Workshop Manual for Refine MPV General

Foreword

Three maintenance manuals have been prepared respectively for the engine, chassis
and body of Refine Vehicles for the purpose to help technical service personnel
correctly understand and get familiar with the Refine Vehicles so that they can make
prompt repairs and reasonable maintenance.

This manual gives detailed description of the dismantling, testing, commissioning

and diagnosis technical standards for all components or systems used on Refine
Vehicles.

No part of this manual shall be reproduced or used in any form or any way without
written authorization.

Editor
Jan. 2006

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 Workshop Manual for Refine MPV General

Table of Contents

General… … … … … … … … … … … … … … … … … … … … … … … … … … ..… … … … … … 3
Basic procedures… … … … … … … … … … … … … … … … … … … … .… … … … … … … … … 13
Electronic systems… … … … … … … … … … … … … … … … … … … … … … .… … … … ....… .17
Maintenance… … … … … … … … … … … … … … … … … … … … … … … … ..… … … … … … .22

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 Workshop Manual for Refine MPV General

General

Contents

·This manual presents all procedures required in the service operation. They can be divided into 5
basic operations:
— dismantling/installation
— disassembling/assembling
— replacing
— checking
— adjusting
·This manual has omitted simple operations that can be done simply by observing the vehicle (such as
dismantling/installation of parts, jacking, vehicle lifting, parts cleaning and visual checks).

Service procedures

Check and adjustment

·Checking and adjusting procedures are divided into several steps. Detailed explanations are provided
for key positions for checking and adjustment and for the operation procedures.

Repair procedures

1. Most of repair procedures start with a Brief Sketch, indicating the components and their mutual fitting,
to describe the visual check of components. Detailed explanation is provided for dismantling/
installation procedures requiring system operations.
2. Consumable parts, tightening torques, fuel and engine oil and sealing glue are shown in the sketches in
signs. In addition, signs of components for which special tools or their equivalent are required to use
are also clearly shown in the figures.
3. All procedure steps are indicated with sequence numbers, and the main steps, components involved and
corresponding sequence numbers are shown in the figures. There may be occasional key or extra
information for a procedure for reference.

How to use this manual

This manual is divided into four parts: engine, chassis and gearbox, body, fault repair cases and technical bulletin.
Each part consists of the dismantling and assembling, working principle and fault symptoms and repair methods
for current Refine Models. All this information conforms to the current models when this manual is published.
A detailed table of contents is provided for each part, to enable quick location of the required chapter and section.

Configuration of different models of Refine business cars

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 Workshop Manual for Refine MPV General

Main specification and configuration of Refine

Standard
Type Diesel international version Standard business Deluxe service
service
Model
HFC6500KAC8
HFC6470KA HFC6500A1 HFC6470A HFC6470AH
KFC6500KAI
Overall dimensions
8, 9, 11 and 12
No. of seats 7 seats 9 seats 7 seats 7 seats
seats
Total length (mm) 4695 5035 5035 4695
Total width (mm) 1820 1820 1820 1820 1820
Total height (mm) 1880 1970 1970 1880 1880
Power system
Original
imported D48H Original imported
in-line cylinder G4JS double overhead
Type ← ← ←
turbo-boosting camshaft 16-valve EI
inter-cooling gasoline engine
diesel engine
Engine Displaceme
2476 2476 2351 2351 2351
nt (cc)
Max. power
76.8/3800 76.8/3800 100.7/5500 100.7/5500 100.7/5500
(Km/rpm)
Max.
torque 235.36/2000 235.36/2000 193/2000 193/2000 193/2000
(Nm/rpm)
Four-shift
Five-shift Five-shift manual Five-shift automatic /
Gearbox Five-shift manual gear
manual gear gear manual gear Five-shift
manual gear
Rear wheel
Driving type ← ← ← ←
driving
Fuel consumption
7.5L 7.5L 10L 10L 10L
(L/100Km)
2-level 3-element
Europe II catalyst converter
environmental closed loop system,
Fuel and emission protection ← conforming to Europe ← ←
emission II environmental
standard protection emission
standard
Double-fork
independent
Front ← ← ← ←
suspension and
Suspension torque spring
5-rod coil spring/
5-rod coil 5-rod coil
Rear Multi-leaved Multi-leaved spring ←
spring spring
spring
Safety configuration
Safety bag for front
▲
driver seat
Safety belts for front
← ← ← ← ←
and back seats
ABS system ← ← ← ← ←

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 Workshop Manual for Refine MPV General
Standard
Type Diesel international version Standard business Deluxe service
service
Model
HFC6500KAC8
HFC6470KA HFC6500A1 HFC6470A HFC6470AH
KFC6500KAI
Surrounding safety
▲ ▲ ▲ ▲ ←
apron
Full metal enclosed
← ← ← ← ←
load bearing body
Side bumper bar ← ← ← ← ←
Electric front and
← ← ← ← ←
rear defroster
Integrated front
← ← ← ← ←
headlamp
Rear tail wing hood
and high position ▲ ▲ ←
brake indicator
Anti-theft ignition
←
key
High effect
maintenance free ← ← ← ← ←
battery
Comfort
configuration
Electrically
controlled front and
rear double sunshine ← ← ▲ ←
roof and overhead
luggage rack
Remote control
keys/motor-driv
Central controlled en
← ← ← ←
door locks programmable
central door
locks
Motor-driven front
← ← ← ← ←
window
Front and rear
separate air
conditioner and rear ← ← ← ← ←
conditioning air
outlet
CD
machine/6-channel
← ← ← ← ←
VDO high fidelity
audio system
Folding type
electrically
← ← ← ← ←
controlled outer rear
view mirror
High grade fabric
← ← ← ← ←
covered seat
Ash tray and cup
← ← ← ← ←
holder
Inlet air filter ← ← ← ← ←
Anti-UV glass ←

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 Workshop Manual for Refine MPV General
Standard
Type Diesel international version Standard business Deluxe service
service
Model
HFC6500KAC8
HFC6470KA HFC6500A1 HFC6470A HFC6470AH
KFC6500KAI
Leather-covered
▲
seat
Note: “▲ ”is optional configuration and “← ”standard configuration, the same for above.

Vehicle nameplate information

The vehicle identification number (VIN) is
located on the right wall side cover of
engine compartment.

Vehicle identification No.

Vehicle identification number consists of 17 digits.
K M J W W H 7 H P Y U 0 0 0 0 0 1

1 2 3 4 5 6 7 8 9 10

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 Workshop Manual for Refine MPV General
1. W.I.C (World manufacturer identification)
KMJ— Hyundai Motor Corporation of Korea
2. Vehicle classification
W: A1
3. Type and series
V: minibus
W: sedan
4. Body type
H: semi-roof
5. Brake system
7: Hydraulic brake system
8: Pneumatic brake system
9: Hybrid brake system
6. Engine type
B: T— 2 2.6
F: 4D56 2.5TC
H: 4D56 2.5TCI
W: G2.4 14
7. Steering wheel position
P: Left
R: Right
8. Year of manufacture
Y— 2000 Version 1— 2001 Version 2— 2002 Version 3— 2003 Version
9. Factory
U— Ulsan (Korea)
10. Vehicle serial No.
000001— 999999

Tightening torque for standard parts

Bolt nominal Pitch Torque Nm
diameter (mm) (mm) Head mark 4 Head mark 7
M5 0.8 3-4 5-6
M6 1.0 5-6 9-11
M8 1.25 12-15 20-25
M10 1.25 23-30 30-50
M12 1.25 35-45 60-80
M14 1.5 75-85 120-140
M16 1.5 110-130 180-210
M18 1.5 160-180 260-300
M20 1.5 220-250 360-420
M22 1.5 290-330 480-550
M24 1.5 360-420 610-700

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 Workshop Manual for Refine MPV General
Note:
1. The torques shown in the table are standard values under the following conditions:
◆ Nuts and bolts are made from steel bar and are plated.
◆ Plated flat steel washers are provided.
◆ All nuts, bolts and flat washers are dry.
2. The torques shown in the table are not applicable to the following:
◆ Spring loaded washers, toothed washers and the like.
◆ There is fixed plastic part.
◆ Self-tapping or self-locking nuts.
◆ Thread and bearing surface coated with grease.
3. The indicated percent of torque in the torque table should be used in the following cases:
◆ Use of spring washer: 85%
◆ Thread and bearing with grease on surface: 85%

Use of lifter
·It is very dangerous to lift a vehicle with incorrect method. During lifting, it is possible that the vehicle is
slipped down from the lifter, causing serious personal injury or death accidents. To avoid such accidents, lifter
operation must be done according to specification during lifting.
1. Place the four legs of the lifter at four supporting points of the vehicle in a correct manner.
2. Adjust the support angle to an appropriate height.
3. Lift the vehicle to an appropriate height and check if the support is firm.
4. Lift the vehicle to the required height and apply the safety latch.

Note:
During lifting and lowering of vehicle, there must be no object or working personnel under the vehicle.

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 Workshop Manual for Refine MPV General
Vehicle support and lifter

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 Workshop Manual for Refine MPV General

Dual-column
lifter

Single-column
lifter

Type H lifter

Note:
1. Never apply the rack below the cross bar or rear suspension assembly.
2. To prevent scratching of the auxiliary beam, place a piece of cloth at the contact surface of jack (to avoid
damaging the coating, which may lead to corrosion).
3. Never support the vehicle with only one jack. Always use the safety column.
4. Do not attempt to lift one side of the vehicle by placing a jack between the front and rear wheels, as this will
cause permanent damage to the vehicle body.

Protection of vehicle
Before work, make sure to place covers on the seats, steering wheel, gear shift bar and foot pad of the vehicle.
Be sure to cover the wing plate of engine compartment with protection pad when the engine cover is opened for
repair of engine section.
Note:
Whenever the engine compartment is check, be sure to insert the support bar into the hole on the engine cover
side, to avoid dropping of engine compartment cover to cause injury.

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 Workshop Manual for Refine MPV General
When the engine compartment cover is closed, make sure that the support bar has been taken out and placed in
the clip provided. Ensure that the cover is firmed closed before driving the vehicle.

Preventive actions before welding

The vehicle is fitted with various electrical parts. Magnetic current

To avoid excessive current being produced on these
parts during welding, do the following as specified:
1. Turn the ignition switch to the locking position.
2. Disconnect the battery wires.

3. Carefully ground the equipment to be

grounded close to the welding area.
4. Cover other surrounding equipment near
the welding area to avoid welding materials
from spilling onto them.

Towing of vehicle
·To avoid unnecessary damage to the vehicle during
operation, it is imperative to adopt suitable lifting and
towing methods. Therefore, provisions of government
and relevant local regulations must be observed in this
operation.

·The front wheel of the vehicle being towed must clear

from ground. If the front wheel cannot be lifted above
ground due to special reason (damage or other cause),
the vehicle should be moved with auxiliary towing
wheels.

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 Workshop Manual for Refine MPV General

Warning:
·During towing, note not to tow it backward while the
driving wheel is on the ground.

Warning:
·Take care not to use equipment with hooks, as this will
cause damage to the vehicle. Please use wheels or trailers
with platform that allows loading and unloading.

Warning:
·Take care not to use buckles with hooks on the front or tail
of the vehicle. These buckles are used only for tying
purpose during transport. If these buckles are used for
towing, the bumper of the vehicle might be damaged.

Vehicle towing hooks

Warning:

·These hooks are used only in emergency (for example:

assisting the vehicle to drive out from a ditch or snow
pile).
·When the towing hooks are used, the rope or chain
should be pulled in the forward direction of the hook.
Towing hook as shown (front)

Warning information
In this manual, you will find some warnings, notes,
standard parameter values and upper and lower limits.

Warning
·Warning: It may cause serious personal injury or even
death if the Warning here is neglected.

Towing hook as shown (rear)

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 Workshop Manual for Refine MPV General

Note
·Note: Negligence here may lead to damage to your
vehicle or parts.
Standard parameter values

·These values indicate the permissible ranges for inspection

or adjustment.
Upper or lower limits

·These values indicate the upper or lower limit values that

cannot be exceeded in inspection or adjustment.

Unit
Current A (Ampere)
Electrical power W (Watt)
Resistance Ω (Ohm)
Voltage V (Volt)
Length mm (mm)
KPa (kilopascal)
2
Negative pressure Kg/cm (kilogram/square centimeter)
Bar (bar)
Kpa (kilopascal)
Positive pressure
Kg/cm2 (kilogram/square centimeter)
Torque Nm (Newton-meter)
L (liter)
Volume
ML (milliliter)
g (gram)
Mass
Kg (kilogram)

Basic procedures

Preparation of tools and measuring devices

·Before starting the work, be sure to get all

necessary tools and measuring devices
ready.

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 Workshop Manual for Refine MPV General

Special service tools

·When necessary, use special service tools or
their equivalents.

Disassembling
·When complicated disassembling procedure is
required, or a number of parts are to be
disassembled, they must all be put at fixed places
and marked, to avoid affecting their performance
and appearance, and facilitate identification for
high efficiency in disassembling work.

Inspection during dismantling and

disassembling
· All parts should be inspected for fault,
deformation, damage or other problems.

Arranging the parts

·All disassembled parts should be arranged for
assembling again.
·Parts that are to be replaced and those for use
again must be separated and identified.

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 Workshop Manual for Refine MPV General
Cleaning of parts
·All parts to be used again should be cleaned
carefully and thoroughly with suitable methods.

Warning
·When is used to clean parts, dust and
other particles may fly out and they are
harmful to eyes. Therefore eye guards
must be worn for using compressed air.

Reassembling

·For reassembling, standard values, such as

torque and adjusting values, must be
observed for all parts.
·The following parts should be replaced
with new ones if dismantled.
— oil seal
— washer
— O-ring
— lock washer
·Depending on part positions
— Sealing glue and washers shall be used at
designated positions. When sealing glue is used,
mounting should be done before it is hardened,
to avoid leakage due to improper sealing.
— Lub oil should be applied to mechanical
moving parts.
— Before re-assembling, specified lub oil or
grease should be applied to designated locations
(such as oil seals).
Adjustment
·Use appropriate metering gauges or testing
devices for adjustment.

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 Workshop Manual for Refine MPV General
Rubber parts and tubular parts
·Take care to prevent gasoline or lub oil from
sticking onto rubber parts or tubular parts.

Rubber tube clamps

·For reassembling, place the rubber tube clamps
at the original positions on rubber tubes, and
gently squeeze the clamps with big pliers to
ensure good fitting.

Inspection during dismantling and

disassembling
Torque formula

·When a torque spanner (special service tool or

equivalent combined tools), there will be an
additional force arm, therefore the torque must
be calculated again.
Re-calculate the torque using the
following formulas:

Torque unit Formula

N·m N·m X[L/(L+A)]
kgf·m kgf·m X[L/(L+A)]
kgf·cm kgf·cm X[L/(L+A)]
ft·
lbf ft·
lbf X[L/(L+A)]
in·
lbf in·
lbf X[L/(L+A)]

A: length at which the force is applied to the

special service tool
L: length of torque spanner

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 Workshop Manual for Refine MPV General

Vice
·Place a protecting metal sheet at the mouth
of a vice to prevent damage to part when
a vice is used.

Electronic systems
Electronic elements
Battery cables
·Before taking off a connector or dismantling an
electronic element, disconnect the negative
cable of the battery.

Harness

·To remove the harness from clips, lift the

buckle on the clips with a flat screwdriver.

Taking off the connector

·When taking off a connector, hold on the
connector instead of pulling the cable.

·Pressing or pulling the connector locking handle as

shown may lead to disconnection in the connector.

Locking a connector
·To lock the connector, a click sound indicates it has
been properly locked.

Inspection
·When a tester is used to check the continuity or
measure the voltage, the test probe should be inserted
from the harness side.

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 Workshop Manual for Refine MPV General

·As the wiring terminal of water-proof connector

cannot be checked from the harness side, make the
check on the connector side.

Note
· To prevent damage to the connector wiring
terminal, wrap the probe with a turn of thin wire
before inserting the testing probe.

Wiring terminals
Inspection
· Lightly pull each wire to check its firm
connection in the socket terminal.

Replacement Type A
·Dismantle a connector using a suitable tool with Type B
the method as shown.
When fitting the terminal, note to insert it to the
locked position.
·Insert a thin piece of metal from the terminal
side of plug, and press the locking lug of the
terminal and pull the terminal out of the plug.

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 Workshop Manual for Refine MPV General

Sensors, switches and relays

·Please operate with the sensors, switches and
relays carefully.
Take care to avoid colliding them with other
objects.

Fuse

Replacement
·Note to replace a fuse with one of the same
capacity. If a fault takes place again with the
fuse, there may be short-circuit in the harness,
therefore the harness should be checked. Name of connecting parts
·Before replacing a main fuse, note to disconnect
the negative terminal of the battery.
·Use the specified fuse puller when replacing a
fuse.

Plugs on vehicle harness side

Observation direction: observe from the harness
side. Observation
Vehicle harness
If there are a number of plug figures, the name of direction
parts should be indicated.

Puller

Fuse

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 Workshop Manual for Refine MPV General

Others
Plugs on the vehicle harness side, such as DLC
must be observed from the terminal side, therefore
in this case, observation should be made along the
terminal side.

Observation
Vehicle harness direction

Tools for removing electrical faults

Jumpers
·A jumper is used to set up a temporary harness.
Connect the jumpers on each terminal of a harness
to a switch in a roundabout way.
Warning:
·Do not connect the jumper from power supply
to the body grounding wire. This may lead to
burning of wire or damage to the harness or
electrical parts.

Voltmeter
·Harness voltage is measured by means of a DC
Black
voltmeter. A DC voltmeter shall have a range of at
harness
least 15V. Connect the positive probe (+) (red cord)
to the voltage measuring point and the negative
probe (-) (black cord) to the body grounding point.
Red
Ohmmeter
harness
·An ohmmeter is used to measure the resistance
between two points in a harness, and also to
check the harness connection and if any
short-circuiting exist.
Warning:
·Note not to connect the ohmmeter when a Power cord
voltage is applied to the circuit, as this will
damage the ohmmeter.
▪ Ground
Ground line

Ohmmeter

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