If problem is corrected, replace
ECM
15
Description
Ebay User ID:No
reveleus1 Replace injector.
Engine stalls on deceleration
· Engine stops unexpectedly during or after deceleration
· Idling condition is normal
(Troubleshooting hint)
Engine speed decreases abruptly when accelerator pedal is released, which can cause connectors to come loose.
Malfunction of idle air control
Malfunction of throttle position sensor system
Malfunction of fuel cut control
Step
1
2
3
4
Check
Remedy
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to Troubleshooting
with Diagnostic Trouble Codes.
No
Go to next step.
Check throttle position sensor, ISC valve
terminal voltage and related wiring harness.
Are sensors OK?
Yes
Go to next step.
No
Repair the wiring harness or replace defective
component.
Check ECM terminal voltages for B04-35, B0434, B04-17m B04-15 and B04-7.
Are voltages within specification?
Yes
Go to next step.
No
Check for cause and repair as necessary.
Yes
Go to next step.
No
Repair or replace.
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Is MIL illuminated longer than 3 seconds after
ignition switch turned ON?
Check contact condition of the following
connectors :
- Throttle position sensor, mass air flow sensor,
ignition coils, injector, crankshaft position
sensor, fuel pump relay, ECM.
Are terminal connections OK?
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User
ID:check
reveleus1
Temporaily install a known good ECM
sensor
and
for proper operation. If problem is corrected, replace
ECM
16
Description
Engine stalls suddenly (Intermittent), sudden engine stop
· Engine stops suddenly and intermittently
· Engine is normal until engine stops
(Troubleshooting hint)
Malfunction of IAC control system
Malfunction of throttle position sensor system
Intermittently loosened contact of electrical wiring harness
Step
1
2
3
4
5
Check
Remedy
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to troubleshooting with
diagnostic trouble codes.
No
Go to next step.
Yes
Go to next step.
No
Repair or replace as necessary.
Measure crankshaft position sensor and mass
air flow sensor signals.
Are sensor signals OK?
Yes
Go to next step.
No
Repair or replace.
Check ECM terminal voltages for B04-35, B0434, B04-17m B04-15 and B04-7.
Are voltages OK?
Yes
Go to next step.
No
Check for causes and repair.
Check that malfunction indicator light is
illuminated while ignition swithc is ON.
Is MIL illuminated longer than 3 seconds after
is turned ON?
Check contact condition of the following
connectors :
- Throttle position sensor, mass air flow sensor,
ignition coils, injector, crankshaft position
sensor, fuel pump relay ECM.
Are connections OK?
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
17
Stumble / Hesistation on acceleration
Description · Vehicle seems to stop for a time immediately after pressing accelerator or rattles a little during acceleration
(Troubleshooting hint)
Lean air/fuel ration on acceleration
·Low fuel line pressure
·Air leakage
·Malfunction of fuel injection control
Step
1
Check
Remedy
Malfunction indicator is illuminated. Check for
Check that malfunction indicator light is
Yes
causes. Refer to troubleshooting with
illuminated while ignition switch is ON.
diagnostic trouble codes.
Is MIL illuminated longer than 3 seconds after
ignition switch is turned ON?
No
Go to next step.
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User ID: reveleus1
Check vacuum in intake manifold while
engine
Yes
Go to next step.
idling.
Check air leakage at air intake system and
Vacuum : more than 18.9 in.Hg (480 mmHg)
No
repair.
Is intake manifold vacuum within specification?
3
Check cleanness of air cleaner element.
Is air cleaner element OK?
4
5
6
7
8
9
10
Yes
Go to next step.
No
Replace air cleaner element.
Yes
Go to next step.
No
Temporarily install a known good MAF sensor
and check for proper operation. If problem is
corrected, replace MAF sensor
Check engine coolant temperature sensor and
related DTC.
Is ECT sensor OK?
Yes
Go to next step.
No
Replace the engine coolant temperature sensor.
Check throttle position sensor and related DTC.
Voltage between terminals :
Idling condition : 0.2~0.8V
Throttle valve full open : 4.0~4.8V
Ia TP sensor OK?
Yes
Go to next step.
No
Temporarily install a known good TP sensor
and check for proper operation. If problem is
corrected, replace TP sensor.
Yes
Go to next step.
No
Check injector.
Yes
Go to next step.
No
Adjust or replace joint or damaged linkage and
adjust deflection of throttle cable.
Yes
Go to next step.
Check if MAF sensor is OK?
Disconnect injector connector one by one while
engine is idling, and check equal engine speed
decrease for each cylinder.
Does engine speed decrease equally for all
cylinders?
Check correct installation and free operation of
throttle linkage.
Is throttle linkage OK?
Check fuel line pressure while engine is idling.
Fuel line pressure : 46~51 psi (320~350 kPa,
3.2~3.5 kg/cm²)
High pressure :
Disconnect return line from filter side.
Blow through line towards tank.
If line is clear, try with new pressure regulator.
If line is blocked, check for blockage in return
line and clean or replace as necessary.
No
Low pressure :
Block return line and check if pressure rises.
If pressure rises, replace pressure regulator.
If pressure does not rise, check fuel filter at fuel
delivery module.
If it is OK, measure fuel pump max.
Pressure and replace as necessary.
Check air passage and vacuum hose
Yes
Go to next step.
installation.
Email: suzlever@gmail.com
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No
Repair as necessary.
Are vacuum hoses OK?
11
12
Check exhaust system clogging.
Is exhaust system clogged?
Yes
Repair or replace necessary.
No
Go to next step.
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
18
Surging while cruising
Description · Repeated engine speed variation occurs at all times
(Troubleshooting hint)
Malfunction of throttle position sensor system
Misfire
Loose contact of wiring harness
Lean air/fuel ratio
Step
1
2
3
4
5
6
7
8
Check
Remedy
Yes
Malfunction indicator is illuminated. Check for
causes. Refer to troubleshooting with
diagnostic trouble codes.
No
Go to next step.
Check vacuum in intake manifold while engine
idling.
Vacuum : more than 18.9 inHg (480 mmHg)
Is intake manifold vacuum within specification?
Yes
Go to next step.
No
Check air leakage at air intake system and
repair.
Check throttle position sensor.
Voltage between terminals :
Idling condition : 0.2~0.8V
Throttle valve full open : 4.0~4.8V
Is TP sensor OK?
Yes
Go to next step.
No
Temporarily install a known good TP sensor
and check for proper operation. If problem is
corrected, replace TP sensor.
Disconnect front heated oxygen sensor
connector and check for proper operation.
Is front HO2S OK?
Yes
Go to next step.
No
Replace front heated oxygen sensor.
Check that vehicle speed sensor signal input to
ECM B02-18.
Is correct. Is signal correct?
Yes
Go to next step.
No
Replace the wiring harness or vehicle speed
sensor.
Check ECM terminal voltages for B04-17, B0315, and B04-7. Are voltages OK?
Yes
Go to next step.
No
Check for causes and repair.
Check correct installation and free operation of
throttle linkage.
Is throttle linkage OK?
Yes
Go to next step.
No
Adjust or replace joint or damaged linkage and
adjust deflection of throttle cable.
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Is MIL illuminated longer than 3 seconds after
ignition switch is turned ON?
Yes
Go to next step.
Check cleanness of air cleaner element.
Is air cleaner element OK?
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No
Replace air cleaner element.
Yes
9
10
11
Check fuel line pressure while engine is idling.
Fuel line pressure : 46~51 psi (320~350 kPa,
3.2~3.5 kg/cm²)
Is fuel line pressure within specification?
Check exhaust system clogging.
Is exhaust system clogged?
Go to next step.
High pressure :
Disconnect return line from filter side.
Blow through line towards tank.
If line is clear, try with new pressure regulator.
If line is blocked, check for blockage in return
line and clean or replace as necessary.
No
Low pressure :
Block return line and check if pressure rises.
If pressure rises, replace pressure regulator.
If pressure does not rise, check fuel filter at fuel
delivery module.
If it is OK, measure fuel pump max.
Pressure and replace as necessary.
Yes
Repair as necessary.
No
Go to next step.
Tempoarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM.
19
Lack of power
· Lack of power at full throttle
Description · Lower maximum vehicle speed
· Idling speed is normal
(Troubleshooting hint)
Insufficient intake air
·Throttle valve does not open fully
·Clogged intake air system
Lean air/fuel ratio
· Fuel line pressure decrease.
· Malfunction of fuel injection.
Malfunction of ignition
Low engine compression pressure
Step
1
2
Check
Remedy
Check the following items.
- Clutch slippage
- Brake dragging
- Lack of tire air pressure
- Improper tire size
Are these systems OK?
Is throttle valve fully open when fully
depressing accelerator pedal fully?
Yes
Go to next step.
No
Repair as necessary.
Yes
Go to step 5.
No
Go to next step.
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3
Ebay User
ID: reveleus1
Yes
Go to next step.
Check correct installation of throttle cable.
Is
throttle cable OK?
No
Repair or replace throttle cable.
4
Check correct operation of throttle body. Is
throttle body OK?
5
6
7
8
9
10
11
12
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Is MIL illuminated longer than 3 seconds after
ignition switch is turned ON?
Check the camshaft position sensor and DTC
related.
Is CMP sensor OK?
Check throttle position sensor and related DTC
Voltage between terminals :
Idling condition : 0.2~0.8V
Throttle valve full open : 4.0~4.8V
Is TP sensor OK?
Check vacuum in intake manifold while engine
is idling.
Vacuum : more than 18.9 in.Hg (480 mmHg)
Is intake manifold vacuum within specification?
Disconnect injector connector one by one while
engine is idling, and check equal engine speed
decrease for each cylinder.
Does engine speed decrease equally for each
cylinder?
Check cleanness of air cleaner element.
Is air cleaner element OK?
Keep engine idling and turn ignition switch OFF.
Check that fuel line pressure is retained.
Fuel line pressure : more than 25 (180 kPa, 1.8
kg/cm²) for 15 minutes.
Is fuel pressure retention within specification?
Does fuel line pressure increase when
accelerating abruptly?
Fuel line pressure : 48 psi (330 kPa, 3.3 kg/cm²)
Yes
Go to next step.
No
Repair or replace throttle body.
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to Troubleshooting
with OBD-II Diagnostic Trouble Codes.
No
Go to next step.
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to trouble shooting
with diagnostic trouble codes.
No
Go to next step.
Yes
Go to next step.
No
Temporarily install a known good CMP sensor
and check for proper operation. If problem is
corrected, replace CMP sensor
Yes
Go to next step.
No
Repair intake system and dynamic chamber.
Yes
Go to next step.
No
Check injector.
Yes
Go to next step.
No
Replace air cleaner element.
Yes
Go to next step.
No
Plug outlet of pressure regulator and turn
ignition switch OFF. Then check fuel line
pressure is kept.
- If normal : replace pressure regulator.
- If not normal : check fuel pump pressure kept.
If fuel pump is normal, check fuel leakage from
injector.
Yes
Go to next step.
No
Check fuel line and fuel filter clogging and
repair if not normal.
Yes
Go to next step.
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13
Check the MAF sensor and related DTC.
Ebay User ID: reveleus1 Temporarily install a known good MAF and
Is MAF sensor OK?
No
check for proper operation. If problem is
corrected, replace MAF sensor.
Check ignition system.
- Check resistance of DLI coil
14
15
16
17
18
Yes
Go to next step.
No
Replace ignition coils or repair wiring harness.
Check spark plug wires.
Are spark plug wires OK?
Yes
Go to next step.
No
Replace spark plug wires.
Check spark plug.
Are spark plugs OK?
Yes
Go to next step.
No
Clean or replace.
Yes
Go to next step.
No
Check engine condition.
- Wear of piston, piston ring and cylinder wall
- Defect of cylinder head gasket
- Deformation of cylinder head
- Improper valve clearance
- Valve guide stuck
Primary : 0.6~0.8Ω
Secondary : 11~15 kΩ
- Check wiring harness between DLI coil and
ECM
Is ignition system OK?
Check engine compression pressure.
Engine compression pressure : 184 psi (1275
kPa, 13.0 kg/cm²) at 300 rpm
Is engine compression pressure within
specification?
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
20
Poor acceleration/Lack of power
· Lack of power on acceleration
· Lack of power at full throttle
Description
· Lower maximum vehicle speed
· Idling speed is normal
(Troubleshooting hint)
Factors except engine malfunction
· Clutch slippage
· Brake dragging
· Lack of tire air pressure
· Improper tire size
· Overload
Insufficient intake air
· Throttle valve does not open fully
· Intake system clogging
Overlean air/fuel ratio
Malfunction of ignition
Low engine compression pressure
Step
Check
Remedy
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1
2
3
4
5
6
7
8
9
10
Check the following items.
- Clutch slippage
- Brake dragging
- Lack of tire air pressure
- Improper tire size
- Overload
Are the items OK?
Ebay User ID: reveleus1
Yes
Go to next step.
No
Repair as necessary.
Is throttle valve open full when fully depressing
accelerator pedal fully?
Yes
Go to step 5.
No
Go to next step.
Check correct installation of throttle cable.
Is throttle cable OK?
Yes
Go to next step.
No
Repair or adjust throttle cable.
Check correct operation of throttle body.
Is throttle body OK?
Yes
Go to next step.
No
Repair or replace throttle body
Yes
Malfunction indicator light is illuminated.
Check for causes. Refer to troubleshooting with
diagnostic trouble codes.
No
Go to next step.
Yes
Go to next step.
No
Replace camshaft position sensor or repair
related wire harness.
Check throttle position sensor.
Voltage between terminals :
Idling condition : 0.2~0.8V
Is TP sensor OK?
Yes
Go to next step.
No
Temporarily install a known good TP sensor
and check for proper operation. If problem is
corrected, replace TP sensor.
Check vacuum in intake manifold while engine
is idling.
Vacuum : more than 18.9 inHg (480 mmHg)
Is intake manifold vacuum within specification?
Yes
Go to next step.
No
Check air leakage into intake system and repair
as neessary..
Disconnect injector connector one by one while
engine is idling, and check equal engine speed
decrease for each cylinder?
Yes
Go to next step.
No
Check injectors.
Check cleanness of air cleaner element.
Is air cleaner element OK?
Yes
Go to next step.
No
Replace air cleaner element.
Yes
Go to next step.
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Is MIL illuminated longer than 3 seconds after
ignition switch is turned ON?
Check camshaft position sensor and connector.
Is CMP sensor OK?
Replace air cleaner element.
Fuel line pressure : 46~51 psi (320~350
Email:kPa,
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11
12
13
14
15
16
17
18
3.2~3.5 kg/cm²)
Ebay User ID: reveleus1 High pressure :
Is fuel line pressure within specification?
Disconnect return line from filter side.
Blow through line towards tank.
If line is clear, try with new pressure regulator.
If line is blocked, check for blockage in return
line and clean or replace as necessary.
No
Low pressure :
Block return line and check if pressure rises.
If pressure rises, replace pressure regulator.
If pressure does not rise, check fuel filter at fuel
delivery module.
If it is OK, measure fuel pump max.
Pressure and replace as necessary.
Yes
Go to next step.
No
Check fuel line and fuel filter clogging and
repair as necessary.
Yes
Go to next step.
Check the MAF sensor and related DTC.
Is MAF sensor OK?
No
Temporarily install a known good MAF sensor
and check for proper operation. If problem is
corrected, replace MAF sensor.
Check ignition system.
-Check resistance of DLI coil
Yes
Go to next step.
No
Replace ignition coils or repair wiring harness.
Yes
Go to next step.
No
Replace spark plug wires.
Yes
Go to next step.
No
Clean or replace as necessary.
Yes
Go to next step.
No
Check engine condition.
- Wear of piston, piston ring and cylinder wall
- Defect of cylinder head gasket
- Deformation of cylinder head
- Improper valve clearance
- Valve guide stuck
Does fuel line pressure increase when
accelerating abruptly.
Fuel line pressure : 48 psi (330 kPa, 3.3 kg/cm²)
Primary : 0.6~0.8Ω
Secondary : 11~15 kΩ
Check wiring harness between DLI coils and
ECM.
Is ignition system OK?
Check spark plug wires.
Are spark plug wires OK?
Check spark plug
- Spark plug gap : 0.027~0.031 in (0.7~0.8mm)
- Excessive carbon deposit
- Contact with high tension cord
Are spark plugs OK?
Check engine compression pressure.
Engine compression pressure : 184 psi (1275
kPa, 13.0 kg/cm²) at 300 rpm
Is engine compression pressure within
specification?
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
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Rough dngine runnin on deceleration / Backfire
21
Description
· Rough engine running on deceleration and backfire
· Transmission is normal
(Troubleshooting hint)
Overrich air/fuel ratio
· Air cleaner element clogged
· Malfunction of fuel injection system(fuel cut control)
· Fuel leakage from injector
· Malfunction of throttle position sensor
Step
1
2
3
4
5
6
7
8
9
Check
Remedy
Yes
Malfunction indicator light is illuminated,
Check for causes. Refer to Troubleshooting
with diagnostic trouble codes.
No
Go to next step.
Yes
Go to next step.
No
Go to next step.
Check cleanness of air cleaner element.
Is air cleaner element OK?
Yes
Go to next step.
No
Check air leakage into air intake system.
Check ECM terminal voltages for B04-20, B0418, B05-6 and B05-4.
Are terminal voltages OK?
Yes
Go to next step.
No
Replace air cleaner element.
Check fuel injection system.
Is fuel injection system OK?
Yes
Go to next step.
No
Check injection system as necessary.
Check mass air flow sensor and related DTC.
Is MAF sensor OK?
Yes
Go to next step.
No
Repair injection system as necessary.
Yes
Go to next step.
No
Temporarily install a known good MAF sensor
and check for proper operation. If problem is
corrected, replace MAF sensor.
Check throttle body contamination.
Is throttle body contaminated?
Yes
Clean or replace as necessary.
No
Go to next step.
Check fuel leakage from injector.
Yes
Go to next step.
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Is MIL illuminated longer than 3 seconds after
ignition switch is turned ON?
Check vacuum in intake manifold while engine
is idling.
Vacuum : more than 18.9 mmHg (480 mmHg)
Is intake manifold vacuum within specification?
Check throttle position sensor and DTC related
to sensor.
- Voltage between terminals
· When idling : 0.2~0.8V
· When opening throttle valve fully : 4.0~4.8V
- Check that idling voltage returns to specified
value when releasing after pulling accelerator
cable.
Is TP sensor OK?
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Ebay User ID: reveleus1
No
Clean or replace as necessary.
Do fuel injectors leak?
10
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
22
Knocking
Description · Abnormal combustion occurs, accompanied by audible "pinging" noise
(Troubleshooting hint)
Improper ignition timing
Carbon deposit in cylinder
Engine Overheat
Overlean air/fuel ratio
· Incorrect fuel injection
· Fuel line pressure decrease on acceleration
Step
1
2
3
4
5
6
Check
Remedy
Yes
Malfunction indicator light is illuminated. Check
for causes. Refer to troubleshooting with
diagnostic trouble code.
No
Go to next step.
Is throttle valve open fully when depressing
accelerator pedal fully?
Yes
Go to step 5.
No
Go to next step.
Check correct installation of throttle cable.
Is throttle cable OK?
Yes
Go to next step.
No
Repair of replace throttle cable.
Check correct installation of throttle body.
Is throttle body OK?
Yes
Go to next step.
No
Repair or replace throttle body.
Yes
Go to next step.
No
Check engine condition.
- Wear of piston, piston rign and cylinder wall
- Defect of cylinder head gasket
- Deformation of cylinder ead
- Improper valve clearnace
- Valve stuck to guide
Yes
Go to next step.
No
Temporarily install a known good CMP sensor
and check for proper operation. If problem is
corrected, replace CMP sensor
Yes
Go to next step.
Check that malfunction indicator light is
illuminated while ignition switch is ON.
Is MIL illuminated longer than 3 seconds after
ignition switch is turned ON?
Check engine compression pressure
Engine compression pressure : 184 psi (1275
kPa, 13.0 kg/cm²)
Is engine compression pressure within
specification?
Check camshaft position sesnor.
Is CMP sensor OK?
Check fuel line pressure while engine
is idling.
Email:
suzlever@gmail.com
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7
8
9
Ebay
User ID: reveleus1 High pressure :
Fuel line pressure : 46~51 psi (320~350
kPa,
3.3~3.5 kg/cm²)
Disconnect return line from filter side.
Is fuel line pressure within specification?
Blow through line towards tank.
If line is clear, try with new pressure regulator.
If line is blocked, check for blockage in return
line and clean or replace as necessary.
Check cooling system.
Is cooling system OK?
No
Low pressure :
Clamp return line and check if pressure rises.
If pressure rises, replace pressure regulator.
If pressure does not rise, check fuel filter at fuel
delivery module.
If it is OK, measure fuel pump max.
Pressure and replace as necessary
Yes
Go to nest step.
No
Repair or replace.
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
23
Fuel odor
Description · Fuel odor in passenger compartment
(Troubleshooting hint)
Loose connection of fuel system of evaporative gas control system
Malfunction of evaporative gas control system
Step
1
2
3
4
5
Check
Check damage or leakage of fuel system or
evaporative gas control system.
Is systems leaking or damaged?
Check that malfunction indicator light is
illuminated while ignition system is ON.
Is MIL illuminated longer than 3 seconds after
ignition switch ON?
Warn up engine fully. After disconnecting
vacuum hose from evaporative emissions
canister to purge solenoid valve, check vacuum
is applied to it.
Is vacuum applied?
Check operational sound of EVAP canister
purge solenoid valve is normal.
Is EVAP canister purge valve OK?
Remedy
Yes
Repair or replace
No
Go to next step.
Yes
Malfunction indicator light is illuminated. Check
for causes. Refer to troubleshooting with
diagnostic trouble codes.
No
Go to next step.
Yes
Go to step 6.
No
Go to next step.
Yes
Check vacuum hose clogging.
No
Go to next step.
Check vacuum is applied to vacuum hose after
Yes
Check ECM terminal voltage.
applying battery voltage to EVAP canister
purge solenoid valve.
Is vacuum applied?
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No
Replace EVAP canister purge valve.
6
Temporarily install a known good ECM and check for proper operation. If problem is corrected, replace ECM
24
High oil consumption
Description · High oil consumption
(Troubleshooting hint)
Malfunction of PCV valve
Malfunction of engine (oil leakage)
Step
1
2
3
Check
Remedy
Check damage, removal, clogging or sticking of
PCV hose, nipples of ventilation hose fittings.
Is PCV system OK?
Check that there is air pressure or oil in
ventilation hose.
Is ventilation hose OK?
Check vacuum is applied on PCV valve while
engine is idling.
Is vacuum applied?
25
Yes
Go to next step.
No
Repair or replace as necessary.
Yes
Go to next step.
No
Check engine condition
- Oil leakage
-Wear of valve seal
-Wear of valve stem
-Wear of valve guide
Yes
Check engine condition.
-Wear of piston ring groove
-Malfunction of piston ring
-Wear of piston or cylinder
No
Replace the PCV valve.
MIL light ON continuously
Description · Hi-scan does not display diagnostic trouble code, but MIL on continuously
(Troubleshooting hint)
Short circuit of wiring harness
Malfunction of ECM
Step
1
26
Check
Remedy
Disconncet wire (L/Y) from ECM and check that
MIL remains illuminated.
Is MIL illuminated?
Yes
Temporarily install a known good ECM and
check for proper operation. If problem is
corrected, replace ECM
No
Check short circuit from meter set to ECM.
MIL does not light
Description · Hi-scan displays malfunction code, but MIL does not illuminate
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(Troubleshooting hint)
Blub is blown
Open circuit
Step
1
2
3
Check
Remedy
Check bulb is OK.
Is bulb OK?
Yes
Go to next step.
No
Replace bulb.
Ground ECM wire (L/Y) with a jumper wire and
check that MIL illuminates.
Does MIL illuminate?
Yes
Go to next step.
No
Repair wiring harness from ECM to meter set.
Yes
Temporarily install a known good ECM and
check for proper operation. If problem is
corrected, replace ECM
No
Repair or replace ECM connector.
Check ECM connections.
Are ECM connections OK?
27
Air conditioner does not operate
Description · Blower motor operates, but magnetic clutch not engaged
(Troubleshooting hint)
Short or open circuit of wiring harness
Malfunction of air conditioner relay, air conditioner switch, magnetic switch
Malfunction of ECM
Step
1
2
Check
Remedy
Check voltage of ECM terminal B04-23.
Is voltage OK?
Check voltage of ECM terminal B04-24.
Is voltage OK?
Yes
Go to next step.
No
Check for causes.
Yes
Check air condition system.
No
Temporarily insatall a known good ECM and
check for proper operation. If problem is
corrected, replace ECM
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ENGINE COOLANT TEMPERATURE SENSOR
The Engine Coolant Temperature (ECT) Sensor provides an input voltage to the ECM relating to coolant
temperature. The ECM uses this input signal along with inputs from other sensors to determine injector pulse width
and ignition timing. As coolant temperaure varies the ECT Sensor's resistance changes. The change in resistance
results in a different input voltage to the ECM. When the engine is cold, the ECM will operate in Open Loop cycle.
It will demand slightly richer air/fuel mixtures and higher idle speeds until normal temperatures are reached.
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FUEL PUMP OPERATION
1. Connect data link connector terminals FUEL PUMP and B+ with jumper wire.
2.
3.
4.
5.
Remove fuel filler cap.
Turn ignition switch ON.
Determine if fuel pump is running by listening for sound of it at fuel filler inlet.
Connect negative battery terminal.
The fuel system remains under pressure when the engine is not running. Release fuel system pressure before
disconnecting any fuel line to reduce the chance of personal injury or fire damage to vehicle components.
6. Connect data link connect terminals FUEL PUMP and B+ with jumper wire.
7. Turn ignition switch ON
8. Measure fuel pump maximum pressure.
Fuel pump maximum pressure : 65~94 psi (450~650 kPa, 4.5~6.5 kg-m)
9. If not within specification, replace fuel delivery module.
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QUICK CONNECTOR
• Position quick connector to male pipe (direction "A") and push quick connector until retainer lock in and a click
is heard.
REMOVAL
Release fuel system pressure before servicing any fuel system connection.
1. Push quick connector to direction "A"
2. Squeeze both sides of lock retainer and pull connection apart to direction "B".
Don's push and pull too hard.
INSPECTION
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• Once installed, pull and push quick connector
to direction
"A" and "B" to make sure the connection is secure.
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Don't press lock retainer.
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FUEL PUMP RELAY INSPECTION
CHECK OPERATION
The fuel system remains under pressure when the engine is not running. Release fuel system pressure before
disconnecting any fuel line to reduce the chance of personal injury or fire damage to vehicle components.
Listen for fuel pump relay clicking as ignition switch is turned "ON".
CONTINUITY INSPECTION
• Check continuity between relay terminals.
B+ : Battery positive voltage
Terminal 85-86
Terminal 87-30
Apply B+ and ground
Continuity
B+ and ground not applied
No continuity
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COMPONENTS
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REMOVAL
1.
2.
3.
4.
Disconnect negative battery cable.
Remove rear seat.
Remove fuel pump cover, and then disconnect fuel pump connector.
Remove components in the order shown in above figure.
FUEL TANK PRESSURE SENSOR
1.
2.
3.
4.
Reconnect tank pressure sensor connector.
Vent fuel tank by removing fuel filler cap.
Turn ignition switch to ON position.
Using voltmeter, measure voltage at all three(3) fuel tnak pressure sensor terminals in the fuel tank sending unit
connector.
3(W)-2.0~3.0V (Signal return voltage/base reading)
5. If signal voltage reads 5.0 volts, check the sensor ground wire.
1(BR)-0.0V (sensor ground)
2(L)-5.0V (reference voltage)
6.
7.
8.
9.
Disconnect hose from fuel tnak at evaporative emissions canister.
Connect hand-held vacuumpump to hose.
Connect voltmeter between fuel tank round and the W wire in the fuel tank sending unit connector.
With ignition switch in the ON position, verify than voltage goes down when vacuum is applied to when pressure
is applied.
10. Disconnect fuel tank pressure sensor connector, then remove the retainer nut, and remove fuel tnak pressure
sensor from the tank.
11. Remove screw attaching fuel tnak pressure sensor ground wire to the fuel tnak sending unit mounting plate.
12. Measure fuel tnak pressure sensor resistance.
1(BR)-3(W) : 5.0~6.0 kΩ
1(BR)-2(L) : 2.5~3.0kΩ
2(L)-3(W) : 5.0~6.0kΩ
13. If not within specification, replace the fuel tank pressure sensor.
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ECM terminal voltage(Connector B-01)
Terminal
Signal
Connected to
Test condition
Voltage
9
Power input
Ignition switch
Key ON
B+
8
Power input
Ignition switch
Key ON
B+
1
Ignition input
Ignition switch
Key ON
B+
4
Ground
Ground
Constant
<0.5V
6
Ground
Ground
Constant
<0.5V
5
Ground
Ground
Constant
<0.5V
3
Diagnosis K-line
7
Power
Data link connector
Battery
-
-
Constant
B+
ECM terminal voltage(Connector B-02)
Terminal
20
18
12
9
15
17
Signal
Connected to
Test condition
Canister close valve
control
Canister close valve
Wheel speed sensor
input
Wheel speed sensor
Wheel speed sensor
ground
Wheel speed sensor
Constant
Fuel tank pressure
ground
Fuel tank
Constant
Fuel tank pressure
input
Fuel tank
HO2S down input
HO2S down
Voltage
Non-operation
B+
Operation
<1V
Wheel stop
Wheel rolling
Key ON/ENG OFF
0V or 5V
1~2V (wave)
<1V
<1V
5V
2~3V
Key ON/ENG OFF
Idle
11
HO2S down ground
HO2S down
19
HO2S down heater
HO2S down
04V
0-1V
Constant
Key ON/ENG OFF
Idle
B+
B+
6~8V (duty 48~52%)
ECM terminal voltage(Connector B-03)
Terminal
47
Signal
Fuel injection valve
control
Connected to
Fuel injector No. 2
Test condition
Key ON/ENG OFF
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Voltage
B+
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48
49
Fuel injection valve
control
Fuel injector No. 4
Fuel injection valve
control
Fuel injector No.1
Key ON/ENG OFF
Idle
Key ON/ENG OFF
Idle
50
31
Fuel injection valve
control
Fuel injector No. 3
Engine RPM signal
output
Instrument cluster
TPS signal output
Transaxle control
module
Key ON/ENG OFF
Idle
Key ON/ENG OFF
B+ (duty)
B+
B+ (duty)
B+
B+ (duty)
B+
B+ (duty)
B+
Idle
6-7V(duty 45~50%)
Key ON(throttle valve
close)
1-2V(duty 8~12%)
Key ON (throttle valve
open)
8-12V (duty 88~92%)
28
27
Torque signal output
15
TPS voltage
42
EVAP purge solenoid
valve
44
ISC valve output
control
Transaxle control
module
TPS
1-2V(duty 8~12%)
Key ON
B+
EVAP purge solenoid
valve
Key ON/ENG OFF
B+
ISC valve
Key ON/ENG OFF
(closing)
43
Idle
Idle
Idle
ISC valve output
control
ISC valve
Key ON/ENG OFF
(opening)
ISC valve
Idle
10~12V (duty)
6-7V(duty 42~52%)
9-10V(duty60-70 %)
7-8V(duty 50~60%)
4-6V (duty 30~40%)
20
Knock sensor shield
Knock sensor
Constant
<0.5V
33
Knock sensor ground
Knock sensor
Constant
<0.5V
46
Knock sensor input
Knock sensor
Key ON
2-3V
MAF sensor
Key ON
0.5V
MAF sensor input
36
Idle
MAF sensor ground
MAF sensor
Constant
0.6-0.8V
<1V
23
HO2S up input
HO2S up
Idle
0- B+
Key ON/ENG OFF
0.4V
Idle
0-1V
35
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22
HO2S up ground
40
HO2S up heater
control
9
Power input
16
Power output
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HO2S
HO2S up
<1V
Key ON/ENG OFF
Idle
Ignition switch
B+
6-8V(duty 48~52%)
Key ON
B+
Tank pressure sensor Key ON
5V
ECM terminal voltage(Connector B-04)
Terminal
33
36
23
24
25
37
30
26
34
7
Signal
Connected to
Cooling fan relay control
Key ON/cooling fan
non-operation
B+
Key ON/cooling fan
operation
<1V
A/C non-operation
B+
A/C operation
<1V
A/C non-operation
B+
A/C operation
<1V
A/C switch ON
B+
A/C switch OFF
<1V
Key ON/switch
operation
<1V
Key ON/switch nonoperation
B+
Key ON/ENG OFF
<1V
Idle (DTC nonpresent_
B+
Idle (DTC present)
<1V
Key ON (P/N range)
<1V
Key ON (other range)
B+
Key ON/switch HEAD
B+
Key ON
<1V
A/C relay
DPS signal input
DPS
A/C switch signal input
A/C switch
Power steering switch input
Power steering switch
MIL (instrument
cluster)
MIL control
Transaxle control
module
Park/Neutral signal input
Headlight switch signal input
TPS ground
Voltage
cooling fan relay
A/C relay control
Main relay control
Test condition
Headlight switch
Key ON (throttle valve
close)
0.2~0.8V
Key On (throttle valve
open)
4.0~4.7
Main relay
TPS
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<1V
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Key ON/ENG OFF
0V or 5V
Camshaft position sensor signal
input
Camshaft position
sensor
8
Camshaft position sensor ground
Camshaft position
sensor
11
Intake air temperature sensor
signal input
Intake air temperature Key ON/ENG OFF (at
sensor
20°C)
1-2V
1
Intake air temperature sensor
ground
Intake air temperature
Constant
sensor
<1V
35
Fuel pump relay control
Fuel pump
18
Idle
Constant
2-3V (duty
40~50%)
<1V
Key ON/ENG OFF
B+
Idle
<1V
Key ON/ENG OFF
<0.5V
Crankshaft position sensor signal
input
Crankshaft position
sensor
10
Crankshaft position sensor ground
Crankshaft position
sensor
Constant
29
Torque reduction control
Transaxle control
module
-
9-10V
15
Engine coolant temperature signal Engine coolant
input
temperature
Key ON/ENG OFF (at
80°C)
1-2V
5
Engine coolant temperature
ground
Engine coolant
temperature
Constant
<1V
TCU MIL signal input
Transaxle control
module
-
Vehicle speed sensor input
Vehicle speed snesor
20
27
Idle
Vehicle stop
22
Vehicle rolling
32
MISS CAP control
MISS CAP
(instrument cluster)
2-3V (duty
40~50%)
<1V
0V or 5V
0V/5V
2-3V
Missing cap
1V
ECM terminal voltage(Connector B-05)
Terminal
Signal
Ignition coil control
Connected to
Test condition
Ignition coil
Key ON/ENG OFF
(cylinder no. 1 & 4)
Idle
Ignition coil
Key ON/ENG OFF
(cylinder no 2 & 3)
Idle
Voltage
B+
4
Ignition coil control
B+ (pulse)
B+
6
DIAGNOSTIC TROUBLE CODES RETRIEVAL PROCEDURE
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B+ (plse)
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1. Connect the Hi-scan pro to the Data Link Connector
(DLC).
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2. Turn the ignition switch ON.
3. Retrieve any DTC in ECM memory.
CLEARING DIAGNOSTIC TROUBLE CODES
1. Connect the Hi-scan pro to the Data Link connector (DLC).
2. Turn the ignition switch ON.
3. Erase any DTC stored in ECM
Data link connector 20 pin layout
PIN NO.
Terminal function
a
Potwer supply for fuel pump test
b
Power supply for IG "ON"
d
Cooling fan test
f
Air bag unit
h
ABS unit
k
Communication diagnosis terminals for Hi-scan pro
m
Fail code output terminal for A/T vehicle
n
Test ground for A/T vehicle
o
Engine rpm check terminal
p
Engine fail code output terminal
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r
Ground
s
Ground
t
Engine monitor terminal
Data link connector 20 pin layout
PIN NO.
Terminal function
4
Ground
5
Ground
7
Communication diagnosis terminal
16
Power supply (ECU 10A)
RELEASING FUEL SYSTEM PRESSURE
The fuel system remains under pressure when the engine is not running. Release fuel system pressure before
disconnectingany fuel line to reduce the chance of personal injury or fire damage to vehicle components.
1.
2.
3.
4.
Start engine.
Disconnect fuel pump connector located below rear seat cushion.
Let engine stall, then turn OFF ignition switch.
Reconnect fuel pump connector.
FUEL LINE HANDING
Fuel is explosive. When working on fuel system make sure to supply adequate ventilation to the work area. Do not
smoke, and keep sparks and open flames away.
1. When disconnecting fuel hose quick connectors, use shop towels to absorb fuel, protecting equipment and personnel.
PRIMING THE FUEL SYTEM
After fuel pressure has been released, system must be primed to avoid excessive cranking to restart the engine.
Follow steps below :
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1. Connect data link connector terminals FUEL PUMP
a jumper wire.
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2. Turn ignition switch ON for no longer then 10 seconds to pressurize system and check for fuel leaks.
(Jumper wire gets hot if it is left in for longer than 10 seconds.)
3. Turn ignition switch OFF and remove jumper wire.
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Precautions for symptom diagnosis
Fuel system pressure release
The fuel system remains under pressure when the engine is not running. Release fuel system pressure before
disconnectingany fuel line to reduce the chance of personal injury or fire damage to vehicle components. Fuel is explosive.
An emptyfuel tank can still contain explosive gases. Supply adequate ventilation to the work area. Do not smoke, and keep
sparks and open flames away. Refer to fuel system pressure release procedure.
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HEATED OXYGEN SENSOR (HO2S)
Two heated O2 Sensors are used in the vehicle. The sensors produce voltages from 0 to 1 volt, depending upon
the oxygen content of the exhaust has in the exhaust manifold. When a large amount of oxygen is present (caused
by a lean air/fuel mixture), the sensors produce a low voltage. When a large amount of oxygen is present (caused
bya lean air/fuel mixture), the sensors produce a low voltage. When there isa lesser amount (rich air/fuel mixture)
the sensors produce a higher voltage.By monitoring the oxygen content and converting it to electrical voltage,the
sensors act as a rich-lean switch.
Both HO2 Sensors are equipped with a heating element that keeps thesensors at proper operating temperature
during all modes of operation. maintainingcorrect sensor temperature at all times allows the system to enter into
closedloop operation faster and allows the system to remain in closed loop duringperiods of extended idle.
FRONT HO2 SENSOR
The front (upstream) HO2 Sensor is located in the exhaust downpipe afterthe TWC and provides an input voltage
to the ECM. The input tells the ECMthe oxygen content of the exhaust gas. The ECM uses this information to
finetune the air/fuel ratio by adjusting injector pulse width.
REAR HO2 SENSOR
The rear (downstream) HO2 Sensor is located near the outlet end of thecatalytic convertor. The rear HO2 Sensor
input is used to detect catalyticconvertor deterioration. As the convertor deteriorates, the input from thedownstream
sensor begins to match the upstream sensor input except for a slighttime delay. By comparing the rear HO2
Sensor input to the input from the frontsensor, the ECM calculates catalytic convertor efficiency.
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INSPECTION OF TERMINAL VOLTAGE FOR FRONT & REAR HEATED OXYGEN
SENSOR
1.
2.
3.
4.
5.
Warm up the engine to normal operating temperature.
Run engine at idle speed.
Connect a voltmeter between terminal 1 (LG/R) and ground.
Increase and decrease engine speed quickly several times.
Verify that meter reading varies between 0~1.0V.
Rear oxygen sensor voltage does not fluctuate as quickly as front oxygen sensor.
6. If not as specified, inspect :
A.On-board diagnostic system
B.System inspection
C.Intake manifold vacuum
D.Fuel line pressure
7. If all systems are normal, replace the heated oxygen sensor.
INSPECTION OF FRONT & REAR HEATED OXYGEN SENSOR
1. Ensure ignition switch is OFF.
2. Disconnect heated oxygen sensor connector.
3. Connect ohmmeter between terminals 1 and 3 and measure resisance.
Specification : Approx. 3~7Ω (68°F(20°C))
4. If not as specified, replace heated oxygen sensor.
Tightening Torque : 22~36 lb-ft (30~49 N·m, 3~5 kg-m)
5. Reconnect heated oxygen sensor connector.
MAIN RELAY
1. Remove cover from main fuse block.
2. Place a finger on main relay.
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3. Verify that relay clicks when ignition switch isEbay
turned
ON.
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ID: reveleus1
4. Verify that main relay clicks when ignition switch is turned ON and OFF.
5. Apply battery voltage (B+) to terminal 85 and ground terminal 86 of the relay.
6. Check continuity of relay as shown.
Terminals
B+ applied
B+ not applied
30~87
Continuity
No continuity
7. If not as specified, replace main relay.
8. Turn ignition switch OFF.
9. Replace the cover on main fuse block.
REMOVAL
1. Disconnect heated oxygen sensor connector.
2. With standard oxygen sensor socket, remove heated oxygen sensor and washer.
INSTALLATION
1. Install heated oxygen sensor and washer.
Tightening Torque : 22-36 lb-ft (30~49 N·m, 3~5 kg-m)
2. Reconnect heated oxygen sensor connector.
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FUEL INJECTOR INSPECTION
CHECK OPERATION
1. Warm up engine and let engine idle.
2. Listen for sound of each injector running by using sound scope or screwdriver.
Fuel is explosive. When working on fuel system, make sure to supply adequate ventilation to the work area.
Do not smoke, and keep sparks and open flames away.
Make sure the fuel injectors are firmly seated on the fuel rail to prevent movement and possible damage.
3. If no sound is heard, measure injector resistance.
4. If injector is OK, check wiring to injector and voltages of ECM terminals B03-47, 48, 49, and 50.
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INTAKE AIR TEMPERATURE SENSOR
This sensor measures the temperature of the intake air and converts its charge into a resistance throught a
thermister similar to the ECT Sensor. By monitoring the IAT Sensor, the ECM detects the intake air temperature
and use it as noe of the signals to control fuel injectors and ignition timing.
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KNOCK SENSOR
The Knock Sensor is a feedback signal used to control of ignition timing.When knocking occurs, the Knock Sensor
sends the signal to the ECM. The ECMthen retards the ignition timing to reduce or eliminate the knock
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INSPECTION
1. Disconnect knock sensor connector and remove knock sensor from vehicle. Mount knock sensor in the jaws of a
bench vise and connect a voltmeter between terminals 1 and 2.
2. Wrap on the bench vise sharply with a hammer and observe voltmeter.
3. Verify that a voltage spike (less than 1V) is output from the knock sensor.
4. If no voltage spike is observed, replace the knock sensor.
REMOVAL
1. Remove intake manifold support bracket.
2. Disconnect wire harness.
3. Loosen bolt and remove sensor.
INSTALLATION
1. Install sensor and tighten bolt.
2. Install wire harness.
3. Reinstall intake manifold support bracket.
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MASS AIR FLOW SENSOR
The Mass Air Flow (MAF) Sensor is the most direct method of measuring engine load because it measures the
mass of air intake. This is also known as a "hot-wire" sensor because it depends on the measurement of current
flowing through heated wires to measure air flow. The hot wire is heated to specific temperature differential above
incoming air. Two wires inside the MAF Sensors are exposed to a portion of the airflow entering the engine :
the ambient temperature wire or "cold wire" isn't heated so this wire is the temperature of the surrounding air and
serves as the reference temperature.
The hot wire is heated by the MAF to be a certain amount above the ambient air. As soon as air flows over the
wire, both wires are cooled. The control circuits then apply more voltage to keep the hot wire at the original
temperature differential. This creates a voltage signal monitored by the ECM. The greater the air flow and wire
cooling, the greater the signal.
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MASS AIR FLOW SENSOR (HOT FILM TYPE)
Do not drop or subject the sensor to shock.
Do not put objects inside the sensor.
1.
2.
3.
4.
5.
Disconnect mass air flow sensor connector.
Loosen air intake hose retaining clamps on both sides of mass air flow sensor.
Disconnect air intake hose from mass air flow sensor.
Remove two bolts attaching mass air flow sensor to mounting bracket.
Remove mass air flow sensor.
INSPECTION
1. Attach mass air flow sensor to air intake hose and to mounting bracket.
2. Replace two bolts to retain mass air flow sensor to mounting bracket.
Tightening Torque : 69~96.3 lb-in (7.8~10.8 N·m, 0.8~1 kg-m)
3. Reconnect air intake hose to the mass air flow sensor.
4. Tighten bolts of retaining clamps on both sides of mass air flow sensor.
5. Reconnect mass air flow sensor connector to sensor.
6.
7.
8.
9.
Warm up engine to normal operating temperature and let engine idle.
Connect voltmeter between terminal 2 (G/L) and ground.
Verify that the voltage varies between 0.6V~0.8V.
Rev up engine and verify that voltage varies between 3.0V~4.0V.
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10. If voltage is not within specification, replaceEbay
massUser
air flow
sensor.
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IGNITION TIMING
1.
2.
3.
4.
Apply parking brake.
Warm up engine to normal operating temperature.
Turn OFF all electrical loads.
connect timing light to number one spark plugh wire.
A rubber inspection plug has been provided in the plastic coil cover (center of the cylinder head cover)
directly over the number one (1) spark plug wire. Remove the inspection plug and connect the inductive pickup of your tachometer or timing light to the number one (1) spark plug wire. If your tachometer/timing light
inductive pick-up is too large, the coil cover will have to be removed.
5. Verify that ignition timing marks on crankshaft pulley and timing mark on timing belt cover are aligned.
Ignition timing : BTDC 6°±5° (at idle speed)
Ignition timing is not adjustable.
6. If timing is not within the specified range, replace the ECM.
IDLE SPEED
1.
2.
3.
4.
Apply parking brake.
Warm up the engine to normal operating temperature.
Turn OFF all electrical loads.
Connect inductive tachometer to number one (1) spark plug wire or connect tachometer pick-up lead to terminal
in the data link connector (DLC). In case of using scan tool connect Hi-scan pro to the DLC.
The base idle speed is not adjustable. The idle speed ia automatically controlled by the engine control
module. Incorrect idle speed indicates a potential problem with the IAC system or an intake manifold leak.
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5. Check that idle speed is within specified range.
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Idle speed (tansaxle in "NEUTRAL") : 750 ± 50 rpm
This is a "wasted spark" ignition system, some tachometers will indicate twice the actual engine speed.
6. Disconnect tachometer from DLC or spark plug wire.
7. Turn off engine
ON-VEHICLE SERVICE
Component
Connector
Terminal
Normal Ranges
TPS
(Throttle Position
Sensor)
1-2
1-3
1-3
1.6 kΩ~2.4kΩ
0.71kΩ~1.38kΩ at close throttle
2.2kΩ~3.4kΩ at wide open
terminal 1 : ground
terminal 2 : power
terminal 3 : signal
ECT
(Engine Coolant
Temperature sensor)
1-3
1-3
1-3
15.04(+1.79, -1.0)kΩ at -4°F(-20°C)
2.45(+1.79, -1.80) at 68°F(20°C)
ATS
(Air Temperature
Sensor)
1-2
1-2
1-2
15.04(+1.79., -1.0)kΩ at -4°F(-20°C)
2.45(+1.79, -1.80) at 68°F(20°C)
INJECTOR
1-2
13.2Ω~15.5Ω at -68°F(20°C)
0.318±0.111 kΩ at 176°F(80°C)
0.318±0.111 kΩ at 176°F(80°C)
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O2 Sensor
Ebay User2-4
ID: reveleus1 Whole snesor is in a temperature chamber
without heater power.
3Ω~7Ω at 68°F(20°C)
ISC (Idle Speed
Control)
2-3
1-2
1.5kΩ~18.5kΩ at 68°F(20°C)
14.5kΩ~16.5kΩ at 68°F(20°C)
terminal 1 : closing coil
terminal 2 : power supply (12V)
terminal 3 : opening coil
CPSV
(Canister Purge
control Valve)
1-2
24Ω~28Ω at 68°F(20°C)
CCV
(Canister Close
valve)
1-2
23.0Ω~26.0Ω at 68°F(20°C)
POWER RELAY
1-2
80Ω~90Ω at 68°F(20°C)
FUEL PRESSURE HOLD INSPECTION
1. Disconnect negative battery terminal.
The fuel system remains under pressure when the engine is not running. Release fuel system pressure before
disconnectingany fuel line to reduce the chance of personal injury or fire damage to vehicle components.
2. Release fuel system pressure.
3. Raise a vehicle.
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4. Install SST (0K2A1 131 001A) to fuel filter asEbay
described
below
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reveleus1
5.
6.
7.
8.
9.
Connect negative battery terminal.
Connect data link connector terminals FUEL PUMP and B+ with jumper wire.
Turn ignition switch ON for 10 seconds to operate fuel pump.
Turn ignition switch OFF and remove jumper wire.
Inspect fuel pressure after 25 minutes.
Fuel pressure : More than 25 psi (180 kPa, 1.8 kg/cm²)
10. If not as specified, check the following components :
do following inspections :
A.Fuel pump
B.Pressure regulator
C.Injectors
FUEL LINE PRESSURE INSPECTION
1.
2.
3.
4.
5.
6.
7.
8.
Disconnect negative battery cable.
Release fuel system pressure.
Raise a vehcicle.
Install SST (0K2A1 131 001A) to fuel filter as shown.
Connect negative battery cable.
Connect data link connector terminals FUEL PUMP and B+ with jumper wire.
Turn ignition switch ON.
Inspect the fuel line pressure.
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Fuel line pressure : 46~51 psi (320~350 kPa, 3.2~3.5 kg/cm²)
Pressure too high :
A.Check for restricted fuel return line
B.If line is clean, replace pressure regulator
Pressure too lwo :
A.Clamp return line and check if pressure rises
B.If pressure does rise, replace pressure regulator.
C.If pressure does not rise, measure fuel pump maximum pressure.
9. Turn ignition switch OFF and remove jumper wire.
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ENGINE CONTRL SYSTEM (B-1A)
ENGINE CONTROL SYSTEM (B-1B)
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ENGINE CONTROL SYSTEM (B-1AC)
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ENGINE CONTROL SYSTEM (B-1D)
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ENGINE CONTROL SYSTEM (B-1E)
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ENGINE CONTROL SYSTEM (B-1F)
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SPECIAL SERVICE TOOLS
Tool
(Number and Name)
Illustration
Use
0K2CA 089 HSP
Hi-scan pro
Used for diagnosis and DTC retrieval and
erasing.
0K2A1 131 AA1
Fuel pressure gauge
Used for measuring fuel pressure.
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SPECIFICATIONS
Engine
Item
A5 DOHC
Idle speed (rpm)
750 ± 50
Ignition timing (BTDC)
6° ± 5°
Type
Horizontal drift
Throttle body
Idle air control valve
Throat diameter (in (mm))
2 (50)
Type (cc (cu in)
Rotary
Resistance (at
Opening
68°F[20°C]) (Ω) Closing
Air cleaner element
EVAP canister
purge vlave
Engine coolant
Temperature sensor
15~16
Dry, paper type
Resistance (at 68°F[20°C]) (Ω)
Resistance
24~28
-4°F(-20°C)
15.04 (+1.79, -1.80)
-68°F(20°C)
2.45 (+0.19, -0.18)
176°F(80°C)
0.318 ± 0.11
Type of drive
Fuel injector
17~18.2
Electromechanical
Number of spray ports
2
Resistance (at 68°F[20°C]) (Ω)
13.5~15.5
Heated oxygen
sensor
Resistance (at 68°F[20°C]) (Ω)
3~7
Main relay
Resistance (at 68°F[20°C]) (Ω)
80~90
Fuel pump maximum pressure (kg/cm²)
4.5~6.5
Low pressure side
Nylon element (in fuel pump)
High pressure side
Paper element
Pressure regulator
Pressure (kg/cm²)
3.25~3.35
Fuel tnak
Capacity (L)
Fuel filter
45
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THROTTLE POSITION SENSOR
The Throttle Position (TP) Sensor is a variable resistor that providesthe ECM with an input signal (voltage) that
represents throttle blade position.The sensor is connected to the throttle blade shaft. As the position of thethrottle
blade changes, the resistance of the TP Sensor changes. The ECM suppliesa 5V reference voltage to the TP
Sensor. The TP Sensor output voltage (inputsignal to the ECM) represents the throttle blade position. This will
usuallyvary from around 0.25V at minimum throttle opening, to around 4.7V at wideopen throttle.
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INSPECTION
1. Disconnect connector from throttle position sensor.
2. Connect ohmmeter between sensor terminals 1 and 2.
3. Verify that resistance increases linearly according to throttle angel.
Specification : 1.6~2.4 kΩ (with throttle valve closed)
4. If resistance is not as specified, replace the throttle position sensor.
5. Connect throttle position sensor connector.
VOLTAGE INSPECTION
1. Verify that throttle is at the closed throttle position.
2. Turn ignition switch ON (engine OFF).
3. Connect voltmeter between terminals 2 (L/G) and 1 (W/G) on throttle position sensor connector. Check for 5V
reference voltage.
4. Connect the voltmeter between terminal 1 (W/G) and terminal 3 (L/O) on the TPS connector.
5. Measure the voltage at the fully open and fully closed position.
Email: suzlever@gmail.com
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6. If not as specified, replace throttle position senosr.
Ebay User ID: reveleus1
Specification :
Measuring condition
Voltage (V)
Fully closed
0.2~0.8V
Fully open
4.0~4.8V
Email: suzlever@gmail.com
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Fundamental procedures
Symbols
There are six primary symbols used to complement illustrations. These symbols indicate the areas to apply such materials during
service.
Symbol
Meaning
Type
Apply oil
New engine oil, gear oil, etc. as appropriate
Apply brake fluid
Only brake fluid
Apply automatic transmission fluid (ATF)
Only ATF
Apply grease
Appropriate grease
Apply sealant
Appropriate sealant
Apply petroleum jelly
Appropriate petroleum jelly
NOTICES, CAUTIONS, AND WARNINGS
As you read through the various procedures, you will encounter Notice, Cautions and Warnings. Each one is there for a specific
purpose. Notice give you added information that will assist you in completing a particular procedure. Cautions prevent you from
making an error that could damage the vehicle. Warnings remind you to be especially careful in specific areaswhere carelessness
can cause personal injury
The following items contain general procedures you should always follow when working on a vehicle:
PROTECTION OF THE VEHICLE
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• Always cover fenders, seats, and floor areas before starting work.
Operate the engine only in a well-ventilated area to avoid carbon monoxide poisoning.
A WORD ABOUT SAFETY
The following precautions must be followed when jacking up the vehicle:
1. Block the wheels.
2. Use only the specified jacking positions.
3. Support the vehicle with safety stands.
The engine compartment must be clear of tools and people before starting the engine.
PREPARATION OF TOOLS AND MEASURING EQUIPMENT
• All necessary tools and measuring equipment should be available before starting any work.
SPECLAL SERVICE TOOLS (SST'S)
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• Use special service tools when they are required. SST's can be found under "preparation" prior to any procedure requiring
them.
REMOVAL OF PARTS
• Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement for
repair.
DISASSEMBLY
• If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way
that will not affect their performance or external appearance. Additionally, these parts should be identified so that reassembly
can be done easily and efficiently.
INSPECTION OF PARTS
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• When removed, each part should be carefully inspected for malfunction, deformation, damage, or other problems.
ARRANGEMENT OF PARTS
• All disassembled parts should be carefully arranged for assembly. Separate or identify the parts to be replaced form those that
will be reused.
CLEANING PARTS FOR REUSE
• All parts to be reused should be carefully and thoroughly cleaned according to the appropriate method.
REASSEMBLY
Standard values, such as torques and certain adjustments, must be strictly observed in the assembly of all parts. When removed,
the following parts should be replaced with new ones:
1. Oil seals
2. O-rings
3. Cotter pins
4. Gaskets
5. Lock washers
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6. Nylon nuts
DEPENDING ON LOCATION :
1. Sealant should be applied or new gaskets used.
2. Oil should be applied to the moving components of parts.
3. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before assembly.
ADJUSTMENT
• Use appropriate gauges and/or testers when making adjustments.
RUBBER PARTS AND TUBING
• Prevent gasoline or oil from getting on rubber parts or tubing.
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ELECTRICAL TROUBLESHOOTING TOOLS
1. Test Light
The test light, as shown in the figure, uses a 12V bulb. The two lead wires should be connected to probes.
The test light is used for simple voltage checks and in checking for short circuits.
When checking the engine control module (ECM), never use a bulb exceeding 3.4W.
2. Jumper Wire
The jumper wire is used for testing by shorting across switch terminals and ground connections.
Do not connect a jumper wire from the power source line to a body ground. Such a connection may cause damage to
harnesses or electronic components.
3. Voltmeter
The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15V or more is used by connecting the
positive (+) probe to the point where voltage is to be measured and the negative (-) probe to a body ground.
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4. Ohmmeter
The ohmmeter is used to measure the resistance between two points in a circuit to check for continuity, and in diagnosis of
short circuits.
Do not attempt to connect the ohmmeter to any circuit to which voltage is applied ; this may bum or otherwise damage the
ohmmeter.
ELECTRICAL PARTS
• Battery Cable
Before disconnecting connectors or replacing electrical parts, disconnect the negative battery terminal.
CONNECTORS (Removal of connector)
1. Never pull on the wiring harness when disconnecting connectors.
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2. Connectors can be removed by pressing or pulling the lock lever.
CONNECTORS (Locking a connector)
• Listen for a click when locking connectors. This sound indicates that they are securely locked.
CONNECTORS (Inspection)
1. When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wire harness side.
2. Check the terminals of waterproof connectors from the connector side because they cannot be accessed from the wire harness
side.
• Use a fine wire to prevent damage to the terminal.
• Do not damage the terminal when inserting the tester lead.
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Terminals
1. Inspection
Pull lightly on individual wires to ensure that they are secured in the terminal.
2. Replacement or terminals
Use the appropriate tools to remove the terminal as shown.
When installing the terminal, be sure to insert it until it locks securely.
(1) Female
Insert a thin piece of metal from the terminal side of the connector, and with the terminal locking tab pressed down, pull the
terminal out from the connector.
(2) Male
Follow the same procedure as female-type terminal.
3. Sensors, switches, and relays
Always handle sensors, switches, and relays carefully. Do not drop them or accidentally strike them against other parts.
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4. Wiring color codes.
Two-color wires are indicated by two color code symbols. The first code symbol indicates the base color of the wire, and the
second the color of the stripe on the base color.
Code
Color
Code
Color
BLK
Blakc
O
Orange
BR
Brown
P
Pink
G
Green
R
Red
GR
Gray
V
Violet
L
Blue
W
White
LB
Light Blue
Y
Yellow
LG
Light Green
JACK AND SAFETY STAND POSITIONS
1. Front end jack position :
At the front subframe
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2. Safety stand positions :
On both sides of the side sills
JACK AND SAFETY STAND POSITIONS
1. Jack position :
At the center of the rear crossmember
2. Safety stand positions :
On both sides of the body frame
VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS
1. Front end
(1) Side sills (both sides)
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2. Rear end
(1) Side sills (both sides)
TOWING
• Proper towing equipment is necessary to prevent damage to the vehicle.
Always observe laws and regulations applicable to vehicles in tow. As a general rule, towed vehicles should be pulled with the
driving wheels off the ground. If excessive damage or other conditions prevent towing the vehicle with the driving wheels off
the ground, use wheel dollies.
With either automatic or manual transmission :
1. Set the ignition switch in the ACC position.
2. Place the selector lever or shift lever in N (Neutral).
3. Release the parking brake.
• Do not tow the vehicle backward with driving wheels on the ground. This may cause internal damage to the
transmission.
• Do not use the hook loops under the front and rear of the vehicle for towing purposes. These hook loops are designed
ONLY for transport tie-down. If tie-down hook loops are used for towing, the front/rear bumper will be damaged.
VIN LOCATIONS
• Vehicle identification number arrangement
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ENGLISH/METRIC CONVERSION TABLE
MULTIPLY
BY
inch (")
foot (ft.)
yard (yd.)
mile
LENGTH
25.4
0.3048
0.9144
1.609
inch² (in²)
Foot² (ft²)
yard² (yd³)
AREA
645.2
6.45
0.0929
0.8361
inch³(in³)
quart (qt.)
gallon (gal.)
yard³ (yd³)
VOLUME
16387
16.387
0.0164
0.9464
3.7854
0.7646
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TO GET
millimeters (mm)
meters (m)
meters
kilometers (km)
millimeters² (mm²)
centimeters² (cm²)
meters² (m²)
meters² (m²)
mm³
cm³
liters (l)
liters
liters
meters³(m³)
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pound (lb.)
ton
MASS
0.4536
907.18
kilograms (kg)
kilograms(kg)
kilogram (kg)
ounce (oz.)
pound (lb)
FORCE
9.807
0.2780
4.448
newtons (n)
newtons
newtons
ACCELERATION
0.3048
0.0254
foot/second² (ft/sec²)
inch/second² (in/sec²)
meter/sec² (m/s²)
meter/sec² (m/s²)
pound-inch (lb-in)
pound-foot (lb-ft)
TORQUE
0.11298
1.355 8
newton-meters (N·m)
newton-meters (N·m)
horsepower (hp)
POWER
0.746
kilowatts (kW)
PRESSURE
6.895
pounds/inch² (psi)
kilopascals (kPa)
ENERGY
1.355 8
3,600,000
foot-pound
kilowaft-hour
joules (J)
joules (J)
FUEL PERFORMANCE
0.4251
miles/gallon (mpg)
kilometers/liter (km/l)
VELOCITY
1.6093
miles/hour (mph)
kilometers/hour
TEMPERATURE
to conver Fahrenheit temperature to
Celsius temperature, use formula :
C
5/9 (F-32)
F
9/5 C (+32)
SCHEDULED MAINTENANCE SERVICES
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I : Inspect and, if necessary, adjust, correct, clean or replace.
R : Replace or change.
L : Lubricate
1. This maintenance is required in all states except California. However, we recommend that it also be performed on California
vehicles.
2. This maintenance is recommended by Kia. However, it is not necessary for emission warranty coverage or manufacturer recall
liability.
SCHEDULED MAINTENANCE SERVICES
SEVERE MAINTENANCE
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I : Inspect and, if necessary, adjust, correct, clean or replace.
R : Replace or change.
L : Lubricate
1. This maintenance is required in all states except California. However, we recommend that it also be performed on California
vehicles.
2. This maintenance is recommended by Kia. However, it is not necessary for emission warranty coverage or manufacturer recall
liability.
3. Inspect, and if necessary, replace.
SCHEDULED MAINTENANCE SERVICES
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NORMAL MAINTENANCE (FOR CANADA)
I : Inspect and, if necessary, adjust, correct, clean or replace.
R : Replace or change.
L : Lubricate
1. This maintenance is recommended by Kia. However, it is not necessary for emission warranty coverage or manufacturer recall
liability
SCHEDULED MAINTENANCE SERVICES
SEVERE MAINTENANCE (FOR CANADA)
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I : Inspect and, if necessary, adjust, correct, clean or replace.
R : Replace or change.
L : Lubricate
1. This maintenance is recommended by Kia. However, it is not necessary for emission warranty coverage or manufacturer recall
liability
2. Inspect, and if necessary, replace.
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INSPECTION
1. Remove A/C switch and check continuity between terminals.
2. If not as specified, replace A/C switch.
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INSPECTION
A/C RELAY
1. Disconnect A/C relay connector.
2. Check continuity between terminals.
Terminals
Continuity
Tester probe: +
Tester probe: -
85
86
Yes
85
87
No
85
30
No
87
86
No
87
30
No
3. If not as specified, replace relay.
4. If correct, go to next step.
5. Apply 12V to terminal 85 and ground terminal 86.
6. Check for continuity between terminals 87 and 30.
Terminals
Continuity
87-30
Yes
7. If not as specified, replace relay.
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INSPECTION
1. Disconnect blower motor connectors.
2. Verify that blower motor runs when connecting 12V to terminal A (R/L)and grounding terminal B (L/R).
3. If not as specified, replace blower motor.
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INSPECTION
1. Disconnect resistor assembly connector. Check continuity between terminals.
2. If not as specified, replace resistor assembly.
3. Measure resistance between terminals.
4. If not as specified, replace resistor assembly.
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REMOVAL
BLOWER/EVAPORATOR
1. Discharge refrigerant from A/C system. (Refer tooperating instructions of your refrigerant recovery/recycling /
charging stationfor proper procedures.)
2. Disconnect inlet and outlet pipe from evaporator.
Immediately plug all open fittings to keep moisture out of system.
3. Remove cover and drain hose.
4. Remove instrument panel and disconnect wiring harness connector.
5. Remove blower unit.
INSTALLATION
1. Install in reverse order of removal.
2. Evacuate refrigerant system.(Refer to operating instructionsof your refrigerant recovery/recycling/ charging
station for proper procedures.)
3. Charge A/C system. (Refer to operating instructionsof your refrigerant recovery/recycling/charging station for
proper procedures.)
INSPECTION
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1. Check continuity between terminals of blower switch connector G-04
2. If not as specified, replace blower switch.
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REMOVAL
1. Discharge refrigeration system. (Refer to operatinginstructions of your refrigerant recovery/recycling/ charging
station forproper procedures.)
2. Remove undercover.
3. Remove compressor as shown in figure, referring to removal note.
INSTALLATION
1. Install compressor in reverse order of removal, referring to installationnote.
2. Install undercover.
3. Charge refrigeration system. (Refer to operatinginstructions of your refrigerant recovery / recycling / charging
station forproper procedures.)
• Immediately plug any open fittings to keep moisture out of system.
• Apply new compressor oil to O-rings before connecting fittings.
• Do not apply compressor oil to fittings.
• Tightening torque: compressor inlet and outlet: 18~23 lb·ft (24~31 N·m, 2.4~3.2 kg·m)
• Adjust belt tension to specification.
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COMPONENTS
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REMOVAL
CONDENSER FAN
1. Disconnect condenser fan connector.
2. Remove bolts and remove condenser fan.
INSTALLATION
CONDENSER FAN AND RELAY
Install in reverse order of removal.
INSPECTION
CONDENSER FAN
1. Disconnect condenser fan connector.
2. Apply 12V to terminal 1 (L/B) and ground terminal 2 (B), and verifythat condenser fan operates.
3. If not as specified, replace condenser fan.
CONDENSER RELAY
1. Disconnect condenser fan relay connector.
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2. Check continuity between terminals of relay.
3.
4.
5.
6.
Terminals
Continuity
85-86
Yes
87-30
No
If not as specified, replace relay.
If correct, go to next step.
Apply 12V to terminal 85 and ground terminal 86.
Check for continuity between terminals 87 and 30.
Terminals
Continuity
87-30
YES (Normal)
7. If not as specified, replace relay.
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REMOVAL
1. Discharge refrigeration system. (Refer to operatinginstructions of your refrigerant recovery/recycling/ charging
station forproper procedures.)
2. Remove liquid pipes.
3. Remove condenser as shown in figure.
• Insert protector such as cardboard between condenser and radiator.
• Immediately plug open fittings to keep moisture out of system.
INSTALLATION
1. Install condenser in reverse order of removal.
• Apply clean compressor oil to O-rings before connecting fittings.
• Do not apply compressor oil to fitting nuts.
• Remove protector before installing radiator brackets.
• When installing a new condenser, add compressor oil through high-pressurepipe port of compressor.
Compressor oil: 1.22 cu in (20 cc)
Tightening torque:
Condenser inlet : 87~174 lb·in (9.8 ~19.6 N·m, 1.0~2.0 kg·m)
INSPECTION
Check for following and repair or replace condenser as necessary.
1. Cracks damage, or refrigerant leakage.
2. Bent fins.
3. Distorted or damaged condenser inlet or outlet.
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DESCRIPTION AND OPERATION
AIR CONDITIONING(A/C) SYSTEM
The A/C system uses principals of thermodynamics to cool passenger compartment of vehicle. Using engine
power, compressor compresses gaseous refrigerant into high temperature/high pressure gas. It then pumps this
gas into a condenser unit built onto vehicle's radiator. Condenser cools gas, changing it into high pressure, low
temperature liquid refrigerant. Liquid then goes to receiver/drier, which first removes any liquid water and then
sends liquid to an evaporator in heater unit inside passenger compartment. Evaporator then uses passenger
compartment temperature to turn liquid back into a gas, extracting heat from passenger compartment. Gas is then
sent back to compressor, and cycle begins again.
A/C RELAY
A/C relay is an electrical switching box that closes circuit to condenser fan relay and compressor clutch. Relay is
controlled by engine control module (ECM) only. If engine coolant exceeds a certain temperature, engine control
module (ECM) sends a signal triggering A/C relay and shutting off A/C system. At starting or lighten acceleration,
engine control module (ECM) sends a signal triggering A/C relay and shutting off A/C system for five seconds. It is
a replaceable item.
BLOWER
The blower draws in hot passenger compartment air and sends it through evaporator coil. It consists of a blower
fan and an electric motor.
BLOWER MOTOR
Blower motor speed is controlled by blower switch and a resistor assembly in blower unit. When blower switch is in
OFF position, motor ground circuit is open and blower motor does not operate. When switch is in first (LO) position,
current flow to blower motor is restricted by three resistors in resistor assembly, and blower motor turns at a low
speed. Changing blower switch to second (M1), third (M2), or fourth (HI) positions causes successive decreases of
circuit resistance, resulting in blower motor speed becoming correspondingly faster.
COMPRESSOR ASSEMBLY
The compressor assembly is primary moving part of air conditioning system. If it fails, there is no compression of
refrigerant, and no movement of refrigerant through system. It is located on left side of engine and is connected to
enginecrankshaft by a drive belt. It consists of compressor, manifold assembly, compressor clutch, and drive pulley.
COMPRESSOR CLUTCH
The compressor clutch engages compressor. It is a magnetic unit operated from air conditioning switch in
passenger compartment. It is a serviceable, replaceable item.
CONDENSER
The condenser is mounted in front of radiator. It consists of a series of coils which cool refrigerant. It is a
serviceable and replaceable item.
CONDENSER FAN
The condenser fan improves air flow through condenser. Condenser will still have a high volume of air flowing
through it even if vehicle is standing still. It is powered by an electric motor connected to condenser fan relay.
Condenser fan relay is an electrical switching box that closes circuit to condenser fan.
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EVAPORATOR ASSEMBLY
The blower/evaporator assembly houses blower fan, blower motor, and A/C relay for air conditioner system. It
consists of evaporator core and expansion valve.
EVAPORATOR CORE
The evaporator core is an air cooler and a dehumidifier. As refrigerant enters, it boils, absorbing heat from air
beingblown through core by heater blower motor. This cools air, which is then directed to passengers through air
ducts. Asair is cooled, moisture in air condenses on core and is drained off. Result is cold, dry air. Evaporator core
is a serviceable, replaceable item.
EXPANSION VALVE
The expansion valve allows high pressure liquid to expand as it enters evaporator. By allowing liquid to expand, it
will absorb more heat in evaporator. Valve also meters amount of refrigerant entering system to prevent evaporator
core from flooding.
HEATER
Dehumidified air is reheated as it passes through heater core in heater unit. Heater is warmed by engine coolant
passing through tubes of heater core. Heat is transferred to core fins and passed off to air flowing past fins.
Position of air temperature valve in air conditioning module determines how much of total airflow is permitted to
pass through heater. This determines warmth of overall air flow that is sent into passenger compartment.
HOSES AND LINES
Hoses and lines carry refrigerant between major components of A/C system. Lines are made of metal and are
rigid. Hoses are made of flexible rubber and are designed for either high or low pressure. They are replaceable
items.
RECEIVER/DRIVER
The receiver/drier is located at front power steering oil tank. It receives liquid refrigerant from condenser, removes
any water in it, and then sends refrigerant to evaporator. It is a replaceable item.
SERVICE PORTS
Service ports allow injection or recovery of refrigerant to A/C system. High-pressure service port is mounted in high
pressure line coming from receiver/drier. Low-pressure service port is in section of flexible hose that connects
evaporator return line to compressor.
REFRIGERANT
• Refrigerant 134a (R-134a) systems
In an effort to avoid use of ozone-depleting CFC refrigerants, Kia Motor Company has introduced a new
refrigerant system for this vehicle. This system uses non-CFC-based refrigerant R-134a.
This new type of refrigerant has many of same properties as R-12 and is similar in form and function. R-134a is
a hydrofluorocarbon (HFC)-based refrigerant, however, R-12 is a chlorofluorocarbon (CFC). With no chlorine
atoms in its molecular structure, use of R-134a refrigerant will not have any harmful effects on atmosphere's
ozone layer.
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• Identifying R-134a and R-12 A/C systems
To determine which types of A/C system a particular vehicle has, inspect A/C system's major components and
refrigerant lines for special tags. If system has yellow R-134a "NON-CFC" tags, it is an R-134a system and
uses R-134a refrigerant. If there are no special R-134a "NON-CFC" tags on A/C system components or lines,
system uses R-12. R-134a systems canalso be identified by brown-colored O-rings (HNBR) used throughout A/
C system.
Do not add R-12 refrigerant to an A/C system that requires use of R-134a refrigerant. Do not add R-134a
refrigerant to an A/C system that requires use of R-12 refrigerant. These two types of refrigerant should
never be mixed. Doing so may cause damage to A/C system.
• Precaution for new refrigerant (R-134a)
R-12 and R-134a components are not interchangeable. Do not replace components from an R-134a system
with components foran R-12 system and vice versa. Mixing components from these two types of systems
may cause component failure and damage to A/C system.
• R-134a system components
The major components of R-134a A/C system are similar to those used previously on R-12 systems. R-12 and
R-134a components are similar in design and function. As a result, all Removal and Installation procedures
outlined for R-12 components can be used for R-134a components.
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REMOVAL
DRIVE BELT
1. Remove drive belt as follows.
VEHICLE WITH POWER STEERING
1.
2.
3.
4.
5.
Loosen bolt A.
Loosen nut C.
Loosen nut B.
Loosen bolt D.
Remove drive belt.
VEHICLE WITHOUT POWER STEERING
1. Loosen nut A.
2. Loosen bolt B.
3. Remove drive belt.
INSTALLATION
Vehicle without power steering
ADJUSTMENT
Adjust deflection of drive belt as follows.
VEHICLE WITH POWER STEERING
1. Loosen bolt A and nuts B and C.
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2. Turn adjusting bolt D and adjust deflection of drive belt to withinspecification.
Belt
Deflection: When applying moderate pressure 22 lb (98 N)
New
0.31~0.35 in (8~9 mm)
Used
0.35~0.39 in (9~10 mm)
3. Tighten bolt A and nuts B and C.
Tightening torque:
Bolt A: 27~39 lb·ft (37~53 N·m, 3.8~5.4 kg·m)
Nut B: 14~19 lb·ft (19~25 N·m, 2.0~2.6 kg·m)
Nut C: 24~34 lb·ft (32~46 N·m, 3.3~4.7 kg·m)
VEHICLE WITHOUT POWER STEERING
1. Loosen nut A.
2. Turn adjusting bolt B and adjust deflection of drive belt to withinspecification.
3. Tighten nut A.
Belt
Deflection: When applying moderate pressure 22 lb (98 N)
New
0.31~0.35 in (8~9 mm)
Used
0.35~0.39 in (9~10 mm)
Tightening torque:
Bolt A: 23~25 lb·;ft (31~34 N·m, 3.2~3.5 kg·m)
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INSPECTION
1. Turn ignition switch OFF.
2. Connect manifold gauge set and measure high-pressure side refrigerantpressure.
High-pressure side:Above 88 psi (608 kPa)
3.
4.
5.
6.
If not as specified, check refrigerant system, (refer to troubleshooting information)
If correct, go to next step.
Disconnect A/C dual pressure switch connector.
Check for continuity of switch.
Terminals
Continuity
1-2
Yes
7. If not as specified, replace switch.
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REMOVAL
BLOWER/EVAPORATOR
1. Discharge refrigerant from A/C system. (Refer tooperating instructions of your refrigerant recovery/recycling /
charging stationfor proper procedures.)
2. Disconnect inlet and outlet pipe from evaporator.
Immediately plug all open fittings to keep moisture out of system.
3. Remove cover and drain hose.
4. Remove instrument panel and disconnect wiring harness connector.
5. Remove blower unit.
INSTALLATION
BLOWER/EVAPORATOR
1. Install in reverse order of removal.
2. Evacuate refrigerant system.(Refer to operating instructionsof your refrigerant recovery/recycling/ charging
station for proper procedures.)
3. Charge A/C system. (Refer to operating instructionsof your refrigerant recovery/recycling/charging station for
proper procedures.)
INSPECTION
EVAPORATOR
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1. Check evaporator fins for blockage. If fins are clogged, clean themwith compressed air.
Never use water to clean evaporator.
2. Check fittings for cracks and other damage. Replace evaporator if necessary.
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ELECTRICAL TROUBLESHOOTING TOOLS
JUMPER WIRE
1. The jumper wire is used for testing by short-circuiting switch terminals and to verify condition of ground
connections.
Do not connect jumper wire between a power source and a body ground. This may cause burning or other
damage to harnesses and electronic components.
VOLTMETER
1. The DC voltmeter is used for measurement of circuit voltage.
A voltmeter with a range of 15V or more must be used. It is used by connecting positive (+) probe (red lead) to
point where voltage is to be measured and connecting negative (Ð) probe (black lead) to a body ground.
OHMMETER
1. Ohmmeter is used to measure resistance between two points in a circuit, to check for continuity, and to
diagnose short circuits.
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Never connect ohmmeter to any circuit to which voltage is applied. Doing so may burn or otherwise damage
ohmmeter.
TEST LIGHT
1. The test light, as shown in figure, uses a 12V bulb. Two leads should be connected to probes. Test light is used
for simple voltage checks and to check for open circuits.
When checking control unit, never use a bulb over 3.4W.
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REMOVAL
1.
2.
3.
4.
5.
6.
Disconnect negative battery cable.
Remove ash tray.
Remove center panel trim.
Remove instrument cluster trim.
Remove grove box.
Remove heater control unit.
INSTALLATION
Install in reverse of removal.
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REMOVAL
1. Drain engine coolant, (refer to Engine Cooling System.)
2. Remove instrument panel, (refer to Body)
3. Remove control cable.
4. Disconnect heater hose from heater unit.
5. Remove heater unit.
INSTALLATION
Install in reverse order of removal.
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COMPONENTS
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DISASSEMBLY
1. Disassemble A/C compressor clutch as shown in figure.
REASSEMBLY
1. Re-assemble A/C compressor clutch in reverse order of removal.
INSPECTION
FLELD COIL
1. Verify continuity between field coil terminals.
ADJUSTMENT
MAGNETIC CLUTCH CLEARANCE
1. Adjust clearance between pressure plate and rotor pulley by selectingand installing proper shim(s).
Clearance: 0.020~0.028 in (0.5~0.7 mm)
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REMOVAL
1. Discharge refrigeration system. (Refer to operatinginstructions of your refrigerant recovery/recycling/ charging
station forproper procedures.)
2. Remove receiver/drier as shown in figure.
Immediately plug open fittings to keep moisture out of system.
INSTALLATION
1. Install receiver/drier in reverse order of removal.
• Apply clean compressor oil to O-rings before connecting fittings.
• Do not apply compressor oil to fitting nuts.
• When installing a new receiver/drier, add compressor oil through high-pressurepipe port of compressor.
Compressor oil: 0.61 cu in (10 cc)
Tightening torque :
Receiver/drier inlet: 43~61 lb·in (4.9~6.9 N·m, 50~70 kg·cm)
Receiver/drier outlet: 43~61 lb·in (4.9~6.9 N·m, 50~70 kg·cm)
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COMPONENTS
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REPLACEMENT
EXPANSION VALVE
Before replacement of expansion valve, carefully check refrigerationsystem.
1.
2.
3.
4.
Remove cooling unit.
Disassemble cooling unit. Remove evaporator and expansion valve as anassembly.
Remove expansion valve.
Install in reverse order of removal.
Apply clean compressor oil to O-rings before connecting fittings.
REFRIGERANT LINE
1. Discharge refrigeration system. (Refer to operatinginstructions of your refrigerant recovery/recycling/ charging
station forproper procedures.)
2. Replace faulty pipe or hose.
• Immediately plug open fittings to keep moisture out of system.
• Apply clean compressor oil to O-rings before connecting fittings.
• Do not apply compressor oil to fitting nuts.
3. Evacuate, charge, and test refrigeration system.
INSPECTION
Check for leakage at connections by using a gas leak tester.
Repair or replace as necessary.
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MECHANICAL SPECIFICATIONS
Description
Tightening torque
Item
Blower/Evaporator assembly mounting nuts
70-96 lb·in (8-11 N·m, 80-110 kg·cm)
Compressor mounting bracket bolts (Front side)
23-35 lb·ft (31-47 N·m, 3.2-4.8 kg·cm)
Compressor mounting bracket bolts (Left side)
12-17 lb·ft (16-23 N·m, 1.6-2.3 kg·cm)
Compressor mounting bolts
18-23 lb·ft (24-31 N·m, 2.4-3.2 kg·cm)
Condenser fan mounting bolts
70-96 lb·in (8-11 N·m, 80-110 kg·cm)
Condenser mounting bolts
70-96lb·in (8-11 N·m, 80-110 kg·cm)
Heater unit mounting nuts
70-96 lb·in (8-11 N·m, 80-110 kg·cm)
Receiver/Drier mounting bolts
44-52 lb·in (5-6 N·m, 50-60 kg·cm)
Receiver/Drier mounting bracket bolts
87-131 lb·in (10-15 N·m, 1.0-1.5 kg·cm)
OTHER SPECIFICATIONS
Description
Specifications
Item
Cooling
Heating
Maximum cooling capacity (450 ㎥/h)
4100 ± 10% kcal/h
Air volume
275 CFM (450 CMH)
Power consumption
240W-12V
Maximum heating capacity (350㎥/h)
3900 ± 10% kcal/h
Air volume
183 CFM (300 CMH)
Power consumption
220W-12V
Outlet flow
155.3 cc/rev
Number of cylinder
10
Maximum speed
9000 rpm
Oil (Capacity)
150 cc
Desiccant used
ZEOLITE
High-pressure control
OFF : 455 psi (32 kg/cm²)
DIFF : 85 psi (6 kg/cm²)
Compressor
Receiver/Drier
Dual pressure
switch
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Low-pressure control
OFF : 28 psi (2 kg/cm²)
DIFF : 4 psi (0.25 kg/cm²)
High pressure side
M10 × 1.25
Lower pressure side
M9 × 1.0
Service ports
Refrigerant (Changed amount)
R-134a (650 ± 50g)
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SYMPTOM-RELATED DIAGNOSTIC PROCEDURE
Symptom
Blower motor does not operate
Compressor clutch does not operate
(Condenser fan operates normally)
Condenser fan does not operate
(A/C compressor clutch operates normally)
Condenser fan and A/C compressor clutch do not operate
Insufficient cooling
No cooling
Intermittent cooling
BLOWER MOTOR DOES NOT OPERATE (STEP 1: CHECK FUSE/RELAY)
1. Check fuse.
Fuse
Amperage
Location
BLOWER
30A
Engine compartment fuse /relay
box
2. If a fuse is open, check for a sort circuit in wiring harness before replacing fuse.
3. If fuse is OK, proceed to inspection.
INSPECTION (BLOWER RELAY)
1. Disconnect blower relay.
2. Check for continuity between following terminals of the relay.
Terminals
Continuity
85-86
Yes
87-30
No
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3.
4.
5.
6.
If not as specified, replace relay.
If correct, go to next step.
Apply 12V to terminal 85 and ground the terminal 86.
Check for continuity between terminals 87 and 30.
Terminals
Continuity
87-30
Yes
7. If not as specified, replace the relay.
8. If fuse is OK, proceed to inspection.
BLOWER MOTOR DOES NOT OPERATE (STEP 2: CHECK VOLTAGE AT BLOWER
MOTOR)
1. Turn the ignition switch to ON position.
2. Verify that the blower switch is in OFF posiotion.
3. Measure voltage at the following termianl of blower motor connector G-02.
Terminal
Voltage
Action
1
12V
Go to Step 3.
(R/L)
0V
Repair or replace blower motor or/and wiring harness
between fuse and blower motor.
BLOWER MOTOR DOES NOT OPERATE (STEP 3: CHECK VOLTAGE AT BLOWER
MOTOR RESISTOR ASSEMBLY)
1. Turn the ignition switch to ON postion.
2. Verify that the blower and A/C switches are in OFF position.
3. Measure voltage at the following terminals of blower motor resistorconnector G-03.
Terminal
Voltage
Action
12V
Proceed to terminal 2 (L).
0V
Repair or replace the wire "L/R".
12V
Proceed to terminal 1 (W).
0V
Check for a poor connection at blower motor resistor.
If OK, replaceresister assembly.
4 (L/R)
2 (L)
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12V
Proceed to terminal 3 (BR).
0V
Check for a poor connection at blower motor resistor,
If OK, replaceresistor assembly.
12V
Go to Step 4.
0V
Check for a poor connection at blowe motor resistor,
If OK, replaceresistor assembly.
1 (W)
3 (BR)
BLOWER MOTOR DOES NOT OPERATE (STEP 4: CHECK VOLTAGE AT BLOWER
SWITCH)
1. Turn the ignition switch to ON position.
2. Verify that the blower and A/C switches are in OFF position.
3. Measure voltage at the following terminals of blower switch connector G-04.
Terminal
Voltage
Action
12V
Proceed to terminal 6 (L).
0V
Repair or replace the wire "L/R".
12V
Proceed to terminal 2 (W).
0V
Repair or replace the wire "L".
12V
Proceed to terminal 5 (BR).
0V
Repair or replace the wire "W".
12V
Proceed to step 5.
0V
Repair or replace the wire "BR".
3 (L/R)
6 (L)
2 (W)
5 (BR)
BLOWER MOTOR DOES NOT OPERATE (STEP 5: CHECK GROUND AT BLOWER
SWITCH)
1. Turn the ignition switch to OFF position.
2. Verify that the blower and A/C switches are in OFF position.
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3. Use ohmmeter to check continuity from ground to following terminal of blower switch connector G-04.
Terminal
Continuity
Action
Yes
Go to next step.
No
Check for a poor connection at ground. If OK,repair
the wire "B"
7 (B)
4. Turn the blower switch to ON position.
5. Use ohmmeter to check continuity from ground to following terminal of blower switch connector G-04.
Terminal
Continuity
Action
Yes
Proceed to inspection
No
Check for a poor connection at blower switch.If OK,
replace the blower switch.
1 (L/R)
INSPECTION (BLOWER SWITCH)
1. Disconnect blower switch.
2. Check for continuity between following terminals of the blower switch.
3. If not as specified, replace the blower switch.
COMPRESSOR CLUTCH DOES NOT OPERATE (STEP 1: CHECK VOLTAGE AT
COMPRESSOR)
1. Run engine at idles.
2. Turn A/C and blower switches to ON position.
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3. Check for voltage at following terminal wire of compressor connector G-09.
Terminal
Voltage
Action
12V
Go to step 2.
0V
Repair or replace the wire "l".
1 (L)
COMPRESSOR CLUTCH DOES NOT OPERATE (STEP 2: CHECK COMPRESSOR
CLUTCH)
1. Disconnect cpmpressor clutch connector.
2. Check for continuity between compressor magnetic clutch and a body ground.
Continuity
Action
Yes
Adjust magnetic clutch clearance or check for compressor internal trouble.
No
Check ground. If ground is OK, replace compressor magnetic clutch.
COMPRESSOR CLUTCH DOES NOT OPERATE (STEP 3: CHECK REFRIGERANT
PRESSURE)
1. Turn the ignition switch to OFF position.
2. Connect high-pressure hose to manifold gauge to high pressure gaugefitting.
3. Check refrigerant pressure at high-pressure side.
High-pressure side: Above 88psi(608kPa)
4. If not as specified, check refrigerant system.(Refer to "Step2: checking refrigerant pressure")
5. If correct, replace cooler pipe No. 1.
CONDENSER FAN DOES NOT OPERATE (STEP 1: CHECK CONDENSER FAN
OPERATION)
1. Disconnect condenser fan connector G-11.
2. Apply 12V to the terminal 1(L/B) and ground terinal 2(B) and verifythat condenser fan operates.
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3. If condenser fan does not operate, replace condenser fan.
4. If condenser fan operates, go to step 2.
CONDENSER FAN DOES NOT OPERATE (STEP 2: CHECK VOLTAGE AT CONDENSER
FAN)
1.
2.
3.
4.
Verify that condenser fan connector G-11 is disconnected.
Run engine at idles.
Turn the A/C and blower switches to ON position.
Check for voltage at following terminal wire of wiring harness connector G-11.
Terminal
Voltage
Action
12V
Replace condenser fan.
0V
Proceed to inspection.
1 (L/B)
INSPECTION (CONDENSER FAN RELAY)
1. Disconnect condenser fan relay from fuse box in engine compartment.
2. Check for continuity between following terminals of the relay.
3. If not as specified, replace the relay.
Terminals
Action
85-86
Yes
87-30
No
4. If correct, go to next step.
5. Apply 12V to the terminal 85 and ground the terminal 86.
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6. Check for continuity between terminals 87 and 30.
Terminals
Action
87-30
Yes
7. If not as specified, replace the relay.
8. If relay is OK, go to step 3.
CONDENSER FAN DOES NOT OPERATE (STEP 3: CHECK VOLTAGE AT CONDENSER
FAN RELAY)
1.
2.
3.
4.
Verify that condenser fan relay is disconnected.
Run engine at idles.
Turn the A/C and blower switches to ON position.
Check for voltage at following terminal of condenser fan relay connector G-10.
Terminal
Voltage
Action
12V
Proceed to terminal 2(G/R).
0V
Repair or replace the wire "L"
12V
Go to next step.
0V
Repair or replace the wire "G/R".
1 (L)
2 (G/R)
5. Check for voltage between terminal 2(G/R) and following terminal ofcondnser fan relay connector G-10.
Terminal
Voltage
Action
12V
Go to step 4.
0V
Check for a poor connection at ground. If OK,repair
the wire "B".
4 (B)
CONDENSER FAN DOES NOT OPERATE (STEP 4: CHECK VOLTAGE AT CONDENSER
FAN)
1. Verify that condenser fan connector G-11 is disconnected.
2. Run engine at idles.
3. Turn the A/C and blower switches to ON position.
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4. Check for voltage at following terminal wire of wiring harness connector G-11.
Terminal
Voltage
Action
12V
Rechck system.
0V
Repair or replace the wire "L/B"
1 (L/B)
COMPRESSOR AND CONDENSER FAN DO NOT OPERATE (STEP 1: CHECK FUSE
AND RELAY
1. Check fuses.
2. If a fuse is open, check for a sort circuit in wiring harness before replacing fuse.
3. If fuse is OK, proceed to inspection.
Terminal
Amperage
Location
BLOWER
30A
Engine compartment fuse/relay box.
COOLING FAN
20A
Engine compartment fuse/relay box.
INJECT
15A
Engine compartment fuse/relay box.
WIPER
15A
LH inner pillar below instrument.
INSPECTION (A/C RELAY)
1. Disconnect A/C relay.
2. Check for continuity between following terminals of the realy.
3. If not as specified, replace the relay.
Terminals
Continuity
85-86
Yes
87-30
No
4. If correct, go to next step.
5. Apply 12V to the terminal 85 and ground the terminal 86.
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6. Check for continuity between terminals 87 and 30.
Terminals
Continuity
87-30
Yes
7. If not as specified, replace the relay.
8. If correct, go to step 2.
COMPRESSOR AND CONDENSER FAN DO NOT OPERATE (STEP 2: CHECK VOLTAGE
AT A/C SWITCH
1. Turn the ignition switch to ON position.
2. Verify that the blower and A/C switches are in OFF position.
3. Check voltage at the following terminal of A/C switch connector G-05.
Terminal
Voltage
Action
12V
Go to next step.
0V
Repair or replace the wire "L"
3 (L)
4. Turn the A/C switch to ON position.
5. Check boltage at following terminal of A/C switch connector G-05.
Terminal
Voltage
Action
12V
Go to next step.
0V
Check for a poor connectiion at A/C switch. If OK,
inspect A/C switch.
5 (BR)
6. Check voltage between the terminal 3(L) and following terminal of A/C switch connector G-05.
Terminal
Voltage
Action
12V
Go to next step.
0V
Repair or replace the wire “L/R” betweenA/C switch
and blower switch.
4 (L/R)
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7. Check voltage between the rerminal 3(L) and following terminal of A/C switch connector G-05.
Terminal
Voltage
Action
12V
Go to step 3.
0V
Check for a poor connection at A/C switch. IfOK,
inspect A/C switch.
1 (BR/Y)
COMPRESSOR AND CONDENSER FAN DO NOT OPERATE (STEP 3: CHECK VOLTAGE
AT A/C THERMOCON)
1. Turn the ignition switch to ON position.
2. Turn blower and A/C switches to ON position.
3. Check voltage at following terminal of A/C thermocon connector G-06.
Terminal
Voltage
Action
12V
Go to next step.
0V
Repair or replace the wire "BR".
1 (BR)
4. Check for voltage between terminal 1(BR) and following terminal of thermocon connector G-06.
Terminal
Voltage
Action
12V
Go to next step.
0V
Repair or replace the wire "BR".
3 (BR/Y)
5. Check for voltage between terminal 3(BR/Y) and following terminal of thermocon connector G-06.
Terminal
Voltage
Action
12V
Proceed to inspection.
0V
Check for a poor connection at A/C thermocon. If OK,
inspect thermocon.
2 (Y/G)
INSPECTION (A/C THERMOCON)
1. Disconnect A/C thermocon connector G-06.
2. Apply 12V to the terminal 1(BR) and ground terminal 3(BR/Y).
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3. Connect a test light between the terminal 2(Y/G) and C(BR/Y) of A/C thermocon connector G-06.
Temperature
Test light
Remark
Above 39.2 F
(4°C)
ON
OK
OFF
NG
ON
NG
OFF
OK
Below 34.7 F
(1.5°C)
4. If not as specifiedm replace the A/C thermocon.
5. If correct, go to step 4.
COMPRESSOR AND CONDENSER FAN DO NOT OPERATE (STEP 4: CHECK VOLTAGE
AT A/C DUAL PRESSURE SWITCH)
1.
2.
3.
4.
Turn the ignition switch to ON position.
Run engine idles.
Turn blower and A/C switches to ON position.
Check voltage at following terminal of A/C dual pressure switch connector G-07.
Terminal
Voltage
Action
12V
Proceed to terminal A(W/R).
0V
Repair or replace the wire "G/Y"
12V
Go to step 5.
0V
Check for a poor connection at A/C dual pressure
switch. If OK, inspectdual pressure switch.
2 (G/Y)
1 (W/R)
COMPRESSOR AND CONDENSER FAN DO NOT OPERATE (STEP 5: CHECK
REFRIGERANT PRESSURE)
1. Turn the ignition switch to OFF position.
2. Connect A/C manifold gauge set.
3. Operate engine at 2000 rpm and set air conditioner to maximum cooling.
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4. Check high-pressure side refrigerant pressure.
Refrigerant pressure
Action
Below 185 psi(1,275kPa)
Normal operation
Above 185 psi(1,275kPa)
Replace dual pressure switch.
INSUFFICIENT COOLING, NO COOLING, INTERMITTENT COOLING (STEP 1:
CHECKING REFRIGERANT CHARGE)
1. Run engine at a fast idle.
2. Operate air conditioner at maximum cooling for a few minutes, go to step 2.
INSUFFICIENT COOLING, NO COOLING, INTERMITTENT COOLING (STEP 2:
CHECKING REFRIGERANT PRESSURE)
1. Connect A/C manifold gauge set.
2. Operate engine at 2,000 rpm and set air conditioner to maximum colling.
3. Check for low-pressure and high-pressure.
Normal pressure :
Low-pressure side: 20~41 psi (137~284 kPa, 1.40~2.90 kg/cm²)
High-pressure side:185~263 psi (1,275~1,814 kPa, 12.0~18.5 kg/cm²)
4. If pressures are not as specified, (refer to following chart and check system.)
TROUBLESHOOTING
Measured pressure
Low-side: 8.5~14.2 psi
High-side: 119~136 psi
Possible causes
Insufficient refrigerant
Action
Refer to case 1
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Low-side: Above 34.1 psi
High-side: Above 327 psi
Excessive refrigerant or
insufficient condenser
cooling
Refer to case 2
Low-side: Above 34.1 psi
High-side: Above 377 psi
Air in system
Refer to case 3
Low-side: Below 20 psi
High-side: Below 88 psi
Moisture in system
Refer to case 4
Low-side: Below 20 psi
High-side: Below 88 psi
No refrigerant circulation
Refer to case 5
Low-side: 35.6 psi
High-side: 307~326 psi
Expansion valve stuck
open
Refer to case 6
Low-side: 57~85 psi
High-side: 107~152 psi
Faulty compressor
Refer to case 7
CASE 1: INSUFFICIENT REFRIGERANT
Measured pressure :
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Low-pressure side:8.5~14.2 psi (58.9~98.1 kPa, 0.6~1.0 kg/cm²)
High-pressure side:119~136 psi (842~942 kPa, 8.4~9.6 kg/cm²)
Outlet air from vents is not cold.
STEP 1
1. Check for oil stains on pipes, hoses and other parts.
2. If oil stains is found at connection of pipes or hoses, replace O-ring; then,evacuate, charge, and test system.
(Refer to operating instructions of your refrigerant recovery/recycling/charging station for proper procedures.)
3. If oil stain is not found, go to step2.
STEP 2
1. Check for leakage from following connection with a gas leak tester.
A.Inlet and outlet of condenser
B.Inlet and outlet of receiver/drier
C.Inlet and outlet of compressor
D.Inlet and outlet of cooling unit
2. If leakage is evident, go to Step 3.
3. If leakage cannot be found, evacuate, charge and test system. (Refer to operating instructions of your refrigerant
recovery/recycling/charging station for proper procedures.)
STEP 3
1. Check tightening torque of connection where leak was detected.
2. If connection is loose, tighten connection to specified torque; then evacuate, charge, and test system. (Refer to
operating instructions of your refrigerant recovery/recycling/charging station for proper procedures.)
3. If connection is properly tightened, replace O-ring; then evacuate, charge, and test system. (Refer to operating
instructions of your refrigerant recovery/recycling/charging station for proper procedures.)
CASE 2: EXCESSIVE REFRIGERANT OR INSUFFICIENT CONDENSER COOLING
Measured pressure :
Low-pressure side: 34.1 psi (235 kPa, 2.40 kg/cm²2)
High-pressure side: 327 psi (2,256 kPa, 23.0 kg/cm²)
If condenser fan does not operate when air conditioner is operating, (Refer to "Condenser Fan Does Not
Operate")
STEP 1
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1. Check condenser for bent fins or damage.
2. If condenser is OK, discharge excess refrigerant. (Refer to operating instructions of your refrigerant recovery/
recycling/charging station for proper procedures.)
Always wear gloves and eye protection when discharging refrigerant.
3. Verify that refrigerant pressure is normal.
CASE 3: AIR IN SYSTEM
Measured pressure
Low-pressure: Above 34.1 psi (235 kPa, 2.40 kg/cm²)
High-pressure: Above 377 psi (2,600 kPa, 26.5 kg/cm²)
1. Condition Insufficient Cooling
STEP 1
Discharge refrigeration system. (Refer to operating instructions of your refrigerant recovery/recycling/charging
station for proper procedures.)
STEP 2
Evacuate system to remove all air from it. (Refer to operating instructions of your refrigerant recovery/ recycling/
charging station for proper procedures.)
STEP 3
Charge system with refrigerant. (Refer to operating instructions of your refrigerant recovery/recycling/ charging
station for proper procedures.)
STEP 4
After charging, measure refrigerant pressure. (Refer to "Checking Refrigerant Pressure")
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STEP 5
If low-and high-pressure sides are still too high, replace receiver/drier.
CASE 4: MOISTURE IN SYSTEM
Measured pressure :
Low-pressure: Below 20 psi (137 kPa, 1.40 kg/cm²)
High-pressure: Below 88 psi (608 kPa, 6.20 kg/cm²)
Intermittent cooling. (Moisture in refrigerationsystem freezes in expansion valve and causes temporary
blocking. After time,ice melts and condition returns to normal.)
STEP 1
Discharge refrigeration system. (Refer to operating instructions of your refrigerant recovery/recycling/ charging
station for proper procedures.)
STEP 2
Evacuate system to remove all air and moisture from it. (Refer to operating instructions of your refrigerant recovery/
recycling/charging station for proper procedures.)
STEP 3
Charge system with refrigerant. (Refer to operating instructions of your refrigerant recovery/recycling/ charging
station for proper procedures.)
STEP 4
After charging, measure refrigerant pressure. (Refer to "Checking Refrigerant Pressure")
STEP 5
If low-and high-pressure sides are still too high, replace receiver/drier.
CASE 5: NO REFRIGERANT CIRCULATION
Measured pressure :
Low-pressure: Below 20 psi (137 kPa, 1.40 kg/cm²)
High-pressure: Below 88 psi (608 kPa, 6.20 kg/cm²)
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Refrigerant flow obstructed by moisture or dirt, causing freezing or blockage of expansion valve.
STEP 1
1. Turn air conditioner OFF for about 10 minutes. Turn air conditioner ON to determine whether blockage is due to
moisture or dirt.
A.If caused by moisture: System will operate normally after being OFF for 10 minutes. (Ice melts and relieves
blockage.)
B.If caused by dirt: System remains abnormal after being OFF 10 minutes. Go to Step 2.
STEP 2
1.
2.
3.
4.
Remove expansion valve.
Blow out dirt with compressed air.
If unable to remove dirt, replace expansion valve.
Evacuate, charge, and test system. (Refer to operating instructions of your refrigerant recovery/recycling/
charging station for proper procedures.)
CASE 6: EXPANSION VALVE STUCK OPEN
Measured pressure :
Low-pressure: Above 35.6 psi (245 kPa, 2.50 kg/cm²)
High-pressure: 307-326 psi (2,119~2,247kPa, 21.6~22.9 kg/cm²)
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Insufficient cooling.
STEP 1
1. Check whether there is frost or heavy dew on suction pipe (between cooling unit and compressor).
2. If neither is found, (refer to "Case 2: Excessive Refrigerant or Insufficient Condenser Cooling")
3. If either is found, replace expansion valve.
CASE 7: FAULTY COMPRESSOR
Measured pressure :
Low-pressure: 57-88 psi (392-608 kPa, 4.0~6.20 kg/cm²)
High-pressure: 107-152 psi 736-1,050 kPa, 7.50~10.7 kg/cm²)
No cooling.
STEP 1
1. Run engine at a fast idle.
2. Verify that A/C compressor clutch is ON when A/C switch and blower switch are ON.
3. If A/C compressor clutch remains OFF, refer to "A/C Compressor Clutch does not Operate".
MANIFOLD GAUGE SET (INSTALLATION)
Fittings for attaching manifold gauge set are on the high-and low-pressure pipes.
1. Close both hand valves of manifold gauge set.
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2. Connect the low-pressure hose to high-pressure gauge fitting.
3. Tighten hose nuts by hand only.
MANIFOLD GAUGE SET (LEAK TEST)
After evacuating system, (refer to operating instructions of your refrigerant recovery/recycling charging station for
proper procedures.) Check for leaks.
1. Connect a full refrigerant container to the service valve.
2. Open the high-pressure manual valve to charge system with refrigerant gas.
3. When low-pressure gauge reads 14 psi (98 kPa), close high-pressure manual valve.
4. Use a gas leak detector to check the system for leaks. If a leak is found, repair faulty component or connection;
then evacuate system again. Refer to operating instructions of your refrigerant recovery/recycling/charging
station for properprocedures.
MANIFOLD GAUGE SET (CHECKING REFRIGERANT PRESSURE)
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1. Connect manifold gauge set.
2. Operate engine at 2,000 rpm and set air conditioner to maximum cooling.
3. Measure low- and high-pressure sides.
Normal pressure
Low-pressure side: 20~41 psi (137~285 kPa, 1.40~2.91 kg·cm²)
High-pressure side: 185~263 psi (1,275~1,815 kPa, 13.0~18.5 kg·cm²)
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DRIVER AIR BAG MODULE
Handling air bag improperly may cause it to deploy, which may cause serious injury. Read all Service Warnings before
servicing.
Never service wiring or electrical components when any air bag is connected.
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REMOVAL
• Failure to follow all warnings, cautions, notices and procedure could result in personal injury or death.
• Surface of a deployed airbag may contain small amounts of sodium hydroxide(NAOH). Prevent contact of
airbag module with liquids, combustibles, and flammable materials.
Immediately wash hands and exposed skin areas with soap and water.
Flush eyes with water if exposed to by products. Failure to following to following these instructions could
result in chemical burns and personal injury.
• A live(undeployed) airbag module may accidently deploy during handling. When carrying a live airbag
module, point trim cover away from you body to lessen chance of injury in case of assidental deployment.
Never carry module by its wiring orconnectors.
• Always place live airbag modules face up to lessen motion of module in case of accidental deployment.
keep area clear of parts, tools, and debris.
• Never place items on or above trim cover of a live airbag module. In case of accidental deployment, such
items may cause serious injury or death.
• Damaged airbag modules should be stored away from all acids, halogens, heavy metals and metal salts.
Damaged units may produce hydrozoic acid if exposed to liquids. If an undeployed airbag module or inflator
is ruptured or tampered with, refer to particular module?
MSDS(Material safety data sheet) for important information concerning constituents of undeployed modules.
Exposure to high concentrations of propellant mixture can cause headaches, cyanosis, lowering of blood
preessure or tachyacrdia.
Failure to comply with this warning can result in fire, noxious fumes, sever personal injury or death.
• Airbag module components are very hot after deployment. Units should be deployed outdoors or in an open
area to prevent fires. Allow components at leats twenty minutes to thoroughly cool. Cooling modules should
be continuously monitored to ensure hot components do not create fires with spilled liquids or other debris.
Failure to allow unit to cool could result in burns fires or personal injury.
• Always wear rubber gloves and safety glasses when handling a deployed airbag module.
Storage, transportation, disposal and recycling of airbag module and components must be performed in
accordance with allapplicable state and local regulations including, but not limited to, environmental protection,
occupational health andsafety, and transportation.
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Failure to follow the following procedures could result in personal injury or death.
1. Remove battery.
2. Wait 10 minutes before proceeding.
3. Disconnect appropriate Airbag Module, and remove from vehicle. For Driver airbag module. For Passenger
Airbag Module.
4. Locate airbag in an area that will provide protection to personnel when it deploys. An example of a safe
deployment siteis a stack of used tires, 6-8 high, with undeployed bag located inside column of tires.
5. Connect the Air Bag Deployment Tool (K95U-6000-BDY) to the Air Bag Module connector, and position the
deployment tool 20 feet away from the deployment site.
6. Connect the red lead to the positive terminal of the battery.
7. Connect the black lead to the negative battery terminal.
Do not place the airbag with the trim cover facing down, as the force of the deploying airbag cause it to
ricochet and cause personal injury.
8. Verify that green POWER indicator on deployment tool is illuminated.
9. Depress and hold READY button (button number 1).
10. Verify that yellow READY indicator is flashing.
11. Depress and hold DEPLOY button (button number 2).
12. Verify that Air Bag module has deployed. If not, verify that red DEPLOY indicator is illuminated.
13. Release both READY and DEPLOY buttons.
14. Verify that both READY and DEPLOY indicators are no longer illuminated.
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15. If air bag successfully deployed, allow a minimum of twenty minutes for bag to cool before handling. Monitor
bag throughout cool-down period to ensure that hot components do not start a fire.
16. If air bag did not deploy, keep area around deployment site clear of personnel for a minimum of 30 minutes.
17. Disconnect the power leads from the battery.
18. Remove the air bag from the stack of tires carefully, wearing rubber gloves and eye/face protection to protect
yourself from possible chemical exposure.
19. Dispose of the complete air bag assembly. No part of the air bag may be reused. Place the air bag into a sturdy
plastic bag and seal securely. Dispose of the deployed air bag according to federal, state and local laws and
regulations including, but not limited to, EPA and OSHA regulations.
20. Install battery.
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CLOCKSPRING
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REMOVAL
Follow General Procedure before removal.
Orange and blue connectors are exclusive to air bag-SRS harness. Connector half with female pins consists of
two separate shells : one for airbag-SRS, other for horn. These two shells are mechanically configured to
provide blue airbag-SRS shell with two retention latches, reducing possibility of an unwanted separation during
a collision. Blue airbag-SRS shell also contains a safety feature that shunts its two pins together when it is
disconnected. This feature helps prevent unintentional airbag deployment.
When disconnecting two shells, it is necessary to remove orange shell first. Reconnection is reverse order of
disconnection.
1)Do not disassemble any of actual airbag-SRS components. Disassembly of components can render system
inoperative, which may result in serious injury or death in event of an accident. Never attempt to
disassemble or repair airbag modules.
2)Any attempt to adapt, re-use, or install an airbag module or its components in another vehicle may result in
serious injury or death to vehicle occupants in event of an accident.
3)Do not cut or otherwise remove airbag module connector. Connector contains a safety shunt and disabling
that shunt couldcause unplanned deployment, which may cause severe personal injury or death.
4)A live(undeployed) airbag may accidently deploy during handling. When carrying a live airbag module, point
trim cover away from your body to lessen chance of injury in case of accidental deployment. Never carry
module by its wiring or connectors.
5)Always place live airbag modules face up to lessen motion of module in case of accidental deployment.
Keep area clear of parts, tools and debris.
6)Never place items on or above trim cover of a live airbag module.
In case of accidental deployment, such items may cause serious injury or death.
1.
2.
3.
4.
Remove four airbag module retaining bolts from backside of steering wheel.
Pull airbag module away from steering wheel.
Disconnect airbag module connector from clockspring assembly and remove driver airbag module from vehicle.
If necessary, dispose of airbag module. Refer to Airbag Deployment and Disposal.
REMOVAL
Clockingspring connector part of combination switch and is not serviced as a separate part.
1. Remove driver airbag module.
2. Remove steering nut. Mark steering wheel and steering shaft so that their relative positions will be known during
re-installation.
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3. Using a suitable wheel puller, remove steering wheel.
4. Remove three clocking assembly retaining screws, disconnect three connectors and remove clockspring
assembly.
INSTALLATION
1. Ensure that front wheels are pointing straight ahead.
2. Holding surface of airbag away from you, couple blue airbag-SRS connectors, them clouple the orange horn
connectors.
Orange and blue connectors are keyed to fit only one (1) way. When properly assembed, whey will slip into
place(using slight pressure) with an audible "click".
Do not force. If undue force required, connectors are not aligned properly.
3. Set module into steering wheel, taking care not to pinch wiring harness.
Tightening torque : 69~104 lb·in (8~12 N·m, 80-120 kg·cm)
4. Verify that no trouble codes are present.(Refer to Diagnostic Trouble Codes and Associated Procedures).
If clockspring assembly has been removed. (Refer to Diagnostic Trouble Codes and Associated Procedures)
INSTALLATION
1. Temporarily install streeing wheel and turn front wheel so that front wheels are pointing straight ahead.
An alignment pin is used to aid alignment of clockspring connector when installing streering wheel onto
steering wheel onto steering column. An alignment pin is provided with a new combination switch, but a
substitute pin will be needed when re-aligning an orginal clockspring.
Substitute pin should be 3mm(0.12in.) in diameter and at least 76mm(3.0in) long.
2. Install clockspring assembly and retain with three screws. Connect three clockspring assembly connectors.
Tightening torque : 8lb·in (0.92N·m, 9.3kg·cm)
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3. Rotate center portion of clockspring connector clockwise until it stops. Proceed to rotate center counterclockwise
2 3/4turns and align arrow on center decal with arrow on housing.
4. While holding arrows aligned, insert alignment pin into hole on front face of center portion until it engages in hole
located on back side of housing.
5. Re-install steering by lining up marks applied during removal. Alignment pin passes through oblong hole in
steering wheel that is located immediately above hole for steering shaft steering wheel nut finger tight.
6. Remove alignment pin and tighten nut.
Tightening torque : 29~36lb·ft (36~49N·m, 4.0~5.0kg·m)
7. Re-install driver airbag module. Refer to Driver Airbag Module Installation.
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REMOVAL
Passenger Airbag Module
Handling airbag improperly may cause it to deploy, which may cause serious injury. Read Service Warnings
before servicing.
• Never service wiring or electrical components when any airbag is connected.
• Follow General Procedures guidelines.
1. Remove instrument panel.
2. Remove two mounting bolts and four screws.
3. Disconnect passenger airbag module connector from wiring harness.
Orange and blue connectors are exclusive to airbag-SRS harness. Connector half with female pins consists
of two separateshells : one for airbag-SRS, other for horn. These two shells are mechanically configured to
provide blue airbag -SRS shell with two retention latches, reducing possibility of and unwanted separation
during a collision. Blue airbag-SRS shell also contains a safety feature that shunts its two pins together
when it is disconnected. This feature helps prevent unintentional airbag deployment. When disconnecting
two shells, it is necessary to remove orange shell first.
Reconnection is reverse order of disconnection.
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• Do not disassemble any of actual airbag-SRS components. Disassembly of components can render
system inoperative, which may result in serious injury or death in event of an accident. Never attempt to
disassemble or repair airbag modules.
• Any attempt to adapt, re-use, or install an airbag module or its components in another vehicle may result
in serious injury or death to vehicle occupants in event of an accident.
• Do not cut or otherwise remove airbag module connector. Connector contains a safety shunt and
disabling that shunt couldcause unplanned deployment, which may cause severe personal injury or death.
• A live(undeployed) airbag may accidently deploy during handling. When carrying a live airbag module,
point trim cover away from your body to lessen chance of injury in case of accidental deployment. Never
carry module by its wiring or connectors.
• Always place live airbag modules face up to lessen motion of module in case of accidental deployment.
Keep area clear of parts, tools and debris.
• Never place items on or above trim cover of a live airbag module. In case of accidental deployment, such
items may cause serious injury or death.
4. Remove module from instrument panel.
5. If necessary, dispose of airbag module. Refer to Airbag Deployment and Disposal.
INSTALLATION
Take care not to pinch wiring harness with other vehicle parts during reassembly. Kinks in harness will fatigue
wires and may lead to intermittent circuit failure.
1. Couple airbag connector to vehicle wiring harness. (Refer to notice in Passenger Airbag Removal.)
2. Install passenger airbag module.
3. Install two mounting bolts.
Tightening torque : 155~232 lb·in (18~27 N·m, 180~270 kg·cm)
4. Install glove box.
5. Perform diagnosis. Refer to Diagnostic Trouble Codes and Associated Procedures.
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REMOVAL(ADU)
Improper handling of ADU may result in unexpected airbag deployment, which can cause serious injury. Read
all service warnings before performing service.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Follow General Procedures.
Remove ashtray.
Remove center panel trim.
Remove two console mounting screws (one each at lower front) and one console mounting screw at center.
Remove console box and remove two mounting bolts in console box.
Remove console.
Disconnect ADU connector.
Remove three mounting nuts.
Lift the ADU up and back and remove ADU from vehicle.
Removing ADU may require loosening of two nuts that secure automatic shift cable housing to tunnel.
• Do not disassemble any AIRBAG-SRS components. Disassembly can render system inoperative, which
may result in serious injury of death in event of an accident. Never attempt to disassemble or repair
airbag modules.
• Any attempt to adapt, re-sure or install an airbag module or its components in another vehicle may result
in serious injury or death to vehicle occupants in event of an accident.
INSTALLATION
Do not connect ADU connector before installing ADU securely. Shock of installtion or pinching wiring harness
between ADUand Its mounting points can cause airbags to deploy, which may cause serious injury.
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1. Install ADU on three mounting studs. Install three nuts and torque to specification.
Tightening torque : 69~120 lb·in (8~14 N·m, 80~140 kg·cm)
2.
3.
4.
5.
Connect wiring harness connector(s) to ADU.
Install console and its five mounting screws and two bolts.
Install center panel trim.
Perform diagnosis. Refer to Diagnostic Trouble Codes and Associated Procedures.
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AIRBAG-SUPPLEMENTAL RESTRAINT SYSTEM
The AirBag-supplemental Restraint System (SRS) is designed to supplement driver seat belts during front-end
collisions, reducing the risk of serious injury or death. Two collision-sensitive sensors are located in the Air Bag
Diagnostic Unit(ADU). These two sensors (Safing sensor and G-sensor) are electrically connected to the air bag
and the battery. In caseof a frontal crash, the G-sensor receives collision deceleration information. The collision
deceleration information is converted into digital data and transmitted to the CPU (Central Processing Unit). The
CPU calculates the digital data andcompares them with preprogrammed data to determine whether it has to send a
signal to deploy the air bag module or not.If the calculation of the CPU corresponds to the preprogrammed data, a
deployment signal is sent. At the same moment, the safing sensor, which is linked linearly on the deployment
circuit, checks whether the deceleration has occurred due to an actual collision, or by other electronic waves and
anomolies. So, the air bags will only deploy with a deploymentsignal from the CPU and closing of safing sensor
switch. The Driver is protected by a steering wheel mounted air bag. The Air bag-Supplemental Restraint System
consists of an Air Bag Module, Air Bag Diagnostic Unit, and wire harness & clock-spring assembly. The driver air
bag module consists of a bag cover, air bag, retainer ring, retainer housing and inflator. The passenger air bag
module consists of a deployment door, air bag assembly, inflator and retainer housing. Because of size difference,
the passenger airbag module incorporates a larger, tubular shaped inflator.
The driver air bag cover is made of TPE (Thermos Plastic Elastomer), and it splits along a tear seam in the event
of a collision. The air bag itself is made of Nylon 66, and the face contact surface is coated with silicone. A vent
hole is provided at back side of air bag to deflate air bag immediately after inflation so that it does not interfere witht
the drivers vision. The inflator produces nitrogen gas by igniting solid propellant pellets inside inflator. The ignitor is
triggered by an electrical current and the ignitors ignition intensifier, which in turn ignites propellant pellets causing
the air bag to deploy. A heat sink and filter within the unit cools and filters nitrogen gas as it enters air bag.
Air Bag Diagnostic unit (ADU) consists of a CPU, memory, auxiliary power supply and G-sensor and safing sensor.
An auxiliary power supply is installed to ensure air bag deployment if battery power is lost in a collision.
The CPU not only initiates air bag deployment but also performs the SRS self-test. CPU initiates a test sequence
every time ignition key is turned "ON" and the Air Bag Indicator is illuminated for 4~6 seconds. When the self test
sequence iscompleted and no fault is found, lamp goes out. If any failure is detected, the warning lamp will stay
"ON" or flash to warn driver. Even while driving, the CPU continually monitors circuits and components of air bag
system. If a failure occurs within system while driving, the warning lamp is immediately illuminated. Details of those
detected failures are stored in memory and can be retrieved with Kia Power Scan Tool.
The clock spring assembly is incorporated into the combination switch to provide a positive connection between
vehicle wire harness and driver air bag module while allowing sufficient rotation for vehicle steering. This assembly
is also replaced as a complete assembly only.
The Air Bag electrical connector has a shorting bar which will short across Air Bag assembly circuits when the Air
Bag connector is disconnected. The Air Bag circuit is automatically shorted by the shorting bar in this way to help
prevent unwanted deployment of the Air Bag when servicing the instrument panel, Air Bags or other SRS
components.
Service Warning
• Personal safety
Failure to follow all warnings, cautions, notices and procedures could result in personal injury or death.
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• Power supply deactivation
Airbag-SRS diagnostic unit contains a backup power supply. Before disconnecting airbag-SRS components,
turn ignition switch to LOCK, disconnect battery (negative terminal first), and wait 10 minutes for backup power
supply to discharge. Failure to follow this procedure could cause airbag modules to deploy during service
procedures, which may cause serious injury.
• Safety equipment
Airbag surface may be contaminated with small amounts of sodium hydroxide(NaOH). Prevent contact of airbag
module with liquids, combustibles, and flammable materials. Immediately wash contaminated hands and skin
areas with mild soap and water, flush eyes with water if exposed to byproducts. Failure to follow these
instructions could result in chemical burnsand personal injury.
• Always wear safety glasses when handling airbag modules.
• Always wear rubber gloves when handling deployed or damaged airbag modules.
• Wiring and electrical components
Never service wiring or electrical components when any airbag and pretensioner is connected. When a
procedure directs use of a multimeter to probe pins of a connector, insert probes into back of connector where
possible. If you must probe front face(terminal side), be certain to use a probe whose tip will not damage
terminals when it is inserted.
• Component disassembly
Do not disassemble any airbag-SRS components. Disassembly can render system inoperative, which may
result in serious injury or death in event of an accident. Never attempt to disassemble or repair airbag modules.
Any attempt to adapt, re-use, or install an airbag module or its components in another vehicle may result in
serious injury or death to vehicle occupants in event of an accident.
• Airbag diagnostic unit (ADU)
Do not connect ADU connector unless ADU is securely installed. Shock of installation or pinching wiring
harness between module and its mounting points can cause airbags and pretensioner to deploy, which may
cause serious injury.
• Airbag module inspection
Do not probe or inspect airbag modules or any of their connectors with an ohmmeter. Inspecting airbag module
with an ohmmeter, which supplies current, can cause airbags to deploy, resulting in serious injury.
• Airbag module connector
Do not cut or otherwise remove the airbag module connector. Connector contains a safety shunt which, if
disabled, could cause an unintended deployment. This may cause severe personal injury or death.
• Airbag module handling
A live(undeployed) airbag may accidently deploy during handling. When carrying a live airbag module, point
plastic trim cover away from your body to lessen chance of injury in case of accidental deployment. Never carry
module by its wiring or connectors.
• Securing modules
Always place live airbag modules face up (plastic trim side up) to lessen motion of the module in case of
accidental deployment. Keep the area clear of parts, tools and other debris. Never place items on or above the
trim cover of a live airbag module. In case of accidental deployment, such items may cause serious injury or
death.
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• Live airbag module storage
Live airbag modules contain solid flammable material. Store in a cool, dry, secure area. Do not expose them to
open flame or temperatures in excess of 300¡ F. Do not cut, drill, braze, solder or weld an airbag module or any
of its components. Never expose the module or any of its components to electricity. Failure to comply with this
warning can lessen the integrity of the module, causing fires, chemical exposure, or unintended deployment,
which may causeserious injury or death.
• Damaged live airbag module storage
Damaged live airbag modules should be stored away from all acids, halogens, heavy metals and metal salts.
Damaged units may produce hydrozoic acid if exposed to liquids. If an undeployed airbag module or inflator is
ruptured or tampered with, refer to the Material Safety Data Sheet (MSDS) for the particular module for
important information concerning the constituents of undeployed modules. Exposure to high concentrations of
propellant mixture can cause headaches, nausea, blurred vision, faintness, cyanosis, lowering of blood
pressure or tachycardia.
Failure to comply with this warning can result in fire, noxious fumes, severe personal injury or death.
• Out-of-vehicle deployment
Out-of-vehicle deployment should be performed in an open area, away from other personnel. Verify that there is
no loose debris or flammable liquid near the air bag assembly. All personnel should be behind protective cover
(i.e., wall, vehicle) to shield their bodies from potential projectiles. Do not attempt to deploy a ruptured airbag
module. Failure to comply with thiswarning may result in severe injury or death. Refer to Airbag Deployment
and Disposal.
• Danger of fire
Airbag module components are very hot after deployment. Units should be deployed outdoors or in open areas
to prevent fires. Allow components at least twenty minutes to thoroughly cool. Cooling modules should be
continuously monitored to ensure hot components do not create fires with spilled liquids or other debris. Failure
to allow the unit to cool could result in burns, fires or personal injury.
• Storage/Transportation/Disposal/Recycling
Storage, transportation, disposal and recycling of airbag module and components must be performed in
accordance with each region regulations.
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CIRCUIT DIAGRAM
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SPECIFICATIONS
Driver airbag installation bolts
Passenger airbag installation bolts
69~104lb·in (8~12N·m, 80~120kg·cm)
155~232lb·in (18~27N·m, 180~270kg·cm)
Steering wheel installation nut
29~36lb·ft (39~49N·m, 180~270kg·cm)
ADU installation nuts
69~120lb·in (8~14N·m, 80~140kg·cm)
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GENERAL PROCEDURE
1. Before servicing
(1) Turn the ignition switch to LOCK.
(2) Disconnect the battery
(3) Wait 10 minutes for the backup power to discharge completely.
2. After servicing
(1) Reconnect the battery.
(2) Turn the ignition switch to ON
(3) Verify that airbag indicator illuminates for 4-6 seconds and then goes off.
Step
1
Inspection
Does the indicator illuminate for a period of 4-6
seconds when ignition switch is turned to ON
position, and then go off?
Action
Yes
Go to step 8.
No
Go to next step.
Yes
Replace the fuse with another 10A fuse and
check for short in its associated wire harness.
Repair as necessary. and then go to step 8.
No
Go to next step.
Follow "General procedures" (see above).
Remove instrument cluster and check
connector C-01. Are pins secure and are
connectors locked in place?
Yes
Go to next step.
No
Repair malfunction and then reinstall cluster.
Go to step 8.
Perform a continuity check between the
terminal A3 (Y) of C-01 and terminal B11 (Y) of
C-01(NOT on wiring harness). Dose continuity
exist?
Yes
Lamp is good. Go to next step.
No
Lamp is burnt. Replace it, reinstall instrument
cluster and go to step 8.
Connect battery and verify battery voltage
(approximately 12V). Turn the ignition switch to
ON position. Are there approximately 12V at
the terminal A3 (Y) of connector C-01?
Yes
Go to next step.
No
Check harness for opens or a short to ground
between "METER" fuse and instrument cluster.
Repair as necessary. Go to step 8.
Connect a voltmeter between the terminal A3
(Y) of C-01 and B11 (Y) of C-01. Is 12V present
for approximately 4~6 seconds when the
ignition switch is turned to ON position, and
then or out.
Yes
Go to step 8.
No
Check harness for open or a short to ground
between instrument cluster and airbag
diagnostic unit.
Repair as necessary and go to next step.
Dose the indicator illuminate for a period of 4~6
seconds when ignition switch is turned to ON
position, and then go out?
Yes
Go to next step.
No
Replace airbag diagnostic unit.
(Refer to Airbag Diagnistic Unit)
Dose the indicator illuminate constantly after
initial 4~6 second period?
Yes
(Refer to Diagnostic Trouble Code
Troubleshooting)
2
Use the fuse extraction tool in passenger
compartment fuse box to extract "METER
(10A)" fuse. Is it open?
3
4
5
6
7
8
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No
Airbag indicator is OK?
DIAGNOSTIC TROUBLE CODES AND ASSOCIATED PROCEDURE
Airbag system
1.
2.
3.
4.
5.
6.
Turn ignition switch to ON.
The Airbag indicator should illuminate. If it does not, see Airbag Indicator Service.
The Airbag Indicator should go out within 4~6 seconds. If it stays out, system is OK.
If Airbag Indicator remains illuminated, there is a problem in Airbag-Supplemental Restraint System(SRS).
Turn ignition switch to LOCK.
Locate Data Link Connector (DLC) in engine compartment and install Hi-Scan Pro Tool.
7. Turn ignition switch to ON and record any Diagnostic Trouble Codes displayed by Hi-Scan Pro Tool.
8. Refer to Airbag Diagnostic Troubles Codes Chart for fault description and actions.
Servicing airbag system improperly may cause it to deploy, which CAN cause serious injury or death. Must read and
follow all service warnings before servicing.
Never service wiring or electrical components when airbag is connected.
Airbag Diagnostic Trouble Code (DTC) Chart
Diagnostic
Trouble Code
Fault Description
Possible Cause
Warning
Light Mode
Corrective Action
01~03
10~11
ADU Fault
Internal Fault
1
Replace Airbag
Diagnostic Unit(ADU)
18~32
ADU Fault
Intermal Fault
1
Replace Airbag
Diagnostic Unit(ADU)
33
ADU Fault
Intermal Fault
1
Replace Airbag
Diagnostic Unit(ADU)
34
Power Supply Low
Power Supply vlotage below 8.0
volts
5
Repair or replace battery
or harness
35
Power Supply High
Power Supply High voltage 16
volts
5
Repair or replace battery
or harness
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36
Warning Light Short
Warning Light damaged, or
short circuit in harness
5
Repair or replace
warning light or harness
53
Drive Module Short to
ground
Driver Module damaged, or
shorted to ground
5
Replace module or
harness
54
Driver Module Short to
battery
Driver Module damaged, or
circuit shorted to battery.
5
Replace module or
harness
55
Driver Module short
Driver Module damaged, or
short circuit in harness
5
Replace module or
harness
56
Driver Module Open
Driver Module Damaged, or
open circuit in harness
5
Replace module or
harness
57
Passenger Module Short
to ground
Passenger Module damaed, or
circuit shorted to ground
5
Replace module or
harness
58
Passenger Module Short
to battery
Passenger Module damaged, or
circuit shorted to battery.
5
Replace module or
harness
59
Passenger Module Short
Passenger Module damaged, or
open circuit in harness
5
Replace module or
harness
60
Passenger Module Open
Passenger Module damaged, or
circuit in harness
5
Replace module or
harness
61
Driver pretensioner short
to ground
Driver pretensioner damaged, or
circuit shorted to ground
5
Replace pretensioner or
harness
62
Driver pretensioner short
to battery
Driver pretensioner damaged, or
circuit shorted to battery
5
Replace pretensioner or
harness
63
Driver pretensioner short
Driver pretensioner damaged, or
open circuit in harness
5
Replace pretensioner or
harness
64
Driver pretensioner open
Driver pretensioner damaged
5
Replace pretensioner or
harness
65
Passenger pretensioner
short to ground
Passenger pretensioner
damaged, or circuit shorted to
ground
5
Replace pretensioner or
harness
66
Passenger pretensioner
short to battery
Passenger pretensioner
damaged, or circuit shorted to
battery
5
Replace pretensioner or
harness
67
Passenger pretensioner
short
Passenger pretensioner
damaged, or short circuit in
harness
5
Replace pretensioner or
harness
68
Passenger prtensioner
open
Passenger pretensioner
damaged, or open circuit in
harness
5
Replace pretensioner or
harness
77~80
ADU Inconsistency(exclusive of PAB)
ADU unmatching, with
components
5
Replace Air Bag
Diagnostic Unit(ADU)
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Warning light operating modes :
Mode 1 :
Warning Light will be illuminated for reminder of ignition ON cycle, but it will not be illuminated after next ignition ON cycle if
fault has self-corrected.
Mode 5:
Warning Light will be illuminated for reminder of ignition ON cycle, but it will go out approximately 10 seconds later if fault has
corrected at the same ignition ON cycle.
Connector Pin
No.
Description
No.
Description
1
Driver pretensioner (+)
16
Short bar (harness side)
2
Driver pretensioner (-)
17
Short bar (harness side)
3
Passenger pretensioner (-)
18
Short bar (harness side)
4
Passenger pretensioner (+)
19
Short bar (harness side)
5
Supply Power (IG1) +
20
-
6
Ground (Airbag warning light LOW)
21
Short bar (harness side)
7
Airbag warning light
22
Short bar (harness side)
23
-
8
-
9
Communication (K-line)
24
-
10
Driver airbag module +
25
Short bar (harness side)
11
Driver airbag module -
26
Short bar (harness side)
27
-
12
-
13
Passenger airbag module +
28
Short bar (harness side)
14
Passenger airbag module -
29
Short bar (harness side)
30
-
15
-
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Airbag Diagnostic Trouble Code
Servicing airbag system improperly may cause it to deploy, which cause serious injury or death.
Must read and follow all service warnings.
Never service wiring or electrical components when airbag is connected.
Diagnostic Trouble Code : 01-03, 10-11, 18-32 Internal Fault
Step
1
Inspection
Internal fault. There is no inspection or service
possible for this diagnostic trouble code.
Action
Replace Airbag Diagnostic Unit(ADU).
(Refer to Airbag Diagnostic Unit (ADU))
Diagnostic Trouble Code : 33/34 Power supply Low/High
Before inspection : There faults are concerned with the operating voltage of the ADU. Therefore, check the battery voltage
first and check it under the engine cranking for additional checking on charging device. "Air bag(10A)" fuse also should be
checked.
Step
1
2
Inspection
Disconnect airbag diagnostic unit connector S01.
Trun the ignition switch to ON position.
Is battery voltage (9~12V) present at the
terminal 5(W/G) of harness connector S-01?
Turn ignition switch to OFF position.
Disconnect X-27 and then turn the ignition
switch to ON position.
Is battery voltage (9~16) present at the terminal
2(W/G) of X-27?
Action
Yes
Go to step 3.
No
Go to next step.
Yes
Replace wire harness between S-01 and X-27.
No
Replace wire harness between "AIRBAG(10A)"
fuse and X-27.
Yes
Temporarily install a known good ADU. Go to
Diagnostic Trouble Codes and Associated
Procedures. If problem is corrected, replace
ADU.
No
Replace harness between S-01 and ground.
3
Check for continuity between the terminal6(B)
of S-01 and ground.
Is continuity present?
Diagnostic Trouble : 35 Warning Light Short
*For the fault concerned with warning light Mode 5, the warning light will go out approximately 10 seconds after the occurred
faults are corrected.
Step
Inspection
1
Action
Yes
Go to next step.
Disconnect airbag diagnostic unit connector S01.
Is ground present at the terminal 7 at the
terminal 7(Y) of harness connector S-01?
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2
3
Disconnect connector X-27.
Is ground present at the terminal 7(Y) of S-01?
Disconnect instrument cluster connector C-01
from instrument cluster.
Is ground present at the terminal B11(Y) of C01?
No
Temporarily install a known good ADU. Go to
Diagnostic Trouble Codes and Associated
Procedures. If problem is corrected, replace
ADU.
Yes
Go to next step.
No
Replace wire harness between S-01 and X-27.
Yes
Go to next step
No
Replace wire harness between S-01 and X-27.
Diagnostic Trouble Code : 36 Warning Light Open
Step
1
Inspection
Disconnect airbag diagnostic unit connector S01.
Is there an open circuit between the terminal 7
(Y) of S-01 and the terminal B11(Y) of
instrument cluster C-01?
Yes
Go to next step.
No
Temporarily install a known good ADU. Go to
Diagnostic Trouble Codes and Associated
Procedures. If problem is corrected, replace
ADU.
Is there an open circuit between the terminal 1C
(Y) of C-01 and the terminal B11(Y) of C-01?
Yes
Repair or replace lamp bulb, socket, and circuit
print in instrument cluster.
No
Replace wire harness between S-01 and X-27.
Yes
Replace wire harness between X-27 and S-01.
No
Replace wire harness between C-01 and X-27.
2
3
Action
Is there an open circuit between the terminal 1
(Y) of X-27 and the terminal 7(Y) of S-01?
Diagnostic Trouble Code : 53 Driver Module Short to Ground
Step
1
2
Inspection
Action
Disconnect airbag diagnostic unit connector S01 and clock spring assembly connector S-09.
Yes
Replace harness between S-01 and S-09.
No
Go to next step.
Disconnect connector S-02 from driver airbag
module.
Is ground at the terminal 2(Y/R) or 3(R) of clock
spring connector S-09?
Yes
Replace clock spring assembly.
No
Replace driver airbag module.
(Refer to Driver Module)
Diagnostic Trouble Code : 54 Driver Module short to Battery
Step
1
Inspection
Disconnect airbag diagnostic unit connector S01 and clock spring assembly connector S-09.
is battery voltage present at the terminal 10(R)
or/and 11(Y/R) of S-01?
Action
Yes
Replace harness between S-01 and S-09.
No
Go to next step.
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2
Disconnect connector S-02 from driver airbag
module.
Is battery voltage at the terminal 2(Y/R) or 3(R)
of clock spring connector S-09?
Yes
Replace clock spring assembly.
No
Replace driver airbag module.
(Refer to Driver Module)
Diagnostic Trouble Code : 55 Driver Module short
Step
1
2
Inspection
Disconnect connector S-02 from driver airbag
module.
Is there short between the terminal 2(Y/R) or 3
(R) of clock spring connector S-09?
Disconnect connector S-09 from clock spring
assembly.
Is there a short circuit between the terminal 2(Y/
R) and terminal 3(R) of airbag harness S-09?
Action
Yes
Go to next step.
No
Replace driver airbag module.
(Refer to Driver Airbag Module)
Yes
Replace airbag harness between S-01 and S09.
No
Replace driver spring assembly.
Diagnostic Trouble Code : 56 Driver Module Open
Step
1
2
3
4
5
Inspection
Disconnect airbag diagnostic unit connector S01 and driver airbag module connector S-02.
Is there an open circuit between the terminal 11
(Y/R) of S-01 and terminal 2(Y/R) of S-02?
Disconnect connector S-05 from clock spring
assembly.
Is there an open circuit between the terminal 11
(Y/R) of S-01 and terminal 2(Y/R) of S-09?
Is there an open circuit between terminal B of S02 and 2(Y/R) of S-09?
Connect connector S-09 to clock spring
assembly.
Is there an open circuit between the terminal 10
(R) of S-01 and terminal C(R) of S-02?
Disconnect connector S-09 from clock spring.
Is there an open circuit between the terminal 10
(R) of S-01 and terminal 3(R) of S-09?
6
Is there an open circuit between terminal 2(Y/R)
of S-02 and terminal 3(R) of S-09?
Action
Yes
Go to next step.
No
Go to step 4.
Yes
Replace airbag harness between S-01 and S09.
No
Go to next step.
Yes
Replace clock spring assembly
No
Go to next step.
Yes
Go to next step.
No
Replace driver airbag module.
Yes
Replace airbag harness between S-01 and S09.
No
Go to next step.
Yes
Replace clock spring assembly.
No
Replace driver airbag module
(Refer to Driver Airbag Module)
Diagnostic Trouble Code : 57 Passenger Module Short to Ground
Step
Inspection
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Action
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1
Disconnect airbag diagnostic unit connector S01 and passenger airbag module connector S03.
Is ground present at the terminal 14(G/Y) or 13
(G/R) of S-01?
Yes
Replace wire harness between S-01 and S-02.
No
Replace passenger airbag module
(Refer to Passenger Airbag Module)
Diagnostic Trouble Code : 58 Passenger Module Short to battery
Step
1
Inspection
Disconnect airbag diagnostic unit connector S01 and passenger airbag module connector S03.
Is battery present at the terminal 14(G/Y) or 13
(G/Y) of S-01?
Action
Yes
Replace wire harness between S-01 and S-02.
No
Replace passenger airbag module
(Refer to Passenger Airbag Module)
Diagnostic Trouble Code : 59 Passenger Module Short
Step
1
Inspection
Disconnect connector S-02 from passenger
module.
Is there short between the terminal 14(G/R) or
13(G/R) of S-01?
Action
Yes
Replace wire harness between S-01 and S-03.
No
Replace passenger airbag module
(Refer to Passenger Airbag Module)
Diagnostic Trouble Code : 60 Passenger Module Open
Step
1
Inspection
Disconnect airbag diagnostic unit connector S01 and passenger airbag module connector S03.
Is there short between the terminal 14(G/Y) or
13(G/R) of S-01?
2
Is there an open circuit between the terminal 13
(G/R) of S-01 and terminal 3(G/R) of S-03?
Action
Yes
Replace wire harness between S-01 and S-03.
No
Go to next step.
Yes
Replace harness between S-01 and S-03.
No
Replace passenger module.
(Refer to Passenger Module)
Diagnostic Trouble Code : 61 Driver Pretensioner Short to Ground
Step
1
2
Inspection
Disconnect airbag diagnostic unit connector S01 and driver pretensioner connector S-07.
Is ground present at the terminal 1(LG) or/and 2
(O) of S-01?
Disconnect connector S-07 from driver
pretensioner.
Is ground at the terminal 1(LG) or/and 2(O) of
pretensioner connector S-07?
Action
Yes
Replace wire harness between S-01 and S-07.
No
Go to next step.
Yes
Replace wire harness between S-01 and S-07.
No
Replace driver pretensioner.
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Diagnostic Trouble Code : 62 Driver Pretensioner short to Battery
Step
1
2
Inspection
Disconnect airbag diagnostic unit connector S01 and passenger connector S-07.
Is battery voltage present at the terminal 1(LG)
or/and 2(O) of S-01?
Disconnect connector S-07 from driver
pretensioner.
Is battery voltage at the terminal 1(LG) or/and 2
(O) of driver pretensioner connector S-07?
Action
Yes
Replace harness between S-01 and S-07.
No
Go to next step.
Yes
Replace harness between S-01 and S-07.
No
Replace driver pretensioner.
Diagnostic Trouble Code : 63 Driver Pretensioner Short
Step
1
Inspection
Disconnect connector S-07 from passenger.
Disconnect connector S-01 from airbag
diagnostic unit.
Is there short between the terminal 1(LG) and
terminal 2(O) of pretensioner S-07?
Action
Yes
Replace harness between S-01 and S-07.
No
Replace driver pretensioner.
Diagnostic Trouble Code : 64 Driver Pretensiomer Open
Step
1
2
Inspection
Disconnect airbag diagnostic unit connector S01 and driver pretensioner connector S-07.
Is there an open circuit between the terminal 1
(LG) of S-01 and terminal 1(LG) of S-07?
Is there an open circuit between terminal 2(O)
of S-01 and 2(O) of S-07?
Action
Yes
Replace harness between S-01 and S-07.
No
Go to next step.
Yes
Replace harness between S-01 and S-07.
No
Replace passenger pretensioner.
Diagnostic Trouble Code : 65 Passenger pretensioner Short to Ground
Step
1
Inspection
Disconnect airbag diagnostic unit connector S01 and passenger pretensioner S-08.
Is ground present at the terminal 3(B) or/and 4
(W) of S-01?
Action
Yes
Replace wire harness between S-01 and S-08.
No
Replace passenger pretensioner.
Diagnostic Trouble Code : 66 Passenger Pretensioner Short to Battery
Step
1
Inspection
Disconnect airbag diagnostic unit connector S01 and passenger pretensioner connector S-08.
Is battery voltage present at the terminal 3(B) or/
and 4(W) of S-01?
Action
Yes
Replace wire harness between S-01 and S-08.
No
Replace passenger pretensioner.
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Diagnostic Trouble Code : 67 Passenger pretensioner Short
Step
Inspection
1
Disconnect connector S-08 from passenger
pretensioner.
Is there short between the terminal 3(B) or/and
4(W) of S-01?
Action
Yes
Replace wire harness between S-01 and S-08.
No
Replace passenger pretensioner.
Diagnostic Trouble Code : 68 Passenger Pretensioner Open
Step
Inspection
1
Disconnect airbag diagnostic unit connector S01 and passenger pretensioner connector S-08.
Is there an open circuit between the terminal 3
(B) of S-01 and terminal 1(B) of S-08?
2
Is there an open circuit between terminal 4(W)
of S-01 and terminal 2(W) of S-08?
Action
Yes
Replace harness between S-01 amd S-08.
No
Go to next step.
Yes
Replace harness between S-01 and S-08.
No
Replace pretensioner.
Diagnostic Trouble Code : 77~80 ADU Inconsistency
Trouble code
77~80
Contents
ADU inconsistency
ADU type
Action
Check ADU type and components
Components
Single
Driver module only
Dual
Driver and passenger module
Single + PT
Driver module + driver and passenger pretensioner
Dual + PT
Driver and passenber module + driver and passenger pretensioner
1)If Driver Module only is installed with ADU configured DAB and PAB, the ADU will show "Passenger module open"
fault.
2)If pretensioner is not installed with ADU configured pretensioner, the ADU will show "Pretensioner open".
Airbag Diagnostic Trouble Code Erasure
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STEERING COLUMNN AND SHAFT(DESCRIPTION)
The power steering system consists of :
• Rack and pinion steering gear
• Power steering pump
• Fluid reservoir
• Interconnecting hydraulic lines
The power steering system uses a hydraulic pressure which is generated by the power steering pump to reduce the effort
required to turn the steering wheel.The power steering pump is mounted on the front of the engine. The pump has a vanetype design, and is driven by the crankshaft through a drive belt.The power steering fluid is drawn into the pump from the
reservoir when the engine is running. The fluid is pressurized by the rotation of the rotor and vanes, then sent to the
steering gear. The fluid pressure is monitored and regulated by a Power Steering Pressure (PSP) switch and a control
valve located in the power steering pump.
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SERVICE ADJUSTEMENT PROCEDURE
STEERING WHEEL EFFORT
Make sure that the power steering system analyzer valve is OPEN to alow thesytem to function properly.
1. Disconnect the high-pressure line and attach Power Steering System Analyzer or equivalent using the
appropriate adapters.
2. Insert a thermometer in to the power steering fluid reservoir.
3. Bleed the system using the following procedure :
A.Check the fluid level in the reservoir, add fluid if necessary.
B.Raise and support vehicle.
C.Turn the steering wheel fully left and fully right ten times.
D.Recheck the fluid level, if the leel has dropped, add fluid to the reservoir.
E.Repeat Steps 3) and 4) unitl the level stabilizes.
F.Key ON and let the engine run at idle.
G.Turn the steering wheel fully left and fully rith the times.
H.Verify that the fluid is not foamy. If the fluid is foamy, air is still present in the system. Repaeat Steps 2)
through 7).
Check the system for an air leak if foam is steill present.
4. Check the power steerin fluid temperature. if the temperature is not at 50~60°C (122~140°F), turn the steering
wheel ack and forth nitl the specified temperature is reached.
The valve on the power steering system analzyer must be closed briefly to read the operating pressure. Do
not leave the valve closed for more than 15 seconds.
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5. Measure the power steering pump output pressure by closing the power steering system analyzer valve and
increasing the engine speed to 1,000~1,500rpm. the pressure specification is 7,358~7,848 kPa(75~80 kg/cm²,
1,067~1,138 psi)
A.If the pressure is within speciification, continue wotj the remaining test procedures.
B.If the pressure is low, repair or replace the power steering pump. If the pressure is too high, check for a
crimped pipe and repair/repace as necessary, or replace the power steering pump.
6. With the powr steering system analyzer valve open, incrase the engine speed to 1,000~1,500 rpm.
Do not hold the steering wheel against a stop for more than 15 seconds at a time.
7. Turn the steering wheel all the way to the right or left and the measured pressure. The pressure specification is
7,358~7,848 kPa (75~80 kg/cm², 1,067~1,138 psi). If the pressure is not within the given specification, repair or
replace the steering gear.
8. Remove the power steering system analyzer and adapters. Reconnect the high-pressure line and tighent the
line fitting to 16~24N·m (16~2.4kg·m, 11.5~17.3 lb·ft)
9. Remove the thermomeer and bleed the system as stated in Step 3.
SERVICE ADJUSTEMNT PROCEDURE(STEERING WHEEL EFFORT)
1. Insert a thermometer into the power steering fluid reservoir.
Do not hold the steering wheel against a stop for more than ten seconds at a time.
2. Start the engine, then turn the steering wheel left and right several times until the fluid temperature reaches
50~60°C (122~140°F).
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3. With the vehicle on a hard, level surface, turn the steering wheel until the wheels are in the straight ahead
position.
4. Attach Spring Scale to the steering wheel rim and measure the steering effort through one full turn of the wheel.
The steering wheel effort should be 39 N (4 kg, 8.8 lbs) or less.
For accurate readings, always pull the scale in the direction the point of the scale attachment is moving
(tangential to the wheel rim) through the full circle.
5. If the effort is greater than the specification, check for low fluid level, air in the system, and fluid leakage.
Checkthe power steering pump pressure, steering gear pressure and tire pressure.
6. Remove the thermometer.
SERVICE ADJUSTMENT PROCEDURE(POWER STEERING FLUID LEVEL INSPECTION
AND ADDING POWER STEERNG)
1. Check the power steering fluid level. If necessary, fill the fluid reservoir until the level is between the MAX and
MIN lines.
2. Run the engine until it reaches normal operating temperature, then turn the steering wheel from lock to lock 10
times.
3. Turn the engine off with the wheels in the straight ahead position.
4. Check the fluid level. If necessary, fill the fluid reservoir until the level is between the MAX and MIN lines.
SERVICE ADJUSTMENT PROCEDUE(AIR BLEEDING)
1. Raise and support the vehicle.
2. Turn the steering wheel fully to the left and right several times with the engine not running.
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3. Recheck the fluid level. If it has dropped, add a fluid.
4.
5.
6.
7.
8.
Repeat Steps 2 and 3 until the fluid level stabilizes.
Start the engine and let it idle.
Turn the steering wheel fully to the left and right several times.
Verify that fluid is not foamy and that the fluid level has not dropped.
Add a fluid if necessary and repeat Steps 7 and 8.
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STEERING COLUMN AND SHAFT(DESCRIPTION)
The manual rack-and-pinion steering gear is sealed against the entry of water or foreign material by rubber boots
enclosing the tie rod inboard ends at each end of the housing and by a third boot surrounding the pinion shaft and
steeringcolumn intermediate shaft. The steering gear is lubricated at assembly and must be removed and disassembled if
relubrication becomes necessary. The rack is positioned and guided in the housing by a bushing at the right end and a
supportyoke holding it in engagement with the pinion at the left end. The support yoke is spring-loaded against the rack.
A yoke plug and locknut keeps the rack fully engaged with the pinion under load.
Rubber insulating mounts at each end of the housing cushion the steering gear mounting points and minimize vibration.
Looseness or deterioration of the mounts can cause noise and vibration problems. These should be checked when
investigating for such concerns.
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SERVICE ADJUSTEMNT POCEDURE
MANUAL STEERING
1. With the ignition OFF and the wheels in the straight ahead position, turn the steering wheel left and right until
wheelresistance is felt. Free play should not exceed 1.18 inches (30 mm) at the wheel rim.
Excessive free play indicates wear in the steering column intermediate shaft universal joints, worn tie rod ends or
ball joints, or improper steering gear preload. To check the steering column joints, grip or feel the lower joint at the
floorboard and repeat the free play check. Any free play between the steering wheel and the lower joint at the
floorboard, which is clamped to the pinion shaft, isin the steering column assembly. Check the tie rods by raising
both wheels off the floor. Check each wheel for wobble. First, check the wheels vertically to verify that front wheel
bearings are correctly adjusted; then, check the wheels horizontally while an assistant grips the steering column
lower joint from inside the vehicle. If horizontal wobble is present, check the tie rod ends for free play or loose
attachment to the steering knuckles. If no free play is detected at the tie rod ends, any horizontal wheel wobble
must be the result of worn tierods, ball joints, or excessive gear free play between steering gear rack and pinion. In
either case the steering gear must be removed, and adjusted, repaired or replaced to correct the condition.
STEERING WHEEL EFFORT
1. Raise the road wheels clear of the floor and position jack stands under the lower control arms, as close to the
wheels as possible without interfering with steering travel.
2. Turn the steering wheel lock-to-lock at least five times to free up any stickiness resulting from front suspension
components being out of their normal riding positions, then place the wheels in the straight ahead position.
3. Attach spring scale to the steering wheel rim and measure the steering effort through one full turn of the wheel.
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For accurate readings, always pull the scale in the direction the point of scale attachment is moving
(tangential to the wheel rim) through the full circle.
4. Steering effort should be approximately 5~20 N (0.5~2.0 kg, 1~4.5 lb) through a full revolution in either direction
from the straight ahead position.
5. If excessive, check for binding or damage in the front suspension and the steering linkage components. Check
for excessive steering gear preload.
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COMPONENTS
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INSTALLATION
1. Tighten the intermediate shaft bolt.
13~19 lb·ft (17~26N·m, 1.8~2.7 kg·m)
2. Install the inermediate shaft dust cover and set plate.
Tightening torque : 4.3~6.5 lb·ft(5.8~8.8N·m), 0.6~0.9kg·m)
3. Install steering joint bolt to steering column.
Tightening torque : 13~19 lb·ft (17~26N·m, 1.8~2.7kg·m)
4. Put the steering column joint into the intermediate shaft and tighten bolt lightly.
5. Tighten the upper column attaching bolt to the steering column.
Tightening torque : 11~17 lb·ft(16~22N·m, 1.6~2.3kg·m)
6. To install the steerng column, push the steering collumn in the shaft directio, The clearance between the lower
clumn attaching bolt and bracket do no have to exceed to MAX 0.02in(0.5mm)
Tightening torque : 14~19lb·ft(18~26N·m, 1.9~2.7 kg·m)
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7. Tighten the inermediate shaft bolt.
Tightening torque : 13~19lb·ft (17~26N·m, 1.8~2.7kg·m)
8. Install the ignition switch assembly on the jacket. Install new ignition switch bolts, and tighten them until the
geads break off.
9. Install the ignition switch connector.
10. Install the combination switch to the steering column shaft.
11. Install the combination swtich connector.
12. Tighten the combination swtich xcrew.
13. Install the bracket.
14. Tighten the steering column cover screws after installing upper and lower steering column cover.
15. Install the steering wheel.
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16. Tighten the steering wheel nut.
Tightening torque : 39~49N·m(4.0~5.0kg·m, 29~36lb·ft)
17. Install the horn cap.
18. Connect the battery - terminal.
INSTALLATION
1. Postion the steering gear in its mounitng location.
2. Attach the inermediate shaft to the steering gear pinion and tighten the mounting bolt to 13~20lb·ft(18~26N·m,
1.8~2.7kg·m)
3. Connect the high pressure and return pipe and then tightne the bolts.
Tightening torque : 29~73lb·ft(39~59N·m, 4.0~6.0kg·m)
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4. Install the steerin gear mounting and tighten mounting bolta and nut.
Tightening torque : 27~38 lb·ft(37~52N·m, 3.8~5.3 kg·m)
5. Install the clatalytic converter to the exhaust pipe
Tightening torque : 27~38lb·ft(37~52N·m, 3.8~5.3 kg·m)
6. Install the tie-rod end to the steering knuckle.
Tightening torque : 27~38 lb·ft (37~52N·m, 3.8~5.3kg·m)
7. Install the tie rod end cotte pin
8. Install thewheel and tire.
Tightening torque : 65~87lb·ft (88~118n·m, 9~12kg·m)
9. Lower the vehicle.
10. Add he power steering fluid and bleed air from the system.
INSPECTION
Check the deformation, damage and cracks of the steering shaft assembly and replace it if necessary.
DISASSEMBLY
1. Secure the steering gear in a vice equiped with the protective jaw caps.
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2. Remove the oil pipe.
3. Place the alignment marks on the left tie rod end to aid an installation.
4. Loosen the lock nut and remove the left tie rod end.
5. Remove the boot clips.
6. Remove the boot wires.
7. Remove the boots.
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8. Revmove the tie rods from the rack.
9. Remove the yoke plug locknut and yoke plug.
10. Remove the spring an support yoke.
11. Remove the spring an support yoke.
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12. Remove the oil seal.
13. Remove the two valve housingattachin bolts.
14. Remove the valve housing and the pinion and control valve assembly.
15. If present, remove the shim(s) from thesteering gear housing.
16. Remove the O-ring.
17. Remove the lower pinion bearing from the steering gear housing.
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18. Tap lightly with a rubber mallet to remove the pinion and conteol vavle asemlby from the valve housing.
19. Remove the four Teflor R seals from the pinion nad control valve assembly.
20. Use the suitable tool to press the bearing out of the valve housing
21. Use the Outet Box Torque Adapter to rotate the rack bushing until the hooked end of the retaining wir is aligned
with the slot in the steering gear housing.
22. Rotate the bushing.
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23. Remove the rack from the right side of the steering gear.
24. Remove the bushing from the rack.
25. Remove the O-ring.
26. Use the Rack Oil Sear Remover to remove the seal by bottoming ti into the rack with a plastic hammer.
27. Use the impact Slide Hammer and th Rack Oil Seal Remover to pull the searl out the rack.
28. Remove the mounting brackets and grommets.
ASSEMBLY
1. Install the grommes and mounting brackets.
Ensure the lip spring of the seal points toward the installation tool.
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2. Use the Rack Oil Seal Replacer and install a new seal.
3. Install a new O-ring by using the Piston Seal Repalcer and the Rack Piston Seal Sizer.
4. Place the Short Rack Seal Protector over the end of the rack to protect the bushing. Install the bushihg on the
rack.
5. Place the Rack Oil Seal Protector over the rack as shown, Install the rack, with the rack oil seal protector, into
the steering gear housing. Remove the rack oil searl protector.
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6. Use the Pinion Bearing Rpalcer to install the lower pinion bearing.
7. If the valve housing steering gear housing or pinion and control vlave assembly hae been replaced, per form the
valve housing adjustemnt proedure oulined in this secton. If none of these components have been replace,
install any shims thea were removed.
8. Use the Seal Installaton Set to install na new Teflon R pinion seals on the pinion and control valve assembly.
A.Install the first seal (the seal closest to the bearing) by sliding the Mandrel over the vlave assembly to the first
seal groove. Push the seal into the groove by using the Pusher.
B.Size the seal by sliding the large end of Sizer over the seal.
C.Before installing the second seal, place one Spacer, on the vlave assembly as shown. Install and size the
seal by using the mandel and the Pusher.
D.Befor instaling the third seal, place two Spacers, on the vlave assembly, Make sure both spacers are
positioned on the malve assemly as theone shown. Install and size the third seal.
E.To install he fourth seal, turn thesecond spacer around so the small ends of the spacers are facing each
other on the vlave assembly.
9. Insert the pinion and control vlave assembly into the valve housing making susre that it seats properly.
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10. Install a noe O-ring.
11. Position the vlave housing and the pinion nad control valve assembly, then install the vlave housing bolts.
Tighten the vlave housing bolts to 15~19 lb·ft(21~26 N·m, 2.1~2.6 kg·m)
12. Use the Pinion Seal Replacer / Torque Adapter to install the bearing.
13. Use the Pinion Seal Replacer / Torque Adapter to install theseal.
14. Install the supprot yoke.
15. Install the spring.
16. Apply a sealant to the yoke plug threads. Insatll the yoke plug and tightent it to the specified torque.
Tightening torque : 14.5 lb·ft, 2kg·m)
17. Loosen the supprot yoke.
18. Tight the yoke plut with torque wrench to 43lb·in(4.9N·m, 50kg·m) theree times, then return it 67.5 degrees.
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19. Measure the pinion torque with the SST and spring scale.
Standard
Center of rack ±90°
6.9~11.3lb·in(0.8~1.3N·m, 8~13kg·cm)
Scale reading : 800~1,300kg(28.2~45.9 oz)
20. If not within the specification, repeat steps 18 through 21.
21. Use the Yoke Locknut Wrench to install the locknut nad tighten to 29~36lb·ft(39~49N·m, 4~5kg·m)
22. Install the tie rods.
23. Align the washer with the rack groove, and then crimp the washer.
24. Install the boots
25. Install the boot wires.
26. Inwatt the boot clips
27. Install the left tie rod end and lock nut.
28. Install the oil pipes.
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COMPONENTS
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REMOVAL
1. Disconnect the electrical connector from the Power Steering Pressure (PSP) switch.
2. Disconnect the suction hose.
3. Disconnect the high pressure hose.
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4. Loosen the mounting bolt.
Remove the lock bolt and disconnect the drive belt.
5. Remove the mounting bolt.
6. Remove the power steering pump.
REPLACEMENT
1.
2.
3.
4.
Loosen the bolt A, B, and C.
Turn the adjusting bolt D to release the belt tension.
Remove the belt.
Install a new drive belt and adjust the tension and deflection. (Refer to above for the adjustment).
INSTALLATION
1. Install the power steering oil pump and install the mounting bolt.
2. Connect the drive belt.
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3. Connect the high pressure hose.
TIghtening torque : 33~40 Ib·ft (44~54N·m, 4.5~5.5 kg·m)
4. Tighten the lock bolt.
Tightening torque : 27.5~38.4 Ib·ft (37.24~51.94 N·m, 3.8~5.3 kg·m)
5. Connect the return hose.
Verify that the white mark on return hose aligned with the white mark on return pipe.
6. Adjust the belt deflection by turning the adjusting bolt.
7. Connect the electrical connector from the Power Steering Pressure (PSP) switch.
INSPECTION
DRIVE BELT
1. Check the drive belts for wear,cracks and fraying: replace if necessary.
2. Check the drive belt deflection by applying moderate pressure (22Ib, 98 N,10kg) midway between the pulleys.
Adjust if necessary.
TORSION
Engine type
B5
Drive belt
New
Used
0.31~0.35(8.0~9.0)
0.35~0.39(90~10.0)
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3. Check the drive belt tension with the tension gauge.
ASSEMBLY NOTE
1. Install the rotor to the shaft with the rotor's identification mark facing upward.
2. Install the cam ring so that its identification mark is facing downward.
3. Install the vanes (10 pieces) to the rotor, with the R part of the vanes facing outward.
ADJUSTMENT
1. Loosen the bolt A, B, and C. Turn the adjusting bolt D to adjust the belt to the specified tension.
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2. Tighten the lock C, bolt A, and B to the specified torques.
Torquening torque : Bolt
A : 13.7~18.8 Ib·ft (18.6~25.5 N·m, 1.9~2.6 kg·m)
B : 26.7~39.8 Ib·ft (36.3~54 N·m, 3.7~5.5 kg·m)
C : 26.8~39.8 Ib·ft (36.3~54 N·, 3.7~5.5 kg·m)
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SPECIAL SERVICR TOOLS
Tool (Number and Name)
Illustration
Use
0K670 321 019
Ball joint puller
For removal of tie-rod end
0K 130 322 020
Attachment, steering worn bearibg
preload measuring
For measruement of pinion preload
0K201 323 AA1A
Power steering pressure gauge
For measurement of power
steering pressure
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SPECIFICATIONS
Item
Type
M/S
Outer dianeter (in(mm))
P/S
14.96 (380)
Steering wheel
Lock-to-lock turns
3.9
3.3
Type
Collapsible
Joint type
2-cross joint
Steering column
Type
Steering rack
Rack-and-pinio
∞
Gear ratio
Rack travel (in(mm))
2.68 × 0.07(68×2)
268 × 0.07(68×2)
Capacity
NA
53.4(875)
Type
NA
PSF-Ⅲ
P/S fluid
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COMPONENTS
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disassembly
1. Secure the steering gear in a vice equipped with the protective jaw caps.
2. Remove the oil pipe.
3. Place the alignment marks on the left tie rod end to aid an installation.
4. Loosen the lock nut and remove the left tie rod end.
5. Remove the boot clips.
6. Remove the boot wires.
7. Remove the boots.
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8. Remove the tie rods from the rack.
9. Remove the yoke plug locknut and yoke plug.
10. Remove the spring and support yoke.
11. Remove the pinion and control valve assembly snap ring.
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12. Remove the oil seal.
13. Remove the two valve housing attaching bolts.
14. Remove the valve housing and the pinion and control valve assembly.
15. If present, remove the shim(s) from the steering gear housing.
16. Remove the O-ring.
17. Remove the lower pinion bearing from the steering gear housing.
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18. Tap lightly with a rubber mallet to remove the pinion and control valve assembly from the valve housing.
19. Remove the four Teflon R seals from the pinion and control valve assembly.
20. Use the suitable tool to press the bearing out of the valve housing.
21. Use the Outer Box Torque Adapter to rotate the rack bushing until the hooked end of the retaining wire is
aligned with the slot in the steering gear housing.
22. Rotate the bushing.
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23. Remove the rack from the right side of the steering gear.
24. Remove the bushing from the rack.
25. Remove the O-ring.
26. Use the Rack Oil Seal Remover to remove the seal by bottoming it into the rack with a plastic hammer.
27. Use the impact Slide Hammer and the Rack Oil Seal Remover to pull the seal out of the rack.
28. Remove the mounting brackets and grommets.
Inspection
Check the deformation, damage and cracks of the steering shaft assembly and replace it if necessary.
Assembly
1. Install the grommets and mounting brackets.
Ensure the lip spring of the seal points toward the installation tool.
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2. Use the Rack Oil Seal Replacer and install a new seal.
3. Install a new O-ring by using the Piston Seal Replacer and the Rack Piston Seal Sizer.
4. Place the Short Rack Seal Protector over the end of the rack to protect the bushing. Install the bushing on the
rack.
5. Place the Rack Oil Seal Protector over the rack as shown. Install the rack, with the rack oil seal protector, into
the steering gear housing. Remove the rack oil seal protector.
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6. Use the Pinion Bearing Replacer to install the lower pinion bearing.
7. If the valve housing, steering gear housing, or pinion and control valve assembly have been replaced, perform
the valve housing adjustment procedure outlined in this section. If none of these components have been
replaced, install any shims that were removed.
8. Use the Seal Installation Set to install a new Teflon R pinion seals on the pinion and control valve assembly.
A.Install the first seal (the seal closest to the bearing) by sliding the Mandrel over the valve assembly to the first
seal groove. Push the seal into the groove by using the Pusher.
B.Size the seal by sliding the large end of Sizer over the seal.
C.Before installing the second seal, place one Spacer, on the valve assembly as shown. Install and size the
seal by using the Mandrel and the Pusher.
D.Before installing the third seal, place two Spacers, on the valve assembly.Make sure both spacers are
positioned on the valve assembly as the one shown. Install and size the third seal.
E.To install the fourth seal, turn the second spacer around so the small ends of the spacers are facing each
other on the valve assembly.
9. Insert the pinion and control valve assembly into the valve housing making sure that it seats properly.
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10. Install a new O-ring.
11. .
12. Use the Pinion Seal Replacer / Torque Adapter to install the bearing.
13. Use the Pinion Seal Replacer / Torque Adapter to install the seal.
14. Install the support yoke.
15. Install the spring.
16. Apply a sealant to the yoke plug threads. Install the yoke plug and tighten it to the specified torque.
Tightening torque :
14.5 Ib·ft (19.6 N·m, 2 kg·m)
17. Loosen the support yoke.
18. .
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19. Measure the pinion torque with the SST and spring scale.
Standard :
Center of rack ± 90°
6.9~11.3 Ib·in (0.8~1.3 N·m, 8~13 kg·cm)
Scale reading : 800~1,300 kg (28.2~45.9 oz)
20. If not within the specification, repeat steps 18 through 21.
21. .
22. Install the tie rods.
23. Align the washer with the rack groove, and then crimp the washer.
24. Install the boots.
25. Install the boot wires.
26. Install the boot clips.
27. Install the left tie rod end and lock nut.
28. Install the oil pipes.
REMOVAL
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1.
2.
3.
4.
Raise the front of the vehicle and upport it with safety stands.
Remove wheel and tire
Pull out cotter ins, and remove nuts.
Separte the tie-rod from the knuckle arm with SST (0K 670 321 019).
Replace nuts temporaily so that screw threads do not become damged.
5. Remove the catalytic converter.
6. Disconnect the high pressure and return pipe. Then seal them with dry cloth to prevent entery of foreign
materials.
7. Remove the intermediate shaft.
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8. Remove the fou steering gear mounting bolts and washers.
9. Slide the steering gear to the left and pull hte right tie rod through the fender opening.
10. Remove the steering gear by sliding it to the right.
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TROUBLESHOOTING GUIDE
POWER STEERING
Problem
Possible cause
Action
Movements of steering
feels heavy
Looseness of damage lf power steering belt
Insufficient power steering fluid or air insertion
Crushed or twisted hoses
Pipe damage
Leakage of power steering fluid
Low fluid pressure
Insufficient air pressrue in tire
Incorect wheel alignment adjustemnt
Steering gear linkage binding
Interference between steering column and /or
parts
Interference between steering column and parts
Adjust or replace power steering
belt
Fluid fill up or air bleeding
Repace hoses
Replace pipes
Repair or repalce Leaking parts
Replace or repair steering gear
linkage
Repair or replace steering
column
Repalce or repair
Poor returning of steering
wheel
Insufficient air pressure in tire
Incorect wheel alignment adjustemnt
Steering gear linkage binding
Malfunction of steering gear
Adjust tire air pressure
Adjust wheel alignment
Repair or repplace steering gear
likage
Repalce steering gear
Lrrehualr steering power
Loosenesso of power sterin belt
Malunction of steering column or looseness of
mounting bolt
Steering gear linkage binding
Malfunction of steering gear
Adjust power steering belt
Repair or tightening of steering
column
Repair or replace steering
linkage
Replace steering gear
Steering wheel pulls to
one side
Insufficient air pressure in tire
Improper preload adjustment orworn of wheel
bearin
Incorrect wheel alignment
Malfunction of steering gear
Adjus tire air pressure
Adjust or replace wheel bearing
Adjust wheel alignment
Repalce steering gear
Porblem with hose couping
Clogged or damaged hoses
Leakage of power steering Dmae of power steering fluid reseroir
fluid
Over flow
Malfunction of power steering pump
Malfunction of steering gear
Repair or repalce hose coupoing
Repalce hoses
Repalce reservoir
Air bleeding or adjust fluid level
Repalce power steering pump
Repalce steering gear
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Abnormal noise
Looseness of power steering pump
Looseness of steering gear
Looseness of power steering pump bracket
looseness of power steering pump pulley nut
Excessive tightness or looseness of belt
Air insertion
Maljuction of steering gear
Malfunction of power steering pump
Interference on steering column or pressure hose
Looseness or excessive tightness of steering
linkage.
Tightening of power steering
pump
Tightening of steering gear
Tightening of power steering
pump bracket
Tightening of power steering
pump pulley nut
Adjust power steering pump belt
Air bleeding
Repalce steering gear
Repalce power steering pump
Remove interference on
steering column or repair/
replace hoses
Adjust tigheness of steering
linkage or repalce steering
linkage
MANUAL STEERING
Problem
Possible cause
Action
Steering feels heavy
(vehicle raised)
Poor lubrication. foregn material in nechanism or
damage of steering ball joint
Inadequate gear oil, foreing material in oil
Improper steering gear preslad
Damaged steering gear
Malfunction of steering shaft joint
Malfunction of steering gear
Cracked or worn steering gear mounting ruber
Damaged suspension
Lubricate or replace
Rubricate or repalce
Adjust
Repalce
Repalce
Replace
Replace
Repair
Steering wheel pulls to one side
Damaged steering linkage
Damaged wheel or tire
Malfunction of brake system and suspension
Repalce
General instability while driving
Worn of damaged steering rack
Improper steering gear preload
Damaged steering linkage
Damaged wheel or tire
Malfunctioning suspension
Replace
Adjust
Repalce
Repair
Repair
Steering feels unstable
Malfunction of steering gear
Malfunction of steering rack
Malfunction of steering linkage
Replace
Replace
Replace
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Excessive steering wheel play
Worn steering gear
Worn of damaged steering linkage
Loose steering gear mounting bolts
Replace
Replace
Replace
Poor steering wheel return
Stuck or damaged steering rack
Improper steering gear prelaod
Damagd wheel or tire
Malfunction of suspension
Repalce
Repalce gear
Repair
Shimmy
(steering wheel vibrates left/
tight)
Damaged steeering linkage
Loose steering gear mounting bolts
Stuck or damaged steringjoint
Damaged or worn front wheel bearings
Damaged wheel or tire
Malfunction of suspension
Replace
Tighent
Replace
Repalce
Repair
Repair
Abnormal noise from steering
system
Loose steering gear monitng bolts
Malfunction of steering gear
Obstruction near steering column
Loose steering column
Worn steering joints
Tighten
Replace
Replace
Tighten
Repalce
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COMPONENT
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REMOVAL
1. Jack up the front of the vehicle and support it with safety stands.
2. Remove the wheel and tire.
3. Remove the tension rod attaching bolt at the frame bracket.
4. Remove the tension rod bushing cotter pin and attaching nut from the rear of the lower arm, and remove the
washer and bushing.
5. Pull the tension rod out of the lower arm and remove the front bushing and washer.
6. Lower the lower arm, prying the ball joint stud out of the steering knuckle, after loosening bolt and nut.
7. Remove the lower arm after loosening the lower arm attaching bolt from the frame bracket.
INSTALLATION
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1. Connect the SST to the ball stud, and measure the torque with a pull scale.
Rotation torque : 7.2~25.2 lb·ft (1.0~3.5 N·m, 10~35 kg·cm)
Pull scale reading : 2.2~7.7 lb (10~35 N, 1~3.5kg)
2. Raise the inner end of the lower arm into the pivot bracket on the frame, and loosely tighten the arm frame
bracket pivot to hold it in place.
3. Position the lower arm ball joint stud in the clamp bore of the steering knuckle and install the ball joint clamp bolt
and nut.
Tightening torque : 40~50 Ib·ft (54~68N·m, 5.5~6.9kg·m)
4. Tighten the lower arm frame bracket pivot bolt.
Tightening torque : 40~50 Ib·ft (54~68N·m, 5.5~6.9kg·m)
5. Insert the tension rod bolt into the lower arm, tighten washer and bushing, and Install cotter pin.
6. Install bushing and rubber on the tension rod.
Tightening torque : 87~108 Ib·ft (118~147N·m, 12~15kg·m)
INSPECTION
Check the following points, replace if necessary.
1. Deformation or cracks in lower arm.
2. Deformation or wear of bushing
3. Rotation torque of ball-joint.
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STABILIZER BAR AND CONTROL LINK
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REMOVAL
1. Support engine with SST (OK201 170 AA0A)
2. Raise and support the vehicle with safety stand.
3. Remove wheel and tire.
4. Remove the stabilizer from the stabilizer control link.
5. Remove the control link from the control link bracket on the strut.
6. Remove the stabilizer bar mounting bracket attaching bolt and mounting bracket.
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7. Remove the engine-mounting member bolts and nuts from the front side of the engine-mounting member.
8. Lower the engine-mounting member enough to pull the stabilizer out from the engine-mounting member.
9. Remove the stabilizer bar.
INSTALLATION
1. Align the stabilizer bushing with the installation position line painted on the stabilizer bar. Locate the bushing
adjacent to the position line on stabilizer bar.
2. Position stabilizer forward of the engine-mounting member.
3. Raise the engine-mounting member into place and tighten the engine-mounting member bolts and nuts on the
front side of the engine-mounting member.
Tightening torque : bolt: 47~66 Ib·ft (65~9N·m,6.5~9.1kg·m), Nut: 28~38 Ib·ft (39~52N·m, 3.9~5.3kg·m)
4. Install the stabilizer bar mounting bracket attaching bolt and mounting bracket and tighten the attaching bolt.
Tightening torque : 26~42Ib·ft (36~56N·m,3.7~5.8 kg·m)
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5. Install the stabilizer control link onto control link bracket on the strut.
Tightening torque : 32~45Ib·ft (43~60.8N·m,4.4~6.2 kg·m)
6. Install the stabilizer bar on the stabilizer control link.
Tightening torque : 32~45Ib·ft (43~60.8N·m,4.4~6.2 kg·m)
Tighten the two stabilizer control link nuts to specified torque before lowering vehicle (unload condition).
7. Install the wheel and tire.
8. Lower the vehicle.
9. Remove the SST (201 170 AA0A) from engine.
INSPECTION
1. Check the following points and replace if necessary.
2. Worn or deteriorated rubber bushing.
3. Bent, cracked, or damaged stabilizer.
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FRONT MACPHERSON STRUT AND SPRING
Raise the front of the vehicle and support it with safety stands.
COMPONENT
COMPONENT
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REMOVAL
Raise the front of the vehicle and support it with safety stands.
1. Remove the clip of the strut side.
2. Remove the flexible hose and ABS sensor cable from the strut bracket.
3. Remove the stabilizer control link from the bracket mounted to the strut.
4. Detach the knuckle from the strut.
5. Remove the attaching nut.
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6. Remove the strut from suspension tower.
INSTALLATION
1. Position the strut, with adjusting plate in place into the strut tower with the raised rubber mounting facing in
board.
2. Install the strut mounting block nuts.
Tightening torque : 34~46 Ib·ft (46~63 N·m, 4.7~6.4 kg·m).
3. Install the steering knuckle in the strut lower bracket and install the two strut lower bracket nuts with attaching
nuts.
Tightening torque : 76~90.4 Ib·ft (103~123 N·m, 10.5~12.5 kg·m).
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4. Install the stabilizer control link to the bracket mounted to the strut.
Tightening torgue : 32~45 Ib·ft (43~60.8 N·m, 4.4~6.2 kg·m)
5. Position the brake line and ABS sensor cable in the cutout on the strut lower bracket and secure it with the
brake line clip.
DISSSEMBLY
1. Secure the mounting block in a vise.
Use protective plates in the jaws of the vise
2. Loosen the piston rod nut a few turns. Do not remove it.
Do not remove the nut.
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3. Use the SST or equivalent, and compress the spring to unload the strut.
4. Remove the strut nut and lockwasher.
5. Remove the strut mounting block and plate.
6. Remove the bearing from the strut rod.
7. Remove the spring seat, seat rubber and spring.
8. Slide the bump stopper off the strut.
If replacing a spring, release the spring compressor progressively to prevent spring arching. Open the
compressor jaws wide enough to grip the new spring in the same position, and tighten the compressor
screws progressively, compressing the spring until the strut can be assembled without interference.
9. Before assembly, inspect the struts.
INSPECTION
Check the following points, repair or replace if necessary.
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1. Oil leakage or abnormal noise from the MacPherson strut.
2. Deterioration or damage to the mounting block.
3. Damaged or loose bearing.
Wear or damage to bump stopper.
ASSEMBLY
1. Slide the bump stopper onto the strut rod and over the body.
2. Install the compressed spring, seat rubber, and upper spring seat, positioning the spring ends against the step in
the seats.
3. Install the bearing on the strut rod.
4. Install the strut mounting block with the white alignment spot on the same side of the strut as the steering
knuckle mounting bracket.
5. Install the plate.
6. Temporarily tighten strut rod nut by hand.
7. Release and remove the spring compressor.
8. Secure the strut rod in the mounting block with the lockwasher and strut rod nut.
Tightening torque : 41~50 Ib·ft (55~68 N·m, 5.6~6.9 kg·m).
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DESCRIPTION
The front syspension system on Rio is a typical MacPherson strut layout with single pivot forged control arms. The front
suspension consist of the following :
• A transverse front tension rod that limits sway nad doubles as a trailing arm on each side ot amintain control arm
alignment.
• The control arms include integral ball joints which allow steering and ride trael of the wheels. The wheels ar mounted
on steering knuckle forgings, clamped to the ontrol arm all joints and bolted to the strut lower ends.
• The upper ends of the struts ar seated in towers in the engine compartment. Caster and camber are not adjustable.
• Ruber bushings at the control arm and tension rod mounting points cushion road shocks.
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INSPECTION(CHECK AND ADJUSTMENT)
COIL SPRING
1. If loading is normal and vehicle attitude is not, check for spring damage, spring sag, or nonpstandard
replacement springs.
STRUTS
Bounce test the vehicle at each front corner and at the rear bumper to check the strut function. Damaping action
should be positive and uniform all around. Inspect the struts for evidence of oil leakage. A thin film is normal.
Check the rear strut upper bushing by shake-testing with the vehicle raised just enough to unload the struts
(wheels steill on the ground). Any looseness is indicative of worn or deteriorated bushings. which must be replaced.
LOWER ARM
Check the following points, repair or replace if necessary.
1. Loose installation bolts nad nuts.
2. Deformation or cracks in the lower arm.
TENSION ROD
Check the following points or replace if necessary.
1. Looseness of the installation bolts and nuts.
2. Worn or deteriorated bushing.
FRONT WHEEL ALIGNMENT
1.
2.
3.
4.
Check the tire inflation and set to the recommended pressure if necessary.
Inspect the front wheel bearing play and correct if necessary.
Inspect the wheel and tire runout.
Inspect the ball-joints and steering linkage for excessive looseness.
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5. Place the vehicle on level ground with no luggage or passenger load.
6. The difference in height from the center of the wheel to the fender brim between the left and right sides should
be within 0.39 in (10 mm)
The caster and camber is not adjustable. The toe-in is adjustable.
INSPECTION
TOE-IN
1.
2.
3.
4.
Raise the front of the vehicle until the wheels clear the ground.
Turn the wheels by hand and mark a line in the center of each tire tread using a scribing block.
Place the front wheels in the straight-ahead position and lower the vehicle.
Measure the distance between the marked lines at the front and rear of the wheels.
Both measurements must be taken at equal distances from the ground.
The distance between the wheels at the rear should be greater than that at the front by 0.12±0.12 in (3±3mm).
ADJUSTMENTS
FRONT WHEEL ALGNMENT
Steering angle?aximum turning angle to left and to right
1. Place both front wheels on a turning radius gauge.
2. Turn wheels fully to left and note angles for left (inner) and right (outer) wheels.
3. Loosen both left and right tie rod jam nuts, then turn both tie rods to achieve specified angles. Tighten jam nuts.
4. Repeat for a full right turn; right is now inner and left is now outer.
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5. Tighten tie-rod jam nuts.
Tightening torque: 25~37 lb·ft (34~50 N·m, 3.5~5.1 kg·m)
6. Inspect and adjust toe after adjusting steering angle.
ADJUSTMENT
TOE-IN
1. To adjust the toe-in, loosen the left and right tie-rod lock nuts and turn the tie-rods by the same amount.
The left and right tie-rods are both right hand thread. To increase the toe-in, turn the right tie-rod toward the
front of the vehicle, and turn the left tie-rod by the same amount toward the rear. One turn of the tie-rod (both
sides) changes the toe-in by about 0.24 in (6 mm). Adjust the toe-in after adjusting the steering angle.
2. Tighten the tie-rod lock nuts to the specified torque.
Tightening torque : 25~36 Ib·ft (34~50 N·m, 3.5~5.1 kg·m)
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COMPONENT(TORSION BEAM AXLE)
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DESCRIPTION
The rear suspension system is the torsion beam axle type separted with spring and damper. The rear suspension system
works as follows :
• Suspension action is semi-independent, with the wheels carried on trailing arms, rigidly connected to each other by a
torsion beam.
• The beam provices positie control of trailing arm alignment, yet flexes in torsion to permit limited independent wheel
action, and is welded with the stabilizer bar at the bearm to prevent it from rolling.
• For isolation of road vibration, heavy rubber bushlings are installed at the torsion beam/trailing arm body brackets, and
fubbe insulators cushion the spring seats in the strut towers.
COMPONENT
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REMOVAL
1.
2.
3.
4.
Raise the rear of the vehicle and support it with safety stands after releasing the parking brake.
Remove the wheel and tire assemblies.
Install the jack under the torsion beam axle.
Loosen the rear shock absorber lower bolt.
5. Remove the coil spring from the torsion beam after lowering the jack slightly.
6. Remove the flexible hose clip and remove the brake pipe from bracket.
Cover the brake pipe and flexible hose to prevent them from leaking fluid and dust contamination.
7. Remove the flexible hose clip.
8. Remove the flexible hose from the torsion beam axle.
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9. Remove the parking brake cable bracket from the torsion beam.
10. Release the backing plates and wheel spindle supports after removing the four brake backing plate/wheel
spindle support assembly nuts from the back of each brake assembly.
11. Remove the torsion beam trailing bracket bolt.
12. Loosen the flange nut and bolt to remove the torsion beam and trailing bracket.
13. Remove the lateral link from the body.
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14. Loosen the lateral link and torsion beam axle tightening nut to remove the lateral link.
Be careful not to damage the parking brake cable.
15. Remove the torsion beam axle
16. Remove the rear shock absorber upper bolt.
17. Remove the spring upper seat bolt.
18. Use the SST or equivalent to press the bushing out of the torsion beam arms from the inboard side.
INSTALLATION
1. Position the bushing on the outboard sides of the torsion beam arms with the marks aligned parallel to the arm
axis and press them in with the SST or equivalent.
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The arrow mark mould on the bushing face should be front side up.
The bushings may be lubricated with soapy water for easier installation. Do not use oil or grease.
2. Install the spring upper seat.
Tightening torque : 27~40 Ib·ft (36~54N·m, 3.7~5.5kg·m)
3. Install the rear shock absorber upper bolt.
Tightening torque : 27~40 Ib·ft (36~54N·m, 3.7~5.5kg·m)
4. Tighten the flange nut and bolt lightly to install trailing bracket to the torsion beam axle.
5. Install the torsion beam axle to the vehicle by using the mission jack.
6. Install the lateral link to the body.
Tightening torque : 58~72 Ib·ft (78~98N·m, 8~10kg·m)
7. Install the lateral link to the torsion beam axle.
Tightening torque : 58~72 Ib·ft (78~98N·m, 8~10kg·m)
8. Tighten the flange bolt and nut of the torsion beam bracket.
Tightening torque : 40~50 Ib·ft (54~68N·m,5.5~6.9kg·m)
9. Tighten the flange bolt and nut of the trailing bracket.
Tightening torque : 72~87 Ib·ft (98~118N·m,10~12kg·m)
10. Install the brake back plate and wheel support assembly.
Tightening torque : 32~45 Ib·ft (43~61N·m,4.4~6.2kg·m)
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11. Install the parking brake cable bracket to the torsion beam axle.
Tightening torque : 14~19 Ib·ft (19~26N·m,1.9~2.6kg·m)
12. Install the flexible hose to the torsion beam axle.
13. Insert the flexible hose clip.
14. Connect the brake pipe to the brake hose.
Tightening torque : 9.4~17 Ib·ft (13~23N·m, 1.3~2.3kg·m)
15. Lower the jack slightly to install the coil spring to the torsion beam axle.
16. Tighten the rear shock absorber lower bolt.
Tightening torque : 58~72 Ib·ft (78~98N·m, 8~10kg·m)
INSPECTION
Check the deformation, damage, or cracks, replace if necessary.
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SPECIAL SERVICE TOOLS
Tool (Number and Name)
Illustration
Use
0K130 322 020
Attachement steering worm
bearing perload measuring
For measurement of ball joint
preload
0K670 990 AA0
Bearing puller set
For removal of bearing
0K2A1 341 001A
Coil spring compressure
For removal of front shock
absober spring
0K201 170 AA0A
Support, engine
used to support engine
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GENERAL
SPECIFICATIONS
Item
Specification
Suspension type
Macpherson strut
Vacancy
0.12±0.12(3±3)
Toe-in (in(mm))
3 passengers laden
0±0.12(0±3)
Vacancy
0.6°±45'
Camber angle
3 passengers laden
Front
0°±45'
Wheel alignment
Vacancy
1°41'±45'
3 passengers laden
2°5'±45'
Caster angle
Vacancy
14°7'
3 passengers laden
14°56'
King pin angle
Front strut type
Cylindrical double-acting
Suspension type
Torsion beam axle
Vacancy
0.20±0.24(5±6)
Toi-in (in(mm))
3 passengers laden
Rear
0.24(6)
Wheel alignment
Vacancy
-0°53'±18'
3 passengers laden
-1°00±18'
Camber angle
Rear strut type
Cylindrical double-acting
* Front caster and camber are not adjustable.
Rear camber and toi-in are not adjustable.
WHEEL AND TIRE
Item
Size
Size
Wheel
13×5J
Off-set in(mm)
Material
1.57±0.04 (40±1)
Steel
Size
Tire
5J*13
P155/80R13 79T
P175/70R13 82T
Front
32(220)
29(200)
Rear
32(220)
29(200)
Air pressure psi(kPa)
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TROUBLESHOOTING GUIDE
Condition
Possible cause
Action
· Wander/Pull/Drift
· Excessive side-to-side dirrerence in
camber or caster
· Tire(s) have excessive wear
· Toe setting unequal
· Vehicle attitude incorect (high or low
at front or rear)
· Steering gear or linkage worn or
defective
· CHECK the alignment. iF the camber is
incorrect, and the camber change option is in the
right direction, CHANGE the camber setting as
described in this section. INSPECT the
suspension components for looseness of
defromation.
· INSPECT the tire for excessivewear. REPLACE
as necessary.
· CHECK alignment. REALIGN as necessary.
· CHECK for abnormal loading, sprig damage,
spring sag, or non-standard springs.
· CHECK the steering system. If necessary.
· Hard Steering
· Excessive negative caster
· Vehicle attitude incorrect (high or
low a front or rear)
· Steering gear or linkage worn,
damaged or improperly adjusted
· Poor lubricaton or wear of lower ball
joint
· CHECK the caster. If incorrect, CHECK the
suspension components for loosensess of
damage.
· CHECK for abnormal loadin, spring damage,
spring sag, or non-standard springs.
· CHECK for steering system conditions.
· LUBRICATE or REPLACE the lower ball joint.
· Brake Pull
· Excessive negative caster
· Unequal tire pressure
· Brake drag or damaged to brake
system
· CHECK the caster. If incorrect, CHECK the
suspension. components for loosensess or
damage.
· INFLATE the tires uniformly to the
recommended pessure.
· CHECK the brakes.
· Shimmy
· Excessiv positive caster or side-toside caster difference
· Wheel/tire imbalance or runout
· Steering gear mounts loose
· CHECK caster. If incorrect, CHECK the
suspension, coponents for looseness or damage.
· CHECK for wheel and tire conditions.
· CHECK for worn or deteriorated steering gear
mount bushings, or loose mounting brackets.
· Excessive side-to-side caster
· Rear suspension damage
· CHECK the caster. If incorrect, CHECK the
suspension. components for looseness or
damage.
· If the caster is uniform, COMPARE the
wheelbase at right side and left side of the
vehicle. If not the same, CHECK for loosensess
or dmamge of rear suspension compaonts.
· Dog-tracking
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· Excessive positive or negative
camber
· Incorrect tire pressure
· Excessie toe adjustment
· REPLACE the steering gear mounting bushings
· TIGHTEN or REPLACE the steering gear
mounting brackets
· ADJUST steering gear mounting
· Outer or Inner
Shoulder Tire wear
· Excessive positive or negative
camber
· Incorrect tire pressure
· Excessive toe adjustemt
· CHECK the camber. If incorrect, and camber
change option is in right direction, ADJUST the
camber setting, CHECK the front susoension
componens for looseness or damage
· ADJUST the tire pressure
· CHECK the toe and ADJUST to REALIGN if
necessary
· SawtoothPattern
orExcessive Tire
Wear
· Excessive toe-in (high inboard
deges) or toe-out (high outboard
edges)
· CHECK the toe and ADJUST to specification
· Cuppng, Dishing or
Excessive Tire wear
· Wheel/tire imbalanced wheels
· Defective struts
· Tires not rotated properly
· CHECK for wheel and tire conditions
· CHECK struts and REPLACE if necessary
· Tires should be ROTATED every 12,000 km
· Steering Wheel
Does Not Return
properly
· Damaged tires or unbalanced wheels
· Improper wheel alignment
· Steering system malfunction
· Damaged or stuck lower control arm
ball joint
· CHECK the tires REPLACE the tires if
necessary. BALANCE the wheels if necessary.
· ADJUST the wheel aignment
· CHECK the steering system, If necessary
· REPLACE the lower control arm ball joint
· Steering wheel
Pulls to One Side
· CHECK the tires REPLACE the tires if
· Damaged tires or unbalanced wheel necessary BALANCE the wheels if necessary
· Braking system malfunction
· CHECK the brakes. If necessary.
· Steering system malfunction
· CHECK the steering system, (Refer to section
· Improper wheel alignment
ST)
· Damaged lower cotrol arm baoo joint · ADJUST the wheel alignment
· Weak coil spring
· REPLACE the lower control arm ball joint
· Damagd lower control arm ball joint
· REPLACE the coil spring
· Damaged or worn stabilizer bushings · REPLACE the lower control arm bushing
· Damaged or worn stabilizer
· Damaged or worn stabilizer
· REPLACE the stabilizer
· Abnormal Noise
From Suspension
System
· Poor lubrication/wear lf lower control
arm ball joint
· Damaged or worn stabilizer
· Damaged o worn torsion beam
· Looseness of suspension connection
· Damaged o worn lower control arm
bushing
· Strut malfunction
· Bump steer
· LUBRKCATE or REPLACE the lower control
arm all joint if necessary
· REPLACE the stabilizer
· REPLACE the torsion beam
· TIGHTEN the connection
· REPLACE the lower control arm bushing
· REPLACE the strut if necessary
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· Front/Rear
Suspension Noises
· Looser/broken strut mount bolts.
· Loose/missing strut mounting block
· Loose/missing strut bolts to lower
control arm
· Dry or rough brake cable holders
· TIGHTEN/REPLACE the strut mount bolts.
REFER to Section SS.
· TIGHTEN/REPLACE the strut mounting block
· TIGHTEN/REPLACE the strut bolts
· LUBRICATE the cable and cable holders.
· Body Rolls
· Weak stabilizer
· Damaged or worn stabilizer bushings
· Damaged or worn lower control arm
bushing
· Damaged or worn lower control arm
bushing
· Strut malfunction
· REPLACE the stabilizer
· REPLACE the stabilizer bushings
· REPLACE the stabilizer bushings
· REPLACE the lower contorl arm bushing
· REPLACE the the strut if necessary
· Body Leans
· Weak coil spring
· REPLACE the coil spring
· Damaged or worn stabilizer bushigns
· REPLACE the stabilizer bushing
· Damaged or worn lower control arm
· REPLACE the lower control arm bushing
bushing
· Poor Riding
Comfort
· Weak coil spring
· Strut malfunction
· REPLACE the coil spring
· REPLACE the lower control
· General Driving
Instability
· Damaged tires or unbalanced wheels
· Improper wheel alignment
· Steering system malfunction
· Damaged lower control arm ball joint
· Weak coil spring
· Strut malfunction
· Damaged or worn lower control arm
bushing
· Damaged or worn stabilizer bushings
· CHECK the tires REPLACE the tires if
necessary. BALANCE the wheels if necessary
· ADJUST the wheel alignment
· CHECK the steering system, If necessary
· REPLACE the lower control arm ball joint
· REPLACE the coil spring
· REPLACE the strut if necessary
· REPLACE the lower control arm bushing
· REPLACE the stabilizerm bushings
WHEEL AND TIRE
Condition
Possible cause
Excessive or irregular tire wear
Action
Page
Wheel and Tire
Premature tire wear
Incorrect tire pressure
Adjust
Section SS
Tire squeal
Incorrect tire pressure
Tire deterioration
Adjust
Replace
Section SS
-
Road noise or body vibration
Insufficient tire pressure
Unbalanced wheel(s)
Deformed wheel(s) or tire(s)
Lrrehular tire wear
Adjust
Adjust
Repair or
replace
Replace
Section SS
Section SS
Section SS
Section SS
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Excessive tire and wheel runout
Loose lug nuts
Unbalanced wheel(s)
Cracked orworn engine mount rubber
Cracked worn transaxle mount tubber
Replace
Tighten
Adjust
Replace
Replace
Section SS
Section SS
Section EM
Section MT
AT
"Shimmy" occurs
(Steering wheel vibrates left/
right)
Excessive tire and wheel runout
Loose lug nuts
Unbalanced wheel(s)
Cracked or worn engine mount rubber
Cracked or worn transaxle mount rubber
Replace
Tighten
Adjust
Adjust
Replace
-
Section SS
Section SS
Section SS
Section DS
Section ST
Section SS
Steering wheel pulls to one side
Incorrect tire pressure
Excessive or irregular tire wear
Malfunction of steering system
Malfunction of braking system
Malfunction of suspension
Adjust
-
Section SS
Section SS
Section ST
Section BR
Scetion SS
General driving instability
Unequal tire pressures
Deformed wheel(s) or tire(s)
Loose lug nuts
Malfunction of steering system
Malfunction of suspension
Adjust
Repair or
replace
Tighten
-
Section SS
Section SS
Section ST
Section SS
Uneven (one-sided) breaking
Unequal tire pressures
Malfunction of braking system
Adjust
-
Section SS
Section BR
Heavy handling
Insufficient tire pressures
Malfunction of steering system
Malfunction of suspension
Adjust
-
Section SS
Section ST
Section SS
Steering wheel doesn't return
properly
Insufficient tire pressure
Malfunction of steering system
Malfunction of suspension
Adjust
-
Section SS
Section ST
Section SS
"Shake" occurs
(Steering wheel vibrates left/
right)
IRREGULAR IRE WEAR
Wear condition
Possible cause
Remedy
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SHOULDER WEAR
· Underinflation (both sides worn)
· Hard cornering
· Lack of rotation
· Measure and adjust pressure
· Reduce speed
· Rotate tires
· Overinflation
· Lack of rotation
· Measure and adjust pressure
· Rotate tires
· Incorrect toe adjustment
· Adjust toe-in
· Incorrect camber or caster
· Malfunctioning suspension
· Unbalanced wheel
· Out-of- fornd brake drum of disc
· Lack of rotation
· Repair or replace axle or
suspension parts
· Repair or replace suspension
· Balance or replace
· Correct or replace
· Rotate tires
CENTER WEAR
FEATHERED EDGE
UNEVEN WEAR
Abnormal ire wear patterns, such as shown in the ullustration, may occur. Refer to the chart for the possible
causes and remedies.
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2006 > G 1.6 CVVT > Automatic Transaxle System
DESCRIPTION
The pulse generator "A" detects the speed of the end clutch retainer. The speed signal is used for damper clutch
control, hydraulic pressure control and incorrect gear detection by PCM.
The pulse generator "B" detects the speed of the transfer driven gear. The speed signal is used for shift timing,
hydraulic pressure control and incorrect gear detection by PCM.
Pulse generator A,B
Inspection item
Standard value
A: 1 terminal ~ 2 terminal
215 ~ 275 Ω
B: 1 terminal ~ 2 terminal
215 ~ 275 Ω
1 terminal ~ ground
2.5 V ± 1.2V
2 terminal ~ ground
2.5 V
Senaor resistance
Output voltage (A,B)
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2006 > G 1.6 CVVT > Automatic Transaxle System
Replacement
1. Remove the battery terminal(A).
2. Remove the intake air hose and air clean assembly.
(Refer to the automatic transaxle - Removal/ installation procedure)
3. Disconnect the sensor wire from the control cable mounting bracket.
4. Remove the pulse generator A, B.
(1) Disconnect the connector from the sensor.
(2) Measure the pulse generator A, B resistance.
Standard value:
Pulse generator A: 245±30Ω/ 20°C(68°F)
Pulse generator B: 245±30Ω/ 20°C(68°F)
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(3) If the result isn't within the standard value, remove the pulse generator A, B.
5. Measure the pulse generator A, B resistance.
Standard value
Pulse generator A : 245±30Ω/20°C(68°F)
Pulse generator B : 245±30Ω/20°C(68°F)
6. If the result isn't within the standard value, replace the pulse generator A, B.
7. Apply the ATF oil around the oil seal before installing the oil seal.
8. Install the pulse generator A, B.
TORQUE :
10~12Nm (100~120Kgf.cm, 7~8lb-ft)
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9. Connect the sensor wire to the control cable mounting bracket.
10. Connect the pulse generator connector.
11. Installation is the reverse of removal.
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2006 > G 1.6 CVVT > Automatic Transaxle System
COMPONENTS (1)
COMPONENTS (2)
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2006 > G 1.6 CVVT > Automatic Transaxle System
Removal
1. Remove the center console cover(A).
2. Remove the center console mounting bolt(A) and screw(4EA) and remove the center console.(Refer to BD
Group)
3. Disconnect lever assembly electrical connector(A).
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4. Remove the control cable cotter pin(A).
5. Remove control cable hold (lever side).
6. Remove the shift lock cable P-LOCK cam(A).
7. Remove the shift lock cable mounting nut(B). (Nut: 1EA)
8. Remove the shift lever bolt(A). (Bolt: 4EA)
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9. Remove the shift lever assembly.
Installation
1. Installation is the reverse of removal.
2. After assembling, check the followings.
(1) When shifting with each position, lever must be operated securely without friction and free from looseness,
noise and so on.
(2) When lever shifting, it shall not be stopped easily between each positions.
(3) When lever should be stopped between "P" and "R" position intentionally. It should not be shifted to "R"
position by vibration added for lever assembly.
(4) Free from noise when being shifted from "R" to "N", push button being released.
(5) Slider must be operated smoothly between each position.
(6) Slider must be operated smoothly without looseness, sticking and noise.
(7) Shift lock must be operated well.
DISASSEMBLY
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1. Remove the push button(A) from the knob sub assembly.
2. Remove the knob sub assembly from the lever sub assembly. (Screw:1EA)
3. Remove the indicator assembly(A).
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4. Remove the detent spring(A). (Bolt:1EA)
5. Loosen the bracket sub assembly nut(A).
6. Remove the screw.
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7. Disassemble the bracket sub assembly(A) after removing the cotter pin (2EA).
8. Disassemble the hinge shaft from the lever sub assembly.
REASSEMBLY
1.
2.
3.
4.
5.
6.
Reassemble the hinge shaft to lever sub assembly.
Reassemble the bracket sub assembly.
Install the detent spring.
Install the indicator assembly.
Reassemble the knob sub assembly to the lever sub assembly.
Install the push button to the knob sub assembly.
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2006 > G 1.6 CVVT > Automatic Transaxle System
COMPONENT(1)
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COMPONENT(2)
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COMPONENT(3)
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COMPONENT(4)
COMPONENT(5)
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COMPONENT(6)
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2006 > G 1.6 CVVT > Automatic Transaxle System
DESCRIPTION
The advanced alpha automatic transaxle is for a 1.6 DOHC engine. The advanced alpha AT is popularly used among
small sized vehicles.
Nowadays PCM(power-train control module), which which integrates the ECU and TCU inside, is new trend of the powertrain system.
The merge of two system guarantees stable quality of the AT as well as better shift feeling and faster response to ECU
information.
COMPONENTS(1)
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COMPONENTS(2)
Mechanical system
COMPONENTS
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Function
Component
Symbol
Function
Front clutch
F/C
Connect input shaft and reverse sun gear
Rear clutch
R/C
Connect input shaft and forward sun gear
End clutch
E/C
Connect input shaft and planetary carrier
Kick down brake
K/D
Hold reverse sun gear
Low&Reverse clutch
L/R
Hold planetary carrier
One way clutch
OWC
Restrict planetary carrier turning direction
Front clutch
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Front clutch is engaged at 3rd gear of D range and R range. When it is engaged, reverse sun gear of the planetary gear
rotates.
Power flow:
Input shaft→ Rear clutch retainer→ Front clutch→ Kick-down drum→ Reverse sun gear→ Long pinion→ Ring
gear→ Transfer driven gear
Rear clutch
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Rear clutch is engaged at 1st~3rd gear of D/2/L range. When it is engaged, forward sun gear of the planetary gear
rotates.
Power flow:
Input shaft→ Rear clutch retainer→ Rear clutch→ Rear clutch hub→ Forward sun gear→ Short pinion
End clutch
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End clutch is engaged at 4th gear (Actually, end clutch is being engaged from 3rd gear. This is only for smooth shifting
to 4th gear). When it operates, planetary carrier rotates.
Power flow:
Input shaft→ End clutch retainer→ End clutch→ End clutch hub→ End clutch shaft→ Planetary carrier→ Ring gear→
Transfer driven gear
Kick down brake
End clutch is composed of a kick down brake band, drum, servo piston and servo switch. It is engaged at 2nd&4th
gear. When it operates, reverse sun gear of the planetary gear is held.
Power flow:
Kick down brake→ Kick down drum hold→ Reverse sun gear hold
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The kickdown brake is a band type brake; it is composed of a kickdown band, drum, kickdown servo, switch and
anchor. When the 2nd pressure is admitted to the apply side chamber of kickdown servo cylinder, the kickdown piston
and rod moves toward the left, tightening the brake band to hold the kickdown drum. As a result, the reverse sun gear
(interlocked with the kickdown drum) is held. This brake functions during 2nd gear and during overdrive.
The kickdown servo switch detects the position of the kickdown piston just before the brake is applied, and sends the
signal to the transaxle control module. Using this signal, the transaxle control module controls the 2nd pressure both
before, and during application of the brake. In the initial control stage or until just before the kickdown brake is applied,
a higher 2nd pressure is supplied to the kickdown servo so that the kickdown piston con move quickly for faster
response to the kickdown condition that has been initiated. In the second control stage or while the brake is being
applied, the 2nd pressure is regulated at an optimum level so that the band is tightened on the drum the proper amount
for good kickdown "feeling".
Low&Reverse brake
Low&Reverse brake is engaged at 1st gear of L range and R range. When it operates, the planetary carrier is held.
Power flow:
Low & Reverse brake→ Planetary carrier hold
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Low&reverse brake is of the multiple disc type and is composed of a center support, disc plates and a piston.
The brake operates when the shift is in 1st gear in the "L" range or back gear. It fastens the carrier in the planetary
gearing set. That is, the shafts of the long and short pinions are fastened.
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One Way Clutch (O.W.C)
One-way clutch is of the sprag type and is incorporated between the pinion carrier and the center support.
In 1st gear (D or 2 range), the long pinion rotates clockwise. This reduces a force which has the tendency to cause the
carrier is blocked from rotating in that direction by the one-way clutch. As a result, the long pinion transmits its force to
the annulus gear. The carrier, which is coupled with the one-way clutch outer race, is free to turn in clockwise direction.
In an engine braking condition under which the annulus gear is turned first, the carrier turns clockwise freely and,
therefore, the engine braking effect is not obtained.
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Planetary Gear
The planetary gear set incorporated in this transaxle consists of a forward sun gear, a reverse sun gear, a short pinion, a
carrier to support both pinions, and an annulus gear.
The reverse sun gear is connected to the front clutch retainer via the kickdown drum, while the forward sun gear is
connected to the rear clutch hub.
The carrier is built in one unit with the low reverse brake's hub and the outer race of the one-way clutch. The carrier is
connected to the end clutch via the end clutch shaft.
The annulus gear, to which the output flange is connected, conveys driving force to the transfer drive gear installed on
the output flange. And the parking sprag is provided on the outer circumference of the annulus gear.
The Ravigneaux type plnetary gear set consists of two sun gears, each meshing with one of two sets of planetary pinion
gears in a single carrier, and a single annulus gear that meshes with one of the sets of pinions. The two sun gears are
called the forward and the reverse sun gears, for the gear conditions they operate in. Power input is to either of these two
sun gears. Power output is through the annulus gear, which has the parking sprag on the outer circumstance. Various
holding elements are built into gear set components.- Ravigneaux type planetary gear ratio.
Parking Mechanism
When the shaft is in the "P" range, the parking pawl engages with the parking sprag provided on outer circumference of
the annulus gear to fasten the output shaft, to prevent the wheels from rotating. In other words, when the select lever is
set to the "P" range, the detent plate and the parking sprag rod move in the direction of arrow, causing the cam on the
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parking sprag rod to push up the parking pawl to engage with the sprag.
In case the parking pawl collides against a crest of the sprag, only the rod moves because the parking pawl cannot be
moved upward, and the cam, while pressing the spring, collides with the parking pawl and the support, and is with held in
this condition. If the car is moved even slightly in this condition, the turning of wheels causes the annulus gear to turn as
well. Since the cam is pressed in the direction of arrow, the parking pawl is pushed up as a bottom of the sprag aligns
with the parking sprag to engage with the sprag.
In this way, the parking mechanism eliminates any chances of the vehicle from being.
No.
Cause
Symptom
Analysis
Remedy
Remarks
1
Locking due to cam
broken
Forward and/ or reverse
drive impossible
intermmittently
Parking sprag locks
the annulus gear due
to drifted cam
Replace parking
sprag rod
2
Detent ball separated
Looseness of manual lever
Detent plate not fixed
properly
Install detent ball
Power flow
Selector lever position
D
Gear
position
P
Parking
R
Reverse
N
Neutral
O/D
S/W
ON
O/D
S/W
OFF
Clutches
Remarks
F/C
R/C
K/D
○
L&R
OWC
○
☆
○
2nd
○
○
○
○
○
∆
○
4th
1st
E/C
☆□
1st
3rd
Brakes
○
○
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○
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2
2nd
○
L
1st
○
○
○
☆ - Engine start possible
□ - Parking mechanism
○ - Element engaged in each gear position
∆ - Pre-engaged element
• F/C : Front Clutch
• R/C : Rear Clutch
• E/C : End Clutch
• OWC : One Way Clutch
• K/D : Kickdown brake
• L&R : Low&Reverse brake
For each shift condition, certain holding units in the transaxle are used. Knowing which holding element is used and how
they are connected in the transaxle, we can trace the power flow through the transaxle for each shift condition. One set of
pinions, the short pinions, meshes with the reverse sun gear.
The other set, the long pinions, meshes with both the forward sun gear and with the annulus gear. The two sets of
pinions also mesh with each other in pairs. The pinion carrier is built as a unit with the low reverse brake hub and the
outer race of the one-way clutch. Power input is to either of the two sun gears.
The reverse sun gear is connected to the front clutch retainer through the kick-down drum. The forward sun gear is
connected to the rear clutch hub. So by engaging either the front or the rear clutch, power is directed to either the reverse
or the forward sun gear. When both front and rear clutches are engaged, the gear set is locked, and power passes
directly through the transaxle. Power output is through the annulus gear, which has the parking sprag on the outer
circumference and is connected to the output flange.
1st Gear ("D" and "2" range)
Operating elements: Rear Clutch, One-Way Clutch
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1st Gear ("L" range)
Operating elements: Rear Clutch, Low & Reverse Brake
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2nd Gear ("D" and "2" range)
Operating elements: Rear Clutch, Kick Down Brake
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3rd Gear ("D" range)
Operating elements: Front Clutch, Rear Clutch, End Clutch
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4th Gear ("D" range)
Operating elements: Front Clutch, Rear Clutch, End Clutch
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"R" range
Operating elements: Front Clutch, Low & Reverse Brake
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Hydraulic Control System
1. The hydraulic pressure during gear shifting engages the clutches and applies the brakes. It is regulated by the
pressure control valve. The hydraulic pressure that works on the pressure control valve is further regulated by the
pressure control solenoid valve which functions under the control of the transaxle control module. The transaxle control
module controls the solenoid valve using a duty cycle signol, thus providing appropriate regulation of the hydraulic
pressure.
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2. The transaxle control module decides the timing of the gear-shifting period (during which it performs hydraulic pressure
control for gear shifting) according to the change in the kickdown drum rotating speed that it detects. The module
identifies the time just before the kickdown brake is applied and uses that as the timing for initiating control of the
hydraulic pressure that is to be applied to the kickdown brake.
3. TCM detects torque change ratio (turbine speed change ratio in torque converter). If input torque is larger than the preset torque in TCM, TCM controls the duty of PCSV and changes oil pressure. Shift shock will be alleviated due to
torque control. Torque change ratio is applied differently according to each pattern.
4. When the transaxle is cold, the fluid viscosity is high, causing slower oil pressure response. In such conditions, the
transaxle control module provides a correction for the oil pressure by changing the control duty of the pressure control
solenoid valve. This control is performed when the fluid temperature as indicated by the oil temperature sensor is lower
than 60°C(140°F).
5. After the engine has been started and the vehicle is in motion, the transaxle control module continues to refine its
performance for smoothest possible gear shifting.
The hydraulic control system consists of an oil pump that generates hydraulic pressure for A/T. It also has valves and
solenoid valves that control the hydraulic pressure or switch the oil passage. The valves and solenoid valves are all
built into the valve body.
For better and smoother shift quality, the rear clutch pressure is controlled independently, 4th→2nd gear skip shift is
available and the line pressure at 3rd/4th gear is reduced.
There are 6 solenoid valves are incorporated on the valve body. 2 of those are duty-controlled type and the rest are
ON/OFF type.
A.Duty control type: Pressure control solenoid valve A/B, Damper clutch control solenoid valve
B.ON/OFF type: Shift control solenoid valve A/B/C
If the mechanical malfunction such as valve sticking occurred, the fail-safe valve has been adopted to prevent
interlock. The line pressure is regulated at the 4th speed to improve the efficiency of power transmission. This function
is performed by High-low pressure valve and regulator valve.
Oil Pump
Oil pump generates pressure for supplying oil to the torque converter, for lubricating frictional parts of the planetary
gearing set and the overrunning clutch, etc.., and for activating the hydraulic control system.
The pump is one of the inner-teeth engaging trochoid type. It always generates the oil pressure when the engine is
running since the drive gear is driven by 2 pawls of the pump drive hub welded at the center of the torque converter shell.
MANUAL VALVE
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PRESSURE CONTROL VALVE-A, B
Pressure control valve A, B regulate the pressure supplied to each clutch under the control of the pressure control
solenoid valve A, B to eliminate shock at the time of shifting.
1. Pressure control valve A - Not operated
PRESSURE CONTROL VALVE-A, B
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1. Pressure control valve A - Operation
PRESSURE CONTROL VALVE-A, B
1. Pressure control valve B - Not Operated
PRESSURE CONTROL VALVE-A, B
1. Pressure control valve B - Operation
The main function of this valve controls the rear clutch independently.
SHIFT CONTROL VALVE(SCV) AND SOLENOID VALVE-A, B, C (SCSV-A,B,C)
The line pressure acting upon the shift control valve is controlled by the two shift control solenoid valves(which are switch
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ON and OFF according to the shifting gear by the transaxle control module command), and the shift control valve is
activated according to the shifting gear, thus switching the oil passages.
The relationship of the shifting gear and the ON-OFF switch of shift control solenoid valve "A", "B" and "C" is shown in the
table below.
Operation
Position
Shift control solenoid valve
A
B
C
1st gear
ON
ON
OFF
2nd gear
OFF
ON
OFF
3rd gear
OFF
OFF
ON
4th gear
ON
OFF
ON
CONTROL SWITCH VALVE(CSV) & END CLUTCH(E/C) VALVE
- Function
Switching the pressure of E/C and SA
CONTROL SWITCH VALVE(CSV) & E/C VALVE
- 2nd Gear
• 2nd pressure is supplied from SA through the CSV.
• SCSV-C maintains OFF as well as 2nd gear.
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CONTROL SWITCH VALVE(CSV) & E/C VALVE
- 2nd → 3rd gear
• SCSV-C maintains OFF as well as 2nd gear.
• The E/C pressure from shift control valve is intercepted at the E/C valve during up-shifting from 2nd to 3rd gear.
• SA pressure is supplied from 1-2 shift valve, but the front clutch and SR pressure is also supplied from the 2-3/4-3
shift valve, so the both SR and SA pressure will be set off..
CONTROL SWITCH VALVE(CSV) & E/C VALVE
- 3rd gear
• SCSV-C is changed from OFF to ON.
• The E/C pressure is supplied from 1-2 shift valve at the CSV after finishing the up-shifting from 2nd to 3rd gear.
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• SA pressure is supplied from shift control valve, but the front clutch and SR pressure is also supplied from the 2-3/43shift valve, so the both SR and SA pressure will be set off.
4 → 2 SKIP SHIFT
1. Operating elements
Speed
R/C
E/C
K/D
4th
-
O
O
2nd
O
-
O
2. Controls
A.R/C engaging duty control
B.E/C releasing duty control
C.Continuous switching to SA
3. Description
A.R/C engaging duty control
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B.E/C releasing duty control
4 → 2 Skip shift only (SCSV-C ON)
When releasing the E/C clutch pressure, it is controlled by duty of PCSV-A only in case of 4 → 2 skip shift.
C.Continuous switching to SA
From (SCV) to SA through (CSV)
Fail Safe Function
1. TCM malfunction in 1st or 2nd gear
CUTTING OFF THE E/C PRESSURE BY E/C VALVE
Speed
F/C
R/C
1st
O
2nd
O
Fail
O
E/C
O
A.F/C, SR : from 2-3/4-3 shift valve
B.R/C : from PCV-B
C.SA : from 1-2 shift valve
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K/D
O
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2. TCM malfunction in 1st or 2nd gear
If the hydraulic pressure is supplied to E/C and the F/C, SR pressure is delayed
Speed
F/C
R/C
E/C
K/D
1st
O
2nd
O
O
Fail
O
O
A.R/C, E/C, S/A : interlock
• SA : Servo Apply pressure
• F/C : Front Clutch pressure
• R/C : Rear Clutch pressure
• K/D : Kick Down
• SCV : Shift Control Valve
• CSV : Control Switch Valve
• PCSV : Pressure Control Solenoid Valve
• SCSV : Shift Control Solenoid Valve
• PCV : Pressure Control Valve
• RCEV : Rear Clutch Exhaust Valve
AUTOMATIC TRANSAXLE HYDRAULIC CIRCUIT
PARKING AND NEUTRAL
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D RANGE(1st)
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D RANGE(2nd)
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D RANGE(3rd)
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D RANGE(4th)
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LOCK
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REVERSE
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ELECTRONIC CONTROL SYSTEM
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SENSOR AND ACTUATOR FUNCTION
Item
Functions
Input shaft speed sensor
Detect the turbine RPM at the E/C retainer
Output shaft speed sensor
Detect the T/F drive gear RPM at the transfer drive gear
Engine RPM signal
Receive the engine RPM via communication with ECU
Vehicle speed sensor
Detect the vehicle speed at the speedometer gear
Kickdown servo switch
Detect the operation starting of kickdown brake
Inhibitor switch
Detect the position of select lever through the contact switch
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Overdrive switch
Detect the position of overdrive(4th gear)
TPS
Detect the throttle open angle through the potentiometer
Fluid temperature sensor
Detect the temperature of ATF through the thermistor
Torque reduction request signal
Transmit the torque reduction request signal to the engine ECU
Torque reduction operation/allowance/
disallowance signal
Receive the signal of engine reduction pressure operation / allowance/
disallowance from the ECU
Pressure control solenoid valve-A
Control the hydraulic pressure to the pressure control valve for shift
control
Pressure control solenoid valve-B
Control the hydraulic pressure to the pressure control valve for shift
control
Shifting control solenoid valve-A
Make the hydraulic passage for shift control
Shifting control solenoid valve-B
Make the hydraulic passage for shift control
Shifting control solenoid valve-C
Make the hydraulic passage for shift control
Damper clutch control solenoid valve
Control the hydraulic pressure for the damper clutch control
* E/C : End Clutch
T/F : Transfer
INTEGRATED TCM SIDE CONNECTOR
INTEGRATED TCM INPUT/OUTPUT TERMINAL VOLTAGE
PIN
No.
Signal
Condition
4
5
Battery voltage
(Main relay)
26
Shift control
solenoid valve-B
27
Shift control
solenoid valve-A
Input/output value
Test result
Type
Level
IG ON
DC
Voltage
VBR
VBR
Shifting
DC
Voltage
V_BAT
Max. 1.0V
Vpeak : Max. -2V
14.01 V
9.2 mV
-0.69 V
Shifting
DC
Voltage
V_BAT
Max. 1.0V
Vpeak : Max. -2V
14.01 V
9.6 mV
-0.69 V
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Remark
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48
Drive position
PWM signal to
trip computer
Idle
'2' Position
'L' Position
Pulse
Duty
↑
HI : V_BAT or Vcc
LO : Max. 1.0V
Freq. : 50Hz±2% (Reference)
72.5±2％
12.5±2％
12.8 V
12 mV
50.0 Hz
72.5 %
12.5 %
V_BAT
Max. 1.0V
Vpeak : Max. -2V
13.97 V
7.9 mV
-0.78 V
50
Shift control
solenoid valve-C
Shifting
DC
Voltage
57
Fluid
temperature
sensor
Idling
Analog
0.5~4.5V
2.16V
60
Pulse Generator
B
60kph
Sine
Wave
Vp_p : Above 1.0V
Freq.: 1.5~2.0kHz (Reference)
1.42 V
1.98 kHz
61
Pulse Generator
A
3,000rpm
Sine
Wave
Vp_p : Above 1.0V
Freq.: 1.1~1.3kHz (Reference)
3.86 V
1.25 kHz
63
Brake SW
Release
Push
Max. 0.5V
V_BAT
0.0 mV
12.24 V
66
Inhibitor SW "D"
"D" range
Otherwise
V_BAT
Max. 1.0V
14.15 V
3.4 mV
67
Inhibitor SW "P"
"P" range
Otherwise
V_BAT
Max. 1.0V
14.21 V
4.2 mV
68
Inhibitor SW "L"
"L" range
Otherwise
V_BAT
Max. 1.0V
14.15 V
3.7 mV
70
PWR4 GND
Idling
Max. 50mV
-4.2mV
Shifting
Pulse
HI : V_BAT
LO : Max. -3.0V
Vpeak : Max. -60V
13.8 V
-0.85 V
-13.5 V
13.8 V
-0.86 V
-13.5 V
DC
Voltage
71
Pressure control
solenoid valve-A
72
Pressure control
solenoid valve-B
Shifting
Pulse
HI : V_BAT
LO : Max. -3.0V
Vpeak : Max. -60V
80
Fluid
temperature
sensor GND
Idling
Analog
0.2V ~ 4.9V
2.5V
(58°C (136°F))
82
Pulse Generator
B
60kph
Sine
Wave
Vp_p : Above 1.0V
Freq.: 1.5~2.0kHz (Reference)
1.42 V
1.98 kHz
83
Pulse Generator
A
3,000rpm
Sine
Wave
Vp_p : Above 1.0V
Freq.: 1.1~1.3kHz (Reference)
3.86 V
1.25 kHz
87
Kickdown(K/D)
servo
1, 3 speed
2, 4 speed
Max. 1.0V
V_BAT
0.0 mV
13.41 V
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@72°C
(161.6°F)
(50.0Hz /
4.3kHz
Chopping)
(50.0Hz/
4.3kHz
Chopping)
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Inhibitor SW "R"
"R" range
Otherwise
89
Inhibitor SW "2"
"2" range
Otherwise
90
O/D OFF SW
91
Inhibitor SW "N"
94
Damper clutch
solenoid valve
88
V_BAT
Max. 1.0V
13.79 V
3.4 mV
V_BAT
Max. 1.0V
14.19 V
4.1 mV
OD OFF
OD ON
V_BAT
Max. 1.0V
14.21 V
0.0 mV
"N" range
Otherwise
V_BAT
Max. 1.0V
14.22 V
3.6 mV
Lock Up ON
HI : V_BAT
LO : Max. -3.0V
Vpeak : Max. -60V
13.9 V
-0.87 V
-13.5 V
DC
Voltage
Pulse
- V_BAT : Battery Voltage
- VBR : Converted battery voltage via main relay
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(35.0Hz/
4.3kHz
Chopping)
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2006 > G 1.6 CVVT > Automatic Transaxle System
REMOVAL
• Use fender covers to avoid damaging painted surfaces.
• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
• Mark all wiring and hoses to avoid misconnection.
1. Disconnect the battery terminals and then remove battery.
2. Remove the battery and battery tray(A).
3. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the AFS(Air Flow Sensor) connector(A).
(2) Disconnect the breather hose(B) from intake air hose(D).
(3) Remove the intake air hose(D) and air cleaner upper cover(C).
(4) Disconnect the ECM connector(A, B).
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(5) Remove the air cleaner element and lower cover(C).
4. Remove the ATF(Automatic transaxle fluid) cooler hose(A).
5. Remove the transaxle ground cable(A).
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6. Remove the transaxle wire harness connectors and control cable from transaxle.
(1) Disconnect the transaxle range switch connector(A).
(2) Disconnect the solenoid valve connector(B).
(3) Disconnect the fluid temperature sensor connector(C).
(4) Disconnect the vehicle speed sensor connector(A).
(5) Disconnect the band servo switch connector(B).
(6) Disconnect the pulse generator A connector(C).
(7) Disconnect the pulse generator B connector(D).
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(8) Remove the control cable nut(A) from transaxle range switch.
(9) Remove the control cable(B).
7. Remove the power steering oil hose(A) and drain the power steering oil.
8. Remove the power steering return hose(A).
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9. Install the special tools(09200-38001), the engine support fixture and the adapter, on the engine assembly.
10. Remove the transaxle mounting support bracket(A).
TORQUE :
70~95Nm (700~950kgf.cm, 50~69lb-ft)
11. Remove the front roll stopper mounting bolt(A).
TORQUE :
50~65Nm (500~650kgf.cm, 36~47lb-ft)
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12. Remove the rear roll stopper mounting bolt(A).
TORQUE :
50~65Nm (500~650kgf.cm, 36~47lb-ft)
13. Remove the under cover(A).
14. Remove the side cover.
15. Remove the front wheel.
16. Remove the drain plug(A) and drain the automatic transaxle fluid.
TORQUE :
35~45Nm (350~450kgf.cm, 25~32lb-ft)
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17. Separate the tie rod end(A) from the pin(B) and nut(C).
18. Remove the ABS wheel speed sensor(A).
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19. Remove the front caliper(A) and use a wire to secure the caliper to the vehicle so that it is out of the way.
20. Remove the knuckle mounting bolts(A).
21. Remove the drive shaft(A) from the transaxle.
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22. Remove the steering U-joint mounting bolt(A).
23. Install the jack(A) for supporting transaxle.
When supporting the transaxle assembly, make sure that the weight is applied to a wide area of the jack
surface.
24. Remove the sub-frame bolt(A) and nut(B).
TORQUE :
Bolts(A): 40~50Nm(400~550Kgf.cm, 29~40lb-ft)
Nuts(B): 160~180Nm(1600~1800Kgf.cm, 110~126lb-ft)
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25. Remove the start motor mounting bolt(A).
TORQUE :
27~34Nm (270~340kgf.cm, 19~24lb-ft)
26. Remove the engine to the torque converter mounting bolts(A). (4EA).
TORQUE :
46~53Nm (460~530kgf.cm, 33~38lb-ft)
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27. Remove the engine to automatic transaxle mounting bolts(A).
TORQUE :
Bolts(12mm): 60~80Nm(600~800Kgf.cm, 43~58lb-ft)
Bolts(10mm): 43~55Nm(430~550Kgf.cm, 32~41lb-ft)
28. Remove the transaxle assembly.
Be careful not damage the other parts during removal.
INSTALLATION
1. Attach the torque converter on the transaxle side and mount the transaxle assembly onto the engine.
If the torque converter is mounted first on the engine, the oil seal on the transaxle may be damaged.
Therefore, be sure to first assemble the torque converter to the transaxle.
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2. Install the transaxle control cable and adjust as follows.
(1) Move the shift lever and the transaxle range switch to the "N" position, and install the control cable.
(2) When connecting the control cable to the transaxle mounting bracket, install the clip until it contacts the
control cable.
(3) Remove any free-play in the control cable by adjusting nut and then check to see that the selector lever
moves smoothly.
(4) Check to see that the control cable has been adjusted correctly.
3. Installation is the reverse of removal.
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2006 > G 1.6 CVVT > Automatic Transaxle System
SPECIAL SERVICE TOOLS
Tool
(Number and name)
Illustration
Use
09431-22100
Oil seal installer
Installation of the differential oil seal.
(Use with 09231-H1100)
09452-21500
Oil pressure gauge
Measurement of the oil pressure.
(Use with 09452-21001 and 09452-21002)
09452-21002
Oil pressure gauge
adapter
Measurement of the oil pressure.
(Use with 09452-21500 and 09452-21001)
09452-21001
Oil pressure gauge
adapter
Measurement of the oil pressure.
(Use with 09452-21500 and 09452-21002)
09200-38001
Engine support fixture
Removal and installation of the transaxle.
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2006 > G 1.6 CVVT > Automatic Transaxle System
SPECIFICATION
ITEM
CONTENTS
Engine displacement
G4ED(1.6)
Torque converter
Type
3 elements, 2 phases, 1 stage
Engine stall speed(rpm)
2400~2800
Stall torque ratio
1.9
Type
Electronically controlled automatic transaxle with four-speed
1st
2.846
2nd
1.581
3rd
1.000
4th
0.685
Reverse
2.176
Transaxle
Gear ratio
Final gear ratio
4.041(G4ED)
Speedometer gear ratio
Drive 36/ Driven 31
Friction elements
3C2B1F (3Clutches 2Brakes 1OWC): 1-band, 4-multiple disc
type
3 Clutches: Front clutch, Rear clutch, End clutch
2 Brakes: Low&reverse brake, Kick-down brake (Band type)
Planetary gear
1 Ravigneaux type planetary gear set with long and short
pinion
Solenoid valve
6 Solenoid valves (3-PWM, 3-ON/OFF)
2-Pressure control solenoid valves (PWM)
1-Damper clutch control solenoid valve (PWM)
3-Shift control solenoid valve (ON/OFF)
TIGHTENING TORQUE
Items
Nm
kgf.cm
lb-ft
Oil pan bolt
10-12
100-120
7-8
Select lever assembly mounting bolt
9-14
90-140
6.5-10
Starter motor mounting bolt
27-34
270-340
19-24
Oil cooler hose connector
15-22
150-220
11-16
3-5
30-50
2-4
Hose bracket
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Bell housing cover to engine
8-10
80-100
6-7
Transaxle mounting lower bolt(dia.10mm)
43-55
430-550
32-41
Transaxle mounting upper bolt(dia.12mm)
60-80
600-800
43-58
Torque converter mounting bolt
46-53
460-530
33-38
Control cable to body
8-11
80-110
6-7.5
Lever assembly to bracket assembly
14-22
140-220
10-16
Oil drain plug
35-45
350-450
25-32
Pressure check plug
8-10
80-100
6-7
Pulse generator
10-12
100-120
7-8
Bearing retainer
17-22
170-220
13-16
Transfer drive gear
16-21
160-210
12-15
One-way clutch inner race
35-45
350-450
25-32
Differential drive gear
130-140
1300-1400
94-101
Manual control lever
17-21
170-210
13-15
Manual control shaft lock screw
8-10
80-100
6-7
Inhibitor switch
10-12
100-120
7-8
Sprag rod support bolt
20-27
200-270
14-19
Pump housing to reaction shaft support bolt
10-12
100-120
7-8
Oil pump assembly mounting bolt
19-23
190-230
14-17
Valve body cover
10-12
100-120
7-8
Valve body assembly mounting bolt
10-12
100-120
7-8
Oil filter
5-7
50-70
4-5
Speedometer driven gear sleeve
3-5
30-50
2-4
Kickdown adjusting screw
15-22
150-220
11-15
End cover bolt
19-23
190-230
14-17
M8
20-27
200-270
14-19
M10
43-55
430-550
32-41
Differential bearing cap
60-80
600-800
43-58
Differential bearing retainer
43-55
430-550
32-41
180-210
1800-2100
130-152
Differential cover
Locking nut(M38)-Input
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Locking nut-Output
Shift cable bracket bolt
Rear roll supt bracket
M12
200-230
2000-2300
146-166
19-23
190-230
14-17
60-80
600-800
43-58
Lubricant
Items
Specified lubricant
Transaxle fluid liter (U.S. lmp.qts.)
GENUINE DIAMOND
ATF SP-III or SK ATF SP-III
Drive shaft and oil seal lip bushing sliding
parts
GENUINE DIAMOND ATF SP-III
CHASSIS GREASE SAE J310, NLGINO.0
Select lever sliding parts
SAE J310, NLGINo.2
Quantity
6.1ℓ (6.4 US qt, 5.4
lmp.qt)
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As required
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2006 > G 1.6 CVVT > Automatic Transaxle System
TROUBLESHOOTING
DIAGNOSITC TORUBLE CODES (INSPECTION PROCEDURE)
Check the Diagnostic Trouble Codes
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1.
2.
3.
4.
5.
Turn the ignition switch to OFF.
Connect the Hi-scan tool to the DLC connector for diagnosis.
Turn the ignition switch to ON.
Check the diagnostic trouble codes using the Hi-scan tool.
Read the output diagnostic trouble codes. Then follow the remedy procedures according to the "DIAGNOSTIC
TROUBLE CODE DESCRIPTION" on the following pages.
• A maximum of 10 diagnostic trouble codes (in the sequence of occurrence) can be stored in the Random
Access Memory (RAM) incorporated within the control module.
• The same diagnostic trouble code can be stored one time only.
• If the number of stored diagnostic trouble codes or diagnostic trouble patterns exceeds 10, already stored
diagnostic trouble codes will be erased in sequence, beginning with the oldest.
• Do not disconnect the battery until all diagnostic trouble codes or diagnostic trouble patterns have been read
out, because all stored diagnostic trouble codes or diagnostic trouble patterns will be cancelled when the
battery is disconnected.
• All diagnostic trouble codes are deleted from memory the 200th time the ATF temperature reaches 50°C(122°F)
after memorization of the most recent diagnostic code.
6. Delete the diagnostic trouble code.
7. Disconnect the Hi-scan tool.
DTC cleaning should only be done with the scan tool.
Diagnostic trouble code table
No.
Code
Item
1
P0605
INTERNAL CONTROL MODULE READ OLNY MEMORY(ROM) ERROR
AT-53
2
P0707
TRANSAXLE RANGE SWITCH CIRCUIT NO INPUT
AT-55
3
P0708
TRANSAXLE RANGE SWITCH CIRCUIT MULTI - INPUT
AT-61
4
P0711
TRANSAXLE FLUID TEMPERATURE SENSOR RATIONALITY
AT-64
5
P0712
TRANSAXLE FLUID TEMPERATURE SENSOR CIRCUIT LOW INPUT
AT-71
6
P0713
TRANSAXLE FLUID TEMPERATURE SENSOR CIRCUIT HIGH INPUT
AT-73
7
P0716
A/T INPUT SPEED SENSOR(PG-A)-TOO MAX
AT-75
8
P0717
A/T INPUT SPEED SENSOR(PG-A) CIRCUIT - OPEN or SHORT(GND)
AT-82
9
P0722
A/T OUTPUT SPEED SENSOR(PG-B) CIRCUIT - OPEN or SHORT(GND)
AT-84
10
P0731
GEAR 1 INCORRECT RATIO
AT-90
11
P0732
GEAR 2 INCORRECT RATIO
AT-98
12
P0733
GEAR 3 INCORRECT RATIO
AT-105
13
P0734
GEAR 4 INCORRECT RATIO
AT-112
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Remark
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14
P0741
TORQUE CONVERTER CLUTCH STUCK OFF
AT-117
15
P0742
TORQUE CONVERTER CLUTCH STUCK ON
AT-122
16
P0743
TCC CONTROL SOLENOID VALVE CIRCUIT - OPEN or SHORT(GND)
AT-125
17
P0745
PRESSURE CONTROL SOLENOID VALVE-A CIRCUIT - OPEN or SHORT(GND)
AT-130
18
P0750
SHIFT CONTROL SOLENOID VALVE-A CIRCUIT - OPEN or SHORT(GND)
AT-135
19
P0755
SHIFT CONTROL SOLENOID VALVE-B CIRCUIT - OPEN or SHORT(GND)
AT-139
20
P0760
SHIFT CONTROL SOLENOID VALVE-C CIRCUIT - OPEN or SHORT(GND)
AT-143
21
P0775
PRESSURE CONTROL SOLENOID VALVE-B CIRCUIT - OPEN or SHORT(GND)
AT-147
22
P1709
KICKDOWN SERVO SWITCH CIRCUIT - OPEN or SHORT
AT-152
23
U0001
CAN BUS OFF
AT-159
24
U0100
CAN TIME OUT
AT-160
• D/C : Damper clutch
• PG-A : Input shaft rotation speed sensor
• PG-B : Output shaft rotation speed sensor
• PCSV : Pressure control solenoid valve
• SCSV : Shift solenoid valve
Check the control system (using the Hi-scan tool)
Diagnosis items
Checking procedures
Check conditions
Fluid temperature sensor Engine doesn't operate before
starting
Kickdown servo switch
Ignition signal
• Engine rpm
Normal value
Equivalent to outside
air temperature
While warming up engine
Gradual increase
After warming up engine
80~110°C
(176~230°F)
Probable cause
- Malfunction of the fluid
temperature sensor or the
circuit harness
ON
- Malfunction of the kickdown
servo adjustment
"D"range :1st or 3rd gear
ON
- Malfunction of the kickdown
servo switch or the circuit
harness
"D"range :2nd or 4th gear
OFF
- Malfunction of the kickdown
servo system
"L"range : Idling
"N"range: Idling
650-900rpm
- Malfunction of the ignition
system
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"N"range, 2500rpm
(Tachometer)
Idling switch
Transaxle range switch
Pulse generator-A
• Turbine rpm
- Malfunction of the ignition
signal pick-up circuit
ON
- Malfunction of the TPS
adjustment
OFF
- Malfunction of the TPS or the
circuit harness
"D"range: Air conditioning ON
ON
"D"range: Air conditioning OFF
OFF
- Malfunction of the air
conditioning power relay circuit
harness
Accelerator pedal fully released
Press accelerator pedal slightly
Air conditioning relay
signal
2400-2600rpm
"D"range: Idling
C(creep)
- Malfunction of the TCM
"L"range: Idling
1st gear
- Malfunction of the idling switch
system
"2"range: 2nd gear
2nd gear
"D"range: Overdrive switch is
turned OFF, 3rd gear
3rd gear
"D"range: Overdrive switch is
turned ON, 4th gear
4th gear
"D"range: Engine stopped
0rpm
"D"range:Driving at 50km/h
(31mph) in 3rd gear
1600~2000rpm
"D"range:Driving at 50km/h
(31mph) in 4th gear
1100~1400rpm
"D"range: Engine stopped
0rpm
"D"range:Driving at 50km/h
(31mph) in 3rd gear
1600~2000rpm
"D"range:Driving at 50km/h
(31mph) in 4th gear
1600~2000rpm
- Malfunction of the inhibitor
switch system
- Malfunction of the TPS system
- Malfunction of the pulse
generator-A or the circuit
harness
- Incoming noise from outside
Pulse generator-B
• Output shaft RPM
sensor
- Malfunction of the pulse
generator-B or the circuit
harness
- Incoming noise from outside
Overdrive switch
Inhibitor switch
Overdrive switch is turned ON
OD:ON
Overdrive switch is turned OFF
OD:OFF
Shift select lever to "P"range
P
Shift select lever to "R"range
R
Shift select lever to "N"range
N
Shift select lever to "D"range
D
Shift select lever to "2"range
2
Shift select lever to "L"range
L
- Malfunction of the overdrive
switch or the circuit harness
- Malfunction of the inhibitor
switch adjustment
- Malfunction of the inhibitor
switch or the circuit harness
- Malfunction of the manual
control cable
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Vehicle speed sensor
Keep vehicle stopped
Driving at 30km/h(19mph)
Driving at 50km/h(31mph)
Pressure control
solenoid valve duty
(PCSV duty)
"D"range : Idling
"D"range: 1st gear
0km/h
30km/h(19mph)
50km/h(31mph)
60~80%
100%
- Malfunction of the vehicle
speed sensor if high speed
signal is delivered while
vehicle is stopping
- In other cases, malfunction of
the vehicle speed sensor or
circuit harness
- When accelerator pedal is
slightly pressed while idling in
"D"range, duty should
become100%
- Malfunction of the TCM
- Malfunction of the TPS system
"D"range: During shift
Damper clutch slip rpm
• Turbine rpm
"D"range: 3rd gear, 1500rpm
(Tachometer)
Varies with condition
200~300rpm
- Malfunction of the idling switch
system
- Malfunction of the damper
clutch
- Malfunction of the ignition
signal wire or pulse generatorB system
"D"range: 3rd gear, 3500rpm
(Tachometer)
0rpm
- Abnormality transaxle fluid
pressure
- Malfunction of the damper
clutch solenoid valve
DCCSV duty
"D"range: 3rd gear, 1500rpm
(Tachometer)
0%
"D"range: 3rd gear, 2500rpm
(Tachometer)
Varies with load
- Malfunction of the TCM
- Malfunction of the TPS system
- Malfunction of the pulse
generator-B system
Fluid leaks inspection
Check for leaks from the transmission. If there are leaks, it is necessary to repair or replace O-ring, seal packings, oil
seals, plugs or other parts.
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Transaxle fluid level inspection
1.
2.
3.
4.
5.
Park the vehicle at even straight surface.
Before removing the oil level gauge, wipe all contaminants from around the oil level gauge.
Set the select lever to the "P"position and engage the parking brake and then start the engine.
Drive the vehicle until the fluid reaches normal.(80~90°C(176~194°F))
Move the select lever through all positions. This will fill the torque converter with transaxle fluid. Set the select lever to
the "N"(Neutral) position.
6. Check that the fluid level is the "HOT" mark on the oil level gauge. If fluid level is low, add automatic transaxle fluiduntil
the level reaches the "HOT" mark.
Automatic transaxle fluid :
GENUINE DIAMOND ATF SP-III or SK ATF SP-III
Quantity: 6.1ℓ (6.4 US qt, 5.4 lmp.qt)
Low fluid level can cause a variety of abnormal conditions because it allows thepump to take in air along with fluid.
Air trapped in the hydraulic system forms bubbles, which are compressible.
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 cause the same
conditions which occur with low fluid level, resulting in accelerated deterioration of automatic transaxle fluid.
In either case, air bubbles can cause overheating, and fluid oxidation, which can interfere with normal valve, clutch,
and brake operation.
Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak.
Also check the condition of the transaxle fluid. If the fluid smells as if it is burning, it means that the fluid has been
ontaminated by fine particles from the bushes and friction material, a transaxle overhaul may be necessary.
Inspect the condition of fluid on the oil level gauge. For the detail check, drain some of the oil fluid out of the pump
and then inspect the condition of the oil fluid.
After checking, insert the oil level gauge into the oil filler tube securely.
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When new, automatic transaxle fluid should be red, The red dve is added so the assembly plant can identify it as
transaxle 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 transaxle fluid will begin to look darker. The color may eventually
appear light brown.
But, the transaxle should be overhauled under the following conditions.
• If there is a "burning"door.
• If the fluid the color has become noticeably blacker.
• If there is a noticeably excessive amount of metal particle in the fluid.
Hydraulic pressure test
1.
2.
3.
4.
Warm up the engine until the automatic transaxle fluid temperature is 80~100°C(176~212°F).
Jack up the vehicle so that the wheels are free to turn.
Connect the engine tachometer.
Connect the oil pressure gauge(09452-21500) and the oil pressure gauge adapter(09452-21002, 09452-21001) to
each pressure discharge port. But use the gauge(30kg/cm²) when measuring the reverse pressure, front clutch
pressure and low&reverse brake pressure.
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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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- "-" is 0.2(0.3)kg/cm² or less and "( )" is the reverse.
- SW-ON : Turn the overdrive control switch ON.
- SW-OFF : Turn the overdrive control switch OFF.
- The hydraulic pressure may be more than standard value at the ambient temperature.
DRIVE SHAFT OIL SEALS REPLACEMENT
1. Disconnect the drive shaft from the transaxle.
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2. Using a flat-tip (-) screwdriver, remove the oil seal(A).
3. Apply a coating of the transaxle fluid to the lip of the oil seal.
4. Using the special tool (09431-21200), tap the drive shaft oil seal into the transaxle.
TORQUE CONVERTER STALL TEST
This test measures the maximum engine speed when the select lever is at the "D" or "R" position and the throttle is fully
opened to test the operation of the torque converter overrunning clutch and the holding ability of clutch and brake inthe
transaxle.
Do not let anybody stand in front of or behind the vehicle while this test is being carried out.
1. Check the automatic transaxle fluid level and temperature and the engine coolant temperature.
A.Fluid level : At the HOT mark on the oil level gauge
B.Fluid temperature : 80~90°C (176~194°F)
C.Engine coolant temperature : 80~90°C (176~194°F)
2. Apply chocks to both rear wheels.
3. Connect the engine tachometer.
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4. Pull the parking brake lever on, with the brake pedal fully depressed.
5. Start the engine.
6. Move the select 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 5 seconds.
• If carrying out the stall test two or more times, move the select lever to the "N" position and run the engine at
1,000 r/min to let the automatic transaxle fluid cool down before carrying out subsequent tests.
• Move the select lever to the "R" position and carry out the same test again.
Stall rpm : 2,400~2,800 RPM
7. Moe the select lever to the "R" position carry out the same test again.
(1) "Stall speed above specification in "D"
If stall speed is higher than specification, the rear clutch or overrunning clutch of the transaxle is slipping. In
thiscase, perform a hydraulic test to locate the cause of slippage.
(2) Stall speed above specification in "R"
If the stall speed is higher than specification, the front clutch of the transaxle or low & reverse brake is slipping. In
this case, perform a hydraulic test to locate the cause of slippage.
(3) Stall speed above specification in "D" and "R"
If the stall speed is lower than specification, insufficient engine output or a faulty torque converter is suspected.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
FRONT MUD GUARD AND WHEEL GUARD
- When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related
parts, to prevent damage.
- Put on gloves to protect your hands.
- Take care not to scratch the body surface.
1. Remove the wheel guard, mud guard(A).
2. Installation is the reverse of removal.
REAR MUD GUARD AND WHEEL GUARD
- When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related
parts, to prevent damage.
- Put on gloves to protect your hands.
- Take care not to scratch the body surface.
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1. Remove the wheel guard(A).
2. Installation is the reverse of removal.
SIDE GARNISH AND SIDE SILL REPLACEMENT
- When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related
parts, to prevent damage.
- Put on gloves to protect your hands.
- Take care not to scratch the body surface.
1. Remove the side garnish(A).
2. Installation is the reverse of removal.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
COMPONENTS
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
FLOOR CONSOLE REPLACEMENT
- When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the
related parts, to prevent damage.
- Put on gloves to protect your hands.
1. Remove the front seat.
2. After disconnecting the console switch assembly(A), remove the connector.
3. Remove the console upper cover(B).
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4. Remove the parking brake cover(A).
5. Loosning the console mounting bolt and clip, remove the console assembly(A).
6. Installation is the reverse of removal.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
CONPONENTS
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
CLUSTER FACIA PANEL REPLACEMENT
- When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the related
parts, to prevent damage.
- Put on gloves to protect your hands.
1. Tilt the steering column down.
2. Disconnet the trip sencor connector(A) then remove the cluster facia panel(B).
3. Installation is the reverse of removal.
- Make sure the connector is plugged in properly.
CENTER FACIA PANEL REPLACEMENT
1. After disconnecting the connector (A), remove the center facia panel (B).
- When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the
related parts, to prevent damage.
- Put on gloves to protect your hands.
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2. Installation is the reverse of removal.
- Make sure the connector is plugged in properly.
LOWER CRASH PAD PANEL REPLACEMENT
1. Remove the fuse box cover(A).
2. Loosening the crash pad lower panel mounting screw. Remove the lower crash pad panel(A).
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3. Installation is the reverse of removal.
HEATER CONTROL UNIT REPLACEMENT
1. Remove the center lower tray(A).
2. After loosen the center facia lower panel mounting screw, remove the center facia lower panel(A). Disconnect the
heater control unit connector(B).
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3. Disconnect the heater control cable(A).
4. Lossen the heater control unit mounting screw. Remove the heater control unit(A).
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5. Installation is the reverse of removal.
- Make sure the connector is plugged in properly.
CLUSTER REPLACEMENT
1. Remove the cluster facia panel.
2. Loosen the mounthing screws.
- Take care not to drop the galss scratch the glass surface.
3. Disconnect the cluster connector (A), then remove the cluster.
- Make sure the connector is plugged in properly.
AUDIO ASSEMBLE REPLACEMENT
1. Remove the center facia panel.
2. Loosen the screws.
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3. Disconnect the audio connector and antenna cable, then remove the audio assembly (A).
4. Installation is the reverse of removal.
- Make sure the connector is plugged in properly.
GLOVE BOX REPLACEMENT
1. Disconnect the damper (B) from the glove box (A).
2. Remove the glove box(A).
3. Installation is the reverse of removal.
COVER REPLACEMENT
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- When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the related
parts, to prevent damage.
- Put on gloves to protect your hands.
1. Remove the crash pad side cover(A).
Drive’s
Passenger’s
AIR VENT REPLACEMENT
- When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the related
parts, to prevent damage.
- Put on gloves to protect your hands.
1. Remove the crashpad side cover.
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2. Using a screw driver remove the air vent(A).
3. Installation is the reverse of removal.
STEERING COLUMN SHROVND REPLACEMENT
1. After loosening shround mounting screw, remove the shround(A).
2. Installation is the rever of removal.
CRASH PAD MAIN REPLACEMENT
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- When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the related
parts, to prevent damage.
- Put on gloves to protect your hands.
1. Remove the following items.
A.Front seat assemble.
B.Cluster facia panel, cluster.
C.Lower crash pad.
D.Glove box.
E.Side cover.
F.Front pillar trim.
G.Center facia upper, lower cover.
H.Cowl side trim.
2. Disconnect the passenger’s air bag connector(A).
3. Losen the bolt`s and nuts then remove the main carash pad assemble(B).
4. Installation is the reverse of removal.
- Make sure the crash pad fits on to the guide pins correctly.
- Before tihgtening 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.
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COWL CROSS BAR ASSEMBLE REPLACE MENT
- When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the related
parts, to prevent damage.
- Put on gloves to protect your hands.
1. Remove the crash pad.
2. Disconnect the connectors, after loosening the mounthing bolts and nuts remove the cowl crossbar(A).
3. Installation is the reverse of removal.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
- When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related
parts, to prevent damage.
- Put on gloves to protect your hands.
- Take care not to scratch the body surface.
- Put on gloves to protect your hands.
- Take care not to scratch the body surface.
1.
2.
3.
4.
5.
Remove the wheel guard and mud guard.
Remove the headlamp assembley.
Remove the quadrant inner cover(A).
After loose the mounting bolts, remove the fander(B).
Installation is the reverse of removal.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
- Put on gloves to protect your hands.
- When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
- Take care not bend or scratch the cover and other parts.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
COMPONENTS
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
DOOR TRIM REPLACEMENT
- Take care not to scratch the door trim and other parts.
- Put on gloves to protect your hands.
1. After disconncting the connector(A), remove the quadrant inner cover(B).
2. After loosen the inside handle cover mounting screw, remove the inside handle cover(A).
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3. Loosen the door trim mounting screws. Disconnect the power window switch connector(A), power mirror
connector(B). Remove the door trim(E).
4. Installation is the reverse of removal.
- Make sure of connectors is plugged in properly and each rod is connected securely.
- Make sure the door lock and opens properly.
GLASS REPLACEMENT
1. Remove the front door trim.
- Using the door switch to align the mounting hole with the hole on the door glass.
- If it is impossible, align the hole with hands after removing the motor.
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).
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- Take care not to drop to glass and scratch the glass surface.
3. Installation is the reverse of removal.
- Roll the glass up down to see if it move freely without binding.
- Adjust the position of the glass as necessary.
INSIDE HANDLE REPLACEMENT
1. Remove the front door trim.
2. Loose the inside handle (A) mounting screw.
Push the inside handle rearward to disconnect from the door module.
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3. Disconnect the lock cable(A) and inside connect cable (B).
4. Installation is the reverse of removal.
- Make sure the door lock and open properly.
SPEAKER REPLACEMENT
1. Remove the front door trim.
2. After disconnect the speaker mounting screw and connector(A), remove the speaker(B).
3. Installation is the reverse of removal.
DOOR WEATHERSTRIP REPLACEMENT
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1. Remove the door weatherstrip(A).
2. Installation is the reverse of removal.
DOOR REGULATOR REPLACEMENT
1.
2.
3.
4.
Remove the door trim.
Remove the door trim seal.
Remove the window glass.
After loosen the door regulator mounting nuts and window motor(B) mounting nuts, remove the door regulator
(A).
POWER WINDOW MOTOR REPLACEMENT
1. Remove the front door trim.
2. Remove the door regulator.
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3. Remove the window motor(A).
4. Installation is the reverse of removal.
- Roll the glass up down to see if it move freely without binding.
FRONT DOOR LATCH REPLACEMENT
1.
2.
3.
4.
Remove the door trim.
Remove the inside handle.
Remove the chennel.
Disconnect the lock cable(A), out side handle cable(B).
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5. After disconnect the connector(B), loosen the mounting bolts. Remove the latch assemble(A).
6. Installation is the reverse of removal.
- Roll the glass up down to see if it move freely without binding.
- Make sure the door lock and opens properly.
OUTSIDE HANDLE REPLACEMENT
1.
2.
3.
4.
5.
Remove front door trim.
Remove the door trim seal.
Disconnect the lock cable(A), out side handle cable(B).
Loosen the outside handle mounting bolts.
Remove the outside handle(C).
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6. Installation is the reverse of removal.
- Make sure the door lock and opens properly.
DOOR BELT WEATHERSRIP REPLACEMENT
1. Remove front door trim.
2. Remove the door belt weatherstrip(A), after straightening hook of weatherstrip.
3. Installation is the reverse of removal.
REAR CHENNEL REPLACEMENT
1. Remove front door trim.
2. Remove the rear chennel(A).
3. Installation is the reverse of removal.
ADJUSTMENT
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GLASS ADJUSTMENT
- Check the glass run channel for damage or deterioration, and replace them necessary.
1. Remove the front door trim.
2. Carefully move the glass (A) until you can see the glass mounting bolts, then loosen them.
3. Check that the glass moves smoothly.
DOOR STRIKER ADJUSTMENT
Make sure the door latches securely without slamming It.
If necessary, adjust the striker (A): The strike nuts Are fixed. The strike 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(A).
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.
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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.
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. CheckThat the door and body edges are parallel. Before
Adjusting, replace the mounting bolts.
1. Place the vehicle on a firm, level surface when adjusting the doors.
2. Adjust at the hinges (A):
A.Loosen the door mounting bolts (B) slightly, and move the door IN or OUT until it aligns flush with the body.)
B.Loosen the hinge mounting bolts (C) slightly, and move the door BACKWARD or FORWARD, UP or DOWN
as necessary to equalize the gaps.
C.Place a shop towel (D) on the jack (E) to prevent damage to the door when adjusting the door.
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3. Check that the door and body edges are parallel.
4. Grease the pivot portions of the hinges indicated by the arrows.
5. Check for water leaks.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
COMPONENTS
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACCEMENT
SEAT ASSEMBLY REPLACEMENT
1. Remove the seat assembly mounting cover.
2. After loosening the seat assembly mounting bolt and nut, remove the seat assembly (A).
3. Disconnect the connector (B), and remove the seat assembly.
4. Installation is the reverse of removal.
- Set the into the most rearward position. Check then each slide is locked, and then Tighten the front
mounting bolt temporarily.
- Set the seat into most forward position.Check that each slide is 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 smoothy and the locking portion locks properly.
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RECLINER COVER, KNOB AND HEIGHT KNOB REPLACEMENT
1. Remove the height adjuster knob (A) and recliner knob(B).
2. Loosen the recliner mounting screw and clip, then remove the recliner cover(C).
SEAT BACK COVER REPLACEMENT
1. Remove the recliner cover, knob and height knob.
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2. Disconnect the airbag connector(A).
3. Disconnect the seat back frame(B), from seat track assemble(A).
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4. After loosening the mounthing screw, remove the front seat armrest(A).
5. Using a screw driver, remove the seat back panel(B).
6. Disconnect the protector(A) from seat back frame.
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7. Disconnect the band(B).
8. Remove the headrest and headrest guide(A).
9. Arter removing the apilx(A) on the front of seat cover and remove the seat cover(B).
10. Installation is the reverse of removal.
- To prevent wrinkles, make sure the material is stretched evenly over the over (A) before securing the
hogring clips (B).
- Replace the hogring clips with new ones using special tool (C).
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SEAT CUSION COVER REPLACEMENT
1. Remove the front seat assemble.
2. Disconnect the connector(A) then remove the track assemble(B) from cusion frame(C).
3. Remove the scuff band(A).
4. Remove the connector(B) then disconnect the protector from cusion frame(C).
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5. After removing the hogring clips(A) on the front of seat cusion and remove the seat cusion(B).
6. Installation is the reverse of removal.
- To prevent wrinkles, make sure the material is stretched evenly over the over (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 recliner cover, knob and height knob.
2. Disconnect the airbag connect(A), heater connect(B).
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3. Disconnect the seat back frame(B) from seat track assembly(A).
4.
5.
6.
7.
Remove the seat back cover.
Remove the head rest and head rest guide.
Remove the seat back cover and sponge, from frame.
After loosening seat back frame mouting bolts, remove the seat back frame(A).
- Remove the side air bag for replacing side air bag installation seat.
- Be fore service, be fully aware of precaution and service procedure relevant to air bag.
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8. Installation is the reverse of removal.
SEAT TRACK REPLACEMENT
1.
2.
3.
4.
5.
Remove the seat back pannel.
Remove the recliner cover, knob and height knob.
Remove the seat back assembly.
Remove the seat cushion.
Remove the seat assembly (A).
6. Installation is the reverse of removal.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
HOOD ASSEMBLY 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.
2. After loose the hood hinge (A) mounting bolts, remove the hood (B).
3. Installation is the reverse of removal.
- Make sure the hood opens properly and locks securely.
- Adjust the hood alignment.
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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.
2. Installation is the reverse of removal.
- Replace any damaged clips.
HOOD SEAL WEATHERSTRIP REPLACEMENT
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1. Remove the hood weatherstrip(A).
2. Installation is the reverse of removal.
HOOD LATCH REPLACEMENT
1. Loosen the latch (A) mounting bolt then disconect the latch cable(B) and release cable(C).
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2. Pull in the direction of the arrow after loosening the radiator mounting bolts then remove the hood latch.
3. Installation is the reverse of removal.
- Make sure the hood latch cable is connected properly.
- Make sure the hood locks securely.
HOOD RELEASE HANDLE REPLACEMENT
1. Remove the cowl side trim.
2. Remove the mounting bolt, then remove the hood release handle (A).
3. Disconnect the hood latch cable (B) from the hood release handle.
4. Installation is the reverse of removal.
- Make sure the hood latch cable is connectedproperly.
- Make sure the hood locks securely.
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HOOD LATCH RELEASE CABLE REPLACEMENT
1. Remove the following items.
A.Hood latch.
B.Hood latch release handle.
C.Weel gurad.
2. Remove the clip, latch cable(A) and then remove the realese cable(B).
- Make sure the hood latch cable is connected.
3. Installation is the reverse of removal.
- Make sure the hood latch cable is connected proterly.
- Replace any damaged clips.
COWL TOP COVER REPLACEMENT
1. Remove the wiper arm.
2. Disconnecting the hood weatherstrip(A), remove the cowl top cover(B).
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ADJUSTMENT
ADJUST HOOD
1. After loosening the hinge (A) mounting bolt, adjust the hood (D) by moving it up or down, or right or left.
2. Adjust the hood height by turning the hood overslam bumpers (B).
3. After loosening the hood latch (C) mounting bolts, adjust the latch by moving it up or down, or right or left.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
FLOOR AND SIDE TRIM
1. Remove the trim.
- Put on gloves to protect your hands.
- 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.
2. Installation is the reverse of removal.
- Replace any damage clips.
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TRUNK TRIM
1. Remove the trunk trim.
- Put on gloves to protect your hands.
- 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.
2. Installation is the reverse of removal.
- Replace any damage clips
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ROOF TRIM
1. Remove the following items.
A.Sunvisor(A),(B).
B.Over head console(E).
C.Room lamp(F).
D.Assist handle(C).
2. Remove the roof trim.
- Put on gloves to protect your hands.
- When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
- Put on gloves to protect your hands.
- 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.
3. Installation is the reverse of removal.
- Replace any damage clips.
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PACKAGE TRAY
1. Remove the package trim.
- Put on gloves to protect your hands.
- 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.
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2. Installation is the reverse of removal.
- Replace any damage clips.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
COMPONENETS
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
OUTSIDE REAR VIEW MIRROR RELPLACEMENT
- When prying with a flat-up screwdriver, wrap it with protective tape, and apply protective tape around the
related parts, to prevent damage.
- Put on gloves to protect your hands.
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).
3. Installation is the reverse of removal.
INSIDE REAR VIEW MIRROR REPLACEMENT
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1. Push the inside rear view mirror base (A) down to remove to inside rear view mirror assembly(B).
2. Installation is the reverse of removal.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
- After remove the rear combinati0n lamp.
- When prying with a flat-tip screwdriver, wrap it with protective tape , and apply protective tape around the related
parts your hands.
- Put on gloves to protect your hands.
- Take care not bend or scratch the cover and other parts.
- Replace any damage clips.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
COMPONENTS
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
REAR DOOR TRIM REPLACEMENT
- Take care not to scratch the door trim and other parts.
- Put on gloves to protect your hands.
1. After loosen the inside handle cover mounting screw, remove the inside handle cover(A).
2. Loosen the door trim mounting screws. Disconnect the power window switch connector(A), power mirror
connector. Remove the door trim(B).
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3. Installation is the reverse of removal.
- Make sure of connectors is plugged in properly and each rod is connected securely.
- Make sure the door lock and opens properly.
GLASS REPLACEMENT
1. Remove the rear door trim.
2. After loosening the fixed glass mounting screw and bolts, remove the glass(A).
3. 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).
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4. Installation is the reverse of removal.
- Take care not to drop to glass and scratch the glass Glass surface.
POWER WINDOW MOTOR REPLACEMENT
1. Remove the rear door trim.
2. Remove the rear door regulator.
3. After loosening the power window motor mounting nuts, remove the power window motor(A).
4. Installation is the reverse of removal.
- Roll the glass up down to see if it move freely without binding.
OUT SIDE HANDLE REPLACEMENT
1. Remove the rear door trim.
2. Remove the rear door trim seal.
3. Remove the road cover(A).
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4. After disconnect the out side handle rod(A), Loosen the outsidr handle mounting bolts.
5. Remove the out side handle(B).
6. Installation is the reverse of removal.
- Roll the galss UP DOWN to see if it move freely without binding.
- Make sure door lock and opens properlt.
REAR DOOR LATCH REPLACEMENT
1.
2.
3.
4.
Remove the rear door trim.
Remove the door trim seal.
Remove the inside handle.
Disconnect the lock cable(A), out side handle cable(B).
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5. After loosen the latch mounting bolts, remove the latch assmble(C).
6. Installation is the reverse of removal.
- Make sure the door lock and opens properly.
DOOR REGULATOR REPLACEMENT
1.
2.
3.
4.
Remove the door trim.
Remove the door trim seal.
Remove the window glass.
After disconnecting window motor connector(B), loosen the door regulator mounting nuts and window mounting
nuts.Remove the door regulator(A).
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5. Installation is the reverse of removal.
- Make sure the connector is plugged in properly and each rod is connected securely.
- Make sure the door lock and open properly.
INSIDE HANDLE REPLACEMENT
1. Remove the rear door trim.
2. Loose the inside handle (A) mounting screw.
Push the inside handle rearward to disconnect from the door module.
3. Disconnect the lock cable and (A) inside connect cable (B).
4. Installation is the reverse of removal.
- Make sure the door lock and open properly.
DOOR BELT WEATHERSTRIP REPLACEMENT
1. Remove the rear door trim.
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2. Remove the door belt weatherstrip(A) after straightening hook of weatherstrip.
3. Installation is the reverse of removal.
DOOR WEATHERSTRIP REPLACEMENT
1. Remove the door weatherstrip(A).
2. Installation is the reverse of removal.
ADJUSTMENT
GLASS ADJUSTMENT
- Check the glass run channel for damage or deterioration, and replace them necessary.
1. Remove the following parts.
A.Door trim.
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2. Carefully move the glass (A) until you can see the glass mounting bolts, then loosen them.
3. Check that the glass moves smoothly.
DOOR STRIKER ADJUSTMENT
Make sure the door latches securely without slamming it.
If necessary, adjust the striker (A) : The strike nuts Are fixed. The strike 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(A).
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.
DOOR POSITION ADJUSTMENT
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- 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. CheckThat the door and body edges are parallel. Before
Adjusting, replace the mounting bolts.
1. Place the vehicle on a firm, level surface when adjusting the doors.
2. Adjust at the hinges (A):
A.Loosen the door mounting bolts (B) slightly, and move the door IN or OUT until it aligns flush with the body.)
B.Loosen the hinge mounting bolts (C) slightly, and move the door BACKWARD or FORWARD, UP or DOWN
as necessary to equalize the gaps.
C.Place a shop towel (D) on the jack (E) to prevent damage to the door when adjusting the door.
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3. Check that the door and body edges are parallel.
4. Grease the pivot portions of the hinges indicated by the arrows.
5. Check for water leaks.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
COMPONENTS
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
SEAT ASSEMBLY REPLACEMENT
1. Loosen the rear seat cushion mounting bolts, then remove the rear seat cushion(A) after pull the stopper(B).
2. Loosenig the seat belt mounting bolt, remove the seat back(A).
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3. Installation is the reverse of removal.
ARM REST REPLACEMENT
1. Remove the rear rear seat.
2. Remove the arm rest cover(A).
3. Loosening the arm rest mounting bolt, remove the arm rest(A).
4. Installation is the reverse of removal.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
COMPONENT LOCATION
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
INSPECTION
1. Check for continuity and measure the resistance between No.1 and NO.3 terminals.
Standard value: 2.45Ω ± 10%
(Cushion: 1.2Ω ± 10%, Back: 1.2Ω ± 10%)
2. Operate the seat warmer after connecting the 3P connector, and then check the thermostat by measuring the
temperature of seat surface.
3. Check for continuity between the terminals after disconnecting the 3P connector.
Standard value :
28 ±3.5°C(Continuity), 37 ±3.0°C(Short)
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
INSPECTION
1. Disconnect the negative (-) battery terminal.
2. Remove the seat warmer switch from the floor console with scraper.
3. Check for continuity between the terminals in each switch position according to the table.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
SPECIAL TOOLS
Tool (Number and name)
Illustration
Use
09793-21000
Door hinge adjusting
wrench
Adjustment, removal and installationOf the
door hinge
09800-21000
Ornament remover
Trim removal
09853-31000
Headliner clip remover
Removal of the headliner clips
09861-31100
Sealant cut-out tool
Cutting the sealant of the windshield
(Use with 09861-31200)
09861-31200
Sealant cutting blade
Cutting the sealant of the windshield
(Use with 09861-31100)
09861-31300
Sealant gun
Application of the sealant to the windshield
09861-31400
Glass holder
Removal and installation of the windshield
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09861-31000
Windshield moulding
remover
Removal of the windshield moulding
09880-4F000
Hogring clip installer
Installation of the hogring clip
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
SPECIFICATIONS
HOOD
Rear hinged, gas lifter type
Type
FRONT DOOR
Front hinged, full door construction
Wire drum type
Pin-fork system
Construction
Regulator system
Locking system
REAR DOOR
Front hinged, full door construction
Wire drum type
Pin-fork system
Construction
Regulator system
Locking system
TRUNK LID
Inner hinged, gas lifter type
Type
GLASS THICKNESS
Laminated clear, tinted
5mm
3.2mm
3.2mm
3.2mm
Windshield glass
Front door glass
Rear door glass
Rear window glass
SEAT BELTS
3 point type with Emergency Locking Retractor (E.L.R)
3 point type with Emergency Locking Retractor (E.L.R)
2 point type
Front
Rear
TIGHTENING TORQUE
Items
Front and rear doors
Door hinge to body
Door hinge to door
Trunk lid
Trunk lid lift to trunk lid
Trunk lid latch to trunk lid
Hood
Hood hinge to body
Hood hinge to hood
Hood latch to body
Gas lifter seat mounting bolts
N·m
Kgf·m
lbf·ft
12.7~25.5
12.7~25.5
1.3~2.6
1.3~2.6
9.4~18.8
9.4~18.8
6.9~10.8
6.9~10.8
0.7~1.1
0.7~1.1
5.1~8.0
5.1~8.0
21.6~26.5
21.6~26.5
6.9~8.8
21.6~26.5
2.2~2.7
2.2~2.7
0.7~0.9
2.2~2.7
15.9~19.5
15.9~19.5
5.1~6.5
15.9~19.5
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Seat
Front seat mounting bolts
Front seat mounting nut
Rear seat mounting bolts
Seat belt
Front seat bet height adjuster
Front seat belt buckle mounting bolt
Front seat belt anchor mounting bolt
Front seat belt lower anchor
Front seat belt upper anchor
Rear seat belt anchor attaching bolt
Rear seat belt retractor mounting bolt
34.3~53.9
23.5~35.3
9.8~14.7
3.5~5.5
2.4~3.6
1.0~1.5
25.3~39.8
17.4~26.0
7.2~10.8
39.2~53.9
39.2~53.9
39.2~53.9
39.2~53.9
39.2~53.9
39.2~53.9
39.2~53.9
4.0~5.5
4.0~5.5
4.0~5.5
4.0~5.5
4.0~5.5
4.0~5.5
4.0~5.5
28.9~39.8
28.9~39.8
28.9~39.8
28.9~39.8
28.9~39.8
28.9~39.8
28.9~39.8
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
COMPONENT LOCATION
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
CIRCUIT DIAGRAM
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
GLASS REPLACEMENT
- Put on glove to protect your hands.
1. Remove both decoration cover (A).
2. Remove the glass (A) by lifting it up.
- Do not damage the roof panel.
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3. Installation is the reverse of removal.
MOTOR REPLACEMENT
1. Remove the over head console.
- Confirm the position of guide whether it is closed or not when you remove the motor.
2. Disconnect the motor connector , remove the screws and then remove the motor (A).
3. Installation is the reverse of removal.
DEFLECTOR REPLACEMENT
1. Open the glass fully.
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2. Disconnect the deflector link (A) from the frame (B), and then remove the deflector (C).
3. Installation is the reverse of removal.
SUNROOF ASSEMBLY REPLACEMENT
1. Remove the follows parts.
A.Front and door scuff trim.
B.Front, center and rear pillar trim.
C.headlining.
D.Sunroof glass.
2. Disconnect the drain tubes (A).
3. After loosening the mounding bolts and nuts, remove the sunroof assembly (B).
- Take care not to scratch the interior trims and other parts.
4. Installation is the reverse of removal.
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SUNSHADE AND DRIP RAIL REPLACEMENT
1. Remove the sunroof assembly
2. Remove the drip link (A) and sunshade stopper (B).
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3. Remove the sunshade (C) and drip rail (D).
4. Installation is the reverse of removal.
GUIDE ASSEMBLY REPLACEMENT
1. Remove the sunroof assembly
2. Remove a guide assembly (A) after lowering a guide thoroughly by pushing a slide to rear.
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3. Remove the guide (A) and slide (B).
4. Installation is the reverse of removal.
- Make sure to align the slide with the center of “A” and “B”
- Make sure to initialize the motor.
ADJUSTMENT
HOW TO INITIALIZE
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1. Check that the glass has been installed.
A.Finished height adjustment.
Front : 0 ~ 1.4mm
Rear : 1.0 ~ 1.4mm
2. Push the up switch. (Keep on pushing the switch)
A.The slide moved 5mm forward after 15 seconds.
Tightening Torque : 0.2 ~ 0.4 kgf·m
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 using the 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.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
COMPONENTS
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
1. Disconnect the negative (-) battery terminal.
2. Open the sunglass case cover from the overhead console then remove the 2 screws holding the overhead
console. Disconnect the connector then remove the overhead console lamp assembly from the headliner.
3. Remove the sunroof motor (A) after removing 3 screws and disconnect.
4. Installation is the reverse of removal.
INSPECTION
1. Disconnect the negative (-) battery terminal.
2. Apply the battery voltage to terminal 3, 6 and ground the terminal 1.
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3. Ground the terminals as below table, and check that the sunroof unit operates as below table.
4. Make these input tests at the connector
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, the sunroof motor must be faulty; replace it.
Terminal
Test condition
Test: Desired result
3
IG2 ON
1
Under all conditions
Check for continuity to ground:
There should be continuity.
6
Under all conditions
Check for voltage to ground:
There should be battery voltage.
Check for voltage to ground:
There should be 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.
2. According to the position of the sunroof, do as follows.
(1) In case that the sunroof has closed completely or been tilted:
Press the TILT UP button until the sunroof has tilted upward completely.
(2) In case that the sunroof has slide-opened:
Press and hold the CLOSE button for more than 5 seconds until the sunroof has closed completely.
Press the TILT UP button until the sunroof has tilted upward completely.
3. Release the TILT UP button.
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4. Press and hold the TILT UP button once again until the sunroof has returned to the original position of TILT UP
after it is raised a little higher than the maximum TILT UP position.
When this is complete, the sunroof system is reset.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
INSPECTION
1. Disconnect the negative (-) battery terminal.
2. Open the sunglass case cover from the overhead console then remove the 2 screws holding the overhead
console.
3. Disconnect the connector then remove the overhead console lamp assembly from the headliner. Check for
continuity between the terminals. If the continuity is not as specified, replace the sunroof switch.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
TROUBLESHOOTING
Symptom
Water leaks from sunroof
Wind noise around sunroof
Sunroof lid makes a noise when
move
Motor runs but sunroof
Does not move or moves only
partially
Suspect Area
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,
defectiveOr cracked clip
Check tube installation and
Flange contact
Deteriorated roof lid weatherstrip
Replace
Excessive roof lid-to-body
clearance and
Improperly fitted weatherstrip
Adjust
Loose or deformed deflector, gaps
In body work
Retighten adjust or replace
Foreign particles lodged in guide rail
Check drive cable and guide
Rails for foreign particles
Loose guide rails and lid
Retighten
Foreign particles lodged in guide rail
Check drive cable and guide
Rails for foreign particles
Incorrect engagement of motor
pinion
With drive cable
Check for loose motor installation
And damaged pinion
Decrease in motor`s clutch slipping
force
Adjust
Increased sunroof sliding resistance
Or interference of sunroof with drive
Cables, weatherstrip, etc. due to
Maladjustment of sunroof
Noise in motor clutch slipping
Noise from motor when sunroof
Is fully opened or closed is not
An unusual noise
Remedy
Adjust or replace
Incorrect engagement of motor
pinion
With drive cable
Check pinion installation and
Retighten motor
Worn out or damaged motor pinion
bearing
Replace motor assembly
Worn out or deformed drive cable
Replace
Incorrect window glass installation
Adjust position
Door glass fails to operate
Up and down
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Door does not open or close
completely
Hood does not open or close
completely
Water leak through windshield end
rear window
Damaged or faulty regulator arm or
regulator
Correct or replace
Incorrect door installation
Adjust position
Defective door check assembly
Correct or replace
Door hinge requires grease
Apply grease
Striker and latch not properly aligned Adjust
Incorrectly installed hood
Adjust
Incorrect hood bumper height
Adjust
Defective seal
Fill with sealant
Defective flange
Correct
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
- When removing and installing the trunk lid, an assistant is necessary.
- Wear gloves to protect hands from injury.
1. Disconnect the key holder connector (A) license plate lamp connector(B) then remove the wirering harness from trunk
lid.
2. Loosen the trunk lid mounting bolt, then remove the trunk lid(C).
3. Installation is the reverse of removal.
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TRUNK LID LATCH REPLACEMENT
1. Loosen the trunk lid latch mounting bolts.
2. Disconnect the trunk lid latch rod(A).
3. Remove the trunk lid latch(B).
4. Installation is the reverse of removal.
TRUNK LID RELEASE HANDLE REPLACEMENT
1. Remove the handle cover(A).
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2. After loosening the mounting bolts.
3. Disconnect the release handle cable (A) and fuel fill door release handle cable (B) then remove the release handle(C).
4. Installation is the reverse of removal.
- Make sure the trunk lid latch cable is connected properly.
- Make sure the trunk lid opens properly and locks securely.
TRUNK LID WEATHERSTRIP REPLACEMENT
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1. Remove the trunk lid weatherstrip(A).
2. Installation is the reverse of removal.
KEY HOLDER REPLACEMENT
1. Loosening the mounting bolts, disconnect the connector (A), rod(C).
2. Remove the key holder(B).
3. Installation is the reverse of removal.
ADJUSTMENT
1. After loosening the trunk lid hinge (A) mounting bolt, adjust the hood by moving it up or down, or right or left.
2. Adjust the trunk lid height by turning the trunk lid overslam bumpers (B).
3. After loosening the trunk lid latch (C) mounting bolts, adjust the trunk lid latch by moving it up or down, or right or left.
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FUEL FILL DOOR REPLACEMENT
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1. Loosen the bolts, then remove the fuel filler door (A).
2. Installation is the reverse of removal.
- Make sure the fuel fill door opens properly and locks securely.
FEUL FILL DOOR RELEAS HANDLE REPLACEMENT
1. Remove the handle cover(A).
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2. After loosening the mouning bolt, remove the releas handle assemble(C).
3. After disconnecting the trunk release handle cable(A), fuel fill door releas handle cable(B), remove the release handle
(C).
4. Installation is the reverse of removal.
- Make sure the fuel fill door opens properly and locks securely.
TRUNK LID, FEUL FILL DOOR RELEAS CABLE REPLACEMENT
1. Remove the following items.
A.Front seat.
B.Rear seat.
C.Front, rear door scuff trim.
D.Center lower pillar trim.
E.Luggage side trim.
F.Fuel fill door releas handle.
2. Disconnect the fule filler door release cable from the release handle.
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3. Remove the release cable(A) from the clip, and disconnect the fule filler door catch(B), then remove the fuel filler door
cable from the vehicle.
4. Installation is the reverse of removal.
- Make sure the fuel fill door opens properly and locks securely.
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
COMPONENTS
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2006 > G 1.6 CVVT > Body (Interior and Exterior)
REPLACEMENT
REMOVAL
- Put on gloves to protect your hands.
- Use seat covers to avoid damaging any surfaces.
1. Remove the following items.
A.Front piller trim.
B.Inside rear view mirror.
C.Windshield wiper arms.
D.Cowl top cover.
E.Windshield glass heater connector.
2. Remove the molding (A) from the edge of the windshield (B). If necessary, cut the molding with a utility knife.
3. Be careful the concealed 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.
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5. Cut out the sealant using the sealant cutting tool [D(09861-31100)].
6. Remove the windshield (B) carefully using the glass holder (E)(09681-31400).
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. When attaching the molding, matching the corner of glass and molding with the windshield glass and attach the
windshield glass pad (E)to the designated place.
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4. Install the windshield glass (B) temperarily with making sure to position them on the center, and then place the
alignment mark (C).
5. 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.
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6. 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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7. 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.
8. 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.
9. 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.
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10. 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.
11. 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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2006 > G 1.6 CVVT > Body Electrical System
REPLACEMENT
1. Remove the rear roof trim (Refer to Body group-roof trim).
2. Disconnect the 1P connector (A) and antenna jack (B) from the roof antenna.
3. Remove the roof antenna after removing a nut.
4. Installation is the reverse of removal.
INSPECTION
ANTENNA CABLE
1. Remove the antenna jack from the audio unit and antenna.
2. Check for continuity between the center poles of antenna cable.
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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.
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2006 > G 1.6 CVVT > Body Electrical System
COMPONENT LOCATION
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2006 > G 1.6 CVVT > Body Electrical System
SPECIFICATION
AUDIO
Item
Specification
AM/FM/Cassette
(M420)
Model
AM/FM/CD (M445)
Power supply
DC 14.4V
Rated output
Max 43W x 4
Speaker impedance
4Ω x 4
Antenna
80PF 75Ω
Tuning type
PLL synthesized type
Frequency range /
Channel space
FM
87.5~107.9 MHz/ 200KHz
AM
530~1710 KHz/ 10KHz
AM/FM/Cassette/
MP3 (M455)
SPEAKER
Item
Specification
Model
Front
Rear
Tweeter
Front
(External
amplifier)
Input power
Max 40W
Max 40W
Max 40W
Max 45W
Max 45W
Impedance
4±0.6Ω
4±0.6Ω
4±0.6Ω
2±0.6Ω
2±0.6Ω
EXTERNAL AMPLIFIER
Item
Specification
Power supply
DC 14.4V
Output power
Max 310W (55W*4Channel+45W*2 Channel)
Speaker impedance
2Ω x 4
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Rear
(External
amplifier)
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2006 > G 1.6 CVVT > Body Electrical System
TROUBLESHOOTING
There are six areas where a problem can occur: wiring harness, the radio, the cassette tape deck, the CD player, and
speaker. Troubleshooting enables you to confine the problem to a particular area.
Chart 1
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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
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2006 > G 1.6 CVVT > Body Electrical System
COMPONENT
AM/FM/Cassette (M420)
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AM/FM/CD (M445)
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AM/FM/Cassette/MP3 (M455)
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2006 > G 1.6 CVVT > Body Electrical System
REPLACEMENT
1. Disconnect the negative (-) battery terminal.
2. Remove the center facia upper panel (A). Take care of fixing clips (C).
3. Remove the connectors of digital clock and hazard switch (B).
4. Remove the mounting screws then remove the audio unit (A).
5. Installation is the reverse of removal.
INSPECTION
TAPE HEAD AND CAPSTAN CLEANING
1. To obtain optimum performance, clean the head, and capstan as often as necessary, depending on frequency of
use and tape cleanness.
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2. To clean the tape head and capstan, use a cotton swab dipped in ordinary rubbing an alcohol. Wipe the head
and capstan.
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2006 > G 1.6 CVVT > Body Electrical System
DESCRIPTION
Body control module (A) receives various input switch
signals controlling time and alarm functions for the rear
defogger timer, seat belts warning, delayed out room
lamp, central door lock, ignition key reminder, power
window timer, door warning, tail lamp auto cut, crash
door unlock, ignition key hole illumination and keyless
entry & burglar alarm.
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2006 > G 1.6 CVVT > Body Electrical System
REPLACEMENT
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad lower panel (A) (Refer to the Body group - crash pad). Take care of fixing clips(B).
3. Remove the body control module (A) after loosening 2 nuts.
4. Installation is the reverse of removal.
INSPECTION
Verify each components operation using related timing charts.
1. TAIL LAMP AUTO CUT
(1) With the tail lamp switched ON, if the ignition
Is switched OFF and the Driver door opened, the tail lamp should be automatically turned OFF.
(2) With the ignition switch ON, if the Driver door is opened and the ignition is switched to OFF, the tail lamp
should be automatically turned OFF.
(3) When the tail lamp is cut automatically and the tail lamp switch is turned OFF and ON, the tail lamp
illuminates and auto cut function is cancelled.
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(4) When the tail lamp is cut automatically and the ignition key is inserted, the tail lamp illuminates and auto cut
function is canceled.
2. DELAYED ROOM LAMP
(1) When the first door (driver, or assist or 4doors) is opened, room lamp is turned on.
(2) When all doors are closed, the room lamp will remain illuminated for 30 seconds; the lamp will then fade out
over a 2-second period.
(3) Regardless of ignition ON/OFF in door open state, room lamp output is ON.
(4) When remote control unlock is received, room lamp is turned on for 30 seconds.
(5) While room lamp is on due to Remote control unlock, if another remote control unlock is received, then room
lamp is again on for 30 sec.
T1 : 30 ± 3 sec.,
T2 : 2 ± 0.2 sec.
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3. CENTRAL DOOR LOCK/UNLOCK (Included 2-Turn unlock)
(1) If assist door unlock knob (below unlock knob) is turn to Unlock from Lock, then the Unlock output shall be
ON to all doors for T1.
(2) If assist door unlock knob is turn to Lock from Unlock, then the Lock output shall be ON to all doors for T1.
(3) If driver/assist door KEY LOCK switch is turn to ON from OFF, then the Lock output shall be ON to all doors
for T1.
(4) When the TX Lock signal is received, the door Lock output shall be ON for T1.
(5) If the driver door Key Unlock switch is turn to ON from OFF, then the driver door Lock switch shall be
unlocked mechanically. (The BCM & RECEIVER shall not be output.)
(After being unlocked mechanically, if the same condition is satisfied within T2, then the Unlock output shall
be ON for T1 to all doors.)
(After the TX Unlock signal is received, if the same condition is satisfied within T2, then the Unlock output
shall be ON for T1 to all doors.)
(6) When the TX Unlock signal is received, the driver door Unlock output shall be ON for T1.
If the TX Unlock signal is received within T2, the Unlock output shall be ON to all doors for T1. (After the
driver door Key Unlock switch is turn to ON from OFF, if the same condition is satisfied within T2, then the
Unlock output shall be ON to all doors.)
A.If, within T2, other registered TX signals are received, they shallbe treated as the same TX signal.
B.The Lock (Unlock) output by the changing of the driver door unlock knob shall not be performed.
C.In the state of being all unlock knob in Lock position, if Lock signals of Tx, driver, assist(Tail Gate) door
Key switch are input, the second Lock output shall not be performed.
D.In the state of being all unlock knob in UnLock position, if UnLock signals of Tx, driver, assist(Tail Gate)
door Key switch are input, the second UnLock output shall not be performed.
T1 : 0.5 ± 0.1sec,
T2 : within 4 ± 1sec,
T3 : over 4 ± 1sec.
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4. KEYLESS ENTRY & CENTROL DOOR LOCK/UNLOCK(BCM & RECEIVER ONLY)
(1) When the TX Lock is ON, the Hazard Lamp shall be output at one time for T2 after Lock Relay is output for
T1.
A.However, after the TX lock is ON, during waiting for the Hazard output, if the Key is inserted(KEY IN
SW=ON), then the Hazard Lamp output shall not be performed.
B.After the TX lock is On, if Key is inserted within 0.5 sec(KEY IN SW=ON), keep the prior state without
alarm being entered.
(2) When TX Unlock is ON, the Unlock Relay for T1, and the Hazard Lamp for T1 outputs are performed at two
times.
(3) In the state that the Key is OUT(KEY IN SW=OFF), the Dr/As/RR door switch are close, if there is no change
during 30 seconds after the TX Unlock is output, then the Hazard lamp output shall be ON for T2 at one time
after the Lock is output for T1.
(4) When the battery is connected, there shall not be sign of any malfunction.
(Even if the Battery is connected when S/Knob is in Lock or Unlock position, the Lock signal shall not be
output.)
T1 : 0.5 ± 0.1sec
T2 : 1 ± 0.2sec.
5. CRASH DOOR UNLOCK
(1) Whenever the air bag (below A/BAG) signal is inputted in the IG SW ON state, the unlock output shall be ON
for T3.
(2) During unlock output, although IG SW is turned to OFF from ON, the unlock output shall maintain for the
remained time period.
(3) If IG SW is turned to ON from OFF after A/BAG signal first is inputted, the Unlock output shall not be
performed.
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(4) If drive or assist door lock switch is turned to lock from unlock after unlock output, the unlock output shall be
On for T3.
T1 : 0.2 sec,
T2 : 0.04 sec,
T3 : 5 ± 0.5 sec.
6. IGNITION KEY REMINDER
(1) In the state that the door warning switch is ON, the driver door is opened, and the driver Safety Knob(below
unlock knob) is locked, only the driver door (RKE only) or all doors (Non RKE) unlock shall be output within
T1 for T2.
※ If the door is locked, the unlock shall be output at one time for T2, at three times for T3 only when the
switch has not been changed within actuator.
(2) During the 3-time UNLOCK output, if the actuator is unlocked, then the next output shall be stopped.
(3) During the 3-time UNLOCK output, if the door is closed or the key is out from the cylinder, then the next
output shall be stopped.
(4) After the 3-time UNLOCK output, if the actuator is locked, then the current state shall be maintained.
(5) If any of the door warning switch, the driver/assist door switch, and the driver/assist door actuator. UNLOCK
switch is changed, then the reset operation shall be performed.
(6) If the door is closed within T4 after the actuator is locked, all the door unlock shall be output for T2.
(7) If the lock switch is ON within T4 sec. when the door is turn to the closed state, then all the door unlock
signal shall be output for T2.
(8) If door warning switch is Off and IGN switch is On, then the IG key reminder function shall not be operated.
T1 : MAX 0.5 sec,
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T2 : 1 ± 0.2sec,
T3 : 0.5 ± 0.1 sec,
T4 : MAX 0.5 sec.
7. SEAT BELT REMINDER FUNCTION
(1) Warning Lamp lights every 0.6sec and Warning Bell sounds every 0.9sec for 6sec when IGN1 switch is ON
under unfastened S/Belt.
(Warning lamp continues to light for 6sec if S/Belt is fastened within 6sec)
30sec-TIME COUNT starts at ALT"L" ON under this state.
(30sec-TIME COUNT starts after 6sec. If ALT"L" is ON within initial 6sec)
(2) Warning Bell stops and the Warning Lamp is turned OFF when IGN1 switch is turned OFF within 6sec-output.
(3) Warning Bell stops and the Warning Lamp is turned OFF 30sec-TIME COUNT also stops when S/Belt is
fastened after IGN1 switch ON.
(4) If unfastened S/Belt state continues after 60sec-TIME COUNT from ALT"L" ON, the Warning Lamp flashes
and Warning Bell sounds 11 times in 30sec-cycle(6sec ON/ 24sec OFF) after 30sec from ALT"L" ON.
(5) Warning Lamp & Warning Bell are turned OFF when IGN1 switch is OFF or S/Belt is fastened during(4).
(6) Operation in (1) is performed when S/Belt is unfastened again under ALT"L" ON and fastened S/Belt.
(7) Operation in (4) is performed when ALT"L" is turned ON again after turning OFF under unfastened S/Belt.
T1 : 0.45 ± 1.0 sec, T2 : 0.3 ± 0.1 sec,
T3 : 6 ± 1.0 sec, T4 : 30 ± 3.0 sec,
T5 : 24 ± 2.0 sec.
8. KEY OPERATED WARNING
(1) If the key is in the key cylinder and the Driver door is opened, the chime bell is sounded (period: 0.9 sec.,
duty rate: 50%).
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(2) If the ignition key is removed, or the door is closed, the chime bell is switched OFF immediately.
T1, T2 : 0.45 ± 0.1sec.
9. DEFOGGER TIMER (INCLUDING OUTSIDE MIRROR HEATER)
(1) Once ALT "L" is ON, if the defogger is switched ON, the defogger will stay ON for 20 minutes duration.
(2) If defogger switch is pressed again (see Step 1), or if ignition is switched OFF, the defogger will shut OFF.
T1 : 20 ± 1 min.
10. POWER WINDOW TIMER
(1) When the ignition is switched OFF, power window output remains ON for 30 seconds and then turns OFF.
(2) Related to Step 1), if the driver door or assist door is opened, window power output is turned OFF
immediately.
(3) When the driver door or assist door is opened, the power window relay output is turned OFF immediately.
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T1: 30 ± 3 sec.
11. Tx LOCK TWICE ALARM
(1) In the state that the door is Locked by TX(alarm state), if Tx Lock signal is received again within 4sec after
the last Tx Lock signal is received, Horn shall be output at one time (0.05 sec)
T1 : 0.5 ± 0.1sec, T2 : 1 ± 0.2 sec, T3 : 0.05 ± 0.01 sec,
T4 : within 4 ± 1 sec, T5 : over 4 ± 1 sec.
12. PANIC ALARM (ETACS ONLY)
(1) If TX Panic signal is received, Panic alarm shall be on for T1 by using horn, hazard.
Panic delay time applied (When Panic switch is on for 0.5sec, Panic alarm should on)
(2) During panic alarm, if (TX LOCK/UNLOCK/PANIC,KEY IN,DOOR KEY LOCK,DOOR KEY UNLOCK,T/
GATE KEY UNLOCK,TRUNK KEY UNLOCK) signals are received, Panic alarm shall be OFF.
(3) During Panic operating, if the alarm condition is satisfied, Panic alarm shall be OFF.
(4) The related matter to the Anti theft alarm function shall be as follows.
A.During the Anti theft alarm sequence, even if the TX Panic signal is received, the Anti theft alarm shall be
maintained. (The Panic signal shall be ignored.)
B.If the Anti theft alarm condition is satisfied during the Panic alarm sequence, the Anti theft alarm shall be
output. (The Panic output shall be OFF.)
C.If the Panic signal is received in the warning standby/warning/alarm completion/RELOCK standby
modes, then the Anti theft function shall be operated and the Panic alarm shall be ON.
(5) During the Panic alarm sequence, although other registered TX signals are received, they shall be treated
as the same TX signal.
T1 : 0.5sec,
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T2 : 30 ± 3sec(0.9seconds with the cycle of 50% DUTY)
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2006 > G 1.6 CVVT > Body Electrical System
CIRCUIT DIAGRAM
BCM & RECEIVER
BCM
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BCM CONNECTOR TERMINALS
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Terminal No.
Connector A
Connector B
1
Door unlock relay
Assist door switch
2
Power window relay
4 door switch
3
Burglar alarm horn relay
Assist door key unlock switch
4
Hazard lamp relay
Driver door key unlock switch
5
Burglar alarm relay
Trunk key unlock switch (4Doors),
Tail gate key unlock switch (5Doors)
6
B+
Door warning switch
7
Chime bell
IG2
8
Code saving
IG1
9
-
B+
10
-
Trunk switch (4Doors),
Tail gate switch (5Doors)
11
Seat belt switch
Driver door switch
12
Room lamp switch
Tail lamp switch
13
Door lock relay
-
14
Rear defogger relay
Rear door actuator unlock switch (4Doors),
Rear door & tail gate actuator unlock switch
(5Doors)
15
Tail lamp relay
Assist door actuator unlock switch
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16
-
Driver door actuator unlock switch
17
Ground
Hood switch
18
Driver door unlock actuator
Alternator (L)
19
-
Driver door key lock switch
20
Seat belt indicator
Ground
21
Assist door key lock switch
-
22
Air bag signal(Crash signal)
-
23
Rear fog lamp switch (EC, Australia)
-
24
Rear defogger switch
-
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2006 > G 1.6 CVVT > Body Electrical System
SPECIFICATION
Items
Rated voltage
Operating voltage
Operating temperature
Specifications
DC 12V
DC 9 ~ 16V
-22°F~176°F(-30°C ~ 80°C)
Insulation resistance
100MΩ or more
Parasitic current draw
Less than 4mA (12.8 V) - BCM & Receiver
Less than 3mA (12.8V) - BCM
Rated load
Burglar horn
Burglar relay
Tail lamp relay
Rear defogger relay
Power window timer relay
Seat belt warning indicator
Room lamp
Door lock relay
Door unlock relay
Hazard lamp relay
Driver door actuator
DC 12V, 200mA (Inductance load)
DC 12V, 200mA (Inductance load)
DC 12V, 200mA (Inductance load)
DC 12V, 200mA (Inductance load)
DC 12V, 200mA (Inductance load)
DC 12V, 40~60mW (LED load)
DC 12V, 30W (Lamp load)
DC 12V, 200mA (Inductance load)
DC 12V, 200mA (Inductance load)
DC 12V, 200mA (Inductance load)
DC 12V, 10W (Motor load)
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2006 > G 1.6 CVVT > Body Electrical System
COMPONENT LOCATION
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2006 > G 1.6 CVVT > Body Electrical System
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).
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6. Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead.
7. Always reinstall plastic covers.
8. Before connecting connectors, make sure the terminals (A) are in place and not bent.
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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.
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.
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2. Remove clips carefully; don't damage their locks (A).
3. Slip pliers (A) under the clip base and through the hole at an angle, and then squeeze the expansion tabs to
release the clip.
4. After installing harness clips, make sure the harness doesn't interfere with any moving parts.
5. Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and
from exposed screws and bolts.
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.
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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.
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.
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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.
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2006 > G 1.6 CVVT > Body Electrical System
COMPONENT LOCATION
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2006 > G 1.6 CVVT > Body Electrical System
REPLACEMENT
1. Remove the radiator grill.
2. Remove the bolt and disconnect the horn connector, then remove the high pitch horn (A).
3. Installation is the reverse of removal.
ADJUSTMENT
Operate the horn, and adjust the tone to a suitable level by turning the adjusting screw.
After adjustment, apply a small amount of paint around the screw head to keep it from loosening.
INSPECTION
Test the horn by connecting battery voltage to the 1 terminal and ground the 2 terminal.
The horn should make a sound. If the horn fails to make a sound, replace it.
HORN RELAY INSPECTION
1. Remove the horn relay (A) from the engine room relay box.
2. There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the
No.3 and No.4 terminals.
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3. There should be no continuity between the No.1 and No.2 terminals when power is disconnected.
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2006 > G 1.6 CVVT > Body Electrical System
DESCRIPTION
The ICM is united with many kinds of relays and installed below the body control module.
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2006 > G 1.6 CVVT > Body Electrical System
INSPECTION
HAZARD LAMP RELAY
Check for continuity between the terminals.
1. There should be continuity between the No.8 and No.6 terminals when power and ground are connected to the
No.8 and No.9 terminals.
2. There should be no continuity between the No.8 and No.6 terminals when power is disconnected.
BURGLAR ALARM HORN
Check for continuity between the terminals.
1. There should be continuity between the No.11 and No.4 terminals when power and ground are connected to the
No.11 and No.3 terminals.
2. There should be no continuity between the No.11 and No.4 terminals when power is disconnected.
BURGLAR ALARM
Check for continuity between the terminals.
1. There should be no continuity between the No.1 and No.5 terminals when power and ground are connected to
the No.1 and No.2 terminals.
2. There should be continuity between the No.1 and No.5 terminals when power is disconnected.
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2006 > G 1.6 CVVT > Body Electrical System
REPLACEMENT
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad lower panel(A) (Refer to the Body group - crash pad). Take care of fixing clips(B).
3. Remove the ignition switch (A) after loosening the screw with IG ON and disconnecting the 6P connector.
4. Remove the steering column shaft (Refer to the ST group).
5. Remove the door warning switch after loosening the screws and disconnecting the 6P connector.
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6. If it is necessary to remove the key lock cylinder (A), remove the key lock cylinder (A) after pushing lock pin with key
ACC.
7. Installation is the reverse of removal procedure.
INSPECTION
1. Disconnect the ignition switch connector and key warning switch connector from under the steering column.
2. Check for continuity between the terminals.
3. If continuity is not specified, replace the switch.
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2006 > G 1.6 CVVT > Body Electrical System
COMPONENT LOCATION
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2006 > G 1.6 CVVT > Body Electrical System
TROUBLESHOOTING
Symptom
Speedometer does not operate
Tachometer does not operate
Fuel gauge does not operate
Low fuel warning lamp does not
light up
Water temperature gauge does not
operate
Oil pressure warning lamp does not
light up
Parking brake warning lamp does
not light up
Possible cause
Remedy
Cluster fuse (10A) blown
Check for short and replace fuse
Speedometer faulty
Check speedometer
Vehicle speed sensor faulty
Check vehicle speed sensor
Wiring or ground faulty
Repair if necessary
Cluster fuse (10A) blown
Check for short and replace fuse
Tachometer faulty
Check tachometer
Wiring or ground faulty
Repair if necessary
Cluster fuse (10A) blown
Check for short and replace fuse
Fuel gauge faulty
Check gauge
Fuel sender faulty
Check fuel sender
Wiring or ground faulty
Repair if necessary
Cluster fuse (10A) blown
Check for short and replace fuse
Bulb burned out
Replace bulb
Fuel sender faulty
Check fuel sender
Wiring or ground faulty
Repair if necessary
Cluster fuse (10A) blown
Check for short and replace fuse
Water temperature gauge faulty
Check gauge
Water temperature sender faulty
Check sender
Wiring or ground faulty
Repair if necessary
Cluster fuse (10A) blown
Check for short and replace fuse
Bulb burned out
Replace bulb
Oil pressure switch faulty
Check switch
Wiring or ground faulty
Repair if necessary
Cluster fuse (10A) blown
Check for short and replace fuse
Bulb burned out
Replace bulb
Brake fluid level warning switch
faulty
Check switch
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Open door warning lamp and trunk
lid warning lamp do not light up
Seat belt warning lamp does not
light up
Parking brake switch faulty
Check switch
Wiring or ground faulty
Repair if necessary
Multi backup fuse (15A) blown
Check for short and replace fuse
Bulb burned out
Replace bulb
Door switch faulty
Check switch
Wiring or ground faulty
Repair if necessary
Cluster fuse (10A) blown
Check for short and replace fuse
Bulb burned out
Replace bulb
Seat belt switch faulty
Check switch
Wiring or ground faulty
Repair if necessary
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2006 > G 1.6 CVVT > Body Electrical System
COMPONENTS
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2006 > G 1.6 CVVT > Body Electrical System
REPLACEMENT
1. Disconnect the negative (-) battery terminal.
2. Remove the cluster facia panel (B) after disconnecting the connector of trip switch (A) and loosening the 2
screws take care of fixing clips(C).
3. Pull out the cluster (A) from the housing after removing 4 screws.
4. Disconnect the cluster connecter (A) and then remove the cluster.
5. Installation is the reverse of removal.
INSPECTION
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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.
[CANADA - km/h]
Velocity
(km/h)
20
40
60
80
100
Tolerance
(km/h)
+4.1
+0.7
+4.2
+1.3
+6.1
+1.9
+7.0
+2.6
+7.8
+3.2
Velocity
(km/h)
120
140
160
180
200
Tolerance
(km/h)
+8.5
+3.9
+9.3
+4.5
+10.2
+5.2
+10.8
+5.8
+11.4
+6.4
[MPH]
Velocity
(MPH)
10
20
40
60
Tolerance
(MPH)
+2.8
+0.4
+3.7
+0.7
+5.0
+1.4
+6.0
+2.0
Velocity
(MPH)
80
100
120
-
Tolerance
(MPH)
+6.6
+2.6
+7.2
+3.2
+7.9
+3.9
-
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VEHICLE SPEED SENSOR
1.
2.
3.
4.
5.
Connect the positive (+) lead from battery to terminal 2 and negative (-) lead to terminal 1.
Connect the positive (+) lead from tester to terminal 3 and the negative (-) lead to terminal 1.
Rotate the shaft.
Check that there is voltage change from approx. 0V to 11V or more between terminals 3 and 1.
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.
Revolution(rpm)
1,000
2,000
3,000
Tolerance(rpm)
±100
±125
±150
Revolution(rpm)
4,000
5,000
6,000
Tolerance(rpm)
±170
±200
±240
FUEL GAUGE
1. Disconnect the fuel sender connector from the fuel sender.
2. Connect a 3.4 watts, 12V test bulb to terminals 1 and 3 on the wire harness side connector.
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3. Turn the ignition switch to the ON, and then check that the bulb lights up and the fuel gauge needle moves to full.
FUEL GAUGE SENDER
1. Using an ohmmeter, measure the resistance between terminals 1 and 3 of sender connector (A) at each float
level.
2. Also check that the resistance changes smoothly when the float is moved from "E" to "F".
Position
Resistance(Ω)
Sender (E)
184 ± 2
Warning lamp
170 ± 2
1/2
66 ± 2
Sender (F)
15 ± 2
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 (Hi model)
1. Disconnect the wiring connector (A) from the engine coolant temperature sender in the engine compartment.
2. Turn the ignition switch ON. Check that the gauge needle indicates cool. Turn the ignition switch OFF.
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3. Connect a 12V, 3.4 wattages test bulb between the harness side connector and ground.
4. Turn the ignition switch ON.
5. Verify that the test bulb flashes and that the indicator moves to HOT position.
If operation is not as specified, replace the cluster. Then recheck the system.
ENGINE COOLANT TEMPERATURE GAUGE (Low model)
1. Turn the ignition switch ON.
2. Check that the high temperature lamp (Red) is ON for 3 seconds and then the low temperature lamp (Blue) is
ON.
3. If operation is not as specified, replace the cluster. Then recheck the system.
ENGINE COOLANT TEMPERATURE SENDER
1. Using an ohmmeter, measure the resistance between the terminal 2 and ground.
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2. If the resistance value is not as shown in the table, replace the temperature sender.
Hi model
Temperature
[°F(°C)]
140
(60)
185
(85)
230
(110)
257
(125)
Resistance (Ω)
142
62
26
17.5
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.
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 (A) from the switch located at the brake fluid reservoir (B).
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2. Verify that continuity exists between switch terminals 1 and 2 while pressing the switch (float) down with a rod.
BRAKE FLUID LEVEL WARNING LAMP
1.
2.
3.
4.
5.
Ignition "ON"
Release the parking brake.
Remove the connector from the brake fluid level warning switch.
Ground the connector at the harness side.
Verify that the warning lamp lights.
PARKING BRAKE SWITCH
The parking brake switch (A) is a pulling type. It is located under the parking brake lever. To adjust, move the
switch mount up and down with the parking brake lever released all the way.
1. Check that there is continuity between the terminal and switch body with the switch ON (Lever is pulled).
2. Check that there is no continuity between the terminal and switch body with the switch OFF (Lever is released).
If continuity is not as specified, replace the switch or inspect its ground connection.
DOOR SWITCH
Remove the door switch and check for continuity between the terminals.
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SEAT BELT SWITCH
1. Remove the connector from the switch.
2. Check for continuity between terminals.
Seat belt condition
Continuity
Fastened
Non-conductive (∞Ω)
Not fastened
Conductive (Ω)
SEAT BELT WARNING LAMP
With the ignition switch turned ON, verify that the lamp glows.
Seat belt condition
Warning lamp
Fastened
OFF
Not fastened
ON
TRIP SWITCH
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1. Disconnect the negative (-) battery terminal.
2. Remove the trip switch (A) from the cluster facia panel (B).
3. Check for continuity between the terminals in each switch position according to the table.
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2006 > G 1.6 CVVT > Body Electrical System
CIRCUIT DIAGRAM
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2006 > G 1.6 CVVT > Body Electrical System
COMPONENT LOCATION
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2006 > G 1.6 CVVT > Body Electrical System
DESCRIPTION
BURGLAR ALARM SYSTEM
The burglar alarm system is armed automatically after the doors, hood, and trunk lid (tailgate) are closed and
locked by transmitter or the key.
The system is set off when any of these things occur :
• A door is forced open.
• A door is unlocked without using the transmitter.
• The trunk lid (tailgate) is opened without using the key.
• The hood is opened.
• The engine starter circuit and battery circuit are bypassed by breaking the ignition switch.
When the system is set off, the alarm (horn) sounds and the hazard lamp flash for about two minutes or until the
system is disarmed by unlocking the transmitter or the key.
For the system to arm, the ignition switch must be off and the key removed. Then, the body control module must
receive signals that the doors, hood, and trunk lid (tailgate) are closed and locked. When everything is closed and
locked, none of the control unit inputs are grounded.
The door switches, hood switch and trunk lid (tailgate) switch are all close and lock the doors with the remote
transmitter or the key and then the system arms immediately.
If anything is opened or improperly unlocked after the system is armed, the body control module gets a ground
signal from that switch, and the system is set off.
If one of the switches is misadjusted or there is a short in the system, the system will not arm. As long as the body
control module continues to get a ground signal, it thinks the vehicle is not closed and locked and will not arm.The
receiver is integrated in the body control module.
KEYLESS ENTRY SYSTEM
The burglar alarm system is integrated with the keyless entry system. The keyless entry system allows you to lock
and unlock the vehicle with the remote transmitter. When you push the LOCK button, all doors lock. When you
push the UNLOCK button, all doors unlock.
The room lamp, if its switch is in the center position, will come on when you press the UNLOCK button on the
transmitter. If you do not open a door, the light will go off in about 30 seconds, the doors will automatically relock,
and the burglar alarm system will rearm. If you relock the doors with the remote transmitter within 30 seconds, the
light will go off immediately. If you open a door, the lamp will go on and go off in about 30 seconds.
You cannot lock or unlock the doors with the remote transmitter if the key is in the ignition switch.
The system will signal you when the doors lock and unlock by flashing the hazard lamp once when they lock, and
twice when they unlock.
FUNCTIONS
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1. ARM Function
(1) When doors will be lock by LOCK on the RKE (Remote Keyless Entry), the hazard lamp will blink once within
1 second and the Anti-Theft System will ARM, if the following conditions have been met.
A.The ignition key is removed from the ignition switch.
B.All entry points are closed (doors, trunk, tail gate and hood)
(2) If either the door or trunk or hood is open when activating LOCK using the RKE or using driver, assistant, tail
gate key LOCK switch, the doors will lock, however the hazard lamp will not flash and the Anti-Theft System
will not arm.
(3) In Step 2) if the opened entry points are subsequently closed. the door will lock, the hazard lamp will blink
once(RKE only) and the Anti-Theft System will ARM.
(4) The ARM mode of the Anti-Theft System can only be set using the LOCK feature of the RKE or using driver,
assistant, tail gate key LOCK switch.
T1 : 0.5 ± 0.1 sec,
T2 : within 2.0 sec,
T3 : 1.0 ± 0.2 sec.
2. DISARM Function
(1) When the UNLOCK button is pressed on the transmitter, the hazard lamps will blink 2 times (indicating a
DISARM event) and the door will unlock.
(Whether entry points are open or Closed is irrelevant)
(2) Once the ignition key is IN (inserted into the ignition switch) and the ignition is turned to the ON position the
Anti-Theft system will immediately DISARM.
(3) If the UNLOCK signal is sent by the RKE or using driver, assistant, tail gate key UNLOCK switch, and either
the ignition key is not inserted or entry (door, trunk, tail gate, hood) to the vehicle is not made within 30
seconds, the LOCK mode will be automatically reset, the hazard lamps will blink(RKE only), and the AntiTheft System will rearm. (Key IN = Key Insertion)
(Provided that there is no automatic lock function at a period of 30 seconds, when the UNLOCK is done by
the RKE with an entry being open).
(4) In steps 3), when UNLOCK is activated within the initial 30 seconds, another period of 30 seconds occurs.
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(5) The DISARM mode of the Anti-Theft System can only be set using the UNLOCK feature of the RKE or using
driver, assistant, tail gate key UNLOCK switch. The door key will not disarm the Anti-theft System.
T1, T2 : 0.5 ± 0.1 sec.
3. ALARM Function
(1) When a point of entry is opened while the Anti-Theft System is in the ARM mode, the hazard lamp and horn
alarm will activate (ON/OFF 3 times each) for a period of 27 seconds.
(2) Output intervals for the horn alarm and hazard lamps are identical.
(3) The alarm sequence, when activated will continue for the duration of the alarm period even when the entry
point is closed. (The alarm will reactivate if entry port is reopened after the initial alarm sequence completes.)
T1: 27 ± 2 sec,
T2: 10 ± 1 sec,
T3: 0.4 ~ 0.5 sec.
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4. New alarm event trigger during existing alarm sequence
(1) When a new alarm event trigger is received during an existing alarm sequence, the existing alarm sequence
will remain active. Horn and hazard lamp output will only continue for the duration of the existing alarm
sequence (event timer will not re-set).
5. Transmitter or Dr/As door, tail gate key lock switch controlled unlock during the alarm sequence
(1) ARM state is released (DISARM state) and the horn, the hazard output and the B/Alarm output shall be OFF,
and the unlock output shall be ON for T1, and hazard lamp output shall be ON twice with cycle of T2(RKE
only).
T1, T2, T3 : 0.5 ± 0.1 sec.
6. Transmitter or Dr/As door, tail gate key unlock switch controlled lock during the alarm sequence
(1) During alarm sequence, if the opened door is open and the Lock signal is received from RKE or Dr/As door,
tail gate key lock switch : The horn alarm output, the hazard lamp output and the B/Alarm output shall be
OFF and, the Lock output shall be ON for T1 and then, if the opened door is closed actuator lock shall be
checked, the hazard lamp output shall be ON once(RKE only) and, it shall be in the ARM state.
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T1 : 0.5 ± 0.1 sec,
T2 : 1.0 ± 0.2 sec.
7. Alarm clearance
If the ignition key is turned to ON for 30 seconds during alarm activation the alarm will be cleared and the start
inhibitor reset.
T1 : 30 ± 3 sec.
8. REALARM Function
(1) Output again horn alarm 3 times when outlet OPEN again, again B/ALARM horn hold "ON", without safety
knob lock at outlet close condition after completing 3 times alarm(120sec.)
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9. Battery Separation
(1) The alarm and starter inbibit functions will remain active if the battery is disconnected, then re-connected
during an alarm event sequence.
(2) The system will remain in an ARM state if the battery is disconnected and re-connected when the system is
armed.
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2006 > G 1.6 CVVT > Body Electrical System
INSPECTION
FRONT DOOR LOCK ACTUATOR
1. Remove the front door trim panel. (Refer to the Body 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
1. Remove the rear door trim panel. (Refer to the Body group - rear door)
2. Disconnect the 6P connector from the actuator.
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3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
TAILGATE LOCK ACTUATOR (5DOORS)
1. Remove the tailgate trim panel. (Refer to the Body group - tailgate)
2. Disconnect the 6P connector from the actuator.
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3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
FRONT DOOR LOCK SWITCH
1. Remove the front door trim panel. (Refer to the Body group - front door)
2. Disconnect the 6P connector from the actuator.
3. Check for continuity between the terminals in each switch position according to the table.
REAR DOOR LOCK SWITCH
1. Remove the rear door trim panel. (Refer to the Body group - rear door)
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2. Disconnect the 6P connector from the actuator.
3. Check for continuity between the terminals in each switch position according to the table.
TRUNK LID SWITCH (4DOORS)
1. Disconnect the negative battery terminal.
2. Remove the rear trunk lid trim, and then remove the trunk lid switch from the trunk lid striker.
3. Disconnect the 1P connector from the rear harness.
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4. Check for continuity between the terminal and body while pushing the rod.
Switch rod condition
Continuity
Push (OFF)
Non-conductive (∞Ω)
Released (ON)
Conductive (0Ω)
TAILGATE LOCK SWITCH (5DOORS)
1. Remove the tailgate trim panel. (Refer to the Body group - tailgate)
2. Disconnect the 6P connector from the actuator.
3. Check for continuity between the terminals in each switch position according to the table.
DOOR SWITCH
Remove the door switch and check for continuity between the terminals.
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HOOD SWITCH
1. Disconnect the 1P connector from the hood switch.
2. Check for continuity between the terminals and ground according to the table.
DOOR WARNING SWITCH
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1. Remove the steering column upper & lower shrouds (A) after loosening 3 screws.
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 HORN
1. Remove the burglar horn after removing 1 bolts and disconnect the 2P connector from the burglar horn.
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2. Test the burglar horn by connecting battery power to the terminal 1 and ground the terminal 2.
3. The burglar horn should make a sound. If the burglar horn fails to make a sound replace it.
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2006 > G 1.6 CVVT > Body Electrical System
TROUBLESHOOTING
1. Alarm does not work. (Hazard lamps work)
2. When hood is opened in ARM mode, burglar horn does not work.
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3. When door is opened in ARM mode, burglar horn does not work (If tailgate and hood is opened, alarm works)
4. When tailgate is opened in ARM mode, burglar 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, even when the alarm is disarmed.
7. Central door lock function works, but keyless entry system does not work.
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2006 > G 1.6 CVVT > Body Electrical System
INSPECTION
1. Check that the red light flickers when the door lock or unlock button is pressed on the transmitter.
2. Remove the battery and check voltage if the red light doesn't flicker.
Standard voltage : 3V
3. Replace the transmitter battery with a new one, if voltage is below 3V then try to lock and unlock the doors with
the transmitter by pressing the lock or unlock button five or six times.
4. If the doors lock and unlock, the transmitter is O.K, but if the doors don't lock and unlock, register the transmitter
code, then try to lock and unlock the doors.
5. If the transmitter is the cause of failure, replace only 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, push "ENTER" key, then the screen will be shown as below.
4. After removing the ignition key from key cylinder, push "ENTER" key to proceed to the next mode for code
saving. Follow steps 1 to 4 and then code saving is completed.
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2006 > G 1.6 CVVT > Body Electrical System
COMPONENT
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2006 > G 1.6 CVVT > Body Electrical System
REPLACEMENT
1. Disconnect the negative (-) battery terminal.
2. Remove the steering column upper and lower shrouds (A) after removing 3 screws.
3. Remove the light switch by pushing the lock pin (B) after disconnecting the connector (A).
4. Remove the wiper switch by pushing the lock pin (B) after disconnecting the connector (A).
5. Installation is the reverse of removal.
INSPECTION
LIGHTING SWITCH INSPECTION
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With the multi function switch in each position, make sure that continuity exists between the terminals below. If
continuity is not as specified, replace the multi-function switch.
TURN SIGNAL SWITCH
WIPER AND WASHER SWITCH INSPECTION
With the multi function switch in each position, make sure that continuity exists between the terminals below. If
continuity is not as specified, replace the multi-function switch.
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REAR WIPER & WASHER SWITCH (5Doors)
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2006 > G 1.6 CVVT > Body Electrical System
SPECIFICATION
Items
Rated voltage
Operating temperature range
Specifications
DC 12 V
-30°C ~ +80°C (-22 ~ +176°F)
Rated load
Dimmer & passing switch
Lighting switch
Turn signal & lane change switch
Wiper & mist switch
Washer switch
Rear wiper & washer switch (5doors)
High : 120W (Lamp load)
Low : 110W (Lamp load)
Passing : 120W (Lamp load)
Lighting : 21W (Lamp load)
69W (Lamp load)
Low, High : 5.0A (Motor load)
Intermittent : 0.07±0.05A (Relay load)
Lock : Max. 25A (Motor load)
Mist: 5A (Motor load)
4.0A (Motor load)
Rear wiper : 3.5A (Motor load)
Rear washer : 5A (Motor load)
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2006 > G 1.6 CVVT > Body Electrical System
INSPECTION
FRONT DOOR LOCK ACTUATOR
1. Remove the front door trim panel. (Refer to the Body 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
1. Remove the rear door trim panel. (Refer to the Body group - rear door)
2. Disconnect the 6P connector from the actuator.
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3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
TAILGATE LOCK ACTUATOR (5DOORS)
1. Remove the tailgate trim panel. (Refer to the Body group - tailgate)
2. Disconnect the 6P connector from the actuator.
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3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
FRONT DOOR LOCK SWITCH
1. Remove the front door trim panel. (Refer to the Body group - front door)
2. Disconnect the 6P connector from the actuator.
3. Check for continuity between the terminals in each switch position according to the table.
REAR DOOR LOCK SWITCH
1. Remove the rear door trim panel. (Refer to the Body group - rear door)
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2. Disconnect the 6P connector from the actuator.
3. Check for continuity between the terminals in each switch position according to the table.
TRUNK LID SWITCH (4DOORS)
1. Disconnect the negative battery terminal.
2. Remove the rear trunk lid trim, and then remove the trunk lid switch from the trunk lid striker.
3. Disconnect the 1P connector from the rear harness.
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4. Check for continuity between the terminal and body while pushing the rod.
Switch rod condition
Continuity
Push (OFF)
Non-conductive (∞Ω)
Released (ON)
Conductive (0Ω)
TAILGATE LOCK SWITCH (5DOORS)
1. Remove the tailgate trim panel. (Refer to the Body group - tailgate)
2. Disconnect the 6P connector from the actuator.
3. Check for continuity between the terminals in each switch position according to the table.
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2006 > G 1.6 CVVT > Body Electrical System
INSPECTION
DRIVER DOOR LOCK SWITCH
1. Disconnect the negative (-) battery terminal.
2. Remove the front door trim panel. (Refer to the Body group - front door)
3. Disconnect the 14P connector from the switch.
4. Check for continuity between the terminals in each switch position according to the table.
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2006 > G 1.6 CVVT > Body Electrical System
COMPONENT LOCATION
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2006 > G 1.6 CVVT > Body Electrical System
TROUBLESHOOTING
1. Lock function works but unlock function does not work. → Since door unlock relay is malfunction, replace the door unlock
relay.
2. Unlock function works but lock function does not work. → Since door lock relay is malfunctioning, replace the door lock
relay.
3. When Assist side knob is controlled, all doors locks, but when driver side knob is controlled, all doors do not lock.
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4. When driver side knob is controlled. All doors lock. But when the Assist side knob is controlled, all doors do not lock.
5. Both sides do not lock either.
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2006 > G 1.6 CVVT > Body Electrical System
INSPECTION
1. Remove the door lock/unlock relay from the junction 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.3 and No.5 terminals.
4. There should be continuity between the No.1 and No.4 terminals when power is disconnected.
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2006 > G 1.6 CVVT > Body Electrical System
INSPECTION
1. Remove the front door quadrant inner cover (B) (Refer to the Body group - front door)
2. Remove the tweeter speaker after disconnecting the connector(A). Avoid damaging retaining clip (C).
3. Disconnect the power door mirror connector from the harness.
4. Apply battery voltage to each terminal as shown in the table and verify that the mirror operates properly.
MIRROR HEATER
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MIRROR FOLDING
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2006 > G 1.6 CVVT > Body Electrical System
INSPECTION
1. Disconnect the negative (-) battery terminal.
2. Remove the front door trim panel. (Refer to the Body group-front door)
3. Disconnect the 12P connector from the switch.
4. Check for continuity between the terminals in each switch position according to the table.
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2006 > G 1.6 CVVT > Body Electrical System
CIRCUIT DIAGRAM
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2006 > G 1.6 CVVT > Body Electrical System
COMPONENT LOCATION
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2006 > G 1.6 CVVT > Body Electrical System
INSPECTION
FRONT POWER WINDOW MOTOR
1. Remove the front door trim panel. (Refer to the Body group-front door)
2. Disconnect the connector from the motor.
3. Connect the motor terminals directly to battery voltage (12V) and check that the motor operates smoothly. Next,
reverse the polarity and check that the motor operates smoothly in the reverse direction. If the operation is
abnormal, replace the motor.
REAR POWER WINDOW MOTOR
1. Remove the rear door trim panel. (Refer to the Body group-rear door)
2. Disconnect the 2P connector from the motor.
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3. Connect the motor terminals directly to battery voltage (12V) and check that the motor operates smoothly. Next,
reverse the polarity and check that the motor operates smoothly in the reverse direction. If the operation is
abnormal, replace the motor.
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2006 > G 1.6 CVVT > Body Electrical System
INSPECTION
POWER WINDOW MAIN SWITCH
1. Disconnect the negative (-) battery terminal.
2. Remove the front door trim panel. (Refer to the Body group - front door)
3. Disconnect the 14P connector from the switch.
4. Check for continuity between the terminals in each switch position according to the table. If the continuity
condition is not normal, replace the switch.
POWER WINDOW LOCK SWITCH
ASSIST/REAR POWER WINDOW SWITCH
1. Disconnect the negative (-) battery terminal.
2. Remove the door trim panel. (Refer to the Body group - door)
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3. Disconnect the 7P connector from the switch.
4. Check for continuity between the terminals in each switch position according to the table. If the continuity
condition is not normal, replace the switch.
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2006 > G 1.6 CVVT > Body Electrical System
CIRCUIT DIAGRAM
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2006 > G 1.6 CVVT > Body Electrical System
COMPONENT LOCATION
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2006 > G 1.6 CVVT > Body Electrical System
TROUBLESHOOTING
1. No windows operate from the main switch on the driver door.
2. Driver side window does not operate.
3. Assist side window does not operate.
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2006 > G 1.6 CVVT > Body Electrical System
COMPONENTS
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2006 > G 1.6 CVVT > Body Electrical System
INSPECTION
POWER RELAY (TYPE A)
Check for continuity between the terminals.
1. There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the
No.3 and No.4 terminals.
2. There should be no continuity between the No.1 and No.2 terminals when power is disconnected.
POWER RELAY (TYPE B)
Check for continuity between the terminals.
1. There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the
No.3 and No.5 terminals.
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2. There should be continuity between the No.1 and No.4 terminals when power is disconnected.
POWER RELAY (TYPE C)
Check for continuity between the terminals.
1. There should be continuity between the No.1 and No.4 terminals when power and ground are connected to the
No.2 and No.3 terminals.
2. There should be no continuity between the No.1 and No.4 terminals when power is disconnected.
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FUSE
1. Be sure there is no play in the fuse holders, and that the fuses are held securely.
2. Are the fuse capacities for each circuit correct?
3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why the fuse blew
first and completely eliminate the problem before installing a new fuse.
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2006 > G 1.6 CVVT > Body Electrical System
COMPONENTS
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2006 > G 1.6 CVVT > Body Electrical System
INSPECTION
POWER RELAY (TYPE A)
Check for continuity between the terminals.
1. There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the
No.3 and No.4 terminals.
2. There should be no continuity between the No.1 and No.2 terminals when power is disconnected.
POWER RELAY (TYPE B)
Check for continuity between the terminals.
1. There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the
No.3 and No.5 terminals.
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2. There should be continuity between the No.1 and No.4 terminals when power is disconnected.
POWER RELAY (TYPE C)
Check for continuity between the terminals.
1. There should be continuity between the No.1 and No.4 terminals when power and ground are connected to the
No.2 and No.3 terminals.
2. There should be no continuity between the No.1 and No.4 terminals when power is disconnected.
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FUSE
1. Be sure there is no play in the fuse holders, and that the fuses are held securely.
2. Are the fuse capacities for each circuit correct?
3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why the fuse blew
first and completely eliminate the problem before installing a new fuse.
REPLACEMENT
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad lower panel (A)(Refer to the Body group - crash pad). Avoid damaging retaining clips (B).
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3. Disconnect the connectors of junction box and loosen the ground cable (A).
4. Remove the junction box (B) after loosening the mounting nuts (2EA).
5. Installation is the reverse of removal procedures.
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2006 > G 1.6 CVVT > Body Electrical System
REPLACEMENT
FRONT SPEAKER
1. Remove the front door trim panel (Refer to the Body group - front door).
2. Remove the front speaker (A) after removing 4 screws.
3. Installation is the reverse of removal.
REAR SPEAKER (4 Doors)
1. Remove the rear door trim panel (Refer to the Body group - rear door).
2. Remove the rear speaker (A) after removing 4 screws.
3. Installation is the reverse of removal.
REAR SPEAKER (5 Doors)
1. Remove the rear seat (Refer to the Body group - rear seat).
2. Remove the rear package tray (Refer to the Body group - rear seat).
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3. Remove the rear speaker (A) after removing 4 bolts.
4. Installation is the reverse of removal.
TWEETER SPEAKER
1. Remove the front door quadrant inner cover (B) (Refer to the Body group - front door).
2. Remove the tweeter speaker after disconnecting the connector(A). Take care of fixing clips (C).
3. Installation is the reverse of removal.
EXTERNAL AMPLIFIER (4 Doors)
1. Remove the right luggage side trim.
2. Remove the external amplifier (B) from the quarter inner panel (A) after removing 3 nuts.
3. Installation is the reverse of removal.
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EXTERNAL AMPLIFIER (5 Doors)
1. Remove the right luggage side trim.
2. Remove the external amplifier (B) from the quarter inner panel (A) after removing 4 bolts.
3. Installation is the reverse of removal.
INSPECTION
1. Check the speaker with an ohmmeter. If an ohmmeter indicates the correct impedance of the speaker when
checking between the speaker (+) and speaker (-) of the same channel, the speaker is ok.
Specified impedance : 2 ~ 4 Ω
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2006 > G 1.6 CVVT > Brake System
COMPONENTS
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2006 > G 1.6 CVVT > Brake System
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 ECU.
This unit has the functions as follows.
- Input of signal from the wheel speed sensors attached to each wheel.
- Control of braking force.
- Failsafe function.
- Self diagnosis function.
- Interface with the external diagnosis tester.
Installation position : engine compartment
- Brake tube 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 17 ± 0.5 V), 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 12 km/h(7 MPH) 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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WARNING LAMP MODULE
1. 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:
A.During the initialization phase after IGN ON. (continuously 3 seconds).
B.In the event of inhibition of ABS functions by failure.
C.During diagnostic mode.
D.When the ECU Connector is seperated from ECU.
2. PARKING/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:
A.During the initialization phase after IGN ON. (continuously 3 seconds).
B.When the Parking Brake Switch is ON or brake fluid level is low.
C.When the EBD function is out of order.
D.During diagnostic mode.
E.When the ECU Connector is seperated from ECU.
ABS CONTROL
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.
Solenoid valve
State
Valve
Passage
Inlet valve (NO)
OFF
Open
Master cylinder ⇔ Wheel cylinder
Outlet valve (NC)
OFF
Close
Wheel cylinder ⇔ Reservoir
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Pump
motor
OFF
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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 open