Optima 2003 2.4L Service-manual-Desbloqueado

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OPTIMA(MS) > 2003 > G 2.4 DOHC > General Information
General Information > General Information > General Information

GENERAL INFORMATION
HOW TO USE THIS MANUAL
This manual is divided into 21 sections. This first page of each section is marked with a black tab at the edge of the
page. You can quickly find the first page of each section without looking through a full table of contents.
Each section includes the essential removal, installation, adjustment and maintenance procedures for servicing all
body styles. This information is current as of time of publication.
An INDEX is provided on the first page of each section to guide you to the item to be replaced.
TROUBLESHOOTING tables are included for each system to help you diagnose the system problem and find the
cause. The repair for each possible cause is referenced in the remedy column to quickly lead you to the solution.
DEFINITION OF TERMS
Standard Value (Service standard)
Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to
which the part or assembly is corrected and adjusted. It is given by a tolerance.
Service Limit
Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum
value within which the part or assembly must be kept functionally or in strength. It is a value established outside the
range of standard value.
WARNING , CAUTION, NOTE, ABBREVIATION
• WARNING
Information about an activity that could cause serious or severe personal injury or death to the driver, occupants
or service technician.
• CAUTION
Information about an activity that could cause damage to the vehicle, or cause some personal injury.
• NOTE
A point of information.
• ABBREVIATIONS
DOHC : Double Over Head Camshaft
V-6 : V-typed 6 Cylinder
VEHICLE IDENTIFICATION NUMBER LOCATION
The vehicle identification number (VIN) is on the top of the firewall and on the lower side of the left front door pillar.
VEHICLE IDENTIFICATION NUMBER

Vehicle identification number consists of 17 digit.
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1 to 3 (Make / Vehicle Type):

KNA - Kia Passenger Car
4 to 5 (Vehicle Line / Series):
GD - OPTIMA
6 to 7 (Body Type):
12 - 4Door Seden
8 (Engine / Restraint):
6-Sirius II 2.4
8 - δ2.7 Gasoline & Air Bags (Manual Belts)
9 (Check Digit):
To be calculated
10 (Model Year):
2 - 2002MY, 3 - 2003MY
11 (Plant):
5 - Hwasung Plant
12 to 17 (Sequential Numbers)
ENGINE IDENTIFICATION NUMBER LOCATION
The engine identification number is stamped at the right front side on the top edge of the cylinder block.
ENGINE IDENTIFICATION NUMBER

Engine identification number consists of 11 digits.
1. Engine fuel
G - Gasoline L - LPG D - Diesel
2. Engine range
4 - In line 4 cycle 4 cylinder
6 - V type 4 cycle 6 cylinder
3. Engine development order
B - V6 Engine
J - SIRIUS II DOHC Engine
4. Engine capacity
N - 1836 cc
P - 1997 cc, 1998 cc
S - 2351 cc
V - 2493 cc, 2497 cc
5. Product year
X - 1999 V - 2000 1 - 2001 2 - 2002 3 - 2003
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6. Engine production sequence number
000001 - 999999
TRANSAXLE IDENTIFICATION NUMBER LOCATION
DESCRIPTION (MANUAL TRANSAXLE)
1. Model
L : M5G Series.
2. Product year
1 : 2001 2 : 2002
3. Final gear ratio
1766 : 3,882
1665 : 4,063
4. Serial NO.
DESCRIPTION (AUTOMATIC TRANSAXLE)
1. Model
C : KM 175-5 D : KM 175-6 H : F4A33
2. Product year
1 : 2001 2 : 2002 3 : 2003
3. Final gear ration
F : 4.350 (KM 175-6) A : 3.958 (F4A33)
4. Classification of detail
AD : 2.4 Liter Engine BD : 2.0/ 2.5 Liter Engine
5. Spare
6. Serial No.
PROTECTION OF THE VEHICLE tomsn048@gmail.com
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Always be sure to cover fenders, seats, and floor areas before starting work.
The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine
compartment to prevent the hood from falling and possibly injuring you.
Assure that the support rod has been released prior to closing the hood. Always double check to be sure the hood
is firmly latched before driving away.
BASIC SAFETY WARNINGS WHEN WORKING ON THE VEHICLE
The following precautions must be followed when jacking up the vehicle.
1. Block wheels.
2. Use only specified jacking positions.
3. Support vehicle with safety stands (jack stands)
4. Never start the engine until you personally make certain the engine compartment is clear of tools and people.
Never rely on another person to make the inspection-make the inspection yourself.
PREPARATION OF TOOLS AND MEASURING EQUIPMENT
Be sure that all necessary tools and measuring equipment are available before starting work activity.
SPECIAL TOOLS
Use special tools when they are required.
REMOVAL OF PARTS
First find the cause of trouble and then make sure whether removing or disassembling is required before starting the
job.
The failure to follow these instructions can lead to serious personal injury or death.
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.
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1. Inspection of parts
Each part when removed should be carefully inspected for malfunction, deformation, damage, and other
problems.
2. Arrangement of parts
All disassembled parts should be carefully arranged for reassembly.
Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
3. Cleaning parts for reuse

All parts to be reused should be carefully and thoroughly clean-ed by the appropriate method.
PARTS
When replacing factory parts, use genuine parts.
If using non-factory parts, you must ensure that such parts are the equivalent quality of genuine factory parts to
avoid exposing customers to the risk of severe injury or death.
REASSEMBLY
Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
If removed, these parts should be replaced with new ones.
1. Oil seals .
2. Gaskets 3.
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts
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Depending on where they are;

1. Sealant should be applied to gaskets.
2. Oil should be applied to moving components of parts.
3. Specified oil or grease should be applied at the prescribed locations (oil seals, etc.) before assembly.
ADJUSTMENT
Use gauges and testers to correct adjustments to standard values.
ELECTRICAL SYSTEM
1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.
2. Never pull on the wiring when disconnecting connectors.

3. Locking connectors will click when the connector is secure.
4. Handle sensors and relays carefully.
Be careful not to drop them or hit them against other parts.
RUBBER PARTS AND TUBING
Always prevent gasoline or oil from touching rubber parts or tubing.
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BODY DIMENSION MEASUREMENT
1. Basically, all measurements in this manual are taken with a tracking gauge.
2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
3. For measuring dimensions, both projected dimension and actual-measurement dimension are used in this manual.
PROJECTED DIMENSIONS
1. These are the dimensions measured when the measurement points are projected into the reference plane, and are
the reference dimensions used for body alterations.
2. If the length of the tracking gauge probes are adjustable, make the measurement by lengthening one probe by the
amount equivalent to the difference in height of the two surfaces.
ACTUAL-MEASUREMENT DIMENSIONS
1. These dimensions indicate the actual linear distance between measurement points, and are the reference
dimensions for use if a tracking gauge is used for measurement.
2. Measure by first adjusting both probes to the same length (A=A')
Check the probes and gauge itself to make sure there is no free play.
MEASUREMENT POINT
1. Measurements should be taken at the center of hole.
CHECKING CABLES AND WIRES
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1. Check the terminal for tightness.

2. Check terminals and wires for corrosion by battery electrolyte, etc.
3. Check terminals and wires for open circuit or potential open circuit.
4. Check wire insulation and coating for damage, cracks and degrading.
5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that wires are clamped so as to prevent contact with sharp corners of the vehicle body, etc. or hot parts
(exhaust manifold, pipe, etc.)
9. Check that wires are clamped firmly to secure enough clearance from the fan pulley, fan belt and other rotating or
moving parts.
10. Check that the wires between the fixed parts such as the vehicle body and the vibrating parts such as the engine
are made with adequate allowance for vehicle vibrations.
CHECKING FUSES
A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block.
The fuse is okay if the test lamp comes on when its one lead is connected to the test taps (one at a time) and the
other lead is grounded. (Change the ignition switch position adequately so that the fuse circuit becomes live.)
SERVICING THE ELECTRICAL SYSTEM
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1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground
cable.
In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic code
retained by the computer will be cleared. Therefore, if necessary, read the diagnostic codes before
removing the battery cable.
2. Secure the wiring harnesses by using clamps so that there is no slack. However, for any harness which passes to
the engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine
vibrations to cause the harness to come into contact with any of the surrounding parts, and then secure the
harness by using a clamp.
3. If any section of a wiring harness interferes with the edge of a part, or a corner, wrap the section of the harness
with tape or something similar in order to protect it from damage.
4. When installing any of the vehicle parts, be careful not to pinch or damage any of the wiring harnesses.
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5. Never throw the relays, sensors and electrical parts, or expose them to strong shocks.
6. The electronic parts used in the computer, relays, etc. are easily damaged by heat. If there is a need for service
operations that may cause the temperature to exceed 80°C (176°F), remove the electronic parts beforehand.
7. Loose connectors could troubles. Make sure that the connec-tors are connected securely.
8. When disconnecting a connector, be sure to pull only the connector, not the harness.
9. Disconnect connectors which have catches by pressing in the direction indicated by the arrows in the illustration.
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10. Connect connectors which have catches by inserting the connectors until a "click" noise is heard.
11. When using a circuit tester to perform continuity or voltage checks on connector terminals, insert the test probe
from the harness side. If the connector is a sealed connector, insert the test probe in through the hole in the
rubber cap for the electrical wires, being careful not to damage the insulation of the wires and continue to insert
the test probe until it contacts the terminal.
12. To avoid overloading the wiring, take the electrical current load of the optional equipment into considerution,
and determine the appropriate wire size.
Permissible current
Nominal size SAE gauge No.
In engine compartment Other areas
0.3 mm² AWG 22 - 5A
0.5 mm² AWG 20 7A 13A
0.85 mm² AWG 18 9A 17A
1.25 mm² AWG 16 12A 22A
2.0 mm² AWG 14 16A 30A
3.0 mm² AWG 12 21A 40A
5.0 mm² AWG 10 31A 54A
PRECAUTIONS FOR A CATALYTIC CONVERTER
If large amounts of unburned gasoline vapors flow into the converter, the gasoline line may overheat and create a
fire hazard. To prevent this, observe the following precautions and explain them to your customer.
1. Use only unleaded gasoline.
2. Avoid prolonged idling.
Avoid running the engine at fast idle speed for more than 10 minutes and at idle speed for more than 20 minutes.
3. Avoid spark jump test.
Spark jump only when absolutely necessary. Perform this test as rapidly as possible and, while testing, never race
the engine.
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4. Avoid prolonged engine compression measurement. Engine compression tests must be made as rapidly as
possible.
5. Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load
on the converter.
6. Avoid coasting with ignition turned off and prolonged braking.
7. Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
SRS SYSTEM COMPONENTS INFORMATION
Failure to carry out service operations in the correct sequence could cause the airbag system to unexpectedly
deploy during servicing, possibly leading to a serious injury or death. Further, if a mistake is made in servicing the
airbag system, it is possible the airbag may fail to operate when required. Before performing servicing (including
removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then
follow the correct procedure described in the repair manual.
1. Malfunction symptoms of the airbag system are difficult to confirm, so the diagnostic codes become the most
important source of information when troubleshooting. When troubleshooting the airbag system, always inspect
the diagnostic codes before disconnecting the battery. 2.
2. Work must be started 30 seconds or longer from the time the ignition switch is turned to the LOCK position and
the negative (-) terminal cable is disconnected from the battery. (The airbag system is equipped with a back-up
power source so that work is started immediately after disconnecting the negative (-) terminal cable of the
battery, the airbag may be deployed.) When the negative (-) terminal cable is disconnected from the battery,
memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents
memorized by the audio memory system. Then when work is finished, reset the audio system as before and
adjust the clock.
3. Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.
4. Never attempt to disassemble and repair the airbag modules, SRSCM, Clock spring and Air-bag wiring harness
in order to reuse it.
5. If the SRSCM or air-bag module have been dropped, or if there are cracks, dents or other defects in the case,
bracket or connector, replace them with new ones.
6. After work on the airbag system is completed, perform the SRS SRI check.
VEHICLE LIFT AND SUPPORT LOCATIONS
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STANDARD PARTS TIGHTENING TORQUE TABLE
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Torque Nm (kg.cm, lb.ft)
Bolt nominal diameter (mm) Pitch (mm)
Head Mark 4 Head Mark 7
M5 0.8 3-4 (30-40, 2.2-2.9) 5-6 (50-60, 3.6-4.3)

M6 1.0 5-6 (50-60, 3.6-4.3) 9-11 (90-110, 6.5-8.0)
M8 1.25 12-15 (120-150, 9-11) 20-25 (200-250, 14.5-18.0
M10 1.25 25-30 (250-300, 18-22) 30-50 (400-500, 29-36)
M12 1.25 35-45 (350-450, 25-32) 60-80 (600-800, 43-58)
M14 1.5 75-85 (750-850, 55-60) 120-140 (1,200-1,400, 85-
M16 1.5 110-130 (1,100-1,300, 80-95) 180-210 (1,800-2,100, 130
M18 1.5 160-180 (1,600-1,800, 115-130) 260-300 (2,600-3,000, 190
M20 1.5 220-250 (2,200-2,500, 160-180) 360-420 (3,600-4,200, 260
M22 1.5 290-330 (2,900-3,300, 210-240) 480-550 (4,800-5,500, 350
M24 1.5 360-420 (3,600-4,200, 270-300) 610-700 (6,100-7,000, 440
1. The torques shown in the table are standard values applicable to tightening performed under the following
conditions:
1. Nuts and bolts are made of steel bar, and galvanized.
2. Galvanized plain steel washers are inserted.
3. All nuts, bolts, and plain washers are dry.
2. The torques shown in the table are not applicable:
1. Spring washers, toothed washers and the like are inserted.
2. If plastic parts are fastened.
3. If threads and surface are coated with oil.
4. If self-tapping screws or self-locking nuts are used.
3. It should be standard practice to reduce the torques given in the table to the percentage indicated below:
1. If spring washers are used. 85%
2. If threads and bearing surfaces are stained with oil. 85%
RECOMMENDED LUBRICANTS AND CAPACITIES
RECOMMENDED LUBRICANTS
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Parts Specifications Remarks
Engine oil API classification SG or For further details, refer
SG/CD to SAE viscosity number
Manual transaxle Hypoid gear oil, API-GL-4 SAE grade number:
SAE 75W/ 90W
Automatic transaxle GENUINE
DIAMOND ATF SP-II M
Brake Conforming to DOT 3 or
equivalent
Rear wheel bearing SAE J310a, Multipurpose
grease NLGI No.2 or
equivalent.
Cooling system High quality ethylene glycol Concentration level 40%
Transaxle linkage, parking brake cable mechanism, Multipurpose grease NLGI
hood lock and hook, door latch, seat adjuster, trunk Grade #2
latch, door hinges, trunk hinges
Door hinges, trunk hinges Engine oil
Power steering PSF-3
LUBRICANTS CAPACITIES
Description Capacities Remarks
Engine oil(For 2.0/ 2.4L DOHC Engine)
Oil pan 3.7 lit (3.91 U.S. qts., 3.26 Imp.qts.)
Oil filter 0.3 lit (0.32 U.S. qts., 0.26 Imp.qts.)
Total 4.0 lit (4.23 U.S. qts., 3.52 Imp.qts.)
Engine oil(For 2.5L V6 Engine)
Oil pan 4.2 lit (4.44 U.S. qts.,3.69 lmp.qts.)
Oil filter 0.3 lit (0.32 U.S. qts.,0.26 Imp.qts.)
Total 4.5 lit (4.76 U.S. qts.,3.95 lmp.qts.)
Cooling system 5.5 lit (5.78 U.S. qts., 4.84 Imp.qts.)
Manual transaxle 2.1 lit (2.2 U.S. qts., 1.8 Imp.qts.)
Automatic transaxle 7.8 lit (8.2 U.S. qts., 6.9 Imp.qts.)
Power steering 1.0 lit (1.05 qts., 0.88 lmp.qts.)
MAINTENANCE SERVICE
CHECKING THE ENGINE OIL
1. Warm up the engine and turn the ignition off.
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2. Remove the filler cap (on the rocker cover), then remove the drain plug and drain the engine oil.
3. Install the drain plug and tighten to specified torque.
Tightening torque - Drain plug : 35-45 Nm (350-450 kg·cm, 26-32 lb·ft)
4. Fill the crankcase with fresh oil through the filler port.
Lit (U.S.qts, lmp.qts.)
Drain and Refill
ENGINE Dry Fill
W/oil filter W/O oil filter
4.3 (4.52, 4.0 (4.23, 3.7 (3.91,
DOHC
3.76) 3.51) 3.25)
4.5 (4.76, 4.2 (4.43,
V-6 -
3.95) 3.69)
5. Pull the dipstick out in order to check the oil level.
6. Install the filler plug.

7. Recheck the level of the engine oil after a road test.
REPLACEMENT OF THE ENGINE OIL FILTER
1. Replace the oil filter at every oil change.
2. Use a filter wrench (available commercially) to remove the oil filter.
3. Drain the oil in the filter.
4. Lightly coat the O-ring (1) of the new oil filter with engine oil, and install the filter by hand.
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REPLACEMENT OF THE AIR CLEANER FILTER
The air cleaner filter will become dirty during use and the filtering effect will be substantially reduced. Replace with a
new one.
1. Disconnect the air cleaner filter cover clip.
2. Remove the air filter cover.
The air filter cover should be removed carefully because it includes the air-flow
sensor.
3. Remove the air cleaner filter.

4. Install a new air cleaner filter and clamp the air cleaner filter cover.
CHECKING BELT TENSION
Apply 100 N (22 lbs.) force to the backside of the belt between the pulleys as shown in the illustration, measure the
amount of deflection Measure tension with a tension gauge.
Standard value (For 2.4L DOHC ENGINE)
Items New Used Inspection
6.3 - 7.3 (0.24- 8.4 -10.6 (0.33-
Deflection mm (in.) 7.7-12.3 (0.3-0.48)
Generator 0.29) 0.42)
Tension Kg (lb) 60 ± 5 (132±10) 40 ± 5 (88±10) 40 ±10 (88±20)
8.8 -11.0 (0.35- 12.5 -14.3 (0.5- 11.7-15.3 (0.46-
A/C Compressor Deflection mm (in.)
0.43) 0.56) 0.6)
Standard value ( For V6 ENGINE)

The belt tension for V6 engine is automatically adjusted by the auto-tensioner.
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ADJUSTMENT OF BELT TENSION

Refer to EM-Section. (For Generator of DOHC Engine)
Refer to HA-Section. (For Compressor)
COOLING SYSTEM
Check the cooling system for damaged hoses, loose or seeping connections, or other possible causes of coolant
leaks.
Antifreeze
The engine cooling system is provided with a mixture of 50% ethylene glycol anti-freeze and 50% water at the time
of manufacture. (For the vehicles of tropical area, the engine cooling system is provided with a mixture of 40%
ethylene glycol anti-freeze and 60% water at the time of manufacture.) Since the cylinder head and water pump
body are made of aluminum alloy casting, be sure to use a 30 to 60% ethylene glycol antifreeze coolant to provide
corrosion protection and freezing prevention.
If the concentration of the antifreeze is below 30%, the anticorrosion property will be adversely affected. In
addition, if the concentration is above 60%, both the antifreezing and engine cooling properties will decrease,
adversely affecting the engine. For these reasons, be sure to maintain the concentration level within the specified
range.
Measurement of Antifreeze Concentration
Run the engine until coolant is fully mixed. Drain some coolant (antifreeze), and measure temperature and specific
gravity of the coolant. Determine concentration and safe working temperature. If the coolant is short of antifreeze,
add antifreeze up to a concentration of 50%. (Tropical Areas : 40%)
Replacement of the Coolant
1. Set the temperature control lever to the hot position.
2. Remove the radiator cap.
Remove cap slowly as the system is pressurized and the coolant may be
hot.
Do not open the cap when engine is hot.
3. Loosen the drain plug to drain the coolant.

4. Drain the coolant from the reserve tank.
5. After draining the coolant, tighten the drain plug securely.
6. Supply the coolant into the radiator until it is filled up to its filler neck.
7. Supply the coolant into the reserve tank.
8. After warming the engine until the thermostat opens, remove the radiator cap and check the coolant level.
9. Supply the coolant into the radiator until it is filled up to its filler neck, and install the radiator cap securely.
10. Fill the reserve tank with coolant up to the "FULL" line.
REPLACEMENT OF IGNITION CABLES
The ignition cables should be replaced periodically with new ones. After replacing, make sure that the ignition cables
and terminals are properly connected and fully seated. tomsn048@gmail.com
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When disconnecting an ignition cable be sure to hold cable cap. If the cable is disconnected by pulling on the cable
alone an open circuit might result.
REPLACEMENT OXYGEN SENSOR

The oxygen sensor is a device which controls the fuel mixture. If the oxygen sensor is damaged, the exhaust-gas
cleaning effect as well as driveability deteriorates. Therefore, its performance should be checked periodically using
the O2 sensor monitoring function of the scan tool and replaced as necessary.
FUEL SYSTEM
Tank, Lines And Connections
1. Check for damage or leakage in the fuel lines and connections.
2. Inspect the surface or fuel hoses for heat and mechanical damage. Hard and brittle rubber, cracking, checking,
tears, cuts, abrasions and excessive swelling indicate deterioration of the rubber.
3. If the fabric casing of the rubber hose is exposed by cracks and abrasions in the fuel system, the hoses should be
changed.
MANUAL TRANSAXLE (Inspect oil level)
Inspect each component for evidence of leakage, and check the oil level by removing the filler plug. If the oil is
contaminated, it is necessary to replace it with new oil.
1. With the vehicle parked at a level place, remove the filler plug and make sure that oil level is the same level as the
plug hole.
2. Check to be sure that the transaxle oil is not dirty.

TRANSAXLE OIL (Replace)
1. With the vehicle parked at a level place, remove the magnet plug to drain transaxle oil.
2. Replace packing with a new one and install the magnet plug.
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3. Supply transaxle oil (through the filler plug part) until the oil level is the same level as the plug hole.
Transaxle oil total capacity :
2.1 liters (2.2 U.S. qts., 1.8 lmp. qts.)
INSPECT STEERING LINKAGE
1. Check steering wheel freeplay.
Maximum steering wheel freeplay : 30 mm (1.181 in.)
2. Check steering linkage for looseness and damage as follows.

(1) Tie rod ends do not have excessive play.
(2) Dust seals and boots are not damaged.
(3) Boot clamps are not loose.
POWER STEERING FLUID LEVEL
(Inspect fluid level)
1. Park the vehicle on a flat, level surface, start the engine, and then turn the steering wheel several times to raise the
temperature of the fluid to approximately 50°C (122°F).
2. With the vehicle still idling, turn the wheel all the way to the left and right several times. Check the fluid in the oil
reservoir for foaming, check the fluid level, and replenish the fluid in the oil reservoir through the oil filter if
necessary.
POWER STEERING HOSES
(Check for deterioration or leaks)
1. Check the hose connections for fluid leaks.
2. The power steering hoses should be replaced if there are severe surface cracking, pulling, scuffing or worn steps.
Deterioration of the hoses could cause premature failure.
BALL JOINT AND STEERING LINKAGE SEALS, STEERING AND DRIVE SHAFT BOOTS
1. These components, which are permanently lubricated at the factory, do not require periodic lubrication. Damaged
seals and boots should be replaced to prevent leakage or contamination of the grease.
2. Inspect the dust cover and boots for proper sealing leakage and damage. Replace them if defective.
INSPECT BRAKE LINE
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1. Check all brake pipes and hoses for damage, wear, cracks, corrosion, leaks, bends, twists.
2. Check all clamps for tightness.

3. Check that the lines are clear of sharp edges, moving parts and the exhaust system.
FRONT DISC BRAKE PADS
Check for fluid contamination and wear. Replace complete set of pads if defective.
If a squealing or scraping noise occurs from the brakes during driving, check the brake pad wear indicator to see if
itis contacting the brake disc. If the brake pad wear indicator is contacting the disc, the brake pad should be
replaced.
The pads for the right and left wheels should be replaced at the same time. Never "split" or intermix brake pad
sets.
All pads must be replaced as a complete set.
Thickness of pad lining "A" [Limit] : 2.0 mm (0.079 in.)
REAR DRUM BRAKE LININGS AND

REAR WHEEL CYLINDERS
1. Remove the brake drum and check the thickness of brake shoe lining for wear. Check the automatic brake
adjusting system by hand to see if it operates smoothly. Also see if the gears are in proper mesh with each other.
To assure smooth functioning, apply a very thin coat of grease to the friction surface of adjuster and link shaft.
2. Inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears or
heat cracks. (A slight amount of fluid on the boot may not be a leak, but may be preservative fluid used at
assembly.)
(1) Checking the brake shoes for wear.
Thickness of lining "B" [Limit] : 0.8 mm (0.032 in.)
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CHECKING THE BRAKE FLUID LEVEL

1. Visually check the level of the brake fluid in the reserve tank of the master cylinder.
2. The level should be between the "MAX" and "MIN" marks.
3. If the level is lower than the "MIN" marks, add fresh brake fluid up to the "MAX" mark.
CHANGING BRAKE FLUID
1. Refer to BR-Section for air-bleeding procedures.
2. Connect a vinyl tube to the bleeder screw of each wheel cylinder. Put the other end of the vinyl tube into a
container to receive the brake fluid.
3. With a vehicle equipped ABS (Anti-lock Breake System), refer to BR-section.

4. Depress the brake pedal a few times. Then loosen the bleeder (with the brake pedal still depressed), and tighten
it after the brake fluid stops flowing.
5. Repeat the above operation until to air bubbles are in the brake fluid.
6. Repeat these steps for the other cylinders.
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7. Add fresh brake fluid up to the "MAX" level in the reserve tank.
Brake fluid : DOT 3 or equivalent
CHECKING OF THE TIRE INFLATION PRESSUE

Check the tire inflation pressures as follows.
Tire inflation pressure (Check with Tires Cool)
Tire size Front Rear
195/ 70 R 14
207 kPa (30 psi) 207 kPa (30 psi)
205/ 60 R 15
ROAD TEST
Drive the vehicle and check for abnormal conditions.
1. Check for oil, fluid, fuel, water and exhaust gas leaks.
2. Check free play of clutch pedal and brake pedal.
3. Check operation of brake booster.
4. Check operation of service brake and parking brake systems.
5. Check stroke of parking brake lever.
6. Check driveability of engine.
7. Check condition of instruments, gauges, indicators, exterior lamps, heater and ventilators.
8. Check abnormal noise of each part.
STEERING AND DRIVE SHAFT BOOTS
1. Aluminum wheels need special attention. If salt or chemicals have adhered to the wheels, they need to be rinsed
off as soon as possible. After cleaning the wheels, apply a coating of wax to prevent corrosion.
2. When cleaning the vehicle with steam, do not apply steam directly onto the aluminum wheels.
A. Clean the hub surface.
B. After finger tightening the wheel nuts, tighten them to specifications.
C. Do not use an impact wrench or push on the wrench with your foot to tighten the wheel nuts.
D. Do not apply oil to the threaded portions.
TIRE CHAINS AND SNOW TIRES
1. Use tire chains only on the front wheels. Do not use tire chains on rear wheels.
2. When using snow tires, use them on all four wheels for maneuverability and safety.
Maintenance Schedule (Normal)
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Maintenance Schedule (Severe)
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Maintenance Schedule (For CANADA)
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OPTIMA(MS) > 2003 > G 2.4 DOHC > Automatic Transaxle System
Automatic Transaxle System > General Information > Special Service Tools
SPECIAL SERVICE TOOLS
Tool
Illustration Use
(Number and Name)
09453-24000 Removal and installation of underdrive clutch snap ring
Spring compressor
09452-21401/0K011 Installation of oil pump

171 002 (Use with 09452-21301)
Guide pin
09453-33100 Measurement of the low and reverse brake and the second
Dial gauge extension brake end play
09431-39000 Installation of differential oil seal

Oil seal installer
09432-33800 1. Removal of transfer driven gear taper bearing (Use with

Bearing installer 09433-21000)
2. Installation or transfer shaft bearing
09433-21000 1. Removal of transafer driven gear taper bearing (Use with

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

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

Bearing installer roller bearing
09453-21100
Spring compressor tomsn048@gmail.com
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09453-21100 Removal and installation of the low-reverse brake snap ring
Spring compressor (Use with 9453-21000)
09455-21000/0K011 Removal of ball bearing and tansfer drive gear

430 017
Bearing and gear puller
09455-21100 1. Intallation of ball bearing and transfer drive gear

Bering installer 2. Installation of the transfer driven gear taper bearing
09532-11500 Installation of differential bearing outer race (Use with

Bearing installer 09500-11000)
09453-21000 • Removal and installation of low-reverse brake snap ring

Spring compressor • Removal and installation of overdrive clutch snap ring
(Use with 09456-39000)
09432-21701 Installation of output shaft outer race

Bearing outer race
installer
09452-33100 Removal of the oil pump

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

Oil pump oil seal installer
09200-38001 Removal and installation of transaxle

Engine support fixture
09456-39100 Measurement of low-reverse brake and second brake end

A/B Clearance dummy plays
plate
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09457-39000 Removal and installation of output shaft lock nut
Special socket (41)

Tool Illustration Use
(Number and Name)
09431-21200 Installation of differential oil seal
Oil seal installer
09432-22000 Installation of output shaft's gear and sleeve

Bearing installer
09432-22100 Installation of input and output shaft bearing

Bearing outer race outer race (Use with 09500-11000)
installer
09432-33200 Removal of input shaft's gear and ball bearing

Bearing removing plate
09432-33300 Installation of input shaft bearing

Bearing installer
09432-33400
Bearing race installer
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09432-33400 Installation of input shaft bearing outer race (Use
Bearing race installer with 09500-21000)
09455-21100 Installation of differential ball bearing

Bearing installer
09455-32200/0K011 Removal of differential bearing spacer

190 008
Oil seal puller
09495-33000 Removal of ball bearing and gear

Bearing and gear puller
09517-21400 Separation of T/M housing from T/M assembly

Drift
09532-11000 Removal and installation of differential bearing

Differential bearing
installer
09532-11500 Installation of output shaft and differential shaft

Pinion bearing outer race bearing outer race
installer (Use with 09500-11000)
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09200-38001(J28467- Removal and installation of transaxle assembly
B)
Engine support fixture
Automatic Transaxle System > General Information > Troubleshooting

TROUBLESHOOTING
Symptom Probable cause Remedy
Vibration, noise Loose or damaged transaxle and engine mounts Tighten or replace mounts
Inadequate shaft end play Correct end play
Worn or damaged gears Replace gears
Use of inadequate grade of gear oil Replace with specified gear oil
Low oil level Replenish
Inadequate engine idle speed Adjust idle speed
Oil leakage Broken or damaged oil seal Replace oil seal
Hard shift Faulty control cable Replace control cable
Poor contact or wear of synchronizer ring and gear cone Correct or replace
Weakened synchronizer spring Replace synchronizer spring
Use of inadequate grade of oil Replace with specified gear oil
Jumps out of gear Worn gear shift fork or broken poppet spring Replace shift fork or poppet spring
Excessive clearance of synchronizer hub to sleeve spline Replace synchronizer hub and sleeve
Worn or damaged gears and/or bearings Replace
Automatic Transaxle System > General Information > Repair procedures

SERVICE ADJUSTMENT PROCEDURES
TRANSAXLE GEAR OIL LEVEL INSPECTION
Inspect each component for evidence of leakage. Check the gear oil level by removing the filler plug. If the oil is
contaminted, it is necessary to replace it with new oil.
1. Remove oil filler plug and check level with finger.
2. Oil level must be up to fill hole, add oil until it runs out. Then reinstall plug.
3. Replace the oil that the transaxle gear oil is noticeably dirty, and that it is not of a suitable viscosity.
REPLACEMENT OF TRANSAXLE GEAR OIL
Use SAE 75W/90 TGO-6.
1. With the vehicle parked on a level surface, remove the drain plug and drain the transaxle oil.
2. Replace the gasket with a new one and install the drain plug .
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3. Add new oil through the filler plug, filling to below the plug opening.
Standard value
Transaxle oil total capacity : 2.1 lit (2.2 U.S.qts., 1.8 lmp.qts.)
DRIVE SHAFT OIL SEAL REPLACEMENT

1. Disconnect the drive shaft form the transaxle (Refer to "DS" group).
2. Using a flat-tip screwdriver, remove the oil seal.
3. Using the special tool (09431-21200), tap the drive shaft oil seal into the transaxle.
4. Apply a coating of gear oil to the oil seal.
Transaxle gear oil : SAE 75W/90 TGO-6.
Automatic Transaxle System > General Information > Specifications

SPECIFICATIONS
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Item F4A42-2
Torque converter type 3-element, 1-stage, 2-phase type
Transmission type 4-speed forward, 1-speed reverse
Engine displacement 2.4D / 2.7D
Gear ratio 1st 2.842
2nd 1.529
3rd 1.000
4th 0.712
Reverse 2.480
Final gear ratio 3.770
SERVICE SPECIFICATIONS
Items Standard value
Output shaft preload 0.01-0.09 mm (0.0004-0.0035 in)
Brake reaction plate end play 0-0.16 mm (0-0.0063 in)
Low-reverse brake end play 1.65-2.11mm (0.0650-0.0830 in)
Second brake end play 0.79-1.25 mm (0.0311-0.0492 in)
Underdrive sun gear end play 0.25-0.45 mm (0.0098-0.0177 in)
Input shaft end play mm 0.70-1.45 mm (0.0276-0.0571 in)
Differential case preload 0.045-0.105 mm (0.0018-0.0041 in)
Underdrive clutch end play 1.6-1.8 mm (0.0630-0.0709 in)
Overdrive clutch return spring retainer end 0-0.09 mm (0-0.0035 in)
play
Overdrive clutch end play 1.6-1.8 mm (0.0630-0.0709 in)
Reverse clutch end play 1.5-1.7 mm (0.0590-0.0670 in)
Backlash between differential side gear and 0.025-0.150 mm (0.001-0.006 in)
pinion
TIGHTENING TORQUE
Items N·m kg·cm lb·ft
Wiring harness bracket 20-26 200-260 14-18
Control cable bracket 20-26 200-260 14-18
Eye bolt 27-33 270-330 19-23
Oil cooler feed tube 10-12 100-120 7-8
Input shaft speed sensor 10-12 100-120 7-8
Output shaft speed sensor 10-12 100-120 7-8
Manual control lever 18-25 180-250
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Transaxle range switch 10-12 100-120 7-8
Vehicle speed sensor 4-6 40-60 3-4
Valve body cover 8-10 80-100 6-7
Valve body mounting bolt 10-12 100-120 7-8
Oil temperature sensor 10-12 100-120 7-8
Manual control shaft detent 5-7 50-70 4-5
Rear cover 20-26 200-260 14-18
Torque converter housing 42-54 420-540 29-38
Oil pump 20-26 200-260 14-18
Transfer drive gear 16-22 160-220 11-15
Output shaft lock nut 160-180 1600- 110-126
1800
Output shaft bearing retainer 20-26 200-260 14-18
Oil filler plug 29-34 290-340 20-24
Oil drain plug 29-34 290-340 20-24
Transfer drive gear lock nut 180-210 1800- 126-147
2100
Differential drive gear 130-140 1300- 91-98
1400
Valve body 10-12 100-120 7-8
Solenoid valve support 5-7 50-70 4-5
Plate 5-7 50-70 4-5
Pressure check plug 8-10 80-100 6-7
Front roll stopper bracket to subframe 60-80 600-800 43-58
bolts
Front roll stopper insulator bolt and nut 50-65 500-650 36-47
Front roll stopper bracket to transaxle 60-80 600-800 43-58
bolts
Rear roll stopper bracket to subframe 50-65 500-650 36-47
bolts
Rear roll stopper insulator bolt and nut 50-65 500-650 36-47
Rear roll stopper bracket to transaxle 60-80 600-800 43-58
bolts
Transaxle mounting sub bracket nut 60-80 600-800 43-58
Transaxle mounting bracket bolts 60-80 600-800 43-58
Transaxle mounting insulator bolt 90-110 900-1100 65-80
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Always follow torque tightening levels. Failure to follow such levels can result in parts breaking if over-tightened or
loosening if under-tightened. In either case, serious personal injury or death could result to the vehicle occupants.
SNAP RING AND SPACER FOR ADJUSTMENT
Identification
Part name Thickness mm (in)
symbol
Thrust washer 1.8 (0.071) 18
(For adjustment of input shaft end play) 2.0 (0.079) 20
2.2 (0.087) 22
2.4 (0.094) 24
2.6 (0.102) 26
2.8 (0.110) 28
Snap ring 1.6 (0.063) None
(For adjustment of underdrive clutch and overdrive
1.7 (0.067) Blue
clutch end plays)
1.8 (0.071) Brown
1.9 (0.075) None
2.0 (0.079) Blue
2.1 (0.083) Brown
2.2 (0.087) None
2.3 (0.091) Blue
2.4 (0.094) Brown
2.5 (0.098) None
2.6 (0.102) Blue
2.7 (0.106) Brown
2.8 (0.110) None
2.9 (0.114) Blue
3.0 (0.118) Brown
Snap ring 2.2 (0.087) Blue
(For adjustment of low-reverse brake and second brake 2.3 (0.091) Brown
reaction plates end plays)
2.4 (0.094) None
2.5 (0.098) Blue
Pressure plate 1.6 (0.063) 6
(For adjustment of low-reverse brake and second brake
1.8 (0.071) 1
end plays)
2.0 (0.079) 0
2.2 (0.087) 2
2.4 (0.094) 4
2.6 (0.102) 6
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2.8 (0.110) 8
3.0 (0.118) D
Snap ring 1.9 (0.075) None
(For adjustment of reverse clutch end play)
2.0 (0.079) Blue
2.1 (0.083) Brown
2.2 (0.087) None
2.3 (0.091) Blue
2.4 (0.094) Brown
2.5 (0.098) None
2.6 (0.102) Blue
2.7 (0.106) Brown
2.8 (0.110) None
Snap ring 1.48 (0.0583) Brown
(For adjustment of reverse clutch and over drive clutch
1.53 (0.0602) None
spring retainers end plays)
1.58 (0.0622) Blue
1.63 (0.0642) Brown
Thrust race 1.6 (0.036) -
(For adjustment of underdrive sun gear end play) 1.7 (0.067) -
1.8 (0.071) -
1.9 (0.075) -
2.0 (0.079) -
2.1 (0.083) -
2.2 (0.087) -
2.3 (0.091) -
2.4 (0.094) -
2.5 (0.098) -
2.6 (0.102) -
Spacer 1.88 (0.074) 88
(For adjustment of output shaft preload)
1.92 (0.076) 92
1.96 (0.077) 96
2.00 (0.079) 00
2.04 (0.080) 04
2.08 (0.082) 08
2.12 (0.083) 12
2.16 (0.085) 16
2.20 (0.087) 20
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2.24 (0.088) 24
2.28 (0.089) 28
2.32 (0.091) 32
2.36 (0.093) 36
2.40 (0.094) 40
2.44 (0.096) 44
2.48 (0.097) 48
2.52 (0.099) 52
2.56 (0.101) 56
2.60 (0.102) 60
2.64 (0.104) 64
2.68 (0.106) 68
2.72 (0.107) 72
2.76 (0.109) 76
Spacer 0.71 (0.028) 71
(For adjustment of differential case preload)
0.74 (0.029) 74
0.77 (0.030) 77
0.80 (0.031) 80
0.83 (0.033) 83
0.86 (0.034) 86
0.89 (0.035) 89
0.92 (0.036) 92
0.95 (0.037) 95
0.98 (0.038) 98
1.01 (0.040) 01
1.04 (0.041) 04
1.07 (0.042) 07
1.10 (0.043) J
1.13 (0.044) D
1.16 (0.046) K
1.19 (0.047) L
1.22 (0.048) G
1.25 (0.049) M
1.28 (0.050) N
1.31 (0.052) E
1.34 (0.053) O
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1.37 (0.054) P
Spacer 0.75-0.82 (0.0295-0.0322) -
(For adjustment of backlash between differential side
0.83-0.92 (0.033-0.036) -
gear and pinion)
0.93-1.00 (0.0366-0.0393) -
1.01-1.08 (0.0340-0.0425) -
1.09-1.16 (0.0429-0.0457) -
LUBRICATIONS
Items Specified lubricant Quantity
Transaxle fluid lit. (U.S. qts., Imp,qts.) GENUINE DIAMOND 7.8 (8.2,6.9)
ATF SP-III or SK ATF SP-III
SEALANTS
Items Specified sealant
Rear cover Genuine sealant FMD546, TB1281B
or equivalant
Torque converter housing Genuine sealant FMD546, TB1281B
or equivalant
Valve body cover Genuine sealant FMD546, TB1281B
or equivalant
SPECIFICATIONS
Model M5GF1 M5GF1-1
Type Forward 5 speed, reverse
1 speed
2.4 DOHC 2.7 DOHC
Gear ratio Firsst 3.455 3.231
Second 1.952 ←
Third 1.296 ←
Fourth 0.943 ←
Fifth 0.775 ←
Reverse 3.455 ←
Final gear ratio 3.882 4.063
SERVICE STANDARD
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Standard value mm (in.)
Differential side bearing end play 0.05T-0.10T (0.0019T-0.0039T)
Gear backlash in 1st~5th 0.02L-0.12L (0.00079L-0.0047L)
gear/reverse
Gear backlash in differential 0.09L-0.21L (0.0035L-0.0083L)
Input front bearing snap ring end play 0.01L-0.12L(0.00038L-0.0045L)
Input rear bearing snap ring end play 0.01L-0.12L(0.00038L-0.0045L)
Output front bearing snap ring end 0.01L-0.12L(0.00038L-0.0045L)
play
Output rear bearing snap ring end 0.01L-0.09L(0.00038L-0.00342L)
play
5TH input gear snap ring end play 0.01L-0.05L(0.00038L-0.0019L)
3RD output gear snap ring end play 0.01L-0.05L(0.00038L-0.0019L)
TIGHTENING TORQUE
Standard value N·m kg·cm lb·ft
Release bearing sleeve bolt 5-8 50-80 4-6
Release fork shaft level nut 27-40 270-400 20-29
Select lever 20-27 200-270 15-20
Oil drain plug 30-35 300-350 22-26
Poppet ball 35-42 350-420 26-31
Clutch housing to transmission case 35-42 350-420 26-31
Speedometer driven gear 4-6 40-60 3-4
Reverse idler bolt 43-55 430-550 32-40
Side cover bolt 10-12 100-120 7-8
Shift control cable bracket 20-27 200-270 15-20
Cylinder and hose assembly 15-22 150-220 11-16
Shift lever bracket 9-14 90-140 7-10
Front roll stopper bracket to subframe 60-80 600-800 43-58
bolts
Front roll stopper insulator bolt and nut 50-65 500-650 36-47
Front roll stopper bracket to transaxle 60-80 600-800 43-58
bolts
Rear roll stopper bracket to subframe 50-65 500-650 36-47
bolts
Rear roll stopper bracket to transaxle 60-80 600-800 43-58
bolts
Transaxle mounting sub bracket nut 60-80 600-800
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Transaxle mounting insulator bolt 90-110 900-1100 65-80
Front bearing retainer & detent body 15-22 150-220 10-16
cover bolt
loosening if under-tightened. In either case, serious personal injury or death could result to vehicle occupants.
LUBRICATIONS
Item Recommended sealants and adhesives Quantity
Transaxle gear oil lit. (U.S. qts., Imp.qts) SAE 75W/90 TGO-6 2.1 (2.2, 1.8)
Transaxle input shaft spline CASMOLY L9508 As required
Transaxle oil seal lip RETINAX AM, MOLYTEX GREASE As required
EP-2
Transaxle case and clutch housing alignment THREE BOND 1216 As required
surface
Transaxle case and rear cover alignment surface THREE BOND 1216 As required
Bearing retain bolt (flush bolt only) THREE BOND 1303 As required
Automatic Transaxle System > Automatic Transaxle System > Flow Diagram
AUTOMATIC TRANSAXLE HYDRAULIC CIRCUIT
PARKING NEUTRAL
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FIRST
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SECOND
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THIRD
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FOURTH
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REVERSE
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Automatic Transaxle System > Automatic Transaxle System > Description and Operation
ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER
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Operating Element and Their Functions

Operating element Code Function
Underdrive clutch UD Connects input shaft and underdrive sun gear
Reverse clutch REV Connects input shaft and reverse sun gear
Overdrive clutch OD Connects input shaft and overdrive planetary carrier
Low-and-reverse brake LR Locks low-and-reverse annulus gear and overdrive
planetary carrier
Second brake 2ND Locks reverse sun gear
Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Components and
Components Location
components
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Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Repair
procedures
REMOVAL
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1. Remove the drain plug and drain the automatic transaxle fluid.
2. Remove the air cleaner assembly.

3. Remove the control cable.
4. Disconnect the vehicle speed sensor connector.

5. Disconnect the transaxle range switch connector, solenoid connector and oil temperature sensor connector.
6. Remove the oil cooler hose.
7. Remove the oil cooler hose.

8. Remove the stabilizer bar, tie rod end, lower arm ball joint, drive shaft. (Refer to DRIVE SHIFT & FRONT
AXLE GROUP).
9. Remove the gear box u-joint bolt and the return tube mounting bolts.
10. Remove the subframe mounting bolts and the subframe.
11. Remove the starter motor.

12. Remove the automatic transaxle mounting bolts.
13. Remove the engine to automatic transaxle bolts.
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14. Remove the automatic transaxle assembly by jack.
1. Engine and transmission mounting insulators should be installed by the specified torque.
2. Mounting bracket installation procedures.
1. Engine mounting bracket.
2. T/M mounting bracket.
3. Rear roll stopper mounting bracket.
4. Front roll stopper mounting bracket.
3. Especially, when installing front roll stopper mounting bracket, be careful not to be crushed the
insulator, If being crushed, idle vibration is high.
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 side may be damaged.
Therefore, be sure to first assemble the torque converter to the transaxle.
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 cale.
(2) When connecting the control cable to the transaxle mounting bracket, instal 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.
1. Installation is the reverse of removal.
DISASSEMBLY
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1. Because the automatic transmission is manufactured from high-precision parts, sufficient care must be taken not
to scratch or damage these parts during disassembly and reassembly.
2. The working area should be convered with a rubber mat to keep it clean at all times.
3. Do not wear any cloth gloves and do not use any rags during disassembly. Use nylon cloth or paper towels if
you need to use something.
4. Parts which have been disassembled should all be cleaned. Metal parts can be cleaned with normal detergent
but they should be dried completely using compressed air.
5. Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF) so
that they do not become dirty.
6. If the transmission body has been damaged, disassemble and clean the cooler system also.
1. Remove the torque converter and set aside.
2. Measure the input shaft end play.
3. Remove the left and right roll stopper brackets.

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

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11. Remove the valve body cover.
12. Remove the manual control shaft detent.
13. Disconnect the harness connectors of the valve body.
To prevent damage to transaxle components make sure that the manual control lever and the park/neutral
switch have been removed before attempting to remove the valve body.
The valve body mounting bolts are different lengths. Note the locations of the bolts to aid in assembly.
14. Remove 28 of the valve body mounting bolts. Do not remove the bolts shown in the illustration at this time.
15. Remove the oil temperature sensor.

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16. Remove the valve body, gasket, and the 2 steel balls.
Make sure not to lose the 2 steel balls.
17. Remove the solenoid valve wiring harness snap ring.

18. Remove the solenoid valve harness.
19. Remove the strainer.

20. Remove the second brake retainer oil seal.
The second brake retainer oil seal must be removed before removing the transaxle powertrain
components from the case or damage to the seal will occur.
21. Remove the 4 accumulator pistons, the 4 large springs, and the 3 small springs.
Number Functional Name
1 Low-Reverse Brake
2 Underdrive Clutch
3 Second Brake
4 Overdrive Clutch
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22. Remove the manual control lever shaft pin (roller).
23. Remove the manual control lever shaft.
24. Remove the parking pawl rod.
25. Remove the torque converter housing and 18 mounting bolts. Tap the housing off with a non-metallic hammer.
26. Remove the 2 O-rings from the case.
27. Remove the differential.
28. Remove the main oil filter.

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

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36. Remove the underdrive clutch hub.
37. Remove the rear cover and mounting bolts.
38. Remove the thrust race #8.

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

44. Remove the overdrive clutch hub.

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46. Remove the planetary reverse sun gear.
47. Remove the second brake piston snap ring.
48. Remove the second brake piston and return spring.
49. Remove the second brake pressure plate, 3 brake discs, and 2 brake plates.
50. Remove the overdrive planetary carrier.

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52. Remove the output planetary carrier.

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

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

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

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

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76. Tap out the output shaft, tapered roller bearing, and the collar from the back side.
77. Tap out the bearing outer race and spacer using a suitable driver.

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

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

15. To determine the proper thickness of the second brake pressure plate.
Standard value : 0.79-1.25 mm (0.0311-0.0492 in.)
16. If the standard value is incorrect, select a pressure plate of the proper thickness from the chart in the service
manual and recheck the clearance.
In steps 18 through 21, you will determine the actual clearance between the low-reverse brake discs and
17. Install the special tool in place of the low/reverse brake pressure plate.
18. Install the 6 brake discs, 5 brake plates and snap ring.
19. Turn the transaxle upside down, install a dial indicator, as shown in the illustration.
20. Move the special tool up and down while observing the end play.
21. To determine the proper thickness of the low/reverse brake pressure plate.
22. If the standard value is incorrect, select a pressure plate of the proper thickness from the chart in the service
manual and recheck the clearance.
24. Install the output shaft.
25. Install the output bearing retainer mounting bolts. Tighten the bolts to 23 Nm (17 lbs·ft) of torque.
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26. Install the output shaft collar and tapered roller bearing using special tool (09455-33200).
The output shaft lock nut is left-hand thread.
27. Apply ATF and install the old lock nut and tighten to 167 Nm (123 lb·ft). Loosen the nut 1 full turn, then re-
tighten tospecifications. Do not stake the lock nut unless instructed to do so by the instructor.
28. Install a dial indicator as shown in the illustration.
29. Move the output shaft in and out to measure the end lay.
30. If the standard value is incorrect, use this formula to select the correct spacer from the chart in the service
manual.
31. Install the output shaft protective cap.
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32. Install the transfer drive gear using special tool (09500-11000).
33. Install the 7 transfer gear mounting bolts. Tighten the bolts to 19 Nm(14 lbs·ft).
34. Install the parking pawl, spacer and spring, then install the parking pawl shaft.
35. Install the parking roller support, then the two parking roller support shafts.
Be sure to install the thrust bearing in the proper direction.
36. Install the underdrive sun gear and thrust bearing #3 to the output planetary carrier.

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37. Install the output planetary carrier and thrust bearing #4.
38. Install the overdrive planetary carrier.
Rotating the output shaft will help align the clutch teeth and help the carrier
seat.
39. Install the reverse planetary sun gear.
40. Install the wave spring.
41. Install the low/reverse pressure plate, 6 brake discs, and 5 brake plates.
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42. Install the snap ring.
43. Install the reaction plate.
45. Install the second brake pressure plate, 3 brake discs, and 2 brake plates.
46. Install the return spring and second brake piston.

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Be sure to install the thrust bearing in the proper

direction.
48. Install thrust bearing #5.

direction.
49. Install the overdrive clutch hub and thrust bearing #6 to the reverse and overdrive clutch.
50. Install the reverse and overdrive clutch and thrust bearing #7.
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51. Install the three O-rings.
52. Install the 3 seal rings into the rear cover.
The cover should be clean and dry for step 56. It is only being installed to measure the underdrive sun
gear end play.
53. Install the used thrust race #8 and rear cover.

54. Using a dial indicator, measure the end play of the underdrive sun gear.
55. If the end play exceeds the standard value, measure the used race with a micrometer and select the proper size
from the chart in the service manual.
56. Reinstall the rear cover and mounting bolts. Tighten the mounting bolts to 23 Nm (17 lbs·ft).
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57. Install the underdrive clutch hub.

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

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61. Install the oil pump, a new gasket, and the oil pump mounting bolts.
62. Using a dial indicator, measure the end play of the input shaft.
63. If the end play exceeds the standard value, measure the used race with a micrometer and select the proper size
from the chart in the service manual.
64. Reinstall the oil pump and mounting bolts. Tighten the mounting bolts to 23 Nm (17 lbs·ft).
65. Install the oil internal filter.
66. Install the differential.

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67. Place two strips of solder, approximately 10 mm (0.39 in) long and 3 mm (0.12 in) thick, on the torque
converter housing.
68. Install the torque converter housing and mounting bolts. Tighten the bolts to 47 Nm (35 lbs·ft) of torque.
69. Remove the torque converter housing, the bolts and the solder.
70. Using a micrometer, measure the thickness of the pressed solder.
71. Select a spacer that will give the following clearance.
Standard value : 0.045 mm (0.0018 in.)-0.105 mm (0.0041 in.)
72. Install the differential spacer selected in the previous step in the torque converter housing.
73. Use special tools 09532-11500 and 09500-11000 to press in the differential bearing outer race.
74. Install the two O-rings.

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75. Install the torque converter housing and mounting bolts. Tighten the bolts to 47 Nm (35 lbs·ft) of torque.
76. Install the manual control lever shaft and parking pawl.
77. Install the manual control shaft roller.

78. Install the three small springs and three larger springs into the accumulator pistons. The accumulator springs are
identified in the illustration and in the chart below.
Number Function Name
1 Low-Reverse Brake
2 Underdrive Clutch
3 Second Brake
4 Overdrive Clutch
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79. Install the accumulators with the springs according to the illustration and the chart below. The accumulators
should be flush with the transaxle case.
Number Function Name Color
1 Low-Reverse Brake None
2 Underdrive Clutch Yellow
3 Second Brake Blue
4 Overdrive Clutch None
80. Install the strainer and the second brake retainer oil seal.
The oil seal orientation in the illustration.
81. Install the solenoid wiring harness, then install the snap ring in its groove.
82. Install the valve body, gasket, and two steel balls.
83. Install the oil temperature sensor. Tighten the mounting bolt to 11 Nm.
84. Install 28 valve body mounting bolts. Tighten all valve body mounting bolts to 11 Nm.
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85. Connect the solenoid wiring and temperature sensor connectors according to the illustration and the chart
below.
No. Part to be connected Wire color Connector housing color
1 Underdrive solenoid valve White, Red, Red Black
2 Overdrive solenoid valve Orange, Red Black
3 Low-Reverse solenoid Brown, Yellow Milky White
valve
4 Second solenoid valve Green, Red,Red Milky White
5 Damper clutch control Blue,Yellow,Yellow Black
solenoid valve
6 Oil temp. sensor Black,Red Black
86. Install the manual control shaft detent. Tighten the nut to 6 Nm (4.4 lb·ft) of torque.
87. Install the valve body cover and mounting bolts. Tighten the mounting bolts to 9 Nm of torque.
88. Install the vehicle speed sensor and mounting bolt. Tighten the mounting bolt to 5 Nm of torque.
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89. Install the park/neutral position switch. Tighten the mounting bolt to 11 Nm (8 lbs·ft) of torque.
90. Install the manual control lever. Tighten the mounting nut to 22 Nm (26 lbs·ft) of torque.
91. Install the input and output shaft speed sensors. Tighten the mounting bolts to 11 Nm of torque.
Make sure that you are installing the correct oil filter. While the engine oil filter and the transaxle oil filter
locksimilar, their filtering action is different. Installing the wrong oil filter could cause damage to the
transaxle. Transaxle oil filters are identified as A/T ONLY.
92. Install the cooler feed tube with a new gasket and the eye bolt. Tighten the eye bolt to 30 Nm (22 lbs·ft) of
torque.
93. Install the dipstick.

94. Install the control cable bracket. Tighten the mounting bolt to 23 Nm (17 lbs·ft).
95. Install the wiring harness bracket. Tighten the mounting bolt to 23 Nm (17 lbs·ft).
96. Install the two roll stopper brackets. Tighten the mounting bolts to 69 Nm (51 lbs·ft).
97. Install the torque convertor and secure it so that dimension A.
Meets the reference value.
Reference value : approx. 12.2 mm (0.480 in.)
Apply ATF to the oil pump drive hub before installing the torque converter. Be careful not to damage the
oil pump seal.
Automatic Transaxle System > Automatic Transaxle System > Troubleshooting

Troubleshooting
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BASIC INSPECTION ITEM ADJUSTMENT

AUTOMATIC TRANSMISSION FLUID CHECK
1. Drive the vehicle until the fluid temperature rises to the normal temperature (70-80°C).
2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, and
then move the selector lever to the N position.
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4. After wiping off any dirt around the oil level gauge, remove the oil level gauge and check the condition of the fluid.
If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from the
bushesand friction materials, a transmission overhaul may be necessary.
When new, automatic transmission fluid should be red. The red dye is added so the assembly plant can
identify it as transmission fluid and distinguish it from engine oil or antifreeze. The red dye, which is not an
indicator of fluid quality, is not permanent. As the vehicle is driven the transmission fluid will begin to lock
darker. The color may eventually appear light brown.
5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is lower than this, pour in
more fluid until the level reaches the HOT mark. Automatic transmission fluid : GENUINE DIAMOND ATF
SP-III
If the fluid level is low, the oil pump will draw in air along with the fluid, which will cause bubbles to form
inside the hydraulic circuit. This will in turn cause the hydraulic pressure to drop, which will result in late
shifting and slipping of the clutches and brakes.
If there is too much fluid, the gears can churn it up into foam and cause the same conditions that can occur
with low fluid levels.
In either case, air bubbles can cause overheating and oxidation of the fluid which can interfere with normal
valve, clutch, and brake operation. Foaming can also result in fluid escaping from the transmission vent, in
which case it may be mistaken for a leak.
6. Securely insert the oil level gauge.

7. The fluid should always be replaced when overhauling the transmission or after the vehicle has been driven under
severe conditions.The replacement procedures are given below.
AUTOMATIC TRANSMISSION FLUID REPLACEMENT
If you have a fluid changer, use this changer to replace the fluid. If you do not have a fluid changer, replace the fluid
by the following procedure.
1. Disconnect the hose which connects the transmission and the oil cooler (inside the radiator).
2. Start the engine and let the fluid drain out.
Running conditions : N range with engine idling.
The engine should be stopped within one minute after it is started.If the fluid has all drained out before then,
the engine should be stopped at that point.
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3. Remove the drain plug from the bottom of the transmission case to drain the fluid.
4. Install the drain plug via the gasket, and tighten it the specified torque.
Tightening torque : 32 Nm (24 lb·ft)
5. Pour the new fluid in through the oil filler tube.
Stop pouring if the full volume of fluid cannot be poured

in.
6. Repeat the procedure in step (2).
Check the old fluid for contamination. If it has been contaminated, repeat the steps (6) and
(7).
7. Pour the new fluid in through the oil filler tube.
8. Reconnect the hose which was disconnected in step (1) above, and firmly replace the oil level gauge.
9. Start the engine and run it at idle for 1-2 minutes.
10. Move the select lever through all positions, and then move it to the N position.
11. Drive the vehicle until the fluid temperature rises to the normal temperature (70-80°C), and then check the fluid
level again. The fluid level must be at the HOT Mark.
12. Firmly insert the oil level gauge into the oil filler tube.
TORQUE CONVERTER STALL TEST
This test measures the maximum engine speed when the selector lever is at the D or R position and the torque
converter stalls to test the operation of the torque converter, starter motor and one-way clutch operation and the
holding performance of the clutches and brakes in the transmission.
Do not let anybody stand in front of or behind the vehicle while this test is being carried out.
1. Check the automatic transmission fluid level and temperature and the engine coolant temperature.
A. Fluid level : At the HOT mark on the oil level gauge
B. Fluid temperature : 80-100°C
C. Engine coolant temperature : 80-100°C
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2. Check both rear wheels (left and right).
3. Pull the parking brake lever on, with the brake pedal fully depressed.
4. Start the engine.
5. Move the selector lever to the D position, fully depress the accelerator pedal and take a reading of the maximum
engine speed at this time.
• The throttle should not be left fully open for any more than eight seconds.
• If carrying out the stall test two or more times, move the selector lever to the N position and run the
engine at 1,000r/min to let the automatic tranmission fluid cool down before carrying out subsequent
tests.
Standard value -Stall speed : 2,100-2,900 r/min
6. Move the selector lever to the R position and carry out the same test again.
Standard value -Stall speed : 2,100-2,900 r/min
TORQUE CONVERTER STALL TEST JUDGEMENT RESULTS

1. Stall speed is too high in both D and R ranges
A. Low line pressure
B. Low and reverse brake slippage
2. Stall speed is too high in D range only
A. Underdrive clutch slippage
3. Stall speed is too high in R range only
A. Reverse clutch slippage
4. Stall speed too low in both D and R ranges
A. Malfunction of torque converter
B. Insufficient engine output
HYDRAULIC PRESSURE TEST
1. Warm up the engine until the automatic transmission fluid temperature is 80-100°C.
2. Jack up the vehicle so that the wheels are free to turn.
3. Connect the special tools oil pressure gauge to each pressure discharge port.
4. Measure the hydraulic pressure at each port under the conditions given in the standard hydraulic pressure table,
and check that the measured values are within the standard value ranges.
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5. If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test
diagnosis table.
STANDARD HYDRAULIC PRESSURE TEST

Measurement condition Standard hydraulic pressure kPa
Selector Shift Engine Under drive Reverse Overdrive Low and Second Torque
lever position speed clutch clutch clutch reverse brake converter
position (rpm) pressure pressure pressure brake pressure pressure
pressure
P - 2,500 - - - 260-340 - 220-360
R Reverse 2,500 - 1.270- - 1,270-1,770 - 500-700
1,770
N Neutral - - - - 260-340 - 220-360
D 1st gear 2,500 1,010- - - 1,010-1,050 - 500-700
1,050
2nd gear 2,500 1,010- - - - 1,010- 500-700
1,050 1,050
3rd gear 2,500 780-880 - 780-880 - - 450-650
4th gear 2,500 - - 780-880 - 780-880 450-650
HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE

Trouble symptom Probable cause
All hydraulic pressures are high Incorrect transmission control cable adjustment
Malfunction of the regulator valve
All hydraulic presures are low Incorrect transmission control cable adjustment
Malfunction of the oil pump
Clogged internal oil filter
Clogged external oil filter
Clogged oil cooler
Malfunction of the relief valve
Incorrect valve body installation
Hydraulic pressure is abnormal in "R" range Malfunction of the regulator valve
only
Clogged orifice
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Hydraulic pressure is abnormal in "3" or "4" Malfunction of the regulator valve
range only Clogged orifice
Malfunction of the overdrive solenoid valve
Malfuction of the overdrive pressure control valve
Malfunction of the switch valve
Clogged orifice
Only underdrive hydraulic pressure is Malfunction of the oil seal K
abnormal
Malfunction of the oil seal L
Malfunction of the oil seal M
Malfunction of the underdrive solenoid valve
Malfunction of the underdrive pressure control valve
Malfunction of check ball
Clogged orifice
Only reverse clutch hydraulic pressure is Malfunction of the oil seal A
abnormal Malfunction of the oil seal B
Malfunction of the oil seal C
Clogged orifice
Only low and reverse hydraulic pressure is Malfunction of the oil seal D
abnormal
Malfunction of the oil seal E
Malfunction of the oil seal F
Malfunction of the overdrive solenoid valve
Malfunction of the overdrive pressure control valve
Malfunction check ball
Clogged orifice
Only second hydraulic pressure is abnormal Malfunction of the oil seal I
Malfunction of the oil seal J
Malfunction of the low and reverse solenoid valve
Malfunction of the low and reverse pressure control valve
Malfunction of the switch valve
Malfunction of the fail safe valve A
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Clogged orifice
Only torque converter presure is abnormal Malfunction of the oil seal G
Pressure applied to non operating element
Malfunction of the oil seal H
Malfunction of the oil seal O
Malfunction of the second solenoid valve
Malfunction of the second pressure control valve
Malfunction of the fail safe valve B
Clogged orifice
Only torque converter presure is abnormal Malfunction of the oil cooler
Malfunction of the oil seal N
Malfunction of the damper clutch control solenoid valve
Malfunction of the damper clutch control valve
Malfunction of the torque converter pressure control valve
Clogged orifice
Pressure applied to non operating element Incorrect valve body installation
Incorrect transmission control cable adjustment
Malfunction of the manual valve
DIAGNOSIS FUNCTION
1. Connect HI-SCAN to the connector for diagnosis.
2. Read the output diagnostic trouble codes. Then follow the remedy procedures according to the "DIAGNOSTIC
TRUBLE CODE DESCRIPTION" on the following page.
• As many a maximum of 8 diagnostic trouble codes (in the sequence of occurrence) can be stored in the
Random Access Memory (RAM) incorporated within the control moduel.
• The same diagnostic trouble code can be stored as many as one time.
• If the number of stored diagnostic trouble codes or diagnostic trouble patterns exceeds 8, 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 canceled
when the battery is disconnected.
3. If the fail-safe system is activated and the transaxle is locked in third gear, the diagnostic trouble code in the fail-
safe code description will be stored in the RAM. Three of these diagnostic trouble codes can be stored.
4. The cancelation will occur if, with the transaxle locked in third gear, the ignition key is turned to the OFF position,
but the diagnostic trouble code is stored in the RAM.
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5. Memorization
A. Up to 8 diagnosis items and 3 fail-safe items can be memorized.
B. If the memory capacity is exceeded, diagnosis and fail-safe items in the memory are overwritten, starting with
the oldest.
C. No code can be memorized more than once.
6. Diagnosis Code Deletion.
A. Automatic Deletion
All diagnosis codes are deleted from memory the 200 th time the ATF temperature reaches 50°C after
memorization of the most recent diagnosis code.
B. Forced Deletion.
C. Memorized diagnosis codes can be deleted using the SCAN-TOOL provided the following conditions are
satisfied :
• The ignition switch is ON;
• There is no detection pulse from the crank angle sensor
• There is no detection pulse from the output shaft speed sensor
• There is no detection pulse from the vehicle speed sensor
• The fail-safe function is not operational
MIL REQUEST ITEM AND DIAGNOSIS CODE
OBD-II FAIL
No. FAIL CAUSE DTC *2 REMARK
DTC *1 MIL SAFE
1 OIL TEMPERATURE OPEN OR +B SHORT O 0713 -

SENSOR 0710
GND SHORT O 0712 -
2 INPUT SPEED (PG A) OPEN OR SHORT (GND,
0715 O 0715 O
+B)
3 OUTPUT SPEED (PG OPEN OR SHORT (GND,
0720 O 0720 O
B) +B)
4 BRAKE SW OPEN OR +B SHORT - - 0703 -
5 LR (DIR) SOLENOID OPEN OR GND SHORT 0750 O 0750 O
6 UD SOLENOID OPEN OR GND SHORT 0755 O 0755 O
7 2ND SOLENOID OPEN OR GND SHORT 0760 O 0760 O
8 OD SOLENOID OPEN OR GND SHORT 0765 O 0765 O
9 DCC SOLENOID OPEN OR GND SHORT 0740 O 0743 O
10 INHIBITOR SW OPEN OR GND SHORT O 0707 -
+B SHORT OR SHORT OF 0705
O 0708 -
SWITCHS
11 1st Control System abnormal 1st 0750
O 0731 O
0755
12 2nd Control System abnormal 2nd 0755
O 0732 O
0760
13 3rd Control System abnormal 3rd 0755
O 0733 O
0765
14 4th Control System abnormal 4th 0760
O 0734 O
0765
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15 Reverse Control System abnormal Reverse 0750 O 0736 O
16 DAMPER CLUTCH abnormal SYSTEM
0740 O 0740 -
OR STUCK ON
17 A/T CONTROL OPEN OR GND SHORT
1723 O 1723 O
RELAY
18 CAN-BUS OFF TCU FAIL OR TCU SIDE
- *3- 1630 -
OPEN/SHORT
19 CAN-TIME OUT ECU ECU FAIL OR ECU SIDE
- O 1631 -
OPEN/SHORT
20 TCU CAN MI-COM CAN MI-COM CIRCUIT
- *3- 1764 -
MALFUNCTION
21 Vehicle Speed Sensor OPEN OR SHORT (GND,
0500 O 0500 -
+B)
*1) : TCU transfers only the DTCs related OBD-II to GST through TEST MODE 03.
*2) : TCU transfers all stored DTCs through TEST MODE 13.
*3) : When the CAN communication line is error, CAN ECU illuminates CHECK ENG LAMP.
INSPECTION CHART FOR DIAGNOSIS CODES
Code Diagnosis item Probable cause
P0713 Oil temperature sensor system Open Malfunction of the oil temperature sensor
P0712 If the oil temperature sensor output voltage is circuit Malfunction of connector
4.57 V or more even after driving for 10 Malfunction of the TCM
minutes or more (if the oil temperature does not
increase), it is judged that there is an open
circuit in the oil temperature sensor and
diagnosis code P0713 is output.
P0715 Input shaft speed sensor system Short Malfunction of the input shaft speed sensor
If no output pulse is detected from the input circuit / Malfunction of the underdrive clutch
shaft speed sensor for 1 second or more while Open retainer Malfunction of connector
driving in 3rd or 4th gear at a speed of 30 km/h circuit Malfunction of the TCM
or more, there is judged to be an open circuit or
short. Circuit in the input shaft speed sensor and
diagnosis code P0715 is output. If diagnosis
code P0715 is output four times, the
transmission is locked into 3rd gear (D range or
3-range) or 2nd gear (2-range or L-range) as a
fail-safe measure, and the N range lamp flashes
at a frequency of 1 Hz.
P0720 Output shaft speed sensor system Short Malfunction of the wide open throttle switch
If the output from the output shaft speed sensor circuit Malfunction of connector
is continuously 50% lower than the vehicle /Open Malfunction of the TCM
speed for 1 second or more while driving in 3rd circuit Malfunction of solenoid valve
or 4th gear at a speed of 30 km/h or more, Malfunction of connector
there is judged to be an open circuit or short- Malfunction of the TCM
circuit in the output shaft speed sensor and
diagnosis code P0720 is output. If diagnosis
code P0720 is output four times, the
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transmission is locked into 3rd gear (D range or
3-range) or 2nd gear (2-range or L-range) as a
fail-safe measure, and the N range lamp flashes
at a frequency of 1 Hz.
P1703 Stop lamp switch system Short Malfunction of the stop lamp switch
If the stop lamp switch is on for 5 minutes or circuit / Malfunction of connector
more while driving, it is judged that there is a Open Malfunction of the TCM
short circuit in the stop lamp switch and circuit
diagnosis code P0703 is output.
P0750 Low and reverse solenoid valve system Short Malfunction of solenoid valve
circuit Malfunction of connector
/Open Malfunction of the TCM
circuit
P0755 Underdrive solenoid valve system Short
circuit
/Open
circuit
P0760 Second solenoid valve system Short
circuit
/Open
circuit
P0765 Overdrive solenoid valve system Short
If the resistance value for a solenoid valve is tool circuit
large or too small, it is judged that there is a /Open
short-circuit or an open circuit in the solenoid circuit
valve and the respective diagnosis code is
output. The transmission is locked into 3rd gear
as a fail-safe measure, and the N range lamp
flashes at a frequency of 1 Hz.
P0743 Damper clutch solenoid valve system Short Malfunction of the damper clutch control
circuit/ solenoid valve
Open Malfunction of connector
circuit Malfunction of the TCM
P0740 Damper clutch solenoid valve system Defective
If the resistance value for the damper clutch system
control solenoid valve is too small, it is judged
that there is a short circuit or an open circuit in
the damper clutch control solenoid valve and
diagnosis code P0743 in output. If the drive
duty rate for the damper clutch control solenoid
valve is 100% for a continuous period of 4
seconds or more, it is judged that there is an
abnormality in the damper clutch control system
and diagnosis code P0740 is output. When
diagnosis code P0743 is output, the
transmission is locked into 3rd gear as a fail-safe
measure, and the N range lamp flashes at a
frequency of 1 Hz.
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P0731 2nd gear ratio does not meet the specification Malfunction of the input shaft speed sensor
If the output from the output shaft speed sensor multiplied by Malfunction of the output shaft speed
the 3rd gear ratio is not the same as the output from the input sensor
shaft speed sensor after shifting to 3rd gear has been Malfunction of the underdrive clutch
completed, diagnosis code P0732 is output. If diagnosis retainer
code P0732 is output four times, the transmission is locked Malfunction of the transfer drive gear or
into 3rd gear as a fail-safe measure, and the N range lamp driven gear
flashes at a frequency of 1 Hz. Malfunction of the low ad reverse brake
system
Malfunction of the underdrive clutch system
Noise generated
P0732 2nd gear ratio does not meet the specification Malfunction of the input shaft speed sensor
flashes at a frequency of 1 Hz. Mlfunction of the underdrive clutch system
Malfunction of the overdrive clutch system
Noise generated
P0733 3rd gear ratio does not meet the specification Malfunction of the input shaft speed sensor
flashes at a frequency of 1 Hz. Malfunction of the underdrive clutch system
Noise generated
P0734 4th gear ratio does not meet the specification Malfunction of the input shaft speed sensor
the 4th gear ratio is not the same as the output from the input sensor
shaft speed sensor after shifting to 4th gear has been Malfunction of the underdrive clutch
flashes at a frequency of 1 Hz. malfunction of the second brake system
Noise generated
P0736 Reverse gear ratio does not meet the specification Malfunction of the input shaft speed sensor
the reverse gear ratio is not the same as the output from the sensor
input shaft speed sensor after shifting to reverse gear has Malfunction of the underdrive clutch
been completed, diagnosis code P0736 is output. If retainer
diagnosis code P0736 is output four times, the transmission Malfunction of the transfer drive gear or
is locked into 3rd gear as a fail-safe measure, and the n driven gear
range lamp flashes at a frequency of 1 Hz. Malfunction of the low and reverse brake
Page 62 of 122
system
Malfunction of the reverse clutch system
Noise generated
P1723 A/T control relay system Short Malfunction of the A/T control relay
If the A/T control relay voltage is less than 7 V circuit to Malfunction of connector
after the ignition switch has been turned ON, it earth/Open Malfunction of the TCM
is judged that there is an open circuit or a short- circuit
circuit in the A/T control relay earth and iagnosis
code P1723 is output. Then the transmission is
locked into 3rd gar as a fail-safe measure, and
the N range lamp flashes at a frequency of 1 Hz.
P0707 Transaxle range switch Malfunction of transaxle range switch
P0708 No signal is continuous for > 30 seconds
Above 2 kinds signals are continuous for > 30 second
P1630 CAN-BUS OFF • TCM Fail
• NO 3 SPEED HOLD FAIL • TCM side open and short
• NO PGA, B FAIL * PGA : Input shaft speed sensor
• BATTRY VOLTAGE > 10V CONTINUOUSLY FOR PGB : Output shaft speed sensor
0.5 SECOND
• NO ENGINE STOP
• RECEIVE BUS OFF INFORMATION FROM CAN
CONTROLLER
P1631 CAN-TIME OUT ECM • ECM fail
• No 3 speed hold fail • ECM side open and short
• No PGA, B fail
• Battry voltage > 10V continuously for 0.5 second
• No engine stop
• No output signal for 1.5 second
• Receive BUS OFF information from CAN
CONTROLLER
P1764 TCM CAN CONTROLLER MALFUNCTION • CAN CONTROLLER circuit
• No 3 speed hold fail malfunction
• No PGA, B fail
• Battry voltage > 10V continuously for 0.5 second
• No engine stop
• Communication error output is continuously for > 1
second
INSPECTION CHART FOR THROUBLE SYMPTOMS

Trouble symptom Probable cause
Communication with HI-SCAN is not possible Malfunction diagnosis line
If communication with the HI-SCAN is not possible, the cause is Malfunction of connector
probably a defective diagnosis line or the TCM is not functioning. Malfunction of the TCM
Driving impossible Starting impossible Malfunction of the engine system
Starting is not possible when the selector lever is in Malfunction of the torque converter
P or N range. Malfunction of the oil pump
Page 63 of 122
In such cases, the cause is probably a defective
engine system, torque converter or oil pump.
Does not move forward Abnormal line pressure
If the vehicle does not move forward when the Malfunction of the underdrive solenoid
selector lever is shifted from N to D,3,2 or L valve
range while the engine is idling, the cause is Malfunction of the underdrive clutch
probably abnormal line pressure or a malfunction Malfunction of the valve body
of the underdrive clutch or valve body.
Does not reverse Abnormal reverse clutch pressure
If the vehicle does not reverse when the selector Abnormal low and reverse brake
lever is shifted from N to R range while the engine pressure
is idling, the cause is probably abnormal pressure Malfunction of the low and reverse
in the reverse clutch or low and reverse brake or a brake solenoid valve
malfunction of the reverse clutch, low and reverse Malfunction of the reverse clutch
brake or valve body. Malfunction of the low and reverse
brake
Malfunction of the valve body
Does not move (forward or reverse) Abnormal line pressure
If the vehicle does not move forward or reverse Malfunction of power train
when the selector lever is shifted to any position Malfunction of the oil pump
while the engine is idling, the cause is probably Malfunction of the valve body
abnormal line pressure or a malfunction of the
power train, oil pump or valve body.
Malfunction when Engine stalling when shifting Malfunction of the engine system
starting If the engine stalls when the selector lever is shifted Malfunction of the damper clutch
from N to D or R range while the engine is idling, control solenoid valve
the cause is probably a malfunction of the engine Malfunction of the valve body
system, damper clutch solenoid valve, valve body Malfunction of the torque converter
or torque converter (damper clutch malfunction). (Malfunction of the damper clutch)
Shocks when changing from N to D and large Abnormal underdrive clutch pressure
time lag Abnormal low and reverse brake
If abnormal shocks or a time lag of 2 seconds or pressure
more occur when the selector lever is shifted from Malfunction of the underdrive solenoid
N to D range while the engine is idling, the cause is valve
probably abnormal underdrive clutch pressure or a Malfunction of the valve body
malfunction of the underdrive clutch, valve body or Malfunction of the idle position switch
idle position switch.
Shocks when changing from N to R and large Abnormal reverse clutch pressure
time lag Abnormal low and reverse brake
If abnormal shocks or a time lag of 2 seconds or pressure
more occur when the selector lever is shifted from Malfunction of the low and reverse
N to R range while the engine is idling, the cause is solenoid valve
probably abnormal reverse clutch pressure or low Malfunction of the reverse clutch
and reverse brake pressure, or a malfunction of Malfunction of the low and reverse
the reverse clutch, low and reverse brake, valve brake
body or idle position switch. Malfunction of the valve body
Malfunction of the idle position switch
Shocks when changing from N to D, N to R Abnormal line pressure
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and large time lag Malfunction of the oil pump
If abnormal shocks or a time lag of 2 seconds or Malfunction of the valve body
more occur when the selector lever is shifted from
N to D range and from N to R range while the
engine is idling, the cause is probably abnormal line
pressure or a malfunction of the oil pump or valve
body.
Malfunction when Shocks and running up Abnormal line pressure
shifting If shocks occur when driving due to upshifting or Malfunction of each solenoid valve
downshifting and the transmission speed becomes Malfunction of the oil pump
higher than the engine speed, the cause is probably
abnormal line pressure or a malfunction of a
solenoid valve, oil pump, valve body or of a brake
or clutch.
Displaced shifting All points Malfunction of the valve body
points If all shift points are displaced while driving, the Malfunction of each brake or each
cause is probably a malfunction of the output shaft clutch
speed sensor, TPS or of a solenoid valve. Malfunction of the output shaft speed
sensor
Malfunction of the throttle position
sensor
Malfunction of each solenoid valve
Abnormal line pressure
Malfunction of the valve body
Malfunction of the TCM
Some points Malfunction of the valve body
If some of the shift points are displaced while
driving, the cause is probably a malfunction of the
valve body, or it is related to control and is not an
abnormality.
Does not shift No diagnosis codes Malfunction of the transaxle range
If shifting does not occur while driving and no Malfunction of the TCM
diagnosis codes are output, the cause is probably
a malfunction of the transaxle range switch, or
TCM
Malfunction while Poor a acceleration Malfunction of the engine system
driving If acceleration is poor even if downshifting occurs Malfunction of the brake of clutch
while driving, the cause is probably a malfunction
of the engine system or of a brake or clutch.
Vibration Abnormal damper clutch pressure
If vibration occur when driving at constant speed Malfunction of the engine system
or when accelerating and deceleration in top Malfunction of the damper clutch
range, the cause is probably abnormal damper control solenoid valve
clutch pressure or a malfunction of the engine Malfunction of the torque converter
system, damper clutch control solenoid valve, Malfunction of the valve body
torque converter or valve body.
Transaxle range switch system Malfunction of the transaxle range
The cause is probably a malfunction of the inhibitor switch circuit, ignition switch
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switch circuit or a defective TCM. Malfunction of the ignition switch
Malfunction of connector
Vehicle speed sensor system Malfunction of the vehicle speed
The cause is probably a defective vehicle speed sensor circuit or a sensor
defective TCM. Malfunction of connector
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1
Communication with the scan tool Probable cause
If communication with the scan tool is not possible, the • Malfunction of diagnostic trouble line
cause is probably a defective diagnostic trouble line or • Malfunction of connector
the TCM is not functioning. • Malfunction of the TCM
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Starting impossible Probable cause
Starting is not possible when the selector lever is in P or • Malfunction of the engine system
N range. In such cases, the cause is probably a • Malfunction of the torque converter
defective engine system, torque converter or oil pump. • Malfunction of the oil pump
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Does not move Probable cause
If the vehicle does not move forward when the selector • Abnormal line pressure
lever is shifted from N to D,3,2 or L range while the • Malfunction of the underdrive solenoid valve
engine is idling, the cause is probably abnormal line • Malfunction of the underdrive clutch
pressure or a malfunction of the underdrive clutch or • Malfunction of the valve body
valve body.
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Does not reverse Probable cause
If the vehicle does not reverse when the selector lever is • Abnormal reverse clutch pressure
shifted from N to R range while the engine is idling, the • Abnormal low and reverse brake pressure
cause is probably abnormal pressure in the reverse • Malfunction of the low and reverse solenoid valve
clutch or low and reverse brake or a malfunction of the • Malfunction of the reverse clutch
reverse clutch, low and reverse brake or valve body.
• Malfunction of the low and reverse brake
• Malfunction of the valve body
Does not move (forward or reverse) Probable cause
If the vehicle does not move forward or reverse when • Abnormal line pressure
the selector lever is shifted to any position while the • Malfunction of the underdrive solenoid valve
engine is idling, the cause is probably abnormal line • Malfunction of the underdrive clutch
pressure, or a malfunction of the power train, oil pump • Malfunction of the valve body
or valve body.
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Engine stalling when shifting Probable cause
If the engine stalls when the selector lever is shifted from • Malfunction of the engine system
N to D or R range while the engine is idling, the cause is • Malfunction of the damper clutch solenoid
probably a malfunction of the engine system, damper • Malfunction of the valve body
clutch solenoid, valve body or torque converter (damper • Malfunction of the torque converter
clutch malfunction) (Malfunction of the damper clutch)
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Shocks when changing from N to D and range time lag Probable cause
If abnormal shocks or a time lag of 2 second or more • Abnormal line pressure
occur when the selector lever is shifted from N to D • Malfunction of the underdrive solenoid valve
range while the engine is idling, the cause is probably • Malfunction of the underdrive clutch
abnormal underdrive clutch pressure or a malfunction of • Malfunction of the valve body
the underdrive clutch, valve body or closed throttle
• Malfunction of the closed throttle position switch
position switch.
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Shock when changing from N to R and large time lag Probable cause
If abnormal shocks or a time lag of 2 seconds or more • Abnormal reverse clutch pressure
occurs when the selector lever is shifted from N to R • Abnormal low and reverse brake pressure
range while the engine is idling, the cause is probably • Malfunction of the low and reverse solenoid valve
abnormal reverse clutch pressure or low and reverse • Malfunction of the reverse clutch
brake pressure, or a malfunction or the reverse clutch,
low and reverse brake, valve body or closed throttle
position switch.
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Shocks when changine from N to R and large time lag Probable cause
If abnormal shocks or a time lag of 2 seconds or more • Abnormal reverse clutch pressure
occurs when the selector lever is shifted from N to R • Abnormal low and reverse brake pressure
range while the engine is idling, the cause is probably • Malfunction of the low and reverse solenoid valve
abnormal reverse clutch pressure or low and reverse • Malfunction of the reverse clutch
brake pressure, or a malfunction of the reverse clutch,
low and reverse brake, valve body or closed throttle
position switch.
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Shocks and running up Probable cause
If shocks occur when driving due to upshifting or • Abnormal line pressure
downshifting and the transaxle speed becomes higher • Malfunction of each solenoid valve
than the engine speed, the cause is probably abnormal • Malfunction of the oil pump
line pressure or a malfunction of a solenoid valve, oil • Malfunctio of the valve body
pump, valve body or of a brake or clutch.
• Malfunction of each brake or each clutch
All points (Displaced shifting points) Probable cause
If all shift points are displaced while driving, the cause is • Malfunction of the output shaft speed sensor
probably a malfunction of the output shaft speed sensor, • Malfunction of the throttle position sensor
TPS or of a solenoid valve. • Malfunction of each solenoid valve
• Abnormal line pressure
• Malfunction of the TCM
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Some points (Displaced shifting points) Probable cause
If some of the shift points are displaced while driving, the • Malfunction of the valve body
cause is probably a malfunction of the valve body, or it
is related to control and is not an abnormality.
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No diagnostic trouble codes (Does not shift) Probable cause
If shifting does not occur while driving and no diagnostic • Malfunction of the Park/Neutral position switch
trouble codes are output, the cause is probably a • Malfunction of the TCM
malfunction of the Park/Neutral position switch, or
TCM.
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Poor acceleration Probable cause
If acceleration is poor even if downshifting occurs while • Malfunction of the engine system
driving, the cause is probably a malfunction of the engine • Malfunction of the brake or clutch
system or of a brake or clutch.
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Vibration Probable cause
If vibration occurs when driving at constant speed or • Abnormal damper clutch pressure
when accelerating in top range, the cause is probably • Malfunction of the engine system
abnormal damper clutch pressure or a malfunction of the • Malfunction of the damper clutch solenoid
engine system, damper clutch solenoid, torque converter • Malfunction of the torque converter
or valve body.
BRAKE REACTIONPLATE END PLAY ADJUSTMENT

Replace the pressure plate of the low-reverse brake with the special tool, and then install the brake disc, brake plate
and snap ring as shown in the figure.Install the reaction plate and the used snap ring. Move the special tool to
measure the end play, and then replace the snap ring to adjust the end play to standard value.
Standard value : 0 - 0.16 mm
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SECOND BRAKE END PLAY ADJUSTMENT

Replace the pressure plate of the second brake with the special tool, and then install the brake disc and brake plate
as shown in the figure. Install the return spring, second brake piston and snap ring.
Standard value : 0.79 - 1.25 mm
LOW-REVERSE BRAKE END PLAY ADJUSTMENT

Reverse the transmission. Measure the axial play.
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IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS

O.D. I.D. Thickness Symbol O.D. I.D. Thickness Symbol
59 47 1.8 #1 48.9 37 1.6 #8
59 47 2.0 #1 48.9 37 1.7 #8
59 47 2.2 #1 48.9 37 1.8 #8
59 47 2.4 #1 48.9 37 1.9 #8
59 47 2.6 #1 48.9 37 2.0 #8
59 47 2.8 #1 48.9 37 2.1 #8
49 34 3.6 #2 48.9 37 2.2 #8
49 34 3.6 #3 48.9 37 2.3 #8
46 31 3.3 #4 48.9 37 2.4 #8
49 34 3.6 #5 48.9 37 2.5 #8
49 34 3.6 #6 48.9 37 2.6 #8
59 37 2.8 #7 - - - -
UNDERDRIVE SUN GEAR END PLAY ADJUSTMENT

Install the used thrust race #8, and then the rear cover. Measure end play of the underdrive sun gear. Replace thrust
race #8 to adjust the play to the standard value.
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Installing the underdrive clutch hub makes it easy to measure the end play of the underdrive sun gear.
DIFFERENTIAL CASE PRELOAD ADJUSTMENT
Place a solder (approx. 10 mm in length, 3 mm in diameter) on the torque converter housing as shown in the figure.
Install the torque converter housing to the transmission case without applying sealant. Tighten its mounting bolts to
the specified torque. Loosen the bolts, and remove the solder. use a micrometer to measure the thickness (T) of the
pressed solder. Select a-spare which thickness is within the following value.
Standard value : (T+0.045 mm) to (T+0.105 mm)
Automatic Transaxle System > Hydraulic System > Oil Pump > Components and Components Location
components
Page 81 of 122
Automatic Transaxle System > Hydraulic System > Oil Pump > Repair procedures
REASSEMBLY
Oil seal replacement
1. Using the special tool (09452-21200), install the oil seal to the pump housing.
2. Apply a thin coat of automatic transaxle fluid to the lip of the oil seal before installation.
Automatic Transaxle System > Valve Body System > Valve Body > Components and Components
Location
components
Page 82 of 122
INSIDE VALVE BODY

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OUTSIDE VALVE BODY

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UNDERDRIVE CLUTCH AND INPUT SHAFT

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Automatic Transaxle System > Valve Body System > Valve Body > Repair procedures
DISASSEMBLY
1. Remove the input shaft snap ring.
2. Remove the input shaft.
4. Remove the clutch reaction plate snap ring.
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5. Remove the clutch reaction plate.
6. Remove the 4 clutch discs and 4 clutch plates.
7. Compress the clutch return springs using special tools, 09453-24000 and 09453-21000 then remove the clutch
spring retainer snap ring.
8. Remove the clutch spring retainer.

9. Remove the D-ring seal.
10. Remove the clutch return spring.
11. Remove the underdrive clutch piston using compressed air.
12. Remove the 2 D-ring seals.
REASSEMBLY
1. Install the 2 D-ring seals.
2. Install the underdrive clutch piston.
3. Install the clutch return spring.
4. Install the D-ring seal.

5. Install the clutch spring retainer.
6. Compress the clutch return springs using special tools, 09453-21100 and 09453-21000, then install the clutch
Dip each clutch disc in ATF before assembling.

Page 87 of 122
7. Align the spaces between the teeth (A) on the clutch plates, clutch discs, and reaction plate to the outer
circumference hole (B) in the underdrive clutch retainer.
8. Install the 4 clutch discs and the 4 clutch plates.

9. Install the clutch reaction plate with the shear droop toward the clutch disc.
10. Install the clutch reaction plate snap ring.
11. Install special tools, MD998924 and MB991628, as shown, then check the clearance between the snap ring
and the reaction plate using a feeler gauge.
Standard value :
1.25-1.45 mm (0.0492-0.0571 in.)
12. If the clearance is correct, measure the old snap ring, then select the correct size from the chart in the service
manual.
13. Install the seal rings.
14. Install the input shaft.
15. Install the input shaft snap ring.
Automatic Transaxle System > Clutch & Brake > Reverse and Overdrive Clutch > Components and
Components Location
components
Page 88 of 122
Automatic Transaxle System > Clutch & Brake > Reverse and Overdrive Clutch > Repair procedures
DISASSEMBLY
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1. Remove the overdrive clutch reaction plate snap ring.
2. Remove the overdrive clutch reaction plate.

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

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

5. Install the overdrive clutch piston.
6. Install the clutch return spring.
8. Install the clutch spring retainer.
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9. Compress the clutch return springs using special tools, 09453-21000 then install the clutch spring retainer snap
ring.
10. Check the clearance between the snap ring and the return spring retainer
Standard value : 0-0.09 mm (0-0.0035 in.)
11. If the clearance is incorrect, measure the old snap ring, then select the correct size from the chart in the service
manual.
circumference hole (B) in the reverse clutch retainer.
13. Install the 4 reverse clutch discs and 4 plates.

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

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

20. Install the overdrive clutch reaction plate.
21. Install the overdrive clutch reaction plate snap ring.
22. Check the clearance between the snap ring and the clutch reaction plate.
Standard value :
1.5-1.7 mm (0.0590-0.0670 in.)
manual.
Automatic Transaxle System > Gear System > Input Shaft > Components and Components Location
COMPONENTS
Page 92 of 122
Automatic Transaxle System > Gear System > Input Shaft > Repair procedures
DISASSEMBLY
1. Remove the snap ring and the ball bearing using the special tool (09432-21300).
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2. Remove the stopper snap ring, snap ring, 5th and 4th speed gear, needle roller bearing, 4th speed gear sleeve,
synchronizer ring (3rd & 4th), synchronizer spring (1st, 2nd, 3rd, 4th), synchronizer sleeve (3rd & 4th), 3rd
speed gear and needle roller bearing.
INSPECTION
INPUT SHAFT
1. Check the outer surface of the input shaft where the needle bearing is mounting for damage or abnormal wear.
2. Check the splines for damage or wear.

SYNCHRONIZER SLEEVE AND HUB
1. Install the synchronizer sleeve on the hub and check that it slides smoothly.
2. Check that the sleeve is free from damage.

3. Check for wear of the hub end surfaces (in contact with each gear).
Replace the synchronizer hub and sleeve as a set.
REASSEMBLY
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1. Install the needle roller bearing, 3rd speed gear, synchronizer sleeve (3rd & 4th), synchronizer spring (1st, 2nd,
3rd, 4th), synchronizer ring (3rd & 4th), 4th speed gear sleeve, needle roller bearing, 5th and 4th speed gar, snap
ring and the stopper snap ring using the special tool (09432-33300).
2. Install the snap ring and the ball bearing using special tool (09432-33300).
Automatic Transaxle System > Gear System > Transfer Drive Gear > Components and Components
Location
components
Page 95 of 122
Automatic Transaxle System > Gear System > Transfer Drive Gear > Repair procedures
DISASSEMBLY
1. Loosen the lock nut caulking.
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2. Remove the lock by using socket.
Reassembly
1. Apply ATF to the new lock nut and tighten to the specified torque. And loosen 1 turn and tighten to the specified
torque again.
2. Caulk the lock nut by using punch.
Automatic Transaxle System > Gear System > Output Shaft > Components and Components Location
components
Page 97 of 122
COMPONENTS
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Automatic Transaxle System > Gear System > Output Shaft > Repair procedures
REASSEMBLY
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1. Remove the transfer driven gear by press.
2. Remove the taper roller bearing.
DISASSEMBLY
1. Remove the taper bearing and the reverse gear using the special tool (03495-33000).
2. Remove the synchronizer ring, synchronizer spring (5th & Rev), sleeve (5th & Rev).
3. Remove the synchronizer hub and the 5th gear using the special tool (03495-33000).
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4. Remove the 4th, 3rd, 2nd, 1st gear all together the special tool (09432-33200).
INSPECTION
OUTPUT SHAFT
1. Check the outer surface of where the needle bearing is mounted for damage or abnormal wear.
2. Check the splines for damage or wear.

NEEDLE BEARING
1. Install the needle bearing on the shaft with the bearing sleeve and gear. Check that it rotates smoothly without
abnormal noise or play.
2. Check the needle bearing cage for distortion.

SYNCHRONIZER RING
1. Check the clutch gear teeth for damage.
2. Check internal surface for damage, wear or broken grooves.
SYNCHRONIZER SLEEVE AND HUB

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1. Install the synchronizer sleeve on the hub and check that it slides smoothly.
2. Check that the sleeve is free from damage.

3. Check for wear of the hub end surfaces (in contact with each gear).
Replace the synchronizer hub and sleeve as a set.

GEARS
1. Check the helical gear and clutch gear teeth for damage or wear.
2. Check the gear cone for rough surfaces, damage or wear.

3. Check the gear bore for damage or wear.
REASSEMBLY
1. Install the needle roller bearing.
2. Install the 1st speed gear.

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3. Install the triple cone assembly.
4. Install the synchronizer sleeve and hub.
5. Install the triple cone assembly.
6. Install the 2nd speed sleeve and the needle roller bearing.
7. Install the 2nd and 3rd speed gear with all together above mentioned using the special tool (09432-22000).
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9. Install the 4th speed gear, the 5th speed gear sleeve, the needle roller bearing, the 5th speed gear, the
synchronizer ring (5th), the synchronizer hub and the sleeve (5 & R).
10. Install the needle roller bearing, the reverse gear assembly and the reverse driven gear sleeve.
11. Install the taper bearing with all together above mentioned using the special tool (09432-22000).
Automatic Transaxle System > Automatic Transaxle Control System > Components and Components
Location
component
Page 104 of 122
Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Repair
procedures
INSTALLATION
PROCEDURE TO INSTALL THE LOCK CAM
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1. Move A/T lever to "P" position to set the key lock cam and the shift lock cam as shown in the figure.
A. Check that the key lock cam is located at "B" by the detent pin.
B. Check that the shift lock cam is located at "A".
2. Check that the key cylinder is at "LOCK".
PROCEDURE FOR ADJUSTING SHIFT LOCK AND KEY LOCK CABLE

1. Check that each lock cam is as shown in the figure.
2. Install the shift lock and key lock cable in position. In this case, the shift lock cable must be fixed to the brake
pedal and the key lock cable must be fixed to the key cylinder.
3. Temporarily install each cable to the A/T lever assembly as shown in the figure. Securely insert the cable end into
the fixing pin of each cam.
4. Slightly pull the shift lock cable in the direction "E".

5. After checking that the portion of the cable end touches the cable fixing pin, fix with the self-tapping bolt.
6. Slightly push the key lock cam to direction "Q".
7. Slightly pull the key lock cable in the direction "G" to stretch the cable. Then fix the cable with the self-tapping
bolt.
8. Check that the key lock and the shift lock cable are secure.
PROCEDURE FOR CHECKING THE SHIFT LOCK
1. When the brake pedal is not depressed, the push button of the shift lever at "P" position must not be operable.
(Shift lever cannot be shifted at the other positions from "P")
2. When the brake pedal stroke is 15-22 mm (with shift lever at "P" postition), the push should be operable without
catching and the shift lever should be shift smoothly to other postitions.
3. When the brake pedal is not depressed, the shift lever should shift smoothly to "P" position from all heading other
positions.
4. The brake pedal must operate smoothly without catching.
5. When the ignition key is at the "LOCK" position, although brake pedal is depressed, the push button should be
operable.
6. The lgnition key must not be able to the turned to the "LOCK" position except in the "P" position.
7. If the shift lever is shifted to the "P" position, the ignition key must turn to the "LOCK" position smoothly.
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Inspection
• Check the detent place for wear.
• Check the bushing for wear or damage.
• Check the spring for damage or deterioration.
• Check the pin at the end of the rod assembly for wear.
Automatic Transaxle System > Automatic Transaxle Control System > Troubleshooting
TRANSAXLE RANGE SWITCH CONTINUITY
SPORTS MODE SWITCH INSPECTION (FAA42-2 & 2.7D)

Inspection
Page 107 of 122
CHECK TRANSAXLE RANGE SWITCH AND CONTROL CABLE ADJUSTMENT

1. Set the selector lever to the "N" position.
2. Loosen the control cable to manual control lever coupling nut to free the cable and lever.
3. Set the manual control lever to the neutral position.
4. Loosen the transaxle range switch body mounting bolts and then turn the transaxle range switch body so the hole
in the end of the manual control lever and the hole (cross section A-A in the figure) in the flange of the transaxle
range switch body flange are aligned.
5. Tighten the transaxle range switch body mounting bolts to the specified torque. Be careful at this time that the
position of the switch body is not changed.
Page 108 of 122
6. Gently push the transmission control cable in the direction of the arrow, and then tighten the adjusting nut.
7. Check that the selector lever is in the "N" position.

8. Check that each range on the transmission side operates and functions correctly for each position of the selector
lever.
A/T CONTROL COMPONENT CHECK
1. THROTTLE POSITION SENSOR CHECK.
(1) Disconnect the throttle position sensor connector.
(2) Measure the resistance between the throttle position sensor side connector terminal 2 and terminal 3.
Standard value : 1.6-2.4 kW
(3) Measure the resistance between the throttle position sensor side connector terminal 1 and terminal 3.
Normal condition :
Throttle valve slowly open until fully open from the Changes smoothly in proportion to the opening angle
idle position of the throttle valve
(4) If the resistance is outside the standard value, or if it doesn't change smoothly, replace the throttle position
sensor.
2. OIL TEMPERATURE SENSOR CHECK
(1) Remove the oil temperature sensor.
(2) Measure the resistance between terminals No.1 and No.2 of the oil temperature sensor connector.
Oil temperature(°C) Resistance(KΩ)

0 16.7-20.5
100 0.57-0.69
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3. VEHICLE SPEED SENSOR CHECK
(1) Remove the vehicle speed sensor and connect 3-10 KΩ resistance as shoen in the illustration.
(2) Turn the shaft of the vehicle speed sensor and check that there is voltage between terminals 2-3 (1 turn=4
pulses).
4. A/T CONTROL RELAY CHECK
(1) Remove the A/T control relay.
(2) Use jumper wires to connect A/T control relay terminal (2) to the battery (-) terminal and terminal (4) to the
battery (+) terminal.
(3) Check the continuity between terminal (1) and terminal (3) of the A/T control relay when the jumper wires
are connected to and disconnected from the battery.
Jumper wire Continuity between terminals No.1
Connected Continuity
Disconnected No continuity
(4) If there is a problem, replace the A/T control relay.

5. SOLENOID VALVE CHECK
(1) Disconnect the solenoid valve connector
Inspection
Page 110 of 122
Automatic Transaxle System > Automatic Transaxle Control System > Repair procedures
REMOVAL
1. Remove the two front console screws.
2. Remove the two rear console screws after moving front seats forward.
3. Remove two seat heater switches on the center panel.
4. Remove lever panel.

5. Remove the center panel, pulling out the center with hand after loosening two screw panel trim.
6. Remove the 12V power outlet connector pin from the center panel.
7. Remove the console after loosening four screws from the console bracket.
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8. Remove the shift lock cable and the key lock cable.
9. Remove the control cable clip and pin from the shift levers.
10. Remove the shift lever mounting bolts and connector.
11. Remove the shift lever assembly.

12. Remove the clip, flange nut from the transaxle sides.
13. Remove the transaxle control cable assembly.

14. Remove the shift lock cable and the key lock cable.
INSTALLATION
1. Apply a coating of the specified grease to the interior of the adjust bushing.
Specified grease : ssis grease SAE J310, NLGI No.0
2. Move the shift lever and the transaxle range switch to the "N" position, and install the transaxle control cable.
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3. When connecting the control cable to the transaxle mounting bracket, install the clip until it contacts the control
cable, in the position shown in the picture.
4. Install the shift lever assembly and connector.

5. When connecting the control cable to the shift lever mounting bracket, install the clip until it contacts the control
cable.
6. Install the control cable, the key lock cable and the shift cable mounting bolt.
7. Position the console and tighten eight screws.
8. Install the center panel after connecting 12V powr outlet pin, then tighten two screws.
9. Install lever panel.

10. Install two seat heater switches to the center panel.
Automatic Transaxle System > Troubleshooting > P0715

INSPECTION PROCEDURES FOR DIAGNOSTIC TROUBLE CODES
input shaft speed sensor system
Code No.P0715 input shaft speed sensor system Probable cause
If no output pulse is detected from the input shaft speed • Malfunction of the input shaft speed sensor
sensor for 1 second or more while driving in 3rd or 4th • Malfunction of the underdrive clutch retainer
gear at a speed of 30 km/h (19 mph) or more, it is • Malfunction of connector
judged to be an open circuit or short-circuit in the input • Malfunction of the TCM
shaft speed sensor and diagnostic trouble code
No.P0715 is output. If diagnostic trouble code P0715 is
output four times, the transaxle is locked into 3rd gar or
2nd gear as a fail-safe measure.
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Output shaft speed sensor system
Code No.P0720 Output shaft speed sensor system Probable cause
If the output from the output shaft speed sensor is • Malfunction of the output shaft speed sensor
continuously 50% lower than the vehicle speed for 1 • Malfunction of the transfer drive gear or driven gear
second or more while driving in 3rd or 4th gear at a • Malfunction of connector
speed of 30 km/h or more, it is judged to be an open • Malfunction of the TCM
circuit or short-circuit in the output shaft speed sensor
and diagnostic trouble code No.P0720 is output. If
diagnostic trouble code No.P0720 is output four times,
the transmission is locked into 3rd gear or 2nd gear as a
fail-safe measure.
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1st gear incorrect ratio
Code No.P0731 1st gear incorrect ratio Probable cause
If the output from the output shaft speed sensor • Malfunction of the input shaft speed sensor
multiplied by the 1st gear ratio is not the same as the • Malfunction of the output shaft speed sensor
output from the input shaft speed sensor after shifting to • Malfunction of the underdrive clutch retainer
1st gear has been completed, diagnostic trouble code • Malefaction of the transfer drive gear or driven gear
NO.P0731 is output. If diagnostic trouble code
• Malfunction of the low and reverse brake system
No.P0731 is output four times, the transaxle is locked
• Malfunction of the underdrive clutch system
into 3rd gear as a fail-safe measure.
• Noise generated
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2nd gear incorrect ratio
Code No.P0732 2nd gear incorrect ratio Probable cause
multiplied by the 2nd gear ratio is not the same as the • Malfunction of the output shaft speed sensor
2nd gear has been completed, diagnostic trouble code • Malfunction of the transfer drive gear or driven gear
No.P0732 is output. If diagnostic trouble code
• Malfunction of the second brake system
• Noise generated
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3rd gear incorrect ratio
Code No.P0733 3rd gear incorrect ratio Probable cause
multiplied by the 3rd gear ratio is not the same as the • Malfunction of the output shaft speed sensor
3rd gear has been completed, diagnostic trouble code • Malefaction of the transfer drive gear or driven gear
• Noise generated
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4th gear incorrect ratio
Code No.P0734 4th gear incorrect ratio Probable cause
multiplied by the 4th gear ratio is not the same as the • Malfunction of the output shaft speed sensor
4th gear has been completed, diagnostic trouble code • Malefaction of the transfer drive gear or driven gear
• Noise generated
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reverse gear incorrect ratio
Code No.P0736 reverse gear incorrect ratio Probable cause
multiplied by the reverse gear ratio is not the same as the • Malfunction of the output shaft speed sensor
reverse gear has been completed, diagnostic trouble • Malefaction of the transfer drive gear or driven gear
code NO.P0736 is output. If diagnostic trouble code
• Noise generated
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Damper clutch solenoid system
Page 120 of 122
Code No.P0743/P0740 Damper clutch solenoid system Probable cause
If the resistance value for the torque converter clutch • Malfunction of the damper clutch solenoid
solenoid is too large or too small, it is judged that there • Malfunction of connector
is a short-circuit or an open circuit in the damper clutch • Malfunction of the TCM
solenoid and diagnostic trouble code No.P0743 is
output. If the drive duty rate for the damper clutch
solenoid is 100% for a continuous period of 4 seconds
or more, it is judged that there is an abnormality in the
damper clutch system and diagnostic trouble code
NO.P0740 is output. When diagnostic trouble code
No.P0743 is output, the transaxle is locked into 3rd
gear as a fail-safe measure. If the lock-up clutch remains
engaged for a continuous period of 10 seconds when the
TCM is attempting to disengage the lock-up clutch, it is
judged that the torque converter clutch is stuck on and
diagnostic trouble code P0740.

solenoid valve
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Code No.P0750 Low and reverse solenoid valve
system
Code No.P0755 Underdrive solenoid valve system Probable cause
Code No.P0760 Second solenoid valve system
Code No.P0765 Overdrive solenoid valve system
If the resistance value for a solenoid valve is too large or • Malfunction of solenoid valve
too small, it is judged that there is a short-circuit or an • Malfunction of connector
open circuit in the solenoid valve and the respective • Malfunction of the TCM
diagnostic trouble code is output. The transaxle is
locked into 3rd gear as a fail-safe measure.

A/T Control relay system
Code No.P1723 A/T Control relay system Probable cause
If the relay voltage is less than 7 V after the ignition • Malfunction of the A/T control relay
switch has been turned to ON, it is judged that there is • Malfunction of connector
an open circuit or a short-circuit in the A/T control relay • Malfunction of the TCM
earth and diagnostic trouble code P1723 is output. The
transaxle is locked into 3rd gear as a fail-safe measure.
Page 122 of 122
Page 1 of 114
OPTIMA(MS) > 2003 > G 2.4 DOHC > Body (Interior and Exterior)
Body (Interior and Exterior) > General Information > Troubleshooting

Bumper
Problem Possible cause Action
Front face damaged Accident Replace
Energy absorbing foam Accident exposure Replace
damaged or deteriorated
Reinforcement damaged Accident Replace
Brackets or stay
Accident Repair or replace
damaged
Missing attaching
Accident or vibration Replace
hardware
Seat belts
Problem Possible cause Action
Buckle release does not release
Faulty spring or dirt in mechanism Replace buckle assembly
reliably
Buckle release does not depress Jammed mechanism Replace buckle assembly
Buckle release button does not Jammed mechanism Replace buckle assembly
return to normal position
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 Cable harness, computer module, or Isolate fault with continuity tester.
but reminder lamp and chime indicator light If test fails, repair or replace
either do not actuate or fail to cable. If test fails, repair or
deactivate replace faulty component.
Body (Interior and Exterior) > General Information > Specifications

Specifications
Tightening specifications
Item Description Tightening torque
Page 2 of 114
Bumper Front bumper back beam mounting 19~28 N.m (1.9~2.8 kg-m, 14~20
nuts lb-ft)
35~55 N.m (3.5~5.5 kg-m, 25~40
Rear bumper mounting bolts
lb-ft)
Doors 7~11 N.m (70~110 kg-cm, 61~95 lb-
Door checker bolts (Door side)
in)
17~22 N.m (1.7~2.2 kg-m, 12~16
Door checker bolts (Body side)
lb-ft)
13~26 N.m (1.3~2.6 kg-m, 10~19
Door hinge mounting bolts (Door side)
lb-ft)
35~42 N.m (3.5~4.2 kg-m, 25~30
Door hinge mounting bolts (Body side)
lb-ft)
8~11 N.m (80~110 kg-cm, 69~95 lb-
Door lock assembly mounting screws
in)
9~14 N.m (90~140 kg-cm, 78~122
Door striker mounting screws
lb-in)
7~11 N.m (70~110 kg-cm, 61~95 lb-
Door outside handle mounting bolts
in)
8~12 N.m (80~120 kg-cm, 69~104
Glass guide bolts/nuts
lb-in)
8~12 N.m (80~120 kg-cm, 69~104
Glass mounting bolts
lb-in)
Regulator assembly mounting nuts 4~6 N.m (40~60 kg-cm, 35~52 lb-in)
Hood 22~27 N.m (2.2~2.7 kg-m, 16~20
Hood hinge bolts/nut
lb-ft)
7~11 N.m (70~110 kg-cm, 61~95 lb-
Hood latch assembly bolt
in)
50~60 N.m (5.0~6.0 kg-m, 36~43
Front buckle assembly anchor bolt
lb-ft)
35~55 N.m (3.5~5.5 kg-m, 25~40
Front seat mounting bolts
lb-ft)
24~36 N.m (2.4~3.6 kg-m, 17~26
Front seat mounting nuts
lb-ft)
Seats
50~60 N.m (5.0~6.0 kg-m, 36~43
Front seatback mounting bolts
lb-ft)
17~26 N.m (1.7~2.6 kg-m, 12~19
Seat cushion mounting bolts
lb-ft)
17~26 N.m (1.7~2.6 kg-m, 12~19
Rear seat back mounting bolts
lb-ft)
Sunroof Glass panel mounting nuts 4~6 N.m (40~60 kg-m, 35~52 lb-ft)
7~11 N.m (70~110 kg-m, 61~95 lb-
Sunroof mounting bolts
ft)
Page 3 of 114
Sunroof mounting nuts 4~6 N.m (40~60 kg-m, 35~52 lb-ft)
Seat belts 35~45 N.m (3.5~4.5 kg-m, 25~33
Front lap belt anchor mounting bolt
lb-ft)
Rear buckle assembly bracket 40~55 N.m (4.0~5.5 kg-m, 29~40
mounting bolt lb-ft)
40~55 N.m (4.0~5.5 kg-m, 29~40
Rear lap belt anchor mounting bolt
lb-ft)
Trunk lid 7~11 N.m (70~110 kg-cm, 61~95 lb-
Trunk lid hinge assembly bolt
in)
7~11 N.m (70~110 kg-cm, 61~95 lb-
Trunk lid latch assembly bolt
in)
Body (Interior and Exterior) > Body Dimension > General Information
Body dimension indications
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.
Front body straight-line dimensions

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Side frame panel straight-line dimensions

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Interior A Straight-line dimensions

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Interior B Straight-line dimensions

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Interior C Straight-line dimensions

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Rear body Straight-line dimensions

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Under body projected dimensions

Page 16 of 114
Measurement
Description Size of hole
Point
A Sub frame mounting hole Ø 18 mm
B Sub frame mounting hole Ø 17.5 mm
C Front side rear member hole Ø 12 mm
D Center floor side member hole Ø 27 mm
E Rear floor side member hole Ø 15 mm
F Rear floor side member hole Ø 16 mm
G Rear bumper mounting hole Ø 16 mm
Page 17 of 114
Under body straight-line dimensions

Page 18 of 114
Measurement
Description Size of hole
Point
A Sub frame mounting hole Ø 18 mm
B Sub frame mounting hole Ø 17.5 mm
C Front side rear member hole Ø 12 mm
D Center floor side member hole Ø 27 mm
E Rear floor side member hole Ø 15 mm
F Rear floor side member hole Ø 16 mm
G Rear bumper mounting hole Ø 16 mm
Page 19 of 114
Body (Interior and Exterior) > Exterior > hood > Description and Operation
DESCRIPTION AND OPERATION
The vehicle hood is a front-opening type secured by a standard double-release latch. The hood release 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 can be adjusted fore-and-aft and side-to-side by loosening hood bolts and moving the hood as
Page 20 of 114
necessary. The hood latch can be adjusted in both axes to match position of the permanently attached striker.
Body (Interior and Exterior) > Exterior > hood > Components and Components Location
COMPONENT
Body (Interior and Exterior) > Exterior > hood > Repair procedures
Removal
1. Raise hood and support with prop.
2. Remove the tubing from the under side of the hood.
3. Support hood so it will not fall when hinges are removed.
Have an assistant help remove hood.

Page 21 of 114
1. Remove hinges from hood by removing four bolts.
2. Remove prop from hood.

3. Remove hood.
Installation
Have an assistant help install hood.

1. Install in reverse order of removal.
2. Tighten four hinge bolts to just over finger-tight.
Tighten hood hinge bolts to

22~27 N·m (2.2~2.7 kg·m, 16~95 lb·ft)
3. Lower and lock the hood.

4. Check fit and adjust as required in accordance with illustrated specifications.
Page 22 of 114
5. Check alignment of locking mechanism and hood striker and align as required.
Tighten latch assembly bolts to

7~11 N·m(70~110 kg·cm, 61~95 lb·in)
Body (Interior and Exterior) > Exterior > trunk lid > Description and Operation
Trunk lid attached to body by two hinges. Two hinges connected to each other by two damper stays and are
installed by bolts. Two hinges connected by two damper stays provide an assist in raising trunk lid and fully supports
it when it is open. A striker at center-top of body secures trunk lid in closed position. Weatherstripping on trunk lid
jamb flange prevents leakage between trunk and body. A latch is attached to center-bottom of trunk lid. Trunk lid is
fully adjustable.
Body (Interior and Exterior) > Exterior > trunk lid > Components and Components Location
component
Page 23 of 114
Body (Interior and Exterior) > Exterior > trunk lid > Repair procedures
REMOVAL
Have an assistant help remove trunk lid.

1. Unfasten upper and lower retaining clips from damper stay.
Page 24 of 114
2. Remove damper stay from hinge assembly.
3. Remove service hole cover from trunk and then remove electrical harness connector.
4. Support trunk lid so trunk lid will not fall when trunk lid installation bolts are removed.
5. Remove four trunk lid installation bolts and then remove trunk lid.
INSTALLATION
Have an assistant help install trunk lid.

2. Tighten four trunk lid installations bolts to just over finger-tight.
3. Lower and lock the trunk lid.
4. Check fit and adjust the clearance on all sides before tightening bolts.
Tighten trunk lid hinge bolts to

7~11 N.m(70~110 kg-cm, 61~95 Ib-in)
Page 25 of 114
5. Install damper stay.
6. Check alignment of the locking mechanism and trunk lid striker and align as required.
Tighten striker bolts to

7~11 N.m(70~110 kg-cm, 61~95 Ib-in)
Disassembly (trunk lid lock)

1. Disconnect negative battery cable.
2. Open trunk lid.
3. Remove the trunk lid trim.
4. Disconnect electrical harness connector.

5. Unfasten lock rod clip and fastener from keylock.
6. Remove one nut from keylock.
7. Disconnect actuator connector.
8. Remove two bolts from trunk lid lock assembly.

Disassembly (Trunk lid molding)
2. Open trunk lid.
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3. Remove three screws and thirteen fasteners from trunk lid trim.
4. Remove back panel molding assembly.

(1) Disconnect electrical connector.
(2) Remove one screw from outside of trunk lid.
(3) Remove thirteen nuts from trunk lid.
Reassembly (Trunk lid molding)

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1. Install back panel molding assembly.
(1) Install thirteen nuts on trunk lid.
(2) Install one screw on outside of trunk lid.
(3) Connect electrical connector.

2. Install three screws and thirteen fasteners on trunk lid trim.
3. Connect negative battery cable.
Body (Interior and Exterior) > Exterior > front door > Description and Operation
DESCRIPTION
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
power window system is comprised of a window regulator assembly (on which glass is fastened), a front glass guide
(which guides movement of glass at front side) and a window power switch (switch for up and down movement of
glass, which is attached to armrest). A plastic door screen covers door frame, protecting all components. The door
striker may be adjusted for proper operation and easy door closure.
Body (Interior and Exterior) > Exterior > front door > Components and Components Location
COMPONENT
Page 28 of 114
Body (Interior and Exterior) > Exterior > front door > Repair procedures
Removal
Page 29 of 114
2. Remove door garnish.
(1) Unfasten garnish.

3. Remove inside handle cover.
(1) Remove one screw.

(2) Unfasten inside handle cover.
4. Remove door trim.
(1) Remove one screw from pull handle.
Page 30 of 114
(2) Remove two screws from right side of door trim.
(3) Remove two screws and cover from left side of door trim.
(4) Remove two screws from bottom of door trim.
(5) Unfasten door trim.
5. Remove inside door handle assembly.
(1) Disconnect two remote control rods from door lock assembly.
(2) Remove two screws from inside door handle.
6. Remove two screws from pull handle bracket.
7. Peel off plastic door screen carefully by pulling it away gradually from door frame.
Peel plastic moisture barrier off carefully so that it can be reused.

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8. Remove window glass.
(1) Reconnect window operating switch.

(2) Connect negative battery cable.
(3) Turn ignition "ON" and position window glass about halfway.
(4) Turn ignition "OFF".
(5) Remove glass run channel.
(6) Remove two glass mounting bolts from window regulator assembly.
(7) 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) Disconnect negative battery cable.

Page 32 of 114
9. Remove regulator assembly.
(1) Disconnect window regulator motor connector.

(2) Remove seven nuts from door frame.
(3) Remove window regulator assembly from out of access hole.
10. Remove door lock assembly.
(1) Disconnect two remote control rods from outside door handle assembly.
(2) Disconnect door lock actuator connector.
(3) Remove two mounting nuts from door lock actuator.
(4) Remove one screw from rod cover of inside door handle.
(5) Remove three screws from door lock assembly and remove assembly from access hole.
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11. Remove outside handle assembly.
(1) Disconnect door lock cylinder connector.

(2) Remove two mounting bolts from outside handle assembly.
(3) Remove door lock cylinder from outside handle assembly.
(4) Push (A) side and pull (B) side with wrenching outside handle upside.
12. Remove two nuts from glass guide.
13. Remove door speaker.

(2) Remove four screws from door speaker.
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14. Remove outside rearview mirror assembly.

(2) Remove three bolts from outside rearview mirror assembly.
15. Remove wiring harness.
(1) Disconnect harness connectors from inner door frame.
(2) Pull out wiring harness from access hole.
16. Remove door checker installation bolt from body.
17. Remove door by removing bolts on both hinges.
Installation
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1. Install door.
(1) Position door on vehicle properly.
(2) Install bolts on both hinges.
Tighten door hinge bolts to

13~26 N.m (1.3~2.6 kg-m, 10~19 Ib-ft)
2. Install dust weatherstrip.

3. Install one bolt on door checker pin assembly.
Tighten one bolt to

17~22 N.m (1.7~2.2 kg-m, 12~16 Ib-ft)
4. Install wiring harness.

(1) Position wiring harness in access hole.
(2) Fasten harness connectors onto door frame.
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5. Install outside rearview mirror on door.
(1) Position rearview mirror on door as originally positioned.

(2) Install three mounting bolts.
6. Install door speaker.
(1) Position door speaker on door as originally positioned.
(2) Install four mounting screws.
7. Install glass guide.
(1) Position glass guide as originally positioned through access hole.

(2) Install two nuts.
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8. Install outside door handle assembly.
(1) Position outside door handle assembly as originally positioned through access hole.
(2) Install door lock cylinder on outside handle assembly .
(3) Install two mounting bolts.
Tighten mounting bolts to

7~11 N.m (70~110 kg-cm, 61~95 Ib-in)
(4) Connect door lock cylinder connector.

9. Install door lock assembly.
(1) Position it as originally positioned through access hole.

(2) Install three mounting screws.
Tighten mounting screws to

8~11 N.m (80~110 kg-cm, 69~95 Ib-in)
(3) Install one screw on rod cover of inside handle.

(4) Install two mounting nuts on door lock actuator.
(5) Connect two remote control rods on outside handle.
(6) Connect door lock actuator connector.
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10. Install regulator assembly.
(1) Position regulator assembly through access hole.

(2) Install seven mounting nuts.
(3) Connect electrical connector for motor of regulator assembly.
11. Install window glass.
(1) 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.
(2) Loosely install two glass mounting bolts on window regulator assembly.

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(5) Turn "ON" ignition and move glass up and down to ensure proper function.
(6) Make adjustments as necessary.
(7) Turn "OFF" ignition.
(8) Disconnect window operating switch.
(10) Tighten two glass mounting bolts on power window regulator assembly.
Tighten two bolts to

8~12 N.m (80~120 kg-cm, 69~104 Ib-in)
12. Install run channel. Use soap and water for lubrication.
13. Install plastic door screen.
(1) Fasten plastic door screen.
(2) Pull out electrical harness connector from plastic door screen.
(3) Pull out remote control rod for inside door handle from plastic door screen.
14. Install pull handle bracket with two mounting screws.
15. Install inside door handle assembly.
(1) Install two mounting screws.

(2) Connect two remote control rods of door lock assembly.
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16. Install door trim.
(2) Place front door trim.
(3) Install two screws on bottom of door trim.
(4) Install two screws and cover on left side of door trim.
(5) Install two screws on right side of door trim.
(6) Install one screw on pull handle bracket.
17. Install inside handle cover.
(1) Fasten inside handle cover.

(2) Install one screw and cover.
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18. Install door garnish.
Door hinge and door lock striker

Adjustment
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.
Body (Interior and Exterior) > Exterior > rear door > Components and Components Location
COMPONENT
Page 42 of 114
Body (Interior and Exterior) > Exterior > rear door > Repair procedures
Removal
Page 43 of 114
2. Remove inside door garnish.
(1) Remove screw cover and one screw.

(1) Remove one screw from pull handle.
(2) Remove screw cover and two screws from left side of door trim.
(3) Remove one screw from right side of door trim.

(5) Disconnect power window switch connector.
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5. Remove inside door handle assembly.
(1) Disconnect two remote control rods from inside door handle.
(2) Remove two screws from inside door handle.
6. Remove two screws from pull handle bracket.
7. Peel off plastic door screen carefully by pulling it away gradually from door frame.
Peel plastic moisture barrier off carefully so that it can be reused.

8. Remove outside belt weatherstrip and door outside garnish.
(1) Remove three screws from door outside garnish.
(2) Unfasten outside belt weatherstrip with door outside garnish.

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9. Remove window glass.

(3) Turn ignition "ON" and position window glass about halfway.
(4) Turn ignition "OFF".
(5) Remove glass run channel.
(6) Remove two glass mounting bolts from window regulator assembly.
(7) 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.
10. Remove regulator assembly.
(1) Disconnect window regulator motor connector.

(2) Remove seven nuts from door frame.
(3) Remove window regulator assembly from out of access hole.
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11. Remove door lock assembly.
(1) Disconnect one remote control rod from outside door handle assembly.
(2) Disconnect door lock actuator connector.
(3) Remove two mounting nuts from door lock actuator.
(4) Remove three screws from door lock assembly and remove assembly from access hole.
12. Remove outside door handle assembly.
(1) Remove two mounting bolts from outside handle assembly.
(2) Push (A) side and pull (B) side with wrenching outside handle upside.
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13. Remove two bolts from glass guide.
14. Remove wiring harness.

(1) Disconnect harness connectors from inner door frame.
(2) Pull out wiring harness from access hole.
15. Remove door checker installation bolt from body.
16. Remove door by removing bolts on both hinges.
Installation
Page 48 of 114
1. Install door.
(1) Position door on vehicle properly.
(2) Install bolts on both hinges.
Tighten door hinge bolts to

13~26 N.m (1.3~2.6 kg-m, 10~19 Ib-ft)
2. Install dust weatherstrip.

3. Install one bolt on door checker pin assembly.
Tighten one bolt to

17~22 N.m (1.7~2.2 kg-m, 12~16 lb-ft)
4. Install wiring harness.

(1) Position wiring harness in access hole.
(2) Fasten harness connectors onto door frame.
5. Install glass guide.
(1) Position glass guide as originally positioned through access hole.
(2) Install two bolts.
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6. Install outside door handle assembly.
(1) Position outside door handle assembly as originally positioned through access hole.
(2) Install two mounting bolts.
Tighten mounting nuts to

7~11 N.m (70~110 kg-cm, 61~95 Ib-in)
7. Install door lock assembly.
(1) Position it as originally positioned through access hole.

(2) Install three mounting screws.
Tighten screws to
8~11 N.m (80~110 kg-cm, 69~95 lb-in)
(3) Connect door lock actuator connector.

(4) Install two mounting nuts on door lock actuator.
(5) Connect one remote control rod on outside door handle assembly.
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8. Install window regulator assembly.
(1) Position window regulator assembly through access hole.

(2) Install seven mounting nuts.
(3) Connect electrical connector for motor of regulator assembly.
9. Install window glass.
(1) 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.
(2) Loosely install two glass mounting bolts on window regulator assembly.
(5) Turn "ON" ignition and move glass up and down to ensure proper function.
(6) Make adjustments as necessary.
(7) Turn "OFF" ignition.
(8) Disconnect window operating switch.
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(10) Tighten two glass mounting bolts on power window regulator assembly.
Tighten two bolts to

8~12 N.m (80~120 kg-cm, 69~104 lb-in)
10. Install run channel. Use soap and water for lubrication.
11. Install outside belt weatherstrip and door outside garnish.
(1) Fasten outside belt weatherstrip with door outside garnish.
(2) Install three screws on door outside garnish.
12. Install plastic door screen.

(1) Fasten plastic door screen.
(2) Pull out electrical harness connector from plastic door screen.
(3) Pull out remote control rod for inside door handle from plastic door screen.
13. Install pull handle bracket with two mounting screws.
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14. Install inside door handle.
(1) Install two mounting screws.

(2) Connect two remote control rods of door lock assembly.
(2) Place door trim.
(4) Install one screw on right side of door trim.

(5) Install one screw on pull handle.
Page 53 of 114

17. Install inside door garnish.
Body (Interior and Exterior) > Exterior > mirror > Description and Operation
Description and operation
The outside rearview mirror assembly is comprised of mirror glass, a mirror frame (which holds the mirror glass), a
motor (only for electric), a wire harness, and an inner garnish trim, Each outside rearview mirror can be adjusted in
four directions from inside the vehicle.
Body (Interior and Exterior) > Exterior > mirror > Components and Components Location
Component
Page 54 of 114
Body (Interior and Exterior) > Exterior > mirror > Repair procedures
Removal and installation
Page 55 of 114
2. Remove outside rearview mirror garnish.
(1) Remove garnish from door frame.

3. Remove outside rearview mirror.
(1) Remove bolts (3).
Tightening torque : bolt

4.5~6.6 N·m (0.45~0.66 kg·m, 3~5 lb·ft)

4. Remove mirror.
Wear gloves to remove and install the mirror holder

(1) Insert flat bladed screwdriver between the outside rearview mirror holder and the mirror assembly.
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5. Remove outside rearview mirror actuator.
When prying with a flat bladed screwdriver, wrap it with a shop towel to prevent
damage.
(1) Remove the outside rearview mirror actuator from the outside rearview mirror housing.
Body (Interior and Exterior) > Sun Roof > sun roof assembly > Components and Components Location
Page 57 of 114
Body (Interior and Exterior) > Sun Roof > sun roof assembly > Repair procedures
Adjustment
Page 58 of 114
1. Adjust the difference between the height of the glass panel and the roof panel.
Front side : -1~0 mm
Rear side : 0~1 m
If the difference is not as specific, adjust the following procedure.
(1) Loosen the front screw and rear screw and adjust the height between the glass panel and roof panel.
(2) Loosen the glass panel mounting nuts and adjust the gap between the glass panel and roof panel.
Removal
1. Remove headliner. Refer to "Trim" in this section.
2. Remove glass panel.
Tighten glass mounting nuts to

4~6 N·m (40~60kg·cm, 35~52 lb·ft)
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3. Disconnect the drain hose.
4. Remove the sunroof mounting bolts and nuts, and remove the sunroof assembly.
Tighten sunroof mounting bolts to

7~11 N·m (70~110 kg·cm, 61~95 lb·ft)
Tighten sunroof mounting nuts to
4~6 N·m (40~60 kg·cm, 35~52 lb·ft)
When removing the sunroof assembly, carefully pull out the sunroof assembly to avoid damage to the other
parts.
Installation
Installation is the reverse of removal.
Check that the limit switches (LS1 and LS2) of the motor are at the fully closed position.
Align the guide roller center and slider mating mark at the fully closed position.
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Disassembly
1. Remove the drip rail.
2. Remove the stopper.
3. Remove the sunshade.
4. Remove the guide assembly.

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5. Remove the deflector.
6. Remove the motor assembly.
When removing the motor, the slider assembly should always be in the fully closed position. If there is a
discrepancy between the glass position and the motor ring fully closed position, the sunroof will not operate
correctly.
Assembly
Assembly is the reverse of disassembly.
Check operating condition after

Installation
1. If the glass panel movement is difficult, check and adjust.
(1) Make sure the battery voltage is normal.
(2) Make sure that the sunroof sliding unit is free of foreign material.
(3) Make sure that, when the glass panel opens, the rear position of panel dose not interfere with the roof panel.
If the stopper is moved forward too far, it may cause malfunction or leaks. Make sure the gap between
the glass panel and roof panel is not more than 0.3 mm.
(4) Measure the driving force of the motor, and adjust it to 15~25 kg (33.1~55.7 lb) with the torque adjustment
nut on the motor.
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(5) To measure, use the deep hole in the center of the lid lower panel.
(6) After adjustment, be sure to sure to lock the nut with the pawl washer.
Body (Interior and Exterior) > Sun Roof > sun roof switch > Repair procedures
Inspection
1. Operate the switch and check for the continuity bytween the terminal.
2. If the continuity is not as specified. replace the switch.
Body (Interior and Exterior) > Sun Roof > sun roof moter > Repair procedures
Inspection of components
Page 63 of 114
1. Remove the overhead console lamp.
2. Disconnect the motor connector from sun roof harness.

3. Apply DC 12V to the terminal 2 and ground the terminal 6.
4. Check that the motor turns.

5. Reverse the connections and check that the motor turns in the opposite directions.
Body (Interior and Exterior) > Sun Roof > Sunroof Relay > Repair procedures
Check for continuity between the terminals.
Page 64 of 114
Body (Interior and Exterior) > Interior > crash pad > Description and Operation
Instrument panel
Instrument panel houses instrument cluster, center panel and a number of special switches and controls. Instrument
panel electrical system is discussed in Wiring Diagram Manual. Ducts installed in instrument panel are discussed in
this section.
Center panel
Center panel is a housing for ventilation control panel, radio, glove box, and with center panel trim serves as a base
for cigarette lighter and ashtray. Center panel may remain in place when instrument panel is removed.
Interior lights control switch
Interior lights control allows adjustment of brightness of panel lights.
Radio and antenna cable
When a radio is installed in vehicle, user instructions are supplied. Radio is located in center panel. Antenna and
electrical connections are located at rear of unit. Antenna cable connects to radio. It is routed behind instrument
panel and connects to antenna. Radio receives signals through antenna cable from antenna. It is necessary to remove
radio when instrument panel is removed.
Ventilation control panel
Ventilation control panel provides control of heating and air conditioning and is mounted in center panel.
Body (Interior and Exterior) > Interior > crash pad > Components and Components Location
COMPONENT
Page 65 of 114
Body (Interior and Exterior) > Interior > crash pad > Repair procedures
Removal
2. Remove drive airbag module. Refer to group RT, Restraints.
3. Remove steering wheel, turn signal assembly, and upper/lower column covers. Refer to Group ST, Steering
system.
4. Remove A pillar trim.
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5. Remove instrument cluster.
(1) Remove three screws from cluster facia trim.
(2) Remove four mounting screws.
(3) Pull cluster from instrument panel.

(4) Disconnect electrical connectors.
(5) Remove instrument cluster.
6. Remove floor console.
(1) Unfasten rear cover from floor console.
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(2) Remove two mounting screws from front cover.

(4) Remove eight mounting screws from floor console.
7. Unfasten center facia panel and then disconnect electrical connector from rear of center facia panel.
8. Remove radio.
(1) Remove four screws from radio.

(2) Disconnect electrical connector and antenna cable from rear of radio.
9. Remove two mounting screws and then disconnect electrical connector from rear of lower LH cover.
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10. Remove lower RH cover.
(1) Remove two grommet from glove box assembly.
(2) Remove two screws and one nut from top of lower RH cover.
(3) Remove two bolts from bottom of lower RH cover.

11. Remove center panel.
(1) Remove five screws from center panel.

(2) Disconnect electrical connector from rear of center panel.
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12. Remove instrument panel.
(1) Remove two bolts from left side of instrument panel.

(2) Remove two bolts from right side of instrument panel.
(3) Remove two bolts from center of instrument panel.
(4) Remove two mounting bolts from passenger airbag.
Installation
1. Install 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 to passenger airbag.
(4) Install two mounting bolts on center of instrument panel.
(5) Install two mounting bolts on right side of instrument panel.
(6) Install two bolts on left side of instrument panel.
2. Install center panel.

(2) Install five screws on center panel.
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3. Install lower RH cover.
(1) Install two bolts on bottom of lower RH cover.
(2) Install two screws and one nut on top of lower RH cover.
(3) Install two grommet on glove box assembly.
4. Install two mounting screws and then connect electrical connector on rear of lower LH cover.
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5. Install radio.
(1) Connect electrical connector and antenna cable on rear of radio.

(2) Install four screws on radio.
6. Connect electrical connector on rear of center facia panel and then fasten center facia panel.
7. Install floor console.
(1) Position console and install eight mounting screws.
(3) Install two mounting screws on front cover.
(4) Fasten rear cover to floor console.

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8. Install instrument cluster.
(1) Position instrument cluster and connect electrical connector.
(2) Install four mounting screws.
(3) Install three screws to instrument cluster trim.
9. Install A pillar trim.

10. Install steering wheel, turn signal assembly and upper/lower column covers. Refer to group ST, Steering System.
11. Install driver air bag module. Refer to group RT, Restraints.
12. Install negative cable onto battery terminal.
Body (Interior and Exterior) > Interior > roof trim > 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 room lamp. Both headliner and insulation are replaceable.
Body (Interior and Exterior) > Interior > roof trim > Components and Components Location
COMPONENT
Page 73 of 114
Body (Interior and Exterior) > Interior > roof trim > Repair procedures
Removal
1. Unscrew two mounting screws from sunvisors.
2. Remove sunvisors and sunvisors retaining clips.
3. Remove assist handle covers, unscrew mounting screws.
4. Remove three assist handles.
5. Gently remove lens assembly on interior and map light.

6. Remove light bulb.
7. Remove two mounting screws.
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8. 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.
11. Remove headliner.
Body (Interior and Exterior) > Interior > package trim > Repair procedures
Removal
1. Remove high-mounted brake light assembly.
2. Remove five screws from left side of partition cover.
3. Repeat for right side.
4. Unfasten C-pillar trim.
5. Unfasten Package trim.

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6. Remove Package trim.
Body (Interior and Exterior) > Interior > trunk trim > Repair procedures
Removal
1. Remove trunk end trim.
A. Remove two fasteners.
B. Unfasten trunk end trim and remove trunk end trim.
2. Remove trunk side trim.
Body (Interior and Exterior) > Interior > interior trim > Description and Operation
Trim is a plastic molding and is used to cover interior of vehicle. It assists vehicle insulation by covering it in addition
to hiding vehicle metal frame. It also acts as a sound barrier. It is used on all four doors of vehicle door opening scuff
plate, A, B and C-pillars, front side, rear side and trunk end trim. All door trim on vehicle includes pull handle. Each
trim on front two doors provides a pocket for keeping maps, etc.
Body (Interior and Exterior) > Interior > interior trim > Components and Components Location
COMPONENT
Page 76 of 114
Body (Interior and Exterior) > Interior > interior trim > Repair procedures
A-PILLAR TRIM
REMOVAL
1. Unfasten A-pillar trim with a trim removal tool.
Page 77 of 114
2. Remove A-pillar trim.
INSTALLATION
1. Position A-pillar trim.
2. Press A-pillar trim into fasten clips.
B-pillar lower trim
REMOVAL
1. Remove front and rear scuff plate.
2. Unfasten B-pillar lower trim with a trim removal tool.
3. Remove B-pillar lower trim.

Installation
1. Position B-pillar lower trim.
2. Press B-pillar lower trim into fasten clips.
3. Install front and rear scuff plate.
B-pillar upper trim
REMOVAL
1. Remove front and rear scuff plate.
2. Unfasten B-pillar lower trim with a trim removal tool.
4. Remove two mounting screws from belt guide.
5. Remove upper anchor mounting bolt from safety belt.
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6. Remove B-pillar upper trim with a trim removal tool.
Installation
1. Position B-pillar upper trim.
2. Install upper anchor mounting bolt to safety belt.
Tighten mounting bracket bolt to

40~55 N.m (4.0~5.5 kg-m, 29~40 Ib-ft)
3. Install two screws to belt guide.

4. Position B-pillar lower trim and press B-pillar lower trim.
5. Install front and rear scuff plate.
C-pillar trim
REMOVAL
1. Unfasten C-pillar trim.
2. Remove C-pillar trim.
Installation
1. Position C-pillar trim and press in.
FRONT DOOR TRIM
REMOVAL
2. Remove door garnish.
(1) Unfasten garnish.
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(1) Remove one screw.

(1) Remove one screw on pull handle bracket.
(2) Remove two screws on right side of door trim.
(3) Remove two screws and cover on left side of door trim.
(4) Remove two screws on bottom of door trim.
(6) Remove front door trim by lifting front door trim up.
Installation
Page 80 of 114
(2) Place front door trim.
(3) Install two screws on bottom of door trim.
(5) Install two screws on right side of door trim.
(6) Install one screw on pull handle bracket.
3. Install door garnish.
FRONT SCUFF PLATE
REMOVAL
1. Unfasten front scuff plate with trim removal tool.
2. Remove front scuff plate.
Installation
1. Position front scuff plate.
2. Press in front scuff plate into fasten clips.
FRONT SIDE TRIM
REMOVAL
1. Remove front scuff plate.
2. Remove one fastener from front side trim. Remove two screws from hood release handle(Left of front side trim
only).
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3. Remove front side trim.
installation
1. Position front side trim.
2. Install one fastener to front side trim.
Install two screws to hood release handle(Left of front side trim only).
3. Install front scuff plate.
REAR DOOR TRIM
REMOVAL
2. Remove inside door garnish.
(1) Remove screw cover and one screw.

(1) Remove one screw on pull handle.
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(2) Remove screw cover and two screws on left side of door trim.
(3) Remove one screw on right side of door trim.

(5) Disconnect power window switch connector.
Installation
(2) Place door trim.
(4) Install one screw on right side of door trim.
(5) Install one screw on pull handle.
3. Install inside door garnish.

REAR SCUFF PLATE
REMOVAL
1. Remove two fasteners from rear scuff plate.
2. Unfasten rear scuff plate.
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3. Remove rear scuff plate.
Installation
1. Position rear scuff plate.
2. Press in rear scuff plate.
3. Install two fasteners to rear scuff plate.
Body (Interior and Exterior) > Interior > windshield glass > Description and Operation
The windshield glass is safety glass-plastic-laminate sand-wiched between two sheets of glass. The windshield is
sealed and bonded to the body with urethane sealant. A molding encloses the body glass joint on the top and both
sides. Molding for the bottom is attached to the cowl vent.
Body (Interior and Exterior) > Interior > windshield glass > Components and Components Location
Component
Page 84 of 114
Body (Interior and Exterior) > Interior > windshield glass > Repair procedures
Removal
Page 85 of 114
1. Remove LH and RH A-pillar moldings by carefully prying them from the pillar.
2. Remove inside rearview mirror by prying its base cover off, and then removing two screw.
3. Remove LH and RH windshield wiper arms by removing one nut each.
4. Remove cowl vent.
5. Remove the rubber molding from around the windshield. Start at a corner.
6. Pierce the sealant with a pull knife and cut all the way around the windshield from outside the vehicle.
7. Remove the glass to a safe place.
Installation
1. Remove the excess sealant from the glass with a window scraper.
Page 86 of 114
2. Remove the exces sealant and foam dam from the body with a knife.
3. Clean the inside of the glass with commercial glass cleaner and a lint-free cloth.
4. Prime an area approximately 3/4 inch (19mm) wide around the complete perimeter of the glass.
5. Prime the contact area on the body.
6. Reprime the same area on the inside surface of the glass.

Do not permit any primed surface to become contaminated with dirt, water, oil, etc. Do not touch primed
surfaces with your hands. Contamination will affect adhesion.
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7. Install the self-adhesive foam dam to the body where the original dam had been.
The following cure times may be critical. Attempting to replace a windshield in ambient temperature over
95°F (35°C) should be avoided because the surface of the sealant may harden before completing the
application.
Time Required Until Vehicle Can Be

Temperature Surface Hardening Time
Returned To Service
41°F (5 °C) Approx 1.5 hrs 12 hrs
68°F (20 °C) Approx 1 hrs 4 hrs
8. Apply the urethane bead to the body just outside the dam. The bead should be slightly higher than the dam.
9. Install molding on the glass.

Page 88 of 114
10. Install the glass into the body making sure the glass rests upon the two spacers at the bottom of the sindshield.
11. Press glass firmly into place.
12. Press molding firmly into place.
13. Lower both front door windows and leave them in that condition until the vehicle can be put back into service. If
the vehicle were completely closed, quickly closing a door could break the seal.
14. Remove excess urethane, if any.
15. Perform water leak test immediately.
16. Clean the outside of the windshield.
17. Install both of the A-pillar trims.
18. Install the rearview mirror with two screws.
19. Install the cowl vent with six screws and two fasteners.
20. Install both wiper arm assemblies with one nut each.
Page 89 of 114
Body (Interior and Exterior) > Interior > rear windows glass > Components and Components Location
Component
Body (Interior and Exterior) > Interior > rear windows glass > Repair procedures
Removal
1. Remove rear header trim, rear pillar trim, and rear package tray.
2. Remove each of the window defroster connectors.
3. Remove the rubber molding from around the window glass.
4. Remove the weatherstripping from the inside.
Page 90 of 114
5. Pierce the sealant with the pull knife and cut around the perimeter of the glass.
6. Remove the glass to a safe place.
Installation
1. Clean the body of excess sealant with a knife.
2. Clean the glass of excess sealant with a window scraper.

3. Prime an area approximately 3/4 inch (19 mm) wide around the perimeter of the glass.
Page 91 of 114
4. Prime the contact area on the body.
5. Reprime the glass.

6. Install the molding around the perimeter of the glass.
7. Install the weatherstripping in the door.
The following cure times may be critical. Attempting to replace a windshield in ambient temperature over
95°F (35°C) should be avoided because the surface of the sealant may harden before completing the
application.
Time Required Until Vehicle Can Be

Temperature Surface Hardening Time
Returned To Service
8. Apply sealant to the door where it was sealed before.
9. Clean the inside of the glass with a commercial glass cleaner and a lint-free cloth.
10. Install molding on the glass.
11. Install the glass into the body.
12. Press the glass firmly into the urethane sealant.
13. Press the molding firmly into place.
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14. Remove excess sealant, if any.
15. Tape the window firmly into place so it will not creep down from its own weight.
16. Perform water leak test immediately.
17. Clean the outside of the glass with a commercial glass cleaner and a lint-free cloth.
18. Remove the tape from the windshield wiper and lower it onto the glass.
19. Connect the rear window defroster connectors.
Body (Interior and Exterior) > Bumper > front bumper > Description and Operation
DESCRIPTION AND OPERATING
Front and rear bumpers consist of three parts; bumper face, energy absorbing foam, and bumper reinforcement. The
bumper face is made of polypropylene and the absorption medium is styrofoam. Reinforcement is constructed of
polypropylene and reinforcing fiber with energy absorbing foam placed between bumper face and the reinforcement.
Body (Interior and Exterior) > Bumper > front bumper > Components and Components Location
Component
Page 93 of 114
Body (Interior and Exterior) > Bumper > front bumper > Repair procedures
Removal
1. Remove headlight and combination light assembly.
2. Remove radiator grille guard.

3. Remove bumper face.
(1) Remove bulb & socket from fog light.
(2) Remove eight fasteners from top of right side of bumper.
(3) Remove two screws from front side of bumper face.

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(4) Remove four fasteners from under cover.
(5) Remove bumper face.

4. Remove energy absorbent foam and reinforcement.
(1) Remove two nuts from left side of bumper back beam.
(2) Repeat for right side.
5. Install front bumper in reverse order of removal.
Tighten bumper mounting nuts to

19~28 Nm (1.9~2.8 kg·m, 14~20 lb·ft)
Inspection
1. Inspect front bumper face for damage and check that front bumper is securely mounted.
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2. Inspect front bumper for missing attaching hardware.
Body (Interior and Exterior) > Bumper > rear bumper > Components and Components Location
COMPONENT
Body (Interior and Exterior) > Bumper > rear bumper > Repair procedures
Removal
1. Remove rear combination light assembly. Refer to BE Gr, Body Electrial System.
Page 96 of 114
2. Remove rear mud flap.
(1) Remove three bolts that secure left rear mud flap to mudguard.
(2) Repeat right side.
3. Remove trunk end trim and trunk side trim. Refer to "Trim" in this section.
4. Remove trunk side trim. Refer to "Trim" in this section.
5. Remove rear bumper assembly.
(1) Remove two bolts from left side of trunk.

(3) Remove one bolt from left side of bumper.

Page 97 of 114
(5) Remove two bolts from top of left side of bumper.

(7) Remove two bolts from bottom of left side of rear bumper stay.

Tighten rear bumper mounting bolts to

35~55 Nm (3.5~5.5 kg·m, 25~40 lb·ft)
Inspection
1. Inspect rear bumper face for damage and check that it is securely mounted.
2. Inspect rear bumper for missing attaching hardware.
Body (Interior and Exterior) > Seat & Power Seat > power seat moter > Repair procedures
Inspection
Page 98 of 114
1. Disconnect the connectors for each motor.
2. When the battery connected directly to the motor terminals, check if the motors run smoothly.
3. Reverse the connections and check that the motor reversely turns.
4. It is an abnormality, replace the motors.
Body (Interior and Exterior) > Seat & Power Seat > powr seat control switch > Repair procedures
Inspection
Operate the power seat switch and check for continuity between terminals. If continuity is not as specified, replace
the switch.
Page 99 of 114
Slide motor limit switch

1. Disconnect the limit switch and operate the limit switch.
2. Check for continuity between the terminals.
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3. If there is an abnormality, replace the limit switch.
Height motor limit switch

The height motor limit switch builts in the height motor.
1. Check that the motor stop after about 1/2 turns counterclockwise.
2. Check that the motor stop after about 1/2 turns clockwise.
3. If operation is not as specified, replace the motor.
Body (Interior and Exterior) > Seat & Power Seat > front seat > Description and Operation
Front seat consists of a seat back and a cushion. Both items are replaceable or serviceable. Both seats can be
reclined or adjusted front-to-rear by two levers, adjusting lever and reclining lever. Head restraint can also be
adjusted or removed. Seat adjuster lever is under right or left front corner of either front seat. Pulling on 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 arm 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 vertical driving position and then lock.
Reclining adjuster is a replaceable item. Driver´s seat is also equipped with a lifter lever. This is controlled by a lever
on left side of driver´s side seat cushion. Lifter control lever is a replaceable item.
Body (Interior and Exterior) > Seat & Power Seat > front seat > Components and Components
Location
Component
Page 101 of 114
Body (Interior and Exterior) > Seat & Power Seat > front seat > Repair procedures
REMOVAL
1. Pull reclining lever and let seatback spring forward.
2. Pull seat adjuster and push seat all of the way back.
Page 102 of 114
3. Remove two mounting bolts from front side of seat.
4. Move seat forward.

5. Remove mounting bolt and nut from rear side of seat.
6. Remove seat.
Tighten bolts to
35~55 N.m (3.5~5.5 kg-m, 25~40 Ib-ft)
Tighten nuts to
24~36 N.m (2.4~3.6 kg-m, 17~26 Ib-ft)
DISASSEMBLY (FRONT SEAT CUSHION)

REMOVAL
1. Remove seat from vehicle.
Page 103 of 114
2. Remove seat side cover.
3. Remove four mounting bolts from bottom of seat assembly.
4. Remove seat cushion.

5. Install in reverse order of disassembly.
Tighten seat cushion mounting bolts to

17~26 N.m (1.7~2.6 kg-m, 12~19 Ib-ft)
Disassembly (Front seatback)

Removal
1. Remove seat from vehicle.
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2. Remove back plate.
(1) Remove two clips from bottom of seat cushion.

(2) Pull out lower side of back plate.
(3) Remove back plate carefully, pulling down with hands.
3. Remove two mounting bolts from left side of seatback.
4. Repeat right side.

Page 105 of 114
5. Remove seatback.
6. Install in reverse order of disassembly.
Inspection
1. Check that seat adjuster and reclining lever move smoothly.
2. Look under seat and visually check seat adjuster for wear or damage.
3. Apply grease to all exposed moving parts.
Body (Interior and Exterior) > Seat & Power Seat > rear seat > Description and Operation
The rear seat consists of two separate seatbacks, two separate side bolsters and a single cushion frame. Frame is
held in place by two mounted hinges. Two side bolsters are attached to vehicle frame by bolt two seatbacks are
attached to frame by mounted hinge bushing and brackets. In passenger carrying position, seatbacks are locked to
vehicle frame by seatback strikers.
Body (Interior and Exterior) > Seat & Power Seat > rear seat > Repair procedures
Removal
Page 106 of 114
1. Remove two mounting bolts from rear side of cushion.
2. Push lock buttons as shown in figure to release cushion, and then pull seat cushion out.
3. Remove two mounting bolts from left side of seat hinge bracket.
4. Repeat right side.
5. Push lock button and fold seatback.
6. Remove four seatback mounting bolts from left, right and center of hinge.
7. Remove one mounting bolts from left side bolster.
8. Remove one mounting bolts from right side bolster.

9. Remove left and right side bolster.
10. Remove left seatback.
11. Repeat for right side.
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Tighten seat mounting bolts to

17~26 N.m (1.7~2.6 kg-m, 12~19 Ib-ft)
Body (Interior and Exterior) > Seat Heater > Components and Components Location
Component
Body (Interior and Exterior) > Seat Heater > Seat Heater switch > Repair procedures
Inspection
Inspect the switch continuity between terminals as below.
If the continuity is not as specified, replace the switch.

Page 108 of 114
Body (Interior and Exterior) > Seat Belt > front seat belt > Description and Operation
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 a warning light on the
instrument panel and an audible chime to remind driver to fasten safety belt. Warning ceases after approximately 60
seconds. There are no warnings on other passengers´s belts. Retractors are securely mounted to body. Buckles are
also securely mounted to floor.
Body (Interior and Exterior) > Seat Belt > front seat belt > Components and Components Location
COMPONENT
Page 109 of 114
Body (Interior and Exterior) > Seat Belt > front seat belt > Repair procedures
INSPECTION
1. Inspect buckle assembly mounting to ensure that it is secure.
2. Inspect anchor assembly mounting to ensure that it is secure.
4. Inspect retractor assembly mounting to ensure that it is secure.
5. Install B-pillar lower trim.
6. Extend safety belt fully to ensure its motion is smooth and easy.
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7. Retract safety belt fully to ensure its motion is smooth and easy.
8. Buckle safety belt. Pull firmly on each side of buckle to ensure that it is secure.
9. 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
belt icon 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 and chime will be heard. Buckle driver's safety belt. Safety belt icon and chime will extinguish. Turn
key to "LOCK" position and remove key.
If a safety belt is not functioning and cannot be immediately repaired, warn the customer not to use that seating
position. If the customer must use that seating position, encourage the customer to use a substitute vehicle until the
proper repairs can be made. If the customer refuses, refer the matter to the Service Manager.
Disassembly (Front buckle assembly

1. Remove screw cover near bottom of assembly.
2. Remove one bolt from mounting bracket.
Tighten mounting bolt to

50~60 N·m (5.0~6.0 kg·m, 36~43 lb·ft)
Front lap/shoulder belt assembly

Removal
1. Remove one mounting bolt from lower anchor.
2. Retract belt slowly as far as it will go.

3. Unsnap captive shoulder belt anchor bolt cover from bottom and lift up.
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4. Remove one upper anchor bolt.
5. Remove retractor assembly.
1. A pretensioner functions one time only. Be sure to replace the pretensioner safety belt after is is
deployed.
2. Do not attempt to disasemble or repair the seat belt pretensioner. If it malfunctions, replace it with a
new pretensioner safety belt.
3. Be cautions in handling a pretensioner safety belt, and do not expose it to water or oil. If crushed,
damaged, or deformed, replace it with a new one.
4. Connect the vattery only after the installation of the pretensioner safety belt bas been correctly
completed.
5. Renivak if oretebsuiber retractor :
1) Turn ignition switch "OFF".
2) Disconnect negative battry cable.
3) Wait for bout 1 minute.
4) Disconnect has generator connector.
5) Remove retractor screw.
(1) Remove B-pillar lower trim.

(2) Disconnect electrical connector from retractor assembly.
(3) Remove one sheet metal screw to remove retractor assembly.
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6. Remove shoulder adjuster.
(1) Remove two sheet metal screws to remove belt guide.
(2) Unfasten B-pillar upper trim.
(3) Remove two mounting bolts from shoulder adjuster.
Body (Interior and Exterior) > Seat Belt > rear seat belt > Repair procedures
Inspection
1. Inspect three buckle assembly mountings to ensure that they are secure. (This is done from rear of vehicle.)
2. Inspect remaining belt´s mounting to ensure that it is secure. (This is done from rear of vehicle.)
3. Pull safety belts to rear between seatback and cushion.
4. Remove seat cushion.
5. Inspect outboard lap belt mountings to ensure that they are secure.
6. Disconnect fasteners of C-pillar trim from body and pull C-pillar trim down completely.
7. Fold rear seatback forward for front side of seat cushion.
8. Remove package tray.
9. Inspect retractor assembly mountings to ensure that they are secure.
If a safety belt is not functioning and cannot be immediately repaired, warn the customer not to use that seating
position. If the customer must use that seating position, encourage the customer to use a substitute vehicle until the
proper repairs can be made. If the customer refuses, refer the matter to the Service Manager.
Rear lap/shoulder belt assembly

Removal
1. Remove rear seat cushion.
2. Remove side bolster.
(1) Fold rear seatback for the floor of body.
(2) Remove two mounting bolts from rear seat hinge.
(3) Remove one bolt from side bolster.
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3. Remove one bolt from lap belt mounting bracket.
4. Retract belt slowly as far as belt will go.

5. Remove C-pillar trim.
6. Remove package tray.
7. Remove one bolt and one sheet metal screw to attach retractor assembly.
Installation
1. Install retractor mounting bolt and sheet metal screw.
2. Install package tray.
3. Install C-pillar trim.
4. Install one bolt through lap belt mounting brakcet.

40~55 N.m(4.0~5.5 kg-m, 29~40 Ib-ft)
5. Install side bolster.

6. Install rear seat cushion.
Disassembly (Rear buckle assembly)

1. Pull safety belts to rear through seats.
2. Remove rear seat cushion.
3. Remove one bolt from rear buckle assembly mounting bracket.
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4. Install mounting bolt through bracket.

40~55 N.m(4.0~5.5 kg-m, 29~40 Ib-ft)
5. Feed buckle between seatback and cushion without any twists.

Page 1 of 61
OPTIMA(MS) > 2003 > G 2.4 DOHC > Body Electrical System
Body Electrical System > General Information > Troubleshooting

Troubleshooting
Instrument and warning system
Symptom Possible cause Remedy
Tachometer does not operate Fuse blown Check for short and replace fuse
Tachometer faulty Check tachometer
Wiring faulty Repair if necessary
Fuel gauge does not operate Fuse blown Check for short and replace fuse
Fuel gauge faulty Check gauge
Fuel sender faulty Check fuel sender
Wiring faulty Repair if necessary
Low fuel warning lamp does not light Fuse blown Check for short and replace fuse
Bulb burned out Replace bulb
Fuel level sensor faulty Check sensor
Wiring or ground fraulty Repair if necessary
Water temperature gauge does not Fuse blown Check for short and replace fuse
operate
Water temperature gauge faulty Check gauge
Water temperature sender faulty Check sender
Wiring or ground faulty Repair if necessary
Oil pressure warning lamp does not Fuse blown Check for short and replace fuse
light
Oil pressure sender faulty Check sender
Low brake fluid warning lamp does Fuse blown Check for short and replace fuse
not light Bulb burned out Replace bulb
Brake fluid level warning switch
Check switch
faulty
Parking brake switch faulty Check switch
Open door warning lamp does not Fuse blown Check for connection
light
Door switch faulty Check switch
Seat belt warning lamp does not light Fuse blown Check for short and replace fuse
Page 2 of 61
Buckle switch faulty Check switch
Lighting system
One lamp does not light Bulb burned out Replace bulb
(all exterior) Socket, wiring or ground faulty Repair if necessary
Head lamps do not light Bulb burned out Replace bulb
Fuse blown - Low beam Check for short and replace fuse
Fuse blown - high beam Check for short and replace fuse
Head lamp relay faulty Check relay
Lighting switch faulty Check switch
Tail lamps do not light Tail lamp fuse blown Replace fuse and check for short
Fusible link blown Replace fusible link
Tail lamp relay faulty Check relay
Lighting switch faulty Check switch
Stop lamps do not light Fuse blown Replace fuse and check for short
Stop lamp switch faulty Adjust or replace switch
Stop lamp relay faulty Replace relay
Stop lamps stay on Stop lamp switch faulty Adjust or replace switch
Stop lamp relay faulty Replace relay
Instrument lamps do not light Rheostat faulty Check rheostat
(Tail lamps light)
Turn signal lamp does not flash on Bulb burned out Replace bulb
one side
Turn signal switch faulty Check switch
Turn signal lamps do not operate Fuse blown Replace fuse and check for short
Flasher faulty Check flasher
Turn signal switch faulty Check switch
Hazard warning lamps do not Fuse blown Replace fuse and check for short
operate
Flasher faulty Check flasher
Hazard switch faulty Check switch
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Flasher rate too slow or too fast Lamps' wattages are smaller or
Replace lamps
larger than specified
Defective flasher Replace flasher
Back up lamps do not light up Fuse blown Replace fuse and check for short
Back up lamp switch faulty Check switch
Overhead console lamp does not Fuse blown Check for short and replace fuse
light up Wiring or ground faulty Repair if necessary
Windshild wiper
Wipers do not operate or return Wiper fuse blown Check for short and replace fuse
to off position.
Wiper motor faulty Check motor
Wiper switch faulty Check switch
Wipers do not operate in INT ETACS Module faulty Check ETACS Module
position Wiper switch faulty Check switch
Wiper motor faulty Check motor
Wiring or ground fautly Repair if necessary
Power window
No windows operate from the main Fuse blown Check for short and rplace fuse
switch on the driver's door Clean and retighten the ground
Poor ground
terminal mounting bolt
Defective power window main Check the switch
switch Replace if necessary
Open circuit in wires or loose or
Repair or replace
disconnected connector
Driver's side window does not Defective power window main
Check for driver's window switch
operate switch
Defective motor or circuit breaker Replace the motor
Check the harness and the connector
Passenger's side window does not Defective power window subswitch Replace the switch
operate
Defective motor or circuit breaker Replace the motor
Wiring faulty or disconnected
Repair if necessary
connector
Power door mirror

Page 4 of 61
No mirrors operate Fuse blown Check the circuit and replace fuse
Clean and retighten the gound
Poor ground
terminal mounting bolt
Defective mirror switch Check the switch
Replace if necessary
Repair or replace
One mirror does not operate Defective mirror switch Check the switch
Replace if necessary
Defective mirror actuator Replace the actuator
Open circuit wires or loose or
Repair or replace
Body Electrical System > General Information > Specifications

Instruments and warning system
Warning Bulb wattage
Color
lamps (w)
Turn signal Green
LED
(LH, RH) Blue
LED
High beam Green
LED
Front fog Yellow
LED
Trunk lid open Red
LED
Door ajar Red
1.4
Air bag Amber
1.4
Engine check Green
LED
Auto Cruise Red
LED
Oil pressure Red
LED
Parking brake Red
LED
Battery charge Yellow
LED
ABS Yellow
LED
TCS Red
LED
Seat belt Yellow
LED
Low fuel
A/T Orange
LED
R Green
LED
P, N, D
Service specifications
Indicators and gauges
Page 5 of 61
Page 6 of 61
Lighting system
Items Bulb wattage(W)
65W / 55W (High /
Head lamp
Low)
Front turn signal lamp 28W
Front position lamp 8W
Front fog lamp 28W
Rear combination lamps
Tail/stop lamp 8W / 27W
Back up lamp 16W
Turn signal lamp 27W
License plate lamp 5W
Sun visor illumi.lamp 5W
Room lamp 10W
Over head lamp 5W
Courtesy lamp 5W
High mount stop lamp 18W
Side mark lamp 5W
Body Electrical System > Audio > Audio Unit > Repair procedures
Tape head and capstan cleaning
Page 7 of 61
1. To obtain optimum performance, clean the head and capstan as often as necessary, depending upon frequency of
use and tape cleanness.
2. To clean the tape head and capstan, use a cotton swab dipped in ordinary rubbing alcohol. Wipe the head and
capstan.
Installation of radio equipment

The electronic control systems have been designed so that external radio waves ill not interfere with their operation.
However, if the antenna or cableof the amateur transceiver is routed near the computers, it may affect the peration of
the computers, even if the output of the transceiver is no morethan 25W.
To protect each of the computers from interference by transmitter (hum, transceiver, etc.) the following should be
observed.
1. Install the antenna on the roof or rear bumper.
2. Because radio waves are emitted from the coaxial cable of the antenna, keep it 200 mm (8 in.) away from the
computers and the wiring harness. If the cable must cross the wiring harness, route it so that it runs at right angles
to the wiring harness.
3. The antenna and the cable should be well matched, and the standing-wave ratio* should be kept low.
4. A transmitter having a large output should not be installed in the vehicle.
5. After installation of transmitter, run the engine at idle, emit radio waves from the transmitter and make sure that
the engine is not affected.
* STANDING-WAVE RATIO
STANDING-WAVE RATIO If an antenna and a cable having different impedances are connected, the input
impedance Zi will vary in accordance with the length of the cable and the frequency of the transmitter, and the
voltage distribution will also vary in accordance with the location. The ratio between this maximum voltage and
minimum voltage is called the standing-wave ratio. It can also be represented by the ratio between the impedances
of the antenna and the cable. The amount of radio waves emitted from the cable increases as the standing-wave ratio
increases, and this increases the possibility of the electronic components being adversely affected.

1. Disconnect the negative (-) battery terminal.
Page 8 of 61
2. Remove the center facia panel and disconnect the wire connectors.
3. Remove the 4 screws holding the audio unit then remove the audio assembly.
4. Disconnect the power connector and antenna cable jack from the audio unit.
Body Electrical System > Audio > Speakers > Repair procedures
Speaker checking
1. Check the speaker by using an ohmmeter If an ohmmeter indicates the impedance of the speaker when checking
between the speaker (+) and speaker (-) of the same channel, the speaker is okay.
standard impedance is stamped at the back of speaker.
2. If clicking sound is emitted from the speaker when the ohmmeter plugs touch the speaker terminals, the speaker
is okay.
Body Electrical System > Audio > Antenna > Description and Operation
Page 9 of 61
The antenna is an intergral part of the AM/FM radio. The antenna is mounted to left rear fender and receives AM
and FM signals which are sent through antenna cable to the radio.
Body Electrical System > Audio > Antenna > Repair procedures
Antenna cable
Inspection
1. Inspect Antenna cable for obvious damage.
2. Inspect Antenna cable connectors for obvious damage.
Removal
1. Remove one screw from center panel trim.
2. pull out center panel trim.
3. Remove four screws that secure radio to center panel.
4. Remove connectors from rear of radio.
5. Disconnect antenna cable connector from antenna.
6. Remove antenna cable connector from antenna.

7. Pull carpet back toward driver seat.
8. Remove antenna cable.
Installation
Install in reverse order of removal.
Antenna mast
Inspection
1. Inspect antenna mast and mount for damage.
2. Make certain antenna mast is clean and not corroded.
3. Make certain antenna mast is secure in antenna mount.
Removal
Remove antenna mast from antenna mount by unscrewing antenna mast from mount.
Installation
Install antenna mast into antenna mount by screwing antenna mast into mount.
Antenna mount
Inspection
Inspect antenna mount for obvious damage.
Removal
1. Remove antenna mast by unscrewing antenna mast from mount.
2. Remove bezel nut from antenna.
3. Disconnect antenna cable from antenna.
4. Remove one nut from antenna mount support.
5. Remove antenna mount from bottom.
Installation
1. Install antenna mount.
Page 10 of 61
2. Connect antenna cable connector to antenna.
3. Install bezel nut.
4. Install antenna mast.
Power antenna inspection

1. Disconnect the 3P connector from the motor.
2. Check battery voltage is measured between terminal 1 and terminal 3 at all time.
3. Check if the battery voltage is measured between terminal 2 and termianl 3 when ignition switch and audio switch
is turned on.
4. Connect battery source to terminal 2 and terminal 1 of component side and check that motor operates (Antenna
moves up).
5. Then, disconnect battery source from terminal 2 and check that motor operates (Antenna moves down).
Checking the antenna
Ohmmeter measurement locations Result
Circuits from F to A, B, C, D and E Continuity
Circuit between G and H Continuity
Circuit from H to A, B, C, D and E No continuity
Page 11 of 61
Body Electrical System > Multifunction switch > Multi Function Switch > Components and Components
Location
Component
Body Electrical System > Multifunction switch > Multi Function Switch > Repair procedures
Page 12 of 61
Prior to removing of the multi function switch assembly in vehicles equipped with air bags, be careful to follow the
following:
• Never attempt to disassemble or repair the air bag module or clock spring. If faulty, replace it.
• Do not drop the air bag module or clock spring or allow contact with water, grease or oil. Replace if a dent,
crack, deformation or rust is detected.
• The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward. Do
not place anything on top of it.
• Do not expose the air bag module to temperatures over 93°C(200°F).
• After deployment of an air bag, replace the clock spring with a new one.
• Wear gloves and safety glasses when handing an air bag that has been deployed.
• An undeployed air bag module should only be disposed of in accordance with the procedures mentioned in the
restraints section.
• When you disconnect the air bag module-clock spring connector, take care not to apply excessive force.
• The removed air bag module should be stored in a clean, dry place.
• Prior to installing the clock spring, align the mating mark and "NEUTRAL" position indicator of the clock
spring, and after turning the front wheels to the straight-ahead position, install the clock spring to the column
switch. If the mating mark of the clock spring is not properly aligned, the steering wheel may not completely
rotate during a turn, or the flat cable within the clock spring may be broken obstructing normal operation of the
SRS and possibly leading to serious injury to the vehicle's driver. To inspect the clock spring, refer to the
restraints section.
Check the continuity between the terminals while operating the switch.
Lighting switch (Connector "1")
Dimmer and passing switch (Connector "1")

Page 13 of 61
Turn signal and lane change switch (Connector "1")
Front fog switch (Connector "1")
Wiper switch (Connector "2")
Washer switch (Connector "2")
Mist switch (Connector "2")

Page 14 of 61
Body Electrical System > Horn > Repair procedures

Removal
2. Disconnect horn wire.
3. Remove one bolt and remove horn.
Installation
Horn is electrically grounded through mounting. Be sure that metal-to-metal contact is established before installing
attaching bolt.
2. Position horn on chassis and install one bolts.
3. Connect two wires to horn.
Inspection
1. Test the horn by connecting battery voltage to the 1 and 2 terminals.
2. The horn should sound, if the horn fails to sound, replace it.
Adjustment
Operate the horn, and adjust the tone to a suitable level by turning the adjusting screw.
After the adjustment, apply a small amount of paint around the screw head to keep it from loosening.
Page 15 of 61
Body Electrical System > Keyless Entry And > Schematic Diagrams
Circuit diagram
Body Electrical System > Keyless Entry And > Description and Operation
Page 16 of 61
Description
The keyless entry and burglar alarm system consists of ETACS components and some other parts.
Without a key, the keyless entry system is able to lock and unlock all the doors at a distance, transmitting a weak
radio wave from a transmitter.
Body Electrical System > Keyless Entry And > Repair procedures
Transmitter
1. Check that the red light flickers when the door lock button or unlock button is pressed on the transmitter.
2. Remove the battery and check voltage if the red light does't flicker.
Standard value : 3V
3. Replace the battery if voltage is below 3V and replace the remote control switch if it is inoperable after replacing
the battery.
Battery : Lithium CR2032 (3V, 220mA/h)
Transmitter code saving methood

1. Store the transmitter cade by using Hi-scan pro.
Transmitter
1. Check that the red light flickers when the door lock button or unlock button is pressed on the transmitter.
2. Remove the battery and check voltage if the red light does't flicker.
Standard value : 3V
3. Replace the battery if voltage is below 3V and replace the remote control switch if it is inoperable after replacing
the battery.
Battery : Lithium CR2032 (3V, 220mA/h)
Body Electrical System > Keyless Entry And > Specifications

Specifications
Page 17 of 61
Items Specifications
Keyless entry transmitter
Power source Lithium 3V battery (1EA)
Transmissible distance 10m or more
Life of battery 2 years or more (at 20 times per day)
Button Door lock, door unlock, trunk lid open
Transmission frequency 315 MHz
Receiver
Operating voltage DC 9V-16V
Operating temperature
-30°C ± 80°C
range
Maximum standby current 3mA or less
Output pattern Door lock, door unlock, trunk lid open
Body Electrical System > ETACS (Electronic Time > ETACS Module > Repair procedures
1. Disconnect the negative (-) battery terminal.
2. Remove the lower crash pad (Refer to BD group).
3. Remove the bolts holding the ETACS moduld and disconnect the connectors.
Operation check of components

While operating the components, check whether the operations are normal with timing chart.
Etacs function
Page 18 of 61
1. Variable intermittent wiper
Time specification
T1 : Max. 0.3 sec.
T2 : Time of wiper motor 1 rotation (0.6~0.8 sec.).
T3 : 2.2 ± 0.2 sec. (VR=0 kΩ)~10.0 ± 1.0 sec. (VR=50 kΩ)
2. Washer related wiper

(1) Time specification
T1 : 0.6 sec.
T2 : 2.5~3.8 sec.
(2) This function should be operated preferentially even though the variable intermitten wiper is operating.
3. Rear window defogger

Time specification
T1 : 60m sec.
T2 20 ± 1 Min.
Page 19 of 61
4. Seat belt warnig
Time specification
T1 : 6 ± 1 sec.
T2 : 0.45 ± 0.1 sec.
T3 : 0.3 ± 0.1 sec,
5. Ignition key hole illumination

Time specification
T1 : 10 ± 1.0 sec.
T2 : 0 ~ 10 sec.
6. Delayed out room lamp

Time specification
T1 : 5.5 ± 0.5 sec.
7. Key operated warning

Time specification
T1, T2 : 0.45 ± 0.1 sec.
Page 20 of 61
8. Ignition key reminder
Time specification
T1 : 0.5 sec.
T2 : 0~0.5 sec.
9. Outside Door key illumination (Without burglar alarm)

Time specification
T1 : 10 ± 1.0 sec.
10. Power window timer

Time specification
T1 : 30 ± 5 sec.
11. Central door lock/unlock (without burglar alarm)

Time specification
T : 0.5 ± 0.1 sec.
Page 21 of 61
12. Central door lock./unlock (with burglar alarm)
(1) When using the door key
Time specification
T : 0.5 ± 0.1 sec.
(2) When using the door lock knob switch

Time specification
T : 0.5 ± 0.1 sec.
(3) When using the transmitter (TX)

Time specification
T : 0.5 ± 0.1 sec.
(4) Power window main door lock switch

Time specification
T : 0.5 ± 0.1 sec.
13. Tail lamp auto cut
Page 22 of 61
14. Two-Turn unlock
Time specification
T1 : 3 ± 0.5 sec.
Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Schematic
Diagrams
Components
Page 23 of 61
Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Repair procedures
Inspection
1. Check for a burnt fusible link with an ohmmeter.
Page 24 of 61
2. If a fusible link burns out, there is a short or some other problem in the circuit. Carefully determine the cause and
correct it before replacing the fusible link
The fusible link will burn out within 15 seconds if a higher than specified current flows through the circuit.
Body Electrical System > Fuses And Relays > Fuses > Schematic Diagrams
Specification
Page 25 of 61
Body Electrical System > Fuses And Relays > Fuses > Repair procedures
Inspection
1. Be sure there is no play in the fuse holders, and that the fuses are held securely.
2. Are the fuse capacities for each circuit correct?
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.
Never use a fuse of higher capacity than specified.
Inspection of fuses
When a fuse is blown, there are two probable causes. The two causes can easily be determined by a visual check
after removing the fuses.
1. Fuse blown due to over-current.
Prior to replacing the fuse with a new one, check the circuit for a short and the related parts for abnormal
conditions. Only after the correction of a short or replacement of abnormal parts, should a fuse with the same
ampere rating be installed.
Page 26 of 61
2. Fuse blown due to repeated on-off current.
Normally, this type of problem occurs after a fairly long period of use, and is less frequent than #1 above. In this
case, you may simply replace with a new fuse of the same capacity.
A blade type fuse is identified by the numbered value in amperes. If the fuse is blown, be sure to replace a
fuse with the same ampere rating. If a fuse of higher capacity than specified is used, parts may be damaged
and a danger of fire exists. To remove or insert a fuse, use the fuse puller in the fuse box.
Body Electrical System > Indicators And Gauges > Instrument Cluster > Schematic Diagrams
Circuit diagram
Page 27 of 61
Body Electrical System > Indicators And Gauges > Instrument Cluster > Components and Components
Location
Component
Page 28 of 61
Body Electrical System > Indicators And Gauges > Instrument Cluster > Repair procedures
Removal
Page 29 of 61
1. Remove three screws from instrument cluster trim.
2. Remove four mounting screws.

3. Pull cluster from instrument panel.
4. Disconnect two connectors.
5. Remove instrument cluster.
Installation
1. Place cluster in instrument panel.
2. Connect two connectors.
3. Push cluster into instrument panel.
4. Install four cluster mounting screws.
5. Install three screws on instrument cluster trim.
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 in the service specifications.
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.
Tachometer
1. Connect the scan tool to the diagnostic link connector or install a tachometer.
Page 30 of 61
2. With the engine started, compare the readings of the tester with that of the tachometer. Replace the tachometer if
the standard values in the service specifications is exceeded.
When removing or installing the tachometer, be careful not to drop it or subject it to severe shock.
Body Electrical System > Power Door Locks > Power Door Lock Actuators > Repair procedures
Door lock control actuator
1. Disconnect the actuator connector from the wiring harness.
2. Apply battery voltage (DC 12 V) to each terminal as shown in the table below and confirm that the actuator
makes corresponding operation.
Body Electrical System > Power Door Mirrors > Schematic Diagrams
Circuit
Page 31 of 61
Body Electrical System > Power Door Mirrors > Power out side mirror switch > Repair procedures
Inspection
1. remove the power door mirror switch from the door trim panel.
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2. Check for continuity between the terminals in each switch position according to the table.
If continuity is not as specified, replace the power door mirror switch.
Body Electrical System > Power Door Mirrors > Power Door Mirror Actuator > Repair procedures
Inspection
1. Disconnect the power door mirror connector from the harness.
2. Apply battery voltage to each terminal as shown in the table and verify that the mirror operates properly.
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Mirror heating inspection
Body Electrical System > Power Windows > Schematic Diagrams

Circuit diagram
Page 34 of 61
Body Electrical System > Power Windows > Power Window Motor > Repair procedures
Inspection
Connect the motor terminals directly to battery voltage (12V) and check that the motor operates smoothly.
Next, reverse the polarity and check that the motor operates smoothly in the reverse direction. If the operation is
abnormal, replace the motor.
Body Electrical System > Power Windows > Power Window Switch > Repair procedures
Inspection
Power window main switch
1. Remove the switch from the door trim panel.
2. Check for continuity between the terminals. If continuity is not as specified in the table, replace the power
window switch.
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Power window sub switch
Door lock switch

Page 36 of 61
Body Electrical System > Rear Window Defogger > Rear Window Defogger Printed Heater > Repair
procedures
Inspection
Wrap tin foil around the end of the voltmeter test lead to prevent damaging the heater line. Apply finger pressure
on the tin foil, moving the tin foil along the grid line to check for open circuits.
1. Turn on the defogger switch and use a voltmeter to measure the voltage of each heater line at the glass center
point. If a voltage of approximately 6V is indicated by the voltmeter, the heater line of the rear window is
considered satisfactory.
2. If a heater line is burned out between the center point and (+) terminal, the voltmeter will indicate 12V.
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3. If a heater line is burned out between the center point and (-) terminal, the voltmeter will indicate 0V.
4. To check for open circuits, slowly move the test lead in the direction that the open circuit seems to exist. Try to
find a point where a voltage is generated or changes to 0V. The point where the voltage has changed is the open-
circuit point.
5. Use an ohmmeter to measure the resistance of each heater line between a terminal and the center of a grid line,
and between the same terminal and the center of one adjacent heater line. The section with a broken heater line
will have a resistance twice as that in other sections. In the affected section, move the test lead to a position
where the resistance sharply changes.
Repair of broken heater line

Prepare the following items:
1. Conductive paint.
2. Paint thinner.
3. Masking tape.
4. Silicone remover.
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5. Thin brush.
Wipe the glass adjacent to the broken heater line, clean with silicone remover and attach the masking tape as
shown. Shake the conductive paint container well, and apply three coats with a brush at intervals of about 15
minutes apart. Remove the tape and allow sufficient time for drying before applying power. For a better finish,
scrape away excess deposits with a knife after the paint has completely dried. (allow 24 hours).
After repairing, clean the glass with a soft dry cloth or wipe along the grid line with a slightly moistened
cloth.
Body Electrical System > Windshield Wiper/Washer > Description and Operation
Washer system
This is equipped with a variable speed (intermittent), modular wiper/washer system. Wiper system consists of a
wiper motor, a wiper link assembly, and two wiper arms with blades. Washer assembly consists of a washer tank, a
washer motor, two washer nozzles, and connecting hoses. Both systems are then connected to a wiper lever and a
timer unit in steering column combination switch.
Hoses
Washer hoses are neoprene lines that carry washer fluid to washer nozzles. There are three hose pieces, a three-
port hose joint, and a two-port hose joint. Hoses can be replaced individually. Washer hose system also has three
replaceable hold-down clips.
Lever assembly
Wiper assembly is located in combination switch on steering column. For switch-related electrical problems, refer to
Wiring Diagram Manual. For removal procedures, refer to Group ST, Steering System.
Motor
Washer motor pumps washer fluid to washer nozzles. It is a single speed 12V DC motor to a pump mechanism. It is
a replaceable item.
Nozzles
Washer nozzles deliver washer fluid directly to windshield. Nozzles are replaceable as an individual item.
Tank assembly
Washer tank assembly stores washer fluid used by washer system. It is a plastic assembly with a fill port and a
connection port to washer motor. It is a replaceable item.
Timer unit
Timer unit controls intermittent operation of wiper system. It is part of wiper unit assembly in steering column
combination switch. For unit-related electrical problems, refer to Wiring Diagram Manual. For removal procedures,
refer to Group ST, Steering System.
Wiper system
ARM
Wiper arms are metal arms which pull wiper blades across windshield. They are spring-loaded to firmly hold blades
onto windshield during operation of wiper system. They are individual units consisting of a driver’s side and a
Page 39 of 61
passenger side arm.
Blades
Wiper blades are metal frames with rubber inserts. They are available as a unit, or inserts can be replaced
separately.
Link assembly
Wiper link assembly connects wiper motor to wiper arms. It consists of two connecting rods and two pivot units.
When in operation, assembly converts wiper motor's rotational motion into proper left/right movement needed by
wiper arms. If faulty, it can be disassembled, but replacement of full assembly is recommended.
Motor and bracket
Motor is a 12V DC, two-speed unit which provides power to wiper system. It is connected to a transmission (gear
box) in mounting bracket which reduces motor rpm and increases torque. This low rpm, high torque motion is then
transmitted to wiper link assembly. Motor and bracket are a single, replaceable item.
Body Electrical System > Windshield Wiper/Washer > Components and Components Location
Component
Page 40 of 61
Body Electrical System > Windshield Wiper/Washer > Front Wiper Motor > Repair procedures
Removal
2. Remove wiper arms and blades. Refer to "Windshield Wiper/Washer System" in this section.
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3. Remove nuts and fasteners from cowl vent.
4. Remove wiper motor and link assembly.
(1) Disconnect wiper motor harness connector.

(2) Remove two bolts from wiper motor and link assembly.
(3) Separate motor assembly from wiper link assembly.
5. Remove three wiper motor mounting bolts from wiper motor and link assembly.
Installation
1. Install three wiper motor mounting bolts on wiper motor and link assembly.
2. Install wiper motor and link assembly.
(1) Attach wiper motor ball joint to wiper link assembly.

(2) Install and tighten two mounting bolts.
(3) Connect wiper motor harness connector.
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3. Place cowl vent in position and install nuts and fasteners.
Inspection
Speed operation check
1. Remove the connector from the wiper motor.
2. Attach the positive (+) lead from the battery to terminal 4 and the negative (-) lead to terminal 1.
3. Check that the motor operates at low speed.
4. Connect the positive (+) lead from the battery to terminal 4 and the negative (-) lead to terminal 2.
5. Check that the motor operates at high speed.
Automatic stop operation check

1. Operate the motor at low speed.
2. Stop the motor operation anywhere except at the off position by disconnecting terminal 1.
3. Connect terminals 1 and 5
4. Connect the positive (+) lead from the battery to terminal 4 and the negative (-) lead to terminal 3.
5. Check that the motor stops running at the off position.
Body Electrical System > Windshield Wiper/Washer > Wiper Arm > Repair procedures
Removal
Wiper arm
1. Before removal check that wiper has stopped at its off position.
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2. Remove nut cover and then wiper arm nut.
3. Check that arms are marked "Dr" (Driver Side) and "As" (Passenger Side). If not, mark them before removal.
4. Remove wiper arms.
Link assembly
Removal
1. Remove wiper arms and blades. Refer to "Windshield Wiper/Washer System" in this section.
2. Remove nuts and fasteners from cowl vent.
3. Remove wiper motor and wiper link assembly.

(1) Disconnect wiper motor harness connector.
(2) Remove two mounting bolts from assembly.
Inspection
1. Check for any resistance by moving each part of link assembly by hand.
2. If any resistance is found, remove linkage and apply grease to indicated joints.
Installation
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1. Install two bolts on wiper motor and link assembly.
2. Connect wiper motor harness connector.
3. Place cowl vent in position and install nuts and fasteners.
4. Install wiper arms and blades. Refer to "Windshield wiper/washer system" in this section.
5. Check system movement. Wiper arms should stop 1.18 inch (30 mm) (Driver side) and 1.46 inch (37 mm)
(Passenger side) from lower windshield edge.
Body Electrical System > Windshield Wiper/Washer > Front Washer Motor > Repair procedures
Removal
washer nozzle
1. Release holding clip by inserting a thin screwdriver between nozzle and bushing.
2. Remove nozzle from hood and then disconnect nozzle from neoprene hose.
Washer hose
1. Disconnect washer nozzles from hood panel.
2. Unclip hoses from hood clips.

3. Disconnect hose clips on side panel.
4. Disconnect hose from washer motor.
Front washer motor
2. Remove fasteners and bolt from mud guard and gently pull mud guard downward fully.
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3. Remove two bolts on washer tank.
4. Remove hose connector from washer motor.

5. Remove washer motor and washer tank.
6. Drain washer tank and then separate washer motor from washer tank.
Installation
2. Connect nozzle to neoprene hose.
3. Face nozzle exit toward windshield and push in place on hood.
Inspection
1. With the washer motor connected to the washer tank, fill the washer tank with water.
2. Connect battery positive (+) and negative (-) cables to termnals 2 and 1 respectively to see that the washer
motor runs and water is pumped.
Adjustment
1. Spray should center on driver and passenger sides of front windshield. If off-line, adjust by slightly turning the
nozzle.
2. If clogged or restricted, use a needle or wire to clelar nozzle exit.
Body Electrical System > Electro chromic Inside > Description and Operation
Description
Page 46 of 61
The electrochromic (EC) inside rear view mirror receives power, ground and a reverse signal on the three wires that
connect to it. It uses two light sensors to sense glare.
1. The forward facing sensor determines if the outside light levels are low enough for the mirror to operate.
2. The rearward facing sensor detects glare from lights behind the mirror. When glare is detected, it outputs a signal
to the mirror to dim at the required level.
3. The mirror dims to the level as directed by the rearward facing sensor. When the glare is no longer detected, the
mirror returns to normal.
4. Press the "O" button to turn the automatic dimming function off.
The mirror indicator light will turn off. (Only Type B)
5. Press the "I" button to turn the automatic dimming function on.
The mirror indicator light will illuminate. (Only Type B)
Body Electrical System > Electro chromic Inside > Repair procedures
Inspection
To determine if the EC mirror will dim, check it as below procedure.
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1. Turn the ignition key to the "ON" position.

2. Cover the forward facing sensor.
3. Shine a flashlight into the rearward facing sensor.
4. The mirror should dim as soon as the rearward facing sensor detects the high light level.
If this test is performed in a bright area, the mirror may darken as soon as the forward facing sensor is
covered.
5. Put the vehicle into reverse, the mirror should not dim.
6. Aim a flashlight at the forward sensor and another flashlight at the rearward sensor the mirror should not darken.
Body Electrical System > Lighting System > Description and Operation
Exterior lights consist of six lighting systems: headlights, turn-signal lights, parking lights, hazard lights, brake lights,
and license plate lights (rear only).Six systems include left and right headlight and combination light assemblies, left
and right rear combination light assemblies, a rear high-mounted brakelight assembly, and two license plate light
assemblies (for rear license only). All lights are powered by 12-volt electrical system.
Body Electrical System > Lighting System > Components and Components Location
Component
Page 48 of 61
Body Electrical System > Lighting System > Head Lamps > Repair procedures
Removal
1. Open hood. Disconnect negative battery cable.
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2. Remove five bolts attaching headlight and combination light assembly to vehicle.
3. Pull headlight and combination light assembly forward clear of vehicle.

4. Rotate back cover counterclockwise to disengage from light assembly.
5. Pull socket with bulb straight out of headlight and combination light assembly.
Replacement
2. Disconnect electrical connector from headlight assembly.
3. Remove back cover by pushing in on cover, then rotating cover counterclockwise to disengage from headlight
assembly.
The headlight bulb is filled with a gas which is under pressure. Damage to glass part of bulb can cause bulb
to explode causing possible personal injury.
Use care when handling halogen headlight bulb. Do not touch glass part of bulb with bare hands. Oil from
skin can cause bulb to fail.
4. Pull socket with bulb straight back and remove it from headlight and combination light assembly.
5. If bulb has failed, place it in new bulb carton and dispose of properly.
6. Hold replacement bulb by base, or use clean cloth or paper to avoid touching glass, and install bulb in socket.
7. Align slots on bulb with corresponding bosses on headlight assembly. Insert bulb into headlight and combination
light assembly.
8. Install back cover to hold bulb in place.
9. Connect electrical connector.
Installation
1. With bulb installed in socket, align grooves of socket with bosses on headlight and combination light assembly
and insert socket into headlight and combination light assembly.
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2. Align back cover with headlight and combination light assembly and install, turning clockwise until properly
engaged.
3. Position headlight and combination light assembly on vehicle.
4. Connect electrical connector to headlight and combination light assembly.
5. Install five bolts.
Disassembly
1. Turn back cover counterclockwise to disengage, then move away from assembly.
2. Pull bulb straight out of assembly.
Reassembly
1. Push bulb into back of headlight and combination assembly.
2. Position back cover to headlight and combination light and turn clockwise to engage.
Pre-aiming instructions
The headlamps should be aimed with the proper beam-setting equipment, and in accordance with the equipment
manufacture's instructions.
If there are any regulations pertinent to the aiming of headlamps in the area where the vehicle is to be used, adjust
so as to meet those requirements.
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Alternately turn the adjusting bolts to adjust the headlamp aiming. If beam-setting equipment is not available,
proceed as follows :
1. Inflate the tires to the specified pressure and remove any loads from the vehicle except the driver, spare tire, and
tools.
2. The vehicle should be placed on a flat floor.
3. Draw vertical lines (Vertical lines passing through respective headlamp centers) and a horizontal line (Horizontal
line passing throught center of headlamps) on the sereen.
4. With the headlamp and battery in normal condition, aim the headlamps so the brightest portion falls on the
horizontal and vertical lines.
Make vertical and horizontal adjustments to the lower beam using the adjusting wheel.
Front fog lamp
The front fog lamps should be aimed as the same manner of the head lamps aiming.
With the front fog lamps and battery normal condition, aim the front fog lamps by turning the adjusting gear.
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1. Turn the low beam on without the driver aboard.
The cut-off line should be projected in the allowable range (shaded region).
2. Turn the high beam on without the driver aboard.

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3. Turn the front fog lamp on without the driver aboard.
Body Electrical System > License Lamps > Repair procedures

Removal (outside)
2. Remove two bolts from service hole cover.
3. Remove four nuts attaching rear combination light assembly to vehicle.
4. Disconnect electrical connector.

5. Remove light assembly.
Removal (Inside)
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2. Remove three screws and thirteen fasteners from trunk lid trim.
3. Remove back panel molding assembly.

(2) Remove one screw from outside of trunk lid.
(3) Remove thirteen nuts from trunk lid.
4. Remove four screws from light assembly.
Replacement (outside)
Page 55 of 61
2. Remove two bolts from service hole cover.
3. With bulb holder disengaged,pull bulb holder carefully forward relative to vehicle, and remove from light
assembly. Disconnect electrical connector.
4. Remove bulb as required from bulb holder.
5. Install new bulb of proper type, as shown on bulb holder.
6. Position bulb holder on light assembly and press to engage with light assembly.
7. Install two bolts on service hole cover.
Replacement (Inside)
2. Remove fasteners and screws from trunk lid trim.
3. Disconnect electrical connector.
4. With bulb holder disengaged, pull bulb holder carefully forward relative to vehicle, and remove from light
assembly.
5. Remove bulb as required from bulb holder.

6. Install new bulb of proper type, as shown on bulb holder.
7. Position bulb holder on light assembly and press to engage with light assembly.
8. Install fasteners and screws on trunk lid trim.
Installation (outside)
1. Position light assembly on vehicle with studs through mounting holes on vehicle.
2. Connect electrical connector.
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3. Install four nuts on rear combination light.
4. Install two bolts on service hole cover.

Installation (Inside)
1. Position light assembly on back panel molding assembly.
2. Install four screws on light assembly.
3. Install back panel molding assembly.

(1) Install thirteen nuts on trunk lid.
(2) Install one screw on outside of trunk lid.
4. Install three screws and thirteen fasteners on trunk lid trim.
Disassembly
All parts except the lens-housing assembly is interchangeable from left to right.
1. Remove bulb holder from lens-housing assembly.

2. Remove bulbs from bulb holder.
Reassembly
All parts except the lens-housing assembly is interchangeable from left to right.
1. Install bulbs in bulb holder in accordance with instructions on bulb holder.
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Body Electrical System > License Lamps > License Lamps > Repair procedures
License lamp
1. Remove two screws attaching each lens; remove each lens from bracket.
2. Remove bulbs.
3. Remove wiring harness from bracket.
Reassembly
1. Install wiring harness on bracket.
2. Install bulbs.
3. Install each lens with two screws.
replacement
2. Remove two screws attaching license plate light assembly.
3. remove bulb.
4. Install replacement bulb.
5. Install lens with two screws.
Body Electrical System > High Mounted stop lamp > High Mounted stop lamp > Repair procedures
Removal
2. Open trunk lid.
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3. Remove two nuts that attach light assembly to vehicle.
4. Disconnect electrical connector from light assembly; remove light assembly.
Replacement
2. Open trunk lid.
3. Remove socket from light assembly.
4. Remove bulb from socket.

5. Install replacement bulb in socket.
Installation
1. Connect electrical connector to light assembly.
2. Position light assembly on package tray.
3. Install two nuts attaching light to vehicle.
4. Connector negative battery cable.
Disassembly
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1. Remove socket from light assembly.
2. Remove bulb from socket.
Reassembly
1. Install bulb.
2. Install socket on light assembly.
Body Electrical System > Auto Lighting Control System > Description and Operation
Description
The auto light control system operates by using the auto light switch, and turns the head lamp and tail lamp on or off
automatically in accordance with the detection illumination.
Body Electrical System > Auto Lighting Control System > Auto Light Contorl unit > Repair procedures
Removal
1. Removal the sensor unit from the defroster nozzel cover using the suitable tool.
Inspection
1. Apply the battery voltage to terminal 1 and ground the terminal 6.
2. Expose the ALCS unit to the sun.
3. Check the continuity between the terminals 2 & 3 and the terminals 2 & 5.
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Body Electrical System > Daytime Running Lights > Schematic Diagrams
Circuit diagram
Body Electrical System > Daytime Running Lights > Repair procedures
Inspection
Page 61 of 61
Operation check
Daytime running unit is installed at the behind of right head lamp.
Check that the light operate according to the following timing chart.
Body Electrical System > Troubleshooting > C1161

Brake light switch
DTC No. C1161 Brake light switch Probable cause
[Comment] • Malfunction of wiring harness or connector
Check relevant connector • Malfunction of brake light switch
Check wiring for open circuit, short to ground. • Malfunction of brake lights
Check function of brake light switch.
Brake pedal not actuated : 0V
Brake pedal actuated : BV
Replace brake light switch
DTC No. ABS, EBD and TCS warning lamp Probable cause
Check HECU connector (Pin No. 19, 20, 21, • Malfunction of warning lamp
25)
Check wiring for open circuit, short to ground.
Check warning lamp
DTC No. TCS off switch Probable cause

Check relevant connector • Malfunction of TCS off switch
Check wiring for open circuit, short to ground.
Check TCS off switch.
TCS off switch not actuated : 0V
TCS off switch actuated : BV
Replace TCS off switch
Page 1 of 73
OPTIMA(MS) > 2003 > G 2.4 DOHC > Brake System
Brake System > General Information > Special Service Tools

SPECIAL TOOLS
Tool
Illustration Use
(Number and Name)
09581-11000/0K130 430 017A Pushing back of the front disc and rear disc brake piston
Piston expander
09526-11001 Removal or installation of front hub and disc
Axle shaft puller
Brake System > General Information > Troubleshooting

TROUBLESHOOTING
Vehicle pulls to one side Grease or oil on pad or lining surface Replace
when brakes are applied
Inadequate contact of pad or lining Correct
Auto adjuster malfunction Adjust
Repair or replace as
Drum eccentricity or uneven wear
necessary
Insufficient braking power Low or deteriorated brake fluid Refill or change
Air in brake system Bleed air
Overheated brake rotor due to dragging of pad or lining Correct
Grease or oil on pad or lining surface Replace
Inadequate contact of pad or lining Correct
Brake booster malfunction Correct
Clogged brake line Correct
Proportioning valve malfunction Replace
Increased pedal stroke Air in the brake system Bleed air
(Reduced pedal to Worn lining or pad Replace
floorboard clearance)
Broken vacuum hose Replace
Brake fluid leaks Correct
Excessive push rod to master cylinder clearance Adjust
Faulty master cylinder Replace
Brake drag Incomplete release of parking brake Correct
Incorrect parking brake adjustment Adjust
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Worn brake pedal return spring Replace
Broken rear drum brake shoe return spring Replace
Lack of lubrication in sliding parts Lubricate
Improper push rod to master cylinder clearance Adjust
Faulty master cylinder piston return spring Replace
Clogged master cylinder return port Correct
Insufficient parking brake Worn brake lining or pad Replace
function
Excessive parking brake lever stroke Adjust the parking
brake lever stroke or
check the parking
brake cable routing
Do the lining BED-
Grease or oil on lining or pad surface
IN
Auto adjuster malfunction Replace
Parking brake cable sticking Adjust
Scraping or grinding noise Worn brake lining or pad Replace
when brakes are applied
Caliper to wheel interference Replace
Dust cover to disc interference Correct or replace
Bent brake backing plate Correct or replace
Cracked drums or brake disc Correct or replace
Squealing, groaning or Worn brake pad anti-squeak shim Replace
chattering noise when
Brake drums and linings, discs and pads worn or scored Correct or replace
brakes are applied
Improper lining parts Correct or replace
Disc brake-burred or rusted calipers Clean or deburr
Dirty, greased, contaminated or glazed linings Clean or replace
Drum brakes-weak, damaged or incorrect shoe hold-down
Correct or replace
springs, loose or damaged shoe hold-down pins and springs
Squealing noise when Bent or warped backing plate causing interference with drum Replace
brakes are not applied
Improper machining of drum causing interference with backing
Replace drum
plate or shoe
Disc brakes-rusted, stuck Lubricate or replace
Drum brakes-weak-damaged or incorrect shoe-to-shoe
Replace
spring
Loose or extra parts in brakes Retighten
Improper positioning of pads in caliper Correct
Improper installation of support mounting to caliper body Correct
Poor return of brake booster or master cylinder or wheel
Replace
cylinder
Page 3 of 73
Incorrect brake pedal or booster push-rod Adjust
Groaning, clicking or Stones or foreign substances trapped inside wheel covers Remove foreign
rattling noise when brakes substances
are not applied
Loose wheel nuts Retighten
Disc brakes-failure of shim Replace
Disc brakes-loose installation bolt Retighten
Worn, damaged or dry wheel bearings Lubricate or replace
Disc brakes-wear on guide rod Replace
Incorrect brake pedal or booster push-rod Adjust
Brake System > General Information > Specifications

SPECIFICATION
Master cylinder
Type Tandem type
I.D.
CBS 23.8 mm (0.94 in.)
ABS 25.4 mm (1.0 in.)
Fluid level sensor Provided
Brake booster
Type Vacuum type with tandem booster
Effective dia.
CBS 7 + 8 in.
ABS 8 + 9 in.
Boosting ratio
CBS 7.0 : 1
ABS 7.5 : 1
Proportioning valve
Cut-in pressure (Split point) 4.51 MPa (46 kg/cm², 654 psi)-
Drum type
3.92 MPa (40 kg/cm², 568 psi)-
Disc type
Decompression ratio 0.32 : 1
Front brake
Type Floating type with ventilated disc
Disc O.D. 280 mm (11.024 in.)
Disc thickness 26.0 mm (1.024 in.)
Pad thickness 11.0 mm (0.433 in.)
Page 4 of 73
Cylinder I.D. 57.2 mm (2.252 in.)
Rear drum brake
Type Leading-trailing drum
Drum I.D. 228.6 mm (9 in.)
Brake lining thickness 4.5 mm (0.177 in.)
Cylinder I.D. 19.05 mm (0.75 in.)
Clearance adjustment Automatic
Rear disc brake
Type Floating type with solid disc
Disc O.D. 262 mm (10.31 in.)
Disc thickness 10 mm (0.39 in.)
Pad thickness 10 mm (0.39 in.)
Cylinder I.D. 34 mm (1.34 in.)
Parking brake
Type Mechanical brake acting on rear
wheels
Braking type Lever type
Cable arrangement V type
O.D. = Outer diameter

I.D. = Inner diameter
ABS = Anti-lock Brake System
CBS = Conventional Brake System
TIGHTENING TORQUE
Nm kg·cm lb·ft
Master cylinder 8-12 80-120 5.9-8.8
to booster
mounting nut
Brake booster 13-16 130-160 9.6-11.8
mounting nut
Bleeder screw 7-13 70-130 5-9.6
Brake tube flare 13-17 130-170 9-12
nut, brake hose
Proportioning 35-55 350-550 26-41
valve mounting to
master cylinder
Caliper guide rod 22-32 220-320 16-24
bolt
Page 5 of 73
Caliper assembly 69-85 690-850 51-63
to knuckle
Brake hose to 25-30 250-300 18-22
front caliper
Wheel cylinder 12-18 120-180 8.8-13
mounting bolt
Brake booster 15-18 150-180 11-13
vaccum hose
fitting to surge
tank
Wheel speed 8-10 80-100 5.9-7.2
sensor mounting
bolt
Rear caliper to 50-60 500-600 36-43
carrier
Disk mounting 5-6 50-60 3.6-4.3
screw
Lubricants
Recommended lubricant Quantity
Brake fluid DOT 3 or equivalent As required
Brake pedal bushing and brake pedal bolt Chassis grease SAE J310, NLGI No.0 As required
Clevis pin Wheel bearing grease SAE J310, NLGI As required
No.2
Parking brake shoe and backing plate contact Bearing grease, NLGI No.0-1 As required
surfaces
Sliding parts of the ratchet or the ratchet pawl. Multipurpose grease SAE J310, NLGI No.2 As required
Brake System > Brake System > Brake Booster > Components and Components Location
Components
Page 6 of 73
Brake System > Brake System > Brake Booster > Repair procedures
REMOVAL
1. Remove the master cylinder.
2. Remove the vacuum hose.
3. Remove the operating rod from the brake pedal.
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4. Loosen the booster mounting nuts to remove the booster assembly.
INSTALLATION
1. Install the master cylinder.
2. Attach the booster/master cylinder to the dash panel.
3. Reinstall the vacuum hose securely to prevent vacuum leaks.
4. Couple the operating rod with the brake pedal.
5. Bleed the system.
Do not attempt to disassemble the brake booster. It´s not

serviceable.
BRAKE BOOSTER OPERATION TEST

TEST WITHOUT A TESTER
For a simple check of brake booster operation, make the following tests.
1. Run the engine for one or two minutes, and then stop it. Depress the brake pedal several times at normal foot
pressure. If the pedal goes down deepest the first time, but gradually rises after the second or third time, the
brake booster is functioning properly. Go to step 2.
2. With the engine stopped, depress the brake pedal several times. Depress the brake pedal and start the engine. If
the pedal goes down slightly, the booster is in good condition. Go to step 3.
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3. With the engine running, depress the brake pedal and then stop the engine. Hold the pedal depressed for 30
seconds. If the pedal height does not change, the booster is in good condition. If one of the above three tests is
not okay, check the vacuum hoses, and the brake booster, and make any necessary corrections. If all tests OK,
unit is good.
BRAKE BOOSTER OPERATION TEST

TEST WITHOUT A TESTER
For a simple check of brake booster operation, make the following tests.
1. Run the engine for one or two minutes, and then stop it. Depress the brake pedal several times at normal foot
pressure. If the pedal goes down deepest the first time, but gradually rises after the second or third time, the
brake booster is functioning properly. Go to step 2.
2. With the engine stopped, depress the brake pedal several times. Depress the brake pedal and start the engine. If
the pedal goes down slightly, the booster is in good condition. Go to step 3.
3. With the engine running, depress the brake pedal and then stop the engine. Hold the pedal depressed for 30
seconds. If the pedal height does not change, the booster is in good condition. If one of the above three tests is
not okay, check the vacuum hoses, and the brake booster, and make any necessary corrections. If all tests OK,
unit is good.
Brake System > Brake System > Master Cylinder > Components and Components Location
COMPONENTS
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Brake System > Brake System > Master Cylinder > Repair procedures
REMOVAL
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1. Detach the brake tubes from the master cylinder, and then install the plugs.
Do not let brake fluid remain on a painted surface. Wash it off

immediately.
2. Remove the master cylinder mounting nuts, and then lift out the master cylinder.
INSTALLATION
1. Install the master cylinder on the brake booster.
2. Connect the brake tubes to the master cylinder.
3. Fill brake reservoir with brake fluid and bleed the system.
DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.
2. Remove reservoir from the master cylinder.
When bleeding by pressurized fluid, do not press the brake

pedal.
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3. Using snap ring pliers, remove the retaining ring.
4. Remove the cylinder pin (ABS only).

5. Remove the primary piston assembly.
6. Using a screwdriver, push the secondary piston all the way down and remove the cylinder pin (ABS only).
Remove the secondary piston assembly.
INSPECTION
1. Inspect the cylinder bore for rust or scoring.
2. Inspect the master cylinder for wear or damage.
If necessary, clean or replace the cylinder.
• If bore is damaged, replace the master cylinder assembly. Do not attempt to bone
bore.
• Clean the master cylinder body with isopropyl alcohol to remove any contamination.
ASSEMBLY
1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
2. Carefully insert the two springs and pistons straight in.

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3. Push the pistons in with a screwdrive and install the retaining ring.
4. Using a screwdriver, push the piston all the way and install the cylinder pin (ABS).
5. Mount the two grommets.
6. Install the reservoir onto the cylinder.
Brake System > Brake System > Proportioning Valve > Description and Operation
Description
Do not disassemble the proportioning valve. The proportioning valve makes the ideal distribution of fluid pressure to
the front and rear brakes to prevent the brakes from skidding in the event of rear wheel lock up and to obtain a
higher brake efficiency within the range of service brake application.
Brake System > Brake System > Proportioning Valve > Repair procedures
Proportioning valve function test
1. Connect two pressure gauges; one to the output valve of the front and rear brake.
Be sure to bleed the system after connecting the pressure gauges.

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

increases.
Installation of proportioning valve

1. Install the proportioning valve according to the illustration (LHD).
2. Tighten the flare nuts and bleed the system.
Tightening torque:
Brake tube flare nut:
13-17 Nm(130-170 kgf·cm, 9-12 Ib·ft)
Proportioning valve mounting nut:
35-55 Nm(350-550 kgf·cm, 30-40 Ib·ft) - LHD
8-12 Nm (80-120 kgf·cm, 5.9-8.8 Ib·ft) - RHD
Brake System > Brake System > Brake Line > Components and Components Location
components
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Brake System > Brake System > Brake Line > Repair procedures
INSTALLATION
1. Install the brake hoses without twisting them.
2. The brake tubes should be installed away from edges, weld beads or moving parts.
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3. Tighten the connections to the specified torque.
Flare nuts : 13-17 Nm (130-170 kg·cm, 9-12 lb·ft)

Brake hose to front caliper :
25-30 Nm (250-300 kg·cm, 18-22 lb·ft)
Inspection
1. Check the brake tubes for cracks, crimps and corrosion.
2. Check the brake hoses for cracks, damage and leakage.
3. Check the brake tube flare nuts for damage and leakage.
BLEEDING OF BRAKE SYSTEM

1. Remove the reservoir cap and fill the brake reservoir with brake fluid.
Do not allow brake fluid remain on a painted surface. Wash it off

immediately.
When bleeding by pressurized fluid, do not depress the brake pedal.
2. Connect the vinyl tube to the wheel cylinder bleeder plug, and insert the other end of the tube in a half full
container of brake fluid.
3. Slowly pump the brake pedal several times.
4. While depressing the brake pedal fully, loosen the bleeder plug until fluid starts to run out. Then close the bleeder
plug.
5. Repeat the 3 and 4 until there are no more bubbles in the fluid.
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6. Tighten the bleeder plug screw.
Bleeder screw tightening torque:

7-13 Nm (70-130 kg·cm, 5-9.6 lb·ft)
7. Repeat the above procedure for each wheel in the sequence shown in the illustration.
Brake System > Brake System > Brake Pedal > Components and Components Location
components
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Brake System > Brake System > Brake Pedal > Repair procedures
REMOVAL
1. Remove the lower crash pad assembly (Refer to Body Group)
2. Remove the stop lamp switch and disconnect the clutch switch connector (Vehicle with automatic speed control
system only).
3. Remove the cotter pin and clevis pin.
4. Loosen the booster mounting nut and remove the brake pedal member.
5. Remove the brake pedal to the driver´s compartment.
Remove the pedal rod bushing and washer.
INSTALLATION
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1. Installation is the reverse of removal procedure.
• Coat the specified grease to the inner surface of the bushings. Specified grease : Chassis grease SAE
J310, NLGI No.0
• Before insert the clevis pin, apply the specified grease to the clevis pin and washer.
INSPECTION
1. Check the bushing for wear.
2. Check the brake pedal for bending or twisting.
3. Check the brake pedal return spring for damage.
INSPECTION
1. Check the bushing for wear.
2. Check the brake pedal for bending or twisting.
3. Check the brake pedal return spring for damage.
Brake System > Brake System > Front Dinode Brake > Components and Components Location
components
Page 19 of 73
Brake System > Brake System > Front Dinode Brake > Repair procedures
REMOVAL(Brake pad)
1. Remove the wheel and tire.
2. Check the pad thickness through the cylinder inspection hole.
If the pad lining thickness is out of specification, replace the pads.
Standard value Service limit
Pad lining thickness 11.0(0.433) 2.0 (0.079)
mm (in.)
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3. Remove two bolts from the torque plate and remove the brake cylinder.
4. Remove the brake cylinder and suspend it with wire.
Do not disconnect the brake hose.
5. Remove the pads.
Be careful not to depress the brake pedal while disassembling the

pads.
REMOVAL (CALIPER)
2. Remove the brake hose from the caliper.
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3. Remove the caliper assembly by removing the torque plate.
INSTALLATION(Brake pad)
1. Install the pad clips.
2. Install the pads onto each pad clip.
• All four pads must be replaced as a complete set.

• Position the pad with its pad wear sensor upward on piston side.
• Remove rust before position the pad clip or replace new one if it is
damaged.
3. Press in piston with a hammer handle or equivalent.

4. Lower and insert the brake cylinder carefully so as not to damage the boot.
5. Install the two guide rod bolts and tighten.
Guide rod bolt : 22-32 Nm (220-320 kg·cm, 16-24 lb·ft)
INSTALLATION (CALIPER)
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1. Install the pads and brake cylinder.
2. Install the brake hose to the caliper.
Bleeder screw tightening torque :

7-13 N·m (70-130 kg·cm, 5-9.6 lb·ft)
1. Fill brake reservoir with brake fluid.

DISASSEMBLY (CALIPER)
1. Loosen the caliper attaching guide bolts and separate the caliper.
2. Remove the boot ring using a flat blade screwdriver.

3. Remove the piston boot.
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4. Remove the piston by applying compressed air through the brake hose fitting hole.
Do not place your fingers in front of the piston when using compressed air.
5. Using a screwdriver, remove the piston seal carefully so as not to damage the cylinder wall.
6. Clean the outer surface of the piston and the inner surface of the cylinder with the specified brake fluid.
ASSEMBLY (CALIPER)
1. Clean the components with isopropyl alcohol except pad and shim.
2. Install the piston seal.
3. After applying specified brake fluid to the piston outer surface, install the piston into the cylinder.
4. Install the piston boot and boot ring.
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5. Install the guide pin boots and guide pin.
INSPECTION(brake pad)
1. Check the pads for wear or oil contamination.
Replace or correct if necessary.
2. Check the shims for damaged or deformed.
INSPECTION (CALIPER)
1. Check the caliper body cylinder inner surface for wear, damage and/or corrosion.
2. Check the piston for wear, damage and/or corrosion.
3. Check the caliper body and sleeve for wear.
4. Check pads for deformation, metal backing for damage, and for oil on the pads.
5. Check the wear indicator for damage.
6. Inspect the brake disc using a dial indicator and micrometer.
Thickness of disc 26.0 (1.024 in.) 24.4 (0.96)
mm (in.)
Runout of disc mm - 0.03 (0.0012)
(in.)
Disc thickness - 0.005 (0.0002)
variation
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7. If necessary, replace the brake disc.
(1) Jack up the vehicle and support it with jack stands.
(2) Remove the wheel and tire.
(3) Remove the front wheel brake assembly from the knuckle and suspend it with a wire.
(4) Remove the front disc from the hub.
FRONT BRAKE DISC THICKNESS CHECK
1. Using a micrometer, measure disc thickness at eight positions, approximately 45° apart and 10 mm (0.39 in.) in
from the outer edge of the disc.
Brake disc thickness
Standard value : 26.0 mm (1.024 in.)
Limit : 24.4 mm (0.96 in.)
Thickness variation (at least 8 positions)
The difference between any thickness measurements should not be more than 0.005 mm (0.0002 in.).
2. If the disc is beyond the limits for thickness, remove it and install a new one. If thickness variation exceeds the
specification, replace the brake disc or turn rotor with on the car type brake lathe ("MAD. DL-8700PF" or
equivalent). Be sure to follow the exact brake lathe manufacturer instructions.
FRONT BRAKE DISC RUN-OUT CHECK
1. Remove the caliper support bolts, then raise the caliper assembly upward and secure by using wire.
2. Inspect the disc surface for groove, cracks, and rust. Clean the disc thoroughly and remove all rust.
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3. Place a dial gauge approximately 5 mm (0.2 in.) from the outer circumference of the brake disc, and measure the
run-out of the disc.
Limit : 0.03 mm (0.0012 in.)
Tighten the nuts in order to secure the disc to the hub.
INSPECTION(brake pad)
1. Check the pads for wear or oil contamination.
Replace or correct if necessary.
2. Check the shims for damaged or deformed.
INSPECTION (CALIPER)
1. Check the caliper body cylinder inner surface for wear, damage and/or corrosion.
2. Check the piston for wear, damage and/or corrosion.
3. Check the caliper body and sleeve for wear.
4. Check pads for deformation, metal backing for damage, and for oil on the pads.
5. Check the wear indicator for damage.
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6. Inspect the brake disc using a dial indicator and micrometer.
Thickness of disc 26.0 (1.024 in.) 24.4 (0.96)
mm (in.)
Runout of disc mm - 0.03 (0.0012)
(in.)
Disc thickness - 0.005 (0.0002)
variation
7. If necessary, replace the brake disc.

(1) Jack up the vehicle and support it with jack stands.
(2) Remove the wheel and tire.
(3) Remove the front wheel brake assembly from the knuckle and suspend it with a wire.
(4) Remove the front disc from the hub.
FRONT BRAKE DISC THICKNESS CHECK
Standard value : 26.0 mm (1.024 in.)
Limit : 24.4 mm (0.96 in.)
specification, replace the brake disc or turn rotor with on the car type brake lathe ("MAD. DL-8700PF" or
FRONT BRAKE DISC RUN-OUT CHECK
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Limit : 0.03 mm (0.0012 in.)
Brake System > Brake System > Rear Dinode Brake > Components and Components Location
COMPONENTS
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Brake System > Brake System > Rear Dinode Brake > Repair procedures
REMOVAL (DISC BRAKE PAD)
1. The procedure is the same with front disc brake pad.
Disassembly (CALIPER)
1. Remove the caliper mounting bolts, and the caliper assembly.
2. Remove the carrier bolt, and the carrier with brake pad.
3. Remove the piston boot.
4. Remove the piston assy.
5. Remove piston seal with finger tip.
Do not use sharpened tools to prevent damage to the inner surface

cylinder.
INSPECTION (DISC BRAKE PAD)

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1. Check the pads for wear or oil contamination and replace if necessary.
The pads for the right and left wheels should be replaced at the same time.
Pad thickness wear limit ; 2.0 mm
2. Check the leading and trailing shoe keys and retaining screw for damage, or wear. Replace the keys and retaining
screw at the same time the pads are replaced.
3. Check for worn or damaged dust boots if dust or mud has entered the caliper assembly through this seal, the
caliper assembly must be replaced or rebuilt.
INSPECTION(DISC THICKNESS)
Standard value : 10 mm (0.39 in.)
Limit : 8.4 mm (0.33 in.)
specification, replace the brake disc or turn rotor with an on the car type brake lathe ("MAD. DL-8700PF" or
INSPECTION (DISC RUN-OUT)
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Limit : 0.03 mm (0.0012 in.)
Assembly
1. Check for worn, damaged, or rusted piston bore and piston.
Replace the damaged parts if necessary.
2. Check for damaged piston seal, boot, and pin insulators.
3. Apply a recommended lubricant to the following parts.

Parts Recommended lubricant Quantity
Piston seal Brake fluid (Dot 3 or Dot 4) As required
Cylinder inner side Brake fluid (Dot 3 or Dot 4) As required
Piston boot Brake fluid (Dot 3 or Dot 4) As required
Piston outer surface Brake fluid (Dot 3 or Dot 4) As required
Guide-rod insulators Rubber grease As required
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4. Push the piston into the caliper.
5. Align the piston matching mark to upward as shown in illustration.
Brake System > Brake System > Rear Drum Brake > Components and Components Location
COMPONENTS
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Brake System > Brake System > Rear Drum Brake > Repair procedures
REMOVAL
1. Remove the wheel and tire, then remove the brake drum.
If the brake drum is difficult to remove, insert bolts into the threaded holes of the drum, then
remove it.
2. After removing the rear hub bearing flange nut, remove the rear hub with the brake drum.
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3. Remove the shoe return spring, cylinder end shoe spring, the shoe hold down spring.
4. Remove the shoes and adjuster as an assembly.
INSTALLATION
1. Apply the specified grease to the locations indicated in the illustration and to each component.
A. Shoe and backing plate contact surfaces
B. Shoe and anchor plate contact surfaces
Recommended grease :
Multipurpose grease SAE J310, NLGI No.2
2. Install the shoe hold down pin.
3. Assemble the return spring by pressing the push rod.
Split pin and hub cap must not be reused.

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4. Check the outside dimension and correct it using auto-adjuster (227.6-228.1 mm).
5. Do the parking brake stroke adjustment after assembling lining.
WHEEL CYLINDER REPLACEMENT

1. Remove the brake shoe.
2. Disconnect the brake tube.
3. Remove the wheel cylinder assembly.
4. Remove the dust boot.

5. Remove the piston and piston cup.
6. Drive out the return spring.
7. Before assembling the wheel cylinder, inspect the following.
(1) Check the cylinder and piston for wear, damage and rust.
(2) Check the cylinder body for damage and cracks.
(3) Check the contact surface of the piston and shoes for wear.
(4) Check the piston spring for looseness.
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8. Assembly is the reverse of the removal.
• Clean the cylinder with isopropyl alcohol before

assembly.
• Apply enough brake fluid to piston cups and cylinder.
• Be sure to use new piston cups and dust boots.
Be careful not to lose the steel ball in the bleeder.
INSPECTION
1. Measure the inside diameter of the brake drum.
Check the run-out of brake drum by using a dial indicator.
Standard Service limit
value
Inside diameter mm 228.6 (9) 230.6 (9.08)
(in.)
2. Measure the brake shoe lining thickness.

Standard Service limit
value
Lining thickness mm 4.45 (0.18) 1.5 (0.059)
(in.)
3. Inspect the brake lining and drum for proper contact.

4. Inspect the wheel cylinder outside for excessive wear and damage.
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5. Inspect the backing plate for wear or damage.
Brake System > Parking Brake System > Parking Brake Assembly > Components and Components
Location
COMPONENTS
Brake System > Parking Brake System > Parking Brake Assembly > Repair procedures
REMOVAL
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1. Remove the main floor console.
2. Detach the parking brake switch.
3. Remove the parking brake lever.

4. Remove the parking brake lever from the parking brake cable.
5. Remove the rear seat cushion and take up the carpet.
6. Remove the parking brake cable clamp and grommet.
7. Move the center muffler heat protector center panel to the front.
8. Remove the washer assembled bolt and detach the clamp bracket.
9. Remove the tire assembly and the brake drum.
10. Remove the rear hub assembly.
11. Remove the springs and shoe hold down pins.
12. Remove the cable clip.
13. Disconnect the cable end from the trailing shoe.

14. Drive out the parking brake cable to the under body side.
INSTALLATION
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1. Check the parking brake cables for an identification mark paint or wind tape and install as appropriate on the left
and right sides.
Identification color
Left side Right side
Rear disc brake None White
Rear drum brake Red Yellow
2. Set the adjuster lever all the way back when installing the shoe-to-shoe spring.
3. Install the grommet in the direction shown in the illustration.
4. Apply a coating of the specified grease to each sliding parts of the ratchet plate or the ratchet pawl.
Specified grease :
Multipurpose grease SAE J310, NLGI No.2
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5. After installing the cable adjuster, adjust the parking brake lever stroke.
INSPECTION
1. Check the parking brake switch operation.
2. Check the parking brake lever ratchet for wear.
3. Check the parking brake cable or operation or damage.
SERVICE ADJUSTMENT
1. After replacing the parking lever.
Perform the cable adjustment after pulling parking brake lever 4-5 times as full stroke.
2. After replacing the cable.
(1) In case of drum brake
Adjust the outer diameter of the drum brake lining to ф227.6-228.1 mm (Refer to page BR-30). After
installing the drum, perform the cable adjustment.
(2) In case of D.I.H (Drum In Hat)
Remove the adjusting hole plug and then turn the adjusting wheel to the direction of the arrow unit the disc
won't rotate by tangential force of 3 kg using a screw driver (flat tip (-)).
Rotate the adjustor as much as 5 notches to the opposite direction of the arrow (Shoe clearance 0.19mm
(0.0075 in) each side).
3. After replacing brake lining (Bed-in procedure)

(1) Pull the parking lever as much as 4~5 notches (or 9 kg).
(2) Drive the vehicle about 400m at the speed of 50 kgh.
(3) Stop the vehicle for 2 minutes.
(4) Parking should be passible on a hill of 30% with gross vehicle weight.
PARKING BRAKE STROKE ADJUSTMENT
1. Loosen parking brake cable using adjusting nut (Rotate counter clockwise).
2. Push the brake pedal 20 times a force approx. 196 N (20kg, 44 lbs.)
3. Tighten parking brake cable using adjusting nut (Rotate clockwise).
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4. Pull the brake lever with a force of approx. 196 N (20 kg, 44 lbs.), and count the number of clicks.
Parking brake lever stroke [Standard value] : 8-9 clicks
5. If the number of notches is not the standard value, adjust the cable length with the adjusting nut of the equalizer.
6. The indicator light will go out when the brake lever is fully released, and will light with the lever pulled one notch If
it does not operate, replace it.
7. After the adjustment, check that the rear brakes do not drag with the parking brake lever released.
Brake System > ABS(Anti-Lock Brake System) > Flow Diagram

SYSTEM DIAGRAM
Page 42 of 73
Brake System > ABS(Anti-Lock Brake System) > Description and Operation
SYSTEM COMPONENT
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The Anti-Lock Brake System (ABS) controls the hydraulic brake pressure of all four gear wheels during sudden
braking and braking on hazardous road surfaces, preventing the wheels from locking. This ABS provides the
following benefits.
1. Enables steering around obstacles with a greater degree of certainty even during panic braking.
2. Enables stopping during panic braking while allowing stability and steerability to a minimum, even on curves.
In case a malfunction occurs, a diagnosis function and fail-safe system have been included for serviceability.
The feeling of vibration in the pedal under emergency braking is not evidence of a system malfunction.
The traction control is a variable system designed to enhance traction during acceleration. It does so by determining
the optimum amount of wheel spin for any given driving situation, then suppressing surplus engine power accordingly.
The integrated control unit (HECU) gets signals about the vehicle's speed, direction and road conditions from
sensors at the wheels and the steering column. Based on these signals, the control unit will determine the optimum
amount of wheel spin. Because the system is variable, the control unit may determine, depending on the driving
conditions, that some wheel spin is beneficial (thus enhancing straight-line acceleration), or that no wheel spin is
beneficial (thus enhancing cornering). For any given driving situation, the control unit will determine the amount of
wheel spin best suited to the driver's needs.
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The system is automatically ready whenever the engine is started, but can be manually canceled with the TCS
switch.
However, once actuated, the system cannot be canceled until it is once again in the ready state.
EBD (Electronic Brake-force Distribution)
The EBD is additionally applied instead of the proportioning valve to make the ideal distribution of a fluid pressure to
the front and rear brake to prevent the brakes from skidding in the event of rear wheel lock and to obtain a higher
brake efficiency within the range of service brake application.
ADVANTAGES
- Function improvement of base-brake system
- Compensation of different friction coefficients
- Elimination of proportioning valve
- Failure recognition by warning lamp
Comparison between with P-valve and with EBD
TCS FUNCTION
1. Driving control
When the drive wheel speed exceeds the vehicle speed by a given amount, the HECU judges that the drive
wheels are slipping, and it outputs the traction control signal to reduce engine power.
2. Rough road control
Based on signals from the wheel sensors, the control unit detects a rough road based on frequency of wheel
rotational vibration. The control unit then signals the TCS control valve actuator and ECM to relax engine power,
thus improving acceleration efficiency.
3. Grip control
Based on signals about wheel speed, the control unit determines the efficiency of the grip of the tires on the road
and signals the TCS control valve actuator and ECM relax engine power if necessary, thus improving grip.
TCS LAMP CONCEPT
The ABS/TCS 5.3 system has three lamps : an ABS warning lamp, EBD lamp and TCS multifunction lamp will
blinking while TCS operation and light on when system failure and EBD failure.
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ABS TCS ABS/TCS
IG ON EBD failure EBD
operation operation failure
ABS Lamp 3 sec. ON OFF OFF ON ON OFF
TCS M.Lamp 3 sec. ON OFF BLINKING ON ON OFF
ON/OFF
EBD 3 sec. ON OFF OFF ON (OFF: WSS OFF
Failure)
Brake System > ABS(Anti-Lock Brake System) > ABS Control Module > Components and
Components Location
COMPONENTS
Brake System > ABS(Anti-Lock Brake System) > ABS Control Module > Repair procedures
REMOVAL
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1. Disconnect the HECU (Hydraulic and Electronic Control Unit) connector.
2. Disconnect the brake tubes from the HECU.
3. Remove the HECU bracket mounting bolt and remove the HECU.
• Never attempt to disassemble the HECU.

• The HECU must be transported and stored in upright position and with sealed ports. The HECU must
not be drained.
• It will cause the HECU to fail if you don't keep.
INSTALLATION
1. Follow the reverse order of removal.
2. Tighten the modulator mounting bolts and brake tube nuts to the specified torque.
Tightening torque
HECU mounting bolt :
8-10 Nm (80-100 kg-cm, 5.6-6.9 lb-ft)
Brake tube nut :
13-17 Nm (130-170 kg-cm, 9-12 lb-ft)
Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Components and
Components Location
COMPONENTS
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Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Repair procedures
Removal
FRONT WHEEL SPEED SENSOR
1. Remove the front wheel speed sensor mounting bolt.
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2. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector.
REAR WHEEL SPEED SENSOR

1. Remove the rear seat cushion.
2. Remove the rear pillar trim assembly.
3. Remove the tire assembly.

4. Remove the rear wheel speed sensor after disconnection the wheel speed sensor connector.
INSPECTION
1. Connect an ohmmeter between the wheel speed sensor terminals and measure the resistance.
Service standard
Front : 1300-1900Ω
Rear : 1300-1900Ω
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2. Connect a voltmeter between the wheel speed sensor terminals, and measure the voltage by turning the wheel.
Set the voltmeter to measure AC voltage. Service standard : AC voltage detected.
Brake System > ABS(Anti-Lock Brake System) > Troubleshooting

INSPECTION AT HECU TERMINALS
TERMINAL VOLTAGE CHART
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Terminal No. Description Condition Output
18 · Battery power source 1 Always System voltage
· Solenoid valve power
source
16 Ground Always - In ABS & TCS
control
11 Diagnosis interface terminal Connect the Hi-Scan
(K-Line)
9 Wheel speed sensor (Left Resistance
rear) R=1.6kΩ ± 50%
Min. detectable voltage
7 Wheel speed sensor (Left
130mV peak to peak
front)
voltage at 50Hz
5 Wheel speed sensor (Right
front)
rear)
rear)
front)
front)
rear)
15 Power input via ignition 2 Ignition 2 condition Over voltage detection
switch 16 V < V < 21 V
Suspend voltage detection
8 V < V < 10 V
7, 11, 14,22 Not used
17 · Battery power source 2 Always System voltage
· Motor power source
19 Ground - 2 (Motor) G/2
20 ABS warning lamp Max. Current: Below
21 EBD warning lamp 200mA
Max. Voltage: 3.6V
31 TCS off switch
24 TCS function lamp
30 CAN - High
29 Can - Low
14 Stop lamp switch
BLEEDING BRAKE SYSTEM

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This procedure should be used to insure adequate bleeding and filling of ABS unit, brake lines, master cylinder.
1. Remove the reservoir cap and fill the brake reservoir with brake fluid.
Do not allow brake fluid remain on a painted surface. Wash it off immediately.
When bleeding by pressured fluid, do not depress the brake pedal. Recommended fluid.........DOT3 or
equivalent
2. Connect the clear plastic tube to the wheel cylinder bleeder plug and insert the other end of tube in a half filled
clear plastic bottle.
Connect Hi-Scan to Data Link Connector located underneath the dash panel.
3. Select and operate according to the instruction on the Hi-Scan screen.
You have to obey maximum operating time (60sec) of ABS motor with Hi-Scan to prevent motor pump
burnt. Do not exceed the maximum pump operating time (60 seconds maximum) when operating the ABS
motor with the scan tool. If the pump operating time is exceeded, damage to the pump motor could occur.
4. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without
bubbles. Then close the bleeder screw.
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5. Repeat the step 5. until there are no more bubbles in the fluid for each wheel in the sequence shown in the
illustration.
6. Tighten the bleeder screw.
Bleeder screw tightening torque :

7-13 Nm (70-130 kg·cm, 5-9.6 lb·ft)
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
* Using the customer problem analysis heck sheet for reference, ask the customer in as much detail as
possible about the problem.
NOTES WITH REGARD TO DIAGNOSIS
The phenomena listed in the following table are not abnormal.
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Phenomenon Explanation of phenomenon
System check sound When starting the engine, a thudding sound can
sometimes be heard coming from inside the engine
compartment, but this is because the system operation
check is being performed, and is not an abnormality.
ABS operation sound 1. Sound of the motor inside the ABS hydraulic unit
operation (whine).
2. Sound is generated along with vibration of the brake
pedal (scraping).
3. When ABS operates, sound is generated from the
vehicle chassis due to repeated brake application and
release. (Thump : suspension; squeak: tires)
ABS operation (Long braking distance) For road surfaces such as snow-covered roads and
gravel roads, the braking distance for vehicles with ABS
can sometimes be longer than that for other vehicle. This
is explained in the vehicle owner's manual. Advise the
customer to read their vehicle owner's manual
thoroughly and to lower the vehicle speed and be
cautious on such road surfaces. Diagnosis detection
condition can vary depending on the diagnosis code.
Make sure that checking requirements listed in the
"Comment" are satisfied when checking the trouble
symptom again after the diagnosis code has been
erased.
Diagnosis detection condition can vary depending on the diagnosis code.

Make sure that checking requirements listed in the "Comment"are satisfied when checking the trouble symptom
again after the diagnosis code has been erased.
Page 54 of 73
HI-SCAN CHECK
1. Turn the ignition OFF.
Page 55 of 73
2. Connect the hi-scan to the data link connector located underneath low crash pad panel.
3. Turn the ignition ON.

4. Use the hi-scan to check the self-diagnosis codes.
After completion of the repair or correction of the problems, turn the ignition switch; then erase the stored faults
codes using the clear key.
5. Disconnect the hi-scan.
connector check
1. Remove the battery negative (-) terminal.
2. Disconnect the connectors and check terminals follow the troubleshooting procedure.
When you check terminals, be sure to use enough small pin which is not damaged to the connector
terminals.
INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES

Inspect according to the inspection chart that is appropriate for the malfunction code.
DTC on Hi-Scan Description Memory
Voltage out of range (Under and over
C1103 O
voltage)
C1161 Brake light switch O
FL wheel sensor : Open or short to
C1200 O
GND
FL wheel sensor : Speed jump or
C1201 O
wrong exciter
FR wheel sensor : Open or short to
C1203 O
GND
FR wheel sensor : Speed jump or
C1204 O
wrong exciter
RL wheel sensor : Open or short to
C1206 O
GND
Page 56 of 73
RL wheel sensor : Speed jump or
C1207 O
wrong exciter
RR wheel sensor : open or short to
C1209 O
GND
RR wheel sensor : Speed jump or
C1210 O
wrong exciter
C1245 Wheel speed sensor freguency error O
C1604 ECU Hardware error O
C1605 CAN hardware error O
C1611 CAN timeout EMS O
C2112 Main relay, fuse O
C2114 Disturbance (Including valve failure) O
C2402 Motor pump O
ACTUATOR DRIVING
No. Description Recognition Remark
01 Motor Motor pump relay Actuation time is limited to
operation (Click sounds) MAX. 20 seconds
02 Front left valve (In) Front left solenoid valve
operation (Click sounds)
03 Front right valve (In) Front right solenoid valve
04 Rear left valve (In) Rear left solenoid valve
05 Rear right valve (In) Rear right solenoid valve
06 Front left valve (Out) Front left solenoid valve
07 Front right valve (Out) Front right solenoid valve
08 Rear left valve (Out) Rear left solenoid valve
09 Rear right valve (Out) Rear right solenoid valve
CURRENT DATA
Page 57 of 73
No. Description Recognition Remark
12 FL wheel speed Front left wheel Minimum level is V≥
SNSR speed sensor 10kgh
13 FR wheel speed Front right wheel
SNSR speed sensor
14 RL wheel speed Rear left wheel
SNSR speed sensor
15 RR wheel speed Rear right wheel
SNSR speed sensor
17 ABS SRI status Warning lamp
18 Brake SW Brake switch
20 Motor pump relay Motor relay
21 Valve relay Valve relay
22 Motor pump status Motor
23 FL valve (In) Front left valve (In)
24 FR valve (In) Front right valve (In)
25 RL valve (In) Rear left valve (In)
26 RR valve (In) Rear right valve (In)
27 FL valve (Out) Front left valve (Out)
28 FR valve (Out) Front right valve
(Out)
29 RL valve (Out) Rear left valve (Out)
30 RR valve (Out) Rear right valve
(Out)
ABS & TCS WARNING LAMP INSPECTION

Check that the ABS & TCS warning lamp illuminates as follows.
1. ABS warning lamp
(1) It is turned on for three seconds at time of ON of ignition Key and turns off afterwards.
(2) It is extinguished at start of operation.
(3) It is lighted if system abnormality arise.
(4) It is lighted during self-diagnosis.
(5) During its lighting, ABS control is interrupted and only ordinary brake operates in same way as ABS
noninstalled vehicle.
(6) It is lighted when ECU connector is removed.
Page 58 of 73
2. EBD (electronic brake-force distribution) warning lamp
(1) It is lighted at time of ON of ignition Key.
(2) It is extinguished at start of operation.
(3) It is lighted when parking brake switch is ON.
(4) It is lighted when brake oil is deficient.
(5) It is lighted when EBD control is infeasible.
A. When there is trouble at solenoid valve.
B. When there is trouble in more than one sensor.
C. When there is trouble in ECU.
D. In case of high voltage.
3. TCS warning lamp
(1) It is turned on for three seconds at time of ON of ignition Key and turns off afterwards.
(2) It is extinguished at start operation.
(3) It is lighted when TCS OFF switch is "ON".
(4) It is lighted if system abnormality arise.
(5) During its lighting, TCS control is interrupted and only ordinary brake operates in same way as ABS, TCS
noninstalled vehicle.
(6) It is blinking during the operation of TCS control.
INSPECTION CHART FOR TROUBLE SYMPTOMS

Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Trouble symptom Inspection procedure No.
Communication with Hi-Scam is Communication with all system is not 1
not possible possible. 2
Communication with ABS only is not
possible.
When the ignition key is turned to "ON" (engine stopped), the ABS warning 3
lamp does not illuminate.
After the engine start, the lamp remains illuminated 4
Faulty ABS operation Unqual braking power on both sides 5
Insufficient braking power
ABS operates under normal braking
conditions
-
Page 59 of 73
ABS operates before vehicle stops under -
normal braking conditions
Large brake pedal vibration (Caution 2.)
During ABS operation, the brake pedal may vibrate or may not be able to be depressed. This does not mean that
the system is defective. Such phenomena are due to intermittent changes in hydraulic pressure inside the brake line
to prevent the wheels from locking. That is what the system is designed to do.
Inspection Procedure 1
Communication with Hi-Scan is not possible.
Probable cause
(Communication with all systems is not possible.)
[Comment] • Malfunction of connector
The reason is probably a defect in the power supply • Malfunction of wiring harness
system (Including ground) for the diagnosis line.
Communication with Hi-Scan is not possible.
Probable cause
(Communication with ABS only is not possible.)
[Comment] • Blown fuse
When communication with Hi-Scan is not possible, the • Malfunction of wiring harness or connector
cause is probably an open circuit in the HECU power • Malfunction of HECU
circuit or an open circuit in the diagnosis output circuit.
Page 60 of 73
Page 61 of 73
When ignition key is turned to "ON" (engine
Probable cause
stopped), ABS warning lamp does not illuminate
[Comment] • Blown fuse
When current flows in the HECU, the ABS relay turns • Burnt out ABS warning lamp bulb
from on to off as the initial check. So the ABS warning • Malfunction of wiring harness or connector
lamp will illuminate when the ABS relay is off even if
there is a problem with the circuit between the ABS
warning lamp and the HECU.
Therefore, if the lamp does not illuminate, the cause may
be : an open circuit in the lamp power supply circuit, a
blown lamp bulb, an open circuit in both the circuit
between the ABS warning lamp and the HECU and in
the circuit between the ABS warning lamp and the ABS
relay
Even after the engine is started, the ABS warning
Probable cause
lamp remains illuminated
[Comment] • Malfunction of combination meter
The cause is probably a short-circuit in the ABS warning • Malfunction of HECU
lamp illumination circuit • Malfunction of wiring harness
This trouble symptom is limited to cases where communication with the Hi-Scan is possible (HECU power
supply is normal) and the diagnosis code is a normal diagnosis code.
Page 62 of 73
Brake operation is abnormal Probable cause
[Comment] • Improper installation of wheel speed sensor
This varies depending on the driving conditions and the • Incorrect sensor harness contact
road surface conditions, so problem diagnosis is difficult. • Foreign material adhering to wheel speed sensor
However, if a normal diagnosis code is displayed, carry • malfunction of wheel speed sensor
the following inspection.
• Malfunction of rotor
• Malfunction of wheel bearing
• Malfunction of hydraulic unit
• Malfunction of HECU
ABS OPERATION CHECK

WHEEL SPEED SENSOR OUTPUT VOLTAGE CHECK
1. Lift up the vehicle and release the parking brake.
2. Disconnect the HECU harness connector and measure from the harness side connector.
Be sure to remove the connector double lock and insert the probe into the harness side. Inserting it into the
terminal side will result in a bad connection.
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3. Rotate the wheel to be measured at approximately 1/2-1 rotation per second, and check the output voltage using
a circuit tester or an oscilloscope.
Wheel speed Front left Front right Rear left Rear right
sensor
Terminal No. 7 5 9 3
6 4 8 1
Output voltage
When measuring with an oscilloscope :
120 mV p-p or more
DIAGRAM OF INPUT/OUTPUT FOR HECU
Page 64 of 73
Wheel speed sensor open or short to GND circuit

DTC No. C1200, C1203, C1206, C1209
Probable cause
[Comment] ‍ Malfunction of wheel speed sensor
The HECU determines that an open or short circuit ‍ Malfunction of wiring harness or connector
occurs in more than one line of wheel speed sensors. ‍ Malfunction of HECU
Page 65 of 73
Speed jump or wrong exciter

DTC No. C1201, C1204, C1207, C1210
Probable cause
(Speed jump or wrong exciter)
‍ Improper installation of wheel speed sensor
[Comment] ‍ Malfunction of wheel speed sensor
A wheel speed sensor outputs an abnormal ‍ Malfunction of rotor
signal ‍ Malfunction of wheel bearing
(other than an open short-circuit). ‍ Malfunction of wiring harness or connector
‍ Malfunction of HECU
Page 66 of 73
Air gap error

DTC No. C1202, C1205, C1208, C1211 (Air
Probable cause
gap error)
‍ Malfunction of wheel speed sensor
‍ Improper installation of wheel speed sensor
[Comment] ‍ Malfunction of rotor
A wheel speed sensor outputs no signal ‍ Malfunction of wheel bearing
‍ Malfunction of wiring harness or connector
Under and over voltage

Page 67 of 73
DTC No. C1103 Voltage out of range (Under and
Probable cause
over voltage)
[Comment]
The voltage of the HECU power supply drops lower or
rises higher than specified value.
If the voltage returns to the specified value, this code is
no longer output.
• If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to
standard value, this code is no longer output.
• Before carrying out the following inspection, check the battery level, and refill it if necessary.
ECU Hardware
DTC No. C1604 ECU Hardware (Error valve
Probable cause
failure)
[Comment]
The HECU always monitors the solenoid valve drive
‍ Malfunction of wiring harness
circuit. It determines that there is an open or short-circuit
‍ Malfunction of hydraulic unit
in the solenoid coil or in a harness : When no current
flows in the solenoid even though the HECU turns on it,
and vice versa.
Valve relay
Page 68 of 73
DTC No. C2112 Valve relay (Including fuse
Probable cause
failure)
[Comment]
When the ignition switch is turned to ON, the HECU
switches the valve relay off and on during the initial
check. In that way, the HECU compares the signals sent
‍ Malfunction of valve relay
to the valve relay with the voltage in the valve power
monitor line. That is how to check if the valve relay is
operating normally. The HECU always checks if current
flows in the valve power monitor line, too.
It determines that there is an open circuit when no
current flows. If no current flows in the valve power
monitor line, this diagnosis code is output.
Whenever reading the diagnostic codes using the ABS warning lamp, this diagnosis code will be output.
HECU error
DTC No.
C1605 CAN hardware error Probable cause
C2114 Disturbance
‍ Interference by means of electronic wave
‍ Mismatching of the calculation between main
[Repair]
and sub processor
Replace the HECU.
‍ Defects of the valve coil and valve coil
operating circuit element
EMS or TCM error

DTC No.
C1611 CAN timeout EMS
Probable cause
C1612 CAN timeout TCM
C1613 CAN transmission unmatching
‍ In case of no message from EMS or TCM during 500
[Repair]
ms
Inspect the EMS or TCM according to the instruction of
‍ In case of A/T or M/T signal mismatch the EMS and
Engine or TM Group.
TCM message
Page 69 of 73
CAN bus off error
DTC No. C1610 CAN bus off error Probable cause
[Repair]
‍ CAN bus cable open or short to ground or
Inspect CAN bus wiring
battery
Check the HECU, TCM or ECM connectors
Electrical
DTC No. C2402 Electrical (Pump-motor) Probable cause
[Comment]
When the motor power line is normal but no signal is
input to the motor monitor line when the motor power
line is faulty.
Because force-driving of the motor by means of the actuator test will drain the battery, the engine should be started
and left to run for a while after testing is completed.
Brake System > Troubleshooting > C1200

DTC No. C1200, C1203, C1206, C1209
Probable cause
[Comment] • Malfunction of wheel speed sensor
The HECU determines that an open or short circuit • Malfunction of wiring harness or connector
occurs in more than one line of wheel speed sensors. • Malfunction of HECU
Page 70 of 73

Speed jump or wrong exciter
DTC No. C1201, C1204, C1207, C1210
Probable cause
(Speed jump or wrong exciter)
[Comment] • Improper installation of wheel speed sensor
A wheel speed sensor outputs an abnormal • Malfunction of wheel speed sensor
signal • Improper air gap
(other than an open short-circuit). • Malfunction of rotor
• Malfunction of wheel bearing
• Malfunction of wiring harness or connector
• Malfunction of HECU
Page 71 of 73

Wheel speed sensor frequency error
DTC No. C1245 (Wheel speed sensor
Probable cause
frequency error)
[Comment] • Malfunction of toothed gear
Check toothed gearing

ECU Hardware
DTC No. C1604 ECU Hardware (Error valve
Probable cause
failure)
[Comment] • Malfunction of wiring harness
The HECU always monitors the solenoid valve drive • Malfunction of hydraulic unit
circuit. It determines that there is an open or short-circuit • Malfunction of HECU
in the solenoid coil or in a harness : When no current
flows in the solenoid even though the HECU turns on it,
and vice versa.

HECU error
Page 72 of 73
DTC No.
C1605 CAN hardware error Probable cause
C2114 Disturbance
[Repair] • Interference by means of electronic wave
Replace the HECU. • Mismatching of the calculation between main
and sub processor
• Defects of the valve coil and valve coil
operating circuit element

EMS error
DTC No.
Probable cause
C1611 CAN timeout EMS
[Repair] • In case of no message from EMS during 500 ms
Inspect the EMS according to the instruction of Engine
Group.

Valve relay
DTC No. C2112 Valve relay (Including fuse
Probable cause
failure)
[Comment] • Malfunction of valve relay
When the ignition switch is turned to ON, the HECU • Malfunction of wiring harness or connector
switches the valve relay off and on during the initial • Malfunction of HECU
check. In that way, the HECU compares the signals sent • Malfunction of hydraulic unit
to the valve relay with the voltage in the valve power
monitor line. That is how to check if the valve relay is
operating normally. The HECU always checks if current
flows in the valve power monitor line, too.
It determines that there is an open circuit when no
current flows. If no current flows in the valve power
monitor line, this diagnosis code is output.
Whenever reading the diagnostic codes using the ABS warning lamp, this diagnosis code will be output.
Page 73 of 73

Electrical
DTC No. C2402 Electrical (Pump-motor) Probable cause
When the motor power line is normal but no signal is • Malfunction of hydraulic unit
input to the motor monitor line when the motor power • Malfunction of HECU
line is faulty.
Because force-driving of the motor by means of the actuator test will drain the battery, the engine should be started
and left to run for a while after testing is completed.
Page 1 of 22
OPTIMA(MS) > 2003 > G 2.4 DOHC > Clutch System
Clutch System > General Information > Special Service Tools

Tool (Number and Name) Illustration Use
09411-11000 Installation of clutch disc
Clutch disc guid
Clutch System > General Information > Troubleshooting

TROUBLESHOOTING
Clutch slipping Insufficient pedal free play Adjust
Car will not respond to engine speed during acceleration Excessive wear of clutch disc Replace
facing
Insufficient car speed Hardened clutch disc facing, Replace
or oil on surface
Lack of power during uphill driving Damaged pressure plate or Replace
flywheel
Weak or broken pressure Replace
spring
Difficult gear shifting Excessive pedal free play Adjust
(gear noise during shifting)
Hydraulic system fluid leaks, Repair or replace parts
air trapping or clogging
Unusual wear or corrosion of Replace
clutch disc spring
Excessive vibration Replace
(distortion) of clutch disc
Clutch noisy When clutch is not used Insufficient play of clutch Adjust
pedal
Excessive wear of clutch disc Replace
facing
A noise is geard after clutch is Unusual wear and/or damage Replace
disengaged of release bearing
A noise is geard when clutch Insufficient grease on the Repair
is disengaged sliding surface of bearing
sleeve
Page 2 of 22
Improperly installed clutch Repair
assembly or bearing
A noise is geard when car is Damaged pilot bushing Replace
suddenly rolled of with clutch
partially engaged
Hard pedal effort Insufficient lubrication of Repair
clutch pedal
Insufficient lubrication of Repair
spline part of clutch disc
Insufficient lubrication of Repair
clutch release lever shaft
Insufficient lubrication of front Repair
bearing retainer
Hard to shift or will not shift Clutch pedal free play Adjust pedal free play
excessive
Clutch release cylinder faulty Repair release cylinder
Clutch disc out of true, runout Inspect clutch disc
is excessive or lining broken
Spline on input shaft or clutch Repair as necessary
disc dirty or burred
Clutch pressure plate faulty Replace clutch cover
Clutch slip Clutch pedal free play Adjust pedal free play
insufficient
Clogged hydraulic system Repair or replace pats
Clutch disc lining oily or worn Inspect clutch disc
out
Pressure plate faulty Replace clutch cover
Release fork binding Inspect release fork
Clutch grabs/chatters Clutch disc lining oily or worn Inspect clutch disc
out
Pressure plate faulty Replace clutch cover
Clutch diaphragm sprig bent Replace clutch cover
Worn or broken torsion Replace clutch disc
spring
Engine mounts loose Repair as necessary
Clutch noisy Damaged clutch pedal bushing Replace clutch pedal
bushing
Loose part inside housing Repair as necessary
Release bearing worn or dirty Replace release bearing
Release fork or linkage sticks Repair as necessary
Page 3 of 22
Clutch System > General Information > Specifications

SPECIFICATIONS
Clutch operating method Hydraulic type
Clutch disc
Type Single dry with diaphragm.
Facing diameter (Outside x Inside) mm (in.) 225 x 150 (8.9 x 5.9) ; 2.4L, 2.7L
Clutch cover assembly
Type Diaphragm spring strap
Setting load N (kg·Ib) 5592-6220 (570~634, 1254~1395) ; 2.4L,
2.7L
Clutch release cylinder
I.D.mm (in.) 20.64 (0.81)
Cluch master cylinder
I.D.mm (in.) 15.87 (0.62)
SERVICE STANDARD
Standard value
8.3-8.9 mm (0.327-0.350 in.) ; 2.4L,
Clutch disc thickness [When free]
2.7L
Clutch pedal height 180.5±0.3 mm
Clutch pedal free play 6-13 mm (0.24-0.51 in.)
Clutch pedal stroke 150 mm (5.90 in.)
Limit
Clutch disc rivet sink 0.3 mm (0.012 in)
Diaphragm spring end height difference 0.5 mm (0.02 in.)
Clutch release cylinder clearance to piston 0.15 mm (0.006 in.)
Clutch master cylinder clearance to piston 0.15 mm (0.006 in.)
TIGHTENING TORQUE
Page 4 of 22
Item Nm kg.m Ib·It
Clutch pedal to pedal support
250-
member 25-35 18-25
350
(clutch pedal bracket)
Clutch master cylinder mounting
8-12 80-120 6-9
bolt
120-
Clutch tube flare nut 12-16 9-12
160
Clutch release cylinder mounting 150-
15-22 11-16
bolt 220
Clutch release cylinder union bolt 25 250 18
200-
Clutch cover assembly (2.7L) 20-27 15-20
270
Clutch cover assembly (2.4L) 15-22 150-
11-16
220
Clutch master cylinder push rod 100-
10-15 7-11
lock nut 150
Clutch master cylinder reservoir 8-10 80-100 6-7
Ignition lock switch 8-10 80-100 6-7
Clutch member 8-12 80-120 6-9
LUBRICANTS
Items Specified lubricants Quantity
Contact surface of release bearing
CASMOLY L 9508 As required
and fulcrum of clutch release fork
Inner surface of clutch release
CASMOLY L 9508 As required
bearing
Inner surface of clutch release
cylinder and outer circumference of Brake fluid DOT3 As required
piston and cup
Inner surface of clutch disc spline CASMOLY L 9508 As required
Inner surface of clutch master
cylinder and outer circumference of Brake fluid DOT3 As required
piston assembly
Clutch master cylinder push rod, Wheel bearing grease SAE J310,
As required
clevis pin and washer NLGI No.2
Chassis grease SAE J310, NLGI
Clutch pedal shaft and bushings As required
No.1
Contact portion of release fork to
CASMOLY L9508 As required
release cylinder push rod
Input shaft spline CASMOLY L9508 As required
Page 5 of 22
Clutch System > Clutch System > Clutch Cover And Dinode > Components and Components Location
components
Clutch System > Clutch System > Clutch Cover And Dinode > Repair procedures
REMOVAL
1. To remove the transaxle assembly, first remove the air cleaner joint, mounting bracket, and wiring etc.
2. Remove the release lever.
(1) Loosen the release lever nut and washer.
(2) Remove the clevis pin and snap ring from the release cylinder.
(3) Remove the release lever.
It is impossible to remove transaxle assembly without doing this step. Because, clutch cover, release
bearing and release fork are combined together.
3. Loosen the bolts attached to the release cylinder and remove the release cylinder.
Page 6 of 22
4. Remove the transaxle assembly, after removing each bolt which connect the transaxle assembly and engine.
5. In the state that the clutch cover is attached to the flywheel remove the release bearing using appropriate tool as
shown.
(1) Rotate the release bearing in the easy direction in order to examine the snap ring.
(2) Insert the tool under the wave washer as shown in the illustration and locate in the center of snap ring.
(3) Widen the space of snap ring by pushing the bearing as shown in the illustration.
(4) The snap ring-widen state is like as shown the figure.
(5) In the snap ring-widen state pull out the release bearing and remove it.
6. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from falling.
Page 7 of 22
7. Loosen the bolts which attach the clutch cover to the flywheel in a star pattern. Loosen the bolts in succession,
one or two turns at a time, to avoid bending the cover flange.
Do not clean the clutch disc or release bearing with cleaning solvent.
8. Remove the release fork shaft and bushing.
INSTALLATION
1. Apply multipurpose grease to the spline of disc.
Grease : CASMOLY L 9508
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease' It can
cause clutch slippage and judder.
2. Install the clutch disc assembly to the flywheel using special tool (09411-11000).
3. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a
star pattern.
Tightening torque
Clutch cover bolt :
----2.4L/2.7L - 20-27 Nm (200-270 kg·cm, 15-20 Ib·t)
Page 8 of 22
4. Align the bearing to the release fork and then install it to the sleeve of housing.
Apply multipurpose grease (CASMOLY L9508) to the grease home of bearing sleeve and contact point
of release fork.
5. installed the release lever to the release fork.
If transaxle assembly is installed to engine without doing this step, release bearing can be separated
according as the release fork rotates free.
6. Install the transaxle assembly to the engine.

7. After finishing step 6, pushing the release lever to the arrow mark it is sounded click that the release bearing and
clutch cover are aligned correctly.
Release lever operating range : 3° or less
If the range is over 3° it is a symptom that the release bearing and clutch cover are not aligned correctly. So, push
the release lever to the arrow mark one more time.
INSPECTION
CLUTCH COVER ASSEMBLY
1. Clean the dust on the clutch housing using the vacuum brush or dry floorcloth and ought not to use the
compressed air absolutely. Check the oil leakage in engine rear bearing oil seal and transaxle front oil seal. If
leaky, repair them.
Page 9 of 22
2. The friction surface of pressure plate must be equalized to entire disc surface. If any part is excessive wear at the
point of contact, the pressure plate is installed badly.
3. Check the friction surface of flywheel for color change, partial damage, small crack and wear.
4. Don't touch the clutch disc with the contaminated hands or gloves. Replace the clutch disc, if the facing is stained
with oil or grease. Measure the rivet sink and replace the clutch disc, if it is less than 3 mm.
Limit : 0.3 mm (0.012 in.)
5. Check the hub spline and torsion spring of clutch disc for excessive wear.
6. Clean the friction surface of pressure plate with cleaning solvent.
7. Measure the flat of pressure plate with a square. If it exceeds 0.5 mm, replace it. Check the pressure plate
surface of wear, cracks and color change.
8. Check that the three-dowel on the flywheel is installed completely.
CLUTCH RELEASE BEARING
The release bearing is packed with grease. Do not use cleaning solvent or oil.
1. Check the bearing for seizure, damage or abnormal noise.
Also check the diaphragm spring contacting points for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.
CLUTCH RELEASE FORK
If there is abnormal wear at the point of contact with the bearing, replace the release fork.
Clutch System > Clutch System > Clutch Master Cylinder > Components and Components Location
COMPONENTS
Page 10 of 22
components
Page 11 of 22
Clutch System > Clutch System > Clutch Master Cylinder > Repair procedures
Removal
1. Drain the clutch fluid through the bleed plug.
2. Remove clevis pin, split pin (cotter pin) and washer.
3. Disconnect the clutch tube (master cylinder side).
Page 12 of 22
4. Remove the master cylinder mounting bolt.
5. Remove the clutch line clips.

6. Hold the nut on the clutch hose and loosen the flare nut on the clutch tube.
7. Remove the clip from the clutch hose to remove clutch hose from bracket.
8. Remove the clutch tube.

9. Disconnect the clutch tube (release cylinder side).
Installation
Page 13 of 22
1. Connect the clutch tube (release cylinder side).
2. Temporarily tighten the flare nut by hand, then tighten it to the specified torque, being careful that the clutch hose
does not become twisted.
3. Install the clutch tube and clips.
4. Install the master cylinder.

Page 14 of 22
5. Apply the specified grease to the clevis pin and washer.
Wheel bearing grease

SAE J310, NLGI No.2
6. Install the push rod to the clutch pedal.

7. Pour the clutch fluid into the clutch master cylinder.
8. Bleed the clutch system.
DISASSEMBLY
1. Remove the piston stop ring.
2. Pull out the push rod and piston assembly.
3. Remove the reservoir band, reservoir cap and reservoir.
1. Use care not to damage the master cylinder body and piston assembly.
2. Do not disassemble the piston assembly.
INSPECTION
Check the clutch hose or tube for cracks or clogging.
INSPECTION
1. Check inside of cylinder body for rust, pitting or scoring.
2. Check the piston cup for wear or distortion.
3. Check the piston for rust, pitting or scoring.
4. Check the clutch tube line for obstructions.
Page 15 of 22
5. Measure the master cylinder inside diameter and the piston outside diameter with a cylinder gauge micrometer.
Measure the inside diameter of the master cylinder at three places (bottom, middle, and top) in
perpendicular directions.
If the master cylinder-to-piston clearance exceeds the limit, replace the master cylinder and/or piston assembly.
Limit : 0.15 mm (0.006 in.)
REASSEMBLY
1. Apply the specified fluid to the inner surface of the master cylinder body and to the entire periphery of the piston
assembly.
2. Install the piston assembly.
Specified fluid
Brake fluid DOT 3
Clutch System > Clutch System > Clutch Pedal > Components and Components Location
COMPONENTS
Page 16 of 22
Clutch System > Clutch System > Clutch Pedal > Repair procedures
DISASSEMBLY
Page 17 of 22
1. Disassemble the cotter pin, washer and clevis pin.
2. Disassemble the clutch pedal mounting bolt.
INSPECTION
1. Check the pedal shaft and bushing for wear.
2. Check the clutch pedal for bending or torsion.
3. Check the return spring for damage or deterioration.
4. Check the pedal pad for damage or wear.
Ignition Lock Switch Inspection
Remove the ignition lock switch and check continuity between the terminals. If the continuity is not as specified,
replace the switch.
REASSEMBLY
1. Apply the specified grease to the clutch pedal and bushings.
Chassis grease :
SAE J310, NLGI No.1
2. Install the clutch pedal mounting bolt.

Page 18 of 22
3. Apply the specified grease to the clevis pin and washer.
Wheel bearing grease :

SAE J310, NLGI No.2
4. Install the push rod to the clutch pedal.

5. Adjust the clutch pedal clevis pin play.
Clutch System > Clutch System > Clutch Release Cylinder > Components and Components Location
components
Page 19 of 22
Clutch System > Clutch System > Clutch Release Cylinder > Repair procedures
REMOVAL
1. Remove the clutch hose, valve plate, spring, push rod and boot.
2. Remove any dirt from the piston bore opening of the release cylinder.
3. Remove the piston from the release cylinder using compressed air.
1. Cover with rags to prevent the piston from popping out and causing injury.
2. Apply compressed air slowly to prevent the fluid from splashing in your eyes or on your skin.
INSTALLATION
1. Coat the clevis pin with the specified grease. Align the hose in the end of the release cylinder push rod with that of
the clutch release fork shaft, and insert the clevis pin into the holes.
Specified grease : CASMOLY L9508
2. Install the clutch release cylinder and the clutch tube.
REASSEMBLY
Page 20 of 22
1. Apply specified brake fluid to the release cylinder bore and the outer surface of the piston and piston cup, and
push the piston cup assembly in the cylinder.
Use the specified fluid

------Brake fluid DOT 3
2. Install the clutch hose, valve plate, spring, push rod and boot.
INSPECTION
1. heck the clutch release cylinder for fluid leakage.
2. Check the clutch release cylinder boots for damage.
3. Check the release cylinder bore for rust and damage.
4. Measure the release cylinder bore at three locations (bottom, middle and top) with a cylinder gauge and replace
the release cylinder assembly if the bore-to-piston clearance to exceeds the limit.
Limit :
Clearance to piston : 0.15 mm (0.006 in.)
Clutch System > Clutch System > Troubleshooting

SERVICE ADJUSTMENT PROCEDURES
CLUTCH PEDAL
Page 21 of 22
1. Measure the clutch pedal height (From the face of the pedal pad to the floorboard) and the clutch pedal clevis pin
play (measured at the face of the pedal pad).
Standard value : (A) 1-3 mm (0.04-0.11 in.)
2. If the clutch pedal clevis pin free-play is not within the standard value range, adjust as follows :
(1) Turn and adjust the bolt, then secure by tightening the lock nut.
After the adjustment, tighten the bolt until it reaches the pedal stopper, and then tighten the lock nut.
(2) Turn the push rod to agree with the standard value and then secure the push rod with the lock nut.
When adjusting the clutch pedal height or the clutch pedal clevis pin play, be careful not to push the
push rod toward the master cylinder.
3. After completing the adjustments, check that the clutch pedal free play (measured at the face of the pedal pad)
within the standard value ranges.
Standard value : 6-13 mm (0.2-0.5 in.)

Page 22 of 22
4. If the clutch pedal free play and the distance between the clutch pedal and the floor board when the clutch is
disengaged do not meet with the standard values, it may be the result of either air in the hydraulic system or a
faulty master cylinder of clutch. Bleed the air or disassemble and inspect the master cylinder or clutch.
BLEEDING
Whenever the clutch tube, the clutch hose, and/or the clutch master cylinder have been removed, or if the clutch
pedal is spongy, bleed the system.
Use the specified fluid. Avoid mixing different brands of fluid. Specified fluid : SAE J1703 (DOT3)
1. Loosen the bleeder screw at the clutch release cylinder.

2. Push the clutch pedal down slowly until all is expelled.
3. Hold the clutch pedal down until the bleeder is retightened.
4. Refill the clutch master cylinder with the specified fluid.
The rapidly-repeated operation of the clutch pedal in B-C range may cause the release cylinder's position
to be forced out from the release cylinder body during the air bleeding, repress the clutch pedal after it
returns to the "A" point completely.
Page 1 of 36
OPTIMA(MS) > 2003 > G 2.4 DOHC > Driveshaft and axle
Driveshaft and axle > General Information > Special Service Tools
SPECIAL TOOLS
Tool (Number and
Illustration Use
Name)
1. Removal of center bearing
09216-21100
2. Press-fitting of the front wheel bearing outer
Mount bushing remover
race.
and installer
(use with 09495-33100)
09216-21600
Removal of the wheel bearing outer race
Mount bushing remover
(use with 09216-22100)
and installer arbor
09216-22100
Mounting bushing Removal of wheel bearing outer race
remover and installation (use with 09216-21600)
base
09221-21000/09221-
M2000 Press fitting of hub bearing
Camshaft oil seal installer
09432-11000
Removal of tone wheel
Mainshaft bearing puller
09432-33300
Installation of center bearing
Bearing installer
Page 2 of 36
Removal and installation of the rear axle carrier

09453-33000B
bushing
Snap ring installer
(use with 09545-21100)
09455-21000/0K011 Removal of the bearing inner race from the front

430 017 hub.
Bearing and gear puller (use with 09545-34100)
09495-33100 Removal and installation of the center bearing.

Center bearing remover, Installation of the inner dust seal (use with
installer 09216-21100)
09517-21500
Front hub remover and Measurement of wheel bearing pre-load
installer
09517-43001
Removal of center bearing bracket
Bearing puller
09532-11600 Measurement of the wheel bearing pre-load

Proload socket (use with torque wrench)
09545-21100
Press-fitting of front hub to the knuckle (use
Ball joint dust cover
with 09453-33000B)
installer
Page 3 of 36
09545-34100 Removal of the bearing inner race from the front

Lower arm bushing hub
remover and installer >(use with 09455-21000/0K011 430 017)
0k670-321-019 Removal of the tie rod end from the knuckle

Tie rod end remover and the upper arm from theknuckle.
Driveshaft and axle > General Information > Troubleshooting

TROUBLESHOOTING
Scoring of drive shaft ball joint Replace
Wear, rattle or scoring wheel bearing Replace
Vehicle pulls to one side
Adjust or
Defective front suspension and steering
replace
Wear, damage or bending of drive shaft Replace
Vibration Drive shaft rattle and hub serration Replace
Wear, rattle or sintering of wheel bearing Replace
Adjust or
Defective wheel balance
replace
Shimmy
Adjust or
replace
Wear, damage or bending of drive shaft Replace
Rattle of drive shaft and hub serration Replace
Rattle of drive shaft and side gear serration Replace
Excessive noise Wear, rattle or scoring of wheel bearing Replace

Adjust or
Loose hub nut
replace
Adjust or
replace
Driveshaft and axle > General Information > Specifications

GENERAL SPECIFICATIONS
Page 4 of 36
E/G, T/M 2.4L M/T 2.4L A/T 2.7L M/T 2.7L A/T
Outer B.J. B.J. B.J. A.C.
Joint type
Drive shaft Inner T.J. T.J. D.O.J. G.I.
Outer 46.5° 46.5° 46.5° 45°
Maximum permissible angle
Inner 23° 23° 22° 21°
Type Radial ball bearing
Center bearing (V6 ENG.)
Dimension (O.D. × I.D.) mm (in.) 62 × 30 (2.44 × 1.18)
Inner shaft (V6 ENG) Length mm (in.) 387.7 (15.3)
Type Double row angular contact ball bearing
Wheel bearing
Dimension (O.D. × I.D.) mm (in.) 80 × 42 (3.15 × 1.65)
Abbreviations
B.J. : Birfield joint
A.C. : Angular Contact (GKN)
D.O.J. : Double offset joint
G.I. : Glaenzer Interior (GKN)
T.J. : Tripod joint
SERVICE STANDARD
Limit
Hub end play mm (in.) 0.0008 (0.0003)
Front wheel bearing
N·m (kg·cm, lb·in.) 1.03 (10.5, 9.11)
starting torque
Rear wheel bearing
N·m (kg·cm, lb·in.) 1.8 (18, 16)
starting torque
TIGHTENING TORQUE
Item N·m kg·cm lb·ft
Drive shaft nut 200-280 2000-2800 148-202
Lower arm ball joint to
100-120 1000-1200 74-88
knuckle
Tie rod end to knuckle 24-34 240-340 18-25
Stabilizer link mounting nut 35-45 350-450 26-33
Brake caliper to knuckle 69-85 690-850 51-62
Upper arm to knuckle 35-45 350-450 26-33
Brake caliper to carrier 50-60 500-600 36-44
Rear axle carrier to hub
70-90 700-900 52-66
mounting bolt
Rear hub bearing flange nut 200-260 2000-2600 148-191
Rear axle carrier stud bolt 90-110 900-1100 66-81
Page 5 of 36
Wheel nut 90-110 900-1100 66-81
Center arm to carrier nut 60-72 600-720 44-53
Assist arm to carrier nut 100-120 1000-1200 74-88
Shock absorber lower
80-90 8000-900 59-66
mounting bolt
Trailing arm to carrier nut 100-120 1000-1200 74-88
Rear upper arm to carrier
100-120 1000-1200 74-88
nut
Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Components and Components
Location
COMPONENTS
Page 6 of 36
COMPONENTS
Page 7 of 36
COMPONENTS
Page 8 of 36
COMPONENTS
Page 9 of 36
Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Repair procedures
REMOVAL
2. Drain the gear oil or transaxle fluid.
Page 10 of 36
3. Remove the split pin and drive shaft nut from the front hub.
4. Remove the 2 bolts and disconnect the ball joint from the knuckle.
5. Using a plastic hammer, disconnect the drive shaft from the axle hub.
6. Push the axle hub toward the outside of the vehicle, and separate the drive shaft from the axle hub.
7. Insert a pry bar between the center bearing bracket and the drive shaft, and then pry the drive shaft from the
transaxle. (V6 ENG.)
Do not pull on the drive shaft; doing so will damage the D.O.J. or T.J.: be sure to use the pry bar.
Page 11 of 36
8. Insert a pry bar between the transaxle case and the drive shaft,and pry the drive shaft from the transaxle
(EXCEPT V6 ENG.).
1. Do not pull on the drive shaft; doing so will damage the D.O.J.; be sure to use the pry bar.
2. Do not insert the pry bar deeply enough to damage the oil seal.
Do not apply the vehicle weight to the wheel bearing while the drive shaft is disconnected. If the vehicle's
weight must be applied (because of vehicle movement or some other reason), use the special tool to hold
the wheel bearing, as shown in the figure.
9. After releasing the auto tensioner, remove the drive belt.(V6 ENG.)
10. Remove the alternator assembly (V6 ENG.)

Page 12 of 36
11. Remove the two center bearing bracket mounting bolts. Insert the pry bar between the center bearing bracket
and the cylinder block to disconnect the bracket from the cylinder block.
12. Remove the inner shaft from the transaxle.

13. Using the special tool, remove the tone wheel.
INSTALLATION
1. Coat gear oil to the drive shaft splines and differential case sliding surface.
2. Before installing the drive shaft, set the opening side of circlip facing downward.
3. After installation, check that the drive shaft cannot be removed by hand.
4. Install the washer under the drive shaft nut with facing the convex side outward as shown in the illustration.
5. Tighten the following parts to the specified torque.
Tightening torque Nm (kg·cm, lb·ft)
200-280 (2000-2800, 148-
Drive shaft nut
202)
Lower arm ball joint to knuckle 100-120 (1000-1200, 74-88)
INSPECTION
1. Check the drive shaft boots for damage and deterioration.
Page 13 of 36
2. Check the splines for wear and damage.
INSPECTION AFTER DISASSEMBLY

1. Check the drive shaft spline part for wear or damage.
2. Check for entry of water and/or foreign material into B.J.
3. Check the spider assembly for roller rotation, wear or corrosion.
4. Check the groove inside T.J. case for wear or corrosion.
5. Check the dynamic damper for damage or cracking.
DISASSEMBLY
1. The drive shaft joint use special grease. do not substitute with another type of grease.
2. The boot band should be replaced with new one.
1. Remove the D.O.J. and B.J. boot bands.
Be careful not to damage the boot.

Page 14 of 36
2. Remove the circlip, then remove the D.O.J. outer race.
3. Remove the snap ring, then remove the D.O.J. inner race, the D.O.J. cage, and the balls as a unit.
4. Clean the D.O.J. inner race, the D.O.J. cage, and the balls, without disassembling them.
1. Be careful that the balls do not drop out of the cage.

2. If the balls drop out, press them back into the D.O.J. cage with the D.O.J. inner
race.
5. Wipe the grease off the spline portion.

6. Remove the D.O.J. boot and B.J. boot.
1. If the boots can be reused, wrap vinyl tape around the drive shaft splines so that the boots are not
damaged when they are removed.
2. Do not disassemble the B.J.
DISASSEMBLY
1. Do not disassemble the spider assembly.

2. The drive shaft joint uses special grease. Do not substitute with another type of grease.
3. The boot band should be replaced with a new one.
Page 15 of 36
1. Remove the T.J. boot bands and pull the T.J. boot from the T.J. case.
Be careful not to damage the boot.
2. Remove the snap ring and spider assembly from the drive shaft.
3. Clean the spider assembly.

4. Remove the B.J. boot bands and pull out the T.J. boot and B.J. boot.
If the boot is to be reused, wrap tape around the drive shaft splines to protect
boot.
DISASSEMBLY
• Do not disassemble the tripod assembly.

• The drive shaft joint uses special grease. Do not substitute with another type of grease.
• The boot clamp should be replaced with a new one
• The boot should be replaced with a new one.
1. Using a side cutter, cut the G.I. and A.C. big clamps and remove them.
2. Using a brass bar and hammer, remove the G.I. and A.C. small clamps.
Page 16 of 36
3. Place amatch marks on the tripod and tulip.
Do not punch the mark.
4. Remove the tulip assembly from the drive shaft.

5. Using a snap ring expander, remove the snap ring.
6. Place a matchmark on the tripod and joint shaft.

7. Using a brass bar and hammer, remove the tripod from the joint shaft.
8. Remove the A.C. boot clamps and pull out the G.I. boot and A.C. boot.
REASSEMBLY
Page 17 of 36
1. Wrap tape around the drive shaft splines (T.J. side) to prevent damage to the boots.
2. Apply grease to the drive shaft and install the boots.
Recommended lubricant :
B.J. Boot grease : CENTOPLEX 278M/136K
T.J. Boot grease : KLK TJ41-182
3. To install the dynamic damper, keep the B.J. and shaft in a straight line and secure the dynamic damper in the
direction illustrated and install the small boot band.
4. Apply grease into the T.J. boot and install the boot.
T.J. boot grease : 2.4L [oz·(g)]

In the joint : 3.52 ± 0.11 (100 ± 3) - M/T, 2.65 ± 0.11 (75 ± 3) - A/T
In the boot : 1.59 ±0.11 (45 ± 3)
5. Add specified grease to the B.J. as much as wiped away at the time of inspection.
B.J. boot grease : 2.4L [oz·(g)]

In the joint : 2.12 ± 0.11 (60 ± 3) - M/T, 1.94 ± 0.11 (55 ± 3) - A/T
In the boot : 1.94 ±0.11 (55 ± 3)
6. Install the boots.

7. Tighten the B.J. boot bands.
Page 18 of 36
8. To control the air in the T.J. boot, keep the specified distance between the boot bands when they are tightened.
Standard value (A) mm (in.)

LH side RH side
2.4L M/T, A/T
525 ± 2 (20.7 ± 0.08) 838 ± 2 (33 ± 0.08)
9. Tighten the T.J. boot bands.

REASSEMBLY
1. Wrap tape around the drive shaft splines (G.I. side) to prevent damage to the boots.
2. Before installing the boots place a new clamps to the small boot ends and install them to the drive shaft.
3. After aligning the matchmark, place the beveled side of the tripod axial spline toward the A.C. joint.
4. Using suitable tool and hammer, tap in the tripod to the drive shaft.
5. Install new snap ring.

Page 19 of 36
6. Add specified grease to the A.C. joint and boot as much as wiped away at the time of inspection.
Specified grease : CENTURY

Grease quantity [oz·(g)]
In the boot : 2.47 ± 0.18 (70 ± 5)
In the joint : 4.06 ± 0.18 (115 ± 5)
7. Apply specified grease to the G.I. joint and boot.
Specified grease : One luber GKN

Grease quantity [oz·(g)]
In the boot : 2.12 ± 0.18 (60 ± 5)
In the joint : 3.53 ± 0.18 (100 ± 5)
8. Align the matchmarks and install the G.I. joint to the shaft.
9. Install the boots.
• Make sure that 2 boots are on the shaft

groove.
• Make sure that the 2 boots are not stretched.
10. Position the holes in the clamp's free end to the closing hooks.
Page 20 of 36
11. Using pliers, secure the clamps.
Clearance (A)
A.C. big clamp : 2.0 mm (0.079 in.) or less
A.C. small clamp : 1.8 mm (0.071 in.) or less
12. To control air in the G.I. boot, keep the specified distance between the boot clamps when they are tightened.
Standard value (A, B) mm(in.)
LH side RH side
524.1 ± 2 543.6 ± 2
(20.63 ± 0.08) (21.4 ± 0.08)
13. Holding the G.I. big clamp near the closing hook, using long noise pliers, position the hole the the clamps free
end over the cosing hook.
14. Secure the clamp by drawing the closing hooks together.

Page 21 of 36
15. Using pliers, secure the G.I. small clamp.
Clearance (A)
G.I. small clamp : 1.6 mm (0.063 in.) or less
INSPECTION
1. Check the drive shaft boots for damage and deterioration.
2. Check the splines for wear and damage.
INSPECTION AFTER DISASSEMBLY

1. Check the drive shaft spline part for wear or damage.
2. Check for entry of water and/or foreign material into B.J.
3. Check the spider assembly for roller rotation, wear or corrosion.
4. Check the groove inside T.J. case for wear or corrosion.
5. Check the dynamic damper for damage or cracking.
Driveshaft and axle > Driveshaft Assembly > Center Bearing And Inner Shaft > Components and
Components Location
COMPONENTS
Page 22 of 36
Driveshaft and axle > Driveshaft Assembly > Center Bearing And Inner Shaft > Repair procedures
DISASSEMBLY
1. Using the special tool, disassemble the center bearing bracket from the inner shaft.
2. Using the special tool, press out the center bearing from the outside to the inside direction of the center bearing
bracket as shown in the illustration.
INSPECTION
Page 23 of 36
1. Check the inner shaft for damage, bending or rust.
2. Check the inner shaft splines for wear or damage.
3. Check the center bearing for scoring, discoloration and roughness of the roller joumal's moving surfaces.
REASSEMBLY
1. Apply multipurpose grease to the center bearing and inside the center bearing bracket.
2. Using the special tools, press the center bearing into the center beairng bracket.
3. Apply multipurpose grease to the rear surface of all dust seals.
Recommended grease : LIG-2 or Sunlight No.2

Inner dust seal : 7-10 g (0.25-0.35 oz)
Outer dust seal : 4-6 g (0.14-0.21 oz)
Page 24 of 36
4. Using the special tool, tap in the outer dust seal and inner dust seal in that order until they are flush with the edge
of the center bearing bracket.
When applying grease, make sure that it does not adhere to anything outside the lip.
5. Using the special tool, support the center bearing as shown in the figure, then press in the inner shaft.
Driveshaft and axle > Front Axle Assembly > Front Hub / Axle > Components and Components
Location
COMPONENTS
Page 25 of 36
Driveshaft and axle > Front Axle Assembly > Front Hub / Axle > Repair procedures
REMOVAL
1. Lift up the vehicle and remove the wheel and tire.
2. Disconnect the wheel speed sensor from the knuckle.
3. Disconnect the brake hose from the knuckle.
Page 26 of 36
4. Remove the caliper assembly and suspend it with wire.
5. Remove the split pin and drive shaft nut from the front hub.
6. Remove the 2 bolts and disconnect the ball joint from the knuckle.
7. Using a plastic hammer, disconnect the drive shaft from the axle hub.
Page 27 of 36
8. Using the special tool, disconnect the tie rod end from the knuckle.
1. Be sure to tie a cord to the special tool and to a nearby

part.
2. Loosen the nut but do not remove it.
9. Loosen the upper arm mounting nut but do not remove it.
10. Using the special tool, disconnect the upper arm from the knuckle.
11. Remove the front axle and knuckle together.

12. Installation is reverse of removal.
DISASSEMBLY
1. Remove the brake disc from the hub.
Page 28 of 36
3. Using the special tool, disconnect the hub from the knuckle.
4. Using the special tool, remove the wheel bearing inner race from the hub.
5. Using the special tool, remove the wheel bearing outer race from the knuckle.
INSPECTION
1. Check the hub for cracks and splines for wear.
2. Check the snap ring for crack or damage.
3. Check the knuckle inner surface for scoring and cracks.
REASSEMBLY
1. Apply thin coat of multi-purpose grease to the knuckle and bearing contact surface.
Page 29 of 36
2. Using the special tool, press-in the bearing to the knuckle.
1. Do not press the inner race of wheel bearing. That will cause damage of the bearing
assembly.
2. When installing bearing assembly, always use the new one.
3. Install the snap ring into the groove of knuckle.
4. Using the special tool, press-in the hub to the knuckle.
Do not press the outer race of the wheel bearing.

That will cause damage of the bearing assembly.
5. Tighten the hub to the knuckle to 200 Nm (2000 kg·cm, 148 lb·ft) with the special tool.
Page 30 of 36
6. Rotate the hub to seat the bearing.
7. Measure the wheel bearing starting torque.
Standard value :
Starting torque : 1.03 N·m (10.5 kg·cm, 9.11 lb·ft) or less
8. Measure to determine whether the end play of the hub is within the specified limit or not.
Standard value :
Hub end play : 0.008 mm (0.0003 in.) or less

10. Install the disc to the hub.
Driveshaft and axle > Rear Axle Assembly > Rear Hub / Carrier > Components and Components
Location
COMPONENTS
Rear Axle/Carrier
Page 31 of 36
Driveshaft and axle > Rear Axle Assembly > Rear Hub / Carrier > Repair procedures
REMOVAL
Rear Axle/Carrier
1. Release the parking brake.
3. Remove the wheel speed sensor from the carrier.
Page 32 of 36
4. Remove the caliper assembly from the carrier and suspend it with a wire.
5. Remove the brake disc.
6. Remove the rear axle hub mounting 4 bolts.
7. Using the special tool, remove the tone wheel.
8. Remove the carrier assembly.
9. Raise the crimped portion of the flange nut and remove the flange nut.
Page 33 of 36
10. While supporting the flange area of the bearing outer race, press-out the rear axle hub
11. Using the special tool, remove the bearing inner race from the axle hub.
12. Using the special tool, remove the 2 bushings from the carrier.
Installation
Rear Axle/Carrier
1. Using the special tool, press-in the 2 bushings to the carrier.
2. Apply thin coat of multi-purpose grease to the hub and bearing contact surface.
Page 34 of 36
3. Using the special tool, press-in the bearing to the hub.
1. Do not press the outer race of the bearing.

That will cause the damage of the bearing assembly.
2. When installing bearing assembly, always use the new
one.
4. After tightening the flange nut, crimp the nut to meet the concave portion of the spindle.
5. Using the special tool, press-in the tone wheel.

Page 35 of 36
6. Fit the hub and bearing assembly to the brake backing plate so that the rounded area of the bearing outer race is
placed facing upward.
If it is difficult to fit, adjust the parking brake adjusting nut to enlarge the space of the shoe and lining
assembly.
7. Tighten the 4 bolts to the specified torque.
8. Install brake disc.

9. Install the caliper assembly to the carrier.
10. Rotate the hub to seat the bearing.
Page 36 of 36
11. Using a spring balance, measure the wheel bearing starting torque.
Standard value
Starting torque :18N·m (18 kg·cm, 16 lb·in) or less
12. Measure to determine whether the end play of the hub is within the specified limit or not.
Standard value
Hub end play : 0.008 mm (0.0003 in.) or less
13. Install the wheel speed sensor to the carrier.

14. Install the parking brake.
15. Adjust the parking brake lever stroke.
(Refer to section BR-Parking brake)
INSPECTION
1. Check the rear hub bearing for wear or damage.
2. Check the rear tone wheel for chipped teeth.
3. Check the hub inner surface for scoring.
4. Check the carrier for crack
Page 1 of 34
OPTIMA(MS) > 2003 > G 2.4 DOHC > Emission Control System
Emission Control System > General Information > Schematic Diagrams

SCHEMATIC DRAWING (2.4 DOHC)
Page 2 of 34
SCHEMATIC DRAWING (V6)
VACUUM HOSES LAYOUT

Page 3 of 34
Emission Control System > General Information > Components and Components Location
EMISSION CONTROLS SYSTEM
EMISSION CONTROLS LOCATION
Page 4 of 34
Component Location
Page 5 of 34
EMISSION CONTROLS LOCATION

Page 6 of 34
Component Location
Page 7 of 34
Emission Control System > General Information > Troubleshooting

TROUBLESHOOTING
Page 8 of 34
Symptom Function Remedy
Engine will not start or Vacuum hose disconnected or damaged Repair or replace
hard to start
EGR valve is not closed Repair or replace
Malfunction of the EVAP Canister
Repair or replace
Purge Solenoid Valve
Rough idle or engine Vacuum hose disconnected or damaged Repair or replace
stalls
EGR valve is not closed Repair or replace
Malfunction of the PCV valve Repair or replace
Malfunction of the EVAP Canister Check the system; if there is a problem,
Purge System check its component parts
Exhaust Emission System Positive crankcase ventilation line
Check positive crankcase ventilation system
clogged
Poor fuel mileage Malfunction of the exhaust gas Check the system : if there is a problem,
recirculation check its component parts
Emission Control System > General Information > Specifications

SPECIFICATIONS
Components Function Remarks
Crankcase Emission System HC reduction
Positive Crankcase Ventilation
Variable flow rate type
(PCV) valve
Evaporative Emission System HC reduction
EVAP Canister
EVAP Canister Purge Solenoid
Duty control solenoid valve
Valve
Exhaust Emission System
MFI system Heated oxygen sensor feedback
CO, HC, NOx reduction
(air-fuel mixture control device) type
Three-way catalytic converter CO, HC, NOx reduction Monolith type
Exhaust gas recirculation system
NOx reduction
[2.4 DOHC only]
EGR valve Single type
Manifold absolute pressure sensor EGR Monitoring Electric pressure type
EVAP : Evaporative Emission
SERVICE STANDARD
Page 9 of 34
EVAP Canister Purge Solenoid
Valve
Coil current 0.45A or below (at 12V)
TIGHTENING TORQUE
Item Nm kg·cm lb·ft
Positive
crankcase
8-12 80-120 6-9
ventilation
valve
Emission Control System > Crankcase Emission Control System > Description and Operation
PCV Valve Operation
Page 10 of 34
Emission Control System > Crankcase Emission Control System > Components and Components
Location
COMPONENTS
Page 11 of 34
COMPONENTS(CONTINUED)
Page 12 of 34
Emission Control System > Crankcase Emission Control System > Repair procedures
DISASSEMBLY
1. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve. Remove the PCV valve from
the rocker cover and reconnect it to the ventilation hose.
Page 13 of 34
2. Run the engine at idle and put a finger on the open end of the PCV valve and make sure that intake manifold
vacuum is felt.
The plunger inside the PCV valve will move back and forth.
3. If vacuum is not felt, clean the PCV valve and ventilation hose in cleaning solvent, or replace if necessary.
INSPECTION
1. Remove the positive crankcase ventilation valve.
2. Insert a thin stick into the positive crankcase ventilation valve from the threaded side to check that the plunger
moves.
3. If the plunger does not move, the positive crankcase ventilation valve will be clogged. Clean or replace it.
INSTALLATION
Install the positive crankcase ventilation valve and tighten to the specified torque.
Tightening torque
PCV valve : 8-12 Nm (80-120 kg·cm, 6-8 lb·ft)
Emission Control System > Evaporative Emission Control System > Canister > Repair procedures
Inspection
For monitor, there are a CCV and an air filter as the illustration.
1. Look for loose connections, sharp bends or damage to the fuel vapor lines.
Page 14 of 34
2. Look for distortion, cracks or fuel leakage.
3. After removing the EVAP Canister, inspect for cracks or damage.
Emission Control System > Evaporative Emission Control System > Purge Control Solenoid Valve
(PCSV) > Schematic Diagrams
EVAPORATIVE (EVAP) CANISTER PURGE SOLENOID VALVE
Emission Control System > Evaporative Emission Control System > Purge Control Solenoid Valve
(PCSV) > Repair procedures
EVAP Canister Purge Solenoid Valve
Page 15 of 34
The EVAP Canister Purge Solenoid Valve is controlled by the ECM; when the engine coolant temperature is low,
and also during idling, the valve closes so that evaporated fuel is not drawn into the surge tank. After engine warm-
up during ordinary driving, it opens to let the stored vapors flow into the surge tank.
INSPECTION
When disconnecting the vacuum hose, make an identification mark on it so that it can be reconnected to its original
position.
1. Disconnect the vacuum hose (black with red stripe) from the solenoid valve.
2. Detach the harness connector.
3. Connect a vacuum pump to the nipple to which the red-striped vacuum hose was connected.
4. Apply vacuum and check when voltage is applied to the EVAP Canister Purge Solenoid Valve and when the
voltage is discontinued.
Battery voltage Normal condition
When applied Vacuum is released
When discontinued Vacuum is maintained
Page 16 of 34
5. Measure the current between the terminals of the solenoid valve.
EVAP Canister Purge Solenoid Valve :
Coil at 20°C (68°F) : 0.45A or below (at 12V)
Coil resistance : 24.5 - 27.5 Ω [at 20°C (68°F)]
Vacuum Hose Inspection

Engine coolant temperature : 80-95°C (176-205°F)
1. Disconnect the vacuum hose from the intake manifold purge hose nipple and connect a hand vacuum pump to the
nipple.
2. Start the engine and check that, after raising the engine speed by racing the engine, vacuum remains fairly
constant.
If there is no vacuum created the intake manifold port may be clogged and require cleaning.
Emission Control System > Evaporative Emission Control System > Fuel Filler Cap > Repair
procedures
FUEL FILER CAP
Check the gasket of the fuel filler cap, and the filler cap itself, for damage or deformation. Replace the cap if
necessary.
Page 17 of 34
Two-way valve
1. Inspect that air flows as shown.
2. Check to connect correctly such as the arrow mark on the valve.
Air filter
Look for distortion, cracks
Emission Control System > Evaporative Emission Control System > The Other Evaporative Emission
Control System Component > Repair procedures
FUEL TANK PRESSURE SENSOR
This is the sensor to detect the fuel tank leakage in way which it measures the differential pressure between the inside
and outside of the fuel tank.
Inspection
Page 18 of 34
Check that fuel level is over 15%. If not, this inspection is not available.
The vehicle must be in turn-on and at idle. Don't forget it.
Check of canister close valve operating
1. Connect the CCV pins to a wire as shown.
2. At idle, disconnect the CCV connector.
3. Inspect that CCV is close when attaching the wire to (-) of battery.
4. Inspect that CCV is open when detaching the wire from (-) of battery.
In this case, if you use a very thin paper and attach it to hose to CCV, you can check easy the CCV
condition.
(1) If the paper is absorbed into or out, CCV is open.
(2) If not, CCV is close.
Emission Control System > Evaporative Emission Control System > Description and Operation
DESCRIPTION
On-Board Refueling Vapor Recovery (ORVR) system is properly designed to prevent the fuel tank vapor (HC)
emission during refueling at the gas station. This system consists of fuel vent valve (ORVR), fuel shut-off valve, fuel
cut valve (roll over), two way valve (pressure/vacuum relief), fuel liquid/vapor separator which is installed beside the
filler pipe, charcoal canister which is mounted under the rear floor LH side member with protector, tubes and
miscellaneous connections. While refueling, the flow and column of the refueling draws the ambient air into the filler
pipe so as not to emit fuel vapor in the air. The fuel vapor in the tank is then forced to flow into the canister via the fill
vent valve and the fuel liquid/vapor separator which isolates liquid fuel ingredient and transfers the pure vapor to the
carbon canister. While the engine is operating, the trapped vapor emission in the canister is drawn and fed by the
intake manifold vacuum into the engine combustion chamber. According to this purge process, the carbon canister is
purged and recovers its adsorbing capability.
Page 19 of 34
Emission Control System > Evaporative Emission Control System > Components and Components
Location
COMPONENTS
Page 20 of 34
Emission Control System > Evaporative Emission Control System > Repair procedures
EVAPORATIVE & ORVR EMISSION CONTROL SYSTEM
Page 21 of 34
1. Prepare a voltmeter and connect it to FTP pins as shown.
2. After 20 min. idling , inspect the voltage.

System voltage : 5V
At acceleration : Max. 4.5, Min. 0.5V
3. At idle, inspect that voltage fluctuates to accelerate rpm up and down.
If voltage is not within spec.as procedures, there is leakage and inspect the fuel tank and hoses toward
canister and fuel neck. Then repair or replace relevant parts.
Emission Control System > Exhaust Emission Control System > Description and Operation
Vehicles with catalytic converter
Exhaust emissions (CO, HC, NOx) are controlled by a combination of engine modifications and the addition of
special control components.
Modifications to the combustion chamber, intake manifold, camshaft and ignition system form the basic control
system. Additional control devices include an exhaust gas recirculation (EGR) system and a catalytic converter.
These systems have been integrated into a highly effective system which controls exhaust emissions while maintaining
good driveability and fuel economy.
AIR/FUEL MIXTURE RATIO CONTROL SYSTEM [Multiport Fuel Injection (MFI) System]
The MFI system employs the signals from the heated oxygen sensor to activate and control the injector installed in
the manifold for each cylinder, precisely regulating the air/ fuel mixture ratio and reducing emissions.
This allows the engine to produce exhaust gases of the proper composition to permit the use of a three-way catalyst.
The three-way catalyst is designed to convert the three pollutants (1) hydrocarbons (HC), (2) carbon monoxide
(CO), and (3) oxides of nitrogen (NOx)into harmless substances. The two operating modes in the MFI system are
as follows:
1. Open Loop-air/fuel ratio is controlled by information programmed into the ECM during the manufacturing
process.
2. Closed Loop-air/fuel ratio is varied by the ECM based on information supplied by the heated oxygen sensor.
Page 22 of 34
Emission Control System > Troubleshooting > P0181
FUEL TEMPERATURE CIRCUIT
Diagnostic trouble code Differential of fuel temperature and engine coolant temperature at start
No. P0181 too large
Diagnostic trouble code
Fuel temperature circuit low input
No. P0182
Fuel temperature circuit high input
No. P0183
[Related items] • Open or short to ground between FTS and main relay
• Open or short to ground between FTS and ECM
• Short to battery battery between FTS and ECM
• Short between FTS wires
• Faulty FTS
step Inspection Action

1 Turn ignition to OFF and disconnect FTS connector. Yes Go to step 2.
Turn ignition to ON
Measure voltage of FTS signal circuit between FTS No Open circuit or short circuit to chassis ground
harness connector and chassis ground. between FTS harness connector and ECM
• Specification : Approximately 5V connector.
Is voltage within specification? Repair as necessary.
2 Thoroughly check FTS and ECM for loose, bent, Yes Temporarily install a known good FTS and
corroded, contaminated, deteriorated or damaged check for proper operation.
connectors. If problem is corrected, replace FTS.
Is connection okay?
No Repair as necessary.
3 Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with SCAN
TOOL connected and monitor for pending codes.

EGR System (FOR 2.4 DOHC)
Page 23 of 34
EGR system malfunction
No. P0401
[Related items] • Blocked and/or leakage vacuum tube between EGR control valve and
intake manifold vacuum port
• Blocked and/or leakage tube between EGR solenoid valve and intake
manifold port
• Misplaced, loose or corroded terminals at MAPS, EGR solenoid valve
• Leakage in EGR control valve
• Poor connection vacuum tubes
• Stuck closed EGR control valve
• Stuck open EGR control valve
If any codes relating to EGR solenoid valve or MAPS are present, do all
repairs associated with them before proceeding with this troubleshooting
procedure

1 First check for DTC relating to EGR solenoid Yes First repair all other malfunctions on DTCs.
valve or MAPS.
Do DTCs exist? No Go to step 2.
2 Thoroughly check all vacuum hoses and EGR Yes Go to step 3.

pipes between:
1. Throttle body and EGR solenoid valve
2. Throttle body and EGR control valve
3. EGR control valve and EGR solenoid valve No Replace all cracked/damaged hoses or pipes.
4. EGR control valve and exhaust manifold
5. EGR control valve and intake manifold
Are vacuum hoses and EGR pipes OK?
3 Check EGR control valve for being tightly Yes Go to step 4.
installed.
Is EGR control valve installation OK? No Repair as necessary.
4 Remove EGR control valve and check for Yes Thoroughly check for loose, bent or corroded
excessive carbon deposits and sticking per terminals at all connectors in circuit.
following check:
Draw a vacuum at nipple and verify EGR control
valve holds vacuum.
Blow air into hose removed from exhaust
manifold and verify air escapes.
Remove a vacuum at nipple and below an air into
hose and verify air does not escape from port.
Repeat this procedure 4 or 5 times to ensure No Temporarily install a known good EGR control
EGR control valve reliability. valve and check for proper operation. If problem is
Is EGR control valve moving freely and is not corrected replace EGR control valve.
carbon fouled?
Page 24 of 34
While EGR control valve is removed,

inspect removed hose for obstructions.
Repair or replace as necessary.
5 Check MAPS for contamination, deterioration or Yes Clean MAPS and check for MAPS and housing for
damage. source of leak and repair as necessary. If damaged
Is MAPS contaminated, deteriorated or or deteriorated, replace.
damaged? No Go to step 6.
6 Thoroughly check for loose, bent or corroded Yes Go to step 7.
connectors at ECM and MAPS.
With ignition off, disconnect ECM and MAPS
connectors.
Measure resistance between MAPS and ECM No Open circuit between MAPS harness connector
on three circuits. and ECM harness connector.
• Specifications: below 1Ω Short circuit to chassis ground between harness
Measure voltage between MAPS reference connector and ECM harness connector.
power terminal and chassis ground. Repair as necessary.
• Specifications: approximately 5V
Is the resistance or voltage within the
specifications?
7 Start an engine and allow an engine to warm up Yes Go to step 8.
to operating temperature. With engine idling,
measure voltage at MAPS output terminal.
Open throttle suddenly and verify that voltage
increases: No If wiring and connections are all okay, temporarily
• 0.8~2.4 V at idle install a known good MAPS and check for proper
• at open throttle suddenly operation. If problem is corrected, replace MAPS.
Is idle voltage within specifications and do
voltage readings increase?

EGR system solenoid valve (FOR 2.4 DOHC)
Diagnostic trouble
code EGR system solenoid valve circuit malfunction
No. P0403
[Related items] • Open between EGR solenoid valve and ECM
• Short to battery between EGR solenoid valve and ECM
• Short to between EGR solenoid valve wires
• Faulty EGR solenoid valve
Page 25 of 34
1 Thoroughly check EGR valve for loose, bent, Yes Repair as necessary.
corroded, contaminated, deteriorated or damaged
connectors. No Go to step 2.
Is any problem present?
2 Turn ignition to OFF and disconnect EGR valve Yes Go to step 3.
connector.
Turn ignition to ON and measure voltage of EGR No Open circuit or short circuit to chassis ground
valve power circuit between EGR valve harness between EGR valve harness connector and
connector and chassis ground. main relay.
• Specification: approximately B+ Repair as necessary.
Is voltage within specification?
3 Turn ignition to OFF. Yes Check EGR valve for poor terminal contacts
EGR valve connector is still disconnected. due to oxidation, bent deformed, or misplaced
Measure resistance between EGR valve battery terminals.
power and signal terminal. Repair as necessary.
• Specification: 30~34 Ω @ 20°C (68°F) No Temporarily install a known good EGR valve
Is resistance within specification? and check for proper operation. If problem is
corrected, replace EGR valve.
4 Turn ignition to OFF and disconnect ECM connector. Yes Go to step 5.
Measure resistance of EGR valve signal circuit
between EGR valve harness connector and ECM No Open circuit between EGR valve harness
harness connector. connector and ECM harness connector.
• Specification: below 1Ω Repair as necessary
Does resistance indicate continuity circuit?
5 ECM connector EGR valve connector is still Yes Temporarily install a known good EGR
disconnected. VALVE and check for proper operation. If
Measure resistance between EGR valve harness problem is corrected, replace EGR valve.
connector and chassis ground at EGR valve signal
No Short circuit to chassis ground between EGR
circuit.
valve harness connector and ECM harness
Measure resistance between EGR valve battery
connector.
voltage circuit and signal circuit.
Short circuit between EGR valve battery power
• Specification: infinite circuit and signal circuit.
Does resistance indicate open circuit? Repair as necessary.

Main catalyst efficiency deterioration (bank1)-(FOR 2.4 DOHC)
Page 26 of 34
Main catalyst efficiency deterioration (bank1)
No. P0421
[Related items] • Catalytic converter deteriorated
If any codes relating to HO2S sensor. MAFS, injectors, a P0171~P0172

are present, do all repairs associated with them before proceeding with
this troubleshooting procedure.

1 Connect SCAN TOOL to data link connector or OBD-II check Yes Do all repairs associated with those
connector. codes before proceeding this
Turn ignition to ON and check other DTCs. procedure.
Are DTC P0300~P0304, P0116, P01117, P0118, P0125,
P0128, P0130~P0135, P0136~P0141, and/or P0171~P0172 No Go to step 2.
set?
2 Start engine and warm up to operating temperature. Yes Replace catalytic converter.
Using SCAN TOOL monitor both front HO2S and rear HO2S
signals. No Go to step 3.
Do both signals switch lean to rich and rich to lean?
3 Release fuel pressure and attach fuel pressure gauge to service Yes Go to step 4.
port on fuel rail.
Start an engine and warm up to operating temperature. Check
for fuel pressure at idle.
• Fuel pressure at idle: 46~49 psi (320~340kPa, No Check fuel delivery system.
3.26~3.47kg/cm2)
Is fuel pressure within specification?
4 Check exhaust system for leaks, cracks, loose connection Yes Go to step 5.
(especially exhaust manifold, catalyst around rear HO2S, etc)
Is exhaust system okay? No Repair or replace as necessary.
5 Check for any split, disconnected or perforated vacuum hoses. Yes Go to step 6.
Also, check PCV valve for proper operation.
No Replace faulty vacuum hoses or
Are vacuum hoses and PCV okay?
PCV.
6 Check for fuel injector operation. Yes Go to step 7.
Are fuel injectors working normal and dispensing proper
volume? No Repair as necessary.
7 Check intake system for leaks, cracks, loose connection as Yes Replace catalytic converter as
following items: necessary.
• Throttle body gasket
• Gasket between intake manifold and surge tank
• Seals between intake manifold and fuel injectors No Repair or replace as necessary.
• Seals between surge tank and PCV valves
Is intake system okay?
Page 27 of 34

EVAP emission control system - PSV (FOR 2.4 DOHC)
Diagnostic trouble code EVAP emission control system purge solenoid valve stuck
No. P0441 opened
[Related items] • Purge solenoid valve stuck opened

1 Connect SCAN TOOL to data link connector or Yes Do all repairs associated with those codes before
OBD-II check connector. Turn ignition to ON and proceeding this procedure.
check other DTC.
Is DTC P0443 set? No Go to step 2.
2 Turn ignition to OFF and disconnect vacuum hose Yes Go to step 2.

from PSV.
Start engine and put a finger on the open end of
vacuum hose. No Repair or replace vacuum hose as necessary.
Is intake manifold felt?
3 Turn ignition OFF and disconnect hose leading Yes Problem is intermittent or was repaired and engine
from PSV to intake manifold at PSV. Draw a control module memory was not cleared. Check
vacuum at nipple and verify PSV holds vacuum. terminal connections at ECM and PSV.
Turn ignition to ON and jumper a wire to chassis
ground at PSV control terminal (should hear a faint
click from PSV). Vacuum should bleed off. No Temporarily install a known good PSV and check
Repeat this procedure 4 or 5 times to ensure PSV for proper operation. If problem is corrected
reliability. replace PSV.
Is PSV working properly?

EVAP emission control system small leak detected (FOR 2.4 DOHC)
Page 28 of 34
EVAP emission control system small leak (1 mm)
No. P0442
EVAP emission control system Small leak (0.5 mm)
No. P0456
EVAP emission control system large leak
No. P0445
[Related items] • Fuel filler 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, do all
repairs associated with those codes before proceeding with this
troubleshooting procedure.

1 Connect SCAN TOOL to data link connector or Yes Do all repairs associated with those codes
OBD-II check connector. before proceeding this procedure.
Turn ignition to ON and check any other DTCs.
Is DTC P0441, P0443, P0446, P0451, P0452, or No Go to step 2.
P0453 set?
2 Using SCAN TOOL proceed EVAP leakage test. Yes Problem is intermittent or was repaired and
Is EVAP system okay? engine control module memory was not
cleared. Check terminal connections at ECM
and PSV.
No Go to step 3.
3 Check fuel filler cap for being tightly installed, has o- Yes Go to step 4.
ring seal installed and is in good condition.
Verify cap releases vacuum at specified values
(approximately 2psi pressure and approximately 1.5 No Replace fuel filler cap.
inches hg vacuum).
Are cap, o-ring and release pressures OK?
4 Check fuel filler pipe for cracks, damage and o-ring Yes Go to step 5.
seat for deformation.
Is fuel filler pipe OK? No Replace fuel filler pipe.
5 Thoroughly check all fuel vapor hoses and hose clamps Yes Go to step 6.
between:
Page 29 of 34
1. canister and rollover/ORVR valves
2. canister and CCV
3. canister and PSV
No Replace all cracked/damaged hoses or loose
4. PSV and intake manifold
clamps.
(At this point, also verify arrow on PSV is pointing
towards intake manifold. If it is not, reverse
installation).
Are vapors hoses and clamps OK?
6 Turn ignition to OFF and remove FTPS access plate. Yes Go to step 7.
Remove FTPS from tank unit. Turn ignition to ON
(engine OFF) and monitor FTPS output voltage with No Temporarily install a known good FTPS and
SCAN TOOL. check for proper operation. If problem is
Is voltage within specification? corrected replace FTPS.
7 Turn ignition OFF and disconnect hose leading from Yes Go to step 8.
PSV to intake manifold at PSV. Draw a vacuum at
nipple and verify PSV holds vacuum.
ground at PSV control terminal 1 (should hear a faint No Temporarily install a known good PSV and
click from PSV). Vacuum should bleed off. check for proper operation. If problem is
Repeat this procedure 4 or 5 times to ensure PSV corrected replace PSV.
reliability.
Is PSV working properly?
8 Turn ignition OFF and disconnect hose connecting Yes Go to step 9.
CCV to canister. Blow air into hose removed from
canister and verify air escapes.
ground at CCV control terminal 1. Blow an air into No Temporarily install a known good CCV and
hose and verify air does not escape from port. check for proper operation. If problem is
Repeat this procedure 4 or 5 times to ensure CCV corrected replace CCV.
reliability.
Is CCV working properly?
9 Thoroughly check fuel gas leaks, cracks, damages of Yes Go to step 10
the following items:
• Fuel filler cap
• Fuel vent valve (ORVR)
• Fuel cut valve (Rollover valve)
• FTPS No Repair or replace as necessary.
• EVAP hoses
• Canister
Are the above items okay?
Page 30 of 34
1) This DTCP0455 may be set in the ECM memory and MIL illuminates if engine is running for refuelling (i.e.if
engine is running when fuel filler cap is opened).
2) Emphasize the following Caution to customers to prevent concern causing unnecessary repairs.
1) Always stop engine before refueling

2) If you open the fuel filler cap when engine is running.
3) It is possible that ECM detects evaporative emission large leak (DTCP0455) and allow MIL to illuminate even
if the evaporative emission system is normal (no leak).

EVAP emission control system PSV circuit (FOR 2.4 DOHC)
Diagnostic trouble code EVAP emission control system purge solenoid valve circuit
No. P0443 malfunction
[Related items] • Open or short between main relay and purge solenoid valve
• Open or short between purge solenoid valve and ECM
• Faulty purge solenoid valve

1 Thoroughly check PSV for loose, bent, corroded, Yes Repair as necessary.
contaminated, deteriorated or damaged connectors. Is
any problem present? No Go to step 2.
2 Turn ignition to OFF and disconnect PSV connector. Yes Go to step 3.

Turn ignition to ON and measure voltage of PSV
power circuit between PSV harness connector and No Open circuit or short circuit to chassis ground
chassis ground. between PSV harness connector and main
• Specification: approximately B+ relay.
3 Turn ignition to OFF. Yes Check PSV for poor terminal contacts due to
PSV connector is still disconnected. oxidation, bent deformed, or misplaced
Measure resistance between PSV battery power and terminals.
signal terminal. Repair as necessary.
• Specification: 20~32Ω @ 20°C (68°F) No Temporarily install a known good PSV and
Is resistance within specification? check for proper operation. If problem is
corrected, replace PSV.
Measure resistance of PSV signal circuit between PSV
harness connector and ECM harness connector. No Open circuit between PSV harness connector
• Specification: below 1Ω and ECM harness connector.
Does resistance indicate continuity circuit? Repair as necessary.
5 ECM connector PSV connector is still disconnected. Yes Temporarily install a known good PSV and
Measure resistance between PSV harness connector check for proper operation. If problem is
and chassis ground at PSV signal circuit. corrected, replace PSV.
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Measure resistance between PSV battery voltage No Short circuit to chassis ground between PSV
circuit and signal circuit. harness connector and ECM harness
• Specification: infinite connector.
Does resistance indicate open circuit? Short circuit between PSV battery power
circuit and signal circuit.
Repair as necessary.

EVAP emission control system vent circuit (FOR 2.4 DOHC)
EVAP emission control system vent circuit malfunction
No. P0446
[Related items] • Open or short to chassis ground between main relay and
CCV
Short to chassis ground between CCV and ECM
• Open or short to battery between CCV and ECM
• Short to chassis ground between CCV and ECM
• Faulty CCV

1 Thoroughly check CCV for loose, bent, corroded, Yes Repair as necessary.
contaminated, deteriorated or damaged connectors.
Is any problem present? No Go to step 2.
2 Turn ignition to OFF and disconnect CCV connector. Yes Go to step 3.

Measure voltage between CCV power terminal and
signal terminal. No Temporarily install a known good CCV and
• Specifications: 23~26 Ω at 20°C (68°F) check for proper operation. If problem is
Is resistance within specification? corrected, replace CCV.
3 Turn ignition to ON and measure voltage of CCV Yes Go to step 4.

power circuit between CCV harness connector and
No Open circuit or short circuit to chassis ground
chassis ground
between CCV harness connector and main
• Specifications: approximately B+ relay.
Measure resistance of CCV signal circuit between
CCV harness connector and ECM harness connector. No Open circuit between CCV harness connector
• Specifications: below 1Ω and ECM harness connector.
Does resistance indicate continuity circuit? Repair as necessary.
5 Measure resistance between CCV harness connector Yes Temporarily install a known good CCV and
and chassis ground at CCV signal circuit. check for proper operation. If problem is
• Specifications: infinite corrected, replace CCV.
Does resistance open circuit?
Page 32 of 34
Does resistance open circuit? No Short circuit to chassis ground between CCV
harness connector and ECM harness
connector.

EVAP emission control system pressure sensor (FOR 2.4 DOHC)
Diagnostic trouble code EVAP emission control system pressure sensor range/performance
No. P0451 problem
[Related items] • Poor connections between FTPS and ECM
• Misplaced, loose, bent or corroded terminals
• Contaminated, deteriorated or damaged FTPS
• Faulty FTPS
• Stuck closed CCV
• Blocked vapor hose between canister and CCV

1 Connect SCAN TOOL to data link connector or OBD-II Yes Do all repairs associated with those codes
check connector. Turn ignition to ON and check any other before proceeding this procedure.
DTCs.
Is DTC P0446, P0452, or P0453 set? No Go to step 2.
2 Using SCAN TOOL monitor FTPS voltage signals. Yes Problem is intermittent or was repaired and
• Specification: 2.2~2.8V engine control module memory was not
Is voltage within specification? cleared. Check terminal connections at
ECM and FTPS.
No Go to step 3.
3 Thoroughly check FTPS for loose, bent, corroded, Yes Repair as necessary.
Is any problem present? No Go to step 4

Turn ignition to ON and measure voltage of FTPS
No If voltage is above specification, short
reference power circuit between FTPS harness connector
circuit to battery.
and chassis ground.
If voltage is below specification, open
• Specification: 4.8~5.2V circuit or short circuit to chassis ground.
5 Turn ignition to ON. Yes Go to step 6.
Measure voltage of FTPS signal circuit between FTPS
No Short circuit to power between FTPS
harness connector and chassis ground.
• Specifications: below 0.5V connector.
Is voltage within specifications? Repair as necessary.
Page 33 of 34
Measure resistance of FTPS signal circuit between FTPS
harness connector and ECM harness connector.
Mrasure resistance of FTPS ground circuit between FTPS No Open circuit between FTPS harness
harness connector and ECM harness connector. connector and ECM harness connector.
• Specifications: below 1Ω Repair as necessary.
Does each resistance indicate continuity circuit?
7 Measure resistance between FTPS harness connector and Yes Temporarily install a known good FTPS
ECM harness connector at FTPS signal circuit and ground and check for proper operation. If problem
circuit. is corrected, replace FTPS.
• Specifications: infinite No Short circuit to chassis ground between
Does each resistance open circuit? FTPS harness connector and ECM
harness connector.
8 Remove CCV and blow through hose and verify air Yes Thoroughly check for loose, bent, or
escapes from port on back of CCV. corroded terminal between FTPS, CCV
Connect battery positive to one terminal on CCV and and ECM.
battery negative to the other terminal. Verify air does not Repair as necessary.
escape from back of CCV. No Temporarily install a known good CCV
Does CCV operate properly? and check for proper operation. If problem
is corrected, replace CCV.

EVAP emission control system pressure sensor (FOR 2.4 DOHC)
EVAP emission control system pressure sensor low input
No. P0452
Diagnostic trouble code EVAP emission control system pressure sensor high
No. P0453 input
[Related items] • Open or short to battery between FTPS and ECM
• Short to chassis ground between FTPS and ECM
• Poor connections between FTPS and ECM
• Misplaced, loose or corroded terminals
• Faulty FTPS
Page 34 of 34
1 Connect SCAN TOOL to data link connector or OBD-II Yes Problem is intermittent or was repaired
check connector. Using SCAN TOOL monitor FTPS and engine control module memory was
voltage signals. not cleared. Check terminal connections
• Specification: 2.2~2.8V at ECM and FTPS.
Is voltage within specification? No Go to step 2.
2 Thoroughly check FTPS for loose, bent, corroded, Yes Repair as necessary.
Is any problem present? No Go to step 3
3 Turn ignition to OFF and disconnect ECM connector. Turn Yes Go to step 4.
ignition to ON and measure voltage of FTPS reference
No If voltage is above specification, short
power circuit between FTPS harness connector and ECM
circuit to battery.
harness connector. If voltage is below specification, open
• Specification: 4.8~5.2V circuit or short circuit to chassis ground.
Measure voltage of FTPS signal circuit between FTPS
No Short circuit to power between FTPS
harness connector and chassis ground. harness connector and ECM harness
Measure resistance of FTPS signal circuit between FTPS
harness connector and ECM harness connector.
Measure resistance of FTPS ground circuit between FTPS No Open circuit between FTPS harness
harness connector and ECM harness connector. connector and ECM harness connector.
6 Measure resistance between FTPS harness connector and Yes Temporarily install a known good FTPS
ECM harness connector at FTPS signal circuit and ground and check for proper operation. If
circuit. problem is corrected, replace FTPS.
• Specifications: infinite No Short circuit to chassis ground between
Does each resistance open circuit? FTPS harness connector and ECM
harness connector.
Page 1 of 44
OPTIMA(MS) > 2003 > G 2.4 DOHC > Engine Electrical System
Engine Electrical System > General Information > Specifications

Specification
Ignition Coil
Item 2.4 Liter Engines
Type Mold coil
Primary coil
0.78 (Ω)
resistance
Secondary coil
20 (Ω)
resistance
Spark plug
Item 2.4 Liter Engines
NGK PRG5C-11
Champion RN10PYP4
1.0~1.1 mm
Plug gap
(0.039~0.043 in)
Starter motor
Item All Engines
Reduction drive (with
Type
planetary gear)
Voltage
12V
Output
1.2kW
No-load characteristics
Terminal voltage 11V
Amperage 90 A
Speed 2,800 RPM MIN.
Number of pinion teeth 8
0.5-2.0 mm (0.0197-0.079
Pinion gap
in.)
Battery
Item 2.4 Liter Engines V6 Engines
Type MF68AH(20HR) MF68AH(20HR)
Coldcranking [at 17.8°C
540 A or more 540 A or more
(0°F)]
Reserve capacity 110 min 110 min
Specific gravity [at 25°C
1.280 ± 0.01 1.280 ± 0.01
(77°F)]
Page 2 of 44
COLDCRANKINGAMPERAGE is the amperagea batteey can deliver for 30 seconds andmaintain a terminal
voltage of 7.2 or greater at a specified temperature.RESERVE CAPACITY RATING is the amount of time a
battery can deliver 25A ANDmaintain a minimum terminal voltage of 10.5 at 26.7°C(80°F).
Generator
Item All Engines
Type
Battery voltage sensing
Rated output
13.5 V 110A
Voltage regulator type
Electronic built-in type
Regulator setting voltage
14.55 ± 0.2V
Temperature
-7 ± 3 mV/°C
compensation
TIGHTENING TORQUE
Items Nm Kg. cm Ib.ft
Generator
terminal 5-7 50-70 3.6-5.1
(B+)
Starter
motor
10-12 100-120 7.3-8.8
terminal
(B+)
Battery
4-6 40-60 2.9-4.3
terminal
Spark plug 20-30 204-306 15-21
Engine Electrical System > Ignition System > Ignition Coil > Repair procedures
INSPECTION
IGNITION COIL (2.4 Liter Engine : Power Transistor Bulilt-in)
Page 3 of 44
1. Measurement of the primary coil resistance
Connect the negative (-) terminal of a 3V power supply to terminal 2 of the power transistor; then check whether
there is continuity between terminal3 and terminal 2 when terminal 1 and the positive (+) terminal are connected
and disconnected.
Terminal 1 and (+) terminal Terminal 3 and terminal 2

Connected Continuity (Approx. 0.78Ω)
Disconnected No continuity
Replace the power transistor if there is a malfunction.

1. Measurement of the secondary coil resistance
Measure the resistance between the high-voltage terminals of the ignition coil.
Standard value: Approximately 20 kΩ
IGNITION COIL (V6 ENGINE)

1. Measurement of the primary coil resistance
Measure the resistance between connector terminals 4 and 3 (the coils at the No. 3 and No. 6 cylinder sides) of
the ignition coil, and between terminals 4 and 1 (the coils at the No. 1 and No. 4 cylinder sides), and between
terminals 4 and 2 ( the coils at the No.2 and No.5 cylinder sides)
Standard value: 0.74 ± 10% (Ω)

Page 4 of 44
2. Measurement of the secondary coil resistance
Measure the resistance between the high-voltage terminal for the No. 3 and No. 6 cylinders, between the high-
voltage terminals for the No. 1 and No. 4 cylinders and between the high-voltage terminals for the No.2 and
No.5 cylinders.
Standard value: 13.3 ± 15% (kΩ)
Be sure, when measuring the resistance of the secondary coil, to disconnect the connector of the ignition
coil.
Engine Electrical System > Ignition System > Ignition Switch > Repair procedures
REMOVAL AND INSTALLATION
1. Disconnect the negative battery terminal.
2. Remove the air bag module.
The SRS system is designed to retain enough power to deploy air bag for a short time even after the
battery has been disconnected, so serious injury and/or death may result from unintended air bag
deployment if service is done on the SRS system immediately after the negative (-) battery terminal is
disconnected. Wait at least 30 seconds after disconnecting the negative (-) battery terminal before working
on the SRS system.
3. Loosen the tapping screw and lift up horn pad and remove it.
4. Remove the lock nut and the washer.
5. Pulling the dynamic damper forward, lift it up and remove it.
Page 5 of 44
6. Install the special tool (09561-11001) and remove the steering wheel.
Do not hammer on the steering wheel to remove it, since that can damage the energy absorbing collapsible
portion of the steering column, increasing the chance of personal injury or death in a frontal collision.
7. Remove the steering column lower and upper shrouds.

8. Remove the lower cover.
9. Disconnect the connectors and remove the multifunction switch. The ignition switch still cannot be removed. The
entire lower portion of the dash has to be removed and the steering column has to be dropped otherwise it's
impossible to remove the ignition switch.
10. Remove the mounting bolts and separate ignition switch from steering column.
Engine Electrical System > Ignition System > Spark Plug > Repair procedures
INSPECTION
1. Remove the spark plug and connect to the spark plug cable.
2. Ground the spark plug outer electrode, and crank the engine.
Page 6 of 44
3. Check to be sure that there is an electrical discharge between the electrodes at this time.
When replacing the spark plug, should use the genuine parts having resistance.
Engine Electrical System > Ignition System > Description and Operation
GENERAL INFORMATION
lgnition timing is controlled by the electric control ignition timing system. The ignition timing data for the engine
operating conditions are programmed in the memory of the engine control module (ECM).
The engine conditions (speed, load, warm-up condition, etc.) are detected by the various sensors. Based upon these
sensor signals and the ignition timing data, signals to interrupt he primary current are sent to the power transistor. The
ignition coil is activated, and timing is controlled at the optimum point.
Engine Electrical System > Ignition System > Troubleshooting

TROUBLESHOOTING GUIDE
Trouble condition Probable cause Remedy
Engine will not start or is hard to start. Ignition lock switch faulty Replace ignition lock switch
(Cranks OK)
Ignition coil faulty Inspect ignition coil
Power transistor faulty Inspect power transistor
Spark plugs faulty Replace plugs
Ignition wiring disconnected or
Inspect wiring
broken
Spark plugs faulty Replace plugs
Rough idle or stalls Ignition wiring faulty Inspect wiring
Ignition coil faulty Inspect ignition coil
Spark plug cable faulty Inspect spark plug cable
Engine hesitates/poor acceleration Spark plugs faulty Replace plugs
Ignition wiring faulty Inspect ignition coil
Poor mileage Spark plugs faulty Replace plugs
Engine Electrical System > Ignition System > Repair procedures

Inspection and Cleaning
Page 7 of 44
1. Disconnect the spark plug cable from the spark plug.
Pull on the spark plug cable boot when removing the spark plug cable, not the cable, as it may be
damaged.
2. Using spark plug wrench, remove all of the spark plugs from the cylinder head.
Take care not to allow contaminants to enter through the spark plug holes because severe engine damage
could occur.
3. Check spark plugs for the following:

(1) Broken insulator
(2) Worn electrode
(3) Carbon deposits
(4) Damaged or broken gasket
(5) Condition of the porcelain insulator at the tip of the spark plug.
4. Check the spark plug gap using a wire gap gauge, and adjust if necessary.
Standard value :
Spark plug gap : 1.0-1.1 mm (0.039-0.043 in.)
Page 8 of 44
5. Install the spark plug and tighten to the specified torque.
If the spark plug is over-tightened, damage to the threaded portion of the cylinder head may
result.
Tightening torque
Spark plug : 20-30 Nm (204-306 kg.cm, 15-21 lb.ft)
When replacing the spark plug, should use the genuine parts having resistance.
Engine Electrical System > Charging System > Alternator > Repair procedures
REASSEMBLY
Perform reassembly in the reverse procedure of disassembly. Pay attention to the following:
Before the rotor is attached to the rear bracket, insert a wire through the small hole in the rear bracket to lock the
brush. After the rotor has beeninstalled, the wire can be removed.
REMOVAL
Page 9 of 44
Installation
1. Place the alternator and insert a support bolt (Do not insert a nut this time).
2. After pushing the alternator forward, count that how many spacers (a spacer thickness : 0.198 mm) should be
inserted between the alternator front leg and front case as shown in "A".
3. After inserting spacers, insert and tighten a nut securely.
BRUSH REPLACEMENT
Page 10 of 44
1. Measure the length of the brush protrusion shown in the illustration, and replace the brush if the measured value is
below the limit value.
Limit : 2mm (0.079 in.) or less
2. The brush can be removed if the solder of the brush lead wire is removed.
3. When installing a new brush, insert the brush into the holder, and then solder the lead wire.
INSPECTION
ROTOR
1. Check the rotor coil for continuity. Make sure there is continuity between the slip rings.
If resistance is extremely low, there is a short. If there is no continuity or if there is a short circuit, replace the
rotor assembly
Resistance value : Approx. 3.1Ω
2. Check the rotor coil for a ground. Check that there is no continuity between the slip ring and the core. If there is
continuity, replace rotor assembly.
STATOR
Page 11 of 44
1. Make a continuity check on the stator coil. Check that there is continuity between the coil leads. If there is no
continuity, replace stator assembly.
2. Check the coil for grounding. Check that there is no continuity between the coil and the core. If there is
continuity, replace the stator assembly.
RECTIFIERS
Positive rectifier test
Check for continuity between the positive rectifier and stator coil lead connection terminal with an ohmmeter. The
ohmmeter should read continuity in only one direction. If there is continuity in both directions, a diode is shorted.
Replace the rectifier assembly.

Negative rectifier test
Check for continuity between the negative rectifier and the stator coil lead connection terminal. The ohmmeter
should read continuity in only one direction. If there is continuity in both directions, a diode is shorted, and the
rectifier assembly must be replaced.
Diode trio test

Page 12 of 44
Check the three diodes for continuity by connecting an ohmmeter to both ends of each diode. Each diode should
have continuity in only one direction.
If continuity is present in both directions, a diode is defective and the heatsink assembly must be replaced.
Engine Electrical System > Charging System > Battery > Description and Operation
DESCRIPTION
1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery cell
caps.
2. Water never needs to be added to the maintenance-free battery.
3. The battery is completely sealed, except for small vent holes in the cover.
Engine Electrical System > Charging System > Battery > Troubleshooting
BATTERY INSPECTION (1)
1. Checking flow
Page 13 of 44
2. Checking Sheet
Decision
Item Trouble Cause Remedy of and battery
User Manufacture
1. Visual • Battery • Dealing Replace O
Inspection terminal carelessness
damage • Bad tightening
condition between
battery cable and
terminal
Cover • Dealing Replace O
Breakage carelessness
• Electrolyte
leakage
- Cover • Dealing Replace O
breakage carelessness
- Cover • Bad cover sealing Replace O
sealing part
leakage
2. Electrolyte • Electrolyte • Cell short Replace O
height height
inspection between
cells is over
10mm
Page 14 of 44
height height
inspection between • Vaporization Replace O
cells is over caused by outer
10mm temperature
• Shortage of • Electrolyte loss Replace O

electrolyte caused by over-
charge
3. Voltage 1. Battery 1. Over charge • Replace O
inspection voltage < 2. Normal • Check the electric
13.2V system
2. 12.5V <
Battery voltage
< 12.9V
3. 12.0V < 1. Insufficient charge • Battery Load Test O
Battery voltage 2. Internal failure (Refer to Load
< 12.4V Test sheet)
(Simple
discharge)
4. 11.0 < O
Batter voltage
<12.0 (Over
discharge)
5. Battery 1. Charge condition Replace O
voltage : 11.0V failure
2. Let the battery
alone on discharge
O
conditionfor long
period
3. Internal circuit O
open
3. Load Test
1. When discharging the battery for 15 seconds at half the rated current, the battery voltage should be more than the
voltage shown in the following table.
Ambient Temperature Voltage
above 20°C 9.6V
~ 18°C 9.5V
~ 10°C 9.4V
~ 4°C 9.3V
~ -1°C 9.1V
~ -7°C 8.9V
~ 12°C 8.7V
2. When the voltage is not within specification, test 2nd load test again, and if not, do the re-charge.
Page 15 of 44
3. If the battery voltage (left alone within 2 hours after re-charging) is over 12.5V and the voltage after load test is
over the standard value, this battery can be used.
Engine Electrical System > Charging System > Battery > Repair procedures
BATTERY INSPECTION (2)
1. Make sure ignition switch is in the Off position and all accessories are Off.
2. Disconnect the battery cables (negative first).
3. Remove the battery from the vehicle.
Care should be taken because of the risk that the battery case is cracked or leaking to protect your skin
from the battery electrolyte. A suitable pair of industrial rubber gloves should be worn when removing the
battery. Do not use household cleaning gloves when handling the battery.
4. Inspect the battery carrier for damage caused by the loss of acid from the battery. If acid damage is present, it
will be necessary to clean the areawith a solution of clean warm water and baking soda. Scrub the area with a
stiff brush and wipe off with a cloth moistened with baking soda and water.
5. Clean the top of the battery with the same solution as described in Step(4).
6. Inspect the battery case, and cover, for cracks. If cracks are present, the battery must be replaced.
7. Clean the battery posts with a suitable battery post cleaner.
8. Clean the inside surface of the terminal clamps with a suitable battery terminal cleaning tool. Replace damaged or
frayed cables and broken terminal clamps.
9. Install the battery in the vehicle.

10. Connect the cable terminals to the battery post, making sure the top of the terminal are flush with the top of the
post.
11. Tighten the terminal nut securely.
Page 16 of 44
12. Coat all connections with light mineral grease after tightening.
When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not use
open flames or smoke near batteries being charged or which have recently been charged. Do not break
live circuits at the terminals of the batteries being charged. A spark will occur where the circuit is broken,
which could ignite the fumes and cause an explosion.
Engine Electrical System > Charging System > Description and Operation
GENERAL INFORMATION
The charging system includes a battery, a generator with integrated voltage regulator and a charging system indicator
light and related circuitry. Thegenerator has six built-in diodes (three positive and three negative), each rectifying AC
current to DC current. Therefore, DC current appears at generator "B" terminal.
Additionally, the generator charging voltage is regulated by the battery voltage detection system. The main
components of the generator are the rotor, stator, rectifier, capacitor brushes, bearings and V-ribbed belt pulley.
The brush holder contains a built-in electronic voltage regulator.
Engine Electrical System > Charging System > Troubleshooting

Charging warning indicator does not light Fuse blown Check fuses
with ignition switch "ON" and engine off
Light burned out Replace light
Wiring connection loose Tighten loose connections
Electronic voltage regulator faulty Replace voltage regulator
Charging warning indicator does not go out Adjust tension or replace drive
Drive belt loose or worn
with engine running (Battery requires belt
frequent recharging) Battery cables loose, corroded
Repair or replace cables
or worn
Fuse blown Check fuses
Electronic voltage regulator or Test generator
generator faulty
Wiring faulty Repair wiring
Engine hesitates/poor acceleration
Page 17 of 44
Engine hesitates/poor acceleration Adjust tension or replace drive
Drive belt loose or worn
Overcharge belt
Wiring connection loose or open Tighten loose connection or
circuit repair wiring
Poor grounding Repair
Electronic voltage regulator or Test generator
generator faulty
Worn battery Replace battery
Electronic voltage regulator faulty Replace voltage regulator
Voltage sensing wire faulty Repair wire
Engine Electrical System > Charging System > Repair procedures

INSPECTION (FOR 2.4 ENGINE)
REGULATED VOLTAGE TEST(2.4L DOHC)
This test determines if the voltage regulator is correctly controlling the generator output voltage.
Page 18 of 44
1. Be sure to check the following:
(1) A. Generator installation and wiring connections
B. Battery fully charged.
C. Generator drive belt tension.
D. Fusible link.
E. Abnormal noise from the generator while the engine is running.
2. Turn the ignition switch to the OFF position.
3. Disconnect the negative battery cable.
4. Connect a digital-type voltmeter between the generator "S" terminal and the ground.
(Connect the (+) lead of the voltmeter to the "S" terminal. Connect the (-) lead of the voltmeter to a secure
ground or to the battery (-) terminal.)
5. Disconnect the generator output wire from the generator "B" terminal.
6. Connect a DC test ammeter with a range of 0-100A in series between the "B" terminal and the disconnected
output wire. (Connect the (+) lead of the ammeter to the "B" terminal. Connect the (-) lead of the ammeter to the
disconnected output wire.)
7. Reconnect the negative battery cable.
8. Connect a tachometer or the scan tool. Check that the reading on the voltmeter is equal to the battery voltage.
If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the generator
"S" terminal and the battery (+) terminal.
9. Make sure all lights and accessories are off.

11. Increase the engine speed to approx. 2,500 r./min.
12. Read the voltmeter when the current output by the generator becomes 10 A or less.
13. If the voltage reading conforms to the value in the voltage regulation table, the voltage regulator is operating
normally. If the voltage is not within the standard value, a malfunction of the voltage regulator or of the generator
exists.
GENERATOR OUTPUT LINE VOLTAGE DROP TEST(2.4L DOHC)
Page 19 of 44
This test determines the condition of the wiring from the generator "B" terminal to the battery (+) terminal (including
the fusible link).
1. Be sure to check the following before testing:
A. Generator installation and wiring connections
B. Generator drive belt tension
C. Fusible link.
D. Abnormal noise from the generator while the engine is running.
4. Disconnect the generator output wire from the generator "B" terminal. Connect a DC test ammeter with a range
of 0-100A in series between the "B" terminal and the disconnected output wire. (Connect the (+) lead of the
ammeter to the "B" terminal. Connect the (-) lead of the ammeter to the disconnected output wire.)
An inductive-type ammeter which enables measurements to be taken without disconnecting the generator
output wire is recommended. Using this equipment will lessen the possibility of a voltage drop caused by a
loose "B" terminal connection.
5. Connect a digital-type voltmeter between the generator "B" terminal and the battery (+) terminal. (Connect the
(+) lead of the voltmeter to the "B" terminal. Connect the (-) lead of the voltmeter to the battery (+) cable.)
6. Reconnect the negative battery cable.
7. Connect a tachometer or the scan tool.
Page 20 of 44
9. With the engine running at approx. 2500 r/min, turn the headlights and other lights on and off to adjust the
generator load on the ammeter slightly above 30A. Decrease the engine speed gradually until the value displayed
on the ammeter is 30 A. Take a reading of the value displayed on the voltmeter at this time.
Limit: max. 0.3V
When the generator output is high and the value displayed on the ammeter does not decrease until 30A, set
the value to 40A. Read the value displayed on the voltmeter. In this case the limit becomes max. 0.4V.
10. If the value displayed on the voltmeter is still above the limit, a malfunction in the generator output wire may
exist. Check the wiring between the generator "B" terminal and the battery (+) terminal (including fusible link).
If a terminal is not sufficiently tight or if the harness has become discolored due to overheating, properly repair
the problem and perform the test again.
11. After the test, run the engine at idle.
12. Turn off all lights and turn the ignition switch to the OFF position.
13. Disconnect the tachometer or the scan tool.
15. Disconnect the ammeter and voltmeter.
16. Connect the generator output wire to the generator "B" terminal.
17. Connect the negative battery cable.
OUTPUT CURRENT TEST(2.4L DOCH)
This test determines if the generator output current is normal.

Page 21 of 44
1. Before testing, be sure to check the following:
A. Generator installation and wiring connections
B. Battery
The battery used should be slightly discharged. The load needed by a fully-charged battery is insufficient
for an accurate test.
A. Generator drive belt tension.

B. Fusible link.
C. Abnormal noise from the generator while the engine is running.
4. Disconnect the generator output wire from the generator "B" terminal. Connect a DC test ammeter with a range
of 0-100 A in series between the "B" terminal and the disconnected output wire. (Connect the (+) lead of the
ammeter to the "B" terminal. Connect the (-) lead of the ammeter to the disconnected output wire.)
Never use clips to connect the line. Use bolts and nuts otherwise loose connections (e.g. using clips) may
lead to a serious accident and personal injury because of the high current.
An inductive-type ammeter which enables measurements to be taken without disconnecting the generator
output wire is recommended.
5. Connect a voltmeter with a range of 0-20 V between the generator "B" terminal and the ground. (Connect the (+)
lead of the voltmeter to the "B" terminal, and then connect the (-) lead of the voltmeter to the ground.)
6. Connect the negative battery cable.
7. Connect a tachometer or the scan tool.
8. Leave the hood open.
9. Check that the reading on the voltmeter is equal to battery voltage.
If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the generator
"B" terminal and the battery (+) terminal.
10. Start the engine, and turn the headlights on.
Page 22 of 44
11. Switch the headlights to high beam, turn the heater blower switch to High, increase the engine speed to approx.
2,500 r/min, and read the maximum current output displayed on the ammeter.
Limit : 70% of nominal output current
• For the nominal current output, refer to the Generator Specifications.

• Because the current from the battery will soon drop after the engine is started, Step #10 should be
carried out as quickly as possible in order to obtain the maximum current output value.
• The current output value will depend on the electrical load and the temperature of the generator body.
• If insufficient electrical load is used while testing, the specified level of current may not be output even
though the generator is normal. In suchcase, increase the electrical load by leaving the headlights on
with the engine off to discharge the battery before testing.
• The specified level of current also may not be output if the temperature of the generator body and/or
ambient temperature is too high. In such cases, allow the generator to cool before testing.
12. The reading on the ammeter should be above the limit value. If the reading is below the limit value and the
generator output wire is normal, remove the generator from the engine and check the generator.
13. Run the engine at idle speed after the test.
15. Disconnect the tachometer or the scan tool.
Engine Electrical System > Starting System > Starter > Components and Components Location
COMPONENTS
Page 23 of 44
Engine Electrical System > Starting System > Starter > Repair procedures
REMOVAL (SNAP RING AND STOP RING)
Page 24 of 44
1. Press the stop ring to the snap ring side using a socket wrench, to the snap ring side.
2. After removing the snap ring (using snap-ring pliers), remove the stop ring and the overrunning clutch.
REPLACEMENT (BRUSHES AND SPRINGS)

1. Brushes that are worn beyond wear limit line, or oil-soaked, should be replaced.
2. When replacing field coil brushes, crush worn brush with pliers, taking care not to damage pigtail.
3. Sand pigtail end with sandpaper to ensure good soldering.

4. Insert pigtail into hole provided in new brush and solder it. Make sure that pigtail and excess solder do not come
out onto brush surface.
5. When replacing ground brush, slide the brush from brush holder by prying retaining spring back.
INSTALLATION OF THE STOP RING AND SNAP RING

Using a suitable pulling tool, pull overrunning clutch stop ring over snap ring
Page 25 of 44
CLEANING
1. Do not immerse parts in cleaning solvent. Immersing the yoke and field coil assembly and/or armature will
damage insulation. Wipe these parts with a cloth only.
2. Do not immerse drive unit in cleaning solvent. Overrunning clutch is pre-lubricated at the factory and solvent will
wash lubrication from clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
INSPECTION
CHECKING THE COMMUTATOR
1. Place the armature on a pair of V-blocks, and check the deflection by using a dial gauge.
Standard value:
Armature deflection : 0.05 mm (0.002 in.)
Limit:
Page 26 of 44
2. Check the outr diameter of the commutator.
Standard value:
Outer diameter of the commutator : 29.4 mm (1.157 in.)
Limit:
3. Check the depth of the undercut between segments.
Standard value:
Depth of the undercut between segments
: 0.5 mm (0.020 in.)
Limit:
: 0.2 mm (0.0079 in.)
BRUSH HOLDER
Check for continuity between the brush holder plate and the brush holder. The normal condition is no continuity.
OVERRUNNING CLUTCH
1. While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but should
not rotate in opposite direction. If clutch does not function properly, replace overrunning clutch assembly.
Page 27 of 44
2. Inspect pinion for wear or burrs. If pinion is worn or burred, replace overrunning clutch assembly. If pinion is
damaged, also inspect ring gear for wear or burrs.
FRONT AND REAR BRACKET BUSHING

Inspect bushing for wear or burrs. If bushing is worn or burred, replace front bracket assembly or rear bracket
assembly.
INSPECTION
CHECKING THE COMMUTATOR
1. Place the armature on a pair of V-blocks, and check the deflection by using a dial gauge.
Standard value:
Limit:
2. Check the outr diameter of the commutator.
Standard value:
Limit:
Page 28 of 44
3. Check the depth of the undercut between segments.
Standard value:
: 0.5 mm (0.020 in.)
Limit:
: 0.2 mm (0.0079 in.)
BRUSH HOLDER
Check for continuity between the brush holder plate and the brush holder. The normal condition is no continuity.
OVERRUNNING CLUTCH
1. While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but should
not rotate in opposite direction. If clutch does not function properly, replace overrunning clutch assembly.
2. Inspect pinion for wear or burrs. If pinion is worn or burred, replace overrunning clutch assembly. If pinion is
damaged, also inspect ring gear for wear or burrs.
FRONT AND REAR BRACKET BUSHING

Inspect bushing for wear or burrs. If bushing is worn or burred, replace front bracket assembly or rear bracket
assembly.
Engine Electrical System > Starting System > Ignition Lock Switch > Repair procedures
CHECK INSPECTION
Page 29 of 44
CLUTCH PEDAL
Check that pedal height, pedal freeplay and clutch pedal clevis pin play are correct. (Refer to clutch group)
STARTER RELAY
Remove the starter relay and check continuity between the terminals. If the continuity is not as specified, replace the
relay.
IGNITION LOCK SWITCH

Remove the ignition lock switch and check continuity between the terminals. If the continuity is not as specified,
replace the switch.
Engine Electrical System > Starting System > Description and Operation
Page 30 of 44
GENERAL INFORMATION
The starting system includes the battery, starter motor, solenoid switch, ignition switch, inhibitor switch (A/T only),
connection wires and the battery cables.
When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid coil. The
solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear. The contacts close
and the starter motor cranks.
In order to prevent damage caused by excessive rotation of the starter armature when the engine starts, the clutch
pinion gear overruns.
Engine Electrical System > Starting System > Troubleshooting

Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded Repair or replace cables
or worn
Transaxle range switch faulty Adjust or replace switch
(Vehicle with automatic transaxle
only)
Starter motor faulty Repair starter motor
Ignition switch faulty Replace ignition switch
Ignition lock switch faulty Replace ignition lock switch
Engine cranks slowly Battery charge low Charge or replace battery
Battery cables loose, corroded Repair or replace cables
or worn
Starter motor faulty Repair starter motor
Starter keeps running Starter motor faulty Repair starter motor
Ignition switch faulty Replace ignition switch
Starter spins but engine will not crank Short in wiring Repair wiring
Pinion gear teeth broken or Repair starter motor
starter motor faulty
Ring gear teeth broken Replace flywheel ring gear or
torque converter
Page 31 of 44
Engine Electrical System > Cruise Control System > General Information
PRE-TROUBLESHOOTING
Before commencing troubleshooting, inspect each of the following sections, and if there is an abnormality, carry out
a repair.
1. Check if the installation and connection routes of the cables and vacuum hoses of the cruise vacuum pump
assembly, actrator and pulley assembly are all normal.
2. Check if the pulley assembly and the movement of all cables are all working smoothly.
3. Check if there is no excessive play or tension in each cable.
TROUBLESHOOTING PROCEDURES
First, select the applicable malfunction symptom from the Trouble Symptom charts. Determine the condition of all
function circuits.
1. Make the following preliminary inspections.
A. Check that the installation of the actuator, accelerator cable are correct, and that the cables and links are
securely connected.
B. Check that the accelerator pedal moves smoothly.
C. Adjust the cable so there is not excessive tension or excessive play on the accelerator cable.
D. Check that the actuator & unit assembly, cruise main and control switch and the connector of each cancel
switch are connected securely.
2. Check in the sequence indicated in the Trouble Symptom chart.
3. If these checks indicate a normal condition, replace the cruise control module.
Engine Electrical System > Cruise Control System > Cruise Control Cable > Repair procedures
ADJUSTMENT
Prior to proceeding with the final cable adjustment, make sure that the lever attached to throttle valve is in the normal
idle position.
1. Assemble the cable to actuator & unit assembly.
2. Tightn nut "b" after pulled cable tightly.
3. Back nut "b" off one turn.
4. Tighten nut "a".
5. Cable should have approximately 1mm off slack with actuator & unit against stop.
Engine Electrical System > Cruise Control System > Description and Operation
COMPONENT PARTS AND FUNCTION OUTLINE
Page 32 of 44
Components part Function
Vehicle-speed sensor Converts vehicle speed to pulse.
Actuator & unit assembly. Receives signals from sensor and control switches;
CCM controls all automatic speed control functions.
And regulates the throttle valve to the set opening by
signals from the actuator unit assembly.
Control switch CRUISE main switch Switch for automatic speed control power supply.
SET switch Controls automatic speed control functions by SET
RESUME switch (COAST) and RESUME (ACCEL).
CRUISE main switch indicator Illuminates when CRUISE main switch is ON (Built into
cluster).
Cancel switch Stop lamp switch/Clutch switch Sends cancel signals to the actuator unit assembly.
(M/T)
Transaxle range switch
ELC 4-speed automatic transaxle control module Controls the overdrive ON and OFF, based on signals
from the actuator unitassembly for the CC.
*CC : Cruise Control
SYSTEM BLOCK DIAGRAM
Engine Electrical System > Cruise Control System > Components and Components Location
COMPONENTS LOCATION
Page 33 of 44
Engine Electrical System > Cruise Control System > Troubleshooting

Trouble Symptom 1
Page 34 of 44
Trouble Symptom 2
Trouble symptom Probable cause Remedy
The set vehicle speed varies greatly upward Malfunction of the vehicle speed Repair the vehicle speed sensor
or downward sensor circuit system, or replace the part
"Surging" (repeated alternating acceleration
Malfunction of the speedometer
and deceleration) occurs after setting
carble or speedometer drive gear
Cruise vacuum pump circuit poor Repair the actuator system, or
contact replace the part
Malfunction of the actuator & Replace the actuator & unit
unit
Trouble Symptom 3
Page 35 of 44
The CC system is not canceled when the Damaged or disconnected wiring Repair the harness or replace the
brake pedal is depressed of the stop lamp switch stop lamp switch
Cruise vacuum pump drive circuit Repair the harness or replace the
short-circuit vacuum pump
Malfunction of the actuator & Replace actuator & unit
unit
Trouble Symptom 4
The CC system is not canceled when the Damaged or disconncted wiring Repair the harness or repair or
shift lever is moved to the "N" position(It is of inhibitor switch input circuit replace the inhibitor switch
canceled, however, when the brake pedal is
Improper adjustment of inhibitor
depressed)
switch
unit
Trouble Symptom 5
Cannot decelerate (coast) by using the SET Temporary damaged or Repair the harness or replace the
switch disconnected wiring of SET SET switch
switch input circuit
Actuator circuit poor contact Repair the harness or replace the
actuator
Malfunction of the actuator
unit
Trouble Symptom 6
Cannot accelerate or resume speed by using Damaged or disconnected Repair the harness or replace the
the RESUME switch wiring, or short circuit, or RESUME switch
RESUME switch input circuit
Actuator circuit poor contact Repair the harness or replace the
actuator
Malfunction of the actuator
unit
Trouble Symptom 7
Page 36 of 44
CC system can be set while driving at a Malfunction of the vehicle-speed Repair the vehicle speed sensor
vehicle speed of less than 40km/h(25mph), sensor circuit system, or replace the part
or there is no automatic cancellation at that
Malfunction of the speedometer
speed cable of the speedometer drive
gear
Malfunction of the actuator &
Replace the actuator & unit
unit
Trouble Symptom 8
The cruise main switch indicator lamp does Damaged or disconnected bulb Repair the harness or replace the
not illuminate (But CC system isnormal) of cruise main switch indicator part
lamp
Harness damaged or
disconnected
Trouble Symptom 9
Malfunction of control function by ON/OFF Malfunction of circuit related to Repair the harness or replace the
switching of idle switch idle switch function part
Malfunction of the actuator &
unit
Trouble Symptom 10
Overdrive is not canceled during fixed speed Malfunction of circuit related to Repair the harness or replace the
driving overdrive cancelation, or part
No shift to overdrive during manual driving malfunction ofactuator & unit
Engine Electrical System > Cruise Control System > Repair procedures
REMOVAL
1. Remove the battery negative terminal.
2. Disconnect the accelerator cable and cruise control cable from throttle assembly by turning the throttle lever to
the full open position.
3. Disconnect the accelerator cable from accelerator pedal connection.
Page 37 of 44
4. Remove the accelerator cable mounting bolts.
5. Remove the actuator & unit assembly mounting bolt.
6. Installation is the reverse order of removal.
CRUISE CONTROL MAIL SWITCH

1. Operate the switch, and check for the continuity between the terminals.
2. If continuity is not as specified, replace the switch.
CRUISE CONTROL MAIL SWITCH

1. Operate the switch, and check for the continuity between the terminals.
2. If continuity is not as specified, replace the switch.
Engine Electrical System > Cruise Control System > Specifications

CRUISE CONTROL SYSTEM
Page 38 of 44
Speed control module
Operating voltage range DC 10 - 16V
Operating temperature -30 + 75°C (-22 + 167°F)
Voltage drop between unit and actuator 0.4V
Operating speed range Low speed limit : 40 ± 3 km/h (25 ± 2
mph)
High speed limit : 145 ± 5 km/h (90 ± 3
mph)
Actuator
Rated voltage DC 12V
Operating temperature -30 + 90°C (-22 + 194°F)
Operating consumption 3A or less (at 12V 20°C)
Insulating resistance 1MΩ or less (at 500V megger)
Cruise main switch
Operating force 0.3 - 1.0 kg
Voltage drop 0.15 V or less
Stop lamp switch
Rated load
Stop lamp 27 x 5W (lamp load)
Cruise control 0.1 - 0.5A (relay load)
Insulating resistance Min 3 MΩ (by 500V megger)
Engine Electrical System > Troubleshooting > C1103

Under and over voltage
DTC No. C1103 Voltage out of range
Probable cause
(Under and over voltage)
The voltage of the HECU power supply drops lower or • Malfunction of HECU
rises higher than specified value.
If the voltage returns to the specified value, this code is
no longer output.
• If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to
standard value, this code is no longer output.
• Before carrying out the following inspection, check the battery level, and refill it if necessary.
Page 39 of 44
Engine Electrical System > Troubleshooting > P0300

Misfire Detected (FOR 2.4 DOHC)
Random misfire detected
No. P0300
Cylinder 1 misfire detected
No. P0301
No. P0302
No. P0303
No. P0304
[Related items] • Vacuum leak in air intake system
• CKPS circuit malfunction
• Ignition circuit malfunction
• Faulty ignition coil or plug wire
• Spark plug malfunction
• Low compression due to blown head gasket, leaking valve or piston ring
• Low/high fuel pressure due to faulty pressure regulator, restricted fuel lines,
plugged fuel filter or faulty fuel pump
• Fuel injector circuit malfunction
• Faulty fuel injector
If any injectors, HO2S, ECTS, and MAFS codes are present, do all
repairs associated with those codes before proceeding this
troubleshooting guide.
Page 40 of 44
1 Connect SCAN TOOL to data link connector or OBD-II check Yes Do all repairs associated
connector. with those codes before
Turn ignition to ON and monitor DTCs. proceeding this procedure.
Are any other codes set? No Go to step 2.
2 Check for any split, disconnected or perforated vacuum hoses. Also, Yes Go to step 3.
check PCV valve for proper operation.
No Replace faulty vacuum hoses
Are vacuum hoses and PCV okay? or PCV.
3 Turn ignition to OFF and disconnect ignition coil connector. Yes Go to step 4.
Turn ignition to ON and measure voltage of ignition coil battery voltage
No Open circuit or short circuit
between ignition coil harness connector and chassis ground.
to chassis ground between
• Specification: approximately B+ ignition coil harness
Is battery voltage within specifications? connector and main relay.
4 Turn ignition to OFF and check ignition coils and plug wires for cracks Yes Go to step 5.
or carbon tracing. Check resistance of primary coils (0.7 ~ 0.86 Ω at
20°C) and secondary coils (17 ~ 23 kΩ at 20°C). No Repair or replace as
Check for resistance of plug wires (16 KΩ per 1m). necessary.
Are ignition coils and plug wires OK?
5 Disconnect CKP connector and measure resistance between CKP Yes Thoroughly check for loose,
terminal 2 and terminal 3 (800~900Ω at 20°C). bent or corroded terminals
Remove CKPS and calculate air gap between sensor and between CKPS and ECM.
flywheel/torque converter (0.3~1.7 mm [0.012~0.067 in]) {measure Measure resistance between
distance from hosing to teeth on flywheel/torque converter (measurement CKPS terminal 3 and
"A") and from mounting surface on sensor to sensor tip (measurement chassis ground(1[Ω).
"B") subtract "B" from "A" = air gap}. Repair as necessary.
Are air gap and resistance measurements within specifications?
6 Release fuel pressure and attach fuel pressure gauge to service port on Yes Go to step 7.
fuel rail.
Start an engine and warm up to operating temperature. Check for fuel
pressure at idle.
• Fuel pressure at idle: 46~49 psi (320~340kPa, No Check fuel delivery system.
3.26~3.47kg/cm2)
Is fuel pressure within specification?
7 and plug condition. Yes Go to step 9.
Are spark plugs gapped properly and in good condition?
8 (no more than 10% between highest and lowest cylinder)]. Yes Go to step 10.
Is compression OK? No Perform leak down test to
determine source of low
compression and repair as
necessary.
Page 41 of 44

Ignition failure system (FOR 2.4 DOHC)
Ignition failure system circuit malfunction
No. P0320
[Related items] • Open or short between ignition failure sensor and ECM
• Open or short between ignition failure sensor and ignition
coil
• Open between ignition failure sensor and chassis ground
• Faulty ignition failure sensor

1 Disconnect ignition failure sensor connector. Yes Go to step 2.
Measure voltage between IFS harness terminal
1 and chassis ground. No Open circuit or short circuit to chassis ground
• Specification: approximately B+ between IFS terminal 1 and ignition switch.
Is measured voltage within specification? Repair as necessary.
2 Measure voltage between IFS harness terminal Yes Go to step 3.

3 and chassis ground.
No Open circuit or short circuit to chassis ground
• Specification: approximately 5V between IFS terminal 3 and ECM.
Is measured voltage within specification? Repair as necessary.
3 Measure resistance between IFS terminal 4 and Yes Go to step 4.
chassis ground. No Open circuit between IFS terminal 4 and chassis
• Specification: approximately 1Ω ground.
Is measured resistance within specification? Repair as necessary.
4 Turn ignition switch to OFF and reconnect Yes Thoroughly check for loose, bent or corroded
ignition failure sensor. terminals at IFS.
Turn ignition switch to ON and measure voltage If OK, temporarily install a known good IFS and
between IFS terminal 2 and chassis ground check for proper operation. If problem is corrected,
• Specification: approximately B+ replace IFS.
Is measured voltage within specification? No Open circuit or short circuit to chassis ground
between IFS and ignition coil.
Repair as necessary

Ignition coil (FOR 2.4 DOHC)
Page 42 of 44
Diagnostic trouble
code Ignition coil primary/secondary circuit malfunction
No. P0350
[Related items] • Open or short between ignition coil and ECM
• Open or short between ignition coil and spark plug
• Short between ignition coil wires
• Faulty ignition coil
• Poor connection at ignition coil
• Faulty ignition system

1 Using SCAN TOOL and monitor any DTCs. Is DTC Yes Do all repairs associated with those codes
P0300, P0301, P0302, P0303, or P0304 set? before proceeding this procedure.
No Go to step 2.
2 Connect SCAN TOOL to data link connector or Yes Problem is intermittent or was repaired and
OBD-II check connector. engine control module memory was not
Start engine and monitor spark plug signal pattern. Is cleared. Check terminal connections at ECM
signal pattern normal? and ignition coils.
No Go to step 3.
3 Thoroughly check all coils and spark plug wires for Yes Repair as necessary.
loose, bent, corroded, contaminated, deteriorated or
damaged connectors. No Go to step 4.
4 Start engine. Yes Go to step 5
Using SCAN TOOL monitor spark plug signal pattern. No Verify what ignition coil is problem and go to
Are all signal patterns normal?
step 5.
5 Turn ignition to OFF and disconnect ignition coil Yes Go to step 6.
connector.
Turn ignition to ON and measure voltage between
ignition coil power circuit from ignition coil harness No Open circuit or short circuit to chassis ground
connector to ignition failure sensor connectorand chassis between ignition coil harness connector and
ground. ignition failure sensor connector.
Measure resistance of ignition coil signal circuit between
ignition coil harness connector and ECM harness
connector. No Open circuit between ignition coil harness
Measure resistance of ignition coil ground circuit connector and ECM harness connector
between ignition coil harness connector and chassis and/or chassis ground.
ground. Repair as necessary.
• Specifications: below 1Ω
Measure voltage of ignition coil signal circuit between
Page 43 of 44
Measure voltage of ignition coil signal circuit between
No Short circuit to power between ignition coil
ignition coil harness connector and chassis ground.
8 Tun ignition to OFF. Yes Temporarily install a known good ignition coil
Measures resistance between ignition coil harness and check for proper operation. If problem is
connector and chassis ground at ignition coil signal corrected, replace ignition coil.
circuit. No Short circuit to chassis ground between
• Specifications: infinite ignition coil harness connector and chassis
Does resistance indicate open circuit? ground.

Battery backup line malfunction (FOR 2.4 DOHC)
Diagnostic trouble
code Battery backup line malfunction
No. P0560
[Related items] • Open or short between ECM and battery
• ECM internal faulty

1 Turn ignition to OFF and disconnect ECM Yes Thoroughly check for poor connection, misplaced,
connector. corroded terminals at ECM connector.
Measure voltage of backup circuit between Repair as necessary.
battery and chassis ground.
No Open circuit or short circuit to chassis ground between
• Specification: approximately B+ ECM harness connector and battery.
2 • Temporarily install a known good ECM and check for proper operation. If problem is corrected replace
ECM.
• Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with
SCAN TOOL connected and monitor for pending codes.

Spark timing adjustment (FOR 2.4 DOHC)
Spark timing adjustment
No. P1330
[Related items] • Short to GND between ROM change tool (RCT) and
ECM
Page 44 of 44
1 Turn ignition to OFF and disconnect ECM Yes Problem is intermittent or was repaired and engine
connector. control module memory was not cleared. Check
Measure resistance between RCT harness connectors at ECM and RCT.
connector and chassis ground at spark timing
adjustment circuit. No Short circuit to chassis ground between RCT and
• Specifications: infinite ECM harness connector.
Page 1 of 110
OPTIMA(MS) > 2003 > G 2.4 DOHC > Engine Mechanical System
Engine Mechanical System > General Information > General Information

CHECKING COMPRESSION PRESSURE
1. Before checking compression pressure, check the engine oil level. Make sure that the starter motor and battery
are in normal operating condition.
2. Start the engine and wait until engine coolant temperature reaches 80-95°C (176-205°F ).
3. Stop the engine and disconnect the spark plug cables.
4. Remove the spark plugs.
5. Crank the engine to remove any foreign material in the cylinders.
6. Attach the compression gauge to the spark plug hole.
7. Depress the accelerator pedal to fully open the throttle.
8. Crank the engine and read the gauge.
Limit : 12.5 kg/ cm²(1.23 MPa, 178 psi) [250-400 rpm]
9. Repeat steps from 6 to 8 over all cylinders, making sure that the pressure differential for each of the cylinders is
within the specified limit.
Limit :
Max. 1.0 kg/cm² (100 kpa, 14 psi) between cylinders
10. If a cylinder's compression or pressure differential is below the specification, add a small amount of oil through
the spark plug hole and repeat steps from 6 to 9.
(1) If the addition of oil brings the compression up, it is possible that there is wear between the piston ring and
cylinder wall.
(2) If compression remains the same, valve seizure, poor valve seating or a compression leak from the cylinder
head gasket are all possible causes.
Tightening torque
Spark plug : 20-30 Nm (200-300 kg.cm, 15-21 lb.ft)
CHECKING ENGINE OIL

1. Position a vehicle on a level surface.
2. Stop the engine.
In the case of a vehicle that has been out of service for a prolonged period, run the engine for several
minutes. Stop the engine and wait 5 minutes at least, and then check the oil level.
Page 2 of 110
3. Check that the engine oil level is within the level range indicated on the oil dipstick. If the oil level is found to have
fallen to the lower limit (the "MIN" mark), refill to the "MAX" mark.
When refilling, use the same type of engine oil as the one currently being used.
4. Check that the oil is not dirty or mixed with coolant or gasoline and it has the proper viscosity.
SELECTION OF ENGINE OIL
Recommended API classification: SG OR SG/CD, SH OR SH/CD
Recommended SAE viscosity grades:
*1. Restricted by driving and climate condition.

Page 3 of 110
*2. Not recommended for sustained high speed vehicle operation.
For best performance and for maximum protection for all types of operation, select only those lubricants
• Confirm the requirements of the API classification.
• Have proper SAE grade number for expected ambient temperature range. Lubricant which do not have both a
SAE grade number and an API service classification on the container should not be used.
CHANGING ENGINE OIL
1. Run the engine until it reaches normal operating temperature.
2. Stop the engine.
3. Remove the oil filler cap (on rocker cover) and the drain plug (on the oil pan). Drain the engine oil.
4. Re-install and tighten the drain plug to the specified torque.
Tightening torque
Drain plug : 35-45 Nm (350-450 kg.cm, 25-33 lb.ft)
5. Fill the crankcase with new engine oil through the oil filler cap opening.
Capacity
Drain and refill
Without oil filter : 4.0 lit (4.23 U.S.qts., 3.51 lmp.qts.)
With oil filter : 4.3 lit (4.5 U.S.qts., 3.8 lmp.qts)
Do not overfill the crankcase. This will cause oil aeration and loss of oil pressure.
6. Install the oil filler cap.
7. Start and run the engine.
8. Stop the engine and then check the oil level. Add oil if necessary.
REPLACING THE OIL FILTER
All Kia engines are equipped with a high quality, throw-away oil filter. This filter is recommended as a replacement
filter on all vehicles. The quality of replacement filters is various considerably. High guality replacement filters should
be used to assure the most efficient service. Make sure that the rubber gasket from the old oil filter is completely
removed from the contact surface on the engine block before installing the new filter.
Page 4 of 110
REPLACING THE OIL FILTER

1. Use a filter wrench to remove the oil filter
2. Before installing the new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket.
3. Tighten the oil filter to the specified torque
Oil filter : 17-25 Nm (170-250 kg.cm, 12-28 lb.ft)
4. Start and run the engine and check for engine oil leak.
5. After stopping the engine, check the oil level and add oil as necessary.
ADJUSTING DRIVE BELTS TENSION
1. Check that the belts are not damaged and are properly fit into the pulley grooves.
• When installing the V-ribbed belt, check that the V-ribs are properly in alignment.
• If noise or slippage is detected, check the belt for wear, damage, or breakage on the pulley contact
surface, and check the pulley for scoring. Also check the degree that the belt is deflected.
Page 5 of 110
2. Apply 100 N (22 lbs.) force to the belt back midway between the pulleys as shown in the illustration, measure
the amount of deflection with a tension gauge
Standard value :
Adjustment
Items Inspection
New Used
For Deflection 7.7-12.3 6.3-7.3 8.4-10.6
generator mm (in.) (0.303-0.484) (0.248-0.287) (0.330-0.417)
Tension 300-500 550-650 350-450
N (lb) (66-110) (121-143) (77-99)
For air
conditioner
compressor Deflection 11.7-15.3 8.8-11.0 12.5-14.3
and power mm (in.) (0.46-0.6) (0.35-0.43) (0.5-0.56)
steering oil
pump
• The belt tension must be measured between the specified pulleys.

• When a new belt is installed, adjust the tension to the central value of the standard range indicated
under "New" in the above table. And then let the engine idle for 5 minutes or more, and check the
standard value indicated under "Inspection".
• When adjusting a belt which has been used or a belt newly installed after 5 minutes or more of
operation, refer to the standard value indicated under "Used" in the above table.
• Refer to the standard value indicated under "Inspection" for periodic inspections.
Type A tension gauge

Do not let the dial section of the tension gauge contact other objects during measurement.
Page 6 of 110
Type B tension gauge

1. When measuring, be sure to turn reset button in the arrow direction to set the gauge needle to the RESET
position.
2. If the tension gauge is removed from the belt, the needle will still indicate the tension. Read the tension value after
removing the gauge.
Adjusting the Generator Belt
If the belt is too loose, there will cause noise or sudden wear. If the belt is too tight, the Engine coolant pump
bearing or the generator will get damaged.
1. Loosen the generator nut "A" and the tension adjuster lock bolt "B".
2. Using the tension adjuster bolt, adjust the belt tension to the specification.
3. Tighten the adjuster lock bolt "B".
4. Tighten the generator nut "A".
Page 7 of 110
5. Check the tension or the deflection of belt, readjust if necessary.
Generator Belt Adjustment

Tightening torque
Generator nut A :
34-54 Nm (340-540 kg.cm, 25-39 lb.ft)
Adjuster lock bolt B :

20-25 Nm (200-250 kg.cm, 14-18 lb.ft)
Tension adjuster bolt :

8-12 Nm (80-120 kg.cm, 6-8 lb.ft)
Adjusting the belt of Power steering and Air conditioner

1. Loosen the tension pulley adjustment bolt A.
2. Adjust the belt deflection with adjustment bolt B.

3. Tighten the fixing bolt A.
4. Re-check the belt deflection and re-adjust, if necessary.
Before re-checking, crank the engine one or more

revolutions.
Checking Lash Adjusters Check
If an abnormal noise is heard from the lash adjusters (tappets), check as follows;
1. While installed to the cylinder head, press the part where the rocker arm contacts the lash adjuster at the very
top. If the adjuster is normal, the part pressed will feel very hard.
2. If it always moves easily downward when pressed, there is a malfunction of the lash adjuster and it should be
replaced with a new one.
3. If it feels spongy or elastic, probably oil mixed with air has entered the lash adjuster, so follow the steps below:
A. Check whether the amount of oil is too much or is not enough.
B. Check whether the reason why air is mixed with oil is a damaged oil screen or oil screen gasket. After
repairing the cause of the air leak, warm up the engine and then drive the vehicle at low speed for a while.
Stop the engine and leave it off for a few minutes; then restart the engine and drive at low speed. Repeat this
proce dure several times during the course of about one hour so as to remove the air from the oil.
CHECKING COOLANT LEAK
1. Loosen the radiator cap.
Page 8 of 110
2. Confirm that the coolant level is up to the filler neck.
3. Install a radiator cap tester in the radiator filler neck and apply 150 kPa (21 psi, 1.53 kg/cm²) pressure. Hold if
for two minutes inthat condition, while checking for leakage from the radiator, hose or connections.
• Radiator coolant may be extremely hot. Do not open the system because hot, or scalding Engine
coolant could spray out causing severe burns and blindness. Allow the vehicle to cool to ambient air
temperature before servicing this system.
• Be sure to completely clean away any moisture from the places checked.
• When the tester is removed, be careful not to spill any coolant from it.
• Be careful, when installing and removing the tester and when testing, not to deform the filler neck of the
radiator.
4. If there is leakage, repair or replace the appropriate part.

RADIATOR CAP PRESSURE TEST
1. Use an adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops moving.
Main valve opening pressure :

96.1-124.5 kPa (0.98-1.27 kg/m², 13.94-18.06 psi)
Main valve closing pressure :

83.4kPa (0.85 kg/cm², 12.1 psi)
3. Check that the pressure level is maintained at or above the limit.

4. Replace the radiator cap if the reading does not remain at or above the limit.
Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an
improper indication
SPECIFIC GRAVITY TEST
Page 9 of 110
1. Measure the specific gravity of the coolant with a hydrometer.
2. Measure the coolant temperature, and calculate the concentration from the relation between the specific gravity
and temperature, using the following table for reference.
RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY

Coolant temperature °C (°F) and Freezing Safe operating Coolant concentration
specific gravity temperature °C temperature °C (°F) (Specific volume)
(°F)
10 20 30 40 50
(50) (68) (86) (104) (122)
1.054 1.050 1.046 1.042 1.036 -16 (3.2) -11 (12.2) 30%
1.063 1.058 1.054 1.049 1.044 -20 (-4) -15 (5) 35%
1.071 1.067 1.062 1.057 1.052 -25 (-13) -20 (-4) 40%
1.079 1.074 1.069 1.064 1.058 -30 (-22) -25 (-13) 45%
1.087 1.082 1.076 1.070 1.064 -36 (-32.8) -31 (-23.8) 50%
1.095 1.090 1.084 1.077 1.070 -42 (-44) -37 (-35) 55%
1.103 1.098 1.092 1.084 1.076 -50 (-58) -45 (-49) 60%
Example
The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant temperature
of 20°C (68°F).
If the concentration of the coolant is below 30%, the anti-corrosion property will be adversely affected. In
addition, if the concentration is above 60%, both the anti-freeze and engine cooling properties will decrease,
affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the specified
range. Do not use together with another brand's product.
RECOMMENDED COOLANT
Mixture ratio of anti-freeze in
Antifreez
coolant
ETHYLENE GLYCOL 50% [Except tropical areas]
BASE FOR ALUMINUM 40% [Tropical areas]
Engine Mechanical System > General Information > Special Service Tools
Tool (Number and name) Illustration Use
Page 10 of 110
09214-32000 / 09214-M2001 Installation of the crankshaft front oil
Crankshaft front oil seal installer seal (use with 09214-32100/09214-
M2100)
09214-32100 / 09214-M2100 Installation of the crankshaft front oil

Crankshaft front oil seal guide seal (use with 09214-32000/09214-
M001)
09221-21000 / 09221-M2000 Installation of the camshaft oil seal

Camshaft oil seal installer (use with 09221-21100/09211-
M2100)
09221-21100 / 09221-M2100 Used as a guide when pressing in the

Camshaft oil seal guide camshaft oil seal
09222-28000 / 0K993 120 001 Removal and installation of the inlet

Valve spring compressor or exhaust (use with 09222-
28100/0K993 120 004)
09222-21100 Installation of the valve stem oil seal

Valve stem oil seal installer
09222-21200 A/B / 09222-M2200 Removal and installation of the valve

A/B guide
Valve guide installer
09231-38000 Fixing the camshaft when replacing

Camshaft locking tool the timing belt
09231-21000 / 09231-M2000
Crankshaft rear oil seal installer
Page 11 of 110
09231-21000 / 09231-M2000 1. Installation of the engine rear oil
Crankshaft rear oil seal installer seal
2. Installation of the crankshaft rear
oil seal
09260-32000 Removal and installation of oil

Oil pressure switch wrench pressure switch
09221-32001 / 09221-M2001 Removal and installation of the

Cylinder head bolt wrench cylinder head bolt
09212-32000 / 09212-M2000 Removal of front bearing of counter

Counter balance shaft bearing puller balance shaft
09212-32100 / 09212-M2100 Removal of rear bearing of counter

Counter balance shaft bearing puller balance shaft (use with 09212-
32300)
09212-32200 Installation of counter balance shaft

Counter balance shaft bearing bearing front and rear (use with
installer 09212-32300)
09212-32300 Removal and installation of counter

Guide plate balance shaft rear bearing (use with
09212-32100 / 09212-M2100,
09212-32200)
09213-33000 Removal and installation of front

Plug cap wrench case cap plug
Page 12 of 110
Engine Mechanical System > General Information > Troubleshooting
TROUBLESHOOTING
Low compression Blown cylinder head gasket Replace gasket
Worn or damaged piston rings Replace rings
Worn piston or cylinder Repair or replace piston and/or
cylinder block
Worn or damaged valve seat Repair or replace valve and/or
seat ring
Oil pressure drop Low engine oil level Check engine oil level
Faulty oil pressure switch Replace
Clogged oil filter Replace
Worn oil pump gears or cover Replace
Thin or diluted engine oil Change and find out cause
Oil relief valve stuck (open) Repair
Excessive bearing clearance Replace
High oil pressure Oil relief valve stuck (closed) Repair
Excessive engine rolling and Loose engine roll stopper (front, rear) Re-tighten
vibration
Loose transaxle mount bracket Re-tighten
Loose engine mount bracket Re-tighten
Loose center member Re-tighten
Broken transaxle mount insulator Replace
Broken engine mount insulator Replace
Broken engine roll stopper insulator Replace
Noisy valves Thin or diluted engine oil (low oil pressure) Change
Worn or damaged valve stem or valve guide Replace
Connecting rod and/main Insufficient oil supply Check engine oil level
bearing noise Thin or diluted engine oil Change and find out cause
Excessive bearing clearance Replace
Timing belt noise Incorrect belt tension (Auto tensioner) Adjust belt tension or Replace
auto tensioner.
Low coolant level Leakage of coolant
Damaged radiator core joint Replace
Corroded or cracked hoses (Radiator hose, Replace
heater hose, etc)
Faulty radiator cap valve or setting of spring Replace
Faulty thermostat Replace
Page 13 of 110
Faulty Engine coolant pump Replace
Clogged radiator Foreign material in coolant Replace
Abnormally high coolant Faulty thermostat Replace
temperature
Faulty radiator cap Replace
Restriction of flow in cooling system Replace
Loose or missing drive belt Adjust or replace
Faulty Engine coolant pump Replace
Faulty temperature gauge or wiring Repair or replace
Faulty electric fan Repair or replace
Faulty thermo-sensor on radiator Replace
Insufficient coolant Refill coolant
Abnormally low coolant Faulty thermostat Replace
temperature
Faulty temperature gauge or wiring Repair or replace
Leakage from oil cooling Loose hose and pipe connection Retighten
system Blocked or collapsed hose and pipe Replace
Inoperative electrical cooling Damaged Replace or repair
fan
Exhaust gas leakage Loose connections Retighten
Broken pipe or muffler Repair or replace
Abnormal noise Detached baffle plate in muffler Replace
Broken rubber hanger Replace
Pipe or muffler contacting vehicle body Correct
Broken pipe or muffler Repair or replace
Engine Mechanical System > General Information > Specifications

SPECIFICATIONS
Description Specification Limit
General
Type In-line, Double Overhead
Camshaft
Number of cylinders 4
Bore 86.5 mm (3.41 in.)
Stroke 100 mm (3.94 in.)
Total displacement 2351 cc (143.5 cu. in.)
Compression ratio 10
Firing order 1-3-4-2
Page 14 of 110
Idle R.P.M 800 ±100 rpm
Ignition timing at idling speed BTDC 5°±2°
Valve timing
valve timing
Intake valve Opens (BTDC) 12°
Closes (ABDC) 56°
Exhaust valve Opens (BBDC) 54°
Closes (ATDC) 14°
Cylinder head
Flatness of gasket surface Max. 0.03 mm (0.0012 in.) 0.2 mm (0.008 in.)
Flatness of manifold mounting surface 0.15 mm (0.0059 in.) 0.3 mm (0.012 in.)
Dimensions for reworking oversize valve seat hole
Intake 0.3 mm (0.012 in.) O.S. 35.300-35.325 mm
(1.3898-1.3907 in.)
0.6 mm (0.024 in.) O.S 35.600-35.625 mm
(1.4016-1.4026 in.)
Exhaust 0.3 mm (0.012 in.) O.S. 33.300-33.325 mm
(1.3110-1.3120 in.)
0.6 mm (0.024 in.) O.S 33.600-33.625 mm
(1.3228-1.3238 in.)
Dimensions for reworking oversize valve seat hole (both intake and exhaust)
0.05 mm (0.002 in.) O.S. 12.050-12.068 mm
(0.4744-0.4751 in.)
0.25 mm (0.010 in.) O.S. 12.250-12.268 mm
(0.4823-0.4830 in.)
0.50 mm (0.020 in.) O.S. 12.500-12.518 mm
(0.4921-0.4928 in.)
Camshaft
Cam height Intake 35.493 mm (1.3974 in.) 34.993 mm (1.3777 in.)
Exhaust 35.317 mm (1.3904 in.) 34.817 mm (1.3707 in.)
Journal O.D. 26 mm (1.02 in.)
Bearing oil clearance 0.040-0.076 mm (0.0020-
0.0029 in.)
End play 0.1-0.2 mm (0.004-0.008
in.)
Valve
Valve length Intake 109.5 mm (4.311 in.)
Exhaust 109.7 mm (4.319 in.)
Stem O.D. Intake 6.565-6.580 mm (0.2585-
Page 15 of 110
0.2591 in.)
Exhaust 6.530-6.550 mm (0.2571-
0.2579 in.)
Face angle 45-45.5°
Thickness of valve head Intake 1.0 mm (0.040 in.) 0.7 mm (0.028 in.)
(margin)
Exhaust 1.5 mm (0.059 in.) 1.0 mm (0.040 in.)
Valve stem to valve guide Intake 0.020-0.047 mm (0.0008- 0.10 mm (0.0040 in.)
clearance 0.0019 in.)
Exhaust 0.050-0.085 mm (0.0020- 0.15 mm (0.0059 in.)
0.0033 in.)
Valve guide
Length Intake 45.5 mm (1.791 in.)
Exhaust 50.5 mm (1.988 in.)
Service size 0.05, 0.25, 0.50 mm
(0.002, 0.010, 0.020 in.)
oversize
Valve seat
Width of seat contact 0.9-1.3 mm (0.035-0.051
in.)
Seat angle 44-44.5
Service size 0.3 mm (0.012 in.), 0.6
mm (0.024 in.) oversize
Valve spring
Free length 45.82 mm (1.804 in.) 44.82 mm (1.765 in.)
Load 248 N (55 lb) at installed
height
Out of squareness Less than 1.5° 4°
Cylinder block
Cylinder bore 86.5-86.53 mm (3.4055-
3.4067 in.)
Out-of-roundness and taper of Less than 0.01 mm
cylinder bore (0.0004 in.)
Flatness of gasket surface Less than 0.05 mm 0.1 mm (0.0040 in.)
(0.0020 in.)
Piston
O.D. 84.97-85.00 mm (3.3453-
3.3465 in.)
Piston-to-cylinder clearance 0.02-0.04 mm (0.0008-
0.0012 in.)
Ring groove width No. 1 1.21-1.23 mm (0.0476-
Page 16 of 110
0.0484 in.)
No. 2 1.51-1.53 mm (0.0595-
0.0602 in.)
Oil 2.81-2.83 mm (0.1106-
0.1114 in.)
Piston ring
Side clearance No. 1 0.03-0.07 mm (0.0012- 0.1 mm (0.004 in.)
0.0028 in.)
No. 2 0.02-0.06 mm (0.0008- 0.1 mm (0.004 in.)
0.0024 in.)
End gap No. 1 0.25-0.35 mm (0.0098- 0.8 mm (0.031 in.)
0.0138 in.)
No. 2 0.40-0.55 mm (0.0157- 0.8 mm (0.031 in.)
0.0216 in.)
Oil ring side rail 0.10-0.40 mm (0.0039- 1.0 mm (0.040 in.)
0.0157 in.)
Connecting rod
Bend 0.05 mm (0.0020 in.) or
less per 100 mm (3.937
in.)
Twist 0.1 mm (0.004 in.) or less
per 100 mm (3.937 in.)
Connecting rod big end to crankshaft 0.10-0.25 mm (0.0040- 0.4 mm (0.0157 in.)
side clearance 0.0098 in.)
Piston pin press-in load 7,500-17,500 N (1,653-
3,858 lb)
Connecting rod bearing
Oil clearance 0.015-0.048 mm (0.0008- 0.1 mm (0.004 in.)
0.0020 in.)
Crankshaft main bearing
Oil clearance No. 1, 2, 4, 5:0.018- 0.1 mm (0.004 in.)
0.036mm (0.0007-0.0014
in.)
No. 3 :0.024-0.042mm
(0.0009-0.0016 in.)
Crankshaft
Pin O.D. 44.980-45.000 mm
(1.7709-1.7717 in.)
Journal O.D. 56.982-57.000 mm
(2.2434-2.2442 in.)
Out-of-roundness of journal and pin Less than 0.015 mm
(0.0006 in.)
Page 17 of 110
Taper of journal and pin Less than 0.005mm
(0.0002 in.)
End play 0.05-0.25 mm (0.0020- 0.25 mm (0.0098 in.)
0.0098 in.)
Flywheel
Runout 0.13 mm (0.0051 in.)
Oil pressure at curb idle speed 80 kPa (11.4 psi) or more
[Oil tempreature is 75 to 90°C167 to 194°F)]
Oil pump
Tip clearance Drive gear 0.160-0.205 mm (0.0063- 0.25 mm (0.0098 in.)
0.0081 in.)
Driven gear 0.180-0.205 mm (0.0071- 0.25 mm (0.0098 in.)
0.0081 in.)
Side clearance Drive gear 0.08-0.14 mm (0.0031- 0.25 mm (0.0098 in.)
0.0055 in.)
Driven gear 0.06-0.12 mm (0.0024- 0.25 mm (0.0098 in.)
0.0047 in.)
Relief spring
Free length 46.6 mm (1.835 in.)
Load [61 N (13.5 lb)] 40.1 mm (1.579 in.)
Right silent shaft
Front journal diameter 41.959-41.975 mm
(1.6519-1.6526 in.)
Rear journal diameter 40.951-40.967 mm
(1.6122-1.6129 in.)
Oil clearance Front 0.020-0.0061 mm
(0.0008-0.0024 in.)
Rear 0.050-0.091 mm (0.0020-
0.0036 in.)
Left silent shaft
Front journal diameter 18.467-18.480 mm
(0.7270-0.7276 in.)
Rear journal diameter 40.959-40.975 mm
(1.6126-1.6132 in.)
Oil clearance Front 0.020-0.054 mm (0.0008-
0.0021 in.)
Rear 0.042-0.083 mm (0.0017-
0.0033 in.)
Cooling method Engine coolant cooling, forced circulation with water
pump (Driven belt)
Page 18 of 110
Cooling system Quantity 7.3 lit (7.7 U.S.qts., 6.4
lmp.qts.) [For DOHC]]
Thermostat Type Wax pellet type with jiggle
valve
Normal opening 82°C (179.6°F)
temperature
Opening temperature range 80.5°C-83.5°C (176.9 -
182.3°F)
Wide open temperature 95°C (203°F)
Radiator cap Main valve opening 86.1-124.5 kPa (0.98-
pressure 1.27 kg/cm², 13.94-18.06
psi)
Main valve closing pressure 83.4 kPa (0.85 kg/cm²,
12.1 psi)
Vacuum valve opening -6.86 kPa (-0.07 kg/cm² -
pressure 1.00 psi)
Air cleaner
Type Dry type
Unwoven cloth type
Exhaust pipe
Muffler Expansion resonance type
Suspension system Rubber hangers
SERVICE STANDARD
Standard value
Coolant concentration
Tropical 40%
area
Other 50%
area
LUBRICANT
Engine coolant Ethylene glycol base for
aluminum radiator
SELANT
Engine coolant temperature sender Three bond No.2310 or
equivalent
Engine coolant temperature sensor LOCTITE 962T or equivalent
Page 19 of 110
O.D. = Outer Diameter

I.D. = Inner Diameter
O.S. = Oversize Diameter
U.S. = Undersize Diameter
TIGHTENING TORQUE
Nm kg·cm lb·ft
Engine mounting insulator bolt [12x15 mm (0.4724x0.5906
90-110 900-1100 65-80
in.)]
Engine mounting bracket nuts 60-80 600-800 43-58
Engine mounting bracket bolts[12x60 mm (0.4724x2.3622
60-80 600-800 43-58
in.)]
Front roll stopper bracket to sub frame bolts 60-80 600-800 43-58
Front roll stopper insulator bolt and nut
50-65 500-650 36-47
[10x85 mm(0.3937x3.3465 in.)]
Front roll stopper bracket to transaxle bolts 60-80 600-800 43-58
Rear roll stopper bracket to sub frame bolts 50-65 500-600 36-47
Rear roll stopper bracket to transaxle bolts 60-80 600-800 43-58
Transaxle mounting sub bracket nut 60-80 600-800 43-58
Transaxle mounting insulator bolt.[12x15 mm (0.4724x0.5906
90-110 900-1100 65-80
in.)]
Air conditioner compressor to bracket 23-27 230-270 17-20
Power steering oil pump to bracket 35-45 350-450 25-33
Front exhaust pipe to exhaust manifold 30-40 300-400 22-29
Rocker cover bolt 8-10 80-100 6-7
Center cover bolt 4-5 40-50 3-3.6
Camshaft sprocket bolt 80-100 800-1000 58-72
Camshaft bearing cap bolt 19-21 190-210 14-15
Crankshaft position sensor 10-13 100-130 7-9
Cam position sensing cylinder bolt 15-22 150-220 11-16
Throttle body stay 15-22 150-220 11-16
Air cleaner body installation bolt 8-10 80-100 6-7
Crankshaft sprocket bolt 110-130 1100-1300 80-94
Crankshaft pulley to crankshaft sprocket 20-30 200-300 14-22
Cylinder head bolt (Cold engine)
Page 20 of 110
With changing parts. 64+Releas all 640+Releas all 48+Releas all
bolt bolt bolt
+20+90°+90° +200+90°+90° +14+90°+90°
Without changing parts 20+90°+90° 200+90°+90° 14+90°+90°
Intake manifold stay 18-25 180-250 13-18
Tension pulley bracket bolt 23-27 230-270 17-20
Auto tensioner bolt 20-27 200-270 14-20
Tensioner pulley bolt 43-55 430-550 31-40
Idle pulley bolt 45-55 450-550 33-40
Front exhaust pipe clamp bolt 20-30 200-300 14-22
Oil pan 10-12 100-120 7-9
Oil pan drain plug 35-45 350-450 25-33
Oil screen 15-22 150-220 11-16
Oil pump sprocket nut 50-60 500-600 36-43
Oil pressure switch 8-12 80-120 5.8-8.7
Oil filter bracket bolt 20-27 200-270 14-20
Oil pump cover bolt 15-18 150-180 11-13
Oil seal case bolt 10-12 100-120 7-9
Plug cap 20-27 200-270 14-20
Oil pump case bolt (M 8) 20-27 200-270 14-20
Driven gear bolt 34-40 340-400 25-29
Engine coolant pump pulley bolt 8-10 80-100 6-7
Timing belt upper cover 8-10 80-100 6-7
Timing belt lower cover 8-10 80-100 6-7
Relief plug 40-50 400-500 29-36
Flywheel 130-140 1300-1400 94-101
Drive plate 130-140 1300-1400 94-101
Timing belt rear right cover 10-12 100-120 7-9
Timing belt rear left cover (lower) bolt also securing left engine
30-42 300-420 22-30
support bracket
Timing belt rear left cover (upper) 10-12 100-120 7-9
18- 180-220 + 13-
Connecting rod cap bolt
22+(90°~94°) (90°~94°) 16+(90°~94°)
Crankshaft bearing cap bolt 25+(90°~94°) 250+(90°~94°) 18+(90°~94°)
Engine hanger
M8 25-30 250-300 8-22
M10 35-55 350-550 25-40
Page 21 of 110
Generator support bolt 20-25 200-250 14-18
Generator brace bolt
(4T) 12-15 120-150 9-11
(5T) 20-27 200-270 14-20
Engine coolant pump to cylinder block bolt
Head mark "7" bolt 15-22 150-220 11-15
Engine coolant temperature gauge unit 10-12 100-120 7-9
Engine coolant temperature sensor 20-40 200-400 14-29
Engine coolant outlet fitting attaching bolt 10-15 100-150 7-11
Air cleaner mounting bolts 8-10 80-100 6-7
Resonator mounting bolt 8-10 80-100 6-7
Resonator mounting nut 4-6 40-60 35-47 lb.in
Delivery pipe bolt to engine 10-13 100-130 7-9
Accelerator cable bolts to intake manifold 4-6 40-60 35-47 lb.in
Throttle body to intake manifold 15-22 150-220 11-16
Intake manifold stay bolts 18-22 180-250 13-18
Intake manifold mounting bolt (M8) 15-20 150-200 11-14
Intake manifold mounting bolt (M10) 18-25 180-250 13-18
Intake manifold mounting nut 30-42 300-420 22-30
Tension rod bracket bolt to tension rod 35-55 350-550 25-40
Ignition coil bolts 8-12 80-120 6-9
Power transistor bolts 10-12 100-120 7-9
EGR valve bolts 17-26 170-260 12-19
EGR temperature sensor (California) 10-12 100-120 7-9
Front exhaust pipe nuts to exhaust manifold 30-40 300-400 22-29
Front exhaust pipe bolt to engine 20-30 200-300 14-22
Center exhaust pipe nuts to catalytic converter 30-40 300-400 22-29
Center exhaust pipe bolts to main muffler 30-40 300-400 22-29
Center exhaust pipe bolt to bracket 10-15 100-150 7-11
Hanger bolt to body
M8: 25-30 250-300 18-22
M10: 35-55 350-550 25-40
Hanger bolt to main muffler 10-15 100-150 7-11
Exhaust manifold nuts to engine nut (M8) 25-30 250-300 18-22
Exhaust manifold nuts to engine nut (M10) 35-55 350-550 25-40
Oxygen sensor 40-50 400-500 29-36
Page 22 of 110
Heat protector bolt to exhaust manifold 12-15 120-150 9-11
Engine Mechanical System > Timing System > Timing Belt > Components and Components Location
COMPONENTS
Page 23 of 110
Engine Mechanical System > Timing System > Timing Belt > Repair procedures
REMOVAL
1. Remove the crankshaft pulley, engine coolant pump pulley and drive belt.
2. Remove the timing belt cover.
3. Turn the crankshaft clockwise and align the timing marks so as to bring the No. 1 cylinder to compression top-
dead-center position. At this time the timing marks of the camshaft sprocket and the timing marks of the rocker
cover should coincide, and the dowel pin of the camshaft sprocket should be at the upper side. Remove the auto
tensioner.
Rotate the crankshaft clockwise.
4. Remove the timing belt.
If the timing belt is reused, make an arrow mark indicating the turning direction (or the front of the engine)
to make sure that the belt is reinstalled in the same direction as before.
Page 24 of 110
5. Remove the camshaft sprockets.
Be careful not to damage the cylinder head with the

wrench.
6. When the oil pump sprocket nut is removed, first remove the plug at left side of the cylinder block and insert a
screwdriver to check the left counter balance shaft in position. Screwdriver used for this purpose should have a
shaft 8 mm (0.3 in.) in diameter which can be inserted more than 60 mm (2.36 in.)
7. Remove the oil pump sprocket retaining nut and remove the oil pump sprocket.
8. Loosen the right counter balance shaft sprocket mounting bolt until it can be loosened by hand.
9. Next, remove tensioner "B" and remove timing belt "B".
After timing belt "B" has been removed, do not attempt to loosen bolt while holding sprocket with pliers,
etc.
10. Remove the crankshaft sprocket "B" from crankshaft.
INSTALLATION
Page 25 of 110
1. Install crankshaft sprocket "B" into crankshaft.
Pay special attention to the direction of the flange. If it is installed in the wrong direction, a broken belt
could result.
2. Lightly apply engine oil to the outer surface of spacer, and then install the spacer to the right counter balance
shaft. Be sure to install in the direction as shown in illustration.
3. Install the counter balance shaft sprocket onto the right counter balance shaft, and then tighten flange bolt by
finger tight.
4. Align the timing mark on each sprocket with the corresponding timing mark on the front case.
5. When the timing belt "B" is installed, make certain that tension side has no slack. Install tensioner "B" with center
of pulley located on the left side of mounting bolt.
Page 26 of 110
6. Lift tensioner "B" to tighten the timing belt "B" so that its tension side will be pulled tight. In this condition, tighten a
bolt to secure tensioner "B". When a bolt is tightened, be careful to prevent from turning together. If the shaft is
turned together, the belt will be overtightened.
7. Check to ensure that timing marks are in alignment.

8. Check to ensure that when the center of span on the tension side is depressed with index finger in direction of
arrow, deflection of belt is within specification.
Belt deflection : 5-7 mm (0.2-0.3 in.)
9. Install sensing blade and crankshaft sprocket onto crankshaft. Be sure to install in the direction as shown in
illustration.
Pay attention to direction of flange. If it is installed in wrong direction, a broken belt could result.
10. Install the special washer and sprocket bolt to crankshaft, and then tighten the sprocket bolt.
Tightening torque
Crankshaft sprocket bolt :
110-130 Nm (1100-1300 kg.cm, 80-94 lb.ft)
Page 27 of 110
11. Insert a screwdriver through the plug hole in left side of cylinder block to keep shaft in position.
12. Install the oil pump sprocket, and tighten the nut to the specified torque.
13. Install the camshaft sprocket and tighten the bolt to the specified torque.
Tightening torque
Camshaft sprocket bolt :
80-100 Nm (800-1000 kg.cm, 56-72 lb.ft)
Page 28 of 110
14. Install the auto tensioner.
Leave the set pin installed in the auto tensioner
Tightening torque
Auto tensioner bolt :
19.6-26.5 Nm (2.0-2.7 kg.cm, 145-19.5 lb.ft)
If the auto tensioner rod is in its fully extended position, reset it as follows.
• Clamp it in the vise with soft jaws in a level position. Apply a plain washer if there is a plug at the
bottom of the auto tensioner.
• Push in the rod slowly with the vise until the set hole A in the rod is aligned with the set hole B in the
cylinder.
• Insert a wire to the set hole A and B.
15. Install the tensioner pulley onto the tensioner arm.
Leave the wire installed in the auto tensioner.

Page 29 of 110
16. Align the timing marks of the camshaft sprocket to the timing marks of the rocker cover. The dowel pin of the
camshaft sprocket should be at the upper side.
• The identification mark is on the camshaft sprocket.

• Before installing timing belt, if the timing marks of cam shaft sprocket and rocker cover are not
concide, do not rotate the cam shaft sprocket more than 2 teeth of sprocket in any direction.
• Rotating sprocket more than 2 teeth makes valve and piston be touched each other.
• In case of rotating the cam shaft sprocket in avoidably more than 2 teeth, rotate the cam shaft
sprocket after rotating crank shaft sprocket counter clockwise on basis of timing mark.
17. Align the timing marks of each sprocket and install the timing belt in this order. Crankshaft sprocket-Oil pump
sprocket-Idler pulley-Exhaust camshaft sprocket-Intake camshaft sprocket-Tensioner pulley.
- In this step, No.1 is in TDC (Compression stroke).

- When the timing mark of oil pump sprocket is aligned, fist remove the plug at left side of the cylinder
block and insert a screwdriver to check the left counter balance shaft in position. Screwdriver used for
this purpose should have a shaft 8mm (0.3in)in diameter which can be inserted more than 60mm
(2.36in).
- Install the plug at left side of the cylinder block after check timing.
Page 30 of 110
18. Remove a wire from the auto tensioner.

Rotate the crankshaft two complete turns clockwise and leave it as is for about 5 minutes. Then, measure the
auto tensioner protrusion "A" (distance between the tensioner arm and auto tensioner body) to ensure that it is
up to specification. If the protrusion exceeds specification, repeat step 14-18

Page 31 of 110
19. Install the timing belt lower cover and the timing belt upper cover.
INSPECTION
Sprockets, Tensioner Pulley, and Idler Pulley
1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks,
or damage. Replace as necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth pulley rotation and check for play or noise.
Replace as necessary.
3. Replace if there is grease leak.

Auto Tensioner
1. Check the auto tensioner for leak and replace as necessary.
2. Check the rod end for wear or damage and replace as necessary.
Page 32 of 110
3. Measure the rod protrusion. If it is out of specification, replace the auto tensioner.
Standard value : 14.5mm (0.57 in.)
4. Using a vise soft jaws push the auto tensioner rod. If the rod can be easily retracted, replace the auto tensioner.
You should feel a great deal of resistance when pushing the rod in.
Clamp the auto tensioner in the vise so that it can be level. Use soft jaws in the vise to avoid damaging the
auto tensioner.
Timing Belt
1. Check the belt for oil or dust deposits. Replace if necessary. Small deposits should be wiped away with a dry
cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the belt in detail. If the following flaws are evident,
replace the belt with a new one.
Description Flaw conditions
Hardened back surface rubber Back surface glossy. Non-elastic and so hard that when a
finger nail is forced into it, no mark is produced.
Page 33 of 110
Cracked back surface rubber
Cracked or separating canvas
Badly worn teeth (initial stage) Canvas on load side tooth flank worn (Fluffy canvas fibers,
rubber gone and color changed to white, and unclear
canvas texture)
Badly worn teeth (last stage) Canvas on load side tooth flank worn down and rubber
exposed (tooth width reduced)
Cracked tooth bottom
Missing tooth
Side of belt badly worn

Page 34 of 110
Normal belt should have precisely cut sides as if

produced by a sharp knife.
Side of belt cracked
Engine Mechanical System > Cylinder Head Assembly > Camshaft > Components and Components
Location
COMPONENTS
Page 35 of 110
Engine Mechanical System > Cylinder Head Assembly > Camshaft > Repair procedures
REMOVAL
1. Disconnect the negative terminal from battery.
2. Drain the engine coolant.
3. Remove the breather hose between the air cleaner and the rocker cover.
4. Remove the air cleaner.
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5. Remove the timing belt cover.
6. Remove the rocker cover, crank angle sensor.
7. Loosen the camshaft, sprocket bolts and remove the camshaft sprockets.
8. Loosen the bearing cap bolts and remove the bearing caps, camshafts, rocker arms, lash adjusters.
INSTALLATION
1. Install the camshafts on the cylinder head.
• Apply engine oil to journals and cams of the cam shafts.

• The intake camshaft has a slit on its rear end for driving the crankshaft position
sensor.
2. Install the bearing caps. Check the markings on the caps for intake/exhaust identification symbol.
R : Intake camshaft
L : Exhaust camshaft
3. Check that the camshaft can be easily turned by hand. After checking, remove the bearing caps and the
camshafts, and then install the rocker arms.
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4. Make sure that the dowel pins on the camshaft sprocket end are located on the top.
5. Tighten the bearing caps to the specified torque in two or three steps as shown.
Tighten the rocker arms uniformly.
Tightening torque
Rocker arm bolts :
19-21 Nm (190-210 kg.cm, 14-15 lb.ft)
6. Using special tools, Camshaft Oil Seal Installer and guide (09221-21000, 09221-21100), press fit the camshaft
oil seal. Be sure to apply engine oil to the external surface of the oil seal. Insert the oil seal along the camshaft
front end and install by driving the installer with a hammer until the oil seal is fully seated.
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7. Install the camshaft sprockets to the specified torque.
Tightening torque
Camshaft sprocket bolts :
80-100 Nm (800-1000 kg.cm, 58-72 lb.ft)
8. Install the rocker cover. Apply sealant as shown.
Tightening torque
Rocker cover bolts : 8-10 Nm (80-100 kg.cm, 6-7 lb.ft)
Center cover bolts : 4-5 Nm (40-50 kg.cm, 3-3.6 lb.ft)
Sealant
A Portion : Threebond No. 1212D or equivalent
B Portion : Threebond No. 1212D or equivalent

Page 39 of 110
Bolt length x Diameter
Center cover bolt : 16 mm x 6 mm
Rocker cover bolt : special bolt
9. Install the spark plugs, ignition coil, connect the connector and then install the center cover.
10. Locate the dowel pin on the sprocket side of the exhaust cam shaft.
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11. Align the notch of the camshaft sensor to the hole in camshaft (intake manifold side) and tighten the bolts.
The camshaft position sensor can be installed even when the punch mark is positioned opposite the notch;
however, the position results in incorrect fuel injection and ignition timings.
12. Install the camshaft position sensor on the cylinder head.
INSPECTION
Rocker Arms
1. Check rotation of the roller. If it does not rotate smoothly or if looseness is evident, replace it.
2. Check the roller and replace if there are any dent, damage or signs of bearing seizure.
3. Check the valve contact surface for possible damage or seizure and replace as necessary.
Camshafts
1. Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is damaged or worn excessively, replace the camshaft.
Cam height [Standard] [Limit]
Intake 35.493 mm (1.3974 in.) 34.993 mm (1.3777 in.)
Exhaust 35.317 mm (1.3904 in.)) 34.817 mm (1.3707 in.)
Engine Mechanical System > Cylinder Head Assembly > Cylinder Head > Components and
Components Location
COMPONENTS
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Engine Mechanical System > Cylinder Head Assembly > Cylinder Head > Repair procedures
Disassembly
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1. Remove the cylinder head bolts as shown in the illustration.
INSPECTION
1. Check the cylinder head for cracks damage and coolant leakage. If cracked, replace the cylinder head.
2. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed
air to them to make certain that the passages are not clogged.
3. Check the cylinder head gasket surface for flatness by using a straight edge in the direction of A, B, ... as shown.
If flatness exceeds service limit in any direction, either replace the cylinder head, or lightly machine the cylinder
head gasket surface.
Flatness of cylinder head gasket surface

[Standard dimension] : Less than 0.05 mm (0.002 in.)
[Limit] : 0.2 mm (0.008 in.)
Reassembly
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1. Install the cylinder head bolts as shown in the illustration.
Check and measure the length of bolt. Maximum length : 99.4 ± 0.35 mm (3.9
in.)
2. Tighten the bolts according to the following procedure.

Step Operation Remarks
1 Tighten to 20Nm (200kg·cm, Carry out as shown in the illustration
14lb·ft)
2 Tighten 90° of a turn As shown in the illustration. Mark
the head of the cylinder head bolt
and cylinder head by paint.
3 Fully loosen Carry out as the reverse order of
the illustration.
4 Tighten to 20Nm (200kg·cm, Carry out as shown in the illustration
14lb·ft)
5 Tighten 90° of a turn As shown in the illustration. Mark
the head of the cylinder head bolt
6 Tighten 90° of a turn As shown in the illustration. Check
that the painted mark of the head
bolt is lined up with that of the
cylinder head.
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Step Operation Remarks

1 Tighten to 2Nm (20kg·m,0.14lb·ft) Carry out as shown in the illustration
Tighten 90° of a turn As shown in the illustration. Mark
2 the head of the cylinder head bolt
Tighten 90° of a turn As shown in the illustration. Check
that the painted mark of the head
3
bolt is lined up with that of the
cylinder head.
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Engine Mechanical System > Cylinder Head Assembly > Valve > Repair procedures
Disassembly
1. Using 12 mm socket, remove the retainer lock. Next remove the spring retainer, valve spring, spring seat and
valve.
Keep these parts so that they can be reinstalled in their orignal positions.
2. Remove the valve stem seals with pliers, and discard.
Do not reuse the valve stem seals.
INSPECTION
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1. Using a wire brush, clean the valve thoroughly.
2. Check each valve for wear, damage and distortion of head and stem at B. Repair or correct if necessary. If stem
end A is pitted or worn, resurface as necessary. This correction must be limited to a minimum. Also resurface the
valve face. Replace the valve if the margin has decreased to less than the service limit.
Margin
[Standard dimension]
Intake : 1.0 mm (0.040 in.)
Exhaust : 1.5 mm (0.059 in.)
[Limit]
Intake : 0.7 mm (0.028 in.)
Exhaust : 1.0 mm (0.040 in.)
Valve Springs
1. Check free length and tension of the valve spring. If they exceed the service limit, replace the spring.
2. Using a square, test the squareness of each spring. If the spring is excessively out of square, replace it.
Valve spring
[Standard Value]
Free height : 45.82 mm (1.804 in.)
Load : 248 N (55 lb)at installed height
Out of square : 1.5°or less
[Limit]
Free height : -1.0 mm (-0.039 in.)
Out of square : 4°
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Valve Guides
Check the valve stem-to-guide clearance. If the clearance exceeds the service limit, replace the valve guide with the
next oversize part.
Valve stem-to-guide clearance

Intake : 0.020-0.047 mm (0.0008-0.0019 in.)
Exhaust : 0.050-0.085 mm (0.0020-0.0033 in.)
[Limit]
Intake : 0.1 mm (0.0040 in.)
Exhaust : 0.15 mm (0.0059 in.)
Valve Seat Insert

Check the valve seat for overheating and improper contact with the valve face. Recondition or replace the seat if
necessary. Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, and
then recondition the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width
should be within specifications and centered on the valve face.
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Procedures for Replacing Valve Seat Insert

1. Any valve seat insert that has been worn over the service limit should be removed at normal temperature after
cutting away most of the insert wall using valve seat cutters as shown in Fig. "A".
2. After removing the seat insert, machine the seat insert bore using a reamer or a cutter. Cut to the size shown in
the table.
3. Heat the cylinder head to about 250°C (480°F) and press in the oversize seat insert. The oversize seat insert
should be at normal room temperature for installation. After installing a new valve seat insert, resurface the valve
seat using the same procedure as in paragraph 1. in Valve Seat Insert.
Valve Seat Insert Oversizes
Description Size mm (in.) Size mark Seat insert height Cylinder head I.D.
H mm (in.) mm (in.)
Intake valve seat 0.3 (0.012) O.S. 30 8.4-8.6 (0.330- 35.300-35.325
0.338) (1.3898-1.3907)
insert 0.6 (0.024) O.S. 60 8.7-8.9 (0.342- 35.600-35.625
0.350) (1.4016-1.4026)
Exhaust valve seat 0.3 (0.012) O.S. 30 8.0-8.2 (0.314- 33.300-33.325
0.322) (1.3110-1.3120)
insert 0.6 (0.024) O.S. 60 8.3-8.5 (0.326- 33.600-33.625
0.334) (1.3228-1.3238)
Procedures for Replacing Valve Guide

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The valve guide is installed by using a press fit. Using a Valve Guide Installer (09222-21200 A/B and 09222-
28400) or suitable tool, replace the valve guide according to the following procedure.
1. Using the push rod of the Valve Guide Installer, push the valve guide out toward the cylinder block with a press.
2. Machine the valve guide insert hole in the cylinder head to the specified oversize of the new valve guide.
3. Using the Valve Guide Installer or suitable tool, press fit the valve guide. The use of the valve guide installer
makes it possible to press fit the valve guide to a predetermined height. The valve guide should be installed from
the top of the cylinder head. Note that intake and exhaust valve guides are different in length [45.5 mm (1.791
in.) for intake and 50.5 mm (1.988 in.) for exhaust.]
4. After the valve guides have been installed, insert new valves and check the clearance.
5. Whenever valve guides are replaced, check that the valve is seated in contact with then and recondition the valve
seats as necessary.
Size mm (in.) Size mark Cylinder head hole
size mm (in.)
0.05 (0.002) O.S. 5 12.050-12.068
(0.4744-0.4751)
0.25 (0.010) O.S. 25 12.250-12.268
(0.4823-0.4830)
0.50 (0.020) O.S. 50 12.500-12.518
(0.4921-0.4928)
INSTALLATION
• Clean each part before assembly.

• Apply engine oil to sliding and rotating parts.
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1. After installing the spring seat, fit the stem seal onto the valve guide. Fit the seal in by lightly tapping the Special
Tool, Valve Stem Oil Seal Installer. The seal is installed in the specified position by means of the special tool.
Incorrect installation of the seal will adversely affect the lip I.D. and eccentricity, resulting in oil leakage down the
valve guides. When installing, therefore, be careful not to twist the seal. Do not reuse old stem seals.
2. Apply engine oil to each valve. Insert the valves into the valve guides. Avoid inserting the valve into the seal by
force. After inserting, check that the valve moves smoothly.
3. Install springs and spring retainers. Valve springs should be installed with the enamel coated side toward the valve
spring retainer.
4. Using the special tool, Valve Spring Compressor (09221-29100) remove the retainer lock. Next remove the
spring retainer, valve spring, spring seat and valve.
Keep these parts so that they can be reinstalled in their original positions.
5. Clean all gasket surfaces of the cylinder block and cylinder head.
6. Install a new cylinder head gasket onto the cylinder head assembly. Do not apply sealant to the gasket and do not
reuse the old cylinder head gasket.
Engine Mechanical System > Engine And Transaxle Assembly > Engine And Transaxle Assembly >
Repair procedures
REMOVAL
1. Remove the battery.
2. Detach the air cleaner.
3. Disconnect the connectors for the backup lamp and engine harness.
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4. For a vehicle with a 5-speed manual transaxle, disconnect the select control valve connector.
5. Disconnect the connectors for the generator harness and the oil pressure gauge wiring.
6. Drain the engine coolant.

7. For vehicles with an automatic transaxle, disconnect the transaxle oil cooler hoses.
When disconnecting the hoses, make identification marks to avoid making any mistakes in reconnecting
them.
Be careful not to spill oil or fluid out of the hoses, and plug the openings to prevent the entrance of foreign
material.
8. Disconnect the radiator upper and lower hoses on the engine side.
9. Disconnect the engine ground.

10. Disconnect the brake booster vacuum hose.
11. Remove the main fuel line, and the return and vapor hoses from the engine side.
To reduce the residual pressure in the hoses, refer to Group Fuel System "Fuel filter
replacement".
12. Disconnect the heater hoses (inlet and outlet) on the engine side.
13. Disconnect the accelerator cable at the engine side.

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14. For vehicles with a manual transaxle, remove the clutch cable from the transaxle.
15. For vehicles with an automatic transaxle, remove the control cable from the transaxle.
16. For vehicles with manual transaxle, remove the shift control rod and extension rod.
17. Disconnect the connector of the vehicle speed sensor from the transaxle.
18. Separate the column shaft from the steering gear box.
19. Remove the engine mounting insulator.
20. Remove the transaxle mounting insulator.

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21. After removing the wheel and attaching the wheel speed sensor and caliper to the body, disconnect the lower
arm and the fork, and then separate the upper arm and knuckle.
22. Jack up the vehicle.

23. Drain the transaxle oil (or fluid).
24. Disconnect the front exhaust pipe from the manifold.
Use wire to suspend the exhaust pipe from the bottom of the
vehicle.
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25. Place the supporter under the sub-frame.
Check that all of the cables, hoses, harnesses, connectors etc are disconnected from the
engine.
26. In order to remove the sub-frame, engine, transaxle, steering gear box and drive shaft all together. Loosen the
sub-frame bolts (6ea) slowly and lift the vehicle with lifter.
27. Remove the driver shaft and hang the engine and transaxle at the hoist, then separate engine and transaxle from
the sub-frame. To separate the engine and transaxle from the sub-frame remove the Engine mounting bracket
and Transaxle mounting bracket, and then lift up the hoist.
INSTALLATION
1. While checking the connections of the harnesses, pipes, hoses, etc., mak sure that none of them is being caught,
damaged, etc.
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2. To place the engine and transaxle assembly on the sub-frame install the front roll stopper and rear roll stoper
between the sub-frame and engine, transaxle assembly.
Especially, when installing front roll stopper mounting bracket, be careful not to be crushed the insulator, If
being crushed, idle vibration is high.
3. To install the engine transaxle and sub-frame follow the removal procedures in the reverse order.
4. Refill the coolant and check for leak.

5. Refill the transaxle fluid, test its operation, and check for leak.
6. Check for the operation of the transaxle control cable and accelerator cable. Adjust as necessary.
7. Check for proper operation of each of the various gauges.
Engine Mechanical System > Cylinder Block > Balance Shaft > Components and Components Location
COMPONENTS
Page 56 of 110
Engine Mechanical System > Cylinder Block > Balance Shaft > Repair procedures
REPLACEMENT
counter balance shaft bearing
1. Using a special tool, remove the right counter balance shaft front bearing from the cylinder block.
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2. Using a special tool, remove the right counter balance shaft rear bearing from the cylinder block.
3. Using a special tool, remove the left counter balance shaft rear bearing from cylinder block. At this time, install
special tool on the front surface of cylinder block to hold the bearing puller.
4. Using a special tool, install the left counter balance shaft rear bearing to the cylinder block.
• Apply engine oil to the rear bearing outer circumference and bearing hole in cylinder
block.
• The left rear bearing has no oil holes.
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5. Using a special tool, install the right counter balance shaft rear bearing to the cylinder block.
• Apply engine oil to the outer surface of bearing.

• Make sure that the bearing oil hole is aligned with the oil hole of cylinder block.
6. Using a special tool, install the right counter balance shaft front bearing to the cylinder block.
Make sure that the bearing oil hole is aligned with the oil hole of cylinder block.
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INSPECTION
Check journals for wear or seizure. If excessive wear or seizure is evident, check the bearing carefully. If necessary,
replace the counter balance shaft bearing or both.
Engine Mechanical System > Cylinder Block > Piston and Connecting Rod > Components and
Components Location
COMPONENTS
Page 60 of 110
COMPONENTS
Page 61 of 110
Engine Mechanical System > Cylinder Block > Piston and Connecting Rod > Repair procedures
Disassembly
Connecting Rod Cap
Keep the bearings in order with their corresponding connecting rods (according to cylinder numbers) for proper
reassembly.
1. Remove the connecting rod cap nuts and then remove the caps and the big end lower bearing.
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2. Push each piston-connecting rod assembly toward the top of the cylinder.
Disassembly
piston pin
1. Use the special tools (09234-33001), to disassemble and reassemble the piston and connecting rod.
2. Place the proper insert in the fork of the tool. Position the insert between the connecting rod and the piston.
3. Insert the proper tool for removal through the hole in the arch of the tool.
Center the piston, rod and pin assembly with the removal arbor.
4. Press the piston pin out of the connecting rod.

5. Install proper pin guide (refer to application chart) through piston and into connecting rod. Hand tap pin guide
into piston for proper retention. Drop piston pin into the other side of the piston.
The pin guide centers the conneting rod in the pistion. When the piston, connecting rod, piston pin and pin
guide assembly are positioned on the fork of the tool, the pin guide will also center this assembly in the
tool. If a pin guide that is too small is used, the piston assembly will not be located centrally in the tool, and
damage may occur to the fork and/or the insert of the tool.
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6. Install the piston assembly onto the fork assembly of tool. The tool will support connecting rod at the piston pin.
Be sure the piston assembly is slid onto the fork until the pin guide contacts the fork insert.
7. Adjust the installing arbor to the proper length by turning the numbered sleeve on the lettered shaft until the
specified alpha numeric setting from the application chart is obtained. Turn knurled nut to lock numbered sleeve
on shaft.
8. Insert the installing arbor through the hole in the arch of the tool. Press the piston pin into the connecting rod until
the sleeve on the installing arbor contacts the top of the tool arch. The pin guide will fall out of the connecting rod
as the piston pin is pressed in.
Do not exceed 5000 pounds of force when stopping the installing arbor sleeve against the arch.
INSPECTION
1. When the connecting rod cap is installed, make sure that cylinder numbers put on the rod end cap at disassembly
match.
When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the
same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end, and also if it has step wear in, or a
severely rough surface on, the inside diameter of the small end.
INSPECTION
Piston and Piston Pins
1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective.
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2. Check each piston ring for breakage, damage and abnormal wear. Replace the defective rings. When the piston
requires replacement, its rings should also be replaced.
3. Check the piston pin fits in the piston pin hole. Replace any piston and pin assembly that is defective. The piston
pin must be smoothly pressed by hand into the pin hole at room temperature.
Piston Rings
1. Measure the piston ring side clearance. If the measured value exceeds the service limit, insert a new ring in a ring
groove to measure the side clearance. If the clearance still exceeds the service limit, replace the piston and rings
together. If it is less than the service limit, replace the piston rings only.
[Standard value]
Piston ring side clearance :
No.1 : 0.03-0.07mm (0.0012-0.0028 in.)
No.2 : 0.02-0.06 mm (0.0008-0.0024 in.)
[Limit] : 0.1 mm (0.004 in.)
2. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to
the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds
the service limit, replace the piston ring.
Piston ring end gap

No.1 : 0.25-0.35 mm (0.0098-0.0138 in.)
No.2 : 0.40-0.55 mm (0.0157-0.0216 in.)
Oil ring side rail :
0.10-0.40 mm (0.0039-0.0157 in.)
[Limit]
No.1, No.2 : 0.8mm(0.031in.)
Oil ring side rail : 1.0 mm (0.039 in.)
Reassembly
1. Make sure that the front mark of piston and front mark (identification mark) of connecting rod are directed
toward front of engine.
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2. When connecting rod cap is installed, make sure that cylinder numbers put on rod and cap at disassembly match.
3. When new connecting rod is installed, make sure that notches for holding bearing in place are on same side.
4. Tighten the connecting rod cap nuts.
Tightening torque
Connecting rod cap nuts :
18-22 Nm (180-220 kg.cm, 13-16 lb.ft) + (90°~94°)
5. Check connecting rod side clearance.
Side clearance : 0.10-0.25 mm (0.004-0.0098 in.)

Limit : 0.4 mm (0.0157 in.)
Reassembly
1. Install the spacer.
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2. Install the upper side rail. To install the side rail, first put one end of the side rail between piston ring groove and
spacer, hole it down firmly, and then press down the portion which is to be inserted into groove with a finger as
illustrated.
Do not use piston ring expander when installing the side rail.
3. Install the lower side rail by same procedure as Step 2.

4. Using piston ring expander, install No.2 piston ring.
5. Install No.1 piston ring.

6. Apply engine oil around a piston and piston rings.
7. Position each piston ring end gap as far apart from neighboring gaps as possible. Make sure that gaps are not
positioned in thrust and pin directions.
8. Hold piston rings firmly in a piston ring compressor as they are inserted into cylinder.
Engine Mechanical System > Cylinder Block > Crankshaft > Components and Components Location
COMPONENTS
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Engine Mechanical System > Cylinder Block > Crankshaft > Repair procedures
Page 68 of 110
Disassembly
1. Remove the timing belt train, 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 be reassembled in the original position and
direction.
4. Remove the main bearing caps and remove the crankshaft.
Keep the bearings in order according to the cap number.
INSPECTION
Crankshaft
1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check oil holes for clogging.
Correct or replace any defective part.
2. Inspect out-of-roundness and taper of crankshaft journal and pin.
Standard value
Crankshaft journal O.D : 56.982-57.000mm(2.2434-2.2442.in.)
Crankshaft pin O.D : 44.980-45.000 mm (1.7709-1.7717in.)
Main Bearings and Connecting Rod Bearings

Visually inspect each bearing for peeling, melt, seizure and improper contact. Replace the defective bearings.
Measuring Oil Clearance
To check the oil clearance, measure the outside diameter of the crankshaft journal and the crank pin and the
inside diameter of the bearing. The clearance can be obtained by calculating the difference between the measured
outside and inside diameters.
Standard value - Oil clearance
Crankshaft main bearing - No. 1, 2, 4, 5 : 0.018-0.036 (0.0007 - 0.0014) and No. 3 : 0.024 -
0.042 (0.0009 - 0.0016)
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Connecting rod bearing : 0.015-0.048 mm
How to Use Plastic Gauge

Plastigauge may be used to measure the clearance.
1. Remove oil and grease and any other dirt from bearings and journals.
2. Cut plastigauge to the same length as the width of the bearing and place it in parallel with the journal, off oil holes.
3. Install the crankshaft, bearings and caps and tighten them to the specified torques. During this operation, do not
turn the crank shaft. Remove the caps. Measure the width of the plastigauge at the widest part by using a scale
printed on the gauge package. If the clearance exceeds the service limit, the bearing should be replaced. When
installing a new crankshaft, be sure to use standard size of bearings. If the clearance exceeds the service limit, the
bearing should be replaced. When installing a new crankshaft, be sure to use standard size of bearing.
Oil Seal
Check front and rear oil seals for damage or worn lips. Replace any seat that is defective.
Bearing Caps
After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct. If the end
play exceeds the limit, replace crankshaft bearings.

Limit : 0.25 mm (0.0098 in.)
Drive Plate
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Replace deformed, damaged, or cracked drive plates.
INSPECTION
1. Check the clutch disc contacting surface of the flywheel for damage and wear. Replace the flywheel if excessively
damaged or worn.
2. Check the clutch disc contacting surface of the flywheel for runout.
Limit
Flywheel run-out : 0.13 mm (0.0051 in.)
3. Check the ring gear for damage, cracks and wear, and replace if necessary.
Reassembly
1. Install grooved main bearing (upper bearing) and thrust bearing on cylinder block side.
2. Install grooveless main bearing (lower bearing) on main bearing cap side.
3. Install crankshaft. Apply engine oil to journal and pin.
4. Caps should be installed with arrow mark directed toward front of engine. Cap number must be correct.
5. Tighten cap bolts to specified torque in sequence of center No.2, No.4, front and rear caps.
Tightening torque
Main bearing cap bolts : 25 Nm(250, 18 lb.ft) + (90°~94°)
6. Cap bolts should be tightened evenly in from 4 to 5 stages before they are tightened to specified torque.
7. Make certain that crankshaft turns freely and has proper end play.
8. Using a special tool install oil seal in oil seal case.
9. Install the oil seal into the oil seal case so that the oil hole in the separator is directed downward (arrow in
illustration).
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10. Install the new oil seal case gasket and oil seal case assembly.
11. Install the rear plate to the cylinder block.

12. Install the flywheel assembly and tighten the bolts to the specified torque.
Tightening torque
Flywheel bolt :
130-140 Nm (1,300-1,400 kg.cm, 94-101 lb.ft)
Engine Mechanical System > Cylinder Block > Cylinder Block > Components and Components
Location
COMPONENTS
Page 72 of 110
Engine Mechanical System > Cylinder Block > Cylinder Block > Repair procedures
REMOVAL
Remove the cylinder head, timing belt train, front case, flywheel, piston and crankshaft. For further details, refer to
the respective chapters.
INSPECTION
Cylinder Block
1. Visually check the cylinder block for scores, rust and corrosion. Also check for cracks or any other defects.
Correct or replace the block if defective.
2. Measure cylinder bore with a cylinder gauge at three levels in directions of A and B.
Level 1 : No.1 piston ring position with piston at TDC
Level 2 : Center of cylinder
Level 3 : Bottom of cylinder
3. If cylinder bores show more the specified out-of-round or taper, or if the cylinder walls are badly scuffed or
scored, the cylinder block should be re-bored and honed and fitted with oversize pistons and rings.
Standard value
Cylinder bore : 85.00-85.03 mm (3.3465-3.3476 in.)
Out-of-roundness and taper of cylinder bore : Max. 0.01 mm (0.0004 in.)
4. If cylinder top ridge is worn in stages, cut away with ridge reamer.
5. Oversize pistons are available in four sizes.
Piston service size and mark mm (in.)

0.25 (0.010) O.S : 0.25
6. To rebore the cylinder to oversize, keep the specified clearance between the oversize piston and the bore, and
make sure that all pistons used are of the same oversize. The standard measurement of the piston outside
diameter is taken at a level 2 mm (0.08 in.) above the bottom of the piston skirt and across the thrust faces.
Piston-to-cylinder wall clearance :

0.02-0.04 mm (0.0008-0.0012 in.)
7. Check for damage and cracks.

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8. Check top surface for flatness. If excessive flatness is evident, grind to minimum limit or replace.
Standard value
Flatness of gasket surface : Max. 0.05 mm (0.0020 in.)
Cylinder block (New) height : 284 mm (11.18 in.)
Service limit
Flatness of gasket surface : 0.1 mm (0.0039 in.)
Overall height : -0.2 mm (-0.0079 in.)
The cylinder block gasket surface should be ground within -0.2 mm (-0.0079 in.) including the ground
surface of cylinder head gasket surface.
Boring Cylinder
1. Oversize pistons to be used should be determined on the base of the largest bore cylinder.
Size Identification mark
0.25 mm (0.010 in.) O.S 0.25
0.50 mm (0.020 in.) O.S 0.50
0.75 mm (0.030 in.) O.S 0.75
1.00 mm (0.039 in.) O.S 1.00
Size mark is stamped on top of piston.

2. Measure outside diameter of piston to be used.
Page 74 of 110
3. On the base of measured piston O.D., calculate boring finish dimension.
Boring finish dimension = Piston O.D + 0.02-0.04 mm (0.0008-0.0016 in.) (clearance between O.D and
cylinder)-0.02 mm (0.008 in.) (honing margin.)
4. Bore each of the cylinders to the calculated size.
To prevent distortion that may result from temperature rise during honing, bore cylinders, working from
No.2 to No.4 to No.1 to No.3.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check clearance between piston and cylinder.
When boring cylinders, finish all of four cylinders to the same oversize. Do not bore only one cylinder to an
oversize.
REASSEMBLY
1. Install the following parts by referring to the respective para-graphs.
(1) Crankshaft
(2) Flywheel
(3) Piston
(4) Cylinder head
(5) Timing belt train
(6) Front case
Engine Mechanical System > Cylinder Block > Engine Mounts > Components and Components
Location
COMPONENTS
Page 75 of 110
Engine Mechanical System > Cylinder Block > Engine Mounts > Repair procedures
REMOVAL
Attach an engine hoist to the engine hooks, and raise just enough so that there is no pressure on the insulators.
Page 76 of 110
Engine Mounting
1. Remove the engine mount insulator bolts.
2. Remove the engine mount bracket from the engine.
Transaxle Mounting
1. Remove the transaxle mount insulator bolts.
2. Remove the transaxle mounting bracket from the transaxle.
Front Roll Stopper

Remove the front roll stopper bracket from the sub-frame.
Rear Roll Stopper

1. Remove the bolt from the rear roll stopper.
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2. Remove the rear roll stopper from the subframe.
INSPECTION ITEMS
Engine Mechanical System > Cooling System > Water pump > Components and Components Location
COMPONENTS
Page 78 of 110
Engine Mechanical System > Cooling System > Water pump > Repair procedures
REMOVAL
1. Drain the coolant and disconnect the radiator outlet hose and Engine coolant by-pass hose from the engine
coolant pump.
2. Remove the drive belt and engine coolant pump pulley.
3. Remove the timing belt covers and the timing belt tensioner.
4. Remove the engine coolant pump mounting bolts and then remove the alternator brace.
5. Remove the engine coolant pump assembly from the cylinder block.
Installation
Page 79 of 110
1. Clean the gasket surfaces of the engine coolant pump body and the cylinder block..
2. Install the new O-ring onto the groove on the front end of the engine coolant pipe, then wet the O-ring with
engine coolant.
Do not apply oil or grease.
3. Install new Engine coolant pump gasket and Engine coolant pump assembly. Tighten the bolts to specified torque.
Tightening torque
Engine coolant pump bolt :
20-27 Nm (200-270 kg.cm, 14-20 lb.ft)
4. Install the timing belt tensioner and timing belt. Adjust the timing belt tension, and then install the timing belt
covers.
5. Install the engine coolant pump pulley and drive belt, and then adjust the belt tension.
6. Refill the coolant.
7. Run the engine and check for leak.
INSPECTION
1. Check the engine coolant pump for cracks, damage or wear, and replace the engine coolant pump assembly if
necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the engine coolant pump
assembly if necessary.
3. Check the seal unit for leaks, and replace the engine coolant pump assembly if necessary.
4. Check for engine coolant leakage. If the engine coolant leaks from hole "A"seal unit is defective. Replace engine
coolant pump assembly.
Engine Mechanical System > Cooling System > Thermostat > Components and Components Location
COMPONENTS
Page 80 of 110
Engine Mechanical System > Cooling System > Thermostat > Repair procedures
REMOVAL
1. Drain the coolant to the thermostat level or below.
2. Remove the Engine coolant outlet fitting and gasket.
3. Remove the thermostat.
INSTALLATION
1. Check to ensure that the flange of the thermostat is correctly seated in the socket of the thermostat housing. If the
thermostat is installed in the wrong direction, the bottom of the thermostat will touch the rib inside the intake
manifold, making it impossible to seat flange in position.
2. Install a new gasket and Engine coolant outlet fitting.
Tightening torque
Engine coolant outlet fitting bolt :
10-15 Nm (100-150 kg.cm, 7-11 lb.ft)
3. Refill the coolant.
INSPECTION
1. Heat the thermostat as shown in the illustration.
2. Check that the valve operates properly.
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3. Check to determine the temperature at which the valve begins to open.
Valve opening temperature :

80.5-83.5°C (176.9-182.3°F)
Full opening temperature : 95°C (203°F)
Engine Mechanical System > Cooling System > Radiator > Components and Components Location
COMPONENTS
Page 82 of 110
Engine Mechanical System > Cooling System > Radiator > Repair procedures
REMOVAL
Never open or disassemble any portion of the cooling system until the engine temperature has dropped to ambient
air temperature. Engine coolant escaping under heat and resulting pressure can cause severe burns and blindness.
1. Disconnect the ground cable from the battery terminal.
Page 83 of 110
2. Disconnect the fan motor connector.
3. Loosen the radiator drain plug to drain the coolant.
4. Disconnect the upper and lower hoses and overflow tube after making marks on the radiator hose and the hose
clamp.
5. For vehicles with automatic transaxle, disconnect the oil cooler hoses from the automatic transaxle.
Cover or plug the hose and nipple part of the radiator so that dust, foreign materials, etc. do not enter after
the hose has been disconnected from the radiator.
6. Remove the radiator mounting bolt.
7. Remove the radiator together with the fan motor.

8. Remove the radiator fan motor, condenser fan motor from the radiator.
INSTALLATION
1. Fill the radiator and reservoir tank with clean coolant mixture.
2. Run the engine until the coolant has warmed up enough so that the thermostat valve opens, and then stop the
engine.
3. Remove the radiator cap and pour the coolant to the filler neck of the radiator. Fill the reservoir tank with the
coolant to the upper level.
4. Check that there is no leakage from the radiator, hoses or connections.
INSPECTION
1. Check for foreign material between radiator fins.
2. Check the radiator fins for damage and straighten if necessary.
3. Check the radiator for corrosion, damage, rust or scale.
4. Check the radiator hoses for cracks, damage or deterioration.
5. Check the reserve tank for damage.
6. Check the automatic transaxle oil cooler hoses for cracking, damage or deterioration.
Engine Mechanical System > Cooling System > Cooling Fan Motor Assembly > Components and
Components Location
Page 84 of 110
COMPONENTS
Engine Mechanical System > Cooling System > Cooling Fan Motor Assembly > Repair procedures
REMOVAL
1. Disconnect the ground cable from battery cable.
2. Disconnect the connectors from the fan motor and the harness from shroud.
3. For vehicles with automatic transaxle, remove the oil cooler hose from the shroud.
4. Remove the shroud mounting four bolts.
5. Remove the shroud with the fan motor.

6. Remove the fan mounting clip and detach the fan from fan motor.
7. Remove the three screws and detach the fan motor.
Page 85 of 110
INSTALLATION
1. Installation is the reverse order of removal procedures.
• Make sure the cooling fan does not come into contact with the shroud when
installed.
• After installation, make sure there is no unusual noise or vibration when fan is
rotated.
Inspection
Radiator fan motor and condenser fan motor
1. Check that the radiator fan rotates when battery voltage is applied between the terminals (as shown table below).
2. Check that abnormal noises are not produced while the motor is turning.
Cooling Fan Control System

ECM controls the cooling fan in 3 steps (LO/ MIDDLE/ HI) according to the vehicle speed, the air-conditioning
load and engine coolant temperature.
Page 86 of 110
ECM Control logic

ECM A/C FAN
LOW HIGH RADIATOR CONDENSOR
OFF OFF ON/OFF OFF OFF
ON OFF OFF LOW OFF
ON OFF ON LOW LOW
OFF ON ON/OFF MID MID
ON ON OFF HIGH MID
ON ON ON HIGH HIGH
Radiator Fan Motor Relay

1. Remove the radiator fan motor relay (High and Low) from the relay box in engine room.
Page 87 of 110
2. Check the continuity of the terminals "86" and "85" with an ohmmeter.
3. Apply DC12 V to the terminals "86" and ground the terminal "85".
4. Check the continuity between the terminals "87" and "30".
Engine Mechanical System > Cooling System > Engine Coolant Hose / Pipes > Components and
Components Location
COMPONENTS
Engine Mechanical System > Cooling System > Engine Coolant Hose / Pipes > Repair procedures
INSTALLATION
Fit O-ring in the groove provided at engine coolant inlet pipe end, wet the periphery of O-ring and insert engine
coolant inlet pipe.
Page 88 of 110
• Do not apply oils or greases to Engine coolant pipe O-ring.

• Keep the Engine coolant pipe connections free of sand, dust, etc.
• Insert Engine coolant pipe to its end bottoms.
• While installing the engine coolant inlet pipe, always replace the O-ring with a new one.
INSPECTION
Check the engine coolant pipe and hose for cracks, damage, and restrictions. Replace if necessary.
Engine Mechanical System > Lubrication System > Oil Pump > Components and Components Location
COMPONENTS
Page 89 of 110
Engine Mechanical System > Lubrication System > Oil Pump > Repair procedures
REMOVAL
1. Remove the timing belt. Refer to "Timing Belt".
2. Remove all the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil screen and gasket.
5. Remove the relief plunger and gasket, and then take off the relief spring and relief valve from the oil filter bracket.
6. Remove the oil pressure switch.
7. Remove the oil filter bracket and gasket.

8. Using the special tool, remove the plug cap from the oil pump portion of front case.
9. Remove the left side of cylinder block plug and insert a screw driver with an 8 mm (0.32 in.) diameter shaft into
plug hole. The screwdriver shaft must be inserted more than 60 mm (2.4 in.)
10. Remove the oil pump driven gear and left the counter balance shaft retaining bolt.
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11. Remove the front case mounting bolts and remove the front case assembly and gasket. Remove the two counter
balance shafts from the cylinder block.
12. Remove the oil pump cover from the front case.
13. Remove the oil pump gears from the front case.
INSTALLATION
1. Apply engine oil to the gear and align the two timing marks.
2. Using the special tool, Crankshaft Front Oil Seal Installer (09214-32000), install the crankshaft front oil seal into
the front case.
Page 91 of 110
3. Set the special tool (09214-32100) on the front end of crankshaft and apply a thin coat of engine oil to the outer
circumference of the special tool to install the front case.
4. Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than
those for tightening the filter bracket).
5. Install the front case assembly with a new gasket, and tighten the bolts to the specified torque.
Front case assembly

Tightening torque
All except : 20-27 Nm (200-270 kg.cm, 14-20 lb.ft)
6. Insert a screwdriver through plug hole in left side of cylinder block. After checking that the shaft is in position,
tighten.
7. Install a new O-ring to the groove of front case.

Page 92 of 110
8. Using a special tool, install the plug case and tighten to the specified torque.
9. Apply sealant into the groove of the pan flange as shown.
• Apply sealant approx. 4 mm (0.16 in.) in thickness.

• After application of sealant, do not exceed 15 minutes before installing the oil
pan.
10. Note the difference in bolt lengths at the location shown. Install the oil pan and tighten the bolts to the specified
torque.
Tightening torque
Oil pan bolt : 10-12 Nm (100-120 kg.cm, 7-9 lb.ft)
Page 93 of 110
11. Using the special tool, install the oil pressure switch after applying sealant to the threaded area.
Sealant : Threebond 1104 or equivalent
Do not torque the oil pressure switch excessively.
Tightening torque
Oil pressure switch : 8-12 Nm (80-120 kg.cm, 6-8 lb.ft)
INSPECTION
1. Assemble the oil pump gear to the front case and rotate it to ensure smooth rotation with no looseness.
2. Ensure that there is no ridge wear on the contact surface between the front case and gear surface of the oil pump
cover.
3. With the drive and driven gears installed into the front case, measure the tip clearance of the gears.
[Standard value]
Drive gear : 0.160-0.205 mm (0.0063-0.0081 in.)
Driven gear : 0.180-0.205 mm (0.0071-0.0081 in.)
[Limit]
Drive gear : 0.25 mm (0.0098 in.)
Driven gear : 0.25 mm (0.0098 in.)
Page 94 of 110
4. Check the side clearance.
[Standard value]
Drive gear : 0.08-0.14 mm (0.0031-0.0055 in.)
Driven gear : 0.06-0.12 mm (0.0024-0.0047 in.)
[Limit]
Drive gear : 0.25 mm (0.0098 in.)
Driven gear : 0.25 mm (0.0098 in.)
Engine Mechanical System > Lubrication System > Front Case > Components and Components
Location
COMPONENTS
Page 95 of 110
Engine Mechanical System > Lubrication System > Front Case > Repair procedures
REMOVAL
1. Remove the timing belt. Refer to "Timing Belt".
2. Remove all the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil screen and gasket.
5. Remove the relief plunger and gasket, and then take off the relief spring and relief valve from the oil filter bracket.
Page 96 of 110
6. Remove the oil pressure switch.
7. Remove the oil filter bracket and gasket.

8. Using the special tool, remove the plug cap from the oil pump portion of front case.
9. Remove the left side of cylinder block plug and insert a screw driver with an 8 mm (0.32 in.) diameter shaft into
plug hole. The screwdriver shaft must be inserted more than 60 mm (2.4 in.)
10. Remove the oil pump driven gear and left the counter balance shaft retaining bolt.
Page 97 of 110
11. Remove the front case mounting bolts and remove the front case assembly and gasket. Remove the two counter
balance shafts from the cylinder block.
12. Remove the oil pump cover from the front case.
13. Remove the oil pump gears from the front case.
INSTALLATION
1. Apply engine oil to the gear and align the two timing marks.
2. Using the special tool, Crankshaft Front Oil Seal Installer (09214-32000), install the crankshaft front oil seal into
the front case.
Page 98 of 110
3. Set the special tool (09214-32100) on the front end of crankshaft and apply a thin coat of engine oil to the outer
circumference of the special tool to install the front case.
4. Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than
those for tightening the filter bracket).
5. Install the front case assembly with a new gasket, and tighten the bolts to the specified torque.
Front case assembly

Tightening torque
All except : 20-27 Nm (200-270 kg.cm, 14-20 lb.ft)
6. Insert a screwdriver through plug hole in left side of cylinder block. After checking that the shaft is in position,
tighten.
7. Install a new O-ring to the groove of front case.

Page 99 of 110
8. Using a special tool, install the plug case and tighten to the specified torque.
9. Apply sealant into the groove of the pan flange as shown.
• Apply sealant approx. 4 mm (0.16 in.) in thickness.

• After application of sealant, do not exceed 15 minutes before installing the oil
pan.
10. Note the difference in bolt lengths at the location shown. Install the oil pan and tighten the bolts to the specified
torque.
Tightening torque
Oil pan bolt : 10-12 Nm (100-120 kg.cm, 7-9 lb.ft)
Page 100 of 110
11. Using the special tool, install the oil pressure switch after applying sealant to the threaded area.
Sealant : Threebond 1104 or equivalent
Do not torque the oil pressure switch excessively.
Tightening torque
Oil pressure switch : 8-12 Nm (80-120 kg.cm, 6-8 lb.ft)
INSPECTION
Front Case
1. Check oil holes for clogging and clean if necessary.
2. Check the counter balance shaft front bearing section for wear, damage and seizure. If there is anything wrong
with the section, replace the front case.
3. Check the front case for crack and other damage. Replace the cracked or damaged front case.
Oil Seal
1. Check the oil seal lip for wear and damage. Replace the oil seal if necessary.
2. Check the oil seal lip for deterioration. Replace the oil seal if necessary.
Oil Pressure Switch
1. If the "OIL PRESSURE" indicating lamp lights up when the ignition switch is "ON" and goes out when engine is
started and runs at idle, everything is in order. If "OIL PRESSURE" lamp does not light when ignition switch is
"ON" check switch, lamp and wiring.
2. If there is current flow when ignition switch is "ON" and if there is no current flow when engine is running at idle,
the switch is good. If the switch is good, check the lamp and wiring.
Oil pressure switch operation pressure :

14.71-29.42 kPa (0.15-0.3 kg/cm² ,2.1-4.3 psi)
Page 101 of 110
3. Using 24mm deep socket, tighten the switch to the specified torque.
Tightening torque
Oil pressure switch and sensor assembly :
8-12 N·m (80-120 kg-cm, 5.8-8.7 lb·ft)
Oil Pressure Sensor Assembly

1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the
oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even
when the fine wire is pushed, replace it.
3. Or, if there is no continuity when a 50 kPa (7 psi) vacuum is applied through the oil hole, the switch is operating
properly.
Check that air doesn't leak. If air leaks, the diaphragm is broken. Replace the switch.
Engine Mechanical System > Intake And Exhaust System > Air Cleaner > Components and
Components Location
COMPONENTS
Page 102 of 110
Engine Mechanical System > Intake And Exhaust System > Air Cleaner > Repair procedures
REMOVAL
1. Remove the air intake hose and air duct connected to the air cleaner, and the resonator.
2. Remove the three bolts attaching the air cleaner mounting brackets.
3. Detach the air cleaner.
INSTALLATION
Install the air cleaner according to the reverse order of removal.
Page 103 of 110
INSPECTION
1. Check the air cleaner body, cover, or packing for distortion, corrosion or damage.
2. Check the air duct for damage.

3. Check the air cleaner element for restriction, contamination or damage.
If the element is slightly restricted, remove the dust and other contaminants by blowing to the inside through the
element.
4. Check the air cleaner housing for restriction, contamination or damage.

5. Check the resonator for damage.
Engine Mechanical System > Intake And Exhaust System > Intake Manifold > Components and
Components Location
COMPONENTS
Page 104 of 110
Engine Mechanical System > Intake And Exhaust System > Intake Manifold > Repair procedures
REMOVAL
1. Disconnect the high pressure fuel hose connection after draining pressure in the fuel pipe line to prevent overflow
of fuel. (Refer to "Fuel system").
Page 105 of 110
2. Remove the delivery pipe with the fuel injectors and pressure regulator attached.
Be careful not to drop the injectors when removing the delivery pipe.
INSTALLATION
1. Make sure that the injector is not dropped, when installing the delivery pipe.
INSPECTION
Intake Manifold
1. Check for damage or cracking of any part.
2. Check for obstructions in the vacuum outlet port and the gas passage.
Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold > Components and
Components Location
COMPONENTS
Page 106 of 110
Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold > Repair procedures
INSPECTION
Check for damage or cracking of any part.
Check for flaking damage of the gasket.
Engine Mechanical System > Intake And Exhaust System > Muffler > Components and Components
Location
COMPONENTS
Page 107 of 110
Engine Mechanical System > Intake And Exhaust System > Muffler > Repair procedures
REMOVAL
Main Muffler
Before removing or inspecting the exhaust system, ensure that the exhaust system is cool enough.
Page 108 of 110
1. Disconnect the main muffler from the center exhaust pipe.
2. Remove the rubber hangers and take out the main muffler.
Center Exhaust Pipe

1. Disconnect the center exhaust pipe from the main muffler.
2. After disconnecting from the front exhaust pipe, remove the center exhaust pipe.
Front Exhaust Pipe (Including rear catalytic converter.)

1. Remove the front exhaust pipe from the center exhaust pipe.
2. Remove the front exhaust pipe from the exhaust manifold (Including front catalytic converter)
Page 109 of 110
3. Remove the front exhaust pipe from the rubber hanger.
INSTALLATION
1. Temporarily install the front exhaust pipe (Rear catalytic converter assembly), the center exhaust pipe, and the
main muffler, in order.
2. Install the rubber hangers so that they are identical (left and right) in length.
3. Tighten the parts securely, and then confirm that there is no interference with any body components.
INSPECTION
1. Check the mufflers and pipes for corrosion and damage.
2. Check the rubber hanger and hangers for deterioration and cracks.
Engine Mechanical System > Troubleshooting > P0128

Thermostat Circuit (FOR 2.4 DOHC)
Engine coolant thermostat open stuck
No. P0128
[Related items] • 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
• Contaminated, deteriorated ECTS
Page 110 of 110
1 Remove thermostat and check that thermostat is Yes Go to step 2.
stuck.
No Temporarily install a known good thermostat and
Is thermostat okay?
check for proper operation.
If problem is corrected, replace thermostat.
OBD-II check connector and turn ignition to proceeding this procedure.
ON.
Is DTC P0116, P0117, P0118, or P0125 set? No Go to step 3.
3 Start engine and allow engine to idle until engine Yes Problem is intermittent or was repaired and engine
reaches operating temperature. control module memory was not cleared. Check
Using SCAN TOOL and monitor ECT signals. terminal connections at ECM and ECTS.
• 2.3~2.9V (2.31~2.59 kΩ) @ 20°C (68°F)
• 0.4~1.0V (0.31~0.33 kΩ) @ 80°C (176°F) No Go to step 4.
Is signal within specifications?
4 Check ECTS for contamination, deterioration or Yes Clean ECTS with cleaner before installing. If
damage. damaged or deteriorated, replace.
Is ECTS contaminated, deteriorated or

connectors at ECM and ECTS connectors.
With ignition OFF, disconnect ECM and ECTS
connectors. Measure resistance between ECTS No Repair as necessary
and ECM on all two circuits.
Is resistance all below 1 Ω?
Page 1 of 146
OPTIMA(MS) > 2003 > G 2.4 DOHC > Fuel System
Fuel System > General Information > Special Service Tools

Tool
Illustration Application
(Number and name)
09353-38000 Connection of fuel pressure gauge to delivery pipe
Fuel pressure gauge for measurement of fuel pressure.
adapter
09353-
24100/0K2A1 131
001A
Fuel pressure gauge
& hose
09353-02000 Removal of quick connector of delivery pipe and

Quick connector return pipe
remover
0K3MS 131 001 Connection of fuel pressure gauge to delivery pipe

Fuel pressure gauge for measurement of fuel pressure (use with 0K3MS
adapter 131 001A)
Fuel System > General Information > Description and Operation

MULTIPORT FUEL INJECTION (MFI)
GENERAL INFORMATION
The Multiport Fuel Injection System consists of sensors which detect the engine conditions, the ENGINE
CONTROL MODULE (ECM) which controls the system based on signals from these sensors, and actuators which
operate under the control of the ECM. The ECM carries out activities such as fuel injection control, idle air control
and ignition timing control. In addition, the ECM is equipped with several diagnostic test modes which simplify the
troubleshooting when a problem develops.
FUEL INJECTION CONTROL
The injector drive times and injector timing are controlled so that the optimum air/fuel mixture is supplied to the
engine to correspond to the continually-changing engine operation conditions. A single injector is mounted at the
Page 2 of 146
intake port of each cylinder. Fuel is sent under pressure from the fuel tank by the fuel pump, with the pressure being
regulated by the fuel pressure regulator. The fuel thus regulated is distributed to each of the injectors. Fuel injection is
normally carried out once for each cylinder for every two rotations of the crankshaft. The firing order is 1-3-4-2.
This is called multiport. The ECM provides a richer air/fuel mixture by carrying out "open-loop" control when the
engine is cold or operating under high load conditions in order to maintain engine performance. In addition, when the
engine is warm or operating under normal conditions, the ECM controls the air/fuel mixture by using the heated
oxygen sensor signal to carry out "closed-loop" control in order to obtain the theoretical air/fuel mixture ratio that
provides the maximum cleaning performance from the three way catalyst.
IDLE SPEED CONTROL
The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle valve in
accordance with changes in idling conditions and engine load during idling. The ECM drives the idle speed control
(ISC) motor to keep the engine running at the pre-set idle target speed in accordance with the engine coolant
temperature and air conditioning load. In addition, when the air conditioning switch is turned off and on while the
engine is idling, the ISC motor operates to adjust the throttle valve bypass air amount in accordance with the engine
load conditions in order to avoid fluctuations in the engine speed.
IGNITION TIMING CONTROL
The ignition power transistor located in the ignition primary circuit turns ON and OFF to control the primary current
flow to the ignition coil. This controls the ignition timing in order to provide the optimum ignition timing with respect
to the engine operating conditions. The ignition timing is determined by the ECM from the engine speed, intake air
volume, engine coolant temperature and atmospheric pressure.
OTHER CONTROL FUNCTIONS
1. Fuel Pump Control : Turns the fuel pump relay ON so that current is supplied to the fuel pump while the engine is
cranking or running.
2. A/C Compressor Clutch Relay Control : Turns the compressor clutch of the A/C ON and OFF.
3. Fan Relay Control : The radiator fan and condenser fan speeds are controlled in response to the engine coolant
temperature and vehicle speed.
4. Evaporative Emission Purge Control.
DIAGNOSTIC TEST MODE
• When an abnormality is detected in one of the sensors or actuators related to emission control, the CHECK
ENGINE/MALFUNCTION INDICATOR LAMP illuminates as a warning to the driver.
• When an abnormality is detected in one of the sensors or actuators, a diagnostic trouble code corresponding to
the abnormality is output.
• The RAM data inside the ECM that is related to the sensors and actuators can be read by means of the scan
tool. In addition, the actuators can be controlled under certain circumstances.
HOW TO COPE WITH INTERMITTENT MALFUNCTIONS
Most intermittent malfunctions occur under certain conditions. If those conditions can be identified, the cause will be
easier to find.
TO COPE WITH INTERMITTENT MALFUNCTION;
1. Ask the customer about the malfunction. Ask what it feels like, what it sounds like, etc. Then ask about driving
conditions, weather, frequency of occurrence, and so on.
2. Determine the conditions from the customer's responses. Typically, almost all intermittent malfunctions occur from
conditions like vibration, temperature and/or moisture change, poor connections. From the customer's replies, it
should be reasoned which condition is influenced.
3. Use simulation test In the cases of vibration or poor connections, use the simulation tests below to attempt to
duplicate the customer's complaint. Determine the most likely circuit(s) and perform the simulation tests on the
connectors and parts of that circuit(s). Be sure to use the inspection procedures provided for diagnostic trouble
codes and trouble symptoms. For temperature and/or moisture conditions related intermittent malfunctions, using
common sense, try to change the conditions of the suspected circuit components, then use the simulation tests
below.
4. Verify the intermittent malfunction is eliminated. Repair the malfunctioning part and try to duplicate the
condition(s) again to verify the intermittent malfunction has been eliminated.
Page 3 of 146
SIMULATION TESTS
For these simulation tests, shake, then gently bend, pull and twist the wiring of each of these examples to duplicate
the intermittent malfunction.
• Shake the connector up-and-down, and right-and-left.
• Shake the wiring harness up-and-down, and right-and-left.
• Vibrate the part or sensor.
A CAUTION FOR I/M TEST (2.7 V6 Vehicle with Traction Control System)
• To prevent the vehicle misfire, disconnect the connector of ABS.
SERVICE POINTS IN INSPECTING A BLOWN FUSE
Remove the fuse and measure the resistance between the load side of the fuse and ground. Set the switches of all
circuits which are connected to this fuse to a condition of continuity. If the resistance is almost 0W at this time, there
is a short somewhere between these switches and the load. If the resistance is not 0W, there is no short at the
present time, but a momentary short has probably caused the fuse to blow.
The main causes of a short circuit are the following.
• Harness clamped by the vehicle body
• Damage to the outer casing of the harness due to wear or heat.
• Water getting into the connector or circuitry
• Human error (mistakenly shorting a circuit, etc.).
INSPECTING THE MFI SYSTEM
If the MFI system components (sensors, ECM, injector, etc.) fail, the interruption or failure to supply the proper
amount of fuel for various engine operating conditions will result. The following situations may be encountered.
1. Engine is hard to start or does not start at all.
2. Unstable idle
3. Poor driveability
If any of the above conditions is noted, first perform an inspection by self-diagnosis and subsequent basic engine
checks (ignition system malfunction, incorrect engine adjustment, etc.), and then inspect the MFI system
components.
ON-BOARD DIAGNOSTICS
• The recording condition of diagnostic trouble code. After the ECM first detects a malfunction, a diagnostic
trouble code is recorded when he engine is restarted and the same malfunction is re-detected. (Malfunction is
detected in driving cycle). However, for fuel system rich/lean misfiring, a diagnostic trouble code is recorded on
the first detection of the malfunction.
• The recording condition of diagnostic trouble code.The diagnostic trouble codes in ECM memory will be erased
when removing the battery terminal from the battery or using scan tool. However, for fuel system rich/lean
misfiring, a diagnostic trouble code is recorded on the first detection of the malfunction.
- When driving conditions (engine speed, engine coolant temperature, etc.) are siMILar to those when the
malfunction was first recorded.
- When the ECM does not re-detect the malfunction for 80 driving cycles.
A "driving cycle" consists of the engine start, vehicle operation beyond the beginning of closed loop operation.
Malfunction Indicator Light (MIL)
An On Board Diagnostic lamp comes on to notify the driver that there is any problem on the vehicle.
However MIL will go off automatically after 3 subsequent sequential driving cycles not redetected same malfunction.
Immediately after the ignition switch turns on, the malfunction indicator light is lit for 5 seconds to indicate that the
malfunction indicator light operates normally.
Following Items will be Indicated by the MIL
• Catalyst
• Fuel system
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• Air flow sensor (MAF sensor)
• Intake Air Temperature Sensor (IAT sensor)
• Engine Coolant Temperature Sensor (ECT sensor)
• Throttle Position Sensor (TPS)
• Upstream Oxygen Sensor
• Downstream Oxygen Sensor Heater
• Downstream Oxygen Sensor
• Upstream Oxygen Sensor Heater
• Injector
• Misfire
• Crankshaft Position Sensor (CKP sensor)
• Camshaft Position Sensor (CMP sensor)
• Evaporative Emission Control System
• Vehicle Speed Sensor (VSS)
• Idle Speed Control
• ECM
• Manifold Absolute Pressure (MAP) Sensor (Except 2.7 V6 engine)
• EGR System (Except 2.7 V6 engine)
INSPECTING THE MALFUNCTION INDICATOR LAMP (MIL)
1. After turning on the ignition key, check that the light illuminates for 5 seconds without engine running.
2. If the light does not illuminate, check for an open circuit in harness, blown fuse and blown bulb.
SELF-DIAGNOSIS
The ECM monitors the input/output signals (some signals at all times and the others under specified conditions).
When the ECM detects an irregularity, it memorize the diagnostic trouble code, and outputs the signal to the self-
diagnosis output terminal. The diagnosis results can be read out Hi-Scan Tool. Diagnostic trouble code (DTC) will
remain in the ECM as long as battery power is maintained. The diagnostic trouble code will, however, be erased
when the battery terminal or the engine control module (ECM) connector is disconnected or erased by Generic
Scan Tool.
CHECKING THE PROCEDURES (SELF-DIAGNOSIS)
• When battery voltage is low, diagnostic trouble codes can not be read. Be sure to check the battery for voltage
and charging system before starting the test.
• Diagnosis memory is erased if the battery or the ECM connector is disconnected. Do not disconnect the
battery before the diagnostic trouble codes are completely read and recorded.
Inspection Procedure (Using Hi-Scan Tool)
1. Turn OFF the ignition switch.
2. Connect the scan tool to the data link connector on the lower crash pad.
3. Turn ON the ignition switch.
4. Use the Hi-Scan Tool to check the diagnostic trouble code.
5. Repair the faulty part from the diagnosis chart.
6. Erase the diagnostic trouble code.
7. Disconnect the Hi-Scan Tool.
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
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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
2400RPM (resulting in 0 volt input to the ECM). Since the condition happens at the engine speed above the
maximum threshold, in this case 2000 RPM, the ECM will not store a DTC.
As a functional test, the MIL (check engine) illuminates at key ON before engine cranking. Whenever the ECM sets
a DTC that affects vehicle emissions, it sends a signal to illuminate the MIL. There are some monitors that may take
consecutive trips, with a detected fault, before the MIL is illuminated. This is also known as "PENDING" codes.
Also, m the MIL flashes when the ECM detects an active engine misfire, then shuts off fuel to the affected cylinder.
OBD-II diagnostics supports not only the standard test mode of OBD-II (Mode 01~Mode 07) but also an
advanced test Mode (Mode 22: Supported PID-analog inputs and outputs, digital inputs and outputs). All of these
diagnostic test modes are supported using Hi-Scan Pro 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
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 ECM to 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 300°C. For this reason, heating of the HO2 sensor is necessary to allow the engine controller 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 heating the sensor properly.
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· 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 is used to compute the injection period. The front HO2S monitors the contaminated exhaust gases. This, in
time, causes aging of the device and a change in the signal.
To monitor the front HO2S responsiveness, the response period of the upstream oxygen 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 outside of 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 diagnosic 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 truned ON if the same fault is again detected during a
second drive cycle.
CATALYST MONITORING
SYSTEM DESCRIPTION
To comply with clean air regulatings, 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 increase in 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, its oxygen
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 in
the exhaust gas before it enters the catalytic converter. A low voltage indicates a high oxgen 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 detected from 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 to front switches is used to determine whether the catalyst is operating
properly. An effective catalyst will have fewer rear switches 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.
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)
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• 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 short FT 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 is part of the basic injection duration calculation. Long FT changes slowly, in response to Short FT. It's
normal range is ±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
affects the basic injection duration calculation in open and closed loop. Because Long FT is stored in a non-
volatile RAM and is not erased when the ignition is swithed OFF, the fuel system is able to correct for variances
in engine and fuel conditions even during warm-up and wide open throttel 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, when the MIL is only turned ON if the same fault is detected
during a second drive cycle.
EVAPORATIVE EMISSION CONTROLS
EVAPORATIVE CONTROL SYSTEM
The evaporation control system prevents the emission of fuel tank vapor into the atmosphere. When fuel evaporates
in the fuel 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.
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.
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.
Evaporative emissions canister
The EVAP 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.
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.
Purge solenoid valve
This valve is actuated by the purge control signal from the ECM and controls fuel vapor from the EVAP Canister to
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the intake manifold.
Fuel tank pressure sensor
The Fuel Tank Pressure Sensor (FTPS) is an integral part of the monitoring system. The FTPS checks Purge
Solenoid Valve operation and leak detection in the Evaporative Emissions System by monitoring pressure and
vacuum levels in the fuel tank during 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
used to close the system and observe tank pressure respectively.
MONITORING CONDITIONS
The leak test is conducted when the vehicle is stopped during 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.
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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 loss will 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 panel will 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 the sensor wheel segment duration has been introduced on the Optima in order to
expand the misfire monitoring range. The sensor wheel segment duration is pre-filtered by this function and then the
filtered value is used to calculate the engine roughness which is compared with the reference value to detect misfiring.
With this function, it is possible to eliminate the influence of the crankshaft-synchronous oscillations on the detection
of misfire. These oscillations can be caused by sensor wheel tolerance or crankshaft torsional vibration. The misfire
monitoring of this vehicle 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 moniotred component/system is monitored. The lack of circuit continuity and rationality, and out-of-range
values to ensure proper operation of the input devices, are monitored for proper response to ECM commands.
EGR SYSTEM MONITORING (EXCEPT 2.7 V6 ENGINE)
The EGR system is monitored by the measurement of manifold pressure variation by turning on EGR during
coasting. The manifold pressure is measured before and after EGR valve has been activated and the corresponding
pressure variation is compared with reference value to detect a EGR system malfunction.
Fuel System > General Information > Troubleshooting

TROUBLESHOOTING
When checking engine trouble, it is important to start with an inspection of the basic systems. If one of the following
conditions exists, (A) engine start failure, (B) unstable idling or (C) poor acceleration, begin by checking the
following basic systems.
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1. Power supply
A. Battery
B. Fusible link
C. Fuse
2. Body ground
3. Fuel supply
A. Fuel line
B. Fuel filter
C. Fuel pump
4. Ignition system
A. Spark plug
B. High-tension cable
C. Ignition coil
5. Emission control system
A. PCV system
B. Vacuum leak
6. Others
A. Ignition timing
B. Idle speed
Trouble with the MFI system is often caused by poor contact of the harness connectors. It is important to check all
harness connectors and verify that they are securely connected.
TROUBLESHOOTING GUIDE CHART
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The numbers in the columms indicate the proper troubleshooting sequence to be followed.
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The numbers in the columns indicate the proper troubleshooting sequence to be followed.
PROBLEM (MFI TROUBLESHOOTING PROCEDURES)
Communication with scan tool is not possible. (Communication with all system is not possible)
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Scan tool communication with ECM is not possible

Comment Probable cause
One of the following causes may be suspected. • Malfunction of the ECM power supply circuit
• No power supply to the ECM • Malfunction of the ECM
• Defective ground circuit of the ECM • Open circuit between the ECM and DLC
• Defective the ECM
• Improper communication line between the ECM and
scan tool
Engine will not start
Difficult to start (Engine turns over)

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Rough idle or engine stalls

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Engine hesitates or accelerates poorly

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Difficult to refuel/Overflowing or Spit-Back while refueling

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The proper operating condition of fuel shut-off valve is at the nominal volume of fuel (app. 65 liter)
TROUBLESHOOTING
Engine will not crank Low battery charge Charge or replace the battery
Battery cables are loose, corroded or Repair or replace cables
worn
Faulty transaxle range switch Adjust or replace the switch
(Vehicle with automatic transaxle only)
Faulty starter motor Repair the starter motor
Faulty ignition switch Replace the ignition swtich
Engine cranks slowly Low battery charge Charge or replace battery
Battery cables are loose, corroded or Repair or replace cables
worn
Faulty starter motor Repair the starter motor
Starter keeps running Faulty starter motor Repair the starter motor
Faulty ignition switch Replace the ignition switch
Starter spins but engine will not Short in wiring Repair the wiring
crank
Pinion gear teeth broken or faulty Repair the starter motor
starter motor
Ring gear teeth broken Replace the flywheel ring gear or torque
converter
FUEL TANK AND FUEL LINE

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Engine malfunctions due to insufficient fuel supply Bent or kinked fuel pipe or hose Repair or replace
Clogged fuel pipe or hose Clean or replace
Clogged fuel filter of in-tank fuel Replace
filter
Water in fuel filter Replace the fuel filter or clean
the fuel tank and fuel lines
Dirty or rusted fuel tank interior Clean or replace
Malfunction of the fuel pump Replace
(Clogged filter in the pump)
Evaporative emission system malfunctions (when Incorrect routing of a vapor line Correct
fuel filler cap is removed, pressure is released)
Disconnected vapor line Correct
Vapor line is folded, bent, Replace
cracked or clogged
Faulty fuel tank cap Replace
Malfunction of the overfill limiter Replace
(Two-way valve)
Fuel System > General Information > Specifications

SPECIFICATIONS
Items Specifications
Throttle body Throttle position sensor Type Variable resistor
(TPS)
Resistance at 2.4 3.5 ~ 6.5 kΩ
curb idle DOHC
2.7 V6 1.6 ~2.4 KΩ
Output voltage at 2.4 300 ~ 900 mV
curb idle DOHC
2.7 V6 250 ~ 800 mV
Idle speed control (ISC) Type Double coil
actuator
Resistance Opening 15.0 ~ 16.0 Ω
Closing 17.0 ~ 18.2 Ω
Sensors Air flow sensor Type 2.4 HOT Film sensor (MAF)
DOHC
2.7 V6 HOT Film sensor (MAF)
Intake air temperature Type 2.4 Thermistor type 2.22~ 2.82KΩ at
(IAT) sensor DOHC (Built in MAF) 20°C(68°F)
Resistance 2.7 V6 Thermistor type
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Engine coolant Type Thermistor type
temperature (ECT) Resistance 2.31~2.59 KΩ at 20°C (68°F)
sensor
0.30~0.34 KΩ at 80°C (176°F)
Heated oxygen sensor Type 2.4 Zirconia type
(HO2S) DOHC
2.7 V6 Zirconia type
Vehicle speed sensor Type Hall effect type
Camshaft position Type Hall effect sensor
(CMP) sensor
Crankshaft position Type Hall effect sensor
(CKP) sensor
Actuators Injector Type, number 2.4 Electromagnetic type, 4
DOHC
2.7 V6 Electromagnetic type, 6
Resistance 13.8 ~ 15.2Ω at 20°C (68°F)
Evaporative emission Type Duty cycle type
purge solenoid
Resistance 20 ~ 32Ω
Fuel pressure Injector opening pressure 300 ± 1.5 kPa (3.35 ± 0.06 kg/cm²)
regulator
Fuel tank Tank capacity 65 lit (17.1 US gal, 14.3 Imp.gal)
Return system Equipped
Canister Volume/Nominal working capacity 3.0 liter/150 g
SEALANT
Item Specified sealant
Engine coolant temperature LOCTITE 962T or equivalent
sensor
SERVICE STANDARDS
Item Standard valve
Basic ignition timing (2.4 DOHC) BTDC 5° ± 2° at curb idle
Actual ignition timing (2.7 V6) BTDC 12° ± 5° at curb idle
Curb idle speed (rpm) 2.4 DOHC 800 ± 100
2.7 V6 700 ± 100
Fuel pressure kPa (psi) Vacuum hose disconnection 330 ~ 350 (47-50) at curb idle
Vacuum hose connection Approx. 270 (38) at curb idle
Evap canister purge solenoid valve resistance 24.5-27.5Ω
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TIGHTENING TORQUE
Item Nm Kg·cm lb·ft
Delivery pipe 10-13 100-130 7-9.5
installation bolt
Engine coolant 20-40 200-400 14-29
temperature
sensor
Heated oxygen 35-45 350-450 25.8-33.1
sensor
Heated oxygen 8-12 80-120 5.8-8.7
sensor connector
bracket bolt
High pressure 30-40 300-400 22-29
hose and fuel
main pipe
High pressure 25-35 250-350 18-25
hose and fuel
filter
High pressure 3-4 30-40 2.2-3
hose to delivery
pipe
Fuel pump 2-3 20-30 1.4-2.2
assembly to fuel
tank
High pressure 30-40 300-400 22-29
hose at fuel tank
Throttle body to 15-22 150-220 11-12.7
surge tank
Fuel tank drain 15-25 150-250 11-18
plug
Fuel filter 9-14 90-140 6.5-10
mounting bolts
Accelerator arm 8-12 80-120 5.8-8.7
bracket bolts
ISC actuator 6-8 60-80 4.4-5.8
Fuel sender to 2-3 20-30 1.4-2.2
fuel tank
Fuel System > Engine Control System > Description and Operation
DIAGNOSTIC TROUBLESHOOTING FLOW
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Fuel System > Engine Control System > Components and Components Location
LOCATION OF MFI COMPONENTS
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ECT Sensor Power Steering Oil Pressure Switch

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Vehicle Speed Sensor Ignition Timing Adjustment Terminal
EVAP Solenoid Valve MAP, TPS, ISA, TR
CMP Sensor CKP
Data Link Connector Heated Oxygen Sensor (HO2S)

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Transaxle Range (TR) Switch Injectors
Knock
SYSTEM DIAGRAM FOR 2.4L DOHC

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Fuel System > Engine Control System > Troubleshooting

INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODE (FOR 2.4 DOHC)
DTC Diagnostic items Trouble area MIL
P0101 Mass or Volume Air Flow Circuit • Dirty air cleaner O
Range/Performance Problem • Air leak in intake system
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• Vacuum leak in intake system
• Improper PCV valve
• Contaminated, deteriorated or damaged MAFS
• Faulty mass air flow sensor or throttle position sensor
• Poor connections at ECM, MAFS, or TPS
P0102 Mass or Volume Air Flow Circuit • Open or short to ground between MAFS and ECM O
Low Input • Open or short to ground between MAFS battery power
and engine main relay
• Faulty MAFS
P0103 Mass or Volume Air Flow Circuit • Short to battery between MAFS signal and ECM O
High Input • Faulty MAFS
P0112 Intake Air Temperature Circuit Low • Open or short to battery between IATS signal and ECM O
Input • Open between IATS ground and ECM
• Faulty IATS
P0113 Intake Air Temperature Circuit High • Short to ground between IATS signal and ECM O
Input • Faulty IATS
P0117 Engine coolant Temperature Circuit • Open or short to ground between ECTS and ECM O
Low Input • Open between ECTS and ECM
• Faulty ECTS
P0118 Engine coolant Temperature Circuit • Short to battery ECTS and ECM O
High Input • Faulty ECTS
P0116 Engine Coolant Temperature Sensor • After engine start-up, the elapsed time before feedback O
Circuit Range/Performance Problem operation is initiated is too long (engine coolant
temperature sensor input is insufficient for closed loop
operation)
• Foreign materials fouled, contaminated, deteriorated
ECTS
• Faulty ECTS
• Faulty thermostat
P0125 Insufficient Coolant Temperature For • After engine start-up, the elapsed time before feedback O
Closed Loop Fuel Control operation is initiated is too long (engine coolant
temperature sensor input is insufficient for closed loop
operation)
• Foreign materials fouled, contaminated, deteriorated
ECTS
• Faulty ECTS
P0128 Coolant thermostat stuck • Thermostat stuck opened O
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P0121 Throttle Position Sensor Circuit • Poor connections between TPS and ECM O
Range/Performance Problem • Misplaced, loose or corrodes terminals
• Contaminated, deteriorated TPS
• Faulty TPS
P0122 Throttle Position Sensor Circuit Low • Open or short to ground between TPS reference power O
Input and ECM
• Short to ground between TPS signal and ECM
• Faulty TPS
P0123 Throttle Position Sensor Circuit High • Open or short to battery between TPS signal and ECM O
Input • Open between TPS ground and ECM
• Faulty TPS
P0130 HO2S Circuit Open (Bank 1, • Open or short to battery or 5V between front HO2S and O
Sensor 1) ECM
• Short to ground between front HO2S and ECM
P0131 HO2S Circuit Short to ground O
• Short between front HO2S wires
(Bank 1, Sensor 1)
• Faulty front HO2S
P0132 HO2S Circuit Short to 5V (Bank 1, • Poor connections between front HO2S and ECM O
Sensor 1) • Misplaced, bent, loose or corroded connector terminals
P0133 HO2S Circuit Slow Responsive • Abnormal combustion O
(Bank 1, Sensor 1) • Improper fuel pressure
• Front and rear HO2S connections reversed
• Faulty fuel delivery system
• Leak in intake system
• Leak in exhaust system
P0134 HO2S Circuit No Activity Detected • Open or short between HO2S signal terminal and ECM O
(Bank 1, Sensor 1) • Contaminated, deteriorated or aged HO2S
• Misplaced, bent, loose or corroded connector terminals
P0135 HO2S Heater Circuit Malfunction • Open or short to battery between front HO2S heater and O
(Bank 1, Sensor 1) ECM
• Short to ground between front HO2S heater and ECM
• Open or short to ground between front HO2S heater and
main relay
• Incorrect front HO2S heater resistance
• Faulty front HO2S heater
P0136 HO2S Circuit Open (Bank 1, • Open or short to chassis ground between rear HO2S and O
Sensor 2) ECM
P0137 HO2S Circuit Short to ground • Short to battery or 5V between rear HO2S and ECM O
(Bank 1, Sensor 2) • Short between rear HO2S wires
P0138 HO2S Circuit Short to 5V (Bank 1, O
Sensor 2) • Faulty rear HO2S
P0139 HO2S Circuit Malfunction (Bank 1,

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P0139 HO2S Circuit Malfunction (Bank 1, • Open or short to chassis ground between rear HO2S and O
Sensor 2) ECM
• Short to battery between rear HO2S and ECM
P0140 HO2S Circuit Malfunction - stick • Short between rear HO2S wires O
(Bank 1, Sensor 2) • Misplaced, bent, loose or corroded connector terminals
• Faulty rear HO2S
P0141 HO2S Heater Circuit Malfunction • Open or short to battery between rear HO2S heater and O
(Bank 1, Sensor 2) ECM
• Short to ground between rear HO2S heater and ECM
• Open or short to ground between rear HO2S heater and
main relay.
• Incorrect rear HO2S heater resistance
• Faulty rear HO2S heater
P0171 Fuel System Too Lean (Bank 1) • Faulty fuel delivery system O
• Clogged fuel injectors
• Faulty fuel injectors
• Faulty MAFS
• Faulty TPS
P0172 Fuel System Too Rich • Faulty ignition system O
• EVAP canister purge valve malfunction
- Clogged fuel injectors
- Faulty fuel injectors
- Fuel pressure too high
- Fuel pressure regulator failure
• Faulty MAFS
• Faulty TPS
P0201 Cylinder 1 Injector Circuit • Open or short to ground between main relay and injectors O
Malfunction • Open or short to ground between ECM and injectors
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P0300 Random Misfire Detected • Vacuum leak in air intake system O
• CKPS circuit malfunction
P0301 Cylinder 1 Misfire Detected • Ignition circuit malfunction O
• Faulty ignition coil or plug wire
• Spark plug malfunction
P0302 Cylinder 2 Misfire Detected O
• Low compression due to blown head gasket, leaking
valve or piston ring
P0303 Cylinder 3 Misfire Detected • Low/high fuel pressure due to faulty pressure regulator, O
restricted fuel lines, plugged fuel filter or faulty fuel pump
P0304 Cylinder 4 Misfire Detected • Fuel injector circuit malfunction O
P0320 Ignition Failure Sensor circuit • Open or short to ground between ignition failure sensor ▲
Malfunction and ECM
• Open or short to ground between ignition failure sensor
and ignition coil
• Open between ignition failure sensor and ground
• Faulty ignition failure sensor
P0325 Knock Sensor Circuit Malfunction • Open or short to ground between knock sensor and ▲
ECM
• Source of high resistance between knock sensor and
ECM
• Faulty knock sensor
P0335 Crankshaft Position Sensor Circuit • Open or short to ground between CKPS and ECM O
Malfunction • Short to battery between CKPS and ECM
• Short between CKPS wires
• Out of allowable air gap
• Faulty Target wheel tolerance
• Faulty CKPS
P0340 Camshaft Position Sensor Circuit • Open or short to ground between CMPS and ECM O
Malfunction • Short to battery between CMPS and ECM
• Short between CMPS wires
• Poor connection between CMPS connector & harness
connector
• Faulty CMPS
P0350 Ignition Coil Primary/Secondary • Open or short between ignition coil and ECM O
Circuit Malfunction • Open or short between ignition coil and spark plug
• Short between ignition coil wires
• Faulty ignition coil
• Poor connection at ignition coil
• Faulty ignition system
P0401 EGR System Malfunction • Blocked and/or leakage vacuum tube between EGR O
control valve and intake manifold vacuum port
• Blocked and/or leakage tube between EGR solenoid
valve and intake manifold port
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• Misplaced, loose or corroded terminals at MAPS, EGR
solenoid valve
• Leakage in EGR control valve
• Poor connection vacuum tubes
P0403 EGR System Solenoid Valve Circuit • Open between EGR solenoid valve and ECM O
Malfunction • Short to battery between EGR solenoid valve and ECM
• Short to between EGR solenoid valve wires
• Faulty EGR solenoid valve
P0421 Main catalyst efficiency deterioration • Catalytic converter deteriorated O
(Bank1)
P0441 EVAP Emission Control System • PSV stuck opened O
Purge Control Valve stuck opened
P0442 EVAP Emission Control System • Fuel filler cap loose or missing O
Small Leak (1mm) • Fuel filler cap o-ring missing or damaged
• Faulty or damaged fuel filler pipe
• Leaking, disconnected or plugged fuel vapor lines
P0456 EVAP Emission Control System • Fuel in lines due to faulty rollover valve, on-board O
Small Leak (0.5 mm) refueling vapor recovery valve or stuck closed CCV
• Canister close valve clogged, stuck open or closed
• Improperly installed purge solenoid valve
P0455 EVAP Emission Control System O
• PSV stuck open or closed
Large Leak
• Faulty fuel tank pressure sensor
• Leaking canister or catch tank
P0443 EVAP Emission Control System • Open or short between main relay and purge solenoid O
Purge Control Valve Circuit valve
Malfunction • Open or short between purge solenoid valve and ECM
• Faulty purge solenoid valve
P0446 EVAP Emission Control System • Open or short to ground between main relay and CCV O
Vent Circuit Malfunction • Open or short to ground between CCV and ECM
• Short to battery between CCV and ECM
• Faulty CCV
P0451 EVAP Emission Control System • Poor connections between FTPS and ECM O
Pressure Sensor Range/Performance • Misplaced, loose, bent or corroded terminals
Problem • Contaminated, deteriorated or damaged FTPS
• Faulty FTPS
• Stuck closed CCV
• Blocked vapor hose between canister and CCV
P0452 EVAP Emission Control System • Open or short to ground between FTPS reference power O
Pressure Sensor Low Input and ECM
• Short to ground between FTPS signal and ECM
• Faulty FTPS
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P0453 EVAP Emission Control System • Open or short to battery between FTPS signal and ECM O
Pressure Sensor High Input • Open between FTPS ground signal and FTPS
• Faulty FTPS
P0460 Fuel Level Sensor Circuit • Open or short to battery between FLS and ECM O
Malfunction • Short to ground between FLS and ECM
P0462 Fuel Level Sensor Low - Stick • Poor connections between FLS and ECM O
P0463 Fuel Level Sensor High - Stick • Faulty FLS or FLS stuck O
P0500 Vehicle Speed Sensor Circuit • Open or short to battery between VSS and ECM O
Malfunction • Short to ground between VSS and ECM
• Open or short between VSS wires
• Faulty VSS
P0506 Idle Control System RPM Lower • Open or short between main relay and IACV O
Than Expected • Open or short between ECM and IACV
• Intake system is plugged
• Carbon fouled throttle plate
• Faulty IACV
P0507 Idle Control System RPM Higher • Short to ground between IACV and ECM O
than Expected • Air leak in intake system
• Improperly adjusted accelerator cable
• Faulty IACV
• Faulty TPS
• Faulty PCV/PSV
P0560 System Voltage Malfunction • Open or short to ground between ECM and battery O
• Reverse battery cable connection (+/- reverse)
• ECM internal faulty
• Faulty Alternator
P0181 Difference of fuel temperature and • Open or short to battery FTS and ECM O
engine coolant temperature at start is • Short to ground between FTS and ECM
too large. • Short between FTS wires
P0182 Fuel temperature Circuit Low Input • Faulty FTS O
P0183 Fuel temperature Circuit High Input O
P0106 Manifold absolute pressure sensor- • Open or short to ground between MAPS and ECM O
EGR System Open/Short • Open between MAPS and ECM
• Open between MAPS and ground
• Faulty MAPS
P0107 Manifold absolute pressure sensor- • Poor connections between MAPS and ECM O
EGR Mode 3 • Misplaced, loose or corroded terminals
• Foreign materials fouled MAPS
P0108 Manifold absolute pressure sensor- • Stuck closed EGR control valve O
EGR Mode 2 • Stuck open EGR control valve
• Faulty MAPS
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P1330 Spark Timing Adjustment • Short to GND between ROM change tool and ECM O
P0551 Power Steering Switch Malfunction • Open between power steering switch and ECM O
• Short to ground between power steering switch and
ECM
• Faulty power steering switch
O : Means fault code memory and MIL ON

▲ : Means fault code memory and MIL OFF
- : Np application
Fuel System > Engine Control System > Repair procedures

MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) SENSOR
The manifold differential pressure (MAP) sensor converts intake manifold pressure into a voltage signal. The engine
control module (ECM) uses this signal to determine the condition of the exhaust gas recirculation (EGR).
Circuit Diagram [2.4 DOHC]
USING VOLTMETER
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Check Data display Check conditions Engine state Test
Item specification
MAP Inlet manifold • Engine coolant temperature: Idle 0.8-2.4V
sensor pressure 18°C (65.4°F)
• Lamps, electric cooling fan,
accessory units: All OFF When the accel. pedal is Rise from 0.8-
• Transaxle: Neutral (P range for depressed suddenly at idle 2.4V
vehicle with A/T)
• Steering wheel: Neutral
HARNESS INSPECTION PROCEDURE
TROUBLESHOOTING PROCEDURES [MAP SENSOR]

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TROUBLESHOOTING HINTS
The MIL (Malfunction Indicator Lamp) is ON or the DTC (Diagnostic Trouble Code) is displayed on the HI-
SCAN under the following conditions;
1. When the manifold pressure is 4.5V or more for 4 second.
2. When the manifold pressure is 0.2V or lower for 4 second.
SENSOR INSPECTION [MAP SENSOR]
1. Connect the voltmeter between 1 and 4 of MAP sensor connector
Terminal 1 : MAP sensor ground
Terminal 4 : MAP sensor output
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2. Measure the voltage of terminals.
Engine state Test
specification
Ignition SW. ON. 4-5V
At idle 0.8 - 2.4 V
3. If the voltage deviates from the standard value, replace the MAP sensor assembly.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
The engine coolant temperature sensor is installed in the engine coolant passage of the cylinder head, detects engine
coolant temperature and emits signals to the ECM. This part employs a thermistor which is sensitive to changes in
temperature. The electric resistance of a thermistor decreases in response to temperature rise. The ECM judges
engine coolant temperature by the sensor output voltage and provides optimum fuel enrichment when the engine is
cold.
Circuit Diagram
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SENSOR CHECKING
Intake air 2.4
Check item Data display Check conditions 2.7 V6
temperature DOHC
Engine coolant temperature Sensor IG ON or Engine When 20 °C (68 2.5 ~ 3.6 ~
sensor temperature running °F) 2.7V 3.8V
When 40 °C (104 1.5 ~ 2.7 ~
°F) 1.7V 3.0V
When 80°C 0.5 ~ 1.2 ~
(176°F) 0.7V 1.5V
Using multi-meter
1. Remove engine coolant temperature sensor from the intake manifold.
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2. With temperature sensing portion of engine coolant temperature sensor immersed in hot engine coolant, check
resistance.
Temperature [°C (°F)] Resistance (KΩ)
20 (68) 2.31-2.59
80 (176) 0.31-0.34
3. If the resistance deviates from the standard value greatly, replace the sensor.
HARNESS INSPECTION
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USING VOLTMETER
Check Item Coolant temperature 2.4 DOHC 2.7 V6
Engine coolant temperature sensor output voltage When 20 °C 2.5 ~ 2.7V 3.6 ~ 3.8V
When 40 °C 1.5 ~ 1.7V 2.7 ~ 3.0V
When 80 °C 0.5 ~ 0.7V 1.2 ~ 1.5V
Troublehsooting hints
If the fast idle speed is not enough or the engine gives off dark smoke during the engine warm-up operation, the
engine coolant temperature sensor might be the cause.
Installation
1. Apply sealant LOCTITE 962T or equivalent to threaded portion.
2. Install engine coolant temperature sensor and tighten it to specified torque.
Tightening torque
Engine coolant temperature sensor : 20-40 Nm (200-400 kg·cm, 14-29 lb·ft)
3. Securely connect the harness connector.

MASS AIR FLOW (MAF) SENSOR [2.7 V6]
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This hot film type air flow sensor is composed of a hot film sensor, housing, metering duct (hybrid, sensor element).
Mass air flow rate is measured by detection of heat transfer from a hot film probe because the change of the mass
air flow rate causes change in the amount of heat being transferred from the hot film probe surface to the air flow.
The air flow sensor generates a pulse so it repeatedly opens and closes between the 5V voltage supplied from the
engine control module. This results in the change of the temperature of the hat film probe and in the change of
resistance.
Circuit Diagram [2.7 V6]

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1. If the engine stalls occasionally, start the engine and shake the MAF sensor harness. If the engine stalls, check for
poor contact at the MAF sensor connector.
2. If the MAF sensor output voltage is other than 0 when the ignition switch is turned on (do not start the engine).
Check for the faulty MAF sensor or ECM.
3. If the engine can be idle even if the MAF sensor output voltage is out of specification, check for the following
conditions;
A. Disturbed air flow in the MAF sensor, disconnected air duct, and clogged air cleaner filter.
B. Poor combustion in the cylinder, faulty ignition plug, ignition coil, injector, and incorrect comparison.
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4. Though no AFS malfunction occurs, check the mounting direction of AFS.
USING VOLTMETER
Check Item Check condition Test specification
Mass aif flow sensor Idle rpm 0.6 ~ 1.0V [2.7 V6]
output voltage 1.2 ~ 1.6V [2.4 DOHC]
• When the vehicle is new [within initial operation of about 500 km (300 MILes)], the mass air flow
sensor air quantity will be about 10% higher.
• Use an accurate digital voltmeter.
• Before checking, warm up the engine until the engine coolant temperature reaches 80 to 90°C (176 to
198°F)
HARNESS INSPECTION PROCEDURE [2.7 V6]
MASS AIR FLOW (MAF) SENSOR and INTAKE AIR TEMPERATURE (IAT) SENSOR [2.4 DOHC]
This hot film type air flow sensor is composed of a hot film sensor, housing, metering duct (hybrid, sensor element).
Mass air flow rate is measured by detection of heat transfer from a hot film probe because the change of the mass
air flow rate causes change in the amount of heat being transferred from the hot film probe surface to the air flow.
The air flow sensor generates a pulse so it repeatedly opens and closes between the 5V voltage supplied from the
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engine control module. This results in the change of the temperature of the hat film probe and in the change of
resistance.
INTAKE AIR TEMPERATURE SENSOR (IAT Sensor) [2.7 V6]

The intake air temperature sensor (IAT Sensor), located on the intake manifold, is a resistor-based sensor for
detecting the intake air temperature. According to the intake air temperature information from the sensor, the ECM
provides necessary fuel injection amount control.
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The MIL is ON or the DTC is displayed on the HI-SCAN under the following condition;
1. When the intake air temperature is detected as below -40°C or higher than 120°C.
2. Input from intake air temperature sensor is below 0.1V or above 4.8V when engine is in a full warm-up
condition.
USING VOLTMETER
Check Data Check Intake air 2.4 DOHC 2.7 V6
Item display conditions temperature
Intake air Air Ignition When 20°C (68°F) 2.5 ~ 2.7V 3.6 ~ 3.8V
temperature temperature switch :
sensor ON or When 40°C (104°F) 1.5 ~ 1.7V 2.7 ~ 3.0V
engine
When 80°C (176°F) 0.5 ~ 0.7V 1.2 ~ 1.5V
running

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SENSOR INSPECTION
1. Use the multimeter, measure the sensor resistance.
2. Measure the resistance between the IAT sensor terminal 1 and 2.
Temperature °C (°F) Resistance (KΩ)
IG ON 20 (68) 2.22-2.82
80 (176) 0.29-0.36
3. If the resistance deviates from the standard value, replace the intake air temperature sensor assembly.
THROTTLE POSITION (TP) SENSOR
The TP Sensor is a variable resistor type that rotates with the throttle body throttle shaft to sense the throttle valve
angle. As the throttle shaft rotates, the output voltage of the TP Sensor changes. The ECM detects the throttle valve
opening based on voltage change.
Circuit Diagram
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SENSOR CHECKING
Check Item Data display Check conditions Throttle valve Test specification
Throttle position sensor Sensor voltage Ignition switch : ON At idle position 300-900 mV (2.4 DOHC)
250-800 mV (2.7 V6)
Open slowly Increases with valve opening
Open widely 4.0 ~ 4.6V [2.4 DOHC]
4.0 ~ 4.4V [2.7 V6]
Using voltmeter
1. Disconnect the throttle position sensor connector.
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2. Measure resistance between terminal 3 (sensor ground) and terminal 2 (sensor power) for 2.4 DOHC, between
terminal 2 (sensor ground) and terminal 3 (sensor power) for 2.7 V6.
Standard value
2.4 DOHC : 3.5-6.5 KΩ
2.7 V6 : 1.6-2.4 KΩ
3. Connect a pointer type ohmmeter between terminal 3 (sensor ground) and terminal 1 (sensor output) for 2.4
DOHC and between terminal 2 (sensor ground) and terminal 1 (sensor output) for 2.7 V6.
4. Operate the throttle valve slowly from the idle position to the full open position and check that the resistance
changes smoothly in proportion with the throttle valve opening angle.
5. If the resistance is out of specification, or fails to change smoothly, replace the throttle position sensor.
Tightening torque
TP Sensor : 1.5-2.5 Nm (15-25 kg·cm, 1.1-1.8 lb·ft)
HARNESS INSPECTION
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The TPS signal is important in the control of the automatic transaxle. Shift shock and other trouble will occur if the
sensor is faulty.
IDLE SPEED CONTROL ACTUATOR
The idle speed control actuator is the double coil type and has two coils. The two coils are driven by separate driver
stages in the ECM. Depending on the pulse duty factor, the equilibrium of the magnetic forces of the two coils will
result in different angles of the motor. In parallel to the throttle valve, a bypass hose line is arrange, where the idle
speed, actuator is inserted in.
Circuit Diagram [2.4 DOHC/2.7 V6]
Page 52 of 146
The MIL is ON or the DTC is displayed on the HI-SCAN under the following conditions;
• When the primary voltage side in ECM is in short or open circuit.
• The ignition closed loop control in ECM is out of order.
• Open or short circuit is observed in idle air control system when ignition switch is turned on.
USING HI-SCAN
Check Item Check condition HI-SCAN Type
display
Idle speed control Start the engine ISCA Activate
actuator
• Actuator

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ACTUATOR INSPECTION
1. Disconnect the connector at the idle speed control actuator.
2. Measure the resistance between terminals.
Standard value
Terminal 3 and 2 : 15.0-16.0Ω
Terminal 1 and 2 : 17.0-18.2Ω [at 20°C (68°F)]
3. Connect the connector to the idle speed control actuator

HEATED OXYGEN SENSOR (HO2S)
The heated oxygen sensor senses the oxygen concentration in exhaust gas, converts it into a voltage, which is sent to
the ECM. The oxygen sensor outputs about 1V when the air fuel ratio is richer than the theoretical ratio, and outputs
about 0V when the ratio is leaner (higher oxygen concentration in exhaust gas). The ECM controls the fuel injection
ratio based on this signal so that the air fuel ratio is maintained at the theoretical ratio. The oxygen sensor has a
heater element which ensures the sensor performance during all driving conditions.
Page 54 of 146

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1. If the HO2S is defective, abnormally high emissions may occur.
2. If the HO2S check results were normal, but the sensor output voltage is out of specification, check for the
following items (related to air fuel ratio control system):
A. Faulty injector
B. Air leaks in the intake manifold
C. Faulty volume air flow sensor, intake air temperature sensor, barometric pressure sensor, engine coolant
temperature sensor.
USING GST
Check Test
Check conditions Engine state
Item specification
Oxygen Engine: Warm-up (make the mixture lean by engine When suddenly 200mV or lower
sensor speed reduction, and rich by racing) deceleration from
4,000 rpm
When engine is
600-1,000 mV
suddenly raced
Engine: Warm-up (using the heated oxygen sensor signal, Idle rpm 400 mV or lower -
check the air/fuel mixture ratio, and also check the (oscilate)
condition of control by the ECM) 600-1,000 mV
2,000 rpm
INSPECTION
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• Before checking, warm up the engine until the engine coolant temperature reaches 80 to 95°C (176 to 205°F).
• Use an accurate digital voltmeter.
1. Disconnect the oxygen sensor connector, and measure the resistance between terminal 3 and terminal 4.
Temperature °C (°F) Resistance (Ω)

20 (68) 3.0 ~ 6.2 Ω [2.4 DOHC]
4.0 ~ 5.2 Ω [2.7 V6]
2. Replace the oxygen sensor if there is malfunction.

3. Apply battery voltage directly between terminal 3 and terminal 4.
Take care when applying the voltage. Damage will result if the terminals are incorrect or are short
circuited.
4. Connect a digital-type volmeter between terminal 1 and terminal 2.
5. While repeatedly racing the engine, measure the oxygen sensor output voltage.
Engine Oxygen sensor output Resistance (Ω)
voltage
Race Min. 0.6V 30 or more
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6. If there is a problem, there may be an oxygen sensor malfunction.
Tightening torque
Heated oxygen sensor :
35 - 45 Nm (350 - 450 kg·m, 28.1 - 33.1 lb·ft)
HARNESS INSPECTION PROCEDURES
HARNESS INSPECTION PROCEDURES [2.7 V6]

Page 58 of 146
CAMSHAFT POSITION SENSOR

The CMP sensor senses the camshaft position sensor on compression stroke of the No.1 and No.4 cylinders,
converts it into a pulse signal, and inputs it to the ECM. The ECM then computes the fuel injection sequence, etc.
based on the input signal.
Circuit Diagram
Circuit Diagram
Page 59 of 146
HARNESS INSPECTION PROCEDURE [DOHC 2.4]

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If the CMP Sensor does not operate correctly, correct sequential injection is not made so that the engine may stall
or run irregularly at idle or fail to accelerate normally.
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If the camshaft position sensor does not operate correctly, correct sequential injection is not made so that the engine
may stall or run irregularly at idle or fail to accelerate normally.
CRANKSHAFT POSITION SENSOR
The crankshaft position sensor senses the crank angle (piston position) of each cylinder and converts it into a pulse
signal. Based on the input signal, the ECM computes the engine speed and controls the fuel injection timing and
ignition timing.
Circuit Diagram
Circuit Diagram
Page 62 of 146
1. If unexpected shocks are felt during driving or the engine stalls suddenly, shake the crankshaft position sensor
harness. If this causes the engine to stall, check for poor sensor connector contact.
2. If the tachometer reads 0 rpm when the engine is cranked, check for faulty crank angle sensor, broken timing belt
or ignition system problems.
3. If the engine can be run at idle even if the crank angle sensor reading is out of specification, check the following:
A. Faulty engine coolant temperature sensor
B. Faulty idle speed control motor
C. Poorly adjusted reference idle speed
USING GST
Page 63 of 146
Check Item Check conditions Check content Normal state
Crankshaft position sensor • Engine cranking Compare cranking speed Indicated speed agree
• Tachometer connected and multi-tester reading
(Check on and off
ignition coil by
tachometer)
Check Item Check conditions Coolant temperature Test specification

Crankshaft position sensor • Engine : Running at idle When -20°C (-4°F) 1,500-1,700 rpm
• Idle position switch : ON When 0°C (32°F) 1.350-1,550 rpm
When 20°C (68°F) 1,200-1,400 rpm
When 40°C (104°F) 1,000-1,200 rpm
When 80°C (176°F) 650-850 rpm
HARNESS INSPECTION PROCEDURE [2.4 DOHC]

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FUEL INJECTOR [2.4 DOHC]

The injectors injector fuel according to a signal coming from the ECM. The amount of fuel injected by the injectors is
determined by the time which the solenoid valve is energized.
Circuit Diagram
Page 65 of 146
HARNESS INSPECTION
Page 66 of 146
Troubleshooting Hints
1. If the engine is hard to start when hot, check for fuel pressure and injector leaks.
2. If the injector does not operate when the engine is cranked, then check the followings;
A. Faulty power supply circuit to the ECM, faulty ground circuit
B. Faulty control relay
C. Faulty crankshaft position (CKP) sensor, camshaft position (CMP) sensor
3. If there is any cylinder whose idle state remains unchanged when the fuel injection of injectors is cut one after
another during idling, check for the following items about such cylinder.
A. Injector and harness
B. Ignition plug and high tension cable
C. Compression pressure
4. If the injection system is ok but the injector drive time is out of specification, check for the following items.
A. Poor combustion in the cylinder (faulty ignition plug, ignition coil, compression pressure, etc.)
B. Loose EGR valve seating
FUEL INJECTOR [2.7 V6]
The injectors inject fuel according to a signal coming from the ECM.
The amount of fuel injected by the injectors is determined by the time during which the solenoid valve is energized.
Circuit Diagram
Page 67 of 146
INJECTOR CHECKING
Check item Data display Check conditions Check content Test specification
Injector drive time Engine : Cranking 0 °C (32 °F) approx. 17 ms
20 °C (68 °F) approx. 35 ms
80 °C (176 °F) approx. 8.5 ms
Check Data Engine Test

Check conditions
item display state specification
Injector drive time • Engine coolant temperature : 80 to 95 °C (176 to Idle rpm 2.2 ~ 2.9 ms
205 °F)
• Lamps, electric cooling fan, accessory modules :
2,000 rpm 1.8 ~ 2.6 ms
All OFF
• Transaxle : Neutral (P range for vehicle with A/T)
Rapid racing To increase
• Steering wheel : Neutral
1. The injector drive time is when the supply voltage is 11V and the cranking speed is less than 250 rpm.
2. When engine coolant temperature is lower than 0 °C (32 °F), the ECM fires all four cylinders simultaneously.
3. When the vehicle is new (within initial operation of about 500 km [300 MILes]), the injector drive time may be
about 10% longer.
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Item Drive
Check item Check condition Normal state
No. content
Injector No. 1 Engine : Idling after warm-up (Shut off the injectors Idle should become
• Actuator 01 injector shut in sequence during and after engine warm-up ; unstable as injector
test off check the idle condition) shuts off.
No. 2
02 injector shut
off
No. 3
03 injector shut
off
No. 4
04 injector shut
off
No. 5
05 injector shut
off
No. 6
06 injector shut
off
Using stethoscope and voltmeter

Operation Sound Check
1. Using a stethoscope, check the injectors for clicking sound at idle. Check that the sound is produced at shorter
intervals as the engine speed increases.
Ensure that the sound from an adjacent injector is not being transmitted along the delivery pipe to an
inoperative injector.
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2. If a stethoscope is not available, check the injector operation with uour finger. If no vibrations are felt, check the
wiring connector, injector or injection signal from ECM.
Resistance Measurement Between Terminals

1. Disconnect the connector at the injector.
2. Measure the resistance between terminals.
Standard value
13 ~ 16 Ω [at 20°C (68°F)]
3. Connect the connector to the injector.
HARNESS INSPECTION
EVAPORATIVE EMISSION CANISTER PURGE SOLENOID VALVE

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The evaporative emission canister purge solenoid valve is a duty control type, which controls purge air from the
evaporative emission canister
Circuit Diagram
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USING HI-SCAN
Check item Check conditions HI-SCAN display Type
Evaporative emission IG ON (Do not start) PCSV Activate
canister purge solenoid
valve
• Actuator test
HARNESS INSPECTION
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KNOCK SENSOR
The knock sensor is attached to the cylinder block and senses engine knocking conditions. A knocking vibration
from the cylinder block is applied as pressure to the piezoelectric element. This vibrational pressure is then
converted into a voltage signal which is delivered as output. If engine knocking occurs, ignition timing is retarded to
suppress it.
CIRCUIT DIAGRAM
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Page 74 of 146
1. The MIL is ON or the DTC is displayed on the HI-SCAN under the following condition;
A. When the knock sensor signal is not detected though the engine is in the over load condition.
2. When knock sensor signal is abnormally low.
HARNESS INSPECTION
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SENSOR INSPECTION
1. Disconnect the knock sensor connector.
2. Measure resistance between the terminal 1 and 2
Standard value : about 5MΩ [at 20°C (68°F)]
3. If the resistance is continual, replace the knock sensor.
Knock sensor : 16-28Nm (160-250 kg·cm, 11.8-18.4 lb·ft)
4. Measure the capcaitance between the terminal 1& 2.
Standard value : 800-1600 pF
CANISTER CLOSE VALVE

The canister close valve is an ON/OFF type which controls the inner pressure of fuel tank caused by fuel
evaporation. It is used to close the evaporative system and to observe tank pressure respectively with the fuel tank
pressure sensor.
Circuit Diagram
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HARNESS INSPECTION
VALVE INSPECTION
Refer to EC GROUP - Emission Control System
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POWER STEERING PRESSURE (PSP) SWITCH [2.4 DOHC]

The power steering oil pressure switch senses the power steering load into low/high voltage and inputs it to ECM,
which then controls the idle speed control motor based on this signal.
Circuit Diagram
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Check Item Data Check Steering wheel Normal

display conditions indication
Power steering oil Switch Engine : Idling Steering wheel neutral position (wheels OFF
pressure switch state straightahead direction)
Steering wheel half turn ON
HARNESS INSPECTION
EGR SOLENOID VALVE

The EGR solenoid valve is a duty control type solenoid valve, which controls EGR valve operating negative pressure
to the throttle body a port.
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TROUBLESHOOTING HINT
If the results of EGR solenoid valve on-vehicle and off-vehicle inspections are normal, but the diagnostic trouble
code for EGR system failure is displayed, check the EGR valve, vacuum hose and EGR passage for blocking.
Check Item Drive content Check conditions Standard value
EGR Solenoid Valve Change solenoid valve Ignition switch : ON Operating sound is heard
from OFF to ON state when driven

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FUEL TANK PRESSURE SENSOR

The fuel tank pressure sensor is a pressure sensitive variable resistor that measures the change of pressure in the fuel
tank to monitor for leaks. It is used in the EVAP leak test monitoring with the canister close and purge solenoid
valves.
Circuit Diagram
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SENSOR INSPECTION
Refer to EC GROUP - Emission Control System
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Fuel System > Engine Control System > Specifications

2.4L DOHC ENGINE ECM TERMINAL LAYOUT
WITHOUT TCM
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CONNECTOR[B-01]
TERMINAL SIGNAL CONNECTED TO
A1 Injector 1 Control Injector 1
A3 - -
A4 Idle Speed Control ISC
Opening Coil Control
A5 - -
A6 EGR Solenoid Valve EGR Solenoid Valve
Control
A7 - -
A8 Fuel Pump Relay Control Fuel Pump
A9 Evaporative Purge PSV
Solenoid Valve Control
A10 Ignition Coil 1 (1 & 4) Ignition Coil 1
Control
A11 - -
A12 Battery Voltage Battery
A13 Power Ground Ground
A16 - -
A17 Idle Speed Control ISC
Closing Coil Control
A18 - -
A19 - -
A20 Cooling Fan Relay High Fan Relay High
Control
A21 Cooling Fan Relay Low Fan Relay Low
Control
A22 A/C Relay Control A/C Relay
Control
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A24 - -
A25 Battery Voltage Battery
A26 Power Ground Ground
CONNECTOR[B-02]
B1 - -
B2 - -
B3 - -
B4 Throttle Position TPS
Signal Input
B5 - -
B6 MIL Control MIL
B7 Power Steering Switch Power Steering SW
Input
B8 Control Realy Control Control Relay
B9 - -
B10 - -
B11 - -
B12 A/C Pressure Switch A/C Pressure Switch
Signal Input
B13 - -
B14 - -
B15 A/C Pressure Switch A/C Pressure Switch
Signal Input
B16 - -
CONNECTOR[B-03]
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C1 - -
C2 Spark Timing Adjustment Spark Timing Adjustment
(+)
C3 - -
C4 Rear HO2S Heater Rear HO2S
Control
C5 Canister Close Valve CCV
Control
C6 - -
C7 - -
C8 IG Failure Sensor Signal IG Failure Sensor
Input
C9 - -
C10 Front HO2S Heater Front HO2S
Control
C11 Fuel Tank Pressue Sensor Tank Pressure Sensor
Signal Input
C12 Diagnosis K-Line Data Link Connector
CONNECTOR[B-04]
D1 "ST" Signal Input Ignition Switch
D2 Intake Air Temperature LATS
Sensor
D3 Map Sensor Signal Input Map Sensor
D4 Fuel Level Sensor Input Fuel Level Sensor
D5 Rear HO2S Ground Rear HO2S
D6 Front HO2S Ground Front HO2S
D7 Fuel Temperature Sensor Fuel Temperature Sensor
Signal Input
D8 Knock Sensor Signal Input Knock Sensor
D9 Flash EEPROM Battery RCT
D10 Battery Back Up Control Relay
D11 Sensor Reference Voltage Sensors
D12 IG + Ignition Switch
D13 Engine Coolant Temperature ECTS
Sensor Signal Input
D14 Throttle Position Sensor TPS
Signal Input
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D15 Mass Air Flow Sensor Signal MAFS
Input
D16 Vehicle Speed Sensor Signal Vehicle Speed Sensor
Input
D17 - -
D18 Campshaft Position Sensor CMPS
Signal Input
D19 Crankshaft Position Sensor CKPS
Signal Input
D20 - -
D21 - -
D22 Sensor Ground Ground
WITH TCM
CONNECTOR B-01
A3 Front HO2S Heater Front HO2S (Bank 1)
Control (Bank 1)
A4 - -
A5 - -
A6 Egr Solenoid Valve Egr Solenoid Valve
Control
A7 - -
A8 Alternator G Terminal Alternator
A10 - -
Control
Control
A13 - -
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A14 Idle Control Opening Coil ISC
Control
A15 - -
A16 - -
A17 Cooling Fan Relay High Fan Relay High
Control
A18 Cooling Fan Relay Low Fan Relay Low
Control
A19 - -
A20 Fuel Pump Relay Control Fuel Pump
A21 A/C Relay Control A/C Relay
A22 MIL Control MIL
A23 Spark Timing Adjustment RCT
(+)
A25 - -
A26 Rear HO2S Heater Rear HO2S (Bank 1)
Control (Bank 1)
A27 - -
A28 Idle Control Closing Coil ISC
Ground
A29 - -
A30 Throttle Position Signal
Output
A31 - -
A32 - -
A33 - -
A34 Evaporative Purge PSV
Solenoid Valve Control
A35 Canister Purge Control CCV
Valve Control
CONNECTOR B-02
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B1 Battery + Battery
B2 Ground -
B3 IG + Ignition Switch
B4 Engine Coolant Temperature ECTS
Sensor Signal Input
B5 Crankshaft Position Sensor CKPS
Signal Input
B6 Sensor Reference Voltage FTPS
B7 Battery + Battery
B8 Ground Ground
B9 Control Relay Control Control Relay
B10 AT Control Relay Control AT Control Relay
B11 Fuel Temperature Sensor Fuel Temperature Sensor
Signal Input
B12 Power Steering Load Input Power Steering SW
B13 - -
B14 Alternator "FR" Terminal Alternator
B15 Mass Air Flow Sensor Signal MAFS
Inpiut
B16 Camshaft Position Sensor CMPS
Signal Input
B17 Sensor Ground Sensors
B18 Starter "S" Signal Input Starter
B19 - -
B20 Fuel Level Sensor Signal Fuel Level Sensor
Input
B21 - -
B22 A/C Pressure Switch Signal A/C Pressure Switch
Input
B23 - -
B24 Intake Air Temperature IATS
Sensor Signal Input
B25 - -
B26 Battery Back Up -
CONNECTOR B-03
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C1 Front HO2S Signal Front HO2S
Input
C2 - -
C3 Rear HO2S Signal Input Rear HO2S
C4 - -
C5 Auto Cruise Control Auto Cruise Unit
Switch
C6 Ground Ground
C7 AT Control Relay AT Control Relay
Control
C8 Throttle Position Sensor TPS
Signal Input
C9
C10 Vehicle Speed Sensor Vehicle Speed Sensor
Signal Input
C11 - -
C12 - -
C13 A/C Pressure Switch A/C Pressure Switch
Signal Input
C14 - -
C15 Diagnosis Data Link K- Data Link Connector
Line
C16 - -
C17 - -
C18 Power Ground Ground
C19 AT Solenoid Power AT Solenoid
C20 Knock Sensor Signal Knock Sensor
Input
C21 MAP Sensor Signal MAP Sensor
Input
C22 Fuel Tank Pressue Tank Pressure Sensor
Sensor Signal Input
C23 - -
C24 - -
C25 - -
C26 - -
C27 Power Ground Ground
C28 IG + Ignition Switch
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CONNECTOR B-04
D1 Inhibitior Switch "P" Inhibitior Switch
Signal Input
D2 Inhibitior Switch "D" Inhibitior Switch
Signal Input
D3 Pulse Generator "A" Pulse Generator "A"
Signal Input
D4 Pulse Generator "B" Pulse Generator "B"
Signal Input
D5 AT 2nd Lamp Control Instrument Cluster
D6 AT 2nd Solenoid 2nd Solenoid
Control
D7 DCC Solenoid Control DCC Solenoid
D8 Inhibitior Switch "R" Inhibitior Switch
Signal Input
D9 Sports Mode Select Sport Mode Select SW
Switch Input
D10 Sports Mode Down Sport Mode Down SW
Switch Input
D11 - -
D12 - -
D13 Flash EEPROM Battery ROM Change Tool
D14 - -
D15 - -
D16 - -
D17 3rd Lamp Control Instrument Cluster
D18 2nd Lamp Control Instrument Cluster
D19 - -
D20 Up Solenoid Control Up Solenoid
D21 Inhibitor Switch "N" Inhibitior Switch
Signal Input
D22 Sports Mode Up Switch Sports Mode Up SW
Signal Input
D23 Stop Lamp Switch Stop Lamp Switch
Signal Input
D24 Oil Temperature Sensor Oil Temperature Sensor
Signal Input
D25 - -
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D26 - -
D27 - -
D28 4th Lamp Control Instrument Cluster
D29 LR Solenoid Control LR Solenoid
D30 O/D Solenoid Control O/D Solenoid
Fuel System > Fuel Delivery System > Fuel Tank > Components and Components Location
COMPONENTS
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Fuel System > Fuel Delivery System > Fuel Tank > Repair procedures
REMOVAL
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1. To reduce the internal pressure of the fuel main pipes and hose, first start the engine and then disconnect the
electrical fuel pump connector in the rear seat side.
Be sure to reduce the fuel pressure before disconnecting the fuel main pipe and hose, otherwise fuel will
spill out, leading to the risk of fire or explosion.
2. Disconnect the battery cable from the negative terminal of the battery.
3. Remove the fuel tank cap.

4. Disconnect the return hose and vapor hose.
5. Disconnect the fuel sender connector.

6. Disconnect the high pressure hose from the fuel tank.
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7. Loosen the two self-locking nuts, that hold tank in the position and remove the two tank bands.
8. Detach the fuel filler hose and leveling hose.

9. Remove the fuel vapor hose and the fuel tank.
INSTALLATION
1. Connect the leveling hose to the tank and approximately 40 mm (1.6 in.) at the filler neck.
2. When connecting the filler hose, connect the end with the shorter straight pipe to the tank side.
3. Confirm that the pad is fully bonded to the fuel tank. Install the fuel tank by tightening the self-locking nuts to the
tank bands until the rear end of the tank band contacts the body.
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4. Connect the vapor hose and return hose. Attach the fuel hose to the line as shown in the illustration.
5. To connect the high pressure hose to the fuel pump, temporarily tighten the flare nut by hand, and then tighten it to
the specified torque. Be careful that the fuel hose does not twist.
Tightening torque :
High pressure hose flare nut :
30~40 Nm (300~400 kg·cm, 22~29 lb·ft)
When tightening the flare nut, be careful not to bend or twist the line to prevent damage to the fuel pump
connection.
6. Connect the electrical fuel pump and fuel sender connector.
INSPECTION
1. Check the hoses and the pipes for cracks or damage.
2. Check the fuel tank cap for proper operation.
3. Check the fuel tank for deformation, corrosion or cracking.
4. Check the fuel tank inside for dirt or foreign material.
5. Check the in-tank fuel filter for damage or restriction.
6. Test the two-way valve for proper operation.
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7. Using a vacuum hand pump, check the operation of the two-way valve.
Valve pump Guide lines for acceptance or rejection
Negative pressure generated and vacuum
When connected to inlet side
maintained
When connected to outlet side No negative pressure generated
Fuel System > Fuel Delivery System > Injector > Repair procedures
INSPECTION
1. Measure the resistance of the injectors between the terminals using an ohmmeter.
Resistance : 13.8 ~ 15.2 Ω [at 20°C (68°F)]
2. If the resistance is not within specifications, replace the injector.
Fuel System > Fuel Delivery System > Accelerator Pedal and Cable > Components and Components
Location
COMPONENTS
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COMPONENTS
Page 98 of 146
Fuel System > Fuel Delivery System > Accelerator Pedal and Cable > Repair procedures
REMOVAL
1. Remove the bushing and inner cable of the accelerator arm side.
2. Pull the left side of the accelerator pedal toward you, and then remove the accelerator pedal from the accelerator
arm.
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3. Loosen the bolts of the accelerator arm bracket and remove.
INSTALLATION
1. When installing the return spring and accelerator arm, apply multi-purpose grease around each moving point of
the accelerator arm.
2. Apply sealant to the bolt mounting hole, and tighten the accelerator arm bracket.
Tightening torque :
Accelerator arm bracket bolts :
8~12 Nm (80~120 kg·cm, 6~7 lb·ft)
3. Securely install the resin bushing of the accelerator cable on the end of the accelerator arm.
INSPECTION
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1. Check the inner and outer cable for damage.
2. Check the cable for smooth movement.
3. Check the accelerator arm for deformation.
4. Check the return spring for deterioration.
5. Check the connection of the bushing to end metal fitting.
6. Check the accelerator proper operation.
It is essential that there is no binding or any interference with the operation of the throttle parts. A jammed
or stuck throttle can cause accidents, severe injury or death.
Fuel System > Fuel Delivery System > Fuel Line > Components and Components Location
COMPONENTS
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COMPONENTS
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COMPONENTS
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Fuel System > Fuel Delivery System > Fuel Line > Repair procedures
REMOVAL
1. Release residual pressure from the fuel line to prevent fuel spilling.
Cover the hose connection with rags to prevent splashing of fuel that could be caused by residual pressure
in the fuel line.
2. Remove the delivery pipe with the fuel injector and pressure regulator.
INSTALLATION
1. Install a new grommet and O-ring to the injector.
2. Apply a coating of solvent, spindle oil or gasoline to the injector O-ring.
3. While turning the injector to the left and right, install it on to the delivery pipe.
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4. Be sure the injector turns smoothly.
If injector does not turn smoothly, the O-ring may be jammed. Remove the injector and re-insert it into the
delivery pipe and re-check.
INSPECTION
1. Check the hoses and pipes for cracking, bending, deformation or restrictions.
2. Check the EVAP Canister for restrictions.
3. Check the fuel filter for restrictions and damage.
Fuel System > Fuel Delivery System > Description and Operation
Fuel Delivery System [2.4 DOHC]
THROTTLE POSITION SENSOR (TPS) ADJUSTMENT [2.4 DOHC]
1. Connect a HI-SCAN to the data link connector.
2. If a HI-SCAN is not used, connect a digital type voltmeter between connector 1 and 3.
3. Turn the ignition switch to the ON position (do not start engine) and check that the TP Sensor output voltage is
as specified. If a HI-SCAN is used, read the voltage.
Standard value : 300-900 mV

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4. If it is out of specification, loosen TP Sensor mounting screws and adjust by turning the TP Sensor.
• Turning the TP Sensor clockwise increases the output voltage.

• Tighten the screws securely after adjustment.

FUEL SENDER REPLACEMENT [2.4 DOHC]
1. Remove the fuel tank cap to lower the fuel tank's internal pressure.
2. Open the trunk door and disconnect the fuel pump connector, remove the fuel feed and return line from the fuel
pump assembly.
3. Remove the fuel pump installation screws, then remove the fuel pump assembly from the fuel tank.
4. Remove the fuel sender from the fuel pump assembly.
5. Inspect and replace, if necessary.
FUEL PUMP OPERATION CHECK [2.4 DOHC]
2. Apply battery voltage to the fuel pump drive connector to check that the pump operates.
The fuel pump is in-tank type and its operating sound is hard to hear without removing the fuel tank
cap.
3. Pinch the hose to check that fuel pressure is felt.
EVAP Canister Purge Port Vacuum Check [2.4 DOHC]

Page 106 of 146
Checking Condition
Engine coolant temperature : 80-95°C (176-205°F)
1. Disconnect the vacuum hose from the throttle body EVAP Canister purge hose fitting and connect a vacuum
pump.
2. Start the engine and check to see that, after increasing the engine speed, vacuum raises fairly constant.
If there is no vacuum created, it is possible that the throttle body port may be restricted and reguired
cleaning.
FUEL PRESSURE TEST [2.4 DOHC]

1. Reduce the internal pressure of the fuel pipes and hoses by the following procedures.
A. Open the trunk door and disconnect the fuel pump harness connector in the trunk room.
B. Start the engine and after it stalls, turn the ignition switch to the OFF position.
C. Disconnect the battery negative (-) terminal.
D. Connect the fuel pump harness connector.
2. Remove the bolt connecting the fuel line to the fuel delivery pipe.
Cover the hose connection with a shop towel to prevent splashing of fuel caused by fuel residual pressure
in the fuel line.
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3. Using the fuel pressure gauge adapter, install the fuel-pressure gauge to the fuel pressure gauge adaptor. Tighten
the bolt to the specified torque.
Fuel pressure gauge to fuel delivery pipe : 25-35 Nm (250-350 kg·cm, 18-26 lb·ft)
4. Connect the battery's negative (-) terminal.

5. Apply battery voltage to the terminal for the pump drive and activate the fuel pump: then, with fuel pressure
applied, check that there is no fuel leakage from the pressure gauge or connection part.
6. Start and run the engine at curb idle speed.
7. Disconnect the vacuum hose from the pressure regulator, and plug the hose end. Measure the fuel pressure at
idle.
Standard value : 320-340 kPa (3.26-3.47 kg/cm², 46-49 psi)
8. Measure the fuel pressure when the vacuum hose is connected to the pressure regulator.
Standard value : Approx. 255 kPa (2.57 kg/cm², 37 psi)

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9. If the results of the measurements made in steps (7) and (8) are not within the standard value, use the table below
to determine the probable cause, and make the necessary repairs.
Condition Probable cause Remedy
Fuel pressure is too low • Clogged fuel filter • Replace fuel filter
• Fuel leakage to the return side, • Replace fuel pressure
caused by poor seating of the fuel regulator
pressure regulator
• Low discharge pressure of the fuel • Check the in-tank fuel
pump hose or replace the fuel
pump
Fuel pressure is toot high • Sticking fuel-pressure regulator • Replace fuel pressure
• Clogged or bent fuel return hose or regulator
pipe • Repair or replace hose
or pipe
There is no difference in fuel pressure • Clogging, or damaged vacuum hose • Repair or replace the
when the vacuum hose is connected and or the nipple vacuum hose or the
when it is not. • Sticking or poor seating of the fuel nipple
pressure regulator • Repair or replace hose
or pipe
10. Stop the engine and check for a change in the fuel pressure gauge reading, which should hold for approximately
5 minutes.
If the gauge indication drops, observe the rate of drop. Determine and remove the causes according to the
following table.
Condition Probable cause Remedy
Fuel pressure drops slowly after engine is • Injector leakage • Replace injector
stopped
Fuel pressure drops immediately after engine is • The check valve within the fuel pump • Replace fuel
stopped is open pump
11. Reduce the pressure in the fuel line.

12. Disconnect the hose and the gauge.
Cover the hose connection with a shop towel to prevent splashing of fuel caused by fuel residual pressure
in the fuel line.
13. Replace the O-ring of the end of the hose.
14. Connect the fuel hose to the delivery pipe and tighten with the specified.
15. Check for fuel leakage.
FUEL FILTER REPLACEMENT [2.4 DOHC]
1. Reduce the internal pressure of the fuel lines and hoses and perform the following operations.
A. Disconnect the fuel pump harness connector in the trunk room.
B. Start the engine and, after it stops, turn the ignition switch to OFF.
C. Disconnect the battery negative (-) terminal.
D. Connect the fuel pump harness connector.
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2. Remove the two fitting nuts while holding the fuel filter nuts securely.
3. Remove the fuel filter mounting bolts, and then remove the fuel filter from the fuel filter clamp.
Tightening torque
Fuel filter fitting nut : 25-35 Nm (250-350 kg·cm, 18-25 lb·ft)
Fuel System > Troubleshooting > P0101

MAF SENSOR CIRCUIT (FOR 2.4 DOHC)
Diagnostic trouble code Mass or volume air flow circuit range/performance
No. P0101 problem
[Related items] • Dirty air cleaner
• Air leak in intake system
• Contaminated, deteriorated or damaged MAFS
• Poor connections at ECM, MAFS, or TPS
• Faulty MAFS or TPS
If any codes relating to MAFS or TPS are present,

do all repairs associated with them before this
Step Inspection Action

Turn ignition to ON and monitor other DTCs.
Is DTC P0102, P0103, P0121, P0122, or P0123 set? No Go to step 2.
2 Yes Problem is intermittent or was repaired and
Using SCAN TOOL monitor MAFS voltage signals.
engine control module memory was not
• 1.4 ~ 1.6V @ idle cleared. Check terminal connections at
• 4.0 ~ 2.2V @ 3000rpm ECM and MAFS.
No Go to step 3.
3 Thoroughly check MAFS for loose, poor connection, Yes Go to step 4.
bent, corrosion, contamination, deterioration, or
damage. No Clean or repair as necessary.
Is MAFS lkay?
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4 Start engine and allow engine to idle until engine reaches Yes Go to step 5.
operating temperature.
Using SCAN TOOL, monitor TP voltage signals.
• 0.3~0.9V @ idle No Do all repairs associated with TPS before
• 4.0~4.6V @ full open proceeding the next step.
5 Turn ignition switch to OFF and disconnect MAFS Yes Go to step 6.
connector.
Turn ignition switch to ON and measure voltage of
MAFS power circuit between MAFS harness No Open circuit or short circuit to chassis
connector and chassis ground. ground between MAFS harness connector
• Specification : approximately 5V and ECM connector.Repair as necessary.
Measure resistance of MAFS signal circuit between
MAFS harness connector and ECM harness connector.
Measure resistance of MAFS ground circuit between No Open circuit between MAFS harness
MAFS harness connector and ECM harness connector. connector and ECM harness connector.
• Specification : below 1Ω Repair as necessary.
7 ECM connector and MAFS connector is still Yes Go to step 8.
disconnected. Turn ignition to ON.
Measure voltage of MAFS signal circuit between No Short circuit to battery between MAFS
MAFS harness connector and ECM chassis ground. harness connector and ECM harness
• Specification below 0.5V connector.
Does voltage within specification? Repair as necessary.
8 ECM connector and MAFS connector is still Yes Tepmorarily install a known good MAFS
disconnected. and check for proper operation.
Turn ignition to OFF. If problem is corrected, replace MAFS
Measure resistance between MAFS harness connector No Short circuit to chassis ground between
and chassis ground at MAFS signal circuit. MAFS harness connector and ECM
• Specification : infinite harness connector.
9 Check air cleaner for dirt, blockage, or damage. Yes Go to step 11
Is air cleaner okay? No Repair or replace as necessary.
10 Check entire air intake system for leaks or blockages Yes Temporarily install a known good MAFS
such as; and check for proper operation.
• Throttle body If problem is corrected, replace MAFS
• PCV valve
• Intake manifold
• Seal between surge tank and PCV pipe
• Etc
Is entire air intake system okay?
Page 111 of 146

MAF SENSOR CIRCUIT (FOR 2.4 DOHC)
Mass or volume air flow circuit low input
No. P0102
Mass or volume air flow circuit high input
No. P0103
[Related items] • Open between MAFS and engine main relay
• Open or short to chassis ground between MAFS and ECM
• Short to battery between MAFS and ECM
• Faulty MAFS

1 Connect SCAN TOOL to data link connector or OBD- Yes Problem is intermittent or was repaired and
II check connector. engine control module memory was not
Turn ignition to ON and monitor MAFS voltage signals. cleared. Check terminal connections at
• Soecification : 1.4~1.6V @ idle ECM and MAFS.
Is signal within specification? No Go to step 2.
2 Turn ignition switch to OFF and disconnect MAFS Yes Go to step 3.
connector.
Turn ignition switch to ON. No Open circuit or short circuit to chassis
Measure voltage of MAFS reference 5V circuit ground between MAFS harness connector
between MAFS harness connector and chassis ground. and ECM connector.
• Specification : approximately 5V Repair as necessary.
Measure resistance of MAFS signal circuit between
MAFS harness connector and ECM harness connector.
Measure resistance of MAFS ground circuit between No Short circuit to battery between MAFS
MAFS ground circuit between MAFS harness harness connector and ECM harness
connector and ECM harness connector. connector.
4 ECM connector and MAFS connector is still Yes Go to step 5.
disconnected.
Turn ignition to ON. No Short circuit to battery between MAFS
Measure voltage at MAFS signal circuit between harness connector and ECM harness
MAFS harness connector and chassis ground. connector.
• Specification : below 0.5V Repair as necessary.
Does voltage within specification?
5 ECM connector and MAFS connector is still Yes Temporarily install a known good MAFS
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Turn ignition to OFF. If problem is corrected, replace MAFS
Measure resistance between MAFS harness connector No Short circuit to chassis ground between
and chassis ground at MAFS signal circuit.
MAFS harness connector and ECM harness
Measure resistance between MAFS signal circuit
connector.
• Specification : infinite Short circuit between MAFS signal circuit
Does each resistance indicate open circuit? and ground circuit.

Manifold absolute pressure sensor (FOR 2.4 DOHC)
Diagnostic trouble code Manifold absolute pressure sensor (EGR system circuit
No. P0106 malfunction)
[Related items] • Open or short to chassis ground between MAPS and ECM
• Open between MAPS and ECM
• Open between MAPS and chassis ground
• Faulty MAPS

1 Connect SCAN TOOL to data link connector Yes Problem is intermittent or was repaired and engine
or OBD-II check connector. control module memory was not cleared. Check
Turn ignition to ON and monitor MAPS voltage terminal connections at ECM and MAPS.
signals.
• Specification: 0.8~2.4V No Go to step 2.
Is signal within specification?
2 Turn ignition switch to OFF and disconnect Yes Go to step 3.
MAPS connector.
Turn ignition switch to ON.
Measure voltage of MAPS reference 5V circuit No Open circuit or short circuit to chassis ground
between MAPS harness connector and chassis between MAPS harness connector and ECM
ground. connector.
• Specification: approximately 5V Repair as necessary.
3 Turn ignition to OFF and disconnect ECM Yes Go to step 4.
connector.
Measure resistance of MAPS signal circuit
between MAPS harness connector and ECM
harness connector. No Open circuit between MAPS harness connector and
Measure resistance of MAPS ground circuit ECM harness connector.
between MAPS harness connector and ECM Repair as necessary.
harness connector.
• Specification: below 1Ω
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4 ECM connector and MAPS connector is still Yes Go to step 5.
disconnected.
Turn ignition to ON.
Measure voltage at MAPS signal circuit No Short circuit to battery between MAPS harness
between MAPS harness connector and chassis connector and ECM harness connector.
ground. Repair as necessary.
• Specification: below 0.5V
5 ECM connector and MAPS connector is still Yes Temporarily install a known good MAPS and check
disconnected. for proper operation.
Turn ignition to OFF. If problem is corrected, replace MAPS
Measure resistance between MAPS harness
connector and chassis ground at MAPS signal No Short circuit to chassis ground between MAPS
circuit. harness connector and ECM harness connector.
Measure resistance between MAPS signal Short circuit between MAPS signal circuit and
circuit and MAPS ground circuit. ground circuit.
• Specification: infinite Repair as necessary.
Does each resistance indicate open circuit?

Manifold absolute pressure sensor (FOR 2.4 DOHC)
Diagnostic trouble
code Manifold absolute pressure sensor (EGR mode 3)
No. P0107
Diagnostic trouble
code Manifold absolute pressure sensor (EGR mode 2)
No. P0108
[Related items] • Poor connections between MAPS and ECM
• Foreign materials fouled MAPS
• Faulty MAPS
Page 114 of 146
1 Check MAPS for contamination, deterioration or Yes Clean MAPS and check for MAPS and housing
damage. for source of leak and repair as necessary. If
Is MAPS contaminated, deteriorated or damaged? damaged or deteriorated, replace.
No Go to step 2.
connectors at ECM and MAPS.
With ignition off, disconnect ECM and MAPS
connectors.
Measure resistance between MAPS and ECM on No Open circuit between MAPS harness connector
three circuits. and ECM harness connector.
• Specifications: below 1Ω Short circuit to chassis ground between harness
Measure voltage between MAPS reference power connector and ECM harness connector.
terminal and chassis ground. Repair as necessary
• Specifications: approximately 5V
Is the resistance or voltage within the specifications?
3 Start an engine and allow an engine to warm up to Yes Go to step 4.
operating temperature. With engine idling, measure
voltage at MAPS signal output terminal.
Open throttle suddenly and verify that voltage
increases: No If wiring and connections are all okay,
• 0.8~2.4V @ idle temporarily install a known good MAPS and
• Raise from 0.8~2.4V @ open throttle check for proper operation. If problem is
suddenly corrected, replace MAPS.
Is idle voltage within specifications and do voltage
readings increase?
4 Remove EGR control valve and check for Yes Thoroughly check for loose, bent or corroded
excessive carbon deposits and sticking per terminals at all connectors in circuit.
following check:
Draw a vacuum at nipple and verify EGR control
valve holds vacuum.
Blow air into hose removed from exhaust manifold
and verify air escapes.
Remove a vacuum at nipple and below an air into
hose and verify air does not escape from port.
Repeat this procedure 4 or 5 times to ensure EGR No Temporarily install a known good EGR control
control valve reliability. valve and check for proper operation. If problem
Is EGR control valve moving freely and is not is corrected replace EGR control valve.
carbon fouled?
While EGR control valve is removed, inspect

removed hose for obstructions. Repair or
replace as necessary.
Page 115 of 146

IAT SENSOR CIRCUIT (FOR 2.4 DOHC)
Intake air temperature circuit low input
No. P0112
Intake air temperature circuit high input
No. P0113
[Related items] • Open or short to chassis ground between IATS and main
relay
• Open or short to chassis ground between IATS and ECM
• Short to battery between IATS and ECM
• Short between IATS wires
• Faulty IATS

1 Connect SCAN TOOL to data link connector or OBD- Yes Do all repairs associated with those codes
II check connector. before proceeding this procedure.
Is DTC P0102 or P0103 set? No Go to step 2.
2 Start engine and allow engine to idle until engine reaches Yes Problem is intermittent or was repaired and
operating temperature. engine control module memory was not
Using SCAN TOOL and monitor IAT voltage signals. cleared. Check terminal connections at
• 2.3~2.9V (2.22~2.82 kΩ) @ 20°C (68°F) ECM and MAFS.
• 0.4~1.0V (0.29~0.36 kΩ) @ 80°C (176°F)
Is signal within specifications? No Go to step 3.
3 Turn ignition to OFF and disconnect IATS connector. Yes Go to step 4.

Turn ignition to ON, measure voltage of IATS battery
power circuit between IATS harness connector and No Open circuit or short circuit to chassis
chassis ground. ground between IATS harness connector
• Specification : approximately B+ and ECM main relay.
4 Turn ignition switch to OFF and disconnect IATS Yes Go to step 5.

connector and ECM connector.
Measure resistance of IAT signal circuit between IATS
harness connector and ECM harness connector. No Open circuit between IATS harness
Measure resistance of IAT ground circuit between connector and ECM harness connector.
IATS harness connector and ECM harness connector. Repair as necessary.
• Specifications : below 0.5V
5 ECM connector and IATS connector is still Yes Go to step 6.
disconnected.
Turn ignition to ON. No Short circuit to battery between IATS
Measure voltage at IATS signal circuit between IATS harness connector and ECM harness
harness connector and chassis ground. connector.
• Specification : below 0.5V
Page 116 of 146
• Specification : below 0.5V Repair as necessary.
6 Ignition OFF, IATS connector and ECM connector is Yes Go to step 7.
still disconnected.
Measure resistance between IATS signal circuit and No Short circuit between IATS signal circuit and
IATS ground circuit. ground circuit.
Measure resistance between IATS harness connector Short circuit to chassis ground between
and chassis ground at IATS signal circuit. IATS harness connector and ECM harness
• Specification : infinite connector.

ECT Sensor Circuit (FOR 2.4 DOHC)
Engine coolant temperature circuit range/performance problem
No. P0116
Insufficient coolant temperature for closed loop fuel control
No. P0125
[Related items] • 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)
• Foreign materials fouled, contaminated, deteriorated ECTS
• Faulty ECTS
If any codes relating to ECTS are present, do all repairs associated with
them before this troubleshooting procedure.
Page 117 of 146
1 Connect SCAN TOOL to data link Yes Do all repairs associated with those codes before
connector or OBD-II check connector proceeding this procedure.
Is DTC P0117 or P0118 set? No Go to step 2.
2 Start engine and allow engine to idle until Yes Problem is intermittent or was repaired and engine
engine reaches operating temperature. control module memory was not cleared. Check
Using SCAN TOOL and monitor ECT terminal connections at ECM and ECTS.
voltage signals.
• 2.3~2.9V (2.31~2.59 kΩ) @ 20°C
(68°F)
• 0.4~1.0V (0.31~0.33 kΩ) @ 80°C No Go to step 3.
(176°F)
3 Check ECTS for contamination, deterioration Yes Clean ECTS with cleaner before installing. If ECTS is
or damage. damaged or deteriorated, replace.
Is ECTS contaminated, deteriorated or

connectors at ECM connector and ECTS
connector.
With ignition OFF, disconnect ECM
connector and ECTS connector. No Open circuit between ECTS harness connector and
Measure resistance of all two circuits between ECM harness connector.
ECTS harness connector and chassis ground Repair as necessary.
Does each indicate continuity circuit?

ECT SENSOR CIRCUIT
Diagnostic trouble
code Engine coolant temperature circuit low input
No. P0117
[Related items] • Open or short to battery between ECTS signal and ECM
• Open between ECTS ground ECM
• Faulty ECTS
Page 118 of 146
1 Start engine and allow engine to idle until engine Yes Problem is intermittent or was repaired and
reaches operating temperature. engine control module memory was not
Using SCAN TOOL and monitor ECT voltage cleared.
signals. Check terminal connections at ECM and
• 2.3 ~ 2.9V (2.31 ~ 2.59 kΩ) @ 20 °C (68 °F) ECTS.
• 0.4~ 1.0V (0.31 ~ 0.33 kΩ) @ 20 °C (68 °F)
No Go to step 2.
2 Turn ignition to OFF and disconnect ECTS connector. Yes Go to step 3
Turn ignition to ON and measure voltage of ECTS
signal circuit between ECTS harness connector and No Open circuit or short circuit to chassis ground
chassis ground. between ECTS harness connector and ECM
• Specification : Approximately 5V harness connector.
3 Turn ignition to OFF and disconnect ECM connector. Yes Go to step 4

Measure resistance of ECTS ground circuit between
ECTS harness connector and ECM harness No Open ciruit between ECTS harness connector
connector. and ECM harness connector.
4 Turn ignition to ON. Yes Temporarily install a known good ECTS and
Measure voltage of ECTS signal circuit between check for proper operation.
ECTS harness connector and chassis ground. If problem is corrected, replace ECTS.
• Specification: below 5V No Short circuit to battery between ECTS harness
Is voltage within specifications? connector and ECM harness connector.

ECT SENSOR CIRCUIT
Diagnostic trouble
code Engine coolant termperature circuit high input
No. P0118
[Related items] • Short to ground between ECTS signal and ECM
• Faulty ECTS
Page 119 of 146
1 Start engine and allow engine to idle until engine Yes Problem is intermittent or was repaired and
reaches operating temperature. engine control module memory was not cleared.
Using SCAN TOOL and monitor ECT voltage Check terminal connections at ECM and
signals. ECTS.
• 2.3 ~ 2.9V (2.31 ~ 2.59 kΩ) @ 20 °C (68 °F)
• 0.4~ 1.0V (0.31 ~ 0.33 kΩ) @ 20 °C (68 °F) No Go to step 2.
2 Ignition OFF, ECTS connector and ECM connector Yes Temporarily install a known good ECTS and
is still disconnected. check for proper operation.
Measure resistance between ECTS signal circuit and If problem is corrected, replace ECTS
ECTS ground circuit.
No Short circuit between ECTS signal circuit and
Measure resistance between ECTS harness
ground circuit.
connector and chassis ground at ECTS signal circuit.
Short circuit between ECTS signal circuit and
• Specification : infinite ground circuit.

TPS Sensor Circuit (FOR 2.4 DOHC)
Diagnostic trouble code Throttle position sensor circuit range/performance
No. P0121 problem
[Related items] • Open or short to chassis ground between TPS and ECM
• Short to battery between TPS and ECM
• Misplaced, loose or corrodes terminals
• Contaminated, deteriorated TPS
• Faulty TPS
Page 120 of 146
OBD-II check connector. proceeding this procedure.
Is DTC P0122, or P0123 set? No Go to step 2.
Using SCAN TOOL, monitor TP voltage signals. terminal connections at ECM and ECTS.
• 0.3~0.9V @ idle
• 4.0~4.6V @ full open No Go to step 3.
3 Ignition ON and engine OFF. Yes Problem is intermittent or was repaired and engine
Using SCAN TOOL and monitor TP voltage control module memory was not cleared. Check
signals while slowly opening the throttle. terminal connections at ECM and TPS.
Does voltage signal increase?
No Temporarily install a known good TPS and check
for proper operation. If problem is corrected,
replace TPS.
4 Turn ignition to OFF and disconnect TPS Yes Go to step 5.
connector.
Turn ignition to ON and measure voltage TPS No Open circuit or short circuit to chassis ground
reference voltage between TPS harness between TPS harness connector and ECM
connector and chassis ground. connector.
Is voltage within specifications?
5 Thoroughly check TPS for loose, poor Yes Temporarily install a known good TPS and check
connection, bent, corrosion, contamination, for proper operation.
deterioration, or damage. If problem is corrected, replace TPS
Is TPS okay?
No Clean TPS with cleaner before installing. If
damaged or deteriorated, temporarily install a
known good TPS and check for proper operation.
If problem is corrected, replace TPS.

TPS Sensor Circuit (FOR 2.4 DOHC)
Page 121 of 146
Diagnostic trouble
code Throttle position sensor circuit low input
No. P0122
Diagnostic trouble
code Throttle position sensor circuit high input
No. P0123
[Related items] • Open or short to chassis ground between TPS and ECM
• Short to battery between TPS and ECM
• Short between TPS wires
• Faulty TPS

Using SCAN TOOL, monitor TP voltage signals. terminal connections at ECM and ECTS.
• 0.3~0.9V @ idle
• 4.0~4.6V @ full open
No Go to step 2.
2 Turn ignition to OFF and disconnect TPS Yes Go to step 3.
connector.
Turn ignition to ON and measure voltage TPS No Open circuit or short circuit to chassis ground
reference voltage between TPS harness between TPS harness connector and ECM
connector and chassis ground. connector.
connector.
Measure resistance of TPS ground circuit
between TPS harness connector and ECM
harness connector. No Open circuit between TPS harness connector and
Measure resistance of TPS signal circuit between ECM harness connector.
TPS harness connector and ECM harness Repair as necessary.
connector.
Measure voltage of TPS signal circuit between
TPS harness connector and chassis ground. No Short circuit to battery between TPS harness
• Specification: below 0.5V connector and ECM harness connector.
5 Ignition OFF, TPS connector and ECM Yes Temporarily install a known good TPS and check
connector is still disconnected. for proper operation.
Measure resistance between TPS signal circuit If problem is corrected, replace MAFS
and ground circuit.
Measure resistance between TPS harness No Short circuit between TPS signal circuit and ground
Page 122 of 146
Measure resistance between TPS harness
connector and chassis ground at TPS signal circuit.
circuit. Short to chassis ground between TPS harness
• Specification: infinite connector and ECM harness connector.

HO2S circuit (bank1, sensor1)
HO2S circuit Open (Bank 1, Sensor 1)
No. P0130
HO2S circuit Short to ground (bank1, sensor1)
No. P0131
HO2S circuit Short to 5V (bank1, sensor1)
No. P0132
[Related items] • Open or short to battery or 5V between front HO2S and
ECM
• Short to chassis ground between front HO2S and ECM
• Short between front HO2S wires
• Poor connection between front HO2S ECM
• Misplaced, bent, loose or corroded terminals

OBD-II check connector. proceeding this procedure.
2 Warm up engine to normal operating temperature Yes Problem is intermittent or was repaired and
for more than 10 minutes. engine control module memory was not cleared.
Using SCAN TOOL, monitor HO2S signal Check terminal connections at ECM and HO2S.
waveform.
Does the HO2S signal switch lean to rich or rich to No Go to step 3.
lean over 6 times for 10 seconds?
3 Turn ignition to OFF and disconnect ECM Yes Go to step 4
connector and HO2S connector.
Measure resistance of HO2S gound circuit between
HO2S harness connector and ECM harness
connector. No Open circuit between HO2S harness connector
Measure resistance of HO2S signal circuit between and ECM harness connector.
HO2S harness connector and ECM harness Repair as necessary.
connector.
• Specification : below 1Ω
Page 123 of 146
4 Turn ignition to ON Yes Go to step 5
Measure voltage of HO2S signal circuit between
HO2S harness connector and chassis ground. No Short circuit to battery between HO2S harness
• Specification : below 0.5V connector and ECM harness connector.
5 Ignition OFF, HO2S connector and ECM Yes Go to step 6

connector is still disconnected.
Measure resistance between HO2S signal circuit No Short circuit between HO2S signal circuit and
and ground circuit. ground circuit.
Measure resistance between HO2S harness Short to chassis ground between HO2S harness
connector and chassis ground at HO2s signal circuit. connector and ECM harness connector.
• Specification : infinite Repair as necessary.
Does resistance indicate open circuit?
6 Thoroughly check HO2S for contamination, Yes Clean HO2S with cleaner before installing.
deterioration or damage. If damaged or deteriorated, temporarily install a
Is HO2S contaminated, deteriorated or damaged? known good HO2S and check for proper
operation.
If problem is corrected, replace HO2S.
No Verify ECM and HO2S connectors are secure.
If connectors are okay, temporarilyinstall a
known good HO2S and check for proper
operation.
If problem is corrected, replace HO2S.

HO2S circuit slow responsive (bank1, sensor1)-FOR 2.4 DOHC
HO2S circuit slow responsive (bank1, sensor1)
No. P0133
[Related items] • Abnormal combustion
• Improper fuel pressure
• Front and rear HO2S connections reversed
If any misfire, purge solenoid valve, MAFS or HO2S heater codes are
present, do all repairs associated with those codes before proceeding this
Page 124 of 146
2 Visually check for leak from exhaust system Yes Repair intake system leaks as necessary.
(especially between TWC converter and front
exhaust pipe). No Go to step 3.
Are any leaks present?
3 Visually check for leak from intake system. Yes Repair exhaust system leaks as necessary.
Are any vacuum leaks present?
No Go to step 4.
4 Start engine after installing fuel pressure gauge at Yes Temporarily install a known good HO2S and
service valve in fuel rail. check for proper operation.
With engine running at operating temperature, is fuel If problem is corrected, replace HO2S.
pressure within specification? No (1) If measured pressure is too high:
Fuel pressure at idle: 46~49 psi Go to step 5
(320~340kPa, 3.26~3.47kg/cm2)
(2) If measured pressure is too low:
Go to step 6
5 Disconnect return line hose from fuel filter. Blow Yes Check for blockage in return line, clean or
through line towards tank. replace as necessary.
Is return line restricted? No Repair pressure regulator
6 Clamp a return line from fuel filter and check if Yes Replace fuel delivery module.
pressure rises.
No Check fuel filter at fuel pump. If it is OK,
Do fuel pressure rise?
measure fuel pump maximum pressure and
repair as necessary.

HO2S circuit no activity detected (bank1, sensor1)-FOR 2.4 DOHC
HO2S circuit no activity detected (bank1, sensor1)
No. P0134
[Related items] • Open or short between front HO2S signal terminal and ECM
• Contaminated, deteriorated or aged front HO2S
If any misfire, purge solenoid valve or HO2S heater codes are present, do
all repairs associated with those codes before proceeding this
troubleshooting procedure
Page 125 of 146
Step Inspection Action
1 Connect SCAN TOOL to data link connector Yes Do all repairs associated with those codes before
or OBD-II check connector. proceeding this procedure.
Turn ignition to ON and monitor any other
DTC. No Go to step 2.
Are any other codes set?
2 Warm up engine to normal operating Yes Problem is intermittent or was repaired and engine
temperature for more than 10 minutes. control module memory was not cleared. Check
Using SCAN TOOL monitor HO2S signal. terminal connections at ECM and HO2S.
Does the HO2S signal switch lean to rich or
rich to lean over 6 times for 10 seconds? No Go to step 3.

Measure resistance of HO2S ground circuit
between HO2S harness connector and ECM
harness connector.
Measure resistance of HO2S signal circuit No Open circuit between HO2S harness connector and
between HO2S harness connector and ECM ECM harness connector.
harness connector. Repair as necessary.
Does each resistance indicate continuity
circuit?
Measure voltage of HO2S signal circuit
between HO2S harness connector and chassis No Short circuit to battery between HO2S harness
ground. connector and ECM harness connector.
• Specification: below 0.5V Repair as necessary.
5 Ignition OFF, HO2S connector and ECM Yes Go to step 6.
Measure resistance between HO2S signal
circuit and ground circuit. No Short circuit between HO2S signal circuit and ground
Measure resistance between HO2S harness circuit.
connector and chassis ground at HO2S signal Short to chassis ground between HO2S harness
circuit. connector and ECM harness connector.
6 Thoroughly check HO2S for contamination, Yes Clean HO2S with cleaner before installing. If
deterioration or damage. damaged or deteriorated, temporarily install a known
Is HO2S contaminated, deteriorated or good HO2S and check for proper operation.
damaged? If problem is corrected, replace HO2S.
No Verify ECM and HO2S connectors are secure. If
OK, temporarily install a known good HO2S and
check for proper operation.
If problem is corrected, replace HO2S
Page 126 of 146
7 Visually check for leak from exhaust system Yes Repair intake system leaks as necessary.
(especially between TWC converter and front
exhaust pipe). No Go to step 8.
Are any leaks present?

HO2S heater circuit malfunction (bank1, sensor1) - FOR 2.4 DOHC
HO2S heater circuit malfunction (bank1, sensor1)
No. P0135
[Related items] • Open or short to battery between front HO2S heater and
ECM
• Short to chassis ground between front HO2S heater and
ECM
• Incorrect front HO2S heater resistance
• Faulty front HO2S heater

1 Visually inspect the HO2S circuit for exposed Yes Repair any concerns found in the visual inspection.
wiring, contamination, corrosion and proper
installation.
Were any concerns found during the visual No Go to step 2.
inspection?
2 Connect SCAN TOOL to data link connector Yes Go to step 3.
or OBD-II check connector.
No Problem is intermittent or was repaired and engine
Turn ignition to ON and monitor DTCs. control module memory was not cleared. Check
Is DTC P0135 also set?
terminal connections at ECM and HO2S.
HO2S connector.
Start engine and allow an engine to idle until ECT
reaches operating temperature.
Measure voltage of HO2S heater battery voltage No Open circuit or short circuit to chassis ground
between HO2S harness connector and chassis between main relay and HO2S harness connector.
ground.
• Specification: approximately B+
Is measured voltage within specification?
Measure resistance of HO2S heater signal circuit
between HO2S harness connector and ECM No Open circuit between HO2S harness connector and
harness connector. ECM harness connector.
• Specification: below 1Ω Repair as necessary.
Page 127 of 146
5 Measure resistance between HO2S heater signal Yes Go to step 6.
and battery power terminal. No Temporarily install a known good HO2S and check
• 3.0 ~ 6.2 Ω at 20°C (68°F) for proper operation. If problem is corrected,
Is measured resistance within specification? replace HO2S.
6 Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with
SCANTOOL connected and monitor for pending codes.

HO2S circuit open (bank1, sensor2)-FOR 2.4 DOHC
HO2S circuit open (bank1, sensor2)
No. P0136
HO2S circuit Short to ground (bank1, sensor2)
No. P0137
HO2S circuit Short to 5V (bank1, sensor2)
No. P0138
[Related items] • Open or short to chassis ground between rear HO2S and
ECM
• Short to battery between rear HO2S and ECM
• Short between rear HO2S wires

Using SCAN TOOL, monitor HO2S signal terminal connections at ECM and HO2S.
waveform.
Does the HO2S signal switch lean to rich or No Go to step 3.
rich to lean over 6 times for 10 seconds?
harness connector.
Measure resistance of HO2S signal circuit No Open circuit between HO2S harness connector and
between HO2S harness connector and ECM ECM harness connector.
harness connector. Repair as necessary.
circuit?
Page 128 of 146
6 Thoroughly check HO2S for contamination, Yes Clean HO2S with cleaner before installing. If damaged
deterioration or damage. or deteriorated, temporarily install a known good
Is HO2S contaminated, deteriorated or HO2S and check for proper operation.
damaged? If problem is corrected, replace HO2S.
No Verify ECM and HO2S connectors are secure. If
connectors are okay, temporarily install a known good
HO2S and check for proper operation.
If problem is corrected, replace HO2S .

HO2S circuit (bank1, sensor2)-FOR 2.4 DOHC
HO2S circuit Malfunction (bank1, sensor2)
No. P0139
HO2S circuit Malfunction - Stick (bank1, sensor2)
No. P0140
[Related items] • Open or short to chassis ground between rear HO2S and
ECM
• Short to battery between rear HO2S wires
• Short between rear HO2S wires
Page 129 of 146
Using SCAN TOOL, monitor HO2S signal terminal connections at ECM and HO2S.
waveform.
Does the HO2S signal switch lean to rich or No Go to step 3.
rich to lean over 6 times for 10 seconds?
harness connector. No Open circuit between HO2S harness connector and
Measure resistance of HO2S signal circuit ECM harness connector.
between HO2S harness connector and ECM Repair as necessary.
harness connector.
circuit?
6 Thoroughly check HO2S for contamination, Yes Clean HO2S with cleaner before installing. If damaged
deterioratin or damage. or dateriorated, temporarily install a known good
Is HO2S contaminated, deteriorated or HO2S and check for proper operation.
damaged?
No Verify ECM and HO2S and check for proper
operation.
If problem is corrected, replace HO2S
Page 130 of 146
HO2S heater circuit malfunction (bank1, sensor2)-FOR 2.4 DOHC
HO2S heater circuit malfunction (bank1, sensor2)
No. P0141
[Related items] • Open or short to battery between rear HO2S heater and
ECM
• Short to chassis ground between rear HO2S heater and ECM
• Incorrect rear HO2S heater resistance
• Faulty rear HO2S heater

1 Visually inspect the HO2S circuit for exposed Yes Repair any concerns found in the visual inspection.
wiring, contamination, corrosion and proper
installation.
Were any concerns found during the visual No Go to step 2.
inspection?
2 Connect SCAN TOOL to data link connector Yes Go to step 3.
or OBD-II check connector.
No Problem is intermittent or was repaired and engine
Turn ignition to ON and monitor DTCs.
control module memory was not cleared. Check
Is DTC P0141 also set?
terminal connections at ECM and HO2S.
HO2S connector.
Start engine and allow an engine to idle until ECT
reaches operating temperature.
Measure voltage of HO2S heater battery voltage No Open circuit or short circuit to chassis ground
between HO2S harness connector and chassis between main relay and HO2S harness connector.
ground.
• Specification: approximately B+
Measure resistance of HO2S heater signal circuit
between HO2S harness connector and ECM No Open circuit between HO2S harness connector and
harness connector. ECM harness connector.
• Specification: below 1Ω Repair as necessary.
5 Measure resistance between HO2S heater signal Yes Go to step 6.
and battery power terminal.
No Temporarily install a known good HO2S and check
• 3.0~6.2 Ω at 20°C (68°F) for proper operation.
Is measured resistance within specification? If problem is corrected, replace HO2S.
Page 131 of 146
Fuel system too lean (bank1)-FOR 2.4 DOHC
Fuel system too lean (bank1)
No. P0171
[Related items] • Faulty fuel delivery system
• Clogged fuel injectors
• Faulty fuel injectors
• Faulty MAFS
• Faulty TPS
If any codes relating to injectors, HO2S, ECTS or MAFS are stored, do

all repairs associated with those codes before proceeding with this
troubleshooting procedure

1 Connect SCAN TOOL to data link connector or OBD-II Yes Do all repairs associated with those
check connector. codes before proceeding this
Turn ignition to ON and monitor DTCs. procedure.
No Go to step 2.
2 Using SCAN TOOL, monitor short-term and long-term on fuel Yes Problem is intermittent or was
trim data. repaired and engine control module
• Short-term: -12.5~12.5% memory was not cleared.
• Long-term: -10~10%
Is short-term and long-term within the specifications indicated? No Go to step 3.
3 Visually/physically inspect the following items: Yes Go to step 4.
• Seals between intake manifold and fuel injectors
• Seals between surge tank and PCV valves No Repair or replace as necessary.
• Crankcase ventilation valve and/or system for leaks
• Contaminated fuel
• Air cleaner element for being restricted.
• MAFS for proper installation and foreign objects
No Repair or replace as necessary.
• Exhaust system for leaks
5 Check vacuum hoses for splits and proper connections to Yes Go to step 6.
engine dynamic chamber (especially PSV, ISC hose, throttle
body, intake manifold, and brake booster). No Repair or replace as necessary.
Are connections OK?
Page 132 of 146
6 With engine idling disconnect hose between EVAP valve and Yes EVAP canister purge valve or circuit
canister. Check for vacuum at EVAP valve failure. Repair according to DTC
Is vacuum available at purge valve when EVAP valve is not P0443 repair procedures.
operating?
No Go to step 7.
7 After installing fuel pressure gauge to service port on fuel rail, Yes Low pressure:
connect DLC F/P and B (B+) with a jumper wire. Clamp return-line and check if
• Fuel pressure at idle: 46~49 psi (320~340kPa, pressure rises:
3.26~3.47kg/cm2) - If pressure rises: replace pressure
Is fuel line pressure correct with ignition switch ON? regulator
- If pressure does not rise: check the
strainer at the fuel pump.
High pressure:
Disconnect return-line from fuel filter
side and blow through line towards
tank.
- If line is clear: replace fuel delivery
module.
- If line is blocked: check for
blockage in return line and clear or
If it is OK, check fuel.
8 Start engine and check for engine rpm decrease when Yes Repair as necessary.
disconnecting each injector connector in sequence.
Measure the decreasing engine rpm of all 4 cylinders. Is there No Go to step 9.
any cylinder with no change in rpm or only a small rpm change?
9 Remove spark plugs and inspect spark plug tips. Check for Yes Check for engine mechanical failure. If
abnormal color of spark plug tips compared to other cylinders. it is OK, replace spark plugs.
Are any spark plugs with abnormal color compared to other
cylinders? No Go to step 10
10 Check for ECM input signal from MAFS, HO2S, TPS and Yes Go to step 11
other input signals.
Are input signals within specification? No Replace all failed parts.

Fuel system (Too Rich) - FOR 2.4 DOHC
Page 133 of 146
Fuel system too rich (bank1)
No. P0172
[Related items] • Faulty ignition system
• EVAP canister purge valve malfunction
- Clogged fuel injectors
- Faulty fuel injectors
- Fuel pressure too high
- Fuel pressure regulator failure
• Faulty MAFS
• Faulty TPS
If any injectors, front HO2S, ECTS, and MAFS codes are present, do all
repairs associated with those codes before proceeding this

1 Connect SCAN TOOL to data link connector or OBD-II Yes Do all repairs associated with those
check connector. codes before proceeding this
Turn ignition to ON and monitor DTCs. procedure.
No Go to step 2.
2 Using SCAN TOOL, monitor short-term and long-term on fuel Yes Problem is intermittent or was
trim data. repaired and engine control module
• Short-term: -12.5~12.5% memory was not cleared.
• Long-term: -10~10%
Is short-term and long-term within the specifications indicated? No Go to step 3.
• Seals between intake manifold and fuel injectors
• Seals between surge tank and PCV valves No Repair or replace as necessary.
• Contaminated fuel
• Air cleaner element for being restricted.
• MAFS for proper installation and foreign objects
No Repair or replace as necessary.
• Exhaust system for leaks
Page 134 of 146
5 Check vacuum hoses for splits and proper connections to Yes Go to step 6.
engine dynamic chamber (especially PSV, ISC hose, throttle
body, intake manifold, and brake booster). No Repair or replace as necessary.
Are connections OK?
6 With engine idling disconnect hose between EVAP valve and Yes EVAP canister purge valve or circuit
canister. Check for vacuum at EVAP valve failure. Repair according to DTC
Is vacuum available at purge valve when EVAP valve is not P0443 repair procedures.
operating? No Go to step 7.
7 After installing fuel pressure gauge to service port on fuel rail, Yes Low pressure:
connect DLC F/P and B (B+) with a jumper wire. Clamp return-line and check if
• Fuel pressure at idle: 46~49 psi (320~340kPa, pressure rises:
3.26~3.47kg/cm2) - If pressure rises: replace pressure
Is fuel line pressure correct with ignition switch ON? regulator
- If pressure does not rise: check the
strainer at the fuel pump.
High pressure:
Disconnect return-line from fuel filter
side and blow through line towards
tank.
- If line is clear: replace fuel delivery
module.
- If line is blocked: check for
blockage in return line and clear or
If it is OK, check fuel.
8 Start engine and check for engine rpm decrease when Yes Repair as necessary.
disconnecting each injector connector in sequence.
Measure the decreasing engine rpm of all 4 cylinders. Is there No Go to step 9.
any cylinder with no change in rpm or only a small rpm change?
9 Remove spark plugs and inspect spark plug tips. Check for Yes Check for engine mechanical failure. If
abnormal color of spark plug tips compared to other cylinders. it is OK, replace spark plugs.
Are any spark plugs with abnormal color compared to other
cylinders? No Go to step 10
10 Check for ECM input signal from MAFS, HO2S, TPS and Yes Go to step 11
other input signals.
Are input signals within specification? No Replace all failed parts.

Injector Circuit (FOR 2.4 DOHC)
Page 135 of 146
Diagnostic trouble
code Cylinder 1 injector circuit malfunction
No. P0201
Diagnostic trouble
No. P0202
Diagnostic trouble
No. P0203
Diagnostic trouble
No. P0204
[Related items] • Open or short between main relay and injectors
• Open or short between ECM and injectors
• Short to battery between ECM and injectors

1 Turn ignition switch to OFF and disconnect injector Yes Go to step 2.
connector.
Measure resistance between injector terminal 1 and No Temporarily install a known good injector
terminal 2. and check for proper operation.
• 13.8 ~ 15.2 Ω at 20°C (68°F) If problem is corrected, replace HO2S.
Is measured resistance within specification?
2 Turn ignition switch to OFF and disconnect injector Yes Go to step 3.
connector.
With ignition ON and measure voltage of battery No Open circuit or short circuit to chassis ground
voltage between injector harness connector and chassis between main relay and injector harness
ground. connector
3 Disconnect ECM connector and injector connector. Yes Go to step 4.
Measure resistance between injector harness connector
and ECM harness connector. No Open circuit between injector harness
• Specification: below 1Ω connector and ECM harness connector.
Does resistance indicate continuity? Repair as necessary.
4 ECM connector and injector connector is still Yes Temporarily install a known good injector
Measure resistance between injector harness connector If problem is corrected, replace HO2S.
and chassis ground at injector signal circuit. No Short circuit to chassis ground between
• Specification: infinite injector terminal 2 and ECM.
Page 136 of 146

Knock sensor Circuit (FOR 2.4 DOHC)
Diagnostic trouble
code Knock sensor circuit malfunction (bank 1)
No. P0325
[Related items] • Open or short to GND between knock sensor and ECM
• Source of high resistance between knock sensor and ECM
• Faulty knock sensor

1 Connect SCAN TOOL to data link connector or OBD- Yes Problem is intermittent or was repaired and
II check connector. engine control module memory was not
Turn ignition to ON and monitor KS voltage signals. cleared. Check terminal connections at
• Specifications: 2.0~3.0V ECM and KS.
Is signal within specifications? No Go to step 2.
2 Start and run engine. Yes Check any other DTCs. If any DTCs is
Using SCAN TOOL monitor KS voltage signals from present, do all repairs associated with those
idle to 3000rpm. codes before proceeding next step.
Does voltage signal increase?
No Go to step 3.
3 Thoroughly check KS and ECM for loose, bent, Yes Repair as necessary.
4 Turn ignition to OFF and disconnect KS connector and Yes Go to step 5.
ECM connector.
Measures resistance of KS signal circuit between KS
harness connector and ECM harness connector. No Open circuit between KS harness connector
Measure resistance of KS ground circuit between KS and ECM harness connector and/or chassis
harness connector and chassis ground. ground.
Is each resistance within specification?
Measures voltage of KS signal circuit between KS
harness connector and chassis ground. No Short circuit to battery between KS harness
• Specifications: below 0.5V connector and ECM harness connector.
Does voltage within specifications Repair as necessary.
6 Ignition OFF, KS connector and ECM connector is still Yes Temporarily install a known good knock
disconnected. Measures resistance between KS harness sensor and check for proper operation. If
connector and chassis ground at KS signal circuit. problem is corrected, replace knock sensor.
Measure resistance between KS signal circuit and
No Short circuit to chassis ground between KS
ground circuit.
• Specifications: infinite connector.
Does resistance indicate open circuit? Short circuit between KS signal circuit and
ground circuit.
Page 137 of 146

CKP Sensor (FOR 2.4 DOHC)
Crankshaft position sensor circuit malfunction
No. P0335
[Related items] • Open or short to chassis ground between CKPS and ECM
• Short to battery between CKPS and ECM
• Short between CKPS wires
• Out of allowable air gap
• Faulty Target wheel tolerance
• Faulty CKPS

1 Thoroughly check CKPS and ECM for loose, bent, Yes Repair as necessary.
2 Turn ignition to OFF and disconnect CKPS Yes Go to step 3.
connector.
Turn ignition to ON and measure voltage of CKPS No Open circuit or short circuit to chassis ground
power circuit between CKPS harness connector and between CKPS harness connector and main
chassis ground. relay.
Measure resistance of CKPS signal circuit between
CKPS harness connector and ECM harness
connector. No Open circuit between CKPS harness
Measure resistance of CKPS ground circuit between connector and ECM harness connector and/or
CKPS harness connector and chassis ground. chassis ground.
Measure voltage of CKPS signal circuit between
CKPS harness connector and chassis ground. No Short circuit to battery between CKPS harness
• Specifications: below 0.5V connector and ECM harness connector.
5 Tun ignition to OFF. Yes Temporarily install a known good CKPS and
Measures resistance between CKPS harness check for proper operation. If problem is
connector and ECM harness connector at CKPS corrected, replace CKPS.
signal circuit.
Page 138 of 146
signal circuit.
No Short circuit to chassis ground between KS
Measure resistance between CKPS signal circuit and
ground circuit.
connector.
• Specifications: infinite Short circuit between CKPS signal circuit and
Does resistance indicate open circuit? ground circuit.

CMP Sensor Circuit (FOR 2.4 DOHC)
Crankshaft position sensor circuit malfunction
No. P0340
[Related items] • Open or short to chassis ground between CMPS and ECM
• Short to battery between CMPS and ECM
• Short between CMPS wires
• Faulty CMPS

1 Thoroughly check CMPS and ECM for Yes Repair as necessary.
loose, bent, corroded, contaminated,
deteriorated or damaged connectors. No Go to step 2.
2 Turn ignition to OFF and disconnect Yes Go to step 3.
CMPS connector.
Turn ignition to ON and measure voltage of
CMPS power circuit between CMPS No Open circuit or short circuit to chassis ground between
harness connector and chassis ground. CMPS harness connector and main relay.
connector.
Measure resistance of CMPS signal circuit
between CMPS harness connector and
ECM harness connector.
Measure resistance of CMPS ground No Open circuit between CMPS harness connector and
circuit between CMPS harness connector ECM harness connector and/or chassis ground.
and chassis ground. Repair as necessary.
circuit?
Measure voltage of CMPS signal circuit
between CMPS harness connector and
chassis ground.
Page 139 of 146
between CMPS harness connector and No Short circuit to power between CMPS harness connector
chassis ground. and ECM harness connector.
• Specifications: below 0.5V Repair as necessary.
5 Tun ignition to OFF. Yes Go to step 6.
Measures resistance between CMPS
harness connector and ECM harness No Short circuit to chassis ground between KS harness
connector at CMPS signal circuit. connector and ECM harness connector.
Measure resistance between CMPS signal Short circuit between CMPS signal circuit and ground
circuit and ground circuit. circuit.
• Specifications: infinite Repair as necessary.
6 Turn ignition to OFF and disconnect Yes Temporarily install a known good CMPS and check for
CMPS connector. proper operation. If problem is corrected, replace
Check for CMPS installation. CMPS.
Is CMPS installed properly? No Remove CMPS, install CMPS correctly, and check
CMPS for proper operation. If not, temporarily install a
known good CMPS and check for proper operation. If
problem is corrected, replace CMPS.

Fuel level sensor (FOR 2.4 DOHC)
Diagnostic trouble
code Fuel level sensor circuit malfunction
No. P0460
Diagnostic trouble
code Fuel level sensor Low - Stick
No. P0462
Diagnostic trouble
code Fuel level sensor High - Stick
No. P0463
[Related items] • Open or short to battery between FLS and ECM
• Short to chassis ground between FLS and ECM
• Poor connections between FLS and ECM
• Faulty FLS or FLS stuck
Page 140 of 146
1 Turn ignition to OFF and disconnect FLS connector. Yes Go to step 2.
Turn ignition to ON
Measure voltage of FLS signal circuit between FLS No Open circuit or short circuit between FLS
harness connector and chassis ground. harness connector and ECM connector.
2 Thoroughly check FLS and ECM for loose, bent, Yes Temporarily install a known good FLS
corroded, contaminated, deteriorated or damaged and check for proper operation.
connectors. If problem is corrected, replace FLS.
Is connection okay?

Vehicle speed sensor (FOR 2.4 DOHC)
Vehicle speed sensor circuit malfunction
No. P0500
[Related items] • Open or short to battery between VSS and ECM.
• Short to chassis ground between VSS and ECM
• Open or short between VSS wires
• Faulty VSS
If any codes relating to VSS (TCM) circuits are present, do all repairs
associated with those codes before proceeding with this troubleshooting
guide.

1 Turn ignition to ON. Yes Problem is intermittent or was repaired and engine
Using SCAN TOOL and monitor VSS control module memory was not cleared. Check terminal
signal. connections at ECM and VSS.
• 5V at ignition ON
• 0~5V at driving No Go to step 2.
2 Turn ignition to OFF and disconnect VSS Yes Go to step 3.
connector.
Turn ignition to ON and measure voltage
between VSS harness terminal and chassis No Open circuit or short circuit to chassis ground between
ground. VSS harness connector and ECM connector
• Specification: approximately 5V
Page 141 of 146
3 Check VSS harness for open and/or short Yes Temporarily install a known good VSS and check for
circuit. proper operation. If problem is corrected, replace VSS.
Is harness okay?
No Repair open or short circuit as necessary.

Idle control system (lower-FOR 2.4 DOHC)
Idle control system rpm lower than expected
No. P0506
[Related items] • Open or short between main relay and IACV
• Open or short between ECM and IACV
• Intake system is plugged
• Carbon fouled throttle plate
• Faulty IACV
If any codes relating to TPS, MAFS, fuel injector or IACV present, do all
repairs associated with them before proceeding with this troubleshooting
guide.

1 Connect SCAN TOOL to data link connector or OBD-II check Yes Do all repairs associated with
connector. Turn ignition to ON and monitor DTCs. those codes before proceeding
Are any other codes also set? this procedure.
No Go to step 2.
2 Check accelerator cable free play [0.040~0.120 in (1.0~3.0 mm)]. Yes Go to step 3.
Is accelerator cable free play within specification/
No Adjust cable.
3 Start engine and allow engine to idle until engine reaches operating Yes Go to step 4.
temperature.
Using SCAN TOOL, monitor TP voltage signals. No Do all repairs associated with
• 0.3~0.9V @ idle TPS before proceeding the
• 4.0~4.6V @ full open next step..
4 Turn ignition to OFF and disconnect IACV connector. Yes Go to step 5.
With ignition ON, measure voltage of IACV battery voltage between No Open circuit or short circuit to
IACV harness connector and chassis ground.
chassis ground between IACV
• Specifications: approximately B+ harness connector and main
Is voltage within specifications? relay.
5 Turn ignition to OFF. Yes Go to step 6.
Measure resistance of IACV opening coil and closing coil.
Page 142 of 146
Measure resistance of IACV opening coil and closing coil.
No Temporarily install a known
• Opening coil: 15~16 Ω at 20°C (68°F) good IACV and check for
• Closing coil: 17~18.2 Ω at 20°C (68°F) proper operation. If problem is
Is each resistance within specification? corrected replace IACV.
6 Remove IACV from throttle body and check for excessive carbon Yes Thoroughly check for loose,
deposits and sticking per following check. bent or corroded terminals at
Connect IACV battery terminal to 12V power. One at a time, all connectors in circuit.
momentarily ground IACV opening coil signal terminal and closing coil
terminal while visually verifying valve closes when the closing coil
terminal is grounded and valve opens when opening coil signal terminal
is grounded.
Repeat numerous times to ensure valve reliability. No Temporarily install a known
Is IACV moving freely and is not carbon fouled? good IACV and check for
proper operation. If problem is
corrected replace IACV.
While IACV is removed, inspect throttle body for obstructions in
idle circuit ports. Repair or replace as necessary.

Measure resistance of IACV opening coil signal circuit between
IACV harness connector and ECM harness connector. No Open circuit between IACV
Measure resistance of IACV closing coil signal circuit between IACV harness connector and ECM
harness connector and ECM harness connector. harness connector.
8 ECM connector and IACV connector is still disconnected. Yes Go to step 9.
Measure resistance between IACV harness connector and chassis
ground at IACV opening coil circuit. No Short circuit to chassis ground
Measure resistance between IACV harness connector and chassis between IACV harness
ground at IACV closing coil circuit. connector and ECM harness
Does each resistance indicate open circuit? Repair as necessary.
9 Remove intake hose and inspect throttle plate for excessive carbon Yes Clean throttle body.
deposits.
Is throttle plate being held open with excessive carbon deposits? No Go to step 10.

Idle control system (higher-FOR 2.4 DOHC)
Page 143 of 146
cted
No. P0507
[Related items] • Short to ground between IACV and ECM
• Air leak in intake system
• Improperly adjusted accelerator cable
• Faulty IACV
• Faulty TPS
• Faulty PCV/PSV
If any codes relating to TPS, PSV, MAFS, fuel injector or IACV are
present, do all repairs associated with them before proceeding with this
troubleshooting guide.

1 Connect SCAN TOOL to data link connector or OBD-II check Yes Do all repairs associated with
connector. those codes before proceeding
Turn ignition to ON and monitor DTCs. this procedure.
Are any other codes also set?
No Go to step 2.
2 Check accelerator cable free play [0.040~0.120 in (1.0~3.0 mm)]. Yes Go to step 3.
Is accelerator cable free play within specification?
No Adjust cable.
3 Start engine and allow engine to idle until engine reaches operating Yes Go to step 4.
temperature.
Using SCAN TOOL, monitor TP voltage signals. No Do all repairs associated with
• 0.3~0.9V @ idle TPS before proceeding the
• 4.0~4.6V @ full open next step..
4 Turn ignition to OFF and disconnect IACV connector. Yes Go to step 5.
With ignition ON, measure voltage of IACV battery voltage between
No Open circuit or short circuit to
IACV harness connector and chassis ground. chassis ground between IACV
• Specifications: approximately B+ harness connector and main
Is voltage within specifications? relay.
5 Turn ignition to OFF. Yes Go to step 6.
Measure resistance of IACV opening coil and closing coil. No Temporarily install a known
• Opening coil: 15~16 Ω at 20°C (68°F) good IACV and check for
• Closing coil: 17~18.2 Ω at 20°C (68°F) proper operation. If problem is
Is each resistance within specification? corrected replace IACV.
6 .Remove IACV from throttle body and check for excessive carbon Yes Thoroughly check for loose,
deposits and sticking per following check. bent or corroded terminals at
Connect IACV battery terminal to 12V power. One at a time, all connectors in circuit.
momentarily ground IACV opening coil signal terminal and closing coil
terminal while visually verifying valve closes when the closing coil
terminal is grounded and valve opens when opening coil signal terminal
Page 144 of 146
is grounded.
No Temporarily install a known
Repeat numerous times to ensure valve reliability.
good IACV and check for
Is IACV moving freely and is not carbon fouled?
proper operation. If problem is
corrected replace IACV.
While IACV is removed, inspect throttle body for obstructions in

idle circuit ports. Repair or replace as necessary.

Measure resistance of IACV opening coil signal circuit between
IACV harness connector and ECM harness connector. No Open circuit between IACV
Measure resistance of IACV closing coil signal circuit between IACV harness connector and ECM
harness connector and ECM harness connector. harness connector.
Specifications: below 1Ω Repair as necessary.
8 ECM connector and IACV connector is still disconnected. Yes Go to step 9.
Measure resistance between IACV harness connector and chassis
ground at IACV opening coil circuit. No Short circuit to chassis ground
Measure resistance between IACV harness connector and chassis between IACV harness
ground at IACV closing coil circuit. connector and ECM harness
Does each resistance indicate open circuit? Repair as necessary.
9 Check for any split, disconnected or perforated vacuum hoses. Also, Yes Go to step 10.
check PCV valve for proper operation and purge solenoid valve for
proper installation and operation. No Replace faulty vacuum hoses,
Are vacuum hoses, PCV and PSV okay? PCV or PSV

• Gasket between intake manifold and cylinder head
• Seals between surge tank and PCV valves
11 With engine idling disconnect hose between EVAP valve and canister. Yes EVAP canister purge valve or
Check for vacuum at EVAP valve circuit failure.
Is vacuum available at purge valve when EVAP valve is not Repair according to DTC
operating? P0443 repair procedures.
No Go to step 12.

Power steering switch (FOR 2.4 DOHC)
Page 145 of 146
ction
No. P0551
[Related items] • Open between power steering switch and ECM
• Short to chassis ground between power steering switch and
ECM
• Faulty power steering switch

1 Turn ignition to OFF and disconnect power Yes Check power steering switch for poor terminal contacts
steering switch. due to bent, damaged, or misplaced terminal at power
Turn ignition to ON. steering switch.
Measure voltage of power steering switch If OK, temporally install a known good power steering
between power steering switch harness switch and check power steering switch for proper
connector and chassis ground. operation. If problem is corrected, replace power
• Specifications: approximately 10~15V steering switch.
Is voltage within specifications? No Open circuit or short circuit to chassis ground between
power steering switch connector and ECM.

Stop lamp switch system
Code No.P0703 Stop lamp switch system Probable cause
If the stop lamp switch is on for 5 minutes or more while • Malfunction of the stop lamp switch
driving, it is judged that there is a short circuit in the stop • Malfunction of connector
light switch and diagnostic trouble code P0703 is output. • Malfunction of the TCM
Page 146 of 146
Page 1 of 38
OPTIMA(MS) > 2003 > G 2.4 DOHC > Heating,Ventilation, Air Conditioning
Heating,Ventilation, Air Conditioning > General Information > Troubleshooting

TROUBLESHOOTING
Before replacing or repairing air conditioning components, first determine if the malfunction is due to the refrigerant
charge, air flow or compressor.
The following diagnostic charts have been developed as a quick reference for determining the cause of the
malfunction. If these charts do not satisfactorily describe the problem, refer to the appropriate section for a more
detailed explanation. After correcting the malfunction, check the complete system to ensure that performance is
satisfactory.
Page 2 of 38
Heating,Ventilation, Air Conditioning > General Information > Specifications

SPECIFICATIONS
A/CON
Page 3 of 38
GASOLINE
ITEM
2.4G (I4) 2.7G (V6)
Compressor Type HS-17 (Swash plate) ←
Oil type & FD46XG (PAG), 150± ←
Capacity 10cc
Comp.pulley Type 5PK 6PK
Pulley Dia. Ø4.921 (Ø125) ←
[in(mm)]
Condenser Type Corrugated ←
Triple High [psi 455±28 (32.0 ± 2.0) ←
Pressure S/W (kg/cm²)]
(Dual pressure
Medium [psi 220±11 (15.5 ± 0.8) ←
S/W) (kg/cm²)]
Low [psi ←
(kg/cm²)]
Expansion Valve Type Block ←
Refrigerant Type R-134a ←
Capacity [oz (g)] 23.99±0.88 (680±25) ←
HEATER UNIT
ITEM FRONT REAR
Heater mode Type Dimpled ←
selection
Heating 4400 kcal/h ± 10%
←
capacity
Operating Actuator
-
method
Temp Operating Actuator
←
selection method
CONTROL UNIT
ITEM MANUAL AUTO
INCAR
SENSOR
AMBIENT X O
SENSOR X O
PHOTO X O
SENSOR X O
HUMIDITY X O
SENSOR
AQS SENSOR
Page 4 of 38
Heating,Ventilation, Air Conditioning > Air conditioning System > General Safety Information and
Caution
INSTRUCTIONS
WHEN HANDLING REFRIGERANT
1. R-134a liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite.
When handling the refrigerant, be sure to wear gloves.
2. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands. If the
refrigerant splashes into your eyes, wash them with clean water immediately.
3. The R-134a container is highly pressurized. Never leave it in a hot place, and check that the storage temperature
is below 52°C (126°F).
4. A electronic leak detector should be used to check the system for refrigerant leakage. Bear in mind that the R-
134a, upon coming into contact with flame, produces phosgene, a highly toxic gas.
5. Use only recommended the lubricant for R-134a systems. If lubricants other than the recommended one used,
system failure may occur.
6. PAG lubricant absorbs moisture from the atmosphere at a rapid rate, therefore the following precautions must be
observed:
A. When removing refrigerant components from a vehicle, cap immediately the components to prevent from the
entry of moisture.
B. When installing refrigerant components to a vehicle, do not remove the cap until just before connecting the
components.
C. Complete the connection of all refrigerant tubes and hoses without delay to prevent the A/C system from
taking on moisture.
D. Use the recommended lubricant from a sealed container only.
7. If an accidental discharge in the system occurs, ventilate the work area before resuming service.
WHEN REPLACING PARTS ON A/C SYSTEM

1. Never open or loosen a connection before discharging the system.
2. Seal the open fittings of components with a cap or plug immediately to prevent intrusion of moisture or dust.
3. Do not remove the sealing caps from a replacement component until it is ready to be installed.
4. Before connecting an open fitting, always install a new sealing ring. Coat the fitting and seal with refrigerant oil
before making the connection.
WHEN INSTALLING CONNECTING PARTS

Page 5 of 38
FLANGE WITH GUIDE PIN
Check the new O-ring for damage (use only the specified) and lubricate it using compressor oil. Tighten the nut to
specified torque.
Tightening torque (N·m (kg·m, lb-ft))

Size General bolt, nut
4T 7T
4 - 6 (0.4 - 0.6, 2.9 - 7 - 11 (0.7 - 1.1, 5.0 -
M6
4.3) 7.9)
9 - 14 (0.9 - 1.4, 6.5 - 17 - 26 (1.7 - 2.6, 12 -
M8
10) 18)
19 - 28 (1.9 - 2.8, 14 - 35 - 55 (3.5 - 5.5, 25 -
M10
20) 39)
Flange bolt, nut
Size
4T 7T
5 - 7 (0.5 - 0.7, 3.6 - 8 - 12 (0.8 - 1.2, 5.8 -
M6
5.0) 8.6)
10 - 15 (1.0 - 1.5, 7 - 19 - 28 (1.9 - 2.8, 14 -
M8
10) 20)
21 - 31 (2.1 - 3.1, 15 - 39 - 60 (3.9 - 6.0, 28 -
M10
22) 43)
HANDLING TUBING AND FITTINGS

The internal parts of the refrigeration system will remain in a state of chemical stability as long as pure moisture-free
refrigerant and refrigerant oil are used. Abnormal amounts of dirt, moisture or air can upset the chemical stability and
cause problems or serious damage.
THE FOLLOWING PRECAUTIONS MUST BE OBSERVED
1. When it is necessary to open the refrigeration system, have everything you will need to service the system ready
so the system will not be left open any longer than necessary.
2. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture.
3. All lines and components in parts stock should be capped or sealed until they are ready to be used.
4. Never attempt to rebend formed lines to fit. Use the correct line for the installation you are servicing.
5. All tools, including the refrigerant dispensing manifold, the gauge set manifold and test hoses, should be kept clean
and dry.
Heating,Ventilation, Air Conditioning > Air conditioning System > Description and Operation
Page 6 of 38
REFRIGERATION CYCLE
Heating,Ventilation, Air Conditioning > Air conditioning System > Components and Components
Location
Page 7 of 38
COMPONENT
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Components and
Components Location
COMPONENTS
Page 8 of 38
2.4G(I4) ENGINE 2.7G(V6) ENGINE
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Repair procedures
DRIVE BELTS TENSION ADJUSTMENT
1. Check that the belts are not damaged and fit properly into the pulley grooves.
1. When installing the V-ribbed belt, check that the V-ribs are properly aligned.
2. If noise or slippage is detected, check the belt for wear, damage, or breakage on the pulley contact
surface, and check the pulley for scoring. Also check for the proper belt deflection measurement.
2. Apply 100 N (22 lbs.) force to the belt back midway between the pulleys as shown in the illustration, measure
the amount of deflection with a tension gauge.
Standard value:
Page 9 of 38
A. For 2.4G(I4) engine
Adjustment
Inspection
New Used
Deflection [mm(in)] 8.8~11.0 12.5~14.3
(0.35-0.43) (0.49~0.56)
B. For 2.7G(V6) Engine.

The drive belt tension is adjusted automatically by auto-tensioner.
The belt tension must be measured between the specified pulleys. When a new belt is installed, adjust the
tension to the center of the standard range indicated under "New." Let the engine idle for 5 minutes or
more, and check the standard value indicated under "Inspection." When adjusting a used belt or a newly
installed belt after 5 minutes or more of operation, refer to the standard value indicated under "Used."
Refer to the standard value indicated under "Inspection" for periodic inspections.
Adjustment
<2.4G( I4) ENGINE>
• Loosen the tension pulley fixing bolt A.
• Adjust the belt deflection with adjustment bolt B.
• Tighten the fixing bolt A.
• Re-check the belt deflection and re-adjust, if necessary.
Before re-checking, crank the engine one or more revolutions.

Page 10 of 38
<2.7G(V6) ENGINE>
1. If the mean indicator is positioned over the max. position, replace the drive belt. (Refer to the "EM Group")
2. When replacing the drive belt, must position the mean indicator between min. position and max. position.

1. Remove the drive belt after loosening the tension pulley.
2. Discharge the refrigerant.
3. Remove the discharge and suction hoses.
4. Remove the compressor.
Tightening torque
20-30 N·m(2.0~3.0 kg-m, 14-21 Ib-ft)
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor oil > Repair procedures
OIL SPECIFICATION
• The HFC-134a system requires a synthetic (PAG) compressor oil whereas the R-12 system requires mineral
compressor oil. The two oils must never be mixed.
• Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of
compressor.
HANDLING OF OIL
Page 11 of 38
• The oil should be free from moisture, dust, metal powder, etc.
• Do not mix with other oil.
• The water content in the oil increases when exposed to the air. After use, seal oil from air immediately.
(HFC-134a Compressor Oil absorbs moisture very easily.)
• The compressor oil must be stored in steel containers, not in plastic containers.
COMPRESSOR OIL CHECK
The oil used to lubricate the compressor is circulating with the refrigerant.
Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the
original amount of oil.
Oil Capacity
Capacity total in system: 150cc ± 10cc
Compressor (Service parts) charging amount: 150cc ± 10cc
Checking and Adjusting Oil Quantity for Used Compressor

1. Perform oil return operation. Refer to Oil Return Operation in this section.
2. Discharge and recover refrigerant and remove the compressor.
3. Drain the compressor oil and measure the extracted oil with a measuring cylinder.
4. If the amount of oil drained is much less than 70 cc, some refrigerant may have leaked out.
Conduct a leak tests on the connections of each system, and if necessary, repair or replace faulty parts.
5. Check the compressor oil contamination. (Refer to Contamination of Compressor Oil in this section.)
6. Adjust the oil level following the next procedure below.
Charging Amount Collected Amount
More than 70 cc Same as collected amount
Less than 70 cc 70 cc
7. Install the compressor, then evacuate, charge and perform the oil return operation.
8. Check system operation.
When it is impossible to perform oil return operation, the compressor oil should be checked in the
following order:
1. Discharge and recover refrigerant and remove the compressor.
Page 12 of 38
2. Drain the compressor oil and measure the extracted oil with a measuring cylinder.
3. Check the oil for contamination.
4. If more than 70 cc of oil is extracted from the compressor, supply the same amount of oil to the compressor to
be installed.
5. If the amount of oil extracted is less than 70 cc recheck the compressor oil in the following order.
6. Supply 70 cc of oil to the compressor and install it onto the vehicle.
7. Evacuate and recharge with the proper amount of refrigerant.
8. Perform the oil return operation.
9. Remove the compressor and recheck the amount of oil.
10. Adjust the compressor oil, if necessary.
Checking and Adjusting for Compressor Replacement
150 cc of oil is charged in compressor (service parts). So it is necessary to drain the proper amount of oil from the
new compressor.
1. Perform oil return operation.
2. Discharge and recover the refrigerant and remove the compressor.
3. Drain the compressor oil and measure the extracted oil.
4. Check the compressor oil for contamination.
5. Adjust the oil level as required.
Amount of oil drained from used
Draining amount of oil from new compressor
compressor
Less than 70 cc Same as drained amount
More than 70 cc 70 cc
6. Evacuate, charge and perform the oil return operation.

7. Check the system operation.
Contamination of Compressor Oil
Unlike engine oil, no cleaning agent is added to the compressor oil. Even if the compressor runs for a long period of
time (approximately one season), the oil never becomes contaminated as long as there is nothing wrong with the
compressor or its method of use.
Inspect the extracted oil for any of the following conditions:
• The capacity of the oil has increased.
• The oil has changed to red.
• Foreign substances, metal powder and etc. are present in the oil.
If any of these conditions exists, the compressor oil is contaminated. Whenever contaminated compressor oil is
discovered, the receiver/drier must be replaced.
Oil Return Operation
There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with the refrigerant in the system. When checking the amount of
oil in the system, or replacing any component of the system, the compressor must be run in advance for oil return
operation. The procedure is as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to "ON" and set the blower motor control knob at its highest position.
3. Run the compressor for more than 20 minutes between 800 and 1,000 rpm in order to operate the system.
4. Stop the engine.
Replacement of Component Parts
When replacing the system component parts, supply the following amount of oil to the component parts to be
installed.
Page 13 of 38
Component parts to
Amount of Oil
be installed
Evaporator 50 cc
Condenser 30 cc
Receiver/dryer 30 cc
Refrigerant line
10 cc
(One piece)
Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser > Components and
Components Location
COMPONENTS
Page 14 of 38
Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser > Repair procedures
CHECKING
CONDENSER
1. Check the condenser fins for clogging and damage.
If clogged, clean them with water, and blow them with compressed air. If bent, straighten them using screwdriver
or a pliers.
2. Check the condenser connections for leakage, and repair or replace it, if required.
CONDENSER FAN
1. Check the condenser fan for proper operation.
2. Check the harness connector.
3. Check the condenser fan motor using battery voltage as shown below.
High speed: 1(+), 4(-)

Low speed: 2(+), 3(-)
Heating,Ventilation, Air Conditioning > Air conditioning System > Receiver/Drier > Repair procedures
Check
1. Check the fusible plug and the fittings for leakage, using a leak detector.
Page 15 of 38
2. Run the engine at fast idle with the air conditioning "ON", and check both the inlet and outlet temperatures. If the
difference in temperatures between the inlet and outlet is large, replace the receiver-drier.
1. Plug the all open fittings immediately to keep moisture out of the system.
2. Do not remove plugs until ready for connection.
3. Evacuate, charge and test the refrigeration system.
Heating,Ventilation, Air Conditioning > Air conditioning System > Triple pressure switch > Repair
procedures
DESCRIPTION
The triple switch is a combination of a medium switch as well as conventional low pressure and high pressure
switches. The low pressure switch will be turned off to stop compressor operation if refrigerant pressure is low. The
high pressure switch will be turned off to stop compressor operation if refrigerant pressure is too high. The medium
switch will be turned on at medium level pressure to cool the A/C system operating radiator fan and condenser fan
at high speed.
OPERATING CHARACTERISTIC
LOW & HIGH

Page 16 of 38
MEDIUM
Heating,Ventilation, Air Conditioning > Air conditioning System > Thermistor > Repair procedures
SENSOR CHECKING
The thermistor will detect the core temperature and interrupt compressor relay power, in order to prevent
evaporator freezing by excessive cooling.
The thermistor is an NTC device.
THERMISTOR CHECK
1. Remove the glove box.
3. Turn on the air conditioner.
Page 17 of 38
4. With the thermostatic switch connector in coupled state, install a voltmeter between 1 and 2 (-) terminal and
check whether there is change in voltage between terminals according to the temperature of the evaporator
surface.
Thermistor Operatng temperrature Output voltage
ON 36.5°F (2.5°C) 0V
OFF 32.9°F (0.5°C) 12V
This check should be carried out on the back probes of the thermostatic switch when it is in coupled state.
5. If above condition is not satisfied, remove the evaporator unit and replace the thermostatic switch.
Heating,Ventilation, Air Conditioning > Air conditioning System > Magnetic Clutch > Repair
procedures
CHECKING THE CLUTCH AIR GAP
1. Check the air gap between the clutch hub and pulley contact surface using a filler gauge.
Clutch air gap : 0.0138~0.0256 in(0.35 - 0.65mm)
2. Check the gap around the pulley at 3 points.

3. If the clutch air gap is outside the normal range, correct it using a shim of proper size.
MAGNETIC CLUTCH OPERATION

Connect the compressor terminal to battery(+) and the battery(-) terminal to the compressor body. Verify magnetic
clutch operation by a clicking noise.
Page 18 of 38
Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Repair procedures
DESCRIPTION
The in-car sensor is located in A/C control assembly. The sensor contains a thermistor which measures the
temperature of the air inside the passenger compartment. It perceives the passenger compartment temperature,
changes the resistance value, and enters the corresponding voltage into the automatic temperature control module.
CHECKING
• Measure the resistance and the temperature.
77°F(25°C): 30 ± 0.36 kΩ
Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Description and
Operation
DESCRIPTION
The photo sensor is located at the main crash pad. In response to photo intensity level in vehicle, the sensor will send
signal to control module to control the blower level and discharge temperature.
CHECKING
1. In bright place, measure amphare between pin 2 and battery (-) terminal.
2. In dark place, measure amphare between pin 2 and battery (-) ternminal.
Page 19 of 38
3. Check the amphare in the bright place is higher than in the dark.
The voltage is same as the amphare.
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Description and
Operation
DESCRIPTION
1. The air temperature sensor is located at the front of the condenser fan and detect ambient air temperature. It is a
negative type thermistor; resistance will increase with lower temperature, and decrease with higher temperatures.
2. The sensor outpout will be used for discharge temperature sensor, sensor fail-safe, temperature regulation door
control, blower motor level control, mix mode control and in-car humidity control.
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Repair procedures
CHECKING
1. Disconnect battery terminal (-).
2. Detach the harness of the ambient temperature sensor.
Page 20 of 38
3. Measure the resistance as shown.
Resistance 68°F(20°C) : 36.5 ± 2.3kΩ
Heating,Ventilation, Air Conditioning > Air conditioning System > A.Q.S (Air Quality Sensor) > Repair
procedures
INSPECTION
1. The A.Q.S sensor, located at the front of the condensor fan, detects hazardous elements in ambient air, and
provides output signals to the control module.
2. It will detect sulfurous acid gas, carbon dioxide, carbon mondxide, hydrocarbon and allergen.
SENSOR OUTPUT
Condition Resistance
Normal condition 5V
Hazardous gas
0V
detection
Heating,Ventilation, Air Conditioning > Air conditioning System > Humidity Sensor > Repair
procedures
HUMIDITY SENSOR
Page 21 of 38
1. Hunmidity sensor is located at the rear package tray and detected in-car humidity for in-car humidity control.
2. If ambient air temperature or in-car humidity is outside certain range, it will turn on A/C to control incar humidity
preventing incar fogging.
Air conditioner operation depending on ambient temperature and humidity.
SENSOR OUTPUT
Tolerance: 2%
Voltage between 2
Humidity (%)
and 3(V)
30 3.13
35 3.07
40 2.94
45 2.67
50 2.35
55 2.01
60 1.54
65 1.29
70 1.12
75 1.05
80 1.01
85 0.98
90 0.94
Heating,Ventilation, Air Conditioning > Air conditioning System > Repair procedures
REFRIGERANT SYSTEM SERVICE BASICS
Page 22 of 38
REFRIGERANT RECOVERY
Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove
HFC-134a(R-134a)from the air conditioning system.
• Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
• Be careful when connecting service equipment.
• Do not breathe refrigerant or vapor.
If accidental system discharge occurs, ventilate work area before resuming service.
Additional health and safety information may be obatined from the refrigerant and lubricant manufacturers.
1. Connect a R-134a refrigerant Recovery/Recycling/Charging System to the high-pressure service port and the
low-pressure service port as shown, following the equipment manufacturer's instructions.
2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be
sure to install the same amount of new refrigerant oil back into the A/C system before charging.
SYSTEM EVACUATION
1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be
evacuated using a R-134a refrigerant Recovery/Recycling/Charging System. (If the system has been open for
several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.)
low-pressure service port as shown, following the equipment manufacturer's instructions.
3. If the low-pressure does not reach more than 93.3 kPa(700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably
a leak in the system. Partially charge the system, and check for leaks (see Leak Test.)
SYSTEM CHARGING
Page 23 of 38
If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety
information may be obtained from the refrigerant and lubricant manufacturers.
Connect a R-134a refrigerant Recovery/Recycling/Charging System to the high-pressure service port and the low-
pressure service port, as shown, following the equipment manufacturer's instructions.
Add the same amount of new refrigerant oil to system that was removed during recovery. Use only Specified
refrigerant oil.
Charge the system with 680±25g (23.99±0.88)of R-134a refrigerant. Do not overcharge the system the
compressor will be damaged.
REFRIGERANT LEAK TEST
• Be careful when connecting service equipment
R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with
compressed air.
• Compressed air mixed with R-134a forms a combustible vapor.

• The vapor can burn or explode causing serious injury.
• Never use compressed air to pressure test r-134a service equipment or vehicle air conditioning systems.
low-pressure service port as shown in the previous column, following the equipment manufacturer's instructions.
2. Open the high-pressure valve to charge the system to the specitled capacity, then close the supply valve, and
remove the charging system couplers.
Refrigerant capacity : 680±25g (23.99±0.88)

Page 24 of 38
3. Check the system for leaks using a R-134a refrigerant leak detector with an accuracy of 14g(0.5 oz)per year or
better.
4. If you find leaks that require the system to be opened(to repair or replace hoses, fittings, etc.) recover the system
according to the Recovery Procedure.
5. After checking and repairing leaks, the system must be evacuated.
PERFORMANCE TEST
1. Install the manifold gauge set.
2. Run the engine at 2,000 rpm and set the controls for maximum cooling and high blower speed.
3. Keep all windows and doors open.
4. Place a dry-bulb thermometer in the cool air outlet.
5. Place a wet-dry thermometer close to the inlet of the cooling unit.
6. Check that the reading on the high pressure gauge is 1,373-1,575 kPa (14-16 kg/cm², 199-228 psi). If the
reading is too high, pour water on the condenser. If the reading to too low, cover the front of the condenser.
7. Check that the reading on the dry-bulb thermometer at the air inlet at 25-35°C (77-95°F).
8. Calculate the relative humidity from the psychrometric graph by comparing the wet-and dry-bulb reading at the
air inlet.
9. Measure the dry-bulb temperature at the cool air outlet, and calculate the difference between the inlet dry-bulb
and outlet dry-bulb temperatures.
10. Check that the intersection of the relative humidity and temperature difference falls within the block below.
If the intersection is within the block, cooling performance is satisfactory.
Page 25 of 38
PERFORMANCE TEST DIAGNOSIS USING MANIFOLD GAUGE

STANDARD VALUE
If cooling cycle is operating normally, the manifold gauge reading will be approx.1.5-2.0kg/cm²(21-28psi) for the
low pressure side and approx. 14.5-15kg/cm²(206-213psi) for the high pressure side. Inlet temperature should be
30-35°C(80-95°F), with the engine at 2,000 rpm, maximum cooling selected, and the blower on highest level.
DIAGNOSIS
PROBABLE
SYMPTOMS REMEDY MANIFOLD GAUGE READINGS
CAUSES
1. Low pressure and high • Gas leak. • Check and repair.
pressure are low. • Add refrigerant.
2. Cooler outlet air is a
little cooler.
Page 26 of 38
1. Low pressure and high • Faulty cooling or • Maintain the
pressure are high. condenser proper level of
freezing. refrigerant. Clean
• Belt slip. the condenser.
• Adjust the belt.
1. Low pressure and high • Air in the system. • Clean or repair

pressure are high. the receiver drier.
2. Low pressure pipe is • Check for oil
not cold. contamination.
1. Low pressure side • Dust or moisture • Repair the

indicates negative frozen at receiver drier and
pressure and high expansion valve. replace the
pressure side indicates • Gas leak. expansion valve.
low pressure. • Replace the
2. Frost or dew on pipes expansion valve if
connected with receiver the receiver-drier
or expansion valve. is faulty.
1. Low pressure side • Intaken moisture • Repair and bleed

pressure sometimes is frozen at receiver drier
goes to negative expansion valve
pressure or normal. hole.
1. Low pressure and high • Expansion valve • Repair receiver

pressure are high. failure. Receiver- drier.
2. Much frost or dew on drier faulty. • Check oil
the low pressure side • Flow control contamination.
piping. faulty.
1. Low pressure side • Leak inside • Replace

pressure is high and high compressor. compressor.
pressure side pressure
is low.
Page 27 of 38
pressure is high and high compressor. compressor.
pressure side pressure
is low.
CHECKING FOR REFRIGERANT LEAKS

Always conduct a leak test with an electronic leak detector whenever leakage or refrigerant is suspected and when
conducting service operations which are accompanied by disassembly or loosening or connection fittings.
In order to use the leak detector properly, read the manual supplied by the manufacturer.
If a gas leak is detected, proceed as follows:
1. Check the torque on the connection fittings and, if too loose, tighten to the proper torque. Check for gas leakage
with a leak detector.
2. If leakage continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect
the fittings, and check their seating faces for damage. Always replace, even if the damage is slight.
3. Check the compressor oil and add oil if required.
4. Charge the system and recheck for gas leaks. If no leaks are found, evacuate and charge the system again.
Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Repair procedures
INSPECTION
1. Temperature control actuator is installed in the heater unit case. The control switches and the vent duct switch will
operate actuator to regulate the temperature and discharge air.
2. Verify that the temp actuator operates to the warm position when connecting 12V to the terminal 1 and grounding
terminal 5.
3. Verify that the temp actuator operates to the cool position when connecting in the reverse.
Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Repair procedures
Page 28 of 38
INSPECTION
1. Apply 12V to mode actuator terminal 2 and ground terminal 1.
2. Verify that the mode actuator operates as below when grounding terminals 7,6,5,4 and 3 in sequence.
VENT → BI/LEVEL → HEAT → D/F → DEF
Heating,Ventilation, Air Conditioning > Blower > Description and Operation

AUTO A/CON OPERATION TABLE
Heating,Ventilation, Air Conditioning > Blower > Components and Components Location
FULL AUTOMATIC AIR CONDITIONER (FATC)
CONTROL RANEL
Page 29 of 38
CONNECTOR PIN DESCRIPTION

Page 30 of 38
Item PIN NO. PIN Name Item PIN NO. PIN Name
Main 1 Ground Main 1 Vcc (5V); sensor Vref
Connector (A) Connector (B)
2 IG1 2 -
3 Rear defog relay 3 -
4 Intake Rec 4 -
5 Mix cool 5 Thermistor input
6 - 6 Ambient sensor input
7 Humidity sensor Input 7 A/C select low
8 - 8 Incar sensor input
9 Power transister (C) 9 Sensor ground
10 Power transister (B) 10 Mode def
11 B+ 11 Mode D/H
12 ILL+ 12 Mode heat
13 ILL- 13 Mode B/L
14 Ground 14 Mode vent
15 IG1 15 Mix F/B signal
16 AQS sensor 16 Incar sensor output
17 Intake Fre
18 Mix warm
19 Rear defog switch
20 Photo sensor ground
21 Photo sensor ground
22 Hi-speed relay
23 A/C output
24 -
25 -
26 -
Heating,Ventilation, Air Conditioning > Blower > Troubleshooting

DIAGNOSIS SYSTEM
OPERATION METHOD (SELF-DIAGNOSIS)
The F.A.T.C. module self test feature will detect electrical malfunction and provide error codes for system
components with suspected failures.
Page 31 of 38
Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Repair procedures
CHECK
1. Connect the battery voltage and check the blower motor rotation.
Page 32 of 38
Heating,Ventilation, Air Conditioning > Blower > Power Transistor > Repair procedures
CHECK (AUTO CONTROL)
1. Manually operate the control switch and measure the voltage of blower motor between pin 1 and 2.
2. Select the control switch to raise voltage until high relay operates.
CHECK
Fan Motor Voltage
First speed 4.0V
Second speed 5.3V
Third speed 6.6V
Fourth speed 7.9V
Fifth speed 9.2V
Sixth speed 10.5V
Seventh speed 12.0V (high relay
operates)
Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Repair procedures
DESCRIPTION
Page 33 of 38
The intake selection switch is located on the control panel. Pressing the switch will shift between recirculation and
fresh air modes.
CHECK
Input (Manual) Output
Fresh/recirculation
+ -
shifting
1 2 Recirculation
2 1 Fresh
Heating,Ventilation, Air Conditioning > Blower > Blower Speed Controller > Repair procedures
CHECK
1. Check for continuity and resistance between terminals.

Terminal Resistance (Ω)
3-1 0.33
3-2 0.85
3-4 2.07
Page 34 of 38
Heating,Ventilation, Air Conditioning > Blower > Control Panel > Components and Components
Location
CONTROL PANEL
CONNECTOR PIN DESCRIPTION

Page 35 of 38
Item PIN NO. PIN Name Item PIN NO. PIN Name
Main 1 Mode heat Front blower 1 Ground
Connector (A) (B)
2 Mode B/L 2 Common
3 Mode vent 3 Middle high
4 Intake Fre 4 Low
5 Rear defog switch 5 Middle low
6 B+ 6 High
7 ILL+
8 IG
9 B+
10 Mode def
11 Mode D/H
12 Intake Rec
13 Rear defog relay
14 A/C output
15 ILL-
16 Ground
Temperature 1 Mix warm
switch(C)
2 Ground
3 IG
4 -
5 Sensor ground
6 Mix F/B
7 Vcc (5V) ; sensor Vref
8 Mix cool
Heating,Ventilation, Air Conditioning > Blower > Control Panel > Repair procedures
DEFOGGING LOGIC
1. IG-ON Logic
A/C
Mode Intake
output
Vent, B/L,
Previous
Heat Fresh
D/H, Def ON
Page 36 of 38
2. D/H, Def logic
Mode Intake
ON Fresh
D/H, Def
OFF Previous
A. Enable to select A/C on/off & Intake switch at D/H, Def mode.
B. Be impossible to enter D/H, Def logic again as D/H ↔ Def changing.
3. DISSOLUTION & REINSTATEMENT OF LOGIC
A. Turn off the blower switch
B. Move to def mode
C. Push rec button 5 tiems or more whthin 3 seconds
D. Indicator of recirculation button is flashed 3 times
E. Complets of logic dissolution & reinstatement of function
F. A/C & intake status is initialized to "A/C off" and "Intake Fresh"
4. Logic after dissoluction
IG ON D/H, Def
Intake A/C Intake A/C
Memory Memory Previous Previous
5. When the battery happens to be disconnected or discharged, the defog logic is reinstated.
Heating,Ventilation, Air Conditioning > Blower > Repair procedures

DIAGNOSTIC TROUBLE CODE DESCRIPTION
1. A/C system is darned OFF during self diagnosis. The result of self diagnosis is displayed using 2 digits of the
temperature display.
2. Diagnostic trouble codes are displayed during self diagnosis. However, after diagnosis is complete, relevant data
is not stored in memory.
3. Self diagnosis of photo sensor is performed using a light bulb over 60W placed within 40cm with sun load
applied.
Without sun load, photo sensor error code displays.

Page 37 of 38
DTC CHART
If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below.
DTC
Detection item Trouble area
code
00 Normal • Incar sensor
• Harness or connector between incar sensor and A/C control
11 Open INCAR Sensor circuit
assembly
12 Shorted INCAR Sensor circuit • A/C control assembly
13 Open Ambient sensor circuit • Ambient sensor

• Harness or connector between ambient sensor and A/C control
assembly.
14 Shorted Ambient sensor circuit
• A/C control assembly
17 Open thermister • Thermister

• Harness or connector between thermister and A/C control
assembly
18 Shorted thermister
Open or shorted temp. door • Harness or connector between temp. door potentiometer and
19
potentiometer A/C control assembly
• Temp. door potentiometer
• Harness or connector between temp. door actuator and A/C
20 Defective temp. door
control assembly
Page 38 of 38
23 Open humidity sensor • Humidity sensor

• Harness or connector between humidity sensor and A/C control
assembly
24 Shorted humidity sensor
FAILURE SAFE FUNCTION

NO. Item Description Fail-safe
Short/open circuit of IN Once diagnosis is occurs, system is regarded as
1 INCAR SENSOR
CAR SENSOR 77°F (25°C) constant.
AMBIENT Short/open circuit of Once diagnosis is occurs, system is regarded as
2
SENSOR AMBIENT SENSOR 68°F (20°C) constant.
Short/open circuit of Once diagnosis is occurs, system is regarded as -
3 Thermister
Thermister 28°F(-2°C) constant.
• Temp.: 17°C ↔ 24.5°C (62°F~76°F)
TEMP. SENSOR Short/open circuit of
Temp. door → MAX COOL
4 TEMP DOOR TEMP. DOOR
• Temp.: 25°C → 32°C(77°F~90°F)
POTENTIOMETER POTENTIOMETER
Temp. door → MAX HOT
DEFOGGING LOGIC
1. DEFOG LOGIC
INTAKE A/C
Mode
IG ON SYSTEM ON IG ON SYSTEM ON
FRESH MEMORY MEMORY MEMORY
Vent, B/L,
(EXCEPT
FLOOR
AQS)
MIX, DEF FRESH FRESH ON MEMORY
A. Enable to select A/C ON/OFF & Intake button at MIX↔DEF changing

2. DISSOLUTION & REINSTATEMENT OF LOGIC
A. Move to def mode
B. Push intake button 5 tiems or more whthin 3 seconds on keeping A/C button selected
C. Intake indicator is flashed 3 times
D. Complete dissolution & reinstatement of logic
E. Be operated on A/C off, fresh mode
INTAKE A/C
Mode
IG ON SYSTEM ON IG ON SYSTEM ON
Vent, B/L,
FLOOR, MIX, Memory Memory Memory Memory
DEF
A. When the battery happens to be disconnected or discharged, the defog logic is reinstated.
Page 1 of 26
OPTIMA(MS) > 2003 > G 2.4 DOHC > Manual Transaxle System
Manual Transaxle System > Manual Transaxle System > Manual Transaxle > Components and
Components Location
COMPONENTS
Page 2 of 26
MANUAL TRANSAXLE DIAGRAM

Page 3 of 26
Manual Transaxle System > Manual Transaxle System > Manual Transaxle > Repair procedures
REMOVAL
1. Remove the battery (-) cable.
2. Remove the air duct.
3. Remove the air cleaner and air flow hose assembly.
Page 4 of 26
4. Disconnect the backup light switch connector.
5. Disconnect the clutch tube and clip.

6. Remove the clutch release cylinder (Refer to "CH" Group).
7. Remove the speedometer cable.

8. Remove the select cable and shift cable (Refer to "MT" Group).
9. Remove the starter motor mounting bolts. Remove the transaxle assembly upper connecting bolts.
10. Attach to the engine hooks using special tool (09200-38001).
11. Remove the transaxle mounting bracket and insulator.

12. Lift up the vehicle.
13. Remove the front tire.
14. Remove the drain plug and drain the transaxle gear oil.
15. Disconnect the tie rod end, lower arm ball joint and drive shaft. (Refer to "DS" Group).
16. Remove the gear box u-joint bolt and the return tube mounting bolts.
17. Remove the front muffler.
18. Remove the sub-frame mounting bolts and the sub-frame.
19. Remove the transaxle front and rear mounting bracket.

20. Remove the transaxle side mounting bolts.
Page 5 of 26
21. Remove the transaxle assembly supporting by a jack.
When supporting the transaxle assembly, make sure that the lifting force is applied to a wide area, not to a
small localized area.
1. Engine and transmission mounting insulators should be installed the specified them.
2. Mounting bracket installation procedures.
1. Engine mounting bracket.
2. T/M mounting bracket.
3. Rear roll stopper mounting bracket.
4. Front roll stopper mounting bracket.
3. Especially, when installing front roll stopper mounting bracket, be careful not to be crushed the insulator, if
being crushed, idle vibration is high.
INSTALLATION
DISASSEMBLY
1. Remove the T/M mounting bracket.
2. Remove the shift control cable bracket.

Page 6 of 26
3. Remove the clutch release cylinder.
4. Remove the backup lamp switch.
5. Remove the speedometer driven gear.
6. Remove the clutch release fork shaft and the release bearing sleeve.
7. Remove the reamer bolt.

Page 7 of 26
8. Remove the poppet ball assembly.
9. Remove the side cover and the reverse idler gear assembly.
10. Remove the select lever, the shift lever and sealing cap.
11. Remove the clutch housing from the transmission case with the snap ring extended.
12. Remove the interlock body and the control shaft.
13. Remove the shift rail.

Page 8 of 26
14. Remove the fork shift (5th & Rev).
15. Remove the fork shift (3rd & 4th).
16. Remove the fork shift (1st & 2nd).
17. Remove the bearing retainer.
18. Remove the output shaft assembly and the input shaft assembly.
Page 9 of 26
19. Remove the differential assembly.
20. Remove the detent body cover and the roller bearing.
21. Remove the differential bearing outer spacer using special tool (09455-33200) and the drive shaft oil seal.
22. Remove the shift arm and the select arm from the transmission case.
REASSEMBLY
1. Install the drive shaft oil seal using the special tool (09431-21200).
Insert the oil seal straightly.

Page 10 of 26
2. Install the shift arm and the select arm in the transmission case.
3. Install the detent body cover and the roller bearing.
4. Install the differential assembly.
5. Install the output shaft assembly and the input shaft assembly.
6. Install the retainer bearing.

Page 11 of 26
7. Install the fork shift (1st & 2nd).
8. Install the fork shift (3rd & 4th).
9. Install the fork shift (5th & Rev).
10. Install the shift rail.
11. Install the interlock body and the control shaft.

Page 12 of 26
12. Assemble the clutch housing and the transmission case with the snap ring extended.
13. Install the select lever, the shift lever and the sealing cap.
14. Install the side cover and the reverse idler gear assembly.
15. Install the poppet ball assembly.
16. Install the reamer bolt.
17. Install the clutch release fork shaft and the release bearing sleeve.
Page 13 of 26
18. Install the speedometer driven gear.
19. Install the backup lamp.
20. Install the clutch release cylinder mounting bracket.
21. Install the shift control mounting bracket.

22. Install the mounting bracket.
Manual Transaxle System > Manual Transaxle Gear System > Differential > Components and
Components Location
components
Page 14 of 26
COMPONENTS
Page 15 of 26
Manual Transaxle System > Manual Transaxle Gear System > Differential > Repair procedures
DISASSEMBLY
1. Clamp the differential case in a vise.
2. Remove the differential drive retaining bolts and remove the differential drive gea from the case.
Page 16 of 26
3. Remove the taper bearing using the special tool (09433-21000).
Do not reuse the bearing removed from the shaft.
4. Drive out the lock pin from the hole A using a punch.
5. Drive out the pinion shaft.

DISASSEMBLY
1. Remove the input shaft snap ring.
2. Remove the input shaft.

4. Remove the clutch reaction plate snap ring.
5. Remove the clutch reaction plate.
6. Remove the 4 clutch discs and 4 clutch plates.
7. Compress the clutch return springs using special tools, 09453-24000 and 09453-21000 then remove the clutch

11. Remove the underdrive clutch piston using compressed air.
REASSEMBLY
Page 17 of 26
1. Install the spacer on the back of the side gear and then install the gear in the differential case.
1. When installing a new side gear, use a spacer of medium thickness [0.83-0.92 mm (0.33-0.036
in.)].
2. Do not reuse the lock pin.
3. The lock pin head must be sunk below the flange surface of the differential case.
2. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with
the side gears by turning them.
3. Insert the pinion shaft.
4. Measure the backlash between the side gears and pinions.

0.025-0.0150 mm (0.001-0.006 in.)
5. If the backlash is out of specification, disassemble and install the correct spacer, reassemble and remeasure.
Adjust the backlash of both side gears to the same specification.

6. Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.

2. The lock pin head must not protrude more than 3 mm (0.0118 in.) gear in the differential
case.
Page 18 of 26
7. Install the tapered roller bearing on both sides of the differential case using the special tool (09455-21100).
When press-fitting the bearing, press on the inner race only.
8. Apply specified sealant to the entire threads of the bolts. Tighten to specifications using the sequence shown in the
illustration.
Specified sealant : BM stud locking No.2471
If a bolt is reused, remove the old sealant from the threads.
DISASSEMBLY
1. Clamp the differential case in a vise.
2. Remove the differential drive retaining bolts and remove the differential drive gear from the case.
3. Remove the taper bearing using the special tool (09433-21000).
Do not reuse the bearing removed from the shaft.

Page 19 of 26
4. Drive out the lock pin from the hole A using a punch.
5. Drive out the pinion shaft.

6. Remove the pinion gears, washers, side gear and spacers.
REASSEMBLY
1. Install the spacer on the back of the side gear and then install the gear in the differential case.
1. When installing a new side gear, use a spacer of medium thickness [0.93-1.00 mm (0.036-0.04
in.)].
3. The lock pin head must be sunk below the flange surface of the differential case.
2. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with
the side gears by turning them.
3. Insert the pinion shaft.
4. Measure the backlash between the side gears and pinions.
Standard value : 0.02-0.12L mm (0.00079-0.0047L in.)

Page 20 of 26
5. If the backlash is out of specification, disassemble and install the correct spacer, reassemble and remeasure.
Adjust the backlash of both side gears to the same specification.

6. Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.

2. The lock pin head must not protrude more than 3 mm (0.118 in.).
7. Install the tapered roller bearings on both sides of the differential case using the special tool (09455-21100).
When press-fitting the bearing, press on the inner race only.
8. Apply specified sealant to the entire threads of the bolts. Tighten to specifications using the sequence shown in the
illustration.
Specified sealant : Three bond 1303
If a bolt is reused, remove the old sealant from the threads.
Manual Transaxle System > Manual Transaxle Gear System > Speedometer Driven Gear Assembly >
Components and Components Location
VEHICLE SPEED SENSOR
components
Page 21 of 26
1. Apply gear oil sparingly to the speedometer driven shaft and insert the shaft.
COMPONENTS
Page 22 of 26
1. Apply gear oil sparingly to the speedometer driven gear shaft and insert the shaft.
2. Install the spring pin in such a way the slit does not face the gear shaft.
Manual Transaxle System > Manual Transaxle Control System > Shift Fork > Components and
Components Location
COMPONENTS
Page 23 of 26
Manual Transaxle System > Manual Transaxle Control System > Manual Transaxle Shift Control >
Components and Components Location
COMPONENTS
Page 24 of 26
Page 25 of 26
Manual Transaxle System > Manual Transaxle Control System > Manual Transaxle Shift Control >
Repair procedures
REMOVAL
1. Remove the console assembly (Refer to CONSOLE).
2. Remove the self locking pin and clips (shift lever side).
3. Remove the shift lever assembly.
4. Remove the retainer and bolts.
5. Remove the snap pin and clips (Transaxle side).
6. Remove the shift cable and select cable.
INSPECTION
1. Check the select cable for proper operation and for damage.
2. Check the shift cable for proper operation and for damage.
3. Check the boot for damage.
4. Check each bushing for wear, abrasion, sticking, restricted movement or damage.
5. Check for a weak or damaged spring.
Page 26 of 26
INSPECTION
1. Inspect the bushing for wear or damage.
2. Inspect the return spring for damage or deterioration.
REASSEMBLY
1. Install the shift lever assembly.
2. Installation of shift lever and select cable.
REASSEMBLY
1. Apply multi-purpose grease to the sliding part of the bushings.
2. Reassembly is reverse of the disassembly.
Page 1 of 57
OPTIMA(MS) > 2003 > G 2.4 DOHC > Restraint
Restraint > General Information > Special Service Tools

SPECIAL SERVICE TOOL
Tool
Illustration Use
(Number and Name)
0957A-38200 Simulator to check the resistance of
Dummy each wiring harness
(Use with 0957A-38000, 0957A-
38300, 0957A-38400)
Adapter connect DAB, PAB, SAB
0957A-38300
Dummy adapter
0957A-38400 Adapter to connect BPT

Dummy adapter
0957A-38000 Wiring harness checker of each

Diagnosis checker module (Use with 0957A-38200,
0957A-38300, 0957A-38400)
0957A-38100 Deployment adapter (Use with

Deployment adapter 0957A-34100A)
Restraint > General Information > Description and Operation

SRSCM(SRS CONTROL MODULE)
The supplement restraint system (SRS AIRBAG) is designed to supplement the seat belt to help reduce the risk or
severity of injury to the driver and passenger by activating and deploying the driver and passenger side airbag in
Page 2 of 57
certain frontal or side collisions.
The SRSCM type equipped with this model is HAE-3. HAE-3 is applied for DAB + 2BPT, DAB + PAB + 2BPT,
DAB + PAB + 2BPT + 2FSAB.
The SRS (Airbag) consists of : a driver side airbag module located in the center of the steering wheel, which
contains the folded cushion and an inflator unit ; a passenger side airbag module located in the passenger side crash
pad contains the folded cushion assembled with inflator unit ; Side airbag modules located in the driver and
passenger seat contain the folded cushion and an inflator unit. SRSCM located on the floor under the heater core
which monitors the system, an accelerometer which senses the vehicle deceleration, a spring interconnection (clock
spring) located within the steering column; system wiring and wiring connector; and a knee bolster located under the
steering column. The impact sensing function of the SRSCM is carried out by electronic accelerometer that
continuously measure the vehicle's acceleration and delivers a corresponding signal through amplifying and filtering
circuity to the microprocessor.
Deployment of the airbag is designed to occur in frontal or near-frontal or side impacts of moderate of severe force.
Only authorized service personnel should do work on or around the SRS components. Those service personnel
should read this manual carefully before doing any such work. Extreme care must be used when servicing the SRS
to avoid injury to the service personnel (by inadvertent deployment of the airbag) or the driver (by render the SRS
inoperative).
CUSTOMER CAUTIONS
Failure to carry out service operations in the correct sequence could cause the airbag system to unexpectedly deploy
during servicing, possibly leading to a serious injury. Further, if a mistake is made in servicing the airbag system, itis
possible that the airbag may fail to operate when required. Before performing servicing (including removal or
installation of parts, inspection or replacement), be sure to read the following items carefully.
1. Be sure to proceed airbag related service after approx. 30 seconds or longer from the time the ignition switch is
turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery. The airbag
system is equipped with a back-up power source to assure the deployment of airbag when the battery cable is
disconneted by an accident. The back-up power is available for approx. 150ms.
2. When the negative(-) terminal cable is disconnected from the battery, memory of the clock and audio systems will
be canceled. So before starting work, make a record of the contents memorized by the audio memory system.
When the work is finished, reset the audio system and adjust the clock.
3. Malfunction symptoms of the airbag system are difficult to confirm, so the diagnostic codes become the most
important source of information when troubleshooting.
4. When troubleshooting the airbag system, always inspect the diagnostic codes before disconnecting the battery.
5. Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.
6. Never attempt to disassemble and repair the airbag modules (DAB,PAB, SAB, BPT), clock spring and wiring in
order to reuse them.
7. If any component of SRS has been dropped, or if there are cracks, dents or other defects in the case, bracket or
connector, replace them with new ones.
8. After work on the airbag system is completed, perform the SRS SRI check. The airbag indicator lamp can be
interrupted by other curcuit fault in some cases. Therefore if the airbag indicator lamp goes on, be sure to erase
the DTC codes using Hi-scan just after repairing or replacing the troubled parts including fuse.
9. Especially in case of welding the body, never fail to disconnect the battery negative (-) terminal.
WARNING/CATTION LABELS
A number of caution labels relating to the SRS are found in the vehicle, as shown in the following illustration.
Followlabel instructions when servicing SRS. If labels are dirty of damaged, replace them with new ones.
Page 3 of 57
Page 4 of 57
A. DAB + PAB B. SUPPLEMENTAL RESTRAINT SYSTEM
CAUTION (AIRBAG) INFORMATION
TO AVOID SERIOUS INJURY : The airbag is a supplemental restraint system (SRS).
• For maximum safety protection in all types of You must always wear the seat belts. The airbag system
crashes, you must always wear your safety belt. condition is normal if "SRS" lamp in cluster flashes
• Do not install rearward-facing child seats in any front approximately 6 times after ignition key is turned on and
passenger seat position. then goes out. If any of the following conditions occur,
• Do not sit or lean unnecessarily close to the airbag. the system must be serviced :
• Do not place any objects over the airbag or between 1. "SRS" lamp does not light when key is turned on.
the airbag and yourself. 2. "SRS" lamp stays lit or flashes continuously.
• See the owner's manual for further information and 3. The airbag has inflated.
explanation. The airbag system must be inspected by an authorized
dealer ten years after vehicle manufacture date shown on
certification label located on left front door opening area.
C. CAUTION : AIRBAG ESPS UNIT D. CAUTION : SUPPLEMENTAL RESTRAINT
Detach connector before removing. Assemble strictly SYSTEM MODULE
according to manual instructions. To help avoid personal injury due to unwanted inflation
do not service or dispose of this unit without following
instructions in the service manual.
E. WARNING : F. CAUTION : SRS clock spring
Contents are poisonous and extremely flammable. Do This is not a repairable part. Do not disassemble or
not probe with electrical devices or otherwise tamper tamper. If defective replace entire unit per service
with in any way. Servicing of this unit to be performed manual instructions. To re-center rotate clockwise until
only by authorized personnel. tight. Then rotate in opposite direction approximately 3
turns and align ><. Failure to follow to instructions may
render SRS system inoperative risking serious driver
injury.
G. CAUTION : SRS H. WARNING
Before removal of steering gearbox, read service This car is equipped with a side airbag in each front seat.
manual, center front wheels and remove ignition key. • Do not use any accessory seat covers.
Failure to do so may damage SRS clock spring and • Use of other seat covers could reduce the effect of
render SRS system inoperative, risking serious driver the system.
injury. • Do not install any accessories on the side or near the
side airbag.
• Do not use excessive force on the side of the seat.
• For further information, see owner's manual.
I. ATTENTION
Do not open, remove or put into another vehicle. Risk of
malfunction and body injury.
SYSTEM COMPONENT AND LAYOUT

Page 5 of 57
AIRBAG SYSTEM (SRS)

Page 6 of 57
SRSCM CONNECTOR (SRE-HMC)

Page 7 of 57
Restraint > Supplemental Restraint System Control Module (SRnodeM) > Description and Operation
INFLATOR MODULE (DAB, PAB, SAB)
DAB (Driver airbag), PAB (Passenger airbag) module and SAB (Side Airbag) are comprised of inflator and
cushion. The initiator (A gas generator igniting device) is assembled in the inflator. When the vehicle is in a frontal or
side crash of sufficient force to close the sensor of SRSCM, current is developed through the deployment loop.
Current passing through the initiator ignites the material in the DAB and PAB module or SAB module and inflates
the airbag.
Page 8 of 57
1. When removing the airbag module or handling a new airbag module, it should be placed with the pad top surface
facing up. In this case, the twin-lock type connector lock lever should be in the lock state and care should be
taken to place it so the conector will not be damaged. Do not store a steering wheel pad on top of another one.
(Storing the pad with its metallic surface up may lead to a serious accident if the airbag should inflate for some
reason.)
2. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very
dangerous.)
3. Store the airbag module where the ambient temperature remains below 93°C (200°F), without high humidity and
away from electrical noise.
4. When using electric welding, disconnect the airbag connectors under the steering column near the MULTI-
FUNCTION SWITCH connector before starting work.
PPD (Passenger Presence Detection)
The passenger presence detection system detects the presence of passenger in the seat. The system is designed
primarilyto prevent replacement of airbag components that fire needlessly in an accident. The PPD system consists
of a weight sensor and an interface unit.
The threshold for PPD is ; occupied (15 kg), not occupied (0.6 kg) The sensor characteristics is defined :
RP ≤ 50 kΩ for W ≥ 15 kg
RP > 50 kΩ for W < 0.6 kg
(RP : Resistance of force sensing resistor)
(W : Mass of weight)
Page 9 of 57
SATELLITE SENSOR (SIDE IMPACT SENSOR)

The release system for the side airbag consists of a HAE-3 installed in the middle of the vehicle and two satellites -
one on the left-hand side and one on the right. Only the HAE-3 is capable of releasing the airbags or the seat-belt
pretensioners systems in the vehicle. In the dialog between the HAE-3 and the satellite, it is the HAE-3 which makes
the release decision. The HAE-3 is supported in connection with the side airbag function by the two satellites, which
act as intelligent acceleration sensors and as such back up the central airbag controller. Both the satellites
continuouslyreport the current system status on the left and right-hand sides of the vehicle to the HAE-3.
It monitors the acceleration sensor continuously. The test results are reported to the HAE-3 by means of periodic
status signals.
Restraint > Supplemental Restraint System Control Module (SRnodeM) > Troubleshooting
TROUVLESHOOTING
DIAGNOSTIC TROUBLESHOOTING FLOW
Page 10 of 57
SPECIFICATION
DIAGNOSIS WITH HI-SCAN

CHECK PROCECURES
1. Connect the Hi-scan DLC to the vehicle data link connector located underneath the dash panel.
2. Turn the ignition key to "ON" position and turn on Hi-scan.

3. Perform the SRS diagnosis according to the vehicle model configuration.
Page 11 of 57
4. If a fault code is retrieved, then replace the component. Never attempt to repair the component.
5. If the Hi-scan finds that a component of the system is faulty, there is a possibility that the fault is not in the
components but in SRS wiring or connector.
INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODE
DTC No. Fault description
B1111 Battery voltage too high
B1112 Battery voltage too low
B1346 DAB Resistance too high or open
B1347 DAB Resistance too low or short
B1348 DAB Short to GND
B1349 DAB Short to Battery
B1352 PAB Resistance too high or open
B1353 PAB Resistance too low or short
B1354 PAB Short to GND
B1355 PAB Short to Battery
B1378 Driver side airbag Resistance too high or open
B1379 Driver side airbag Resistance too low or short
B1380 Driver side airbag Short to GND
B1381 Driver side airbag Short to Battery
B1382 Passenger side airbag Resistance too high or open
B1383 Passenger side airbag Resistance too low or short
B1384 Passenger side airbag Short to GND
B1385 Passenger side airbag Short to Battery
B1361 Driver seat belt pretensioner Resistance too high or
open
B1362 Driver seat belt pretensioner Resistance too low or
short
B1363 Driver seat belt pretensioner Short to GND
B1364 Driver seat belt pretensioner Short to Battery
B1367 Passenger seat belt pretensioner Resistance too high
or open
B1368 Passenger seat belt pretensioner Resistance too low
or short
B1369 Passenger seat belt pretensioner Short to GND
B1370 Passenger seat belt pretensioner Short to Battery
B1401 Satellite left side short to GND or short
B1402 Satellite left side short to Battery or open
B1400 Satellite left side defect
Page 12 of 57
B1404 Satellite right side short to GND or short
B1405 Satellite right side short to Battery or open
B1403 Satellite right side defect
B1408 Satellite left communication error
B1410 Satellite right communication error
B1407 PPD communication error
B1406 PPD defect
B1661 ECU mismatching
B1511 Driver seat-belt buckle switch short to Battery or
open
B1512 Driver seat-belt buckle switch short to GND or short
B1513 Passenger seat-belt buckle switch short to Battery or
open
B1514 Passenger seat-belt buckle switch short to GND or
short
B1650 Crash recorded front airbag
B1655 Crash recorded side airbag
B1657 Ignition recorded belt pretensioner
B2500 Warning lamp failure
B1620 Internal fault
Restraint > Supplemental Restraint System Control Module (SRnodeM) > SRS Control Module
(SRnodeM) > Description and Operation
ELECTRICAL SYSTEM
The SRS airbag system has sophisticate electrical and electronic components, therefore the airbag operating
components should be handled very carefully.
SRSCM(Supplemental Restraint System Control Module)
SRSCM determines to deploy the airbag module by sensing the frontal and side impact sensed by the sensor built in
SRSCM.
• DC/DC convertor : The power supply DC/DC converters include a step-up and step-down converter, which
provides the firing voltage for two firing circuits and the internal operating voltage. If the internal operating voltage
falls below a defined threshold, a reset is executed.
• Arming sensor/safing sensor : The arming/safing sensor built in the airbag firing circuit has the function of arming
the airbag circuit under all required deployment condition and maintaining the airbag firing circuits unarmed under
normal driving conditions. The safing sensor is a dual-contact electromechanical switch which closes if it
experiences a deceleration exceeding a specified threshold.
• Back-up power : The SRSCM reserves the energy supply to provide deployment energy for a short second
when the vehicle voltage is low or if lost in a vehicle frontal crash.
• Malfunction detection : The SRSCM continuously monitors the current SRS operation status while the ignition
key is turned on and detects the malfunction of the system. The malfunction can be displayed in the form of
diagnostic trouble code using Scan tool (Hi-scan).
Page 13 of 57
• MIL (Malfunction Indication Lamp) notification : If any fault is detected, the SRSCM sends signal to the
indicator lampon the cluster to warn the vehicle driver. The MIL indicator is the key to driver notification of SRS
faults. Verify lamp and SRSCM operation by flashing 6 times when the ignition switch is first turned on.
• Malfunction recording : Once a fault occurred in the system SRSCM records the fault in the memory in the form
of DTC and the DTC can only be erased with the scan tool.
• Data link connector : The SRSCM memory stored data is accessed through the OBD-II Data Link Connector
(DLC) using a scan tool. The DLC is located underneath the driver side crash pad.
• After firing the airbags once, the SRSCM cannot be used again and must be replaced.
• Crash output
• The crash output is used to control an external device such as door control module in case of a crash event. The
crashoutput is specified as follows : The crash output is open-collector type switch logic output with 500mA of
sine current and its output impedance is 100Ω. The crash output is switched to ground for 200ms after the crash
detected.
SRS HARNESS
The SRS harness is wrapped in a yellow split-wrap tube so that it can be easily identified from the other vehicle
harness. A shorting bar is included inside the wiring connectors of DAB, PAB SAB and BPT inflator side. The
shorting bar shorts the current flow DAB, PAB SAB and BPT module circuit when the connectors are
disconnected. The circuits to the inflator module are shorted in this way to help prevent unwanted deployment of the
airbag when servicing the airbag module.
SRSCM INDEPENDENT LAMP ACTIVATION
The SRS malfunction indicator lamp (MIL) is located on the cluster and provides information of SRS operating
conditions by the control signals from SRSCM.
There are certain fault conditions in which the SRSCM (SRS Control Module) cannot function and thus cannot
control the operation of the lamp. In these cases, the lamp is directly activated by appropriate circuitry that operates
independently of the SRSCM, as follow :
1. Loss of ignition voltage supply to the SRSCM : lamp turned on continuously.
2. Loss of internal operating voltage : lamp turned on continuously.
3. SRSCM not connected : lamp turned on through shorting bar in wiring harness connector.
MIL OPERATION METHOD
Page 14 of 57
Restraint > Airbag Module > Repair procedures
AIRBAG MODULE DISPOSAL
FIELD DEPLOYMENT PROCEDURES
When handling the deployed airbag, be careful not to let the by-product dust enter to eye and always wear gloves
to avoid direct contact the by-product material.
AIRBAG MODURE DISPOSAL PROEDURES
Before either disposing of a vehicle equipped with an airbag, or prior to disposing of the airbag module, be sure to
first follow the procedures described below to deploy the airbag.
AIRBAG REMOTE DEPOLYMENT DEVICES
Tool, Number, Name Use
Deploymint tool (0957A-34100-A)
SRS DEPOLYMINT ADAPTER HARNESS
DAB : 0957A-38000
PAB : 0957A-34200
○Deploymint insede the vehicle (when wehicle eill not

longer be driven)
DISPOSAL PLAN
When the provblem occurs, thake disposal steps as follows.
Case Disposal plan
Abonormal problems in airbag module
Retrun to KMC
Deploy the airban module in the ssscrapper yard

Car scrapping DAB, PAB, SAB, BPT
with SST
Crash (Deployed) Service station disposes the Airbag module
UNDEPLOYED AIRBAG MODULE DISPOSAL
1. If the vehicle is to be scrapped, junked, or otherwise disposed of, deploy the airbag inside the vehicle.
2. Since there is a loud noise when the airbag is deployed, avoid residential areas whenever possible. If anyone is
nearby, give warning of the impending noise.
3. Since a large amount of smoke is produced when the airbag is deployed, select a well-ventilated site.
Moreover, never attempt the test near a fire or smoke sensor.
DEPLOYMENT INSIDE THE VEHICLE(When vehicle will no longer be driven)
1. Open all windows and doors of the vehicle. Move the vehicle to an isolated spot.
Page 15 of 57
2. Disconnect the negative (-) and positive (+) battery cables from the battery terminals, and then remove the
battery from the vehicle.
Wait at least 30 seconds after disconnecting the battery cable before doing any further work.
3. Remove the center crash pad side cover.
4. Disconnect airbag SRSCM connector.
5. Connect deployment tool to the connector of each module.
6. At location as far away from the vehicle as possible, press the push button (removed from the vehicle) to deploy
the airbag.
1. Before deploying the airbag in this manner, first check to be sure that there is no one in or near the
vehicle. Wear safety glasses.
2. The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to allow
it to cool before attempting to handle it. Although not poisonous, do not inhale gas from airbag
deployment. See Deployed Airbag Module Disposal Procedures for post-deployment handling
instructions.
3. If the airbag fails to deploy when the procedures above are followed, do not go near the module.
Contact your local distributor.
DEPLOYMENT OUTSIDE VEHICLE
1) Failure to follow all warnings, cautions, notices and procedures could result in personal injury or death.
2) Surface of a deployed airbag may contain small amounts of sodium hydroxide(NaOH). Prevent contact of
airbag module withliquids, combustibles, and flammable materials. Immediately wash hands and exposed skin
areas with mild soap and water. Flush eyes with water if exposed to by products. Failure to following these
instructions could result in chemical burns and personal injury.
3) A live(undeployed) airbag module 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.
4) 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.
5) 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..
Page 16 of 57
6) Damaged airbag modules should be stored away from all acids, halogens, heavy metals, and metal salts.
Damaged units mayproduce hydrozoic acid if exposed to liquids. If an undeployed airbag module or inflator is
ruptured or tampered with, refer to particular module´s msds(material safety data sheet) for important
information concerning constituents of undeployed modules. Exposure to high concentrations of airbag
porpellant mixture can cause headaches, nausea, blurred vision, faintnesss, cyanosis, lowering of blood pressure
or tachycardia. Failure to comply with this warning can result in fire, noxious fumes, severe personal injury, or
death.
7) Air bag module components are very hot after deployment. Units should be deployed outdoors or in an open
area to prevent fires. Allow components at least twenty minutes to thoroughly cool. Cooling modules should be
continuously monitoredto ensure hot components do not create fires with spilled liquids or other debris. Failure
to allow unit to cool couldresult in burns, fires or personal injury.
8) 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 all applicable state and local regulations including, but not limited to, environmental protection,
occupational health and safety, and transportation.
Failure to follow the following procedures could result in personal in jury or death.
1. Remove battery.
2. Wait 30 seconds before proceeding.
3. Disconnect appropriate Airbag Module, and remove from vehicle.
4. Locate airbag in an area that will provide protection to personnel when it deploys. An example of a safe
deployment site is 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 could 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.
Page 17 of 57
14. Verify that both READY and DEPLOY indicators are no longer illuminated.
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
plasticbag 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.

DEPLOYED AIRBAG MODULE DISPOSAL PROCEDURES
After deployment, the airbag module should be disposed of in the same manner as any other scrap parts, except that
the following points should be carefully noted during disposal.
1. The inflator will be quite hot immediately following deployment, so wait at least 30 minutes to allow it to cool
before attempting to handle it.
2. Do not put water or oil on the airbag after deployment.
3. There may be, adhered to the deployed airbag module, material that could irritate the eyes and/or skin, so wear
gloves and safety glasses when handling a deployed airbag module. IF DESPITE THESE PRECAUTIONS,
THE MATERIAL DOES GET INTO THE EYES OR ON THE SKIN, IMMEDIATELY RINSE THE
AFFECTED AREA WITH A LARGE AMOUNT OF CLEAN WATER. IF ANY IRRITATION
DEVELOPS, SEEK MEDICAL ATTEN-TION.
4. Tightly seal the airbag module in a strong vinyl bag for disposal.
5. Be sure to always wash your hands after completing this operation.

Page 18 of 57
Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring > Components and
Components Location
COMPONENTS
CLOCK SPRING
1. The clock spring (coil spring) consists of two current carrying coils. It is attached between the steering column
and the steering wheel. It allows rotation of the steering wheel while maintaining continuous contact of the
deployment loop through the inflator module.
The steering wheel must be fitted correctly to the steering column with the clock spring at the neutral position,
otherwise cable disconnection and other troubles may result.
Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring > Repair procedures
REMOVAL
Page 19 of 57
1. Disconnect the negative battery cable and keep it secured away from the battery.
Wait at least 30 seconds after disconnecting the battery cable before doing any further work to prevent
inadvertent deployment of the airbags.
2. When disconnecting the clock spring connector from the airbag module, pull the locking device on the connector
outward and spread it open.
3. When disconnecting the connector of the clock spring from the airbag module, pull the airbag's lock toward the
outer side to spread it open.
• When disconnecting the airbag module-clock spring connector, take care not to apply excessive force
to it
• The removed airbag module should be stored in a clean, dry place with the pad cover face up.
Page 20 of 57
4. Remove the steering wheel.
Do not hammer on the steering wheel. Doing so may damage the collapsible column mechanism, thus
reducing the protection to the driver in a frontal crash.
INSPECTION
AIRBAN MODULE
If any improper parts are found during the following inspection, replace the airbag module with a new one.
Dispose the old module according to the specified procedure.
Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the specified
tester. If the circuit resistance is measured with a tester, accidental airbag deployment will result in serious personal
injury.
1. Check pad cover for dents, cracks or deformities.
2. Check the airbag module for denting, cracking or deformation.
3. Check hooks and connectors for damage, terminals for defor-mities, and harness for binds.
4. Check airbag inflator case for dents, cracks or deformities.
5. Install the airbag module to steering wheel to check fit or align with the wheel.
CLOCK SPRING
If, as a result of the following checks, even one abnormal point is discovered, replace the clock spring with a new
one.
Page 21 of 57
1. Check connectors and yellow protective tube for damage, and terminals for deformities.
Restraint > Airbag Module > Passenger Airbag (PAB) Module > Repair procedures
REMOVAL
1. Never attempt to disassemble or repair the airbag module.

2. Do not drop the airbag module or allow contact with water, grease or oil. Replace it if a dent, crack,
deformation or rust are detected.
3. The airbag module should be stored on a flat surface and placed so that the pad surface is facing upward. Do
not place anything on top of it.
4. Do not expose the airbag module to temperature over 93°C (200°F)
5. An undeployed airbag module should only be disposed of in accordance with the procedures contained in this
manual.
6. Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the specified
tester. If the circuit resistance is measured with a tester, accidental airbag deployment will result in serious
personal injury.
7. Whenever the PAB is deployed, it should be replaced with a new PAB assembled with an extension wire.
When the PAB deploys, the squib melts making the extension wire on the deployed airbag module useless.
1. Disconnect the battery negative (-) terminal cable.
Wait at least 30 seconds in order to prevent inadvertent airbag

deployment.
2. Remove the glove box.
3. Disconnect the PAB module connector.
4. Remove the crash pad assy and then do the PAB module.
REASSEMBLY
Refer to BD section of this manual for crash pad removal procedures.
Page 22 of 57
Restraint > Troubleshooting > B1111

TROUBLESHOOTING FOR DTC
B1111 Battery voltage too high
DTC
B1112 Battery voltage too low
CIRCUIT DESCRIPTION
Since the source voltage can fluctuate, the SRS is equipped with a voltage-increase/voltage-decrease circuit
(DC/DC converter) in the SRSCM to adjust for any fluctuations in the source voltage. When the battery voltage
fluctuates, the DC/DC converter adjust the voltage to the SRS by either increasing or decreasing to maintain normal
system voltage. The diagnosis system malfunction display for this circuit is different than other circuits-when the SRS
warning lamp remains lit up and the DTC is a B1111 or B1112 code, battery voltage too high or low is indicated.
Malfunction in this circuit is not recorded in the B1111 or B1112 code, battery voltage too high or low, and the
voltage returns to normal, the SRS warning light automatically goes off.
INSPECTION PROCEDURE
1. Preparation.
(1) Disconnect negative (-) terminal cable from the battery, and wait at least 30 seconds.
(2) Remove the DAB module.
(3) Disconnect connectors of PAB left and right side airbag,belt pretensioner and satellite sensor.
(4) Disconnect connector of SRSCM.
Store the DAB with the front surface facing upward.

Page 23 of 57
2. Check source voltage.
(1) Connect negative (-) terminal cable to battery.
(2) Turn ignition switch ON.
[CHECK]
Measure voltage between the battery supply 5 of SRS connector and body ground.
LIMIT : 10 - 16.5 V
3. Does SRS warning light turn off?

[PREPARATION]
(1) Turn ignition switch to LOCK.
(2) Connect the DAB module.
(3) Connect PAB connector, left and right side airbag, belt pretensioner and satellite connectors.
(4) Connect SRSCM connector.
(5) Turn ignition switch ON.
[CHECK]
Check that SRS warning light goes off.

Troubleshooting for DTC
B1346 DAB resistance too high
DTC
B1347 DAB resistance too low
CIRCUIT DESCRIPTION
Page 24 of 57
The DAB squib circuit consists of the SRSCM, clock spring and DAB. The squib is what causes the airbag to
deploy when airbag deployment conditions are satisfied. The above DTC's are recorded when DAB resistance too
high or low is detected in the DAB squib circuit.
DTC Detecting Condition Trouble Area
• Too high or low resistane between DAB high (+) • DAB squib
wiring harness and DAB low (-) wiring harness of • Clock spring
squib. • SRSCM
• DAB malfunction • Wire harness
• Clock spring malfunction
• SRSCM malfunction
WIRING DIAGRAM
1. Preparation.
(1) Disconnect negative (-) terminal cable from the battery, and wait at least 30 seonds.
(3) Disconnect connectors of PAB, left and right side airbag, belt pretensioner and satellite sensor.
Page 25 of 57
2. Check DAB resistance.
[PREPARATION]
Release airbag activation prevention mechanism on SRSCM side of airbag squib side.
Connect the dummy (0957A-38200) to clock spring side connector.
[CHECK]
Measure the resistance between DAB high (+) and low (-).
1.7 Ω< R <2.3 Ω
3. Check DAB squib.

[PREPARATION]

(3) Connect DAB connector.
(4) Connect negative (-) terminal cable to the battery, and wait at least 30 seconds.
[CHECK]
(1) Turn ignitin switch to ON, and wait at least 30 seconds.
(2) Clear malfunction code stored in memory with Hi-scan.
(3) Turn ignition switch to LOCK, and wait at least 30 seconds.
(4) Turn ignition switc to ON, and wait at least 30 seconds.
(5) Using Hi-scan, check DTC.
DTC is not output.
[HINT]
Codes other than these ones may be output at this time, but they are not relevant to this check.
Page 26 of 57
4. Check Clock spring.

[PREPARATION]
Disconnect connector between SRSCM clock spring, and connect the dummy connector (0957A-38200) to
clock spring side connector.
[CHECK]
Measure the resistance between DAB high (+) and low (-).
1.7 Ω< R <2.3 Ω

Page 27 of 57
B1348 DAB Short to ground
B1354 PAB Short to ground
B1380 Driver SAB Short to ground
B1384 Passenger SAB Short to ground
B1363 Driver BPT Short to ground
DTC B1369 Passenger BPT Short to ground

B1401 Satellite left side short to gound
B1404 Satellite right side short to gound
Driver seat belt buckle switch to ground or
B1512
short
Passenger seat belt buckle switch to
B1514
ground or short
CIRCUIT DESCRIPTION
The squib circuit consists of the SRSCM, clock spring, DAB, PAB, SAB, BPT, BBS, and front satellite sensors. If
it causes the SRS to deploy when the SRS deployment conditions are satisfied.The above DTC's are recorded
when a short to ground is detected in the squib circuit.
• Short circuit in squib wire harness (to ground) • DAB squib
• Squib malfunction • PAB squib
• Clock spring malfunction • SAB squib
• SRSCM malfunction • BPT squip
• BBS squib
• Satellite sensor
• Clock spring
• SRSCM
• Wire harness
WIRING DIAGRAM
Page 28 of 57
1. Preparation
2. Check DAB squib circuit.
[CHECK]
For the connector (on the clock spring side) between clock spring and DAB, measure the resistance between
DAB high and body ground.
Resistance: ∞
Page 29 of 57
3. Check PAB squib circuit.
[CHECK]
For the connector (on the SRSCM side) between SRSCM and PAB, measure the resistance between PAB high
and body ground.
Resistance: ∞
4. Check SAB squib circuit.
[CHECK]
For the connector (on the SRSCM side) between SRSCM and SAB, measure the resistance between SAB high
and body ground.
Resistance: ∞
Page 30 of 57
5. Check BPT squib circuit
[CHECK]
For the connector (on the SRSCM side) between SRSCM and BPT, measure the resistance between BPT high
and body ground.
Resistance: ∞
6. Check Satellite sensor circuit.
[CHECK]
For the connector (on the SRSCM side) between SRSCM and Satellite sensor, measure the resistance between
Satellite high and body ground.
Resistnace: ∞
Page 31 of 57
7. Check SRSCM.
[PREPARATION]
(1) Connector to SRSCM.
(2) Using a service wire, connect DAB high and DAB low on the clock spring side of connector between clock
spring and DAB.
(3) Using a service wire, connect PAB high and low on SRSCM side of connector between SRSCM and PAB.
(4) Connect SAB and BPT using the same method.
(5) Connect negative (-) terminal cable to battery, and wait at least 30 seconds.
[CHECK]
(1) Turn ignition switch to ON, and wait at least 30 seconds.
DTC iss not output.
[HINT]
(1) Codes other than these ones may be output at this time, but they are not relevant to this check.
Page 32 of 57
8. Check DAB squib.
[PREPARATION]
(3) Connect DAB connector.
[CHECK]
(2) Clear malfunction cede stored in memory with Hi-scan.
DTC is not output.
[HINT]
Page 33 of 57
9. Check PAB squib.
[PREPARATION]
(3) Connect PAB connector.
[CHECK]
DTC is not output.
[HINT]
Page 34 of 57
10. Check SAB squib.
[PREPARATION]
(2) Disconnet negative (-) terminal cable from the battery, and wait at least 30 seconds.
(3) Connect SAB connector.
(4) Connect negative (-) terminal cable from the battery, and wait at least 30 seonds.
[CHECK]
(1) Turn ignition switch to ON, and wait at least 30 secods.
(3) Turn ignition switch to LOCK, and wait at least 30 secods.
DTC is not output.
[HINT]
Page 35 of 57
11. Check BPT squib.
[PREPARATION]
(3) Connect BPT connector.
(4) Connect negative (-) terminal cable from the battery, and wait at least 30 seconds.
[CHECK]
DTC is not output.
[HINT]
Page 36 of 57
12. Check Satellite sensor.
[PREPARATION]
(3) Connect Satellite sensor connector.
(4) Connect negative (-) terminal cable from the battery, and wait at least 30 seconds.
[CHECK]
DTC is not output.
[HINT]
Page 37 of 57
13. Check clock spring circuit.
[PREPARATION]
Disconnect connector between SRSCM and clock spring.
[CHECK]
Measure resistance between DAB high on clock spring side of connector between clock spring and DAB and
body ground.
Resistance: ∞

DAB Short to battery
B1319 PAB Short to battery
B1355 SAB (Driver) short to battery
B1381 SAB (Passenger) short to battery
B1385 BAT (Driver) short to battery
B1364 BPT (Passenger) short to battery
DTC
B1370 Satellite left side short to battery
B1402 Satellite right side short to battery
B1405 Driver seat belt buckle switch short to
B1511 battery
B1513 Passenger seat belt buckle switch short
to battery
CIRCUIT DESCRIPTION
The squib circuit consists of the SRSCM, clock spring, DAB, PAB, SAB, BPT, BBS, and satellite sensor. If it
causes the SRS to deploy when the SRS deployment conditions are satisfied. The above DTC's are recorded when
a B+ short is detected in the squib circuit.
Page 38 of 57
• Short circuit in squib wire • DAB squib
harness (to B+) • PAB squib
• Squibl malfunction • SAB squib
• Spiral cable malfunction • BPT squib
• SRSCM malfunction • Satellite sensor
• Wire harness
WIRING DIAGRAM
1. Preparation.
Page 39 of 57
2. Check DAB squib circuit.
[CHECK]
For the connector (on the clock spring side) between clock spring and DAB, measure the voltage between DAB
high and body ground.
Voltage : 0 V
3. Check PAB squib circuit.
[CHECK]
For the connector (on the SRSCM side) between SRSCM and PAB, measure the voltage between PAB high
and body ground.
Voltage : 0 V
Page 40 of 57
4. Check SAB squib circuit.
[CHECK]
For the connector (on the SRSCM side) between SRSCM and SAB, measure the voltage between SAB high
and body ground.
Voltage : 0 V
5. Check BPT squib circuit.
[CHECK]
For the connector between SRSCM and BPT, measure the voltage between BPT high and body ground.
Voltage : 0 V
Page 41 of 57
6. Check Satellite sensor circuit.
[CHECK]
For the connector between SRSCM and Satellite sensor, measure the voltage between Satellite sensor high and
body ground.
Voltage : 0 V
7. Check SRSCM.
[PREPARATION]
A. Connect connector to SRSCM.
B. Using a service wire, connect DAB high and low on the clock spring side of connector between clock spring
and DAB.
C. Using a service wire, connect PAB high and low on SRSCM side of connector between SRSCM and PAB.
D. Using a service wire, connect SAB high and low on SRSCM side connector between SRSCM and SAB.
E. Using a service wire, connect BPT high and low on SRSCM side connector between SRSCM and BPT.
F. Using a service wire, connect satellite high and low on SRSCM side connector between SRSCM and satellite
sensor.
G. Connect negative (-) terminal cable to battery, and wait at least 30 seconds.
[CHECK]
A. Turn ignition switch to ON, and wait at least 30 seconds.
B. Clear malfunction code stored in memory with Hi-scan.
C. Turn ignition switch to LOCK, and wait at least 30 seconds.
D. Turn ignition switch to ON, and wait at least 30 seconds.
E. Using Hi-scan, check DTC.
DTC is not output.
Page 42 of 57
[HINT]
8. Check DAB squib.

[PREPARATION]
A. Turn ignition switch to LOCK.
B. Disconnect negative (-) terminal cable from the battery, and wait at least 30 seconds.
C. Connect DAB connector.
D. Connect negative (-) terminal cable to the battery, and wait at least 30 seconds.
[CHECK]
DTC is not output.
[HINT]
Page 43 of 57
9. Check PAB squib.
[PREPARATION]
C. Connect PAB connector.
[CHECK]
DTC is not output.
[HINT]
10. Check SAB squib.

[PREPARATION]
A. Turn ignition swich to LOCK.
C. Connect SAB connector.
D. Connect negative (-) terminal cable from the battery, and wait at least 30 seconds.
[CHECK]
Page 44 of 57
DTC is not output.
[HINT]
11. Check BPT squib.

[PREPARATION]
C. Connect BPT connector.
[CHECK]
DTC is not output.
[HINT]
Page 45 of 57
12. Check Satellite sensor.
[PREPARATION]
C. Connect Satellite connector.
[CHECK]
DTC is not output.
[HINT]
13. Check Clock spring.

[PREPARATION]
B. Disconnect connector between SRSCM and clock spring.
[CHECK]
Turn ignition switch to ON, and measure voltage DAB high on side and body ground.
Voltage : 0 V
Page 46 of 57

B1352 PAB resistance too high
DTC
B1353 PAB resistance too low
CIRCUIT DESCRIPTION
The PAB squib circuit consists of the SRSCM and PAB. The squib is what causes the airbag to deploy when airbag
deployment conditions are satisfied.The above DTC's are recorded when PAB resistance too high or low is
detected in the PAB squib circuit.
DTC Detecting Condition Trouble area
• Too high or too low resistance between PAB high • PAD squib
(+) wiring harness nad PAB low (-) wiring harness of • SRSCM
squib. • Wire harness
• PAB malfunction
WIRING DIAGRAM
Page 47 of 57
1. Preparation.
2. Check PAB resistance.
[PREPARATION]
Release airbag activation prevention mechanism on SRSCM side of airbag squib side. Connect the dummy
connector (0957A-38200) to PAB connector of the SRSCM connector side.
[CHECK]
Measure the resistance between PAB high (+) and PAB low (-).
1.7Ω < R < 2.3Ω
Page 48 of 57
3. Check PAB squib.

[PREPARATION]
A. Turn ignition swich to LOCK.
C. Connect PAB connector.
[CHECK]
DTC is not output.
[HINT]

DSAB Resistance too
B1378
high
B1379
DTC DSAB Resistance too low
B1382
PSAB Resistance too high
B1383
PSAB Resistance too low
Page 49 of 57
CIRCUIT DESCRIPTION
The SAB squib circuit consists of the SRSCM and SAB. If it causes the airbag to deploy when the airbag
deployment conditions are satisfied. The above DTC's are recorded when SAB resistance too high or low is
detected in the SAB squib circuit.
DTC Detecting Condition Trouble area
• Too high or too low resistance between SAB high • SAB squib (LH, RH)
(+) wiring harness nad SAB low (-) wiring harness of • SRSCM
squib. • Wire harness
• SAB malfunction
WIRING DIAGRAM
1. Preparation.
Page 50 of 57
2. Check SAB resistance.
[PREPARATION]
Release airbag activation prevention mechanism on SRSCM side of airbag squib side.
Connect the dummy connector (0957A-38200) to SAB connector of the SRSCM connector side.
[CHECK]
Measure the resistance between SAB high (+) and SAB low (-).
1.9 Ω < R <2.5 Ω
3. Check SAB squib.

[PREPARATION]
C. Connect SAB connector.
[CHECK]
DTC is not output.
[HINT]
Page 51 of 57

Satellite left side defect
B1400 Satellite right side defect
B1403 Satellite left communication
DTC
B1408 error
B1410 Satellite right communication
error
CIRCUIT DESCRIPTION
The release system for the airbag consists of the SRSCM and two satellites-one on the left-hand side and one on the
right. The above DTC's are recorded when the defect or communication error of satellite is detected in the satellite
circuit.
WIRING DIAGRAM
Page 52 of 57
1. Preparation.
2. Check Satellite circuit (Communication error).
[PREPARATION]
Check continuity between SRSCM connector and satellite connector as high (+) and high, low (-) and low (-).
OK : Continuity
3. Check Satellite sensor (Defect).

[PREPARATION]
C. Connect satellite connector.
[CHECK]
DTC is not output.
Page 53 of 57
[HINT]

B1346 DAB resistance too high
DTC
B1347 DAB resistance too low
CIRCUIT DESCRIPTION
The release system for the airbag consists of the SRSCM, an interface unit and PPD. The above DTC's are
recorded when the defect or communication error of PPD is detected in the PPD circuit.
WIRING DIAGRAM
Page 54 of 57
1. Preparation.
2. Check PPD circuit (Communication error).
Check continuity between SRSCM connector and PPD interface unit as high (+) and high, low (-) and low (-).
OK : Continuity
3. Check PPD interface unit.

Check continuity of PPD interface unit as high (+) and high (+), low (-) and low (-).
4. Check PPD sensor (Defect).
[CHECK]
Check the resistance in accordance with the changed weight.
R ≤ 50 kΩ for W ≥ 15 kg
R > 50 kΩ for W ≤ 0.6 kg
Page 55 of 57
5. Check PPD squib.
[PREPARATION]
A. Connect connector to SRSCM.
B. Connect negative (-) terminal cable to battery, and wait at least 30 seconds.
[CHECK]
DTC is not output.
[HINT]

ECU mismatching
B1661
Crash recorded front airbag
B1650
Crash recorded side airbag
DTC B1655
Ignition recorded belt
B1657
pretensioner
B1620
Internal fault
CIRCUIT DESCRIPTION
SRSCM MALFUNCTION
The SRSCM also cyclically monitors the following :
1. Functional readiness of the firing circuit activation transistors.
2. Adequacy of deployment energy reserves.
3. Safing sensor integrity : detection of faulty closure.
4. Plausibility of accelerometer signal.
Page 56 of 57
5. Operation of SRSCM components.
The timely completion of all tests is monitored by a separate hardware watchdog. During normal operation, the
watch dog is triggered periodically by the SRSCM ; If the SRSCM fails to trigger the watchdog, the watchdog will
reset the SRSCM and activate the SRI (Service Reminder Indicator). The SRSCM must be replaced once the fault
codes above mentioned are confirmed.

DTC B2500 Warning lamp failure
CIRCUIT DESCRIPTION
The SRS warning lamp is located on the cluster. When the airbag system is normal, the Service Reminder Indicator
(SRI) or SRS Warning Lamp flashes for approximately 6 seconds after the ignition switch is turned ON, and then
turns off automatically. If there is a malfunction in the airbag system, the SRI lights up to inform the driver of the
abnormality. The SRSCM measures the voltage at the airbag SRI output pin, both when the lamp is on and when
the lamp is off, to detect whether the commanded state matches the actual state.
1. Check the fuse.
[PREPARATION]
A. Remove the fuse No. 11 and 14 from the junction block.
B. Inspect the condition of fuse.
C. Replace if necessary.
2. Check SRS warning lamp circuit.
[PREPARATION]
A. Connect negative (-) terminal cable to the battery.
B. Turn ignition switch to ON.
[CHECK]
A. Measure voltage of harness side connector of SRSCM.
Voltage : 10-16.5 V
B. Check SRS SRI (Service Reminder Indicator).

Page 57 of 57
A. OK : SRS SRI ON
Page 1 of 48
OPTIMA(MS) > 2003 > G 2.4 DOHC > Steering System
Steering System > General Information > Special Service Tools

SPECIAL SERVECE TOOLS
Tool (Number and Name) Illustration Use
09222-21100
Installation of the pinion gear bearing
09222-32100
Installation of the oil pump oil seal
09431-11000
Installation of the pinion gear oil seal
Front oil seal installer
09432-21601
Installation of the pinion gear bearing
Bearing installer
1)Removal of pinion gear bearing

09571-21400
2)Removal of pinion bearing outer
Drift
race
Removal and installation of the oil

09555-21000
seal (use with 09573-33001,
Bar
09573-21200, 09573-21000)
Page 2 of 48
09565-11100 Measurement of the main shaft pre-

Pre-load socket load
09565-21000 Removal and installation of pinion

Pinion bearing remover and installer gear bearing
09565-31300 Removal. installation and adjustmint

Yoke plug torque wrench socket of wteering gear yoke plug
0K670-321-019 Separation of the tie rod end ball

Ball joint remover joint
09572-21000/0K201 323 AA1 Measurement of the oil pressure (use

Oil pressure gauge with 09572-33100, 09572-21200)
09572-22000
Measurement of the oil pressure (use
Oil pressure gauge adapter V6,
with 09572-21000, 09572-22100)
DOHC ENG.
09572-22100
Measurement of the oil pressure (use
Oil pressure gauge adapter V6,
with 09572-21000, 09572-22000)
DOHC ENG.
Page 3 of 48
Installation of the ack up washer and

09573-21000
oil seal (use with 09573-33000,
Oil searl installer guide
09573-33100, 09555-21000)
Installation of the back up washer

09573-33000
and oil sea (use with 09573-21000,
Oil seal installer
09573-33100, 09555-21000)
Removal and installation of the oil

09573-33100
seal (use with 09573-21000,
Oil seal guide
09573-33000, 09555-21000)
Steering System > General Information > Troubleshooting

TROUBLESHOOTING
Steering wheel return Incorrect tire pressure Adjust the tire pressure
malfunction
Steering operation is "hard" Incorrect tire pressure Adjust the tire pressure
Loose belt Adjust the belt tension
Damaged belt Replace the belt
Low fluid level Refill fluid
Air in fluid line Bleed the system
Steering wheel pulls to one side Twisted hose Correct the hose routing or replace the
hoses
Incorrect mounting of the steering gear Retighten
box on the crossmember
Fluid leakage Check the fluid leakage and retighten or
replace
Incorrect wheel alignment (especially Adjust the wheel alignment
caster)
Malfunction of gear box Check and replace the gear box if
necessary
Page 4 of 48
Malfunction of oil pump Check the oil pump pressure and repair
oil pump
Excessive steering wheel play Adjust the steering wheel play
Insufficient tire inflation pressure Adjust the tire pressure
Unevenly worn or deformed tire Rotate the wheel or replace the tire
Dragging brake Adjust
Deteriorated or broken front spring Replace
Deformed knuckle arm Replace
Poor wheel alignment Adjust the wheel alignment
Damaged wheel bearing Replace
Deformed or loose lower arm Retighten or replace
Loose linkage joints Retighten
Malfunction of ball joints (Too small Replace
ball joint starting torque)
Deteriorated or broken lower arm Replace
bushing
Incorrect installation or internal damage Correct or replace
in gear
Malfunction of shock absorber Replace
Steering wheel vibrates Insufficient tire inflation pressure Adjust the tire pressure
Unevenly worn or deformed tire(s) Rotate the wheels or replace the tire(s)
Loose hub nut Retighten
Excessive runout, or unbalance of tire Adjust the wheel balance or replace
and wheel
Poor wheel alignment Adjust the wheel alignment
Damaged wheel bearing Replace
Deformed or loose lower arm Retighten or replace
Deformed linkage Repair or replace
Loose linkage joints Retighten
Malfunction of ball joints (Too small Replace
ball joint starting torque)
Malfunction of front suspension Check and adjust; replace the parts if
necessary
Incorrect installation or internal damage Correct or replace
in gear box
Malfunctioning of shock absorber Replace
Road shock is felt in steering Insufficient steering wheel play Adjust the steering wheel play
wheel
Insufficient tire inflation pressure Adjust the tire pressure
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Unevenly worn or deformed tire(s) Rotate the wheels or replace the tire(s)
Malfunction of shock absorber Replace
Poor recovery of steering wheel Insufficient tire inflation pressure Adjust the tire pressure
to straight ahead position
Stuck or damaged ball joint Replace
Improper wheel alignment angles Adjust the wheel alignment
Rattling noise Loose installation of oil pump or gear Retighten the oil pump and gear box
box
Steering linkage looseness or play Retighten or replace the steering linkage
Loose oil pump pulley nut Retighten the oil pump pulley nut
Interference around column or between Correct or replace the pressure hose
pressure hose and other parts and the parts around the column
Abnormal noise inside the gear box and Replace the gear box or oil pump
oil pump
Strident noise Air sucked into oil pump Check the oil level and hose clips;
bleed the system or replace the oil
pump
Seizure inside oil pump Replace the oil pump
Squealing noise 1) Loose belt Adjust the belt tension
Seizure inside oil pump Replace the oil pump
Hissing noise Air sucked into oil pump Check the oil level and hose clips;
bleed the system
Damage to the gear box port section Replace the gear box
Malfunction of return hose Replace the hose
Whistling noise Malfunction of gear box port section Replace the gear box
Droning noise Loose mounting bolt on oil pump or oil Retighten the pump bracket and pump
pump bracket installing bolt
Poor condition of oil pump body 2) Replace the oil pump
Squeaking noise 2) Malfunction of steering stopper contact Check and adjust the steering stopper
Interference of wheel with vehicle body Adjust the steering angle
Interference of steering shaft and joint Reposition the interfering parts
assembly with other parts
Malfunction of gear box Replace the gear box
Shuddering vibration 3) Air suction Bleed the system
Malfunction of gear box Replace the gear box
Oil leakage from hose Improperly tightened flare nut Check, repair or replace
connection
Incorrectly inserted hose
Improperly clamped hose
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Oil leakage from hose assembly Damaged or clogged hose Replace
Hose connector malfunction
Oil leakage from oil reservoir Leaking reservoir Replace
Overflow Bleed the system or adjust the oil level
Oil leakage from oil pump Malfunction of oil pump housing Replace the oil pump
Malfunction of O-ring and/or oil seal Replace the O-ring and oil seal
Oil leakage from gear box Malfunction of gear box housing Replace the gear box
(including leakage from air hole)
Malfunction of O-ring and/or oil seal Replace the O-ring and oil seal
Steering System > General Information > Specifications

Specifications
Item Specification
Shaft and joint type Collapsible, crossjoint with tilt column
Steering gear type Rack and pinion
Rack stroke 150 ± 1 mm
Oil pump type Vane type
Steering sheel free play 0-30 mm (0-1.1 in.)
Steering angle Inner wheel 40.70°
Outer wheel 32.40°
Tie rod end ball joint starting torque 0.5-2.5N·m (5-25 kg·cm, 0.36-1.78lb·ft)
Stationary steering effort 3.0 kg Max.
Belt deflection [under 98 N(10kg, 22 lbs) 8.8-11.0 mm (New one)
force] 11.7-15.3 mm (Refular inspection)
SERVICE STANDARD
Steering sheel free play 0-30 mm (0-1.1 in.)
Inner wheel 40.70° ±2°
Steering angle
Outer wheel 32.40°
Tie rod end ball joint starting torque 0.5-2.5Nm (5-25 kg·cm, 0.36-1.78 lb·ft)
Stationary steering effort 3.0 kg Max.
Belt deflection [under 98 N(10kg, 22lbs) 8.8-11.0 mm (New one)
force] 11.7-15.3 mm(Refular inspection)
TIGHTENING TORQUE
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Nm kg·cm lb·ft
Airbag module mounting bolt 8-11 80-110 6-8
Steering column to column member
13-18 130-180 8-13
mounting(upper)
Steering column
Steering column to cloumn member
and shaft 13-18 130-180 8-13
mounting(lower)
Steering wheel lock nut 40-50 400-500 30-36
Joint assembly 15-20 150-200 10-15
Pressure hose to gear box 12-18 120-180 8.8-13
Return tube to gear box 12-18 120-180 8.8-13
Steering gear
Tie rod to rack (MANDO) 80-100 800-1000 59-74
box
Tie rod end lock nut 50-55 500-550 37-41
Rack support plug lock nut(MANDO) 50-70 500-700 36-51
Pinion and valve assembly to self locking nut
45-50 450-500 33-36
(MANDO)
Steering gear End plug 45-55 450-550 33-40

box Feed tubes 12-18 120-180 8.8-13
Tie rod end to knuckle 75-90 750-900 55-66
Mounting bracket to crossmember 60-80 600-800 43-58
Pressure hose to oil pump 55-65 550-650 41-47
Oil pump mounting bolt 39-60 390-600 30-43
Heat protector mounting bolt 45-55 450-550 33-40
Oil pump Oil pump bracket mounting bolt 39-60 390-600 30-43
pump cover to pump body 21-29 210-290 14.9-20.6
Suction connector to pump body 13.6-18.4 136-184 9.7-13.1
Flow control valve connector to pump body 70-80 700-800 51-58
Oil reservoir bracket mounting bolt 4-6 40-60 3-4.4
Cooler tube clamp mounting bolt(MANDO) 4-6 40-60 3-4.4
Steering hoses
Trbe clip and tube bracket 4-6 40-60 3-4.4
and oil reservoir
pressure gose bracket mounting bolt 4-6 40-60 3-4.4
Hose clamp 4-6 40-60 3-4.4
LUBRICANTS
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Items Quantity
Multipurpose grease SAE J310a, NLGI
Steering column bearing
No.2 As required
Steering gear box rack. pinion gear
Multipurpose grease SAE J310a, NLGI As required
part
No.2 As required
Bellows
Silicone grease As required
Oil pump
Power steering fluid(PSF-3) 1.0 lit (0.88 qts.)
Power steering fluid
Power steering fluid(PSF-3)
Steering System > Hydraulic Power Steering System > Troubleshooting

SERVICE ADJUSTMENT PROCEDURE
CHECKING STEERING WHEEL FREE PLAY
1. Start the engine with the steering wheel in the straight ahead position. Apply a force of 5 N (1.1 lb) to the steering
wheel in the peripheral direction.
2. Measure the play at the circumference of the steering wheel.
Steering wheel free play [Standard value] : 30 mm (1.1 in.)
3. If the play exceeds the standard value, inspect the contact of the steering shaft and tie rod ball joints.
CHECKIN STEERING ANGLE
1. Place the front wheel on a turning radius gauge and measure the steering angle.
Wheel angle [Standard value]

Inside wheel : 40.70°
Outside wheel : 32.40°
2. If the measured value is not within the standard value. Adjust the linkage.
CHECKING STEERING WHEEL RETURN

Check the steering wheel return and confirm the following points :
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1. The force required to turn the steering wheel and the wheel return should be the same for left and right for both
moderate turns and sharp turns.
2. When the steering wheel is turned 90° and held for a couple of seconds while the vehicle is being driven at 20-30
kph (12-19 mph), the steering wheel should return at least 70° from the neutral position when it is released.
If the steering wheel is turned very quickly, the steering wheel operation may be momentarily difficult. This
is not a malfunction.
CHECKING TIE ROD END BALL JOINT STARTING TORQUE
1. Disconnect tie rod and knuckle.
2. Shake the ball joint stud several times.
3. Mount two nuts on the ball joint, and then measure the ball joint starting torque.
Standard value : 0.5-2.5 Nm (5-25 kg·cm, 0.36-1.78 lb·ft)
4. If the starting torque exceeds the upper limit of standard value, replace the tie rod end.
5. Even if the starting torque is below the lower limit of the standard value, the ball joint may be reused unless it has
drag and excessive play.
CHECKING POWER STEERING FLUID LEVEL
1. Position the vehicle on a level surface.
2. Start the engine. With the vehicle kept stationary, turn the steering wheel several times continuously to raise the
fluid temperature from 50-60°C (122-140°F).
3. With the engine at idle, turn the steering wheel fully clockwise and counterclockwise several times.
4. Make sure that there is no foaming or cloudiness in the reservoir fluid.
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5. Stop the engine and check for any difference in fluid level between a stopped and a running engine.
1. If the fluid level varies 5 mm (0.2 in.) or more, bleed the system again.
2. If the fluid level suddenly rises after stopping the engine, it shows that bleeding is not
satisfactory.
3. Incomplete bleeding will produce a chattering sound decreasing durability of the pump, etc.
REPLACING POWER STEERING FLUID

1. Jack up the front wheels and support with rigid racks.
2. Disconnect the return hose from the oil reservoir and install a plug on the oil reservoir.
3. Connect a vinyl hose to the disconnected return hose, and drain the oil into a container.
4. Disconnect the high-tension cable at the ignition coil side. While operating the starter motor intermittently, turn the
steering wheel all the way to the left and then to the right several times to drain the fluid.
5. Connect the return hoses securely, and then fill the oil reservoir with the specified fluid.
6. Bleed system.
Power steering fluid (PSF-3)type :

Total quantity : Approx. 1.0 liter
AIR BLEEDING
1. Disconnect the high tension cable, and while operating the starting motor intermittently (for 15-20 seconds), turn
the steering wheel all the way to the left and to the right five or six times.
1. During air bleeding, replenish the fluid supply so that the level never falls below the lower position of the
filter.
2. If air bleeding is done while the vehicle is idling, the air will be broken up and absorbed into the fluid; be
sure to do the bleeding only while cranking.
2. Connect the high tension cable, and then start the engine (idling).
3. Turn the steering wheel to the left and then to the right until there are no air bubbles in the oil reservoir.
Do not hold the steering wheel turned all the way to either side for longer than ten seconds.
4. Confirm that the fluid is not milky, and that the level is up to the specified position on the level gauge.
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5. Confirm that there is little change in the surface of the fluid when the steering wheel is turned left and right.
1. If the surface of the fluid changes considerably, air bleeding should be done again.
2. If the fluid level rises suddenly when the engine is stopped, it indicates that there is still air in the system.
3. If there is air in the system, a jingling noise may be heard from the pump and the control valve may also
produce unusual noises. Air in the system will shorten the useful life of the pump and other parts.
CHECKING POWER STEERING BELT TENSION

1. Press the V-belt applying a pressure of 98 N (10 kg, 22 lb) at the specified point, and measure the deflection to
confirm that it is within the standard value range.
V-belt deflection [Standard value]

Rdgular inspection : 11.7-15.3 mm (0.46-0.60 in.)
New one : 8.8-11.0 mm (0.35-0.43 in.)
2. To adjust the belt tension, auto tensioner does automatically adjust to obtain the standard value (V6 ENG).
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3. To adjust the belt tension, loosen the tensioner adjusting bolt, and then retighten the bolts. (I4 ENG.)
OIL PUMP PRESSURE TEST

1. Disconnect the pressure hose from the oil pump, and then connect the special tool between the oil pump and
pressure hose as illustrated.
2. Bleed the air. Start the engine and turn the steering wheel several times so that the fluid temperature rises to
approximately 50°C (122°F) operating temperature.
3. Set the engine speed to 1,000 rpm.
4. Fully close and then fully open the shut-off valve of the special tool and measure the fluid pressure to confirm that
it is within the standard value range.
Oil pump pressure [Standard value]

Gauge hose valve closed : 80 kg/cm² (0038 psi )or less
Be sure not to keep the shut-off valve on the pressure gauge closed for longer than ten seconds.
5. Remove the special tools and then tighten the pressure hose to the specified torque.
Tightening torque : 55-65Nm (50-650 kg·cm)
Steering System > Hydraulic Power Steering System > Power Steering Gear Box > Components and
Components Location
COMPONENTS
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COMPONENTS
Page 14 of 48
Steering System > Hydraulic Power Steering System > Power Steering Gear Box > Repair procedures
REMOVAL
1. Loosen the tapping screws and lift up the horn pad and remove it.
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2. Remove the lock nut and the washer.
Before doing these procedures, see the SRS section (RT Group) for further information (SRS equipped
vehicle only).
3. Remove the steering wheel useing the special tool. (09561-11001)
Do not hammer on the steering wheel to remove it; doing so may damage the collapsible
mechanism.
4. Remove the steering column lower and upper shrouds.
5. Remove the lower cover.
6. Disconnect the connectors and remove the multifunction switch.

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7. Remove the bolts securing the coupling and universal joint.
Pull out the coupling and universal joint from the gear box.
8. Remove the dust cover mounting bolts.

9. Remove the steering column mounting bolts (4 bolts).
10. Remove the steering column and shaft together with the universal joint and dust cover.
REMOVAL
1. Drain the power steering fluid.
2. Remove the joint assembly connecting bolt.
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3. Using the special tool (0K670-321-019), disconnect the tie rod end from the knuckle arm.
4. Disconnect the front muffler temporarily.
5. Remove the connecting bolts of front of front and rear roll stopper.
6. Remove mounting bolts(6EA) of crossmember complete assembly.
7. Disconnect the pressure hose and the return tube.

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8. Remove the steering gear box mounting brackets and remove the steering gear box assembly together with
mounting rubber.
Move the rack completely to the right and then remove the gear box to the left from the crossmember.
When removing the gear box, pull it out carefully and slowly to avoid damaging the boots.
9. Remove the stabilizer bar.
INSTALLATION
1. Before installation, apply multipurpose grease to the groove on the inside of the bearing and mating surfaces of
the boot and cover assembly.
2. Connect the steering lower shaft and joint assembly.
When installing, secure the U-joint to the gear box first, then to the steering column
shaft.
3. Install the dust cover with column shaft assembly.
4. Install the steering column assembly to the column member assembly (4 bolts).
5. Install the multi function switch and connect the connectors.
6. Install the lower cover and upper and lower shroud.
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7. Install the steering wheel.
When installing, do not use a hammer as the collapsible column shaft could be
damaged.
INSTALLATION
1. When installing the mounting rubber, align the projection of the mounting rubber with the indentation in the
crossmember to install the gear box.
2. Confirm that there is no oil leak.
3. Confirm that the steering wheel rotates smoothly when it is turned.
4. Adjust the toe-in.
5. Install the parts by reference to torque specifications.
DISASSEMBLY
1. Remove the coupling and universal joint from the steering column and shaft assembly.
2. If it is necessary to remove the steering and ignition lock assembly, use a hack saw to cut the torsion bolt at the
key holder assembly side.
DISASSEMBLY
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1. Remove the tie rod end from the tie rod.
2. Remove the dust cover from the ball joint.
3. Remove the bellows band.
4. Remove the bellows clip.

5. Pull the bellows out toward the tie rod.
Check for rust on the rack when the bellows are

replaced.
6. Remove the feed tubes from the gear housing.

7. While moving the rack slowly, drain the fluid from the gear housing.
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8. Unstake the tab washer which fixes the tie rod and rack with a chisel.
9. Remove the tie rod from the rack.
Remove the tie rod from the rack, taking care not to twist the
rack.
10. Remove the rack support plug lock nut.
11. Using the special tool (09565-31300), remove the rack support plug.
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12. Remove the rack support spring, rack support and bushing from the gear box.
13. Remove the end plug self-locking nut.

14. Detach the dust seal.
15. Remove the snap ring with a snap ring plier.
16. Remove the pinion and valve assembly together with the oil seal (upper) using a soft hammer.
17. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the gear housing.
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18. When the end of the circlip comes out from the notched hole of the housing rack cylinder, turn the rack stopper
counterclockwise and remove the circlip.
Do not damage the rack.

19. Remove the rack stopper, rack bushing and rack from the gear housing by moving it toward the piston side.
When the rack gas ben removed, be sure to replace the housing side oil seal with a new one.
20. Remove the O-ring from the rack bushing.
21. Remove the oil seal from the rack bushing.

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22. Drive out the ball bearing using special tool (09517-21400) and hammer.
Do not damage the pinion valve cylinder inside of the gear housing.
23. Drive out the needle bearing and oil seal.
24. Use the special tools (09555-21000, 09573-33100) to remove the back washer and oil seal from the gear
housing.
Do not damage the rack cylinder inside of the gear housing.
INSPECTION
1. Check the steering shaft for damage, play and round movement.
2. Check the joints for excessive play, damage or rough movement.
3. Check the tilt bracket for cracks or damage.
4. Check the cover or boot for damage
5. Check that the steering lock mechanism operates properly. If necessary, replace.
INSPECTION
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1. Rack
(1) Rack tooth face damage or wear
(2) Oil seal contact surface damage
(3) Bending or twistion
(4) Oil seal ring damage or wear
(5) Oil seal damage or wear
2. Pnion valve
(1) Pinion gear tooth face damage or wear
(2) Oil seal contact surface damage
(3) Seal ring damage or wear
(4) Oil damage or wear
3. Bearing
(1) Sezure or abnormal noise during bearing rotation
(2) Escessive poay
(3) missing nedle bearing rollers
4. Others
(1) Damage of the gear housing cylinder bore
(2) Boot damage, cracking or ageing
ASSEMBLY
1. When installing the steering ignition lock and steering lock bracket to the column tube, temporarily install the
steering lock in alignment with the column boss.
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2. After checking that the lock works properly, tighten the special bolts unitl the head twists off.
The steering lock bracket and bolts must be replaced with new ones when the steering lock is
installed.
3. Cover the inside lip of the inner cover with grease and pull the outside of the cover onto the joint.
4. Fill the inside of the bearing with multipurpose grease.
5. Install the bearings to the shaft on the joint assembly.
ASSEMBLY
1. Apply the specified fluid to the entire surface of the oil seal and gear housing.
Recommended fluid : Power steering fluide (PSF-3)
2. Using the special tools (09555-21000, 09573-21000, 09573-33000, 09573-33100), install the backup washer
and oil seal to the specified position in the gear housing.
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3. Apply the specified grease to the entire surface of the needle bearing.
Recommended trease : Multipurpose grease SAE H310a, NLGI No.2
4. Install the needle bearing in the gear housing using special tool (09222-21100).
5. Set the scribed side of the oil seal (inner) in the special tool (09431-11000) and install in the gear housing.
1. Note the direction of the oil seal.

2. Use a new oil seal.
6. Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recinnebdead fkyud : Power steering fluid (PSF-3)
7. Install the oil seal on the rack bushing.

8. Apply the specified fluid to the entire surface of the O-ring and install to the rack bushing using the special tool
(09431-11000).
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9. Apply the specified grease to the rack teeth and wrap with vinyl tape.
Recommended trease : Multipurpose grease SAE J310a, NLGI grade 2 EP
Do not plug the vent hole in the rack with grease. All cautions must clearly state the possible harmful result
or risk. What would happen if the vent hole was plugged with grease?
10. Insert the rack into the gear housing.

Install the rack bushing and rack stopper.
11. Push in the rack stopper until the circlip groove of the rack stopper is aligned with the notched hole of the rack
housing and then install the circlip while turning the rack stopper.
The circlip end should not be vilsble through the notched hole of the rack housing.
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12. Apply the specified fluid and grease to the pinion valve assembly and install to the gear housing assembly.
Recommened fluid : Power steering fluid (PSF-3)

Recommended grease : Mutipurpose grease SAE J310A, NLGI Grade 2 EP
13. Install the ball bearing using special tool (09222-21100).
14. Install the pinion and valve assembly to the valve housing.
15. Install the oil seal using the special tool (09432-21601).
16. Install the snap ring with snap ring plier.

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17. With the pinion turned all the way clockwise, thghten the self-locking nut.
Tightening torque :
45~50 Nm (450~500 kg·cm, 33~36 lb·ft)
Always replace the self-locking nut with a new one.
18. Apply semi-drying sealant to the threaded section of the end plug and tighten to the specified torque.
Tightening torque : 45~55Nm(450~550 kg·cm, 33~40 lb·ft)
19. Stake the end plug at two points on its circumference with a punch.
20. Install the tab washer and then the tie rod and peen the tab washer end at two points to the tie rod.
1. Align the tab washer pawls with the rack grooves.

2. Use a new tab washer.
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21. Install the bushing, rack support, rack support spring and rack support cover in the order shown. Apply thread
sealant to the threaded section of the rack support cover before installation.
22. With the rack placed at the center position, attach the rack support plug to the gear housing. Temporary tighten
yoke plug with 200 kg·cm and return. Tighten yoke plug with 50~60 kg·cm and return 35° and adjust torque to
the standard value.
Total pinion torque[Standard value] : 25-35 Nm (250-350 kg·cm, 0.4-0.9 lb·ft)
23. After adjusting, lock rack support plug with lock nut.
When it cannot be adjusted within the specified return angle, check rack support plug components or
replace.
24. Tighten the feed tube to the specified torque and install the mount rubber using adhesive.
25. Apply the specified grease to the bellows fitting position (fitting groove) of the tie rod.
Recommended grease : Multipurpose grease SAE J3120a, NLGI gread 2 EP

Page 32 of 48
26. Install the new attaching band to the bellows.
Whenever the bellows are installed, a new band must be

used.
27. Install the bellows in, taking care not to twist it.
28. Fill the dust cover inner side and lip with the specified multipurpose grease, and fix the dust cover in position
with the clip ring attached in the groove of the tie rod end.
Recommended grease : Multipurpose rease SAE J310a, NLGI grade 2 EP
29. Install the tie rods so that the length of the left and right tie rods will be equal to the standard value.
Tie rod free length [Standafd value] : 43 mm(1.69 in.)
Steering System > Hydraulic Power Steering System > Power Steering Hoses > Components and
Components Location
COMPONENTS
Page 33 of 48
Steering System > Hydraulic Power Steering System > Power Steering Hoses > Repair procedures
REMOVAL
1. Drain the power steering fluid.
2. Disconnect the return hose and the suction hose from the oil reservoir.
3. Remove the flare nut of pressure hose.
4. Remove the return tube and rubber hose together with the flare nut and O-ring.
5. Remove the cooler tube.
Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Components and
Components Location
COMPONENTS
Page 34 of 48
Be sure to cover te Generator with a protector when servicing the oil pump.
Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Repair procedures
REMOVAL
Page 35 of 48
1. Remove the pressure hose from the oil pump.
When assembling, use a new O-ring.
2. Disconnect the suction hose from the suction connector and drain the fluid into a container.
When removing the suction hose, cover the generator with vinyl not to be damaged by the oil
inflowing.
3. Remove the V-belt. (V6 ENG.)
4. Loosen the tensioner adjusting bolt to remove the V-belt (I4 ENG).
5. Remove the oil pump mounting bolts and disconnect the pressure switch connector.
1. Install the oil pump to the oil pump bracket.

Page 36 of 48
2. Install the suction hose.
3. Install the ribbed V-belt and adjust the belt tension.
4. Connect the pressure hose to the oil pump, and the suction hose to the oil reservoir.
Install the hoses so that they are not twisted and they do not come in contact with any other
parts.
5. Replenish the reservoir.
Recommended fluid : Power steering fluid (PSF-3)

7. Check the oil pump pressure.
8. Install parts by reference to the torque specification.
DISASSEMBLY
1. Remove the suction pipe and the O-ring from the oil pump.
2. Remove the rear cover with the gasket.

3. Remove the cam ring.
4. Remove the rotor and vanes.
5. Remove the front side plate.
6. Remove the inner and outer O-ring.

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7. Remove the spring.
When assembling, use a new gasket and O-ring.
8. Remove the pulley nut and the spring washer.

9. Pull off the pulley and the woodruff key.
10. Remove the snap ring using the snap ring pliers.
11. Drive out the pulley shaft and bearing.

If necessary, use a plastic hammer.
12. Remove the oil seal from the oil pump body.
When assembling, use a new oil seal.
13. Remove the connector from the oil pump body, and then remove the flow control valve and flow control spring.
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14. Remove the O-ring from the connector.
Do not disassemble the flow control valve.
15. Remove the oil pump switch.

16. Take out the spring and the spool.
17. Remove the O-ring from the oil pump switch.
INSPECTION
1. Clean all disassembled parts with a suitable cleaning solvent.
2. If any inside parts of the oil pump have been damaged, replace the pump as an assembly.
3. If the pulley is cracked or deformed, replace it.
4. If oil leaks around the pulley shaft oil seal, replace the oil seal.
5. If the serrations of the pulley or pulley shaft are deformed or worn, replace them.
ASSEMBLY
1. Install the oil pump switch.
2. Install the flow control valve spring, valve and connector in the pump body.
Apply a thin coat of Power steering fluid type to all aparts including the oil seal and O-
ring.
3. Using special tool (09222-32100), install the oil seal into the pump body.
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4. Gently insert the shaft assembly and install the snap ring.
5. Install the pump pulley with woodruff key in place.

6. Install the spring and the inner and outer O-rings.
7. Install the front side plate.
8. Insert the pins into the pin grooves of the front housing, then install the cam ring, paying attention to its direction.
9. Install the rotor with its punch marked side facing towards the front side plate.
10. Install the vane plates with the round end facing outward.
11. Install the gasket and rear cover.

12. Tighten the suction connector.
Steering System > Electronic Power Steering System > Description and Operation
GENERAL
The electronic power steering (EPS) system uses the same components at that of conventional power steering
system. In addition, it has a solenoid valve on power steering gear box, and a control unit underneath the audio of
Page 40 of 48
the center facia. To control the oil flow of steering gear box, a solenoid is provided and it functions by the current
from control module which receives signal from VSS (Vehicle Speed Sensor).
EPS performs the conventional power steering function in case a fail has occurred in the system.
EPS electronically controls the current to the solenoid of by-pass valve by input sensor's signal to control the
hydraulic amount in cylinder chamber thereby varying the steering effort versus the hydraulic pressure according to
vehicle speed.
ELECTRONIC POSER STEERING CONTROL MODULE(Electronic power module)
The EPSCM is installed underneath the audio inside the center facia.
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EPS SLENOID(Solenoid valve)

A solenoid valve is provided in the gear box to control the flow of power steering oil. The solenoid valve is
composed of a releasing spring, a piston and a plunger. The input current is varying from 0A to 1A according to the
vehicle speed and is controlled by EPS control module. When the ignition switch is turned on, current is sent to the
solenoid valve to push up the plunger and accordingly the piston contacting the plunger is pushed up while
overcoming the spring force. As the vehicle speed increasing the current flow to the solenoid decreased pulling down
the piston bottom by the releasing spring force. When the piston is pushed up, it closes the oil passing hole, therefore
the power steering oilpressure is delivered into the cylinder without any interruption. But when the hole is opened as
the piston is pulling down, some of the oil coming from the rotary valve is drained into reservoir via the hole inside
the rotary valve.
Page 42 of 48
When it is necessary to remove the EPS gear box, be sure to disconnect the connector to avoid damage.
EPS GEAR BOX(OPERATION)
LEFT TURN (CONTERCLOCKWISE)
The power steering oil pump generates the oil pressure and the oil enters into the rotary valve. And the torsion bar
istwisted by the force between the steering wheel rotation and the resistance of the tire to the ground. At a high
speed of vehicle, the oil passing the rotary valve comes into the solenoid valve through the lower hole and goes out
through the upper hole flowing the connecting space of piston. At this time the piston is back away due to the spring
force overcoming the solenoid plunger. The oil flows through the space between the piston and side wall. And then
the oil flows again into the rotary valve and finally drained to reservoir through the drain hole between the rotary
valve and the torsion bar. Therefore the oil pump pressure does not affect to the steering effort.
Page 43 of 48
As the vehicle speed decreasing the hole of piston connecting the left chamber and right chamber is gradually closed
asthe oil pressure produced by oil pump is delivered to the left chamber. Therefore, the steering effort is reduced.
RIGHT TURN(CLOCKWISE)
The operation procedure of right turn is the reverse sequence of left turn.
Page 44 of 48
Steering System > Electronic Power Steering System > Troubleshooting

TROUBLESHOOTING <E.P.S>
Page 45 of 48
Trouble symptom Trouble area Inspection item
Steering wheel movement is heavy (When Steering gear Solenoid valve continuity
ignition key is turned to ON, no current flows and linkage
By-pass valve
through the solenoid)
Harness of Blown fuse
fuse Remove the control unit connector and check the
continuity in the solenoid harness (between terminal
No. 1 and No. 2)
Control Turn the ignition key momentarily to ACC or
module LOCK
Check for continuity in each harness and for
abnormalities in the control module power circuit
While driving at medium or high speed, Control Use a tester to check the stationary steering effort
steering remains light module
Check the solenoid current in relation to changes in
vehicle speed
Steering gear Solenoid by-pass valve operation
and linkages
Trouble Symptom 1
Trouble Symotom 2
Page 46 of 48
Page 47 of 48
Steering System > Electronic Power Steering System > Repair procedures
The removal and installation procedure is the same as that of conventional power steering system except the
solenoid valve components and EPS control module. Refer to the following figures.
Page 48 of 48
Page 1 of 40
OPTIMA(MS) > 2003 > G 2.4 DOHC > Suspension System
Suspension System > General Information > Special Service Tools

SPECIAL TOOLS
Tool(Number and name) Illustration Use
09216-21600 Removal and installation o trailing

Mount brshing remover and installer arm bushin
arbor (use with 09552-38100)
Removal and installation of rear

09453-33000B
center arm bushin
Snap ring installer
(use with 09552-38200)
09455-21000/0K011 430 017 Removal of the front lower arm all

Bearing and gear puller joint
09529-21000
measurement of the wheel alignment
Wheel alignment gauge attachment
Measurement of the front lower arm

0953-11600
ball joint startin torque.
Preload socket
(use with torque wrench)
Removal and installation of the

09545-21100
shock absorer mountin bush
Ball joint dust cover remover
(use with 09551-31000)
Page 2 of 40
0K670-321-019
Removal of rear center arm ball joint
Ball joint remover
Removal and installation of the

09551-31000
shock bsorber mounting vush
Upper arm bushing remover /installer
(use 09545-21100)
09552-38000
Removal and installation of the assist
Assis arm bushing remover and
arm bushing
installer
09552-38100 Removal and installation of teh rear

Rear trailing arm bushin remover and trailing arm bushing
installer (use with 09216-21600)
09552-38200
Remval and installation of the rear
Rear center arm bushin remover and
center arm bushing
installer
09624-34000
Removal and installation of the lower
Trailing arm bushing remover and
arm bush(G)
installer
0K2A1 341 AA1A

Compression of coil spring
Coil spring compressor
Page 3 of 40
Suspension System > General Information > Troubleshooting

TROUBLESHOOTING
Hard steering Improper front wheel alignment Correct
Excessive turning resistance of lower arm ball Replace
joint
Flat tire Repair
No power assist Repair or replace
Poor return of steering wheel to Improper front wheel alignment Correct
center
Poor riding Improper front wheel alignment Correct
Malfunctioning shock absorber Repair or replace
Broken or worn stabilizer Replace
Broken or worn coil spring Replace
Worn lower arm bushing Replace
Improper tire inflation pressure Correct
Abnormal tire wear Improper front wheel alignment Correct
Malfunctioning shock absorber Replace
Wandering Improper front wheel alignment Correct
Poor turning resistance of lower arm ball joint Repair
Loose or worn lower arm bushing Retighten or replace
Vehicle pulls to one side Improper front wheel alignment Correct
joint
Bent lower arm Replace
Steering wheel shimmy Improper front wheel alignment Correct
joint
Broken or worn stabilizer Replace
Worn lower arm bushing Replace
Bottoming Broken or worn coil spring Replace
Abnormal sound Loose installation parts Replace
Damaged or worn wheel bearings Replace
Page 4 of 40
Faulty shock absorber Replace damaged parts
Defective tire Replace
Poor ride control Excessive tire pressure Adjust pressure
Faulty shock absorber Replace
Loose wheel nuts Tighten to specified
torque
Sagging or broken coil spring Replace
Vehicle body tilts to one side Defective tire Replace
Worn bushing Replace
Deformation of torsional axle and arm assembly Replace
Worn bushings Replace
Sagging or broken coil spring Replace
Wheel and tire

BOTH SIDES OF CHUNKING OF ONE SIDE TIRE
CENTER OF TREAD WORN
TREAD WORN TIRE WORN
Over-Inflation Center-tread down Under-Inflation Bulge When a patch of Incorrect camber

to fabric due to at the shoulder Wear tread has been angle
excessive over- rapidly loosened, it can be
Inflation torn off the tire by
centrifugal force
when traveling at high
speeds
UNEVEN TIRE TOTALLY
FLAT SPOT FEATHERING BAD PLUGGING
WEAR UNSAFE TIRE
Page 5 of 40
Excessive TOE-IN Bad wheel balance

Caused by heavy Using morre than one Tread worn below
TOE-OUT fault in suspension
braking which makes tire plug can distort the limit
the wheels lock and steering gear or
the tire tread and
scrubs the tires along bearing
cause tire failure
the road surface
Suspension System > General Information > Specifications

Specification
Front suspension system
Item Specification
Double wishbone with stabilizer bar
Suspension Type
type
Free height mm (in.) 383.4 (15.1)
I.D color White-Green
Type Gas pressuirzde type
Stroke (mm(in)) 125.5 (4.94)
Shock absorber Expansion (N(kg)) 1160 ± 170 (116 ± 17)
Damping force at
0.3 m/s Compression
680 ± 130 (68 ± 13)
(N(kg))
Rear suspension system

Item Specification
Suspension Type Multi link type
Free height mm (in.) 354 (13.94)
I.D color Green-Red
Type Gas pressuirzde type
Stroke (mm(in)) 170 (6.7)
Shock absorber Expansion

620 ± 100 (62 ± 10)
Damping force (N(kg))
at 0.3 m/s Compression
300 ± 70 (30 ± 7)
(N(kg))
Wheel and tire

Page 6 of 40
Item Specification
Wheel Type Steel Aluminum
Size 6J x 15 6J x 15 6J x 16
Tire Size P205/60 R 15 P205/60 R 15 P205/55 R 16
Tire inflation pressure (kg/cm²
2.1 (30) 2.0 (30) 2.1 (30)
(psi))
Temporary Wheel size 4T x 15
spare tire
Tire size T125/70 D 15
Tire inflation pressure (kg/cm²
4.2 (60)
(psi))
Service standard
Item Specification
Toe-in Front 0 ± 2 mm (at the center of tire tread)
Rear 2 ± 2 mm (at the center of tire tread)
Camber Front 0° ± 30' (Max. difference between LH and RH : 0°30')
-30' ± 30' (Max. difference between LH and RH :
Rear
0°30')
3°15' ± 1° (Max. difference between LH and RH :
Caster Front
0°30')
King pin
Front 8°29'
angle
TIGHTENING TORQUE
Nm Kg·cm lb·ft
Wheel nut 90-110 900-1100 67-81
Front upper arm ball joint self-
35-45 350-450 26-33
locking nut
Front upper arm shaft nut 55-65 550-650 40-48
Front upper arm mounting nut 90-110 900-1100 65-80
Lower arm ball joint self-locking
75-90 750-900 55-66
nut
Lower arm ball joint to knuckle
100-120 1000-1200 74-88
mounting bolt
Lower arm to connector nut 100-120 1000-1200 74-88
Lower arm bushing (A) to sub-
100-120 1000-1200 74-88
frame mounting bolt
Lower arm bushing (G) to sub-
120-140 1200-1400 88-103
frame mounting bolt
Page 7 of 40
Fork to lower arm connector nut 100-120 1000-1200 74-88
Fork to strut mounting bolt 60-80 600-800 44-59
Strut upper mounting nut 45-60 450-600 33-43
Strut mounting self-locking nut 20-25 200-250 15-18
Stabilizer link mounting self-
35-45 350-450 26-33
locking nut
Stabilizer bar bracket to sub-
30-45 300-450 22-33
frame bolt
Stabilizer bar bracket to
35-45 350-450 26-33
crossmember bolt
Shock absorber lower mounting
80-90 800-900 59-66
bolt
Shock absorber mounting self-
20-25 200-250 15-18
locking nut
Rear upper arm to carrier nut 100-120 1000-1200 74-88
Rear upper arm bracket to body
40-50 400-500 30-36
mounting bolt
Rear upper arm to bracket nut 60-78 600-780 43-56
Assist arm to carrier nut 100-120 1000-1200 74-88
Assist arm to crossmember nut 80-100 800-1000 59-73
Center arm to carrier nut 60-72 600-720 44-53
Center arm to crossmember nut 100-120 1000-1200 74-88
Trailing arm to body nut 140-160 1400-1600 103-118
Trailing arm to carrier nut 100-120 1000-1200 74-88
Crossmember to body mounting
100-120 1000-1200 74-88
bolt
Tie rod end lock nut 50-55 500-550 37-40
LUBRICANTS
Item Recommended Quantity
lubricant
Front upper arm ball joint Sunlight MB-2 or As required
equivalent
Stabilizer link (front and Sunlight MB2 or As required
rear) equivalent
Rear upper arm pillow ball Polylub 801K As required
Page 8 of 40
Suspension System > Front Suspension System > Front Strut Assembly > Components and
Components Location
components
Suspension System > Front Suspension System > Front Strut Assembly > Repair procedures
Page 9 of 40
REMOVAL
2. Detach the brake hose from the fork.
3. Remove the bolt from the shock absorber bushing.
4. Remove the bolt then remove the fork from the shock absorber.
5. Remove the strut upper mounting 3 nuts and top mounting ring.
6. While pushing the axle assembly upward remove the strut assembly.
INSTALLATION
Page 10 of 40
1. Place the fork bracket of the strut toward the inside of the vehicle, then install the strut assembly to the wheel
house.
2. Install the fork to the strut assembly.
3. Install the brake hose.

4. Install the wheel and tire.
DISASSEMBLY
1. Using the special tool, spring compressor, compress the coil spring.
Do not use an impact wrench.
2. Remove the self-locking nut.

3. Remove the special tool, bracket, spring pad and coil spring.
Page 11 of 40
INSPECTION
1. Check the rubber parts for damage or deterioration.
2. Check the spring for deformation, deterioration or damage.
3. Check the shock absorber for abnormal resistance or unusual sounds.
When discarding the gas pressurized shock absorber, follow the disposa.
precedure.
REASSEMBLY
1. Install the special tool, spring compressor, on the coil spring and compress the spring.
After spring is fully compressed, install it on the shock absorber assembly.
Do not use and impact wrench.

Coil spring installation chart to load classification.
LH spring ↔ RH spring
White ↔ White
Yellow ↔ Yellow
Red ↔ Red
Page 12 of 40
2. Install the dust cover, upper spring pad, bushing (B), bracket, bushing (A) in that order and hand tighten the new
self-locking nut.
3. Position the upper and lower ends of the coil spring in the upper spring pad and lower spring seat groove.
4. Place the bracket to align the bracket bolt with the projection of the fork bracket in a straight line.
5. Loosen the special tool.
6. While holding the piston rod, tighten the new self-locking nut to the specified torque.
Tighten torque :
20~25 N·m (200~250 kg·cm, 15~18 lb·ft)
DISPOSAL
1. Fully extend the shock absorber rod.
Page 13 of 40
2. Drill a hole to remove gas from the cylinder.
The gas coming out is harmless, but be careful of chips that may fly up when
drilling.
Suspension System > Front Suspension System > Front Lower Arm > Components and Components
Location
components
Page 14 of 40
Suspension System > Front Suspension System > Front Lower Arm > Repair procedures
REMOVAL
2. Loosen the ball joint nut but do not remove it
3. Using the special tool, disconnect the lower arm ball joint from the lower arm connector.
4. Remove the ball joint assembly.
5. Remove the bolt, fork to lower arm connector.
6. Remove the stabilizer link from the lower arm.

Page 15 of 40
7. Remove the 2 bolts from the lower arm bushing (A).
8. Remove the bolt from the lower arm bushing (G).
9. Remove the steering gear box (see steering system).

10. Remove the stabilizer bar.
INSTALLATION
1. Install the stabilizer link so that the distance (A) is at the standard value.
Standard value (A) : 3~5 mm(0.0118-0.197 in.)
DISASSEMBLY
1. Remove the connector from the lower arm.
Page 16 of 40
2. Using the special tool, remove the shock absorber mounting bushing.
3. Using the special tool, remove the lower arm bushing (G).
INSPECTION
1. Check the bushing for wear and deterioration.
2. Check the lower arm for bending or breakage.
3. Check the ball joint dust cover for cracks.
4. Check all bolts.
5. Check the lower arm ball joint for rotating torque.
(1) If a crack is noted in the dust cover, replace the ball joint assembly.
(2) Shake the ball joint stud several times.
(3) Measure the ball joint rotating torque.
Standard value : 0.2~1.0Nm, (2~10 kg·cm, 1.77~8.5 lb·in)
(4) If the rotating torque is below the lower limit of standard value, replace the ball joint assembly.
(5) Even if the rotating torque exceeds the upper limit of standard value, it may be reused unless it is 1.5 Nm (15
kg·cm, 13.3 lb·in.) or more.
Page 17 of 40
6. Check the stabilizer link ball joint rotating torque.
(1) If there is a crack in the dust cover, replace it and add grease.
(2) Shake the stabilizer link ball joint stud several times.
(3) Mount the self-locking nut on the ball joint, and then measure the ball joint rotating torque.
Standard value : 1.7-3.2 Nm (17-32kg·cm, 15-27 lb·in.)
(4) If the rotating torque exceeds the upper limit of standard value, replace the stabilizer link.
(5) Even if the rotating torque is below the lower limit of the standard value, the ball joint may be reused unless it
has drag and excessive play.
REASSEMBLY
1. Using the special tool, press-fit the shock absorber mounting bushing.
2. Position the lower arm bushing (G) at the angle indicated in the illustration.
Page 18 of 40
3. Using the special tool, press-fit the lower arm bushing (G).
4. Install the connector to the lower arm assembly.
Suspension System > Front Suspension System > Front Upper Arm > Components and Components
Location
COMPONENTS
Page 19 of 40
Suspension System > Front Suspension System > Front Upper Arm > Repair procedures
REMOVAL
2. Loosen the ball joint nut but do not remove it.
Page 20 of 40
3. Using the special tool, disconnect the upper arm ball joint from the knuckle.
4. Remove the 2 nuts from the wheel house panel then remove the upper arm assembly.
5. Remove the upper arm shaft.
INSPECTION
1. Check the bushing for wear and deterioration.
2. Check the upper arm for bending or breakage.
Page 21 of 40
3. Check the ball joint for rotating torque.
Standare value : 0.5~1.5 Nm (5~15 kg·cm, 4.43~13.27 in.)
(4) If the rotating torque exceeds the upper limit of standard value, replace the upper arm assembly.
(5) Even if the rotating toque is below the lower limit of the standard value, the ball joint may be reused unless it
Suspension System > Front Suspension System > Front Sub Frame > Repair procedures
Replacement
1. Raise the hood.
2. Remove the battery (C).
3. Remove the air cleaner (D).
4. Remove the 2 main wiring harness mounting nuts (E) then make the wiring harness loose.
Page 22 of 40
5. Remove the rear roll stopper mounting bolt (F).
6. The portion where the rear roll stopper mounting bolts had been installed (G).
7. Lift the vehicle off the ground.

8. Remove the 2 right under covers (I).
9. Remove the front exhaust pipe (J).

Page 23 of 40
10. Remove the front roll stopper mounting bolt (K).
11. Remove the 2 steering gearbox mounting bolts (L) from the left side.
12. Remove the steering gearbox mounting bolts (M) from the right side.
13. Remove the power steering hose mounting bolt (N) from the top of the steering gear box.
The bolt can be invisible to the naked eye from under the vehicle.
Page 24 of 40
14. Remove the power steering hose mounting bolts (O) between the steering pump and the steering gearbox.
15. Remove the sub frame brackets and mounting bolt (P).
16. Support the sub frame with a jack (Q).
17. Remove the ball joint mounting bolt (R).

18. Remove the bolts (S) from the lower end of the strut assembly.
Page 25 of 40
19. Remove the sub frame center mounting nut (T).
20. Detach the sub frame (U) from the steering gearbox and then remove the sub frame.

22. Refil the power steering fluid and bleed the air.
Suspension System > Rear Suspension System > Rear Shock Absorber > Components and
Components Location
components
Page 26 of 40
Suspension System > Rear Suspension System > Rear Shock Absorber > Repair procedures
REMOVAL
1. Remove the wheel and tire
Page 27 of 40
2. Remove the shock absorber mounting bracket bolts.
3. Remove the upper arm and rear carrier mounting bolt.
4. Remove the shock absorber mounting bracket.
INSTALLATION
1. When installing the rear shock absorber, be sure to clear the connection surface.
2. Tighten the components below to the specified torque as follows.
Items Torque N·m(kgf·cm,lb·ft)
Shock absorber lower mouning bolt. 80-90(800-900, 59-66)
Rear upper arm to rear carrier mounitng. 100-1200(1000-1200, 74-88)
Rear upper arm to rear shock absorber
60-78(600-780, 44-58)
mounting bracket.
DISASSEMBLY
Page 28 of 40
1. Using the special tool, spring compressor, compress the coil spring.
Do not use an impact wrench.

2. While holding the piston rod, remove the self locking nut.
3. Remove the shock absorber mounting bracket, dust cover and spring upper pad.
4. Remove the special tool, bushing, bracket, spring pad, dust cover and coil spring.
INSPECTION
1. Check the rubber parts for damage or deterioration.
2. Check the spring for deformation, deterioration or damage.
3. Check the shock absorber for abnormal resistance or unusual sounds.
when discarding gas pressurized shock absorber, follow the disposal

procedure.
DISPOSAL
1. Fully extend the shock absorber rod.
Page 29 of 40
2. Drill a hole to remove gas from the cylinder.
The gas coming out is harmless, but be careful of chips that may fly up when
drilling.
REASSEMBLY
1. Install the special tool, spring compressor, on the coil spring and compress the spring.
After spring is fully compressed, install it on the shock bsorber.
Do not sue an impact wrench.

Coil spring installation chart to load classification.
LH spring ↔ RH spring
Whith ↔ White
Yellow ↔ Yellow
Red ↔ Red
2. Install the dust cover, bushing (B), upper spring pad, bracket, bushing (A) and washer in this order and tighten
the new selflocking nut temporarily.
Page 30 of 40
3. Position the upper and lower ends of the coil spring inthe upper spring pad and lower spring seat groove.
1. Install so that the upper spring pad is fit in the shock absorber mounting bracket correctly.
2. Install so that the spring urethane tube is located down.
4. With the position of the bracket assembly is as shown in the illustration, tighten the new self-locking nut.

6. Tighten the new self-locking nut to the specified torque.
Suspension System > Rear Suspension System > Rear Suspension Arm > Components and
Components Location
COMPONENTS
Page 31 of 40
Suspension System > Rear Suspension System > Upper Arm, Lower Arm And Assist Link > Repair
procedures
REAR UPPER ARM REPLACEMENT
Page 32 of 40
1. Remove the rear upper arm assembly.
2. Using the special tool, remove the pillow ball.
3. Set the pillow ball so that identification color is visible on the outside of the upper arm.
4. Press fit the pillow ball to the upper arm.

5. Install the upper arm assembly.
REAR ASSIST ARM REPLACEMENT

Page 33 of 40
1. Remove the assist arm assembly.
2. Using the special tool. replace the bushing.
3. When press fitting, apply a soap solution to the bushing and inside the assist arm.
4. Install he assist arm assembly.

REAR CENTER ARM REPLACEMENT
1. Loosen the ball joint nut but do not remove it.
2. Using the special tool, disconnect the ball joint from the rear axle carrier.
3. Remove the center arm mounting bolt.

Page 34 of 40
4. Remove the center arm assembly.
5. Using the special tool, replace the bushing.
Suspension System > Rear Suspension System > Trailing Arm > Repair procedures
TRAILING ARM REPLACEMENT
1. Remove the rear side bolt.
2. Remove the front side trailing arm nut.
3. Remove the trailing arm assembly.
4. Using the special tool, removal and press fit the bushing.
Page 35 of 40
5. When press fitting, apply a soap solution to the outside surface of the bushing to aid in assembly. Position it as
shown in the illustration.
6. Install the trailing arm.
Suspension System > Rear Suspension System > Rear Stabilizer Bar > Repair procedures
REAR STABLIZER LINK REPLACEMENT
1. Remove the stabilizer link assembly.
2. Check the stabilizer link ball joint rotating torque.

Standard value : 1.7-3.2 Nm(17-32kg·cm, 15-27 lb·ft)
(4) If the rotating torque exceeds the upper limit of standard value, replace the stabilizer link.
(5) Even if the rotating torque is below the lower limit of the standard value, the ball joint may be reused unless it
Suspension System > Tires/Wheels > Tire > Repair procedures

TIRE WEAR
Page 36 of 40
1. Measure the tread depth of the tires.
Tread depth of tire [Limit] : 1.6 mm(0.06 in.)
2. If the remaining tread depth is less than the limit, relpace the tire.
When the tread depth of the tires is reduced to 1.6mm (0.06 in.) or less, the wear indicators will
appear.
Suspension System > Tires/Wheels > Wheel > Repair procedures

WHEEL RUNOUT
1. Jack up the vehicle and support it with jack stands.
2. Measure wheel runout with a dial indicator as illustated.
3. Replace the wheel of wheel runout exceeds the limit
Wheel runout : 0.25 mm (0.01 in).
Tightening Wheel Nut

Page 37 of 40
1. Tightening torque
Specified torque : 90 - 110 N·m(900 - 1100 kg·m, 65 - 80 lb·ft)
When using an impact gun, ensure to use the correct tightening torque.
2. Tighten all wheel nuts in the such order as shown in the illustration.
Suspension System > Tires/Wheels > Repair procedures

FRONT WHEEL ALIGNMENT
When using a wheel alignment tester to inspect front wheel alignment, always position the car on a level surface and
the front Wheels in the straight ahead position. Prior to inspection make sure that the front suspension and steering
system are in normal operating condition and that wheels and tires are free of deflection and tires are inflated to
specification.
Page 38 of 40
1. Toe-in
Toe-in (B-A or angle alpha;+ beta;) is adjusted by turning the tie rod turnbuckles. Toe in on the left front wheel
can be reduced by turning the tie rod toward the rear of the car. Toe change is achieved by turning the tie for the
right and left wheels simultaneously the same amount as follows :
Toe-in (B-A) : -2 mm~ +2 mm

Toe-in (α+β) : -10'48''~ +10'48''
Description Toechange
No.of turn of tie rod 1/2 Approx. 4.8 mm (57'40'')
(same amount for right and left) 1 Approx. 9.6 mm (1°55'20'')
• Toe-in adjustment should be made by turning the right and left tie rods the same amount.
• When adjusting toe-in, loosen the outer bellows clip to prevent twisting the bellows.
• After the adjustment, firmly tighten the tie rod end lock nuts and reinstall the bellows clip.
Tightening torque
Tie rod end lock nuts tigtening torque : 50-55 Nm(500-550 kg·cm, 37-40 lb·ft)
2. Camber
The steering knuckle which is integral with the strut assembly is preadjusted to the specified camber at the factory
and requires no adjustment.
Camber : (0° ± 30' For general suspension)

Page 39 of 40
3. Caster
Caster is pre-set at the factory and can not be adjusted. If caster is not within standard value, replace the bent or
damaged parts.
1. The front suspension assembly must be free of worn, loose or damaged parts prior to measuring front
wheel alignment.
2. Measure wheel alignment by using the special tool (09529-21000).
3. Camber and caster are pre-set at the factory and cannot be adjusted.
4. If camber and caster are not within specifications, replace bent or damaged parts.
REAR WHEEL ALIGNMENT INSPECTION

1. Toe-in
Standard value : 2 ± 2 mm
The assist arm mounting bolt (crossmember side) should be turned an equal amount on both sides when
adjusting.
Page 40 of 40
Inside direction of the vehicle : toe-in

Outside direction of the vehicle : toe-out
The scale has gradations of approximaterly 2.4 mm (14').

2. camber
Standard value : (-30' ± 30' For general suspension), (38' ± 30' For high suspension)
1. The rear suspension assembly must be free of worn, loose or damaged parts prior to measuring rear
wheel alignment.
2. Camber is pre-set at the factory and cannot be adjusted.
3. If camber is not within the specifications, replace bent or damaged parts.

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Page 1 of 26

OPTIMA(MS) > 2003 > G 2.4 DOHC > General Information

General Information > General Information > General Information

VEHICLE IDENTIFICATION NUMBER

1 to 3 (Make / Vehicle Type):

ENGINE IDENTIFICATION NUMBER

3. Cleaning parts for reuse

Depending on where they are;

2. Never pull on the wiring when disconnecting connectors.

CHECKING CABLES AND WIRES

1. Check the terminal for tightness.

SERVICING THE ELECTRICAL SYSTEM

PRECAUTIONS FOR A CATALYTIC CONVERTER

STANDARD PARTS TIGHTENING TORQUE TABLE

M5 0.8 3-4 (30-40, 2.2-2.9) 5-6 (50-60, 3.6-4.3)

3. Install the drain plug and tighten to specified torque.

Tightening torque - Drain plug : 35-45 Nm (350-450 kg·cm, 26-32 lb·ft)

5. Pull the dipstick out in order to check the oil level.

6. Install the filler plug.

3. Remove the air cleaner filter.

Standard value ( For V6 ENGINE)

ADJUSTMENT OF BELT TENSION

3. Loosen the drain plug to drain the coolant.

REPLACEMENT OXYGEN SENSOR

2. Check to be sure that the transaxle oil is not dirty.

Maximum steering wheel freeplay : 30 mm (1.181 in.)

2. Check steering linkage for looseness and damage as follows.

2. Check all clamps for tightness.

Thickness of pad lining "A" [Limit] : 2.0 mm (0.079 in.)

REAR DRUM BRAKE LININGS AND

Thickness of lining "B" [Limit] : 0.8 mm (0.032 in.)

CHECKING THE BRAKE FLUID LEVEL

3. With a vehicle equipped ABS (Anti-lock Breake System), refer to BR-section.

Brake fluid : DOT 3 or equivalent

CHECKING OF THE TIRE INFLATION PRESSUE

Maintenance Schedule (Severe)

Maintenance Schedule (For CANADA)

09452-21401/0K011 Installation of oil pump

09431-39000 Installation of differential oil seal

09432-33800 1. Removal of transfer driven gear taper bearing (Use with

09433-21000 1. Removal of transafer driven gear taper bearing (Use with

09500-11000 Installation of differential bearing outer race

09455-33200 Installation of differential ball bearing and output shaft taper

09455-21000/0K011 Removal of ball bearing and tansfer drive gear

09455-21100 1. Intallation of ball bearing and transfer drive gear

09532-11500 Installation of differential bearing outer race (Use with

09453-21000 • Removal and installation of low-reverse brake snap ring

09432-21701 Installation of output shaft outer race

09452-33100 Removal of the oil pump

09452-21200 Installation of the oil pump oil seal

09200-38001 Removal and installation of transaxle

09456-39100 Measurement of low-reverse brake and second brake end

SPECIAL SERVICE TOOLS

09432-22000 Installation of output shaft's gear and sleeve

09432-22100 Installation of input and output shaft bearing

09432-33200 Removal of input shaft's gear and ball bearing

09432-33300 Installation of input shaft bearing

09455-21100 Installation of differential ball bearing

09455-32200/0K011 Removal of differential bearing spacer

09495-33000 Removal of ball bearing and gear

09517-21400 Separation of T/M housing from T/M assembly

09532-11000 Removal and installation of differential bearing

09532-11500 Installation of output shaft and differential shaft

Automatic Transaxle System > General Information > Troubleshooting