CHERY Tiggo5 T21 Service Manual EN1

CHERY T21 CAUTION:
This manual is only for specialized

technicians. If non-specialized or uncertified
Service Manual individuals privately perform repairs or
maintenance only referring to this manual or
2014 without proper equipment and tools, it may

damage the customer's vehicle and hurt you
and other persons nearby.
01
In order to prevent dangerous operation and

FOREWORD damage to the vehicle, be sure to follow the
instructions shown below:
This manual contains on-vehicle diagnosis
and service procedures for Chery T21. - The contents in this manual must be read
thoroughly. Have a good understanding of
It is very important to read and be familiar all the contents written in the
with this manual thoroughly for proper repair PRECAUTION of "INTRODUCTION"
and maintenance. This manual should be section.
kept in a handy place for quick and easy
reference. - Before performing the repair procedures,
be sure to wear safety equipment properly
The contents in this manual, including all to avoid personal injury.
illustrations and specifications, are current at
the time of printing. Any modifications - When performing the repair procedures,
involving with repair and maintenance occur, be sure to use specified and
relevant information supplementary to this recommended tools to prevent damage to
volume will be made available at Chery the customer's vehicle. Be sure to confirm
dealers. the safety of technicians before operating
to avoid personal injury.
Chery Automobile Co., Ltd. reserves all
rights. Specifications and contents in this - If a part needs to be replaced, use Chery
manual are subject to change without genuine part with the same part number.
notification, and Chery Automobile Co., Ltd. Do not use any inferior quality part.
takes no legal obligations and - Observe the "WARNING" and
responsibilities. "CAUTION" in this manual carefully in
All rights reserved. Any unit or individual order to reduce the risk of personal injury
shall not reproduce or copy this manual in and vehicle damage due to improper
any form or by any means, or transmit it on operation during service and
the network by any form for any purpose maintenance.
without written permission of Chery
Automobile Co., Ltd.
This manual only applies to the models
listed below:
T21 2.0L MT
T21 2.0L CVT
All Rights Reserved © 2014

Chery Automobile Co., Ltd.
FOREWORD 01
INTRODUCTION 02
PREPARATION 03
SERVICE SPECIFICATIONS 04
MAINTENANCE 05
SQR484F ENGINE MANAGEMENT SYSTEM 06
SQR484F ENGINE MECHANICAL 07
SQR484F FUEL SUPPLY SYSTEM 08
SQR484F EMISSION CONTROL SYSTEM 09
SQR484F INTAKE SYSTEM 10
SQR484F EXHAUST SYSTEM 11
SQR484F COOLING SYSTEM 12
SQR484F LUBRICATION SYSTEM 13
SQR484F IGNITION SYSTEM 14
SQR484F STARTING SYSTEM 15
SQR484F CHARGING SYSTEM 16
QR525MHE TRANSMISSION 17
QR019CHB CVT 18
CLUTCH 19
DRIVE SHAFT 20
DIFFERENTIAL 21
AXLE 22
SUSPENSION 23
TIRE AND WHEEL 24
BRAKE CONTROL SYSTEM 25
BRAKE 26
PARKING BRAKE 27
STEERING COLUMN 28
HYDRAULIC ASSIST STEERING 29
ELECTRONIC POWER STEERING 30
AIR CONDITIONING 31
SUPPLEMENTAL RESTRAINT SYSTEM 32
SEAT BELT 33
ENGINE IMMOBILIZER 34
LIGHTING SYSTEM 35
WIPER AND WASHER 36
DOOR LOCK 37
INSTRUMENT CLUSTER 38
AUDIO SYSTEM 39
REVERSING RADAR SYSTEM 40
HORN 41
OTHER SYSTEM 42
WINDSHIELD/WINDOW GLASS 43
REAR VIEW MIRROR 44
INSTRUMENT PANEL 45
SEAT 46
ENGINE HOOD/DOOR 47
EXTERIOR 48
INTERIOR 49
BODY DIMENSIONS 50
WIRE HARNESS 51
INTRODUCTION
SERVICE INFORMATION 02-3 Diagnosis and Troubleshooting 02-16
How to Use This Manual 02-3 Circuit Simulation Test 02-17
Preparation 02-4 Precautions for Control Module and 
Service Operation 02-7 Electrical Components Inspection 02-19
VEHICLE INFORMATION 02-11

How to Check Connector 02-21 02
Vehicle Identification Information 02-11 CIRCUIT INFORMATION 02-22
Symbols 02-14 How to Read Circuit Diagram 02-22
Circuit Diagram Index 02-26
CIRCUIT DIAGNOSIS 
INFORMATION 02-15 ABBREVIATION TABLE 02-28
How to Use Tester 02-15 Abbreviation Table 02-28
ECM Control System 
Troubleshooting 02-15
Chery Automobile Co., Ltd. 02–1

02
02–2 Chery Automobile Co., Ltd.

02 - INTRODUCTION
SERVICE INFORMATION
INTRODUCTION
How to Use This Manual

1. General information
This manual includes all the necessary procedures for service operations.
These procedures can be divided into following three categories:
 Diagnosis 02
 Removal and installation, replacement, disassembly and assembly, inspection and adjustment
 Inspection
The following procedures are omitted from this manual. However, they must be performed.
 Use a transmission carrier or lifter to perform the operations.
 Clean all the removed parts.
 Perform a visual check.
This manual includes the following prompt information:
WARNING This indicates that injuries to you or other people may happen.
This indicates that damage to repairing components may
CAUTION
happen.
ENVIRONMENTAL PROTECTION Dispose of the waste materials according to local regulations.
Provide additional information to help you with the service
HINT
operations.
2. Service procedure
Illustrations attached with the service procedure are used to identify components, show the assembling
relevance of parts, and explain the visual check for parts. Removal and installation procedures are
explained in words.
Service procedures include:
 Detailed removal and installation instruction
 Illustration
 Torque specifications
 Specifications
Sometimes, the illustrations of similar models are used. In this case, minor details may be different from
the actual vehicle.
3. Diagnosis procedure
Diagnosis procedures are divided as below:
 Diagnostic Trouble Code (DTC)
DTC is an important hint when troubleshooting is difficult to simulate. The malfunction can be
diagnosed quickly and accurately by performing the specified DTC diagnosis and check.
 Problem symptoms table
Malfunction locations can be determined quickly by troubleshooting in accordance with the symptom
type.
4. Specifications
This manual categorizes specifications as below:
 Torque specifications
 Clearance specifications
 Capacity specifications

02 - INTRODUCTION
Preparation
1. Preparation for vehicle service
02
6 3
RT21020010

02 - INTRODUCTION
 Always wear a clean uniform.

1 Attire
 A hat and safety shoes must be worn.
Before starting work, prepare radiator grille cover, fender cover, seat
2 Vehicle Protection
cover and floor mat.
 When working with two or more persons, be sure to check safety each
other.
 When working with engine running, make sure to provide ventilation 02
for exhaust gas in workshop.
 If working on high temperature, high pressure, rotating, moving, or
3 Safety Operation
vibrating parts, be sure to wear appropriate safety equipment and take
extra care not to injure yourself or others.
 When jacking up vehicle, be sure to support the specified location with
a safety stand.
 Use appropriate safety equipment to lift vehicle.
Preparation for Tools and Before starting work, prepare a tool stand, special tools, gauge, oil and
4
Measuring Gauge replacement parts.
 Diagnose after thoroughly understanding the proper service
procedures and reported problem.
 Before removing parts, inspect the general condition of assembly to
check for any deformation or damage.
Removal and Installation,  Take notes for the complicated assembly. For example, note the total
5 Disassembly and number of electrical connections, bolts, or hoses that are removed.
Assembly Operations  Add matchmarks to ensure that each component is assembled to its
original position. Temporarily mark the hoses and their joints as
necessary.
 Clean and wash removed parts as necessary and assemble them
after a thorough inspection.
 Place the removed parts in a separate box to avoid mixing them up
with new parts or contaminating new parts.
6 Removed Parts  For non-reusable parts such as gaskets, O-rings, and self-locking
nuts, replace them with new ones as instructed in this manual.
 Retain removed parts for customer inspection, if requested.

02 - INTRODUCTION
2. Jacking up and supporting vehicle

Care must be taken when jacking up and supporting vehicle. Be sure to jack up and support vehicle at
proper locations.
a. Precautions for using a swing arm type lifter
 Follow the safety procedures described in the instruction manual.
 Keep vehicle stable when using a lifter to prevent vehicle from tilting during operation. Stabilize the
vehicle by adjusting the length of lifter arm and vehicle position.
02
Lifter Center
Front
RT21020020

02 - INTRODUCTION
b. Precautions for using a plate type lifter

 Follow the safety procedures described in the instruction manual.
 Use plate type lifter attachments (rubber lifting blocks) on the plate surface.
02
Attachment
RT21020030
Service Operation
1. How to use fasteners
WARNING
 Using incorrect fasteners may cause damage to components. Injury and death may occur without
observing the instructions below.
 The reference values of fasteners and torque specifications in this service manual use metric unit.
 Recycling all the fasteners (nuts, bolts, etc.) during maintenance and service operation is important for
assembly.
If it's impossible to recycle fasteners, be sure to use other fasteners with the same specifications.

02 - INTRODUCTION
2. Remove parts
When repairing malfunction, try to determine the cause.
Before starting work, the parts or sub-assemblies that
have to be removed and replaced should be confirmed
first. After removing parts, block all holes and ports to
prevent foreign objects from entering.
02
RT21020040
3. Disassemble components
If disassembly procedures are complicated and multiple parts need to be disassembled, make sure that
disassembly methods won't affect the performance or appearance of parts. Identify each part for assembly.
4. Check parts
After removal, check each part for deformation, damage or other problems.
5. Arrange parts
Carefully arrange all the disassembled parts to make assembly easier.
Always separately arrange the replaced parts and reusable parts, and make marks on them.
6. Clean parts
Make a thorough and careful cleaning for reusable parts.
WARNING
 Blowing out the dirt or other particles with compressed air may hurt your eyes. Be sure to wear goggles
during operation.
7. Assemble components
When assembling parts, always strictly use the standard values (tightening torque and clearance value,
etc.).
If following parts need to be replaced, replace them with
new ones.
Oil Seal Cotter Pin
 Oil seal
 Gasket
 O-ring Gasket Nylon Nut
 Lock washer
 Cotter pin
O-ring Lock Washer
 Nylon nut
RT21020050

02 - INTRODUCTION
8. Lubrication and seal

Use seal gum and gasket based on the position.
If seal gum is applied, install components before the seal gum dries to prevent leakage.
Apply lubricant to the movable area and friction area of components.
During assembly, apply permitted lubricant or grease to the specified area (such as oil seal).
9. Adjustment
Use proper meter and tester for adjustment.
10.Pre-coated parts 02
Pre-coated parts are the bolts and nuts that are coated
with seal lock adhesive in the factory.
If a pre-coated part is retightened, loosened, or moved in
any way, be sure to reapply the specified adhesive.
Seal Lock Adhesive
RT21020060
11. Rubber parts and rubber hoses

Avoid gasoline or oil dripping on the rubber parts or rubber hoses.
12.Hose clamp
Before removing hose, observe the position of clamp so
as to reinstall it to the same position. Elastic Clamp
Replace the deformed or dented clamps with new ones.
When reusing a hose, fix the clamp on the clamp track
portion of hose.
For elastic clamp, push tabs in the direction of arrow as
shown in the illustration after installation to widen the tabs
slightly.
Clamp Track
RT21020070
13.Vise
When using vise, install protective plates on the jaws of
vise to prevent parts from being damaged.
RT21020080

02 - INTRODUCTION
14.Dynamometer
When testing vehicle on the dynamometer, pay attention to the followings:
 Place a fan in front of the vehicle. It's best to use a fan of which the power changes in proportion to the
vehicle speed.
 Connect an exhaust gas ventilator.
WARNING
02  Exhaust gas may cause injury and death. There is odorless, colorless Carbon Oxide (CO) in the exhaust
gas. People will faint and get poisoned after inhaling it.
 Cool the exhaust pipe with a fan.

 Keep the area around vehicle clean and tidy.
 Monitor the engine coolant thermometer.

02 - INTRODUCTION
VEHICLE INFORMATION
Vehicle Identification Information
1. Vehicle Identification Number (VIN)
VIN is located on the upper left part of instrument panel
on driver side, and can be seen from the outside through * *
windshield. LVTDBXXXXXXXXXXXX
02
RT21020090
VIN is also stamped on deck board under the front

passenger side seat. * *
LVTDBXXXXXXXXXXXX
RT21020100
Vehicle Identification Number (VIN)

The Vehicle Identification Number (VIN) consists of World Manufacturer Identifier (WMI), Vehicle
Descriptor Section (VDS) and Vehicle Indicator Section (VIS), with a total of 17-digit characters. The
detailed descriptions are as follows:
WMI VDS VIS
ƶƶƶ ƶƶƶƶƶƶ ƶƶƻƻƻƻƻƻ
1 2 3 4 5 6
RT21020110
□: represents a letter or a number (letters I, O and Q cannot be used); ○: represents a number.

02 - INTRODUCTION
No. Definition
1 World Manufacturer Identifier
2 Vehicle Features
3 Accuracy Check Digit
4 Model Year
02 5 Production Plant
6 Sequential Number
 The first three digits of VIN represent world manufacturer identifier.
No. WMI Code Vehicle Category

1 LVV Category M1 (for vehicle type number started with 7)
 The fourth digit of VIN represents vehicle type.

- Letter "D" means all vehicles in the category M1.
 The fifth digit of VIN represents vehicle body type and drive type.
- Letter "B" means 5-door 2-box 4 × 2 type.
 The sixth digit of VIN represents transmission type.
- "1" means manual transmission.
- "2" means automatic transmission.
 The seventh digit of VIN represents dynamic characteristics.
- "4" means the gasoline engine that is 2.0 L - 2.5 L (2.5 L excluded).
 The eighth digit of VIN represents restraints system.
- "B" means seat belt and airbag.
 The ninth digit of VIN represents check digit.
- It is used to check the accuracy of VIN record, and made out through computation after confirming
the other sixteen digits of VIN.
 The tenth digit of VIN represents model year.
- "E" represents 2014.
 The eleventh digit of VIN represents assembly plant code.
- "C" represents Chery Automobile Co., Ltd Dalian Branch.
 The last six digits of VIN represent production sequence number.
- The number means the real production serial number of this model.
2. Vehicle name plate
The vehicle name plate is located on the right shock
absorber holder in engine compartment.
CHERY AUTOMOBILE COMPANY Ltd.,CHINA
LVTDBXXXXXXXXXXXX
1870 kg 1- 1012 kg
2- 971 kg
RT21020120

02 - INTRODUCTION
3. Engine number
The engine number is stamped on the engine block
under the exhaust manifold.
* * *
SQR484F XXXXXXXXX
02
RT21020130
4. Transmission number
The transmission number (for MT model) is stamped on
the transmission case.
QR525MHE
XXXXXXXXX
RT21020140
The transmission number (for CVT model) is stamped on

the transmission case, close to the transmission oil
dipstick. QR019CHA
XXXXXXXXX
RT21020150

02 - INTRODUCTION
Symbols
The symbols below are instrument cluster display symbols and some international standard symbols.
+ -
1 2 3 4 5 6
02 EPC
7 8 9 10 11 12
13 14 15 16 17 18
OFF
19 20 21 22 23 24
25 26 27 28 29 30
1 - Charging System Warning Light 2 - Daytime Running Light Indicator

3 - Front Fog Indicator 4 - Rear Fog Indicator
5 - High Beam Indicator 6 - Engine Immobilizer System Warning Light
7 - Maintenance Indicator 8 - High Coolant Temperature Indicator
9 - Position Indicator 10 - EPC Warning light
11 - Engine Malfunction Warning Light 12 - Low Engine Oil Pressure Warning Light
13 - Turn Signal Indicator 14 - SRS Warning Light
15 - Driver Seat Belt Reminder Light 16 - Brake System Warning Light
17 - ABS Warning Light 18 - Front Seat Belt Reminder Light
19 - ESP Warning Light 20 - ESP OFF Warning Light
21 - Low Fuel Level Warning Light 22 - Electronic Steering System Warning Light
23 - Cruise Indicator 24 - Transmission Malfunction Warning Light
25 - Parking Brake Indicator 26 - Hazard Flasher Warning light
27 - Horn 28 - Cigarette Lighter
29 - Hood Open 30 - Windshield Washer

02 - INTRODUCTION
CIRCUIT DIAGNOSIS INFORMATION

How to Use Tester
Connect tester cable to DLC, turn ignition switch ON and try
to use the tester. If communication malfunction appears on
the display, it indicates that the vehicle or tester is defective.
ཽ⪔⊳䖜
 If communication is normal when the tester is connected
to another vehicle, inspect the DLC on the original
02
vehicle.
 If communication is still not possible when the tester is
connected to another vehicle, the tester itself is probably
defective.
RT21020160
ECM Control System Troubleshooting

This model uses ECM control system. Most malfunction inspection procedures only involve in checking the
circuits of ECM control system one by one. An adequate understanding of the system and a basic knowledge
of electricity are enough to perform effective troubleshooting, accurate diagnosis and necessary repairs.

02 - INTRODUCTION
Diagnosis and Troubleshooting

1. Diagnosis basis and troubleshooting methods
Procedure Types Details Troubleshooting Methods

Use eliminating methods to
determine malfunctioning parts in
accordance with DTC detection
Diagnosis procedure is based on
02 Diagnosis based on DTC
stored DTC.
conditions.
Inspect relevant parts with tester
and eliminate possible
malfunctions one by one.
Use eliminating methods to
determine the malfunctioning parts
Diagnosis based on symptoms (no Diagnosis procedure is based on in accordance with symptoms.
DTCs stored) problem symptoms. Inspect relevant parts with tester
and eliminate possible
malfunctions one by one.
2. Detailed troubleshooting steps
Step Description
1 Obtain detailed information when electrical malfunction occurs.
Operate affected system, and perform a road test as necessary.
2 Confirm malfunction parameter.
If it is impossible to duplicate malfunction, refer to "Electrical Malfunction Simulation Test".
Collect proper diagnosis materials, which includes:
 Circuit Diagram
 System Schematic Diagram
3  Relevant Chapter in Service Manual
 Service Bulletin
Perform diagnosis according to the mastered system operation knowledge and customer's
feedback.
Check if there is any bonding, loose connector or damaged wire harness in the system.
4 Determine related circuits and components, and diagnose according to the circuit diagram and
wire harness layout diagram.
5 Repair circuit and replace component as necessary.
Operate system in all modes. Confirm that system can operate normally in all conditions.
6 Confirm that you have not inadvertently created new malfunctions during your diagnosis or
repair steps.

02 - INTRODUCTION
Circuit Simulation Test

The non-regular malfunctions and other malfunctions that cannot be detected through a road test can be
detected by circuit simulation test. The possible vehicle malfunction can be determined efficiently by
simulating condition/environment when the malfunction occurs.
Simulation test can be classified into the following 7 types:
 Vehicle vibration test
 Thermosensitive test
 Freezing test 02
 Leakage test
 Load test
 Cold/hot start test
 Voltage drop test
HINT:
It is extremely important to listen carefully to customer's description about the malfunction for simulating the
conditions when the symptoms occur.
1. Vehicle vibration test
When the vehicle is running on an uneven road or the engine is vibrating (A/C is on and engine is idling),
malfunctions may occur. In this case, check the conditions related to vibration. Check the following areas
on vehicle:
a. Connector and wire harness
Determine the connectors and wire harnesses that
may affect the electrical system being inspected. Slightly Vibrate
When monitoring whether the system has

malfunctions that are being simulated, vibrate or
wiggle each connector and wire harness slightly. This
test may show loose or poor electrical connections.
Slightly Vibrate
Slightly Wiggle
RT21020170
HINT:
When connector is exposed to humid environment, a layer of corrosive film may form on its terminals.
With the connector connected, this condition may not be found by visual check.If an intermittent
malfunction occurs, it may be caused by corrosion. It is recommended that the terminals of relevant
connectors in the system should be checked and cleaned after disconnecting the connectors.
b. Sensors and relays.
Slightly vibrate the sensors and relays that you want to check in the system. The sensors or relays that
are loose or poorly installed may be found through this test.

02 - INTRODUCTION
c. Engine compartment
 There are many reasons for the electrical malfunction that occurred due to vehicle vibration, and it is
necessary to check the following conditions:
- Connectors are not installed correctly.
- Wire harness is not long enough, so it is extended when engine is vibrating or shaking.
- Wire harness hangs over the bracket or movable components.
- Ground wire is loose, dirty or corrosive.
02 - Wire harness is too close to the high temperature components.
 To inspect the components under the engine hood, first confirm that the ground connection is in
perfect condition (refer to the grounding inspection described below). First confirm that the system is
correctly grounded. Then slightly vibrate the wire harness or components as previously instructed to
check if the connection is loose. Refer to the circuit diagram to check the continuity of wire harness.
d. Backside of instrument panel
 Improper wire clamping will cause the wire harnesses to be entangled when installing accessories.
The vibration of vehicle will cause the wire harnesses near the bracket or mounting screw to wind
excessively.
 When vehicle vibrates, unclamped or loose wire harness will be stuck in the seat components (such
as slide guide). When wire harness passes through the underside of mounting area, check if it is
damaged or stuck.
2. Thermosensitive test
In hot weather or after the vehicle is parked for a short time, the user may worry about the vehicle
condition. At this time, it is necessary to perform thermosensitive test.
Perform test by heating components with a heat gun or equivalent.
CAUTION
 DO NOT heat components to a temperature higher than 60°C (140°F).

 Perform test by heating components with a heat gun or equivalent.
3. Freezing test
If malfunction disappears after warming up the vehicle in winter, it may be caused by freeze of some parts
in the wire harness/electrical system. Use the following two methods to check this condition:
Method 1: Put vehicle outdoors overnight. Make sure that the temperature is low enough to duplicate the
malfunction. Perform a quick and thorough diagnosis on the component that may be affected in the
morning.
Method 2: Put suspected part in refrigerating room and wait until it is frozen. Reinstall the component to
vehicle and check if malfunction reoccurs. If malfunction occurs, repair or replace the component.
4. Leakage test
Malfunction may occur only during high humidity or in
rainy or snowy weather. In this case, malfunction may
occur due to water entering electrical parts. Leakage can
be checked by spraying water to vehicle (similar to car
wash).
RT21020180

02 - INTRODUCTION
5. Load test
Malfunction occurs only when electrical device is turned
on. Turn on the electrical equipment (A/C, rear window
defogger, radio, fog light, etc.) one by one and determine
the relationship between electrical equipment and
malfunction. Confirm the malfunction by a load test.
02
RT21020190
6. Cold/hot start test

Some malfunctions occur in cold start and disappear when engine warms up. In this case, park vehicle
without operation for a whole night and restart it the next day. Perform test and determine the cause
quickly.
7. Voltage drop test
Generally, the voltage drop test is used to find out the possible causes that affect the normal function of
electrical components or circuits.
Check the circuit with a digital multimeter.
If resistance of single wire harness measured by a digital multimeter is very low (0 Ω or close to 0 Ω), the
wire harness or circuit is normal.
The unnecessary resistance in circuit may be caused by poor, loose grounding, corrosive switch contact
and loose wire connector or adapter.
Precautions for Control Module and Electrical Components

Inspection
 Before performing electrical operations, turn ignition
switch to LOCK and disconnect the negative battery
cable, then wait for 2 minutes until the backup power
supply of airbag module is depleted (w/ airbag system).
RT21020200
 Disconnecting the battery cable will delete the clock, audio and DTC records. Therefore, it is necessary to
confirm these records before disconnecting the cable.
 Never connect the electrodes of battery terminals reversely.
 Only install components that meet the vehicle specifications.
1. Inspect input and output conditions of components and their functions before replacing control module.
 When disconnecting components:
- Do not use excessive force when disconnecting connector.
- If connector is installed by tightening bolt, loosen mounting bolt and then disconnect the connector
by hand.
 When connecting components:
- Make sure that terminals are not bent or damaged, and then connect it correctly before installing
connector.

02 - INTRODUCTION
- Tighten the mounting bolt until the painted area of connector is flush with the surface when installing
connector by tightening bolt.
 Never drop or hit the control module to prevent excessive impact.
 Note that the condensation is not formed on control module due to extreme change of temperature and
keep it free from water drop or rain. If water is found on the control module, dry it thoroughly and then
install it to vehicle.
 Be careful not to allow fluid to adhere to the control module connector.
 Avoid cleaning the control module with volatile fluid.
02
 When using digital multimeter, be careful not to get
the testing probes to contact with each other to result
in a short circuit. Avoid damaging the battery due to
short circuit in power transistor inside the control
module.
RT21020210
 Use specified test adapter to check the input and output signals of control module.
2. Check fuse
 Check that fuse wire is connected.
Good Blown
RT21020220
 If fuse wire is blown, confirm that there is no short in the circuit.

 A fuse with the same rated amperage must be used for replacing.

02 - INTRODUCTION
How to Check Connector

Many electrical malfunctions are caused by electrical
Crimping Looseness
connections or wire malfunctions, and also may be caused
by the bonding of components or relays. Before determining Cord Wire
if malfunction is caused by components or wire harness
assembly, check if connection of connectors is good.
Terminal
02
Deformation
Slightly Pull
RT21020230
1. Check connector with a digital multimeter

 Damaged connectors and poor connections are caused by incorrect connector detection during the
circuit inspection.
 The probe of digital multimeter may be connected incorrectly with the socket of connector. To detect the
connector correctly, use a "T" shaped pin and follow the procedures below. To obtain optimal
connection, clamp the "T" shaped needle with a spring clamp.
a. Detect from wire harness side
- If there is a back cover for connector, remove the back cover before detecting terminal.
- Do not detect the water-proof connector from the wire harness side. Failure to do this may
damage the seal between wire harness and connector.
b. Detect from terminal side
- Female terminal:
Do not insert any object that is bigger than male terminal into the female connector.
- Male terminal:
Carefully detect the contact surfaces of each terminal with a "T" shaped needle. Do not bend the
terminal.
2. Check terminal contact spring for proper tension
 The contact spring on terminal may produce intermittent signals in the circuit.
 If intermittent open circuit occurs, follow the procedures below to check open wire harness and contact
spring on the female terminal.
- Use a male terminal matched with female terminal.
- Disconnect the suspected defective connector and secure the terminal side upward.
- When securing the wire harness of male terminal, try to insert the male terminal into female terminal.
- Move connector and check if male terminal can be inserted easily.
HINT:
If male terminal can be inserted into female terminal easily, replace the female terminal.

02 - INTRODUCTION
CIRCUIT INFORMATION
How to Read Circuit Diagram
1. Connector symbols
 Most of the connector symbols in circuit diagrams
indicate the terminal side.
02 Terminal Side
Harness Side
RT21020240
 The terminal side view in circuit diagram is shown at

the bottom of circuit diagram.
Female
Connector Symbol Connector

RT21020250
2. Option splices
Option splice is indicated by diamonds (solid line), and marked with pin number inside.
MANUAL TRANSMISSION AUTO TRANSMISSION

CONTROL CONTROL
UNIT UNIT
E-106 E-106
E-106 E-106
16 15 8 4
E-106 E-106
SENSOR SENSOR
E-106 E-106
RT21020260

02 - INTRODUCTION
3. Circuit diagram example
EXAMPLE
[1] BATTERY
IGNITION SWITCH
ON OR START [14]
ENGINE
[15]
[2] EF05
30A
COMPARTMENT
FUSE AND RELAY BOX 02
E-049
D3
[3] A
A11 A13
2 3
INSTRUMENT
[4] MAIN
RF14 PANEL FUSE [16]
RELAY AND RELAY BOX
10A
1 5 I-004
RF19
15A
A4 A3 A1 A2 [13]
VR
SENSOR
I-003
MT CVT [12]
1 2
G
B
I-013
BW
[5] [6] 2 3 E-010

[17]
RW
RW
[8]
10 13 11 3 4
1 CONTROL
MODULE
I-001
MOTOR 7 8 9
[7] M E-011
GR
TO BACKLIGHT [18]
V
POWER SUPPLY
2 1 6
SWITCH
[9]
B
I-009
[11] TO CAN
[19] SYSTEM
[10]
E-014 3 5
[20]
I-006
D1 D2 D3 D4 D5
1 2 3 4 5 6 7 8 9 10 11 12 13 A16 A15 A14 A9 A8 A7
14 15 16 17 18 19 20 21 22 23 24 25 26
A6 A5 A4
A13 A12 A11 A10
A3 A2 A1
[21] D6 D7 D8 D9 D10 D11 D12
E-049
I-001 I-004 [22] W
W W
1 2 3 4 5 6 7 8 4 5 6 1 2
1 2 1 2 3
9 10 11 12 13 14 15 16
I-009 I-003
I-013
E-011 W W
W
Gr ET21020000

02 - INTRODUCTION
The following is a list of symbols defined in circuit diagram.
No. Definition Description

It indicates the power supply from battery positive to electrical
[1] Battery
equipment.
This symbol indicates a fuse; "EF05" indicates the fuse number;
[2] Fuse
"30A" indicates the rated amperage of fuse.
02 [3] Splice Point The solid circle indicates that each intersecting wire is interconnected.
This symbol indicates a relay; "MAIN RELAY" indicates the relay
[4] Relay
name; "1", "2", "3" and "5" indicate the terminal numbers of relay.
It indicates the color of this wire. The color codes are as follows:
B = Black;
W = White;
R = Red;
G = Green;
L = Blue;
Y = Yellow;
[5] Color Br = Brown;
O = Orange;
Gr = Gray;
P = Pink;
V = Violet;
Lg = Light Green.
For example: "BrR" indicates that the main color is brown in the wire
color, and the second color is red.
It indicates the junction connectors. "Λ" is the female connector, and 
"I-013" is the applicable number; "◊" is the male connector, and "E-010"
[6] Connector is the applicable number. The number "2" and "3" inside male
connector indicates the terminal number. "----" indicates different
terminals come from the same junction connectors.
[7] Motor This symbol indicates a motor.
[8] Component Name It indicates the name of component.

02 - INTRODUCTION

"E-011" indicates the connector number of this component, and the
letter "E" indicates the wire harness code in which the connector is
located. The connector codes are as follows:
E = Engine Compartment Wire Harness;
E = Engine Wire Harness;
I = Instrument Panel Wire Harness;
B = Body Wire Harness;
02
F = Front Left Door Wire Harness;
[9] Connector No. H = Front Right Door Wire Harness;
L = Rear Left Door Wire Harness;
R = Rear Right Door Wire Harness;
T = Back Door Wire Harness;
P = Battery Wire Harness;
U = Automatic Transmission Wire Harness (For CVT);
N = Ground Wire Harness.
K = A/C
[10] Ground Point It indicates the ground connection.
[11] Switch This symbol indicates a switch.
[12] Vehicle Model "CVT" indicates it is for CVT model; "MT" indicates it is for MT model.
[13] Terminal No. It indicates the terminal number in the connector of this component.
It indicates the power supply from ignition switch to electrical
[14] Ignition Switch
equipment.
It indicates that the wire harness is connected to the circuit diagram
[15] Connected to … on next page. The letter "A" is connected with "A" in circuit diagram on
the next page.
[16] Fuse and Relay Box Name It indicates the name of fuse and relay box.
[17] Twisted-pair It indicates that the two wires are twisted.
It indicates the illumination power supply output from backlight
[18] Backlight Power Supply
adjustment dial.
It is used for indicators, warning lights or illuminations in the switches
[19] LED
or instrument cluster.
It indicates CAN wire in the electrical schematics. It is connected to
[20] CAN
CAN system.
It indicates the cross section of connector and description of the
[21] Connector View
terminal number.
The letter "W" indicates the color of connector. The color codes are
[22] Connector Color
the same as above.

02 - INTRODUCTION
Circuit Diagram Index

Use the table below to find the location of components or vehicle systems in the circuit diagram. It is easy to
find the circuit diagrams throughout the service manual based on components or vehicle systems.
It has been marked under "If There Is Any Circuit Diagram" column to tell you that if there is any circuit
diagram in the components or vehicle systems.
Service Manual Chapter If There Is Any Circuit Diagram

02 Foreword -
Introduction -
Preparation -
Service Specifications -
Maintenance -
SQR484F Engine Management System Yes
SQR484F Engine Mechanical -
SQR484F Fuel Supply System Yes
SQR484F Emission Control System Yes
SQR484F Intake System Yes
SQR484F Exhaust System -
SQR484F Cooling System Yes
SQR484F Lubrication System -
SQR484F Ignition System Yes
SQR484F Starting System Yes
SQR484F Charging System Yes
QR525MHE Transmission -
QR019CHA Transmission Yes
Clutch -
Drive Shaft -
Differential -
Axle -
Suspension -
Tire and Wheel -
Brake Control System Yes
Brake Yes
Parking Brake Yes
Steering Column Yes
Hydraulic Assist Steering -
Electronic Assist Steering Yes
Air Conditioning Yes
Supplemental Restraints System Yes
Seat Belt Yes

02 - INTRODUCTION
Service Manual Chapter If There Is Any Circuit Diagram

Engine Immobilizer Yes
Lighting System Yes
Wiper and Washer Yes
Door Lock Yes
Instrument Cluster Yes
02
Audio System Yes
Reversing Radar System Yes
Horn Yes
Other System Yes
Windshield/Window Glass Yes
Rear View Mirror Yes
Instrument Panel -
Seat Yes
Engine Hood/Door -
Exterior -
Interior -
Body Dimensions -
Wire Harness Yes

02 - INTRODUCTION
ABBREVIATION TABLE
Abbreviation Table
Term Abbreviation
Anti-lock Brake System ABS
02 Acceleration Sensor AES
Accelerator Pedal Position Sensor APS
Automatic Temperature Control ATC
Automatic Transmission Fluid ATF
Body Control Module BCM
Brake Pressure Sensor BPS
Camshaft Position Sensor CMPS
Clutch Pedal Position Switch CPP Switch
Crankshaft Position Sensor CKPS
Data Link Connector DLC
Diagnostic Trouble Code DTC
Engine Control Module ECM
Engine Coolant Temperature ECT
Engine Speed RPM
Evaporative Emission EVAP
Evaporative Emission Canister EVAP Canister
Evaporative Emission System EVAP System
Exhaust Gas Recirculation Valve EGR Valve
Front Left Wheel Speed Sensor FLS
Front Right Wheel Speed Sensor FRS
Rear Left Wheel Speed Sensor RLS
Rear Right Wheel Speed Sensor RRS
Ground GND
Heated Oxygen Sensor O2S
Idle Air Control IAC
Intake Temperature IAT
Ignition IGN
Ignition Control IC
Immobilizer Control Module ICM
Injector INJ
Input Shaft Speed Sensor ISS Sensor
Knock Sensor KS
Manifold Absolute Pressure MAP

02 - INTRODUCTION
Term Abbreviation
Mass Air Flow MAF
Malfunction Indicator Light MIL
Oil Pressure Switch OPS
Output Shaft Speed Sensor OSS Sensor
Positive Crankcase Ventilation Valve PCV Valve
02
Power Supply PWR
Supplemental Restraints System SRS
Throttle Position Sensor TPS
Transmission Control Module TCM
Turbine Speed Sensor TSS
Vehicle Identification Number VIN
Vehicle Speed Sensor VSS

- MEMO -

PREPARATION
SQR484F ENGINE MANAGEMENT  BRAKE 03-30
SYSTEM 03-3 Tools 03-30
Tools 03-3
PARKING BRAKE 03-31
SQR484F ENGINE MECHANICAL 03-5 Tools 03-31
Tools 03-5
STEERING COLUMN 03-32
SQR484F FUEL SUPPLY SYSTEM 03-12 Tools 03-32 03
Tools 03-12
HYDRAULIC ASSIST STEERING 03-33
SQR484F EMISSION CONTROL  Tool 03-33
SYSTEM 03-13
Tool 03-13
ELECTRONIC POWER STEERING 03-34
Tools 03-34
SQR484F INTAKE SYSTEM 03-14
Tools 03-14
AIR CONDITIONING 03-35
Tools 03-35
SQR484F EXHAUST SYSTEM 03-15
Tools 03-15
SUPPLEMENTAL RESTRAINT 
SYSTEM 03-36
SQR484F COOLING SYSTEM 03-16 Tools 03-36
Tools 03-16
SEAT BELT 03-37
SQR484F LUBRICATION SYSTEM 03-17 Tool 03-37
Tools 03-17
ENGINE IMMOBILIZER 03-38
SQR484F IGNITION SYSTEM 03-18 Tools 03-38
Tool 03-18
LIGHTING SYSTEM 03-39
SQR484F STARTING SYSTEM 03-19 Tools 03-39
Tools 03-19
WIPER AND WASHER 03-40
SQR484F CHARGING SYSTEM 03-20 Tool 03-40
Tool 03-20
DOOR LOCK 03-41
QR525MHE TRANSMISSION 03-21 Tools 03-41
Tools 03-21
INSTRUMENT CLUSTER 03-42
QR019CHB CVT 03-23 Tools 03-42
Tools 03-23
AUDIO SYSTEM 03-43
CLUTCH 03-24 Tool 03-43
Tools 03-24
REVERSING RADAR SYSTEM 03-44
DIFFERENTIAL 03-25 Tool 03-44
Tools 03-25
HORN 03-45
AXLE 03-26 Tool 03-45
Tools 03-26
WINDSHIELD/WINDOW GLASS 03-46
SUSPENSION 03-28 Tools 03-46
Tools 03-28
REAR VIEW MIRROR 03-47
BRAKE CONTROL SYSTEM 03-29 Tool 03-47
Tools 03-29

INSTRUMENT PANEL 03-48 Tool 03-50
Tools 03-48
EXTERIOR 03-51
SEAT 03-49 Tool 03-51
Tool 03-49
INTERIOR 03-52
ENGINE HOOD/DOOR 03-50 Tool 03-52
03

03 - PREPARATION
SQR484F ENGINE MANAGEMENT SYSTEM

PREPARATION
Tools
Special Tool
03
ཽ⪔⊳䖜
X-431 3G Diagnostic Tester
RCH0000001
General Tools
Fuel Injector Cleaning Analyzer
RCH0000062
Ignition Timing Light
RCH0000016
Digital Multimeter
RCH0000002

03 - PREPARATION
Cylinder Pressure Gauge
RCH0000044
03
Fuel Pressure Gauge
RCH0000048
Oscilloscope YES ENTER
ESC
NO
1 2 3 4 5
6 7 8 9 0
RCH0000061

03 - PREPARATION
SQR484F ENGINE MECHANICAL

Tools
Special Tools
03
Crankshaft Front Oil Seal Guide Tool
RCH0000049
Crankshaft Front Oil Seal Installer
RCH0000067
Camshaft Oil Seal Installer
RCH0000017
Valve Spring Compression Adapter
RCH0000050
Valve Spring Compressor
RCH0000028

03 - PREPARATION
Crankshaft Rear Oil Seal Installer
RCH0000031
03
Valve Oil Seal Installer
RCH0000034
Valve Oil Seal Guide Sleeve
RCH0000035
Clutch Pressure Plate Installer
RCH0000018
Valve Oil Seal Remover
RCH0000037

03 - PREPARATION
Valve Cotter Installer
RCH0000029
03
Flywheel Holding Tool
RCH0000040
Oil Filter Remover
RCH0000054
Camshaft Timing Tool
RCH0000033
Crankshaft Timing Tool
RCH0000027

03 - PREPARATION
General Tools
Piston Installer
03 RCH0000039
20
10
30
0
40
90
50
80
Dial Indicator and Magnetic Holder
60
70
RCH0000023
1.5
50
1.0
5
0
Outer Diameter Micrometer 0.01mm
50 75mm
RCH0000064
Vernier Caliper
RCH0000019
Precision Ruler
RCH0000063

03 - PREPARATION
Feeler Gauge
RCH0000060
03
Cylinder Gauge
RCH0000065
Caliper Gauge
RCH0000069
Digital Multimeter
RCH0000002
Flexional Magnetic Rod
RCH0000042

03 - PREPARATION
Engine Hoist
RCH0000043
03
Engine Equalizer
RCH0000026
Transmission Carrier
RCH0000005
Fuel Pressure Gauge
RCH0000048
RCH0000044

03 - PREPARATION
Engine Service Platform
RCH0000057
03

03 - PREPARATION
SQR484F FUEL SUPPLY SYSTEM

Tools
Special Tool
03
Fuel Tank Pressure Cap Remover
RCH0000004
General Tools
Digital Multimeter
RCH0000002
Fuel Pressure Gauge
RCH0000048
RCH0000005

03 - PREPARATION
SQR484F EMISSION CONTROL SYSTEM

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
SQR484F INTAKE SYSTEM

Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tools
Digital Multimeter
RCH0000002
Precision Ruler
RCH0000063
Feeler Gauge
RCH0000060

03 - PREPARATION
SQR484F EXHAUST SYSTEM

Tools
General Tools
03
Precision Ruler
RCH0000063
Feeler Gauge
RCH0000060

03 - PREPARATION
SQR484F COOLING SYSTEM

Tools
General Tools
03
Digital Multimeter
RCH0000002
Cooling System Pressure Tester
RCH0000055
Freezing Point Tester
RCH0000007

03 - PREPARATION
SQR484F LUBRICATION SYSTEM

Tools
Special Tools
03
Oil Pan Remover and Scraper
RCH0000056
Oil Filter Remover
RCH0000054
General Tool
Oil Pressure Tester
RCH0000006

03 - PREPARATION
SQR484F IGNITION SYSTEM

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
SQR484F STARTING SYSTEM

Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
SQR484F CHARGING SYSTEM

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
QR525MHE TRANSMISSION
Tools
Special Tools
03
Input Shaft Oil Seal Installer
RCH0000008
Differential Oil Seal Installer
RCH0000009
Installer Joint
RCH0000010
Bearing Remover
RCH0000011
Punch
RCH0000015

03 - PREPARATION
Puller
RCH0000059
03
General Tools
RCH0000005
Engine Equalizer
RCH0000026
Hydraulic Press
RCH0000012

03 - PREPARATION
QR019CHB CVT
Tools
Special Tools
03
Puller
RCH0000059
RCH0000009
General Tools
Engine Equalizer
RCH0000026
RCH0000005

03 - PREPARATION
CLUTCH
Tools
Special Tool
03
RCH0000018
General Tools
Vernier Caliper
RCH0000019
Digital Multimeter
RCH0000002

03 - PREPARATION
DIFFERENTIAL
Tools
Special Tools
03
Bearing Remover
RCH0000011
Punch
RCH0000015
General Tools
Hydraulic Press
RCH0000012
20
10
30
0
40
90
50
80

60
70
RCH0000023

03 - PREPARATION
AXLE
Tools
Special Tool
03
Ball Pin Separator
RCH0000024
General Tools
20
10
30
0
40
90
50
80
60
70
RCH0000023
RCH0000005
Hydraulic Press
RCH0000012

03 - PREPARATION
Bearing Remover
RCH0000011
03
Engine Equalizer
RCH0000026

03 - PREPARATION
SUSPENSION
Tools
Special Tool
03
Spring Compressor
RCH0000021
General Tools
RCH0000005
Engine Equalizer
RCH0000026

03 - PREPARATION
BRAKE CONTROL SYSTEM

Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
BRAKE
Tools
Special Tool
03
Brake Caliper Piston Pressing Tool
RCH0000053
General Tools
20
10
30
0
40
90
50
80
60
70
RCH0000023
Vernier Caliper
RCH0000019
Digital Multimeter
RCH0000002

03 - PREPARATION
PARKING BRAKE
PREPARATION
Tools
General Tools
03
Digital Multimeter
RCH0000002
Vernier Caliper
RCH0000019

03 - PREPARATION
STEERING COLUMN
Tools
Special Tool
03
Steering Wheel Remover
RCH0000014
General Tool
Electric Drill
RCH0000013

03 - PREPARATION
HYDRAULIC ASSIST STEERING

Tool
Special Tool
03
Ball Pin Separator
RCH0000024

03 - PREPARATION
ELECTRONIC POWER STEERING

Tools
Special Tools
03
Ball Pin Separator
RCH0000024
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
AIR CONDITIONING
Tools
General Tools
03
Refrigerant Recycling Machine
RCH0000046
Digital Multimeter
RCH0000002

03 - PREPARATION
SUPPLEMENTAL RESTRAINT SYSTEM

Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
SEAT BELT
Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
ENGINE IMMOBILIZER
Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
LIGHTING SYSTEM
Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
WIPER AND WASHER

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
DOOR LOCK
Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
INSTRUMENT CLUSTER
Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
AUDIO SYSTEM
Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
REVERSING RADAR SYSTEM

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
HORN
Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
WINDSHIELD/WINDOW GLASS
Tools
Special Tool
03
Interior Crow Plate
RCH0000025
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
REAR VIEW MIRROR

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
INSTRUMENT PANEL
Tools
Special Tools
03
RCH0000014
Interior Crow Plate
RCH0000025

03 - PREPARATION
SEAT
Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
ENGINE HOOD/DOOR
Tool
General Tool
03
Interior Crow Plate
RCH0000025

03 - PREPARATION
EXTERIOR
Tool
General Tool
03
Interior Crow Plate
RCH0000025

03 - PREPARATION
INTERIOR
Tool
General Tool
03
Interior Crow Plate
RCH0000025

SERVICE SPECIFICATIONS
SQR484F ENGINE MANAGEMENT  TIRE AND WHEEL 04-33
SYSTEM 04-3 Specifications 04-33
Specifications 04-3
BRAKE CONTROL SYSTEM 04-34
SQR484F ENGINE MECHANICAL 04-4 Specifications 04-34
Specifications 04-4
BRAKE 04-35
SQR484F FUEL SUPPLY SYSTEM 04-12 Specifications 04-35
Specifications 04-12
PARKING BRAKE 04-37 04
SQR484F EMISSION CONTROL  Specifications 04-37
SYSTEM 04-13
STEERING COLUMN 04-38
SQR484F INTAKE SYSTEM 04-14
HYDRAULIC ASSIST STEERING 04-39
SQR484F EXHAUST SYSTEM 04-15
ELECTRONIC POWER STEERING 04-40
SQR484F COOLING SYSTEM 04-16
AIR CONDITIONING 04-41
SQR484F LUBRICATION SYSTEM 04-18
SUPPLEMENTAL RESTRAINT 
SYSTEM 04-43
SQR484F IGNITION SYSTEM 04-19 Specifications 04-43
SEAT BELT 04-44
SQR484F STARTING SYSTEM 04-20 Specifications 04-44
LIGHTING SYSTEM 04-45
SQR484F CHARGING SYSTEM 04-21 Specifications 04-45
WIPER AND WASHER 04-46
QR525MHE TRANSMISSION 04-22 Specifications 04-46
DOOR LOCK 04-47
QR019CHB CVT 04-23 Specifications 04-47
NSTRUMENT CLUSTER 04-48
CLUTCH 04-25 Specification 04-48
AUDIO SYSTEM 04-49
DRIVE SHAFT 04-26 Specifications 04-49
REVERSING RADAR SYSTEM 04-50
DIFFERENTIAL 04-27 Specification 04-50
HORN 04-51
AXLE 04-28 Specification 04-51
WINDSHIELD/WINDOW GLASS 04-52
SUSPENSION 04-30 Specifications 04-52

REAR VIEW MIRROR 04-53 ENGINE HOOD/DOOR 04-57
Specifications 04-53 Specifications 04-57
INSTRUMENT PANEL 04-54 EXTERIOR 04-59

SEAT 04-56 INTERIOR 04-61

04

04 - SERVICE SPECIFICATIONS

Specifications
Torque Specifications
Description Torque (N·m)

Coolant Temperature Sensor 11 - 16
Knock Sensor Fixing Bolt 20 ± 5
Engine Speed Sensor Fixing Bolt 8±2 04
Camshaft Position Sensor Fixing Bolt 8 ± 0.5
VVT Control Valve Fixing Bolt 8±2
Engine Control Module Bracket Fixing Nut 7±1


Specifications
SQR484F Engine Specifications
Item Specification
Vertical, in-line 4-cylinder, water-cooled, 4-stroke, DOHC, electronic
Engine Type
controlled sequential multiport fuel injection, Variable Valve Timing (VVT)
Engine Model SQR484F
04 Valve Number Per Cylinder 4
Cylinder Diameter (mm) 83.5
Piston Stroke (mm) 90
Displacement (L) 1.971
Compression Ratio 10:1
Combustion Chamber Type Pentroof type
Fuel Supply Type Electronic controlled sequential multiport fuel injection
Ignition Type Electrical control
Ignition Sequence 1-3-4-2
Idle Speed (r/min) 750 ± 50
Rated Power (kW) 102
Rated Power Speed (r/min) 5750
Max. Torque (N·m) 182
Max. Torque Speed (r/min) 4300 - 4500
Max. Permissible Speed (r/min) 5800
Min. Fuel Consumption Rate 
250
(g/kW·h)
Oil and Fuel Consumption
≤ 0.15
Percentage
Fuel Octane Number (Not Less
Unleaded gasoline, octane number 93
Than)
In Summer SAE 10W-40 (SM grade or higher)
Oil Octane Number
In Winter SAE 5W-40 (SM grade or higher)
Oil Capacity (L) 3.9 ± 0.5
Crankshaft Rotation Direction Counterclockwise (viewed from cross section of engine flywheel)
Starting Type Electrical starting
Cooling Type Forced circulation type antifreeze cooling
Lubrication Type Compound type (pressure, splash lubrication)
Fuel Pressure (bar) 4

Item Specification
Cylinder Compression
Pressure (bar) 10 - 13.5
(180 ~ 250) r/min
Higher than 150 kPa
Low Idling Speed (700 ± 50 r/min)
(when oil temperature is 90°C)
Higher than 360 kPa
Oil Pressure (kPa) High Idle Speed (2000 r/min)
Higher than 470 kPa
High Speed (4000 r/min)
(when oil temperature is 90°C) 04
Thermostat Operation Open Temperature 87 ± 2
Temperature (°C) Full Open Temperature 102
Net Weight (kg) 148
Boundary Dimension (Length ×
641 × 613 × 644
Width × Height) (mm)
With atmospheric temperature at -25°C, engine can start smoothly within
30 seconds without taking special measures. Starting test shows that
Starting Performance
staring can be performed 3 times consecutively. If it fails to start once,
perform starting again after 2 minutes.
Engine Mechanical Specifications
Item Specification
Intake Cam 37.65
Cam Height (mm)
Exhaust Cam 37.06
Camshaft Journal Intake Cam 23.947 - 23.960

Camshaft
Diameter (mm) Exhaust Cam 23.947 - 23.960
Camshaft Axial Intake Cam 0.15 - 0.20

Clearance (mm) Exhaust Cam 0.15 - 0.20
Lower Surface Flatness (mm) 0.04
Cylinder Head Overall Height (mm) 139.83 ± 0.335
Surface Grinding Limit Grinding is not permitted

Item Specification
Valve Head Margin Intake Valve 0.9

Thickness (mm) Exhaust Valve 0.7
Valve Stem Diameter Intake Valve 5.98 ± 0.008

(mm) Exhaust Valve 5.96 ± 0.008
Intake Valve 2.263
Grommet Width (mm)
Exhaust Valve 2.828
Valve
Clearance Between Intake Valve 0.012 - 0.043
04 Valve Stem and Guide
Exhaust Valve 0.032 - 0.063
(mm)
Intake Valve 90 - 90.5
Grommet Cone Angle (°)
Exhaust Valve 90 - 90.5
Intake Valve 107.998
Height (mm)
Exhaust Valve 106.318
Free Height 47.7
Valve Spring
Operating Preload/Operating Height 260 ± 11 N/41 mm
Valve Guide Length (mm) 38 ± 0.25
Inner Diameter (mm) 6 - 6.015
Valve Guide Outer Diameter (mm) 11.040 - 11.051
Depression Depth (mm) 16 ± 0.3
Valve Stem Protrusion Amount (mm) 31.497 - 31.515
Piston Piston Skirt Diameter (mm) 83.455 ± 0.009
First Ring 0.04 - 0.08
Side Clearance (mm)
Second Ring 0.025 - 0.070
End Gap (mm)
Piston Ring Second Ring 0.4 - 0.6
-0.01
First Ring 1.2 -0.05
-0.006
Height (mm) Second Ring 1.5 -0.050
Oil Ring 2.5
+0.06
First Ring 1.2 +0.05
+0.04
Piston Ring Groove Height (mm) Second Ring 1.5 +0.02
+0.05
Oil Ring 25 +0.01
0
Diameter (mm) 21 -0.006
0
Piston Pin Length (mm) 60 -0.5
+0.010
Piston Pin Hole Diameter (mm) 21 +0.006

Item Specification
Axial Clearance (mm) 0.070 - 0.265
Radial Clearance (mm) 0.021 - 0.059
0
Coaxially (mm) 0.04
Crankshaft Main Journal
Crankshaft Cylindricity (mm) 0.007
Roundness (mm) 0.004
0
Diameter (mm) 47.9 -0.016
Connecting Rod Journal Parallelism to Main 04
0.008
Journal
Overall Height (mm) 293
Bore Roundness (mm) 0.008
Cylinder Block Cylindricity (mm) 0.01
Upper Surface Flatness (mm) 0.04
Connecting Rod Big End Radial Clearance (mm) 0.021 - 0.056
Connecting Rod
Big End Axial Clearance (mm) 0.15 - 0.40
Engine Torque Specifications

Accessory Drive Belt Upper Idler Pulley Assembly
40 + 5
Fixing Bolt
Accessory Drive Belt Lower Idler Pulley Assembly
40 + 5
Fixing Bolt
Accessory Drive Belt Tensioner Assembly Fixing Bolt 40 + 5
Timing Belt Front Cover Upper Body Fixing Bolt 7
1st step: 25 ± 5
Crankshaft Pulley Fixing Bolt
2nd step: 30° ± 5°
Timing Belt Front Cover Lower Body Fixing Bolt 7
Plug for Installing Crankshaft Timing Tool on Bottom
40 + 5
of Engine Block
Timing Belt Tensioner Fixing Bolt 20 + 5
Exhaust Phaser Cover 30
Exhaust Camshaft Phaser Assembly Fixing Bolt 120 ± 5
Intake Phaser Cover 30
Intake Camshaft Phaser Assembly Fixing Bolt 120 ± 5
1st step: 130 ± 10
Crankshaft Timing Pulley Fixing Bolt
2nd step: 65° ± 5°
1st step: 35 ± 5
Flywheel Fixing Bolt
2nd step: 45° ± 5°


Engine Wire Harness Assembly Fixing Bolt 7±1
Intake Camshaft Position Sensor Fixing Bolt 8 ± 0.5
Exhaust Camshaft Position Sensor Fixing Bolt 8 ± 0.5
Cylinder Head Cover Fixing Bolt 8+3
Timing Belt Idler Pulley Fixing Bolt 40 + 5
Timing Belt Rear Cover Fixing Screw 5+2
Camshaft First Bearing Cap Fixing Bolt 8+3
04 Camshaft Bearing Cap Fixing Bolt 8+3
1st step: 45 ± 5
Cylinder Head Fixing Bolt
2nd step: 180° ± 10°
Coupling Bolt Between Rear Mounting Cushion
Assembly and Front Sub Frame Welding Assembly 70 ± 5
(for MT Model)
Rear Mounting Cushion Assembly Fixing Nut (for MT
70 ± 5
Model)
Locking Nut for Through Bolt Between Rear
Mounting Bracket and Rear Mounting Cushion 70 ± 5
Assembly (for MT Model)
Coupling Bolt Between Rear Mounting Bracket and
55 ± 5
Transmission Case (for MT Model)
(for CVT Model)
Assembly (for CVT Model)
80 ± 6
Transmission Case (for CVT Model)
Coupling Bolt Between Front Mounting Cushion
70 ± 5
Assembly and Side Rail Welding Assembly
Locking Nut for Through Bolt Between Front
Mounting Cushion Assembly and Front Mounting 70 ± 5
Bracket
Coupling Bolt Between Front Mounting Bracket and
55 ± 5
Transmission Case
Locking Nut for Through Bolt Between Left Mounting
Cushion Assembly and Left Mounting Bracket (for 105 ± 10
MT Model)
Coupling Bolt Between Left Mounting Cushion
90 ± 5
Assembly and Body (for MT Model)
Fixing Nut Between Left Mounting Bracket and
80 ± 6
Left Mounting Cushion Assembly Locking Nut (for
80 ± 6
CVT Model)


70 ± 5
Assembly and Body (for CVT Model)
80 ± 6
Coupling Bolt Between Left Mounting Bracket and
80 ± 6
Expansion Tank Fixing Bolt 7±1
Coupling Bolt and Nut Between Right Mounting
80 ± 6
Cushion Assembly and Right Mounting Bracket 04
Coupling Bolt Between Right Mounting Cushion
70 ± 5
Assembly and Body
Right Mounting Cushion Assembly Fixing Bolt 55 ± 5
Left Coupling Bolt Between Precatalytic Converter
23 ± 2
Assembly Bracket and Engine Block
Right Coupling Bolt Between Precatalytic Converter
50 ± 5
Coupling Nut Between Shift Cable and Shift Arm (for
18 ± 2
CVT Model)
Coupling Plug Between Pipe II Assembly and Clutch
16 ± 2
Release Cylinder
Bracket II Fixing Bolt 15 ± 2
Bracket I Fixing Bolt 15 ± 2
Transmission Ground Wire Fixing Bolt 15 ± 2
High Pressure Pipe Hollow Bolt 45 ± 5
Fixing Bolt Between A/C High/Low Pressure Line
25 ± 2.5
and Compressor Assembly
Battery Wire Harness Fixing Nut 7±1
Knock Sensor Inner Torx Fixing Bolt 20 ± 5
Small Circulation Metal Tube Fixing Bolt 20 ± 5
Engine Accessory Bracket Fixing Bolt 40 + 5
Power Steering Pump Bracket Fixing Bolt 30 + 5
Oil Cooler Bracket Fixing Bolt 40 + 5
Trim Cover Rear Right Bracket Fixing Bolt 7±1
Oil Deflector Assembly Fixing Bolt 8±3
1st step: 25 ± 3
Connecting Rod Bearing Cap Fixing Bolt
2nd step: 90° ± 5°
Crankshaft Frame Fixing Bolt 20 + 3
1st step: 45 ± 5
Main Bearing Cap Fixing Bolt
2nd step: 180° ± 10°

Lubrication Areas during Engine Assembly
Lubrication Area Note

Piston Pin SM10W-40
Piston Ring SM10W-40
Piston SM10W-40
Cylinder Bore SM10W-40
Main Bearing Shell and Crankshaft Main Journal SM10W-40
Crankshaft Thrust Washer (Oil Groove Side) SM10W-40
04 Connecting Rod Bearing Cap Bolt Head and Thread
SM10W-40
Part
Connecting Rod Bearing Shell and Crankshaft
SM10W-40
Connecting Rod Journal
Main Bearing Cap Bolt Head SM10W-40
Crankshaft Front Oil Seal Lip and Crankshaft Oil
SM10W-40
Seal Journal
Crankshaft Rear Oil Seal Lip and Crankshaft Oil Seal
SM10W-40
Journal
Valve Guide Hole SM10W-40
Valve Stem SM10W-40
Camshaft Cam and Journal SM10W-40
Hydraulic Lifter SM10W-40
Hydraulic Lifter Hole, Valve Rocker Arm SM10W-40
Valve Small End, Valve Rocker Arm Head SM10W-40
Valve Retainer Hole (Cylinder Head Assembly) SM10W-40
Valve Guide or Guide Bottom Hole (Cylinder Head) SM10W-40
Camshaft Oil Seal Lip and Camshaft Journal SM10W-40
Oil Filter Gasket Surface SM10W-40
All engine lubricants should be 5W-40 (for winter)/10W-40 (for summer) SM grade or higher.

Areas with Seal Gum Applied during Engine Assembly
Area with Seal Gum Applied Seal Gum Type

Cylinder Block Bowl Plug Loctite 747
Cylinder Block Main Oil Passage Plug Loctite 5910

Joint Surface Between Crankshaft Frame and
Loctite 518
Cylinder Block
Crankshaft Frame and Oil Pan Loctite 5910
Cylinder Head Bowl Plug Loctite 11747

04
Cylinder Head Oil Passage Plug Loctite 577
First Bearing Cap Bottom Plate Loctite 574
Coolant Temperature Sensor Loctite 243
Oil Pressure Sensor Loctite 577
Camshaft Variable Valve Timing Control Valve Loctite 243
Oil Deflector Bolt Loctite 243
Oil Pump Mounting Bolt Loctite 5910

Timing Gear Rear Cover Fixing Screw Loctite 243


Specifications

Fuel Filter Ground Wire Fixing Nut 7±1
Fuel Filter Bracket Fixing Screw 3.5 ± 0.5
04 Fuel Tank Pressure Cap 75 ± 5

Coupling Bolt Between Filler Tube Assembly and
22 ± 2
Body
Filler Tube Assembly Fixing Nut 7±1
Fuel Tank Fixing Strap Fixing Bolt 25 ± 3
Fuel Level Sensor Fixing Screw 5±1
Fuel Rail Fixing Bolt 8+3
Worm Clamp 3.5 ± 0.5
Fuel Pressure Specifications
SQR484F Pressure (kPa)

Fuel Pressure on Fuel Rail - Key (ON) 400
Fuel Pressure on Fuel Rail - Engine Idling 400
Fuel Pressure on Fuel Rail - Key (LOCK) 400


Specifications

Activated Charcoal Canister Solenoid Valve Bracket
7±1
Fixing Bolt
Coupling Bolt Between Activated Charcoal Canister
Assembly and Body
7±1 04
Exhaust Manifold Heat Insulator Fixing Bolt 23 ± 2
Upstream Oxygen Sensor 40 - 60
Downstream Oxygen Sensor 40 - 60


Specifications

Trim Cover Front Bracket Fixing Bolt 7±1
04 Trim Cover Rear Left Bracket Fixing Bolt 7±1

Coupling Screw between Air Filter Upper Housing
1.3 ± 0.2
and Lower Housing
Air Induction Pipe Assembly Fixing Bolt 7±1
Air Filter Assembly Left Fixing Bolt 7±1
Air Filter Assembly Right Fixing Bolt 7±1
Hot Wire Air Flow Meter Fixing Bolt 4.5 ± 0.5
Air Filter Assembly Bracket Fixing Bolt 7±1
Electronic Throttle Assembly Fixing Bolt 8±3
Intake Manifold Bracket Fixing Bolt 18 ± 2
Oil Dipstick Fixing Bolt 8±3
Engine Wire Harness Fixing Bolt 8±3
Intake Manifold Assembly Fixing Nut 8±3
Electronic Accelerator Pedal Fixing Bolt 10 ± 2
Worm Clamp 5 ± 0.5


Specifications

Coupling Nut Between Exhaust Manifold Assembly
50 ± 5
and Precatalytic Converter Assembly
Exhaust Manifold Assembly Fixing Nut 23 ± 2
04
Coupling Nut Between Precatalytic Converter Upper
Body Assembly and Precatalytic Converter Lower 50 ± 5
Body Assembly
23 ± 2
Assembly Bracket and Cylinder Block
50 ± 5
Coupling Nut Between Precatalytic Converter Lower
Body Assembly and Main Catalytic Converter 50 ± 5
Assembly
Coupling Nut Between Main Catalytic Converter
50 ± 5
Assembly and Center Pipe Assembly
Coupling Spring Bolt Between Center Pipe Assembly
50 ± 5
and Muffler Assembly
Muffler Assembly Left Hanger Block III Assembly
50 ± 5
Fixing Bolt
Muffler Assembly Right Hanger Block III Assembly
50 ± 5
Fixing Bolt


Specifications

Coupling Bolt Between Air Induction Pipe Assembly
7±1
and Tank Upper Crossmember Assembly
Radiator Left Tension Plate Fixing Bolt 7±1
04 Radiator Right Tension Plate Fixing Bolt 7±1
Tank Upper Crossmember Assembly Fixing Bolt 7±1
7±1
Fixing Bolt
Thermostat Housing Fixing Bolt 8±3
Engine Ground Wire Fixing Bolt 7±1
Engine Speed Sensor Bracket Fixing Bolt 7±1
Thermostat Seat Fixing Bolt 8+3
Fan Controller Fixing Bolt 7 ± 1.5
Cooling Fan Assembly Fixing Bolt 7±1
Water Pump Assembly Fixing Bolt 8+3
Coolant Capacity
Item Capacity (L)

Cooling System 7.5
Coolant Concentration
G11 Additive Soft Water

50% 50%
Coolant Freezing Point
Item Freezing Point Value (°C)

Coolant -35

Cooling System Test Pressure
Item System Pressure (bar)

Cooling System (Test Pressure) 1.3 ± 0.2
04


Specifications
System Pressures
Condition Pressure (bar)

Idling Speed (750 ± 50 r/min) Above 1.5 (oil temperature 90°C)
High Idling Speed (2000 r/min) Above 3.6 (oil temperature 90°C)
04 High Speed (4000 r/min) Above 4.7 (oil temperature 90°C)
Oil Specifications
Engine Type SQR484F

Oil Capacity (L) 4 ± 0.5
Summer: SAE 10W - 40 (SM grade or higher)
Oil Specifications
Winter: SAE 5W - 40 (SM grade or higher)

Drain Plug 35 ± 3
Oil Filter 25 ± 3
Coupling Bolt Between Oil Pan and Transmission
45 ± 5
Case
Fixing Bolt of Baffle Plate Between Oil Pan and
45 ± 5
Transmission Case
Oil Pressure Switch 20 ± 2
Oil Pan Fixing Bolt 11 ± 1
Oil Pan Baffle Plate Fixing Bolt 8+3
Oil Strainer Bracket Fixing Bolt 17 - 23
Oil Strainer Bracket Fixing Nut 17 - 23
Coupling Bolt Between Oil Strainer and Oil Pump 17 - 23
Oil Pump Fixing Bolt 8 - 11


Specifications

Spark Plug 30 ± 3
Ignition Coil Fixing Bolt 8+3
04
Spark Plug Specifications
Engine Type SQR484F

Spark Plug Type FR7DTC
Spark Plug Gap (mm) 0.8 - 0.9


Specifications

Starter Power Cable Nut 13 ± 1
Starter Fixing Bolt 35 ± 5
04 ignition Starting Switch Fixing Screw 13 ± 2


Specifications

Battery Pressure Plate Fixing Nut 7±1
Coupling Bolt Between Battery Pressure Plate and
7±1
Tank Upper Crossmember
Coupling Bolt Between Battery Tray and Air Filter
04
7 ± 1.5
Bracket
Battery Tray Fixing Bolt 20 ± 2
Battery Tray Bracket Fixing Bolt 20 ± 2
Alternator Output Cable Fixing Nut 18 - 22
Alternator Fixing Bolt 20 + 5
Battery Specification
Engine Type Battery Type Specification

SQR484F 6-QW-70QR 12 V, 70 Ah, CCA (SAE) 560 A

Specifications

Coupling Bolt Between Clutch Case and
25 ± 2
Transmission Case
Reverse Idler Gear Shaft Locating Bolt 40 ± 4
04 Coupling Bolt Between Gear Shift Mechanism and
25 ± 2
Transmission Case
Gear Shift Mechanism Locating Bolt 35 ± 5.25
Back-up Light Switch 20 ± 2
Shift Shaft Locating Bolt 35 ± 5.25
Gear Shift Control Mechanism Fixing Bolt 23 ± 2
Drain/Retaining Plug 40 ± 6
Shift Arm Bracket Bolt 25 ± 2
Reverse Lock Mechanism Fixing Bolt 18 ± 2
Reverse Gear Fork Fixing Bolt 25 ± 2
Transmission Lower Coupling Bolt 50 ± 5
Transmission Upper Coupling Bolt 60 ± 5
Engine Side Coupling Bolt 60 ± 5
Transmission Gear Ratio Table
Gear Ratio Type

QR525MHE
Gear
Gear Gear Ratio
1st 3.583
2nd 2.053
3rd 1.379
4th 1.03
5th 0.821
Reverse 3.417
Final Drive 4.313
Speedometer 0.806

QR019CHB CVT
Specifications

Transmission Drain Bolt 29 - 34
Primary Shaft Speed Sensor Fixing Bolt 10 - 12
Secondary Shaft Speed Sensor Fixing Bolt 10 - 12 04
Turbine Speed Sensor Fixing Bolt 10 - 12
Primary Shaft Pressure Sensor 15 - 22
Secondary Shaft Pressure Sensor 15 - 22
Gear Shift Cable to Arm Nut 16 - 20
Valve Body Case Fixing Bolt 10 - 12
Transmission Range Sensor Fixing Bolt 10 - 12
Gear Shift Arm Fixing Nut 18 - 25
Gear Shift Control Mechanism Fixing Bolt 18 - 22
Gear Shift Cable Dust Boot Fixing Bolt 8 - 10
TCU Fixing Bolt 6-8
Transmission Ground Wire Harness Fixing Bolt 18 - 22
Engine to Upper Part of Transmission Bolt 75 - 85
Dust Baffle Fixing Bolt 45 - 55
Flywheel to Torque Converter Bolt 50 - 60
Transmission to Engine Front Bolt 75 - 85
Transmission to Engine Bolt 75 - 85
Valve Body Fixing Bolt 8 - 10
Transmission Fluid Cooler Fixing Bolt 22 - 28
General Specifications
Item Parameter
Model QR019CHB
Type CVT
Central Distance (mm) 204
Maximum Input Torque (N·m) 190
Final Drive Ratio 5.141
Pulley Speed Ratio Scope 0.44 - 2.39
Solenoid Quantity 4
Gear Shift Positions P, R, N, D, L, M (manual mode)

Item Parameter
Fluid Type SP - III
Transmission Fluid Capacity (L) 8.0 ± 0.2
04

CLUTCH
Specifications

Clutch Pedal Fixing Nut 25 ± 2
Pipe Assembly II Joint 16 ± 2
Clutch Release Cylinder Fixing Bolt 22 ± 2 04
Clutch Pressure Plate 25 ± 2
Clutch Driven Disc Specifications
Measurement Item Specification (mm)

Clutch Driven Disc Standard Thickness 7.6 ± 0.2
Minimum Rivet Depth 1.2

DRIVE SHAFT
Specifications

Drive Shaft Fixing Nut 300 ± 20
Coupling Nut Between Steering Knuckle and Control
180 ± 10
Arm Ball Pin
04 Coupling Bolt Between Front Left Wheel Speed
10 ± 1
Sensor and Front Left Steering Knuckle Assembly

DIFFERENTIAL
Specifications
Torque Specification

Final Drive Driven Gear Bolt 111 - 118
Clearance Specification
04
Description Acceptable Range (mm)
Clearance Between Differential Case and Planetary
0.025 - 0.150
Gear

AXLE
Specifications

Wheel Mounting Bolt 110 ± 10
Front Drive Shaft Assembly Locking Nut 300 ± 20
04 Coupling Bolt Between Front Hub Assembly and

Front Steering Knuckle Assembly
70 - 75
Coupling Bolt Between Front Wheel Speed Sensor

10 ± 1
and Front Steering Knuckle Assembly
Locking Nut Between Steering Tie Rod Assembly
47 ± 3
Ball Pin and Front Steering Knuckle Assembly
Coupling Nut Between Front Control Arm Assembly
120 ± 12
Coupling Bolt Between Front Shock Absorber
180 ± 10
Assembly and Front Steering Knuckle Assembly
Coupling Nut Between Front Shock Absorber
180 ± 10
Coupling Bolt Between Engine Lower Protector
10 ± 1
70 ± 5
Assembly and Rear Mounting Bracket
Coupling Nut Between Rear Mounting Cushion
70 ± 5
70 ± 5
Assembly and Front Mounting Bracket
Coupling Nut Between Front Mounting Cushion
70 ± 5
Coupling Bolt Between Side Rail Welding Assembly
80 ± 6
and Body
70 ± 5
and Front Mounting Cushion Assembly
70 ± 5
and Rear Mounting Cushion Assembly
Coupling Nut Between Side Rail Welding Assembly
70 ± 5
Coupling Bolt Between Front Stabilizer Bar and Front
20 ± 3
Sub Frame Welding Assembly
Coupling Bolt Between Front Sub Frame Welding
120 ± 10
Assembly and Steering Gear Assembly
Coupling Bolt Between Upper Part of Front Sub
180 ± 10
Frame Welding Assembly and Body


Coupling Bolt Between Rear Part of Front Sub
180 ± 10
Coupling Nut Between Rear Hub Bearing Unit and
68 ± 5
Rear Brake Bottom Board Assembly
Coupling Bolt Between Rear Suspension Upper
Swing Arm Assembly and Rear Sub Frame 120 ± 10
Assembly
Coupling Nut Between Rear Suspension Upper
Assembly 04
Coupling Bolt Between Rear Suspension Lower
Assembly
Coupling Nut Between Rear Suspension Lower
Assembly
Coupling Bolt Between Rear Sub Frame Assembly
120 ± 10
and Body
Coupling Nut Between Rear Sub Frame Assembly
120 ± 10
and Body

SUSPENSION
Specifications

Coupling Nut Between Front Stabilizer Link
45 ± 5
Assembly and Front Shock Absorber Assembly
04 Assembly and Front Steering Knuckle Assembly
180 ± 10

180 ± 10
60 ± 6
Assembly and Body
Front Shock Absorber Assembly Locking Nut 82 ± 5
120 ± 12
Coupling Bolt Between Front Part of Front Control
Arm Assembly and Front Sub Frame Welding 180 ± 10
Assembly
Coupling Bolt Between Rear Part of Front Control
Assembly
Coupling Nut Between Front Control Arm Ball Pin
150 ± 10
Assembly and Front Control Arm Assembly
Coupling Bolt Between Front Control Arm Ball Pin
150 ± 10
Coupling Nut Between Front Stabilizer Bar Assembly
45 ± 5
and Front Stabilizer Link Assembly
70 ± 5
70 ± 5
120 ± 10
180 ± 10
180 ± 10
Coupling Bolt Between Front Stabilizer Bar
25 ± 3
Assembly and Front Sub Frame Welding Assembly
Coupling Bolt Between Lower Part of Rear Shock
45 ± 5
Absorber Assembly and Rear Trailing Arm Assembly
Coupling Nut Between Upper Part of Rear Shock
45 ± 5
Absorber Assembly and Body


Coupling Nut Between Rear Stabilizer Link Assembly
45 ± 5
and Rear Suspension Lower Swing Arm Assembly
Coupling Bolt Between Rear Shock Absorber
Assembly Fixing Bracket and Rear Trailing Arm 80 ± 8
Assembly
Swing Arm Assembly and Rear Trailing Arm 120 ± 10
Assembly
Swing Arm Assembly and Rear Trailing Arm 120 ± 10 04
Assembly
Assembly
Assembly
Coupling Bolt Between Rear Rubber Cushion
25 ± 5
Assembly and Body
Assembly
Assembly
Assembly
Assembly
Coupling Bolt Between Rear Wheel Speed Sensor
23 ± 2
Fixing Bracket and Rear Trailing Arm Assembly
Coupling Bolt Between Parking Brake Cable Fixing
23 ± 2
Bracket and Rear Trailing Arm Assembly
Coupling Bolt Between Rear Brake Line Fixing
23 ± 2
Coupling Bolt Between Rear Trailing Arm Assembly
120 ± 10
and Mounting Bracket
Coupling Nut Between Rear Trailing Arm Assembly
120 ± 10
45 ± 5
and Rear Stabilizer Bar Assembly
Rear Brake Line Fixing Plug 16 ± 2
Coupling Bolt Between Rear Stabilizer Bar Assembly
25 ± 3
and Body


Steering Tie Rod Locking Nut 55 ± 5
Steering Wheel Locking Nut 35 ± 5
04

TIRE AND WHEEL

Specifications

Tire Type
04
Description Parameter
Tire Type 225/65 R17 102H
Rim Type
Rim Type 17 × 7J
Tire Pressure Specifications of Cold Tire
Description Pressure (kPa)

Front Tire (Unloaded) 230
Rear Tire (Unloaded) 230
Spare Tire 250


Specifications

Brake Pipe Coupling Plug 16 ± 2
04 ABS Control Module Assembly Mounting Bracket

Fixing Bolt
23 ± 2
ABS Control Module Assembly Mounting Bracket

23 ± 2
Fixing Nut
ABS Control Module Assembly Bottom Mounting Nut 8±2
Front Wheel Speed Sensor Fixing Bolt 10 ± 1
Rear Wheel Speed Sensor Fixing Bolt 10 ± 1

BRAKE
Specifications

Coupling Nut Between Brake Fluid Reservoir
9±1
Assembly and Body
Coupling Plug Between Brake Master Cylinder
04
16 ± 2
Assembly and Brake Pipe
Coupling Nut Between Brake Master Cylinder
21 - 25
Assembly and Vacuum Booster Assembly
Coupling Bolt Between Brake Fluid Reservoir
3-5
Assembly and Brake Master Cylinder Assembly
Coupling Nut Between Vacuum Booster Assembly
25 ± 3
and Brake Pedal Assembly
Coupling Nut Between Brake Pedal Assembly and
25 ± 3
Body
Coupling Bolt Between Front Brake Caliper
27 ± 2
Assembly and Front Brake Hose Assembly
100 ± 10
Front Brake Disc Positioning Screw 10 ± 1
Front Brake Caliper Bleeder Plug 9 - 11
Locating Bolt Between Front Brake Caliper Fixing
25 ± 3
Bracket and Front Brake Cylinder Assembly
Coupling Plug Between Front Brake Hose Assembly
16 ± 2
and Front Brake Pipe
Coupling Bolt Between Rear Brake Caliper
20 ± 2
Assembly and Rear Brake Hose Assembly
100 ± 10
Assembly and Rear Brake Bottom Board Assembly
Rear Brake Disc Positioning Screw 10 ± 1
Rear Brake Caliper Bleeder Plug 9 - 11
Locating Bolt Between Rear Brake Caliper Fixing
25 ± 3
Bracket and Rear Brake Cylinder Assembly
Coupling Plug Between Rear Brake Hose Assembly
16 ± 2
and Brake Pipe

Front Disc Brake
Standard Thickness Minimum Thickness

Description Maximum Runout (mm)
(mm) (mm)
Front Brake Disc 25 23 0.06
Front Brake Lining 9.2 2 -
Rear DIH (Drum-in-hat)

04 (mm) (mm)
Rear Brake Disc 10 8 0.06
Rear Brake Lining 8.2 2 -

PARKING BRAKE
Specifications
Description Tightening Torque (N·m)

Coupling Bolt Between Parking Brake Control
23 ± 2
Mechanism Assembly and Body
Coupling Bolt Between Parking Brake Rear Cable
04
23 ± 2
Assembly Fixing Bracket and Body
Assembly
Assembly Fixing Bracket and Rear Brake Bottom 23 ± 2
Board Assembly
23 ± 2
Bracket and Rear Brake Bottom Board Assembly
Description Standard Thickness (mm) Minimum Thickness (mm)

Rear Brake Shoe Lining 3 1
Description Standard Inner Diameter (mm) Maximum Inner Diameter (mm)

Rear Brake Disc 186 188

STEERING COLUMN
Specifications

Steering Wheel Assembly Fixing Nut 35 ± 3
Combination Switch Cover Fixing Screw 2 ± 0.5
04 Steering Column Assembly Upper Bracket Fixing Nut 25 ± 3

Steering Column Assembly Lower Bracket Fixing
25 ± 3
Bolt
Coupling Bolt Between Steering Column with
Intermediate Shaft Assembly and Steering Gear 30 ± 3
Input Shaft
Coupling Bolt Between Electronic Power Steering
Column with Intermediate Shaft Assembly and 60 ± 5
Steering Gear Input Shaft
Ignition Starting Switch Fixing Screw 15 ± 2
Steering Boot Fixing Nut 10 ± 1
50
Column and Intermediate Shaft
Data Specifications
Description Standard Value

Steering Wheel Free Play (Rotation Angle) ≤ 15°
Steering Wheel Centering/Returnability (Rotation
> 70°
Angle)


Specifications

Steering Gear Heat Insulation Cover Fixing Bolt 9±1
High Pressure Fluid Pipe Bracket Bolt 1 9±1
High Pressure Fluid Pipe Bracket Bolt 2 9±1 04
Clamping Bolt Between High Pressure Fluid Pipe
30 ± 3
and Steering Gear Assembly
Clamping Bolt Between Fluid Return Pipe and
30 ± 3
Steering Gear Assembly
Fluid Return Pipe Bracket Bolt 1 9±1
Fluid Return Pipe Bracket Nut 2 7±1
High Pressure Fluid Pipe Joint Hollow Bolt 40 ± 3
Cooling Pipe Bracket Nut 1 7±1
Mounting Bolt Between Steering Gear and Sub
120 ± 10
Frame
Power Steering Pump Bracket Fixing Bolt 25 ± 3
Coupling Bolt Between Power Steering Pump
25 ± 3
Assembly and Steering Pump Bracket
Locking Nut Between Ball Pin Assembly and
45 ± 5
Steering Knuckle Assembly
Mounting Bolt Between Steering Gear Assembly and
120 ± 10
Front Sub Frame Welding Assembly
Steering Tie Rod Adjustment Nut 55 ± 5


Specifications

Ball Pin Locking Nut 35 ± 3
Coupling Bolt between Steering Gear Input Shaft
and Steering Column with Intermediate Shaft 60 ± 5
04 Assembly
Steering Gear Fixing Bolt 120 ± 10

AIR CONDITIONING
Specifications

A/C Control Panel Assembly Fixing Screw 2.5 ± 0.5
Coupling Bolt Between A/C High/Low Pressure Line
7±1
and Expansion Valve
Fixing Nut Between HVAC Assembly and Instrument
04
7±1
Panel Crossmember Assembly
Fixing Bolt Between HVAC Assembly and Instrument
4±1
Fixing Bolt Between HVAC Assembly and Body 7±1
Air Inlet Assembly Right Fixing Screw 2.5 ± 0.5
Air Inlet Assembly Left Fixing Screw 2.5 ± 0.5
Air Inlet Assembly Rear Fixing Screw 2.5 ± 0.5
Left Foot Fan Shield Fixing Screw 2.5 ± 0.5
Right Foot Fan Shield Fixing Screw 2.5 ± 0.5
Coupling Bolt Between Expansion Valve and
7±1
Expansion Valve Mounting Pressure Plate
Blower Case Assembly Upper Fixing Screw 2.5 ± 0.5
Blower Case Assembly Lower Fixing Screw 2.5 ± 0.5
Evaporator Case Assembly Fixing Screw 2.5 ± 0.5
Heater Core Line Pressure Plate Fixing Screw 2.5 ± 0.5
Heater Core Line Cover Plate Fixing Screw 2.5 ± 0.5
Mode Damper Adjustment Mechanism Set Fixing
2.5 ± 0.5
Screw
Coupling Nut Between A/C High/Low Pressure Line
7±1
Fixing Bracket and Body
Fixing Bolt Between A/C Low Pressure Line and
25 ± 2.5
Compressor Assembly
Fixing Bolt Between A/C High Pressure Line and
25 ± 2.5
Compressor Assembly
Fixing Nut Between A/C High Pressure Line I and
7±1
Condenser Assembly
Fixing Nut Between A/C High Pressure Line II and
7±1
Condenser Assembly
70 ± 5
70 ± 5


70 ± 5
70 ± 5
80 ± 6
Assembly and Right Mounting Bracket
Coupling Nut Between Right Mounting Cushion
80 ± 6
04 Coupling Bolt Between Right Mounting Cushion

70 ± 5
Assembly and Body
Coupling Bolt Between Compressor Assembly and
40 ± 5
Mounting Bracket
Fixing Bolt Between Condenser Assembly and Tank
7±1
Upper Crossmember Fixing Bracket
Refrigerant Charging Specification
Description Charging Capacity (g)

R134a Refrigerant 600 ± 10
Refrigerant Oil Charging Specifications
Description Charging Capacity (ml)

It is necessary to pour out 50 ml of refrigerant oil
Compressor Assembly Replacement
from the new compressor assembly
Condenser Replacement 50
Evaporator Replacement 50
A/C Line Replacement 10


Specifications

Coupling Bolt Between Front Passenger Airbag and
10 ± 1
Instrument Panel Crossmember Assembly
Coupling Nut Between SRS Control Module
Assembly and Body
10 ± 1 04

SEAT BELT
Specifications

Height Adjuster Fixing Bolt 23 ± 2
Front Seat Belt Assembly Fixing Bolt 50 ± 5
04 Front Seat Belt Retractor Fixing Screw 3 ± 0.5

Front Seat Belt Assembly Center Fixing Screw 1.5 ± 0.5
Rear Seat Belt Assembly Fixing Bolt 50 ± 5
Rear Seat Belt Assembly Fixing Screw 1.5 ± 0.5
Center Seat Belt Assembly Fixing Bolt 50 ± 5
Center Seat Belt Inner Trim Cover Fixing Screw 3 ± 0.5
Rear Seat Belt Buckle Assembly Fixing Bolt 50 ± 5
Rear Center Seat Belt Buckle Assembly Fixing Bolt 50 ± 5
Rear Right Seat Belt Buckle Assembly Fixing Bolt 50 ± 5
Front Seat Belt Buckle Fixing Nut 50 ± 5

LIGHTING SYSTEM
Specifications
Bulb Specifications
Bulb Name Nominal Light Source (Model/Type)

Headlight (High Beam/Low Beam) H1/H7
Front Position Light LED
Front Turn Signal Light PY21W 04
Brake Light LED
Front Fog Light H7
Rear Fog Light P21W
License Plate Light C5W
High Mounted Stop Light LED
Rear Position Light LED
Rear Turn Signal Light PY21W
Back-up Light W16W
Side Turn Signal Light LED
Front Dome Light C10W
Rear Dome Light 10W
Luggage Compartment Light C5W
Front Door Courtesy Light 3W

Headlight Assembly Fixing Bolt 3.5 ± 0.5
Front Fog Assembly Fixing Screw 1.5 ± 0.5
Rear Combination Light Assembly Fixing Nut 4.5 ± 1
Rear Combination Light Assembly Fixing Screw 1.5 ± 0.5
Front Dome Light Assembly Fixing Screw 1.5 ± 0.5
Rear Dome Light Assembly Fixing Screw 1.5 ± 0.5
Rear Fog Light & Reflector Assembly Fixing Screw 1.5 ± 0.5
High Mounted Stop Light Fixing Nut 3.5 ± 0.5

WIPER AND WASHER

Specifications

Front Wiper Arm Assembly Fixing Nut 18 ± 2
Wiper Motor and Link Rod Assembly Fixing Bolt 10 ± 1
Front Wiper Motor Assembly Fixing Screw 10 ± 1
04
Front Wiper Motor Assembly Fixing Nut 10 ± 1
Rear Wiper Arm Assembly Upper Fixing Nut 10 ± 1
Rear Wiper Motor Assembly Fixing Bolt 10 ± 1
Guide Pipe Assembly Fixing Bolt 7±1
Washer Fluid Reservoir Assembly Fixing Bolt 7±1
Brake Fluid Reservoir Assembly Fixing Nut 9±1
Rain Gutter Rail Reinforcement Assembly Fixing Bolt 10 ± 1

DOOR LOCK
Specifications

Tank Upper Crossmember Deflector Fixing Nut 10 ± 1
Engine Hood Lock Assembly Fixing Nut 10 ± 1
Front Door Lock Assembly Fixing Screw 5.8 ± 0.7 04
Front Door Key Cylinder Cover Fixing Screw 5±1
Front Door Lock Striker Assembly Fixing Screw 10 ± 1
Rear Door Lock Assembly Fixing Screw 5.8 ± 0.7
Rear Door Lock Striker Assembly Fixing Screw 10 ± 1
Back Door Lock Assembly Fixing Bolt 10 ± 1
Back Door Lock Striker Assembly Fixing Screw 10 ± 1
Auxiliary Fascia Console Rear Cover Plate
1.5 ± 0.5
Assembly Fixing Screw
Front Door Outside Handle Fixing Screw 1.5
Wireless Key Upper Cover Fixing Screw 0.4 ± 0.1

NSTRUMENT CLUSTER
Specification

Instrument Cluster Fixing Screw 1.5 ± 0.5
04

AUDIO SYSTEM
Specifications

No Disc DVD Assembly Fixing Screw 2 ± 0.5
Tweeter Assembly Fixing Screw 3 ± 0.5
Front Woofer Assembly Fixing Screw 2.5 ± 0.5 04
Rear Woofer Assembly Fixing Screw 2.5 ± 0.5
Antenna Assembly Fixing Nut 5±1
No Disc DVD Control Panel Fixing Screw 2 ± 0.5
Wire Harness Fixing Screw 0.7 ± 0.2
Steering Wheel Quick Button Trim Cover Fixing
0.7 ± 0.2
Screw
Steering Wheel Quick Button Fixing Screw 0.7 ± 0.2


Specification

Fixing Bolt Between Reversing Radar Control
5±1
Module Assembly and Body
04

HORN
Specification

Horn Fixing Bolt 16 ± 2
04

Specifications

Power Glass Regulating Control Master Switch
2 ± 0.5
Power Glass Regulating Switch Assembly Fixing
04 Screw
2 ± 0.5
Front Door Outer Weather Bar Fixing Screw 1.3 ± 0.2

Rear Door Outer Weather Bar Fixing Screw 1.3 ± 0.2
Front Door Glass Rear Guide Rail Assembly Fixing
9±1
Bolt
Rear Door Glass Rear Guide Rail Assembly Fixing
9±1
Bolt
5 ± 0.5
Screw
Front Door Glass Assembly Fixing Bolt 9±1
Rear Door Glass Assembly Fixing Bolt 9±1
Front Door Power Glass Regulator Assembly Fixing
9±1
Bolt
Rear Door Power Glass Regulator Assembly Fixing
9±1
Bolt
A/C Control Panel Fixing Screw 2 ± 0.5

REAR VIEW MIRROR

Specifications

Outside Rear View Mirror Assembly Fixing Bolt 6±1
Inside Rear View Mirror Assembly Fixing Screw 1.5 ± 0.5
04

INSTRUMENT PANEL
Specifications

Auxiliary Fascia Console Front Protector Fixing Bolt 5±1
Auxiliary Fascia Console Assembly Fixing Screw 1.5 ± 0.5
04 Auxiliary Fascia Console Assembly Fixing Bolt 5±1

Front Storage Box Fixing Screw 1.5 ± 0.5
Armrest Box Assembly Fixing Screw 1.5 ± 0.5
1.5 ± 0.5
Cup Holder Assembly Fixing Screw 1.5 ± 0.5
Auxiliary Fascia Console Front Trim Ring Fixing
1.5 ± 0.5
Screw
Gear Backlight Fixing Screw 1.5 ± 0.5
Instrument Panel Lower Left Protector Assembly
2 ± 0.5
Fixing Screw
Front Passenger Airbag Assembly Fixing Bolt 10 ± 1
Instrument Panel Assembly Fixing Bolt 7±1
Face Air Duct Assembly Fixing Screw 1.5 ± 0.5
Defroster Duct Assembly Fixing Screw 1.5 ± 0.5
Center Defroster Duct Assembly Fixing Screw 1.5 ± 0.5
Instrument Panel Right Outlet Assembly Fixing
1.5 ± 0.5
Screw
Instrument Panel Fuse and Relay Box Fixing Bolt 7±1
Connector Mounting Bracket Fixing Bolt 7±1
Diagnostic Interface Fixing Screw 1.5
Smart Entry Start Controller Fixing Nut 7±1
Instrument Panel Crossmember Lower Bracket
25 ± 3
Assembly
Steering Column Assembly Fixing Nut 25 ± 3
Steering Column Assembly Fixing Bolt 25 ± 3
Blower Fixing Bolt 4±1
Ground Wire Fixing Nut 15 ± 2
Instrument Panel Crossmember Assembly Fixing
25 ± 3
Bolt
7±1
Nut


7±1
Screw
Instrument Panel Crossmember Bracket Assembly
25 ± 3
Fixing Bolt
04

SEAT
Specifications

Front Seat Assembly Fixing Bolt 50 ± 5
Seat Track Unlock Handle Fixing Screw 4.8 ± 0.5
04 Seat Front Mounting Foot Cover Assembly Fixing

Screw
4.8 ± 0.5
Seat Rear Mounting Foot Cover Assembly Fixing

4.8 ± 0.5
Screw
Seat Height Adjuster Handle Fixing Screw 4.8 ± 0.5
Seat Reclining Adjuster Handle Fixing Screw 4.8 ± 0.5
Seat Outer Shield Assembly Fixing Screw 4.8 ± 0.5
Seat Belt Buckle Assembly Fixing Nut 50 ± 5
Seat Inner Shield Assembly Fixing Screw 4.8 ± 0.5
Seat Track Assembly Fixing Bolt 24 ± 2.4
Rear Seat Assembly Fixing Bolt 50 ± 5
Attachment Trim Cover Fixing Screw Between Rear
4.8 ± 0.5
Seat Cushion and Seatback
Rear Seat Armrest Assembly Fixing Screw 4.8 ± 0.5
Child Seat Upper Fixing Point Trim Cover Fixing
4.8 ± 0.5
Screw
Rear Seatback Unlock Mechanism Assembly Fixing
4.8 ± 0.5
Screw
Rear Seat Mounting Foot Cover Assembly Fixing
4.8 ± 0.5
Screw
Fixing Bolt Between Rear Seat Cushion Assembly
48 ± 4.8
and Seatback Assembly
Rear Seat Folder Mechanism Assembly Outer Cover
4.8 ± 0.5
Fixing Screw
Rear Seat Reclining Adjuster Inner Cover Fixing
4.8 ± 0.5
Screw
Rear Seat Bracket Assembly Fixing Bolt 48 ± 4.8

ENGINE HOOD/DOOR
Specifications

Fixing Bolt Between Hood Assembly and Hood
23 ± 2
Hinge Assembly
Hood Lock Assembly Fixing Nut 10 ± 1
Fixing Bolt Between Hood Hinge Assembly and
04
10 ± 1
Fender Assembly
23 ± 2
Body
Water Tank Upper Crossmember Deflector Fixing
10 ± 1
Nut
Hood Grip Assembly Fixing Screw 1.5 ± 0.5
Hood Air Spring Ball Pin Assembly 10 ± 1
Front Door Inside Handle Assembly Fixing Screw 1.5 ± 0.5
Front Door Protector Assembly Fixing Screw 1.5 ± 0.5
Front Door Assist Grip Assembly Fixing Screw 1.5 ± 0.5
Front Door Assist Grip Mounting Bracket Assembly
1.5 ± 0.5
Fixing Screw
Front Door Outside Handle Base Assembly Fixing
5±1
Screw
Fixing Bolt Between Front Door Hinge Assembly and
70 ± 3
Door
70 ± 3
Body
Rear Door Inside Handle Assembly Fixing Screw 1.5 ± 0.5
Rear Door Protector Assembly Fixing Screw 1.5 ± 0.5
Rear Door Assist Grip Assembly Fixing Screw 1.5 ± 0.5
Rear Door Assist Grip Mounting Bracket Assembly
1.5 ± 0.5
Fixing Screw
Rear Door Outside Handle Base Assembly Fixing
5±1
Screw
Fixing Bolt Between Rear Door Hinge Assembly and
70 ± 3
Door
70 ± 3
Body
Back Door Grip Assembly Fixing Screw 7±1
Back Door Lower Protector Assembly Fixing Screw 1.5 ± 0.5


Back Door Locating Seat Fixing Bolt 1.5 ± 1
Back Door Locating Block Fixing Bolt 1.5 ± 1
Fixing Bolt Between Back Door Hinge Assembly and
23 ± 2
Back Door
Back Door Hinge Assembly Fixing Nut 23 ± 2
Back Door Upper Trim Board Assembly Fixing Screw 3±1
04 Back Door Upper Trim Board Assembly Fixing Nut 5±1

Back Door Opener Switch Assembly Fixing Bolt 10 ± 1
Back Door Air Spring Assembly Ball Pin 10 ± 1

EXTERIOR
Specifications

Front Name Plate CAC Assembly Fixing Screw 2.5 ± 0.5
Front Bumper Upper Grille Fixing Screw 2.5 ± 0.5
Front Bumper Assembly Fixing Screw 3±1 04
Front Bumper Assembly Fixing Bolt 10 ± 1
Front Bumper Mounting Bracket Assembly Fixing
10 ± 1
Bolt
Headlight Fixing Bolt 3.5 ± 0.5
Front Bumper Upper Mounting Bracket Assembly
10 ± 1
Fixing Bolt
Front Bumper Lower Mounting Bracket Assembly
10 ± 1
Fixing Bolt
Front Bumper Crossmember Assembly Fixing Nut 23 ± 2
Apron Plate Cover Assembly Fixing Screw 3±1
Apron Plate Assembly Fixing Screw 3±1
Front Bumper Center Stiffener Bracket Assembly
10 ± 1
Fixing Bolt
Front Bumper Lower Stiffener Bracket Assembly
10 ± 1
Fixing Nut
Front Wheel House Protector Assembly Fixing
3±1
Screw
Fender Assembly Fixing Bolt 10 ± 1
Engine Lower Protector Assembly Fixing Bolt 10 ± 1
Engine Lower Protector Assembly Fixing Screw 3±1
Rear Bumper Assembly Fixing Screw 3±1
Rear Bumper Assembly Fixing Bolt 3±1
Rear Bumper Mounting Bracket Assembly Fixing
3±1
Screw
Rear Bumper Crossmember Assembly Fixing Bolt 23 ± 2
Front Wheel House Protector Assembly of Rear
3±1
Wheel Fixing Screw
Rear Wheel House Protector Assembly Fixing Screw 3±1
Front Windshield Lower Garnish Assembly Fixing
3±1
Screw
Roof Rack Assembly Fixing Bolt 9±1
Rear Spoiler Assembly Fixing Nut 5±1


Rear Bumper Energy Absorber Fixing Bolt 23 ± 2
Rear Fog Light Fixing Screw 1.5 ± 0.5
Back Door Upper Trim Board Assembly Fixing Nut 5±1
Camera Fixing Screw 6 ± 0.5
04

INTERIOR
Specifications

A-pillar Lower Protector Assembly Fixing Nut 5±1
B-pillar Upper Protector Assembly Fixing Screw 1.5 ± 1
Back Door Baffle Plate Assembly Fixing Screw 1.5 ± 1 04
Back Door Baffle Plate Assembly Fixing Nut 1.5 ± 1
C-pillar Lower Protector Assembly Fixing Screw 1.5 ± 1
C-pillar Upper Protector Assembly Fixing Screw 1.5 ± 1
Sun Visor Assembly Fixing Screw 3 ± 0.5
Sun Visor Holder B Fixing Screw 3 ± 0.5
Front Seat Belt Assembly Lower Fixing Bolt 50 ± 5
Rear Seat Belt Lower Fixing Bolt 50 ± 5
Passenger Grip Assembly Fixing Bolt 5±1
Interior Front Dome Light Assembly Fixing Screw 1.5 ± 0.5
Interior Rear Dome Light Assembly Fixing Screw 1.5 ± 0.5
High Pitched Speaker Fixing Screw 3 ± 0.5
Fuel Tank Opening Bracket Assembly Fixing Bolt 10 ± 1
Ground Wire Harness Fixing Nut 15 ± 2

- MEMO -

MAINTENANCE
MAINTENANCE ITEMS 05-3 On-vehicle Inspection 05-8
Maintenance Schedule Table 05-3 Engine Compartment Inspection 05-10
Brake System Inspection 05-10
REPLACEMENT INSTRUCTION 05-6
Power Steering System Inspection 05-11
ADJUSTMENT ITEM 05-7 Chassis Inspection 05-12
Final Inspection 05-13
INSPECTION ITEMS 05-8
Off-vehicle Inspection 05-8
05

05

05 - MAINTENANCE
MAINTENANCE ITEMS
MAINTENANCE
Maintenance Schedule Table

The maintenance schedule table lists the vehicle maintenance items required to be performed. Please take
your vehicle to a Chery authorized service station for maintenance service according to the mileage specified
in the maintenance schedule table.
Maintenance Schedule Table (Note: I = Inspect, adjust and replace as necessary; R = Replace; C = Clean; 
L = Lubricate)
Mileages
Maintenance Items
Every 5000 km Every 15000 km Every 30000 km
Lights, hazard lights, horn: Check operation. I I I 05
Windshield wiper and washer system: Check
I I
operation. Add washer fluid if necessary.
Check clutch free travel: Adjust if necessary. I I
Cooling system: Check coolant level and lines. Add
I I I
coolant if necessary.
Engine oil: Replace R R R
Engine oil filter: Replace R R R
Engine: Check for fluid leakage (engine oil, coolant,
I I I
fuel, etc.).
Air conditioning system: Check for air conditioning
line leakage and contaminated filter element. Add I I I
refrigerant and replace filter element if necessary.
Hood hinges and lock: Lubricate L L L
Door hinges and door locks: Lubricate L L L
Window glass regulator: Check that regulator
I I I
works properly. Adjust or replace if necessary.
Sunroof: Check operation of sunroof. I I I
Air filter: Clean cover and filter element.
R R R
Replace if necessary.
Spark plugs: Check spark plugs. Replace if
I I
necessary.
Fuel filter: Replace R R
Exhaust system: Check for air leakage and
I I
damage.
Drive belt: Check tension. Adjust or replace if
I I
necessary.
Transmission: Check for fluid leakage and damage. I I
Constant velocity universal joint boot: Check for
I I
damage of boot.
Steering tie rod end: Check for proper clearance
I I I
and boot damage.

05 - MAINTENANCE
Mileages
Maintenance Items
Every 5000 km Every 15000 km Every 30000 km
Steering universal joint assembly boot: Check for
I I
misalignment or damage.
Power steering system: Check power steering fluid
level and whether clearance between steering gear I I
and rack is proper.
Brake system: Check brake fluid level and system
I I I
for leakage and damage.
Parking brake: Check stroke. Adjust if necessary. I I I
Brake lining: Check thickness of brake lining.
05 Replace if necessary.
I I I
Underbody protection layer: Visually check

I
protection layer for damage.
Seat belt: Check seat belts for damage. I I
Toe-in and camber: Check and adjust if necessary. I I
Ball pin: Check clearance of ball pin. I I
Rear axle rubber bush: Check for damage. I I
Engine oil pan set bolts: Check bolts for looseness.
I
Tighten bolts to specified torque if necessary.
Control arm rubber boot: Check for damage. I I
Brake hoses: Check for aging or damage. I I
Brake pipes: Check for damage, corrosion and
I I
check each connection for leakage.
Fuel system connections: Check each connection
for aging, damage, abnormal looseness or I
abrasion.
Tires (including spare tire): Check tire tread depth
and torque of wheel bolts. Adjust tire inflation I I I
pressure if necessary.
Coupling bolts between chassis and vehicle body:
Check torque of bolts. Tighten bolts to specified I I
torque if necessary.
Wheels: Check torque. I I I
Inspection while engine idling: Check if engine
working condition, electronic injection parameter I I I
and emission are proper while idling.
Test driving: Check if mechanisms function
I I I
properly.
1. For CVT model, it is recommended to replace the transmission oil every 40000 km.
2. For MT model, it is recommended to replace the transmission oil every year or every 30000 km (whichever
comes first).
3. It is recommended to replace the brake fluid every 2 years or every 40000 km (whichever comes first).
4. It is recommended to check the power steering fluid every 10000 km and replace every 2 years or every
30000 km (whichever comes first).

05 - MAINTENANCE
5. It is recommended to check the coolant every 10000 km. Add or replace if necessary.
6. It is recommended to rotate tires every 10000 km.
7. It is recommended to check four-wheel alignment every 20000 km and adjust if necessary.
8. It is recommended to clean the throttle valve body every 15000 km.
9. It is recommended to check the air filter every 5000 km. Clean or replace the filer element if necessary.
10.It is recommended to replace the timing belt every 40000 km.
11. The battery is maintenance-free.
CAUTION
 Depending on different surrounding environment and road conditions, the replacing intervals may be
shortened.
05

05 - MAINTENANCE
REPLACEMENT INSTRUCTION
Replacement Item See page

Front Wiper Arm Blade Replacement 36-24
Rear Wiper Arm Blade Replacement 36-31
Air Filter Element Replacement 10-14
Fuel Filter Replacement 08-12
Engine Oil Replacement 13-11
Oil Filter Replacement 13-13
05 Transmission Oil Replacement 17-14
Automatic Transmission Fluid (ATF) Replacement 18-110
Power Steering Fluid Replacement 29-7
Coolant Replacement 12-13
Brake Fluid Replacement 26-13
Electronic Throttle Replacement 10-20
Electronic Throttle Cleaning 10-22
Spark Plug Replacement 14-12
A/C Element Replacement 31-72

05 - MAINTENANCE
ADJUSTMENT ITEM
Adjustment Item See page

Front Combination Light Adjustment 35-70
05

05 - MAINTENANCE
INSPECTION ITEMS
Off-vehicle Inspection
1. Check the wheel nut.
a. Check wheel nuts for looseness or missing. Tighten if necessary.
2. Check the wheel and tire (spare tire included) (See page 24-5).
3. Rotate tires.
a. Chery recommends you to rotate tires every 10000 km. However, the best suitable time for tire rotation
differs depending on driver's driving habits and road conditions.
Tire rotation method (See page 24-11).
4. Check the front wiper blade (See page 36-24).
05 5. Check the rear wiper blade (See page 36-31).
6. Check the hood and door.
a. Check the hood (See page 47-15).
b. Check the front doors (See page 47-35).
c. Check the rear doors (See page 47-46).
d. Check the back door (See page 47-55).
On-vehicle Inspection
1. Check the seat belt.
a. Check the seat belt buckle and retractor.
 Pull out the seat belt quickly and repeatedly when it is static. If seat belt retractor cannot lock the
seat belt at one time during inspection, replace the seat belt assembly.
 Engage the tab on the seat belt buckle, and pull the seat belt by hand repeatedly to check the
engagement. If buckle cannot lock the seat belt at one time, replace the seat belt assembly.
WARNING
 When inspecting the vehicle that has been involved in a collision, be sure to check the seat belt system.
If there is any damage or malfunction in the seat belt system, replace it.
b. Pull out the seat belt and check the belt for oil stains or damage. Clean or replace if necessary.
c. Replace the seat belt as soon as possible if any of the following occurs.
 Seat belt is broken, cracked or worn.
RT21050010

05 - MAINTENANCE
 Seat belt webbing is cracked.
RT21050020
 There is burnt mark by cigarette on seat belt.
05
RT21050030
2. Check the horn.

a. Check that horn operates.
3. Check the vehicle lights.
a. Check that headlights, brake lights, rear combination lights, turn signal lights and other vehicle lights
illuminate or blink. Furthermore, check the brightness of vehicle lights.
4. Check the windshield.
a. Check for scratch, dent or wear.
5. Check the windshield wipers and washers.
a. Check that washers are aimed properly. Also, check that washer fluid hits the center of operating range
of each wiper on the windshield.
b. Check wiper blades for cracks. Replace the wiper blades if necessary (See page 36-24).
6. Check the windshield defroster.
a. When the air conditioning defroster mode switch is pressed, check that air comes out of defroster
outlets.
b. Press the rear defroster switch for a period of time, then check that rear windshield heats.
WARNING
 DO NOT touch the heated rear windshield for a long time to prevent burns.
7. Check the rear view mirror.

a. Check that rear view mirrors are securely installed.
8. Check the sun visor.
a. Check that sun visors are securely installed and move freely.
9. Check the seat.
a. Check the front seat assembly (See page 46-22).
b. Check the rear seat assembly (See page 46-34).

05 - MAINTENANCE
10.Check the clutch pedal (See page 19-9).

11. Check the accelerator pedal.
a. Check that accelerator pedal operates smoothly. Check that pedal does not have uneven resistance or
stick in certain position.
Engine Compartment Inspection

1. Check the engine oil level (See page 13-9).
2. Check the accessory drive belt (See page 07-24).
3. Check the engine for oil leakage.
a. Turn off all the electrical equipment and ignition witch, and remove the key.
b. Support and raise the vehicle.
c. Check the crankshaft pulley for oil stains. If there are oil stains, check crankshaft front oil seal for
05 leakage. If there are leaks, replace the crankshaft front oil seal.
d. Check oil pan and drain plug for oil stains. Repair or replace related parts if necessary.
e. Check transmission filler plug, drain plug and case for oil stains. Repair or replace related parts if
necessary.
f. If crankshaft front oil seal leaks after repair, it may be caused by the following 3 reasons:
 Crankshaft thrust washer wear
 Crankcase ventilation system blockage
 Excessive engine oil
4. Check the battery.
a. Check the battery and battery voltage (See page 16-7).
b. Check the charging voltage of charging system (See page 16-6).
5. Check the cooling system hoses.
a. Check that there are no cracks, bent, corrosion or loose connections on the cooling system hoses.
Brake System Inspection

1. Check the brake fluid level.
CAUTION
 Generally, brake fluid level will change slightly because of wear of brake pad, but it must be kept between
"MIN" and "MAX" lines.
a. Park the vehicle on a level ground.

b. Make sure there is no air in the brake system and the depressing feel of brake pedal is well. Perform
brake bleeding procedures if necessary (See page 26-12).
c. Check if brake fluid level is between "MAX" and "MIN"
lines.
d. If brake fluid level drops to the "MIN" line or below,
add brake fluid and check brake system for leakage.
RT21260050

05 - MAINTENANCE
HINT:
 When brake fluid level drops close to the "MIN" line, the wear of brake pad may approach its limit.
 After brake pad is replaced, the brake fluid level should be at the upper limit between "MAX" and "MIN"
lines.
2. Check the brake pedal (See page 26-23).
3. Check the brake lines and hoses.
HINT:
Work in a well-lighted area. Turn front wheels fully to the right or left before inspection.
a. As shown in the illustration, check the entire
circumferential surface of the brake lines and hoses
with a mirror. Check for the following conditions:
 Damage
 Wear 05
 Deformation
 Crack
 Corrosion
 Leakage RT21050040
 Bent
 Twists
b. Check all clamps for tightness and check the connections for leakage.
c. Check that hoses and lines are not near the sharp edges, moving parts or exhaust system.
4. Check the parking brake.
a. Check that parking brake can stop the vehicle steadily on a slight grade.
5. Check the front disc brake assembly (See page 26-32).
6. Check the rear disc brake assembly (See page 26-45).
Power Steering System Inspection

1. Check the steering wheel free play (See page 28-9).
2. Check the steering wheel centering/returnability (See page 28-9).
3. Check the power steering fluid level (equipped with hydraulic assist steering).
a. Park the vehicle on a level ground.
b. Start the engine. When engine is running, turn the steering wheel left or right to the maximum stroke
and repeat the operation several times.
c. Check if fluid in the steering fluid reservoir is foamed or emulsified. Perform bleeding procedures if
necessary.
d. If fluid is normal, check if the steering fluid level is between "MIN" and "MAX" lines.
e. If fluid level is above the "MAX" line, drain the
excessive steering fluid. If fluid level is below the
"MIN" line, add steering fluid to correct level, and
check power steering system for leakage.
RT21290030
4. Check the ball pin assembly (equipped with hydraulic assist steering) (See page 29-19).
5. Check the ball pin assembly (equipped with electronic assist steering) (See page 30-22).

05 - MAINTENANCE
6. Check the steering tie rod assembly and tie rod boot (equipped with hydraulic assist steering) (See page
29-21).
7. Check the steering tie rod assembly and tie rod boot (equipped with electronic assist steering) (See page
30-23).
8. Check power steering system for leakage (equipped with hydraulic assist steering).
CAUTION
 Generally, leakage from hydraulic assist steering system commonly occurs on the high pressure line.
a. Turn off all the electrical equipment and ignition witch, and remove the key.
b. Support and raise the vehicle.
05 c. Check the power steering system.
If power steering fluid is found on the steering system lines or other components, check steering
system for leakage. Replace related parts if necessary.
Components to be checked mainly include:
 Power steering pump assembly
 Steering fluid reservoir assembly
 Steering gear assembly
 Steering gear high pressure line
 Steering gear return line
 Steering gear suction line
Chassis Inspection
1. Check the front shock absorber assembly (See page 23-13).
2. Check the front control arm ball pin assembly (See page 23-23).
3. Check the front stabilizer bar assembly (See page 23-26).
4. Check the front stabilizer link assembly (See page 23-27).
5. Check the rear shock absorber assembly (See page 23-32).
6. Check the rear coil spring (See page 23-36).
7. Check the rear stabilizer bar assembly (See page 23-44).
8. Check the rear stabilizer link assembly (See page 23-45).
9. Check the exhaust pipe.
a. Visually check the pipes, hanger blocks and connections for corrosion, leakage or damage.

05 - MAINTENANCE
Final Inspection
1. Check the operation of body parts.
a. Hood
 Hydraulic tappet of engine hood operates properly.
 Hood locks securely when closed.
2. Front and rear doors
 Door locks operate properly.
 Doors close properly.
3. Back door
 Door lock operates properly.
 Back door closes properly.
4. Seat 05
 Seat adjusts easily and locks securely in any position.
 Front seatback locks securely in any position.
 Rear seatbacks lock securely after folding down.
5. Be sure to deliver a clean vehicle. Focus on the following items:
 Steering wheel
 Shift lever knob
 All switch knobs
 Door handles
 Seat

- MEMO -

GENERAL INFORMATION 06-3 P0140-00 06-75
Description 06-3 P2270-00 06-75
System Function 06-4 P2271-00 06-75
Precautions 06-5 P0201-00 06-81
Specifications 06-6 P0271-00 06-86
Tools 06-6 P1106-00 06-91
ECM Pin Definition 06-8 P1110-00 06-91
Circuit Diagram 06-10 P1111-00 06-91
P1568-00 06-91
DIAGNOSIS & TESTING 06-18
P0606-00 06-91
Diagnostic Help 06-18
P0300-00 06-98
Intermittent DTC Troubleshooting 06-18
P0301-00 06-98 06
Ground Inspection 06-18
P0302-00 06-98
Throttle Self-learning 06-19
P0303-00 06-98
Diagnostic Trouble Code (DTC) 
P0304-00 06-98
Chart 06-19
P0322-00 06-106
ECM Power Supply Circuit & 
Ground Circuit Testing 06-23 P0327-00 06-111
P0030-00 06-31 P0328-00 06-111
P0031-00 06-31 P0341-00 06-116
P0032-00 06-31 P0346-00 06-116
P0053-00 06-31 P0420-00 06-122
P0036-00 06-38 P0444-00 06-125
P0037-00 06-38 P0458-00 06-125
P0038-00 06-38 P0459-00 06-125
P0054-00 06-38 P0480-00 06-132
P0101-00 06-45 P0481-00 06-132
P0102-00 06-45 P0691-00 06-132
P0103-00 06-45 P0560-00 06-138
P0112-00 06-52 P0562-00 06-138
P0113-00 06-52 P0563-00 06-138
P0116-00 06-57 P0627-00 06-145
P0117-00 06-57 P0628-00 06-145
P0118-00 06-57 P0629-00 06-145
P0121-00 06-63 P0645-00 06-150
P0122-00 06-63 P0646-00 06-150
P0123-00 06-63 P0647-00 06-150
P0130-00 06-69 P0688-00 06-155
P0131-00 06-69 P0604-00 06-160
P0132-00 06-69 P0605-00 06-160
P0133-00 06-69 P1619-00 06-162
P0134-00 06-69 P0531-00 06-164
P2195-00 06-69 U0101-87 06-169
P2196-00 06-69 U0129-87 06-172
P0136-00 06-75 U0140-87 06-175
P0137-00 06-75 U0155-87 06-178
P0138-00 06-75 U0164-87 06-182

U0167-87 06-186 Operation 06-248
P000A-00 06-189 Removal 06-248
P000B-00 06-189 Installation 06-248
P0010-00 06-192 Engine Speed Sensor 06-249
P0013-00 06-192 Description 06-249
P0012-00 06-198 Operation 06-249
P0015-00 06-198 Removal 06-249
P0016-00 06-200 Installation 06-249
P0018-00 06-200 Air Flow Meter 06-250
Engine Problem Symptom  Description 06-250
Diagnosis 06-209 Operation 06-250
ON-VEHICLE SERVICE 06-242 Removal & Installation 06-250
Ignition Coil 06-251
Intake/Exhaust VVT Control Valve 06-242
Description 06-242 Description 06-251
06 Operation 06-242
Operation 06-251
Removal & Installation 06-251
Removal 06-242
Installation 06-242 Electric Fuel Pump 06-252
Description 06-252
Coolant Temperature Sensor 06-243
Operation 06-252
Description 06-243
Operation 06-243
Fuel Injector 06-253
Removal 06-243
Description 06-253
Installation 06-244
Operation 06-253
Knock Sensor 06-245
Description 06-245
Electronic Throttle Assembly 06-254
Operation 06-245
Description 06-254
Removal 06-245
Operation 06-254
Installation 06-246
Oxygen Sensor 06-247
Canister Solenoid Valve 06-255
Description 06-247
Description 06-255
Operation 06-247
Operation 06-255
Upstream Oxygen Sensor 06-247
Downstream Oxygen Sensor 06-247
Engine Control Module (ECM) 06-256
Removal & Installation - 
Upstream Oxygen Sensor 06-247 Description 06-256
Removal & Installation -  Operation 06-256
Downstream Oxygen Sensor 06-247 Removal 06-256
Camshaft Position Sensor 06-248 Installation 06-257
Description 06-248

06 - SQR484F ENGINE MANAGEMENT SYSTEM
GENERAL INFORMATION
Description
The engine of T21 model adopts UAES engine management system. This system mainly consists engine
Control Module (ECM), sensors and actuators, which controls intake air amount, injection volume and ignition
timing, etc. when engine is operating.
In engine management system, sensors are used as the input part to measure various physical signals
(temperature and pressure, etc.), and converts them into corresponding electrical signals; the function of ECM
is to receive the input signals from sensors and perform calculation according to set procedure, producing
corresponding control signals and outputting them to power drive circuit. The power drive circuit drives each
actuator to perform various actions, thus making the engine run according to preset program.
Also, the trouble diagnosis system of ECM monitors each component and control function in this system.
Once detecting and confirming a fault, it will store trouble code and recall "Limp Home" function. When
detecting that fault has been eliminated, it will return to use normal value.
06
Basic Components of Engine Management System
3 6
2 5 7
4 9
1
8
10
15
12
14 11
13
16
17
18
RT21060010

1 - Canister 2 - Air Flow Meter

3 - Canister Solenoid Valve 4 - Intake VVT Control Valve
5 - Camshaft Position Sensor (Intake) 6 - Ignition Coil
7 - Camshaft Position Sensor (Exhaust) 8 - Fuel Injector
9 - Exhaust VVT Control Valve 10 - Upstream Oxygen Sensor
11 - Downstream Oxygen Sensor 12 - Coolant Temperature Sensor
13 - Crankshaft Position Sensor 14 - Knock Sensor
15 - Electronic Throttle 16 - Engine Control Module (ECM)
17 - Electronic Accelerator Pedal 18 - Electric Fuel Pump
06 System Function
 Calculate air flow
ECM calculates air flow by the signals from air flow meter and then adjusts injection volume to make air-
fuel ratio meet the requirements of various operating conditions.
 Measure crankshaft position and engine speed
ECM determines crankshaft position and engine speed according to the signals from crankshaft position
sensor and accurately controls engine ignition and injection timing.
 Determine operating sequence of cylinders
ECM recognizes the top dead center of No.1 cylinder by camshaft position sensor, so as to determine the
operating sequence of cylinders.
 Fuel control
There are two modes of fuel control: closed-loop fuel control and open-loop fuel control. The closed-loop
fuel control can accurately regulate the air-fuel ratio of engine, thus effectively controlling emissions. The
open-loop fuel control is applied when engine is starting or warming up, or when a oxygen sensor is
malfunctioning.
 Ignition control
The ignition control system of engine adopts packet control.
 Knock control
When a knocking is detected by knock sensor, the system will calculate the ignition advance angle that
needs to be delayed or advanced according to current operating conditions and knock intensity and
adjusts ignition angle, thus avoiding or reducing knocking.
 Emission control
The three-way catalytic converter can convert engine exhaust gas into harmless gas and discharge it into
atmosphere. When engine temperature becomes normal after warming up, ECM will activate closed-loop
fuel control to correct air-fuel ratio, thus realizing the optimum conversion efficiency of three-way catalytic
converter.
 Three-way catalytic converter protection
The engine management system has the function to protect three-way catalytic converter. The ECM
estimates three-way catalytic converter temperature according to engine operating conditions. When it is
estimated that exhaust temperature will exceed the converter's maximum permissible temperature for a
long time, ECM will automatically activate the protection function of three-way catalytic converter to keep
the temperature normal.
 System voltage protection
When system voltage becomes extremely high due to charging system malfunction, engine management
system will activate the protection program to limit engine speed, thus avoiding damage to ECM and
battery.

Precautions
General service requirements
 Only digital multimeter can be used to perform inspection for engine management system.
 Use genuine components to perform service work, otherwise, the appropriate engine management system
operation cannot be guaranteed.
 Only use unleaded gasoline during servicing.
 Please observe normative service and diagnostic flowchart to perform service work.
 Never disassemble the components of engine management system during servicing.
 When holding electronic elements (ECM, sensor, etc.) during servicing, take extra care not to drop them on
the ground.
 Set up a consciousness of environmental protection and dispose of the waste effectively that is produced
during servicing.
Precautions during servicing
1. Do not causally remove any component or its connector of engine management system from its installation 06
position to prevent damage accidentally, or foreign matter, such as moisture, oil from entering connectors,
which will affect the normal operation of engine management system.
2. Be sure to turn ignition switch off when disconnecting and connecting connectors. Otherwise, electric
elements may be damaged.
3. When simulating hot operating condition of malfunction and performing other service work that may cause
the temperature to rise, never allow ECM temperature to exceed 80°C.
4. As the supplying pressure of fuel system is high (approximately 400 kPa), all the fuel pipes are high
pressure resistant pipe. The fuel pressure in fuel lines is still high even when engine is not running.
Therefore, be careful not to casually remove the fuel pipe during servicing; when it is necessary to service
the fuel system, discharge the pressure in fuel system before removing fuel pipe. The way to discharge
pressure is as follows:
Remove fuel pump relay, start the engine and idle it until the engine stops running by itself. Then attempt to
start the engine 2 - 3 times to ensure fuel pressure is discharged completely. The removal of fuel pipe and
replacement of fuel filter should be performed in a well-ventilated area by professional service men.
5. Do not energize electric fuel pump when removing it from fuel tank to prevent electric sparks, which will
cause a fire.
6. Running test for fuel pump is prohibited when it is empty or in water; otherwise, it will shorten the service
life. Never connect the positive and negative of fuel pump in reverse.
7. When checking ignition system, only perform spark jump test when it is necessary and the time should be
shortened as much as possible. Do not open throttle during test; otherwise, a large amount of unburned
gasoline will enter the exhaust pipe, causing damage to three-way catalytic converter.
8. As idling adjustment is performed by engine management system completely, manual adjustment is not
required. The accelerator pedal stopper screw of throttle body has been adjusted at the factory, and the
user is not allowed to change its original position.
9. Do not connect battery with its polarity reversed to prevent damage to electronic elements. This system
adopts negative ground.
10.Never remove battery cable when engine is running.
11. The positive, negative battery cables and ECM must be removed before performing welding on vehicle.
12.Do not puncture wire outer coat to detect electric signals input and output by components.

Specifications

Knock Sensor Fixing Bolt 20 ± 5
Engine Speed Sensor Fixing Bolt 8±2
Camshaft Position Sensor Fixing Bolt 8 ± 0.5
VVT Control Valve Fixing Bolt 8±2
Engine Control Module Bracket Fixing Nut 7±1
06 Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tools
Fuel Injector Cleaning Analyzer
RCH0000062
Ignition Timing Light
RCH0000016

Digital Multimeter
RCH0000002

06
RCH0000044
Fuel Pressure Gauge
RCH0000048
Oscilloscope YES ENTER
ESC
NO
1 2 3 4 5
6 7 8 9 0
RCH0000061

ECM Pin Definition

ECM connector 1
Pin No. Definition Pin No. Definition

1 - 25 Knock Sensor B
2 - 26 Knock Sensor A
3 Fuel Injector (Bank 2) 27 Air Flow Meter
4 Fuel Injector (Bank 1) 28 -
Variable Camshaft Timing Valve
5 29 Camshaft Position Sensor 1 (Intake)
(Exhaust)
6 - 30 Canister Solenoid Valve
06 7
Variable Camshaft Timing Valve
31 Sensor Ground
(Intake)
8 Fuel Injector (Bank 3) 32 Engine Speed Sensor A
9 Upstream Oxygen Sensor Heater 33 Engine Speed Sensor B
10 Fuel Injector (Bank 4) 34 5 V Power Supply 1
11 Throttle Actuator (+) 35 Ignition Coil Drive 2
12 - 36 Ignition Coil Drive 1
13 Throttle Position Sensor 1 37 Engine Coolant Temperature Sensor
14 Throttle Position Sensor 2 38 Intake Temperature Signal
15 - 39 -
16 Oxygen Sensor Ground 40 Upstream Oxygen Sensor
Camshaft Position Sensor 2
17 - 41
(Exhaust)
18 - 42 -
19 - 43 Throttle 5 V Power Supply
20 Ground 44 -
21 Air Flow Meter Ground 45 5 V Power Supply
22 Throttle Ground 46 -
23 Throttle Actuator (-) 47 ECU Ground 4
24 - 48 ECU Ground 3

ECM connector 2
Pin No. Definition Pin No. Definition

1 CAN Bus Line High 33 -
2 - 34 -
3 - 35 Ignition Switch
4 - 36 5 V Power Supply
5 Main Relay Coil 37 5 V Power Supply
6 Clutch Switch (MT) 38 -
Accelerator Pedal Position Sensor 1
7 39 -
Ground
8 - 40 -
06
9 - 41 Fuel Pump Relay Coil
10 - 42 A/C Compressor Relay Coil (MT)
11 - 43 Oxygen Sensor Ground
12 - 44 -
13 Ignition Switch Start (MT) 45 Electronic Accelerator Pedal Sensor 1
14 - 46 -
15 Noncontinuous Power Supply 47 Ground
16 Noncontinuous Power Supply 48 Downstream Oxygen Sensor Heater
17 CAN Bus Line Low 49 -
18 - 50 -
19 5 V Power Supply 1 51 -
20 Battery Continuous Power Supply 52 -
21 Downstream Oxygen Sensor 53 -
22 - 54 -
23 Brake Switch 55 -
24 A/C Pressure Sensor 56 Fan Control
25 Brake Light Switch 57 -
A/C Compressor Relay Coil (CVT)
26 - 58
Starter Relay Coil (MT)
Electronic Accelerator Pedal Sensor
27 - 59
2 Ground
28 A/C Switch 60 -
29 - 61 -
30 Electronic Accelerator Pedal Sensor 2 62 -
31 - 63 ECU Ground 2
32 5 V Power Supply 64 ECU Ground 1

Circuit Diagram
SQR484F Engine Management System (Page 1 of 8)
IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
06 EF17
10A
EF19
10A
86 30
C
FUSE AND
RELAY BOX
E-069
EF40 EF39 E-076
10A 10A
A4 A2 F14 A6 A7
R
R
R
1 4 DOWN- 1 4
STREAM UPSTREAM
OXYGEN
RL
OXYGEN
Br
R
L
SENSOR SENSOR
E-084
2 3 E-043 2 3
WG
GW
GL
RL
YL
YL
2-35 2-20 2-5 2-15 2-16 2-43 2-21 2-48 1-16 1-40 1-9
ECM-1
E-035
ECM-2
E-033
A1 A2 A3 A4 A5 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1

1 2 3 4 1 2 3 4
E-043 E-084
E-076 E-069 B B
Gr W
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
E-035
E-033 B
B ET21060010

A A
B B
C C ENGINE
COMPARTMENT
FUSE AND
EF07 EF27 EF26 RELAY BOX
15A 10A 10A E-023
C4
RL
C9 C10 06
R
RL
RL
RG
CYL1 CYL4 CYL3 CYL2 3 1 2 4 5 1 2
3
IGNITION CANISTER ELECTRICAL
COIL SOLENOID HEATING
E-018 VALVE E-004
1 2 2 E-024 1
AIR FLOW METER
E-017
B
GGr
GBr
LG
LG
LR
LY
E-019
E-007
32 33 16 23 18 17 11
E-038
GGr
GBr
LG
LG
LR
LR
1-36 1-35 1-38 1-21 1-27 1-45 1-30
ECM-1
E-035
42 38 34 30 25 20 15 10 5
41 37 33 29 24 19 14 9 4 C1 C2 C3 C4 C5
28 23 18 13 8 3
40 36 32
27 22 17 12 7 2 C6 C7 C8 C9 C10
39 35 31 26 21 16 11 6 1 37 38 39 40 41 42 43 44 45 46 47 48
E-023
25 26 27 28 29 30 31 32 33 34 35 36
L
E-007
13 14 15 16 17 18 19 20 21 22 23 24
B
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5
1 2 3 4 1 2 2 1
E-017 E-024 E-035

E-018 B E-004 B
B
B B ET21060020

A A
B B
C C ENGINE
COMPARTMENT
FUSE AND
EF08 RELAY BOX
15A E-023
06
C3
RL
RL
RL
RL
RL
RL
RL
1 1 1 1 1 1
VARIABLE VARIABLE
INJEC- INJEC- INJEC- INJEC- CAMSHAFT CAMSHAFT
TOR 1 TOR 2 TOR 3 TOR 4 TIMING TIMING
E-010 E-011 E-012 E-013 (INTAKE) (EXHAUST)
2 2 2 2 2 E-006 2 E-008
GBr
GW
GR
GR
GB
RL
E-007
15 14 13 12 20 19 E-038
GBr
GW
GR
GR
GB
RL
1-4 1-3 1-8 1-10 1-7 1-5
ECM-1
E-035
42 38 34 30 25 20 15 10 5
41 37 33 29 24 19 14 9 4
C1 C2 C3 C4 C5
28 23 18 13 8 3
40 36 32 37 38 39 40 41 42 43 44 45 46 47 48
27 22 17 12 7 2
C6 C7 C8 C9 C10
39 35 31 26 21 16 11 6 1 25 26 27 28 29 30 31 32 33 34 35 36
E-023 13 14 15 16 17 18 19 20 21 22 23 24
E-007 L 1 2 3 4 5 6 7 8 9 10 11 12
B
2 1 2 1 E-035
1 2 1 2 1 2 1 2
B
E-010 E-011 E-012 E-013 E-008 E-006
B B B B B B
ET21060030

A A
B B
ENGINE
1 5 A/C 1 5 86 87 COMPARTMENT
COMPRE- FUEL FUSE AND
SSOR PUMP FAN
EF38 RELAY BOX
CLUTCH RELAY RELAY
7.5A E-023
2 3 RELAY 2 3 85 30 E-069
06
E-073
EF10 EF35 MF02 E-076
10A 15A 60A E-059
F1 C1 A8 F6 F7 B6 F21 F22 2
RL
RL
RL
R
B
R
1 E-078
A/C E-070
COMPRESSOR 13 B-048 3
1 VOTAGE
E-002 REGULATOR
2
R
INPUT
MICROPR
2 OCESSOR
B
LG
BY
B
3
OUTPUT
FUEL
E-019 PUMP
M E-051
MOTOR
BY
B-038 M
4
B
MT CVT FAN CONTROLLER

B-036 E-046
2-42 2-58 2-41 2-56
ECM-2
E-033
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
E-033 E-069
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10
1 2 3 4
11 12 13 14 15 16 17 18 19 20 21 22
B-038
E-070 B
W
2
C1 C2 C3 C4 C5 A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 2 1 1 2 3
C6 C7 C8 C9 C10 A6 A7 A8 A9 A10 B6 B7 B8 B9 B10
E-046 E-059
E-076 E-073 E-002
E-023 B Gr
L Gr Y ET21060040

IGNITION SWITCH
START
A
INSTRUMENT
30 86 PANEL FUSE
ENGINE RF35 RF09 AND RELAY
STARTER COMPARTMENT
10A 7.5A BOX
RELAY FUSE AND I-007
RELAY BOX B-060
RB
87 85 E-022
E-067 F18 9
EF41 E-069
L
30A
I-006
06 17
GR
F13 L1 H5 B-003
RB
B
MT
L
1 1 2
L
E-071 I-004
CVT MT MT CVT
BRAKE
1 SWITCH
RB
RB
STARTER BRAKE BRAKE B-052

B
CONTROL LIGHT SWITCH

E-014 J110 SWITCH
3 4
GW
RB
E-078
PEPS (J1) 14 13 B-054
B
I-029 E-029
GW
RB
2-58 2-13 2-25 2-23
ECM-2
E-033
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 H8 H7 H6 H5 H4 H3 H2 H1 2 1 1

L2 L1
4 3
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 H16 H15 H14 H13 H12 H11 H10 H9 E-014
E-022
B-052 B
W
E-069 E-067 Lg
W W
1 2 3 4 5 6 7 8 9 10 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 J108 J107 J106 J105 J104 J103 J102 J101
22 21 20 19 18 17 16 15 14 13 12 11 7 8 9 10 11 12 13 14 J116 J115 J114 J113 J112 J111 J110 J109

12 13 14 15 16 17 18 19 20 21 22
B-054 I-006 E-071 I-029

W W B Gr
F1 F2 F3 F4 F5 F6 F7 B-060
F11 F12 F13 F14 W
F8 F9 F10 F15 F16 F17 F18
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
E-033 1 2 3 4 5 6 7 8 9 10 11 12
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B
13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
27 25 26 I-007
87 B
85 86 86 86
87 30 87 30
30 85 85
ET21060050

KNOCK ELECTRONIC
SENSOR THROTTLE
M
E-009
E-005
1 2
1 4 2 5 3 6
TO HVAC
CONTROL
06
PANEL
WY
WL
RG
GY
RB
RL
RL
L
15 K-007
I-039
E-007
1 2 3 6 4 7 5 8
Y
E-038
I-034
4
E-027
WY
WL
RG
GY
RB
RL
RL
R
Y
1-26 1-25 1-23 1-11 1-22 1-14 1-43 1-13 2-28
ECM-1
E-035
ECM-2
E-033
4 3 2 1
1 2 3 4 5 6 7 8 9 8 7 6 5 42 38 34 30 25 20 15 10 5
1 2 3
9 10 11 12 13 14 15 14 13 12 11 10 41 37 33 29 24 19 14 9 4
4 5 6 1 2 3
28 23 18 13 8 3
19 18 17 16 15 40 36 32
27 22 17 12 7 2
E-027 22 21 20
39 35 31 26 21 16 11 6 E-009 E-005
1
W B B
I-039
B
E-007
B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
E-035
E-033 B
B ET21060060

ECM-1
E-035
ECM-2
E-033
2-6 2-19 2-24 2-47 1-37 1-20 1-34 1-29 1-31 1-41
MT
WR
LG
LR
Br
W
Y
06
V
E-038
WL
LG
YL
E-029 9 10 24 25 27 26
15 E-007
B-054
LG
Y
V
WR
LR
LR
Br
Br
W
1 3 2 1 2 1 3 2 1 3 2 1
A/C
CLUTCH PRESSURE
ON SWITCH SENSOR
B-051 COOLANT
OFF E-041
TEMPERATURE
SENSOR CAMSHAFT CAMSHAFT
2 POSITION POSITION
E-021
B
SENSOR SENSOR
(INTAKE) (EXHAUST)
E-020 E-015
B-042
1 2 3 2 1
42 38 34 30 25 20 15 10 5
11 10 9 8 7 6 5 4 3 2 1
1 2 B-051 E-015 41 37 33 29 24 19 14 9 4
22 21 20 19 18 17 16 15 14 13 12 3 2 1 28 23 18 13 8 3
B B
40 36 32
27 22 17 12 7 2
E-029 E-021
E-041 39 35 31 26 21 16 11 6 1
W L
B 3 2 1
E-020
B
E-007
B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
E-035
E-033 B
ET21060070
B

ECM-1
E-035
ECM-2
CAN L1 CAN H1 E-033
2-45 2-37 2-7 2-30 2-36 2-59 2-32 1-32 1-33 2-63 2-64 1-47 1-48 2-17 2-1
OB
RL
RL
O
06
WG
GW
WR
WR
WR
RL
LR
LY
Br
Br
B
B
TO CAN
SYSTEM
E-029 29 28 E-038
4 7 12 6 8 5 E-007
B-054
WG
GW
WR
WR
WR
WL
YR
LR
Br
B
4 6 5 1 3 2 1 2
ELECTRONIC E-026 E-028
ENGINE
ACCELERATOR SPEED
PEDAL S
SENSOR
B-053 N E-016
42 38 34 30 25 20 15 10 5
11 10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 41 37 33 29 24 19 14 9 4
28 23 18 13 8 3
1 2 3 22 21 20 19 18 17 16 15 14 13 12 40 36 32
27 22 17 12 7 2
B-053
E-029 39 35 31 26 21 16 11 6 1
B
E-016 W
B
E-007
B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
E-035
E-033 B ET21060080
B

DIAGNOSIS & TESTING

Diagnostic Help
1. Connect X-431 3G Diagnostic tester (the latest software) to Data Link Connector (DLC), and make it
communicate with vehicle electronic module by the data network.
2. Confirm that malfunction is current, and carry out diagnostic test and repair procedures.
3. If DTC cannot be deleted, the malfunction is current.
4. Only use a digital multimeter to measure the voltage of electronic system.
5. Refer to any Technical Bulletin that may apply to the malfunction.
6. Visually check the related wire harness.
7. Check and clean all Engine Control Module (ECM) grounds related to the current DTC.
8. If multiple trouble codes were set, use circuit diagrams and look for any common ground circuit or power
supply circuit applied to the DTC.
06
Intermittent DTC Troubleshooting
If malfunction is intermittent, perform the following:
 Check if connectors are loose.
 Check if wire harnesses are worn, pierced, pinched or partially broken.
 Monitor X-431 3G diagnostic tester (the latest software) data that is related to this circuit.
 Wiggle related wire harnesses and connectors and observe if the signal is interrupted in the related circuit.
 If possible, try to duplicate the conditions under which the DTC was set.
 Look for the data that has changed or the DTC to reset during the wiggle test.
 Look for broken, bent, protruded or corroded terminals.
 Inspect sensors and mounting areas for damage, foreign matter, etc. that will cause incorrect signals.
 Use data recorder and/or oscilloscope to help diagnose intermittent malfunctions.
 Remove the Engine Control Module (ECM) from the malfunctioning vehicle and install it on a new car to
perform test. If DTC cannot be cleared, ECM is malfunctioning. If DTC can be cleared, reinstall ECM to the
original vehicle.
Ground Inspection
Groundings are very important to proper operation of circuits. Ground points are often exposed to moisture,
dirt and other corrosive environments. Corrosion (rust) can increase resistance which will change the way in
which a circuit works.
Electrical control circuits are very sensitive to proper grounding. A loose or corroded ground can seriously
affect control circuit. Perform the following operations when checking ground points:
1. Remove the ground bolt or nut.
2. Check all contact surfaces for tarnish, dirt and rust, etc.
3. Clean as necessary to ensure that contacting is in a good condition.
4. Reinstall the ground bolt or nut securely.
5. Check if add-on accessories interfere with the ground circuit.
6. If several wire harnesses are crimped into one ground terminal, check if they are installed correctly. Make
sure all wire harnesses are clean, securely fastened and well contacted without crimping any excessive
insulation coat.

Throttle Self-learning
Perform throttle self-learning in the following conditions:
 Battery is removed and negative battery cable is disconnected.
 ECM is replaced.
 ECM is disconnected and reconnected.
 Throttle is replaced or cleaned.
Throttle self-learning conditions:
 Engine intake temperature > 5°C
 100.5°C > coolant temperature > 5°C
 Engine speed less than 250 rpm
 Vehicle speed = 0
 Battery voltage > 10 V
 Accelerator pedal opening angle < 14.9%
Throttle self-learning procedures:
06
Turn ignition switch to OFF and then to ON. Wait for 1 minute to finish throttle self-learning.
Diagnostic Trouble Code (DTC) Chart

DTC Code DTC Definition
P000A-00 "A" Camshaft Position Slow Response
P000B-00 "B" Camshaft Position Slow Response
P0010-00 "A" Camshaft Position Actuator Circuit/Open
P0012-00 "A" Camshaft Position - Timing Over-Retarded
P0013-00 "B" Camshaft Position Actuator Circuit/Open
P0015-00 "B" Camshaft Position - Timing Over-Retarded
P0016-00 Crankshaft Position-Camshaft Position Correlation Bank 1 Sensor A
P0018-00 Crankshaft Position-Camshaft Position Correlation Bank 2 Sensor A
P0030-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 1)
P0031-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 1) Low
P0032-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 1) High
P0036-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 2)
P0037-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 2) Low
P0038-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 2) High
P0053-00 O2 Sensor Heater Resistance (Bank1 (1) Sensor 1)
P0054-00 O2 Sensor Heater Resistance (Bank1 (1) Sensor 2)
P0105-00 Manifold Absolute Pressure/Barometic Pressure Circuit
P0106-00 Manifold Abs. Pressure or Bar. Pressure Range/Performance
P0107-00 Manifold Abs. Pressure or Bar. Pressure Low Input
P0108-00 Manifold Abs. Pressure or Bar. Pressure High Input
P0112-00 Intake Air Temp. Circ. Low Input
P0113-00 Intake Air Temp. Circ. High Input


P0116-00 Engine Coolant Temp. Circ. Range/Performance
P0117-00 Engine Coolant Temp. Circ. Low Input
P0118-00 Engine Coolant Temp. Circ. High Input
P0121-00 Throttle/Pedal Pos. Sensor A Circ. Range/Performance
P0122-00 Throttle/Pedal Pos. Sensor A Circ. Low Input
P0123-00 Throttle/Pedal Pos. Sensor A Circ. High Input
P0130-00 O2 Sensor Circ., Bank1-Sensor1 Malfunction
P0131-00 O2 Sensor Circ., Bank1-Sensor1 Low Voltage
P0132-00 O2 Sensor Circ., Bank1-Sensor1 High Voltage
P0133-00 O2 Sensor Circ., Bank1-Sensor1 Slow Response
06
P0134-00 O2 Sensor Circ., Bank1-Sensor1 No Activity Detected
P0136-00 O2 Sensor Circ., Bank1-Sensor2 Malfunction
P0137-00 O2 Sensor Circ., Bank1-Sensor2 Low Voltage
P0138-00 O2 Sensor Circ., Bank1-Sensor2 High Voltage
P0140-00 O2 Sensor Circ., Bank1-Sensor2 No Activity Detected
P0170-00 Fuel Trim, Bank1 Malfunction
P0171-00 Fuel Trim, Bank1 System too Lean
P0172-00 Fuel Trim, Bank1 System too Rich
P0201-00 Cylinder 1 - Injector Circuit
P0271-00 Cylinder 4 - Injector Circuit High
P0300-00 Random/Multiple Cylinder Misfire Detected
P0301-00 Cyl.1 Misfire Detected
P0322-00 Ign./Distributor Eng. Speed Inp. Circ. No Signal
P0327-00 Knock Sensor 1 Circ. Low Input
P0328-00 Knock Sensor 1 Circ. High Input
P0341-00 Camshaft Pos. Sensor Circ. Range/Performance
P0346-00 Camshaft Pos. Sensor Circ. Range/Performance (Bank2)
P0420-00 Catalyst System, Bank1 Efficiency Below Threshold
P0444-00 Evaporative Emiss. System Purge Control Valve Circ. Open
P0458-00 Evaporative Emission System Purge Control Valve Circuit Low
P0459-00 Evaporative Emission System Purge Control Valve Circuit High
P0480-00 Cooling Fan 1 Control Circuit
P0481-00 Cooling Fan 2 Control Circuit
P0501-00 Vehicle Speed Sensor Range/Performance


P0506-00 Idle Control System RPM Lower than Expected
P0507-00 Idle Control System RPM Higher than Expected
P0560-00 System Voltage Malfunction
P0562-00 System Voltage Low Voltage
P0563-00 System Voltage High Voltage
P0568-00 Cruise Control Signal (CVT only)
P0571-00 Brake Switch "A" Circuit
P0604-00 Internal Contr. Module Random Access Memory (RAM) Error
P0605-00 Internal Contr. Module ROM Test Error
P0606-00 ECM/PCM Processor
06
P0627-00 Fuel Pump "A" Control Circuit/Open
P0628-00 Fuel Pump "A" Control Circuit Low
P0629-00 Fuel Pump "A" Control Circuit High
P0645-00 A/C Clutch Relay Circuit
P0646-00 A/C Clutch Relay Control Circuit Low
P0647-00 A/C Clutch Relay Control Circuit High
P0660-00 Intake Manifold Tuning Valve Control Circuit/Open (Bank 1)
P0661-00 Intake Manifold Tuning Valve Control Circuit Low (Bank 1)
P0662-00 Intake Manifold Tuning Valve Control Circuit High (Bank 1)
P0688-00 EMC/PCM Power Relay Sense Circuit Open
P0691-00 Cooling Fan 1 Control Circuit Low
P1106-00 Throttle Pos. Contr. Malfunction
P1110-00 Throttle Actuator Electrical Malfunction (MT only)
P1111-00 Idle Speed Control Throttle Position Mechanical Malfunction
P1130-00 Diagnosis of Brake Booster Pump
P1131-17 Diagnosis of Brake Booster Pump Control Circuit High
P1132-16 Diagnosis of Brake Booster Pump Control Circuit Low
P1133-13 Diagnosis of Brake Booster Pump Control Circ. Open
P1336-00 Engine Torque Control Adaption at Limit (CVT only)
P1137-13 Diagnosis of Pressure Sensor in Brake Booster Pump
P1138-16 Diagnosis of Pressure Sensor in Brake Booster Pump
P1139-7A Diagnosis of Pressure Sensor in Brake Booster Pump
P1270-00 ECU Defective Secret Key and Security
P1271-00 Immo Wrong Security Code Received Security
P1272-00 Electronic Control Module Incorrect Coding
P1273-00 MIL Call-up Circ. Open/Short to B+ IMMO
P1274-00 MIL Call-up Circ./Transm. Contr. Module Range/Performance


P1275-00 Manufacturer Controlled Computer and Auxiliary Outputs
P1615-00 ECM Status Unknown
P1616-00 Authentication not OK
P1617-00 No Response from SIM During Challenge Period
P1618-00 Fail to Write EOL Confiditional Data into EEPROM
P1619-00 ECM Not Programmed (Virgin State)
06
P2188-00 System Too Rich at Idle
P2195-00 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 1
P2196-00 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 1
P2270-00 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 2
P2271-00 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 2
U0101-87 Lost Communication With TCM (CVT only)
U0129-87 Lost Communication With BSM
U0140-87 Lost Communication With BCM
U0155-87 Lost Communication With ICM
U0164-87 Lost Communication With CLM
U0167-87 Lost Communication With IMMO
P0101-00 Mass or Volume Air Flow Circ. Range/Performance
P0102-00 Mass or Volume Air Flow Circ. Low Input
P0103-00 Mass or Volume Air Flow Circ. High Input
P0531-00 A/C Refrigerant Pressure Sensor "A" Circuit Range/Performance
P1568-00 DV-E Cause of Failure: Spring Check
U0001-00 High Speed CAN Defective

ECM Power Supply Circuit & Ground Circuit Testing

Power Supply Circuit (Page 1 of 1)
IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
EF17
10A
EF19
10A
86 30 FUSE AND
RELAY BOX 06
E-069
EF40 E-076
10A
A4 A2 F14 A6
R
RL
Br
R
L
2-35 2-20 2-5 2-15 2-16
ECM-2
E-033
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 E-069
W
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A1 A2 A3 A4 A5
A6 A7 A8 A9 A10
E-033 E-076
B Gr
ET21065000

Ground Circuit (Page 1 of 1)
ECM-1
E-035
ECM-2
E-033
2-63 2-64 1-47 1-48
06
Br
Br
B
Br
B
E-026 E-028
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
E-035
E-033 B
B
ET21065001

Confirmation Procedure
Before performing the following procedures, confirm that battery voltage is higher than 12 V.
 Turn ignition switch off.
 Connect X-431 3G diagnostic tester (the latest version) to Data Link Connector (DLC).
 Turn ignition switch ON.
 Using diagnostic tester, select Read Datastream.
 If the datastream is not detected, the malfunction indicated by the datastream is current. Go to the
diagnosis procedure - Step 1.
 If the datastream is detected, the malfunction indicated by the datastream is intermittent (See page 06-18).
Diagnosis Procedure
1 Check ECM power supply circuit
a. Turn ignition switch off. 06

b. Disconnect ECM connector E-033.
c. Check voltage between terminals of ECM connector 
E-033 and body ground. V
+ -
Multimeter Specified
Condition
Connection Condition
E-033 (20) - Body
Always 11 to 14 V
Ground
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
OK Go to step 4 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065001
NG
2 Check ECM fuse
a. Unplug ECM fuse EF19 (10A) from engine compartment fuse and relay box.
b. Check resistance of fuse.
Standard resistance: less than 1 Ω
NG Replace ECM fuse
OK

3 Check wire harness and connector (ECM - engine compartment fuse and relay box)
a. Disconnect engine compartment fuse and relay box

connector E-076.
b. Check wire harness between connector terminals on wire A1 A2 A3 A4 A5
harness side. A6 A7 A8 A9 A10
Check for Open + -
E-076
Specified
Multimeter Connection
Condition
E-033 (20) - E-076 (A2) Continuity
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Check for Short 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
06 Multimeter Connection
Specified 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Condition
E-033 (20) or E-076 (A2) - Body
No continuity
ground E-033
RT21065002
E-033 (20) or E-076 (A2) - Battery
No continuity
positive
NG Repair or replace wire harness or

connector
OK
Repair or replace engine compartment fuse and relay box or wire harness (engine compartment fuse
and relay box - battery)
4 Check main relay circuit voltage
a. Remove main relay from engine compartment fuse and

relay box.
b. Measure voltage between terminals of main relay and
body ground. V
+ -
Condition
Main relay
terminals 85 and
87 (engine
30
86 85
87
compartment fuse Always 11 to 14 V

and relay box
side) - Body
ground

connector (main relay - battery) RT21060030

OK
5 Check main relay and fuse EF40
a. Check if fuse EF40 is normal.

b. Check for continuity between terminals of main relay. + -
Multimeter 87 85
Specified Condition
Connection
30 - 87 No continuity
Continuity
30 86
30 - 87 (when battery voltage is applied
between terminals 85 and 86)
87
06
NG Replace fuse or main relay
86
85
30
RT21060020
OK
a. Check wire harness between connector terminals.

b. Disconnect engine compartment fuse and relay box
connector E-069. A1 A2 A3 A4 A5
Check for Open A6 A7 A8 A9 A10

+ -
Specified E-076
Condition
E-033 (15, 16) - E-076 (A6) Continuity
Check for Short 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Specified 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Condition 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033 (15, 16) or E-076 (A6) - Body

No continuity
ground
E-033
E-033 (15, 16) or E-076 (A6) - Battery
No continuity RT21065003
positive

Check for Open
Specified
Condition F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
E-033 (5) - E-069 (F14) Continuity + - F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
Check for Short E-069
Specified
Condition
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
E-033 (5) or E-069 (F14) - Body
No continuity 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
ground 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
E-033 (5) or E-069 (F14) - Battery 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

No continuity
positive
06 NG Repair or replace wire harness or E-033

RT21065004
connector
OK
7 Check ECM power supply circuit (ignition switch voltage)
a. Connect fuse and relay box connector E-076.

b. Turn ignition switch to ON.
c. Check voltage between terminals of ECM connector.
V
Multimeter Specified + -
Condition
E-033 (35) -
Ignition switch ON 11 to 14 V
E-033 (63, 64)
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
OK Replace ECM 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065005
NG
8 Check ECM fuse
a. Unplug ECM fuse EF17 (10A) from engine compartment fuse and relay box.
NG Replace ECM fuse

OK
Check wire harness and connector (ECM - body ground and engine compartment fuse and
9 relay box)

connector E-076.
b. Check wire harness between connector terminals on wire A1 A2 A3 A4 A5
harness side. A6 A7 A8 A9 A10
Check for Open + -
E-076
Specified
Condition
E-033 (35) - E-076 (A4) Continuity 06
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Check for Short 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Specified 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Condition
E-033 (35) or E-076 (A4) - Body
No continuity
ground E-033
RT21065006
E-033 (35) or E-076 (A4) - Battery
No continuity
positive
c. Disconnect ECM ground point E-026 and E-028.

d. Check ECM ground point (See page 06-18).
e. Check ECM ground wire harness.
Check for Open + -
Specified E-026
Condition
E-033 (63, 64) - E-026 Continuity
E-035 (47, 48) - E-028 Continuity 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
NG Repair or replace wire harness or 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
connector
E-033
RT21065007
OK

10 Check ignition switch assembly (See page 15-67)
NG Replace ignition switch assembly
OK
and relay box - ignition switch)
06

DTC P0030-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 1)
DTC P0031-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 1) Low
DTC P0032-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 1) High
DTC P0053-00 O2 Sensor Heater Resistance (Bank1 (1) Sensor 1)
06

IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
EF17 EF19 86 30 FUSE AND
10A 10A RELAY BOX
E-069
EF40 EF39 E-076
10A 10A
06 A4 A2 F14 A6 A7
R
R
1 4
UPSTREAM
OXYGEN
RL
Br
R
L
SENSOR
E-084
2 3
GL
RL
YL
2-35 2-20 2-5 2-15 2-16 1-16 1-40 1-9

ECM-1
E-035
ECM-2
E-033

1 2 3 4
E-084
E-076 E-069 B
Gr W
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
E-035
E-033 B
B ET21065002

DTC Detection
DTC Code DTC Definition Possible Cause
Condition
O2 Sensor Heater
P0030-00 Contr. Circ. (Bank1 (1)
Sensor 1)
O2 Sensor Heater
P0031-00 Contr. Circ. (Bank1 (1)  Upstream oxygen sensor
Sensor 1) Low Ignition switch ON  Wire harness or connector
O2 Sensor Heater Engine running  Fuse
P0032-00 Contr. Circ. (Bank1 (1)  ECM
Sensor 1) High
O2 Sensor Heater
P0053-00 Resistance (Bank1 (1)
Sensor 1) 06
DTC Confirmation Procedure
Confirm that battery voltage is over 12 V before performing the following procedures.
 Turn ignition switch to LOCK.
 Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC).
 Turn ignition switch to ON.
 Use X-431 3G diagnostic tester to record and clear the DTCs stored in the ECM.
 Start the engine and warm it up to normal operating temperature, and then select Read Code.
 If the DTC is detected, the malfunction indicated by the DTC is current. Go to the diagnosis 
procedure - Step 1.
 If DTC is not detected, the malfunction indicated by the DTC is intermittent (See page 06-18).
CAUTION
 When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and
component information.
Diagnosis Procedure
1 Check ECM ground point
a. Turn ignition switch to LOCK.

b. Check ECM grounds E-026 and E-028 (See page 06-18).
NG Repair or replace ground wire harness or

ground point
OK

2 Check upstream oxygen sensor connector
a. Disconnect upstream oxygen sensor connector E-084.

b. Check upstream oxygen sensor connector.
NG Repair or replace connector
RT21090110
OK
06
3 Check upstream oxygen sensor heater power supply voltage
a. Turn ignition switch to ON.

b. Check voltage between terminal 4 of upstream oxygen
sensor connector E-084 and body ground.
V
Condition
E-084 (4) - Body
Ignition switch ON 11 to 14 V 1 2 3 4
ground
E-084
OK Go to step 5
RT21065008
NG

4 Check upstream oxygen sensor power supply circuit

b. Check fuse EF39 and main relay.
c. Disconnect engine compartment fuse and relay box
connector E-076.
+ -
d. Check wire harness between upstream oxygen sensor
connector terminals and engine compartment fuse and
relay box connector terminals.
1 2 3 4
Check for Open
E-084
Condition
E-084 (4) - E-076
(A7)
Always Continuity A1 A2 A3 A4 A5 06
A6 A7 A8 A9 A10
Check for Short

E-076
Multimeter Specified RT21065009

Condition
E-084 (4) or
E-076 (A7) - Body Always No continuity
ground
E-084 (4) or
E-076 (A7) - Always No continuity
Battery positive
NG Replace fuse, main relay, wire harness or

connector (upstream oxygen sensor -
engine compartment fuse and relay box)
OK

5 Check upstream oxygen sensor heater control circuit
a. Disconnect ECM connector E-035.

b. Check wire harness between upstream oxygen sensor
connector terminals and ECM connector terminals.
Check for Open 1 2 3 4
+ -
E-084
Condition
E-084 (3) - E-035
Always Continuity
(9)
37 38 39 40 41 42 43 44 45 46 47 48
Check for Short 25 26 27 28 29 30 31 32 33 34 35 36

13 14 15 16 17 18 19 20 21 22 23 24
06 Multimeter
Condition
Specified 1 2 3 4 5 6 7 8 9 10 11 12
E-084 (3) or
E-035 (9) - Body Always No continuity E-035
ground RT21065010
E-084 (3) or
E-035 (9) - Always No continuity
Battery positive

ECM)
OK
6 Check upstream oxygen sensor heater
a. Measure resistance of upstream oxygen sensor.

+ -
Condition
Connection Condition D C B A
Terminal C -
20°C 7 - 11 Ω
Terminal D
Terminal A -
Terminal B
Terminal A - RT21090140
Terminal C
Terminal A -
Always No continuity
Terminal D
Terminal B -
Terminal C
Terminal B -
Terminal D
NG Replace upstream oxygen sensor

OK
7 Check for DTCs
a. Use X-431 3G diagnostic tester to read the ECM DTC.

b. Refer to "DTC Confirmation Procedure".
c. Check if DTC P0030-00, P0031-00, P0032-00 or P0053-00 still exists.
NG Replace ECM
OK
System is operating normally. 06

Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has
been repaired.

DTC P0036-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 2)
DTC P0037-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 2) Low
DTC P0038-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 2) High
DTC P0054-00 O2 Sensor Heater Resistance (Bank1 (1) Sensor 2)
06

IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
10A 10A RELAY BOX
E-069
EF40 EF39 E-076
10A 10A
06
A4 A2 F14 A6 A7
R
R
1 4 DOWN-
STREAM
RL
Br
OXYGEN
R
R
L
SENSOR
2 3 E-043
WG
GW
YL
2-35 2-20 2-5 2-15 2-16 2-43 2-21 2-48
ECM-2
E-033
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1

E-069 A1 A2 A3 A4 A5
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
W
A6 A7 A8 A9 A10
E-076
Gr
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
E-033 1 2 3 4
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B
E-043
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B
ET21065003

DTC Detection
Condition
O2 Sensor Heater
P0036-00 Contr. Circ. (Bank1 (1)
Sensor 2)
O2 Sensor Heater
P0037-00 Contr. Circ. (Bank1 (1)  Downstream oxygen sensor
Sensor 2) Low Ignition switch ON  Wire harness or connector
O2 Sensor Heater Engine running  Fuse
P0038-00 Contr. Circ. (Bank1 (1)  ECM
Sensor 2) High
O2 Sensor Heater
P0054-00 Resistance (Bank1 (1)
06 Sensor 2)

procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check downstream oxygen sensor connector
a. Disconnect downstream oxygen sensor connector.

b. Check downstream oxygen sensor connector.
RT21060040
OK
06
3 Check downstream oxygen sensor heater power supply voltage

b. Check voltage between terminal 4 of downstream oxygen
sensor connector E-043 and body ground.
V
Condition
E-043 (4) - Body
Ignition switch ON 11 to 14 V 1 2 3 4
ground
E-043
OK Go to step 5
RT21065011
NG

4 Check downstream oxygen sensor power supply circuit

connector E-076.
+ -
d. Check wire harness between downstream oxygen sensor
relay box connector terminals.
1 2 3 4
Check for Open
E-043
Condition
06 E-043 (4) - E-076

(A7)
Always Continuity A1 A2 A3 A4 A5
A6 A7 A8 A9 A10
Check for Short

E-076

Condition
E-043 (4) or
E-076 (A7) - Body Always No continuity
ground
E-043 (4) or
E-076 (A7) - Always No continuity
Battery positive
NG Replace fuse, main relay, wire harness or

connector (downstream oxygen sensor -
OK

5 Check downstream oxygen sensor heater control circuit

b. Check wire harness between downstream oxygen sensor
Check for Open 1 2 3 4
+ -
E-043
Condition
E-043 (3) - E-033
Always Continuity
(48)
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Check for Short 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Multimeter
Condition
Specified 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
06
E-043 (3) or
ground RT21065013
E-043 (3) or
Battery positive

ECM)
OK
6 Check downstream oxygen sensor heater
a. Measure resistance of downstream oxygen sensor.

+ -
Condition
Connection Condition D C B A
Terminal C -
20°C 7 - 11 Ω
Terminal D
Terminal A -
Terminal B
Terminal A - RT21090140
Terminal C
Terminal A -
Terminal D
Terminal B -
Terminal C
Terminal B -
Terminal D
NG Replace downstream oxygen sensor

OK
7 Check for DTCs

c. Check if DTC P0036-00, P0037-00, P0038-00 or P0054-00 still exists.
NG Replace ECM
OK
06 System is operating normally.

been repaired.

DTC P0101-00 Mass or Volume Air Flow Circ. Range/Performance
DTC P0102-00 Mass or Volume Air Flow Circ. Low Input
DTC P0103-00 Mass or Volume Air Flow Circ. High Input
06

IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
10A 10A RELAY BOX
E-069
EF40 E-076
EF27
10A E-023
10A
A4 A2 F14 A6
06
C9
RL
R
3 1 2 4 5
AIR FLOW METER

RL
Br
E-017
LG
LG
R
LR
L
LY
E-007
16 23 18 17
E-038
LG
LG
LR
LR
2-35 2-20 2-5 2-15 2-16 1-38 1-21 1-27 1-45
ECM-1
E-035
ECM-2
E-033
42 38 34 30 25 20 15 10 5
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 1 2 3 4 5 A1 A2 A3 A4 A5 C1 C2 C3 C4 C5
41 37 33 29 24 19 14 9 4
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
A6 A7 A8 A9 A10 C6 C7 C8 C9 C10 28 23 18 13 8 3
E-017 40 36 32
27 22 17 12 7 2
E-069 B 39 35 31 26 21 16 11 6
E-076 E-023 1
W
Gr L
E-007
B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
E-033 25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
E-035 ET21065004
B

DTC Detection
Condition
Mass or Volume Air
P0101-00 Flow Circ. Range/
Performance  Air flow meter
Ignition switch ON
Mass or Volume Air  Wire harness or connector
P0102-00 Engine running
Flow Circ. Low Input  ECM
Mass or Volume Air
P0103-00
Flow Circ. High Input

06
 Select Read Code.
procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check air flow meter connector
a. Disconnect air flow meter connector E-017.

b. Check air flow meter connector.
RT21060050
OK
06
3 Check air flow meter signal voltage
a. Connect air flow meter connector E-017.

b. Turn ignition switch to ON and start the engine.
c. Using multimeter, measure voltage between connector 
E-017 terminal 5 and body ground. V
+ -
Condition
Voltage is about 1 2 3 4 5
1.3 V (value
Idle
changes with E-017
model)
E-017 (5) - Body
ground Instantaneous
voltage is about
Rapidly depress
4 V (value
accelerator pedal
changes with
model)
RT21060060
OK Go to step 8
NG

4 Check air flow meter power supply voltage

b. Check voltage between air flow meter connector
terminals and body ground.
V
Condition
E-017 (4) - Body
5V
ground 1 2 3 4 5
Ignition switch ON
E-017 (2) - Body
11 to 14 V E-017
ground
OK Go to step 6 06
RT21065014
NG
5 Check air flow meter power supply circuit

b. Disconnect ECM connector E-035 and engine
compartment fuse and relay box connector E-023.
1 2 3 4 5
c. Check wire harness between connector terminals.
+ -
Check for Open E-017
Condition
E-017 (4) - E-035
Always Continuity 37 38 39 40 41 42 43 44 45 46 47 48
(45)
25 26 27 28 29 30 31 32 33 34 35 36
Check for Short 13 14 15 16 17 18 19 20 21 22 23 24

1 2 3 4 5 6 7 8 9 10 11 12
Condition
E-017 (4) or E-035
RT21065015
E-035 (45) - Body Always No continuity
ground
E-017 (4) or
Battery positive

Check for Open
Condition
E-017 (2) - E-023 + -
Always Continuity
(C9)
1 2 3 4 5
Check for Short
E-017
Condition
E-017 (2) or C1 C2 C3 C4 C5
E-023 (C9) - Body Always No continuity C6 C7 C8 C9 C10

ground
E-023
E-017 (2) or
06 E-023 (C9) - Always No continuity
Battery positive RT21065016
NG Replace wire harness or connector (air

flow meter - ECM or engine compartment
fuse and relay box)
OK
6 Check air flow meter signal circuit
a. Check wire harness between air flow meter connector

terminals and ECM connector terminals.
Check for Open
1 2 3 4 5
Condition E-017
E-017 (5) - E-035
Always Continuity
(27)
Check for Short 37 38 39 40 41 42 43 44 45 46 47 48
25 26 27 28 29 30 31 32 33 34 35 36
Condition 13 14 15 16 17 18 19 20 21 22 23 24
Connection Condition 1 2 3 4 5 6 7 8 9 10 11 12
E-017 (5) or
ground E-035
RT21065017
E-017 (5) or
Battery positive

connector (air flow meter - ECM)
OK

7 Check air flow meter
a. Remove air flow meter.

b. Check air flow meter for debris and damage.
NG Clean or replace air flow meter, and go to

next step
OK
8 Check for DTCs

b. Refer to "DTC Confirmation Procedure". 06
c. Check if DTC P0101-00, P0102-00 or P0103-00 still exists.
NG Replace ECM
OK
System is operating normally.

been repaired.

DTC P0112-00 Intake Air Temp. Circ. Low Input
DTC P0113-00 Intake Air Temp. Circ. High Input
IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
06
10A 10A RELAY BOX
E-069
EF40 E-076
EF27
10A E-023
10A
A4 A2 F14 A6 C9
RL
R
3 1 2 4 5
AIR FLOW METER

RL
Br
E-017
LG
LG
R
LR
L
LY
E-007
16 23 18 17
E-038
LG
LG
LR
LR
2-35 2-20 2-5 2-15 2-16 1-38 1-21 1-27 1-45

ECM-1
E-035
ECM-2
E-033
42 38 34 30 25 20 15 10 5
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 1 2 3 4 5 A1 A2 A3 A4 A5 C1 C2 C3 C4 C5
41 37 33 29 24 19 14 9 4
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
A6 A7 A8 A9 A10 C6 C7 C8 C9 C10 28 23 18 13 8 3
E-017 40 36 32
27 22 17 12 7 2
E-069 B 39 35 31 26 21 16 11 6
E-076 E-023 1
W
Gr L
E-007
B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
E-033 25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
E-035 ET21065004
B

DTC Detection
Condition
Intake Air Temp. Circ.
P0112-00  Air flow meter
Low Input Ignition switch ON
 Wire harness or connector
Intake Air Temp. Circ. Engine running
P0113-00  ECM
High Input

 Use X-431 3G diagnostic tester to record and clear the DTCs stored in the ECM. 06
procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check air flow meter connector

b. Check air flow meter connector.
RT21060050
OK
06
3 Check intake temperature sensor signal
a. Connect air flow meter connector E-017.

b. Turn ignition switch to ON and start the engine.
c. Using multimeter, measure voltage between connector 
E-017 terminal 1 and body ground. V
+ -
Condition
Voltage is about 1 2 3 4 5
1.6 V (value
changes with E-017
E-017 (1) - Body Engine running
model); signal
ground after warming up
voltage does not
change when
increasing speed.
OK Go to step 7
RT21060070
NG

4 Check intake temperature sensor voltage

c. Check voltage between connector terminal and body
ground. V
+ -
Condition
E-017 (1) - Body 1 2 3 4 5
Ignition switch ON 5V
ground
E-017
OK Go to step 6
06
RT21065018
NG
5 Check intake temperature sensor signal circuit

c. Check wire harness between air flow meter connector 1 2 3 4 5
+ -
Condition
E-017 (1) - E-035
(38)
25 26 27 28 29 30 31 32 33 34 35 36
Check for Short 13 14 15 16 17 18 19 20 21 22 23 24

1 2 3 4 5 6 7 8 9 10 11 12
Condition
E-017 (1) or E-035
RT21065019
ground
E-017 (1) or
Battery positive
NG Replace wire harness or connector (air

flow meter - ECM)
OK

6 Check intake pressure sensor ground circuit

Check for Open
1 2 3 4 5
Condition
Connection Condition + -
E-017
E-017 (3) - E-035

Always Continuity
(21)
Check for Short

37 38 39 40 41 42 43 44 45 46 47 48
Condition 25 26 27 28 29 30 31 32 33 34 35 36
06 E-017 (3) or 1 2 3 4 5 6 7 8 9 10 11 12

ground
E-017 (3) or E-035
RT21065020
Battery positive

connector (air flow meter - ECM)
OK
Replace air flow meter, and go to step 7
7 Check for DTCs

c. Check if DTC P0112-00 or P0113-00 still exists.
NG Replace ECM
OK

been repaired.

DTC P0116-00 Engine Coolant Temp. Circ. Range/Performance
DTC P0117-00 Engine Coolant Temp. Circ. Low Input
DTC P0118-00 Engine Coolant Temp. Circ. High Input
ECM-1
E-035
1-37 1-20
06
LG
Y
9 10 E-038
E-007
LG
Y
2 1
COOLANT
TEMPERATURE
SENSOR
E-021
42 38 34 30 25 20 15 10 5
37 38 39 40 41 42 43 44 45 46 47 48
41 37 33 29 24 19 14 9 4
1 2
25 26 27 28 29 30 31 32 33 34 35 36 28 23 18 13 8 3
40 36 32
27 22 17 12 7 2
13 14 15 16 17 18 19 20 21 22 23 24 E-021
39 35 31 26 21 16 11 6 1
1 2 3 4 5 6 7 8 9 10 11 12
L
E-007
B
E-035
B
ET21065005

DTC Detection
Condition
Engine Coolant Temp.
P0116-00 Circ. Range/
Performance  Engine coolant temperature sensor
Ignition switch ON
Engine Coolant Temp.  Wire harness or connector
P0117-00 Engine running
Circ. Low Input  ECM
Engine Coolant Temp.
P0118-00
Circ. High Input

06
procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check engine coolant temperature sensor connector
a. Disconnect engine coolant temperature sensor connector

E-021.
b. Check engine coolant temperature sensor connector.
RT21060090
OK
06
3 Check engine coolant temperature sensor power supply voltage

b. Check voltage between engine coolant temperature
sensor terminal and body ground.
V
Condition
E-021 (2) - Body
ground
1 2
E-021
OK Go to step 5
RT21065021
NG

4 Check engine coolant temperature sensor power supply circuit

c. Check wire harness between engine coolant temperature
sensor connector terminals and ECM connector 1 2
terminals. + -
E-021
Check for Open
Condition
37 38 39 40 41 42 43 44 45 46 47 48
E-021 (2) - E-035
(37)
13 14 15 16 17 18 19 20 21 22 23 24
06 Check for Short 1 2 3 4 5 6 7 8 9 10 11 12
Condition
Connection Condition E-035
RT21065022
E-021 (2) or
ground
E-021 (2) or
Battery positive
NG Replace wire harness or connector

(engine coolant temperature sensor -
ECM)
OK

5 Check engine coolant temperature sensor ground circuit
a. Check wire harness between engine coolant temperature

sensor connector terminals and ECM connector
terminals.
Check for Open 1 2
+ -
E-021
Condition
E-021 (1) - E-035
Always Continuity
(20)
37 38 39 40 41 42 43 44 45 46 47 48
Check for Short 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
Multimeter
Connection
Condition
Specified
Condition
1 2 3 4 5 6 7 8 9 10 11 12 06
E-021 (1) or
ground RT21065023
E-021 (1) or
Battery positive

connector (engine coolant temperature
sensor - ECM)
OK
6 Check engine coolant temperature sensor
a. Remove engine coolant temperature sensor.

b. Check resistance of engine coolant temperature sensor. + -
Multimeter
Specified Condition 1 2
Connection
Resistance is 2.5 kΩ ± 5% (20°C),
300 - 400 Ω in boiled water (value
1-2
changes with boiled water
temperature)
RT21060100
NG Replace engine coolant temperature

sensor
OK

7 Check for DTCs

NG Replace ECM
OK

been repaired.
06

DTC P0121-00 Throttle/Pedal Pos. Sensor A Circ. Range/Performance
DTC P0122-00 Throttle/Pedal Pos. Sensor A Circ. Low Input
DTC P0123-00 Throttle/Pedal Pos. Sensor A Circ. High Input
ELECTRONIC
THROTTLE
06
M
E-009
1 4 2 5 3 6
WL
RG
RB
RL
RL
L
E-007
3 6 4 7 5 8
E-038
WL
RG
RB
RL
RL
R
1-23 1-11 1-22 1-14 1-43 1-13
ECM-1
E-035
42 38 34 30 25 20 15 10 5
1 2 3
37 38 39 40 41 42 43 44 45 46 47 48 41 37 33 29 24 19 14 9 4
4 5 6
28 23 18 13 8 3
25 26 27 28 29 30 31 32 33 34 35 36 40 36 32
27 22 17 12 7 2
39 35 31 26 21 16 11 6 1 E-009
13 14 15 16 17 18 19 20 21 22 23 24
B
1 2 3 4 5 6 7 8 9 10 11 12
E-007
B
E-035
B
ET21065006

DTC Detection
DTC Code DTC Definitions Possible Cause
Conditions
Throttle/Pedal Pos.
P0121-00 Sensor A Circ. Range/
Performance
Throttle/Pedal Pos.  Throttle position sensor 1
Ignition switch ON
P0122-00 Sensor A Circ. Low  Wire harness or connector
Engine running
Input  ECM
Throttle/Pedal Pos.
P0123-00 Sensor A Circ. High
Input

06 Confirm that battery voltage is over 12 V before performing the following procedures.
procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check electronic throttle connector
a. Disconnect electronic throttle connector E-009.

b. Check electronic throttle connector.
RT21060110
OK
06
3 Check throttle position sensor 1 signal voltage
a. Connect throttle position sensor connector E-009.

c. Using diagnostic tester, check throttle position sensor 1
signal voltage.
Standard Value
Datastream
Condition Datastream name Value Unit
(V) lambda controller output 1.00
multiplicative correction of the mixture adaptation 1.03
Accelerator pedal released 0.78 sensor voltage from throttle potentiometer 1 0.78 V
sensor voltage from throttle potentiometer 2 4.22 V
Accelerator pedal depressed 4.29 additive correction of the mixture adaptation 0.00 %
Voltage PWG potentiometer 1 0.77 V
OK Go to step 8 Doubled PWG potentiometer-2 voltage 0.75 V
RT21060120
NG

4 Check throttle position sensor power supply voltage

b. Disconnect electronic throttle connector E-009.
c. Turn ignition switch to ON and check voltage between
electronic throttle connector terminal and body ground. V
+ -
Condition
1 2 3
E-009 (3) - Body 4 5 6
ground
E-009
OK Go to step 6
06
RT21065024
NG
5 Check throttle position sensor power supply circuit

1 2 3
c. Check wire harness between electronic throttle connector 4 5 6
+ -
Condition
E-009 (3) - E-035
(43)
25 26 27 28 29 30 31 32 33 34 35 36
Check for Short 13 14 15 16 17 18 19 20 21 22 23 24

1 2 3 4 5 6 7 8 9 10 11 12
Condition
E-009 (3) or E-035
RT21065025
E-035 (43) - Body
ground
E-009 (3) or
E-035 (43) -
Battery positive

(electronic throttle - ECM)
OK

6 Check throttle position sensor 1 signal circuit and ground circuit
a. Check wire harness between electronic throttle connector

Check for Open 1 2 3
4 5 6
Condition E-009
E-009 (6) - E-035
(13)
Always Continuity
E-009 (2) - E-035
37 38 39 40 41 42 43 44 45 46 47 48
(22)
25 26 27 28 29 30 31 32 33 34 35 36
Check for Short 13 14 15 16 17 18 19 20 21 22 23 24

1 2 3 4 5 6 7 8 9 10 11 12 06
Condition
E-009 (6) or E-035
RT21065026
E-035 (13) - Body
ground
E-009 (6) or
E-035 (13) -
Battery positive
E-009 (2) or
E-035 (22) - Body
ground
E-009 (2) or
E-035 (22) -
Battery positive

connector (electronic throttle - ECM)
OK

7 Check electronic throttle
a. Check electronic throttle for carbon deposits and foreign

matter accumulation inside.
+ -
b. Check if throttle valve body is stuck. 3 2 1
c. Check resistance of electronic throttle. 6 5 4
Condition
Terminal 3 - At normal
1.067 kΩ
Terminal 2 temperature
RT21100211
Resistance
Terminal 6 - increases as
06 Terminal 2 throttle valve
opens
Resistance
Terminal 6 - decreases as
Terminal 3 throttle valve
Throttle valve is opens
rotated Resistance
opens
Resistance
opens
NG Clean or replace electronic throttle

assembly, and go to next step
OK
8 Check for DTCs

NG Replace ECM
OK

been repaired.

DTC P0130-00 O2 Sensor Circ., Bank1-Sensor1 Malfunction
DTC P0131-00 O2 Sensor Circ., Bank1-Sensor1 Low Voltage
DTC P0132-00 O2 Sensor Circ., Bank1-Sensor1 High Voltage
DTC P0133-00 O2 Sensor Circ., Bank1-Sensor1 Slow Response
DTC P0134-00 O2 Sensor Circ., Bank1-Sensor1 No Activity Detected
DTC P2195-00 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 1

06
DTC P2196-00 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 1

IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
10A 10A RELAY BOX
E-069
EF40 EF39 E-076
10A 10A
06
A4 A2 F14 A6 A7
R
R
1 4
UPSTREAM
OXYGEN
RL
Br
R
L
SENSOR
E-084
2 3
GL
RL
YL
2-35 2-20 2-5 2-15 2-16 1-16 1-40 1-9

ECM-1
E-035
ECM-2
E-033

1 2 3 4
E-084
E-076 E-069 B
Gr W
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
E-035
E-033 B
B ET21065002

DTC Detection
Conditions
O2 Sensor Circ.,
P0130-00 Bank1-Sensor1
Malfunction
O2 Sensor Circ.,
P0131-00 Bank1-Sensor1 Low
Voltage
O2 Sensor Circ.,
P0132-00 Bank1-Sensor1 High
Voltage
O2 Sensor Circ.,  Upstream oxygen sensor
Ignition switch ON
P0133-00 Bank1-Sensor1 Slow  Wire harness or connector
Engine running
Response  ECM 06
O2 Sensor Circ.,
P0134-00 Bank1-Sensor1 No
Activity Detected
O2 Sensor Signal
P2195-00 Stuck Lean; Bank 1
Sensor 1
O2 Sensor Signal
P2196-00 Stuck Rich; Bank 1
Sensor 1

procedure - Step 1.
CAUTION

Diagnosis Procedure


ground point
OK
2 Check upstream oxygen sensor connector

06
a. Disconnect upstream oxygen sensor connector E-084.
b. Check upstream oxygen sensor connector.
RT21090110
OK
3 Check upstream oxygen sensor signal
a. Connect upstream oxygen sensor connector E-084.

b. Turn ignition switch to ON, start the engine and idle it for
about 3 minutes.
c. Using multimeter, measure voltage between terminals 2 V
and 1 of connector E-084. + -
Condition
Fluctuates fast 1 2 3 4
between 0.1 and
E-084
E-084 (2) - E-084 0.9 V (when
Engine running
(1) operating
temperature is
350°C)
OK Go to step 7
RT21060130
NG

4 Check upstream oxygen sensor signal circuit

c. Disconnect upstream oxygen sensor connector E-084.
1 2 3 4
d. Check wire harness between upstream oxygen sensor
+ -
connector terminals and ECM connector terminals. E-084
Check for Open
Condition
37 38 39 40 41 42 43 44 45 46 47 48
E-084 (2) - E-035
(40) 13 14 15 16 17 18 19 20 21 22 23 24
Check for Short

1 2 3 4 5 6 7 8 9 10 11 12 06
Condition
RT21065027
E-084 (2) or
E-035 (40) - Body
ground
E-084 (2) or
E-035 (40) -
Battery positive

(upstream oxygen sensor - ECM)
OK
5 Check upstream oxygen sensor ground circuit
a. Check wire harness between upstream oxygen sensor

Check for Open
1 2 3 4
Condition E-084
E-084 (1) - E-035
Always Continuity
(16)
37 38 39 40 41 42 43 44 45 46 47 48
25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12
E-035
RT21065028

Check for Short
Condition
E-084 (1) or
E-035 (16) - Body
ground
E-084 (1) or
E-035 (16) -
Battery positive

ECM)
06
OK
6 Check upstream oxygen sensor
a. Remove upstream oxygen sensor.

b. Check upstream oxygen sensor for following problems.
 Moisture enters the internal of sensor, temperature changes greatly, and probe is broken.
 Oxygen sensor is "poisoned" (Pb, S, Br, Si, etc.).
NG Replace upstream oxygen sensor
OK
7 Check for DTCs

c. Check if DTC P0130-00, P0131-00, P0132-00, P0133-00, P0134-00, P2195-00 or P2196-00 still exists.
NG Replace ECM
OK

been repaired.

DTC P0136-00 O2 Sensor Circ., Bank1-Sensor2 Malfunction
DTC P0137-00 O2 Sensor Circ., Bank1-Sensor2 Low Voltage
DTC P0138-00 O2 Sensor Circ., Bank1-Sensor2 High Voltage
DTC P0140-00 O2 Sensor Circ., Bank1-Sensor2 No Activity Detected
DTC P2270-00 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 2
DTC P2271-00 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 2

06

IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
10A 10A RELAY BOX
E-069
EF40 EF39 E-076
10A 10A
06
A4 A2 F14 A6 A7
R
R
1 4 DOWN-
STREAM
RL
Br
OXYGEN
R
R
L
SENSOR
2 3 E-043
WG
GW
YL
2-35 2-20 2-5 2-15 2-16 2-43 2-21 2-48
ECM-2
E-033
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1

E-069 A1 A2 A3 A4 A5
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
W
A6 A7 A8 A9 A10
E-076
Gr
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
E-033 1 2 3 4
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B
E-043
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B
ET21065003

DTC Detection
Conditions
O2 Sensor Circ.,
P0136-00 Bank1-Sensor2
Malfunction
O2 Sensor Circ.,
P0137-00 Bank1-Sensor2 Low
Voltage
O2 Sensor Circ.,
P0138-00 Bank1-Sensor2 High
 Downstream oxygen sensor
Voltage Ignition switch ON
O2 Sensor Circ., Engine running
 ECM
P0140-00 Bank1-Sensor2 No
Activity Detected 06
O2 Sensor Signal
P2270-00 Stuck Lean; Bank 1
Sensor 2
O2 Sensor Signal
P2271-00 Stuck Rich; Bank 1
Sensor 2

procedure - Step 1.
CAUTION

Diagnosis Procedure


ground point
OK
2 Check downstream oxygen sensor connector

06
a. Disconnect downstream oxygen sensor connector.
b. Check downstream oxygen sensor connector.
RT21060040
OK
3 Check downstream oxygen sensor signal
a. Connect downstream oxygen sensor connector E-043.

b. Turn ignition switch to ON, start the engine and idle it for
about 3 minutes.
c. Using diagnostic tester, measure downstream oxygen
sensor signal voltage, or using multimeter, measure Datastream
voltage between terminals 2 and 1 of connector E-043. Datastream name Value Unit
ISO15031_PID03a Close loop,u

sing oxygen
sensor(s) as
feedback for
Condition fuel control
E-043 (2) - E-043 Fluctuates slightly
relative air mass (calc.load value) acc. To SAE J1979 23.83 %
Engine running Air mass flow 8 kg/h
(1) at about 0.45 V output voltage oxygen sensor downstream catalyst 0.46 V
relative air charge 17.25 %
OK Go to step 7
RT21060140
NG

4 Check downstream oxygen sensor signal circuit

c. Disconnect downstream oxygen sensor connector E-043.
1 2 3 4
d. Check wire harness between downstream oxygen sensor
+ -
connector terminals and ECM connector terminals. E-043
Check for Open
Condition
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
E-043 (2) - E-033
Always Continuity 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
(21) 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Check for Short

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
06
Condition
RT21065029
E-043 (2) or
E-033 (21) - Body
ground
E-043 (2) or
E-033 (21) -
Battery positive

(downstream oxygen sensor - ECM)
OK
5 Check downstream oxygen sensor ground circuit
a. Check wire harness between downstream oxygen sensor

Check for Open
1 2 3 4
Condition E-043
E-043 (1) - E-033
Always Continuity
(43)
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065030

Check for Short
Condition
E-043 (1) or
E-033 (43) - Body
ground
E-043 (1) or
E-033 (43) -
Battery positive

ECM)
06
OK
6 Check downstream oxygen sensor
a. Remove downstream oxygen sensor.

b. Check downstream oxygen sensor for following problems.
 Moisture enters the internal of sensor, temperature changes greatly, and probe is broken.
 Oxygen sensor is "poisoned" (Pb, S, Br, Si, etc.).
OK
7 Check for DTCs

c. Check if DTC P0136-00, P0137-00, P0138-00, P0140-00, P2270-00 or P2271-00 still exists.
NG Replace ECM
OK

been repaired.

DTC P0201-00 Cylinder 1 - Injector Circuit
IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
10A 10A RELAY BOX
E-069 06
EF40 EF08 E-076
10A E-023
15A
A4 A2 F14 A6 C3
RL
R
1
INJECTOR 1
E-010
2
RL
Br
R
L
GW
E-007
15 E-038
GW
2-35 2-20 2-5 2-15 2-16 1-4

ECM-1
E-035
ECM-2
E-033
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 A1 A2 A3 A4 A5 C1 C2 C3 C4 C5

42 38 34 30 25 20 15 10 5
1 2 41 37 33 29 24 19 14 9 4
E-007
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 A6 A7 A8 A9 A10 C6 C7 C8 C9 C10 28 23 18 13 8 3
40 36 32 B
27 22 17 12 7 2
E-069 E-010
E-076 E-023 39 35 31 26 21 16 11 6 1
W B
Gr L
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
E-033
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
B
ET21065007

DTC Detection
Conditions
 Injector of cylinder 1
Cylinder 1 - Injector
P0201-00 Engine running  Wire harness or connector
Circuit
 ECM

06  Select Read Code.
procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK
2 Check injector connector of cylinder 1
a. Disconnect injector connector E-010 of cylinder 1.

b. Check injector connector.
RT21060150

OK
3 Check injector power supply voltage of cylinder 1

c. Check voltage between injector connector terminal of
cylinder 1 and body ground. V
+ -
Condition
E-010 (1) - Body
Ignition switch ON 11 to 14 V 1 2
ground
E-010 06
OK Go to step 5
RT21065031
NG
4 Check injector power supply circuit of cylinder 1

connector E-023.
+ -
d. Check wire harness between injector connector terminals
and engine compartment fuse and relay box connector
terminals.
1 2
Check for Open
E-010
Condition
E-010 (1) - E-023
Always Continuity C1 C2 C3 C4 C5
(C3)
C6 C7 C8 C9 C10
E-023
RT21065032

Check for Short
Condition
E-010 (1) or
E-023 (C3) - Body
ground
E-010 (1) or
E-023 (C3) -
Battery positive

connector (injector of cylinder 1 - engine
compartment fuse and relay box)
06
OK
5 Check injector control circuit of cylinder 1

b. Check wire harness between injector connector terminals
and ECM connector terminals.
Check for Open 1 2
+ -
Multimeter Specified E-010

Condition
E-010 (2) - E-035
Always Continuity
(4)
37 38 39 40 41 42 43 44 45 46 47 48
Check for Short 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
Multimeter Specified 1 2 3 4 5 6 7 8 9 10 11 12
Condition
E-010 (2) or
E-035 (4) - Body E-035
ground RT21065033
E-010 (2) or E-
035 (4) - Battery
positive

connector (injector of cylinder 1 - ECM)
OK

6 Check injector of cylinder 1
a. Check resistance of injector of cylinder 1.
Specified + -
Multimeter Connection 1 2
Condition
1-2 12 Ω (at 20°C)
NG Replace injector of cylinder 1
RT21080290
OK
06
7 Check for DTCs

c. Check if DTC P0201-00 still exists.
NG Replace ECM
OK

been repaired.

DTC P0271-00 Cylinder 4 - Injector Circuit High
IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
06 10A 10A RELAY BOX

E-069
EF40 EF08 E-076
10A E-023
15A
A4 A2 F14 A6 C3
RL
R
1
INJECTOR 4
E-013
2
RL
Br
R
L
GBr
E-007
12 E-038
GBr
2-35 2-20 2-5 2-15 2-16 1-10

ECM-1
E-035
ECM-2
E-033

42 38 34 30 25 20 15 10 5
1 2 41 37 33 29 24 19 14 9 4
E-007
40 36 32 B
27 22 17 12 7 2
E-069 E-013
E-076 E-023 39 35 31 26 21 16 11 6 1
W B
Gr L
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
E-033
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
B
ET21065008

DTC Detection
Conditions
 Injector of cylinder 4
Cylinder 4 - Injector
P0271-00 Engine running  Wire harness or connector
Circuit High
 ECM

 Select Read Code. 06
procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK
2 Check injector connector of cylinder 4

b. Check injector connector.
RT21060160

OK
3 Check injector power supply voltage of cylinder 4

c. Check voltage between injector connector terminal of
cylinder 4 and body ground. V
+ -
Condition
E-013 (1) - Body
Ignition switch ON 11 to 14 V 1 2
ground
06 E-013
OK Go to step 5
RT21065034
NG
4 Check injector power supply circuit of cylinder 4

connector E-023.
+ -
d. Check wire harness between injector connector terminals
and engine compartment fuse and relay box connector
terminals.
1 2
Check for Open
E-013
Condition
E-013 (1) - E-023
Always Continuity C1 C2 C3 C4 C5
(C3)
C6 C7 C8 C9 C10
E-023
RT21065035

Check for Short
Condition
E-013 (1) or
E-023 (C3) - Body
ground
E-013 (1) or
E-023 (C3) -
Battery positive

connector (injector of cylinder 4 - engine
06
OK
5 Check injector control circuit of cylinder 4

b. Check wire harness between injector connector terminals
and ECM connector terminals.
Check for Open 1 2
+ -

Condition
E-013 (2) - E-035
Always Continuity
(10)
37 38 39 40 41 42 43 44 45 46 47 48
Check for Short 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
Multimeter Specified 1 2 3 4 5 6 7 8 9 10 11 12
Condition
E-013 (2) or
E-035 (10) - Body E-035
ground RT21065036
E-013 (2) or
E-035 (10) -
Battery positive

connector (injector of cylinder 4 - ECM)
OK

6 Check injector of cylinder 4
a. Check resistance of injector of cylinder 4.
Specified + -
Condition
1-2 20 Ω (at 20°C)
NG Replace injector of cylinder 4
RT21080290
OK
06
7 Check for DTCs

NG Replace ECM
OK

been repaired.

DTC P1106-00 Throttle Pos. Contr. Malfunction
DTC P1110-00 Throttle Actuator Electrical Malfunction (MT only)
Idle Speed Control Throttle Position Mechanical

DTC P1111-00
Malfunction
DTC P1568-00 DV-E Cause of Failure: Spring Check
DTC P0606-00 ECM/PCM Processor
06

ELECTRONIC
THROTTLE
M
E-009
1 4 2 5 3 6
06
WL
RG
RB
RL
RL
L
E-007
3 6 4 7 5 8
E-038
WL
RG
RB
RL
RL
R
1-23 1-11 1-22 1-14 1-43 1-13
ECM-1
E-035
42 38 34 30 25 20 15 10 5
1 2 3
37 38 39 40 41 42 43 44 45 46 47 48 41 37 33 29 24 19 14 9 4
4 5 6
28 23 18 13 8 3
25 26 27 28 29 30 31 32 33 34 35 36 40 36 32
27 22 17 12 7 2
39 35 31 26 21 16 11 6 1 E-009
13 14 15 16 17 18 19 20 21 22 23 24
B
1 2 3 4 5 6 7 8 9 10 11 12
E-007
B
E-035
B
ET21065006

DTC Detection
Conditions
Throttle Pos. Contr.
P1106-00
Malfunction
Throttle Actuator
P1110-00 Electrical Malfunction
(MT only)
 Electronic throttle
Idle Speed Control
Ignition switch ON  Wire harness or connector
Throttle Position
P1111-00  ECM
Mechanical
Malfunction
DV-E Cause of Failure:
P1568-00
Spring Check
P0606-00 ECM/PCM Processor 06

 If the DTC is detected, the malfunction indicated by the DTC is current. Go to the diagnosis
procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK
2 Check electronic throttle connector

a. Disconnect electronic throttle connector E-009.

b. Check electronic throttle connector.
RT21060110
OK
3 Check throttle position sensor signal voltage

06
a. Connect electronic throttle connector E-009.
c. Using diagnostic tester, check throttle position sensor
signal voltage.
Datastream
Standard Value
Item Condition Datastream name Value Unit
(V) lambda controller output 1.00
Accelerator pedal sensor voltage from throttle potentiometer 1
0.78
0.78 V
Throttle position released sensor voltage from throttle potentiometer 2 4.22 V
additive correction of the mixture adaptation 0.00 %
sensor 1 Accelerator pedal Voltage PWG potentiometer 1 0.77 V
4.29
depressed Voltage PWG potentiometer 2 0.38 V
Doubled PWG potentiometer-2 voltage 0.75 V
Accelerator pedal
4.22
Throttle position released
sensor 2 Accelerator pedal RT21060180
0.71
depressed
OK Go to step 7
NG

4 Check electronic throttle actuator circuit

b. Disconnect electronic throttle connector E-009.
1 2 3
c. Disconnect ECM connector E-035. 4 5 6
d. Check wire harness between connector terminals.
+ -
E-009
Check for Open
Condition
E-035 (23) -
E-009 (1) 25 26 27 28 29 30 31 32 33 34 35 36
E-035 (11) - 13 14 15 16 17 18 19 20 21 22 23 24
E-009 (4)
Always Continuity 1 2 3 4 5 6 7 8 9 10 11 12 06
Check for Short

Condition RT21065037
E-035 (23) or
ground
E-035 (23) or
Battery positive
E-035 (11) or
ground
E-035 (11) or
Battery positive
NG Repair or replace related wire harness
OK

5 Check throttle position sensor circuit

Check for Open
1 2 3
Multimeter Specified 4 5 6
Condition
E-009
E-035 (22) -
Always Continuity
E-009 (2)
E-035 (14) -
Always Continuity
E-009 (5)
37 38 39 40 41 42 43 44 45 46 47 48
E-035 (43) - 25 26 27 28 29 30 31 32 33 34 35 36
Always Continuity
E-009 (3) 13 14 15 16 17 18 19 20 21 22 23 24
06 E-035 (13) -
1 2 3 4 5 6 7 8 9 10 11 12
Always Continuity
E-009 (6)

RT21065038
Condition
E-035
(22, 14, 43, 13) or
E-009 (2, 5, 3, 6) -
Body ground
E-035
(22, 14, 43, 13) or
E-009 (2, 5, 3, 6) -
Battery positive

(electronic throttle - ECM)
OK

6 Check electronic throttle
a. Check electronic throttle for carbon deposits and foreign

matter accumulation inside.
+ -
b. Check if throttle valve body is stuck. 3 2 1
c. Check resistance of electronic throttle. 6 5 4
Condition
Terminal 3 - At normal
1.067 kΩ
RT21100211
Resistance
opens
06
Resistance
Throttle valve is opens
rotated Resistance
opens
Resistance
opens
NG Clean or replace electronic throttle

assembly, and go to next step
OK
7 Check for DTCs

c. Check if DTC P1106-00, P1110-00, P1111-00, P1568-00 or P0606-00 still exists.
NG Replace ECM
OK

been repaired.

DTC P0300-00 Random/Multiple Cylinder Misfire Detected
DTC P0301-00 Cyl.1 Misfire Detected
06

IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
10A 10A RELAY BOX
E-069
EF40 EF07 E-076
10A 15A E-023
06
A4 A2 F14 A6 C4
R
R
CYL1 CYL4 CYL3 CYL2

3
IGNITION
COIL
E-018
RL
1 2
Br
R
L
GGr
GBr
E-007
32 33 E-038
GGr
GBr
2-35 2-20 2-5 2-15 2-16 1-36 1-35

ECM-1
E-035
ECM-2
E-033

42 38 34 30 25 20 15 10 5
1 2 3 4 41 37 33 29 24 19 14 9 4
E-007
40 36 32 B
27 22 17 12 7 2
E-069 E-076 E-023 E-018 39 35 31 26 21 16 11 6 1
W Gr L B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
E-033
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
B
ET21065009

DTC Detection
Conditions
Random/Multiple
P0300-00 Cylinder Misfire
Detected  Ignition coil
P0301-00 Cyl.1 Misfire Detected  Spark plug
Engine running
P0302-00 Cyl.2 Misfire Detected  Wire harness or connector
 ECM

06  Turn ignition switch to LOCK.
procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check ignition coil connector

b. Disconnect ignition coil connector E-018.
c. Check ignition coil connector.
RT21060190
OK
06
3 Check spark plug of misfiring cylinder
a. Remove the spark plug of misfiring cylinder.

b. Check spark plug for burns, cracks or deposits.
c. Check spark plug gap.
OK: 0.8 - 0.9 mm
NG Clean or replace spark plug
RT21140100
OK
4 Check spark
a. Connect ignition coil connector.

b. Connect spark plug and ignition coil, and ground spark plug housing.
c. Start and run the engine for no more than 2 seconds, and check if spark is generated.
NG Go to step 6
OK

5 Check compression of misfiring cylinder
a. Measure the compression of misfiring cylinder (See page 07-20).
NG Check engine to confirm cause of low

compression
OK
Check injectors, valve clearance, intake system and fuel pressure, etc. of misfiring cylinder
6 Check spark of misfiring cylinder with a normally functioning spark plug

06
a. Replace the spark plug with a normally functioning one.
b. Perform spark test.
 Connect ignition coil connector.
 Connect spark plug and ignition coil, and ground spark plug housing.
 Start and run the engine for no more than 2 seconds, and check if spark is generated.
OK Replace spark plug
NG
7 Check ignition coil
a. Check resistance of primary winding of ignition coil.
Multimeter + -
1 2 3 4
Condition Specification (Ω)
Connection
Terminal 1 - Normal
0.50 - 0.64
Terminal 2 - Normal
0.50 - 0.64
RT21140070
b. Check resistance of secondary winding of ignition coil.
Multimeter Specification
Condition
Connection (kΩ)
2 4
Normal
Post 1 - Post 4 9.5 - 12.1
temperature
3 1
Normal
Post 2 - Post 3 9.5 - 12.1
temperature
RT21140080
NG Replace ignition coil

OK
8 Check ignition coil power supply voltage

b. Check voltage between ignition coil connector terminals
and body ground.
V
Condition
E-018 (3) - Body
ground 1 2 3 4
OK Go to step 10 E-018 06
RT21065039
NG
9 Check ignition coil power supply circuit

c. Check wire harness between ignition coil connector
terminals and engine compartment fuse and relay box
connector terminals. + -
Check for Open

1 2 3 4
Condition E-018
E-018 (3) - E-023
Always Continuity
(C4)
C1 C2 C3 C4 C5
Check for Short C6 C7 C8 C9 C10

Condition
RT21065040
E-018 (3) or
E-023 (C4) - Body Always No continuity
ground
E-018 (3) or
E-023 (C4) - Always No continuity
Battery positive


(ignition coil - engine compartment fuse
and relay box)
OK
10 Check ignition coil control circuit

c. Check wire harness between ignition coil connector
terminals and ECM connector terminals. 1 2 3 4
+ -
Check for Open
06 E-018
Condition
E-018 (1) - E-035
37 38 39 40 41 42 43 44 45 46 47 48
(36)
E-018 (2) - E-035 13 14 15 16 17 18 19 20 21 22 23 24
(35) 1 2 3 4 5 6 7 8 9 10 11 12
Check for Short

E-018 (1) or
ground
E-018 (1) or
Battery positive
E-018 (2) or
ground
E-018 (2) or
Battery positive

connector (ignition coil - ECM)
OK
11 Check for DTCs

c. Check if DTC P0300-00, P0301-00, P0302-00, P0303-00 or P0304-00 still exists.

NG Replace ECM
OK

been repaired.
06

DTC P0322-00 Ign./Distributor Eng. Speed Inp. Circ. No Signal
ECM-1
E-035
ECM-2
E-033
1-32 1-33 2-63 2-64 1-47 1-48
06
GW
WR
Br
Br
B
29 28 E-038 B
E-007
GW
WR
Br
B
1 2
E-026 E-028
ENGINE
S
SPEED
SENSOR
N E-016
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
B
E-033
B
42 38 34 30 25 20 15 10 5
41 37 33 29 24 19 14 9 4
E-007
28 23 18 13 8 3
E-016 40 36 32 B
27 22 17 12 7 2
1 2 3 B 39 35 31 26 21 16 11 6 1
ET21065010

DTC Detection
Conditions
 Engine speed sensor
Ign./Distributor Eng.  Flywheel gear ring
P0322-00 Speed Inp. Circ. No Engine running
Signal  Wire harness or connector
 ECM

procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check engine speed sensor signal waveform
a. Turn ignition switch to ON, start the engine and observe the signal waveform of engine speed sensor with
an oscilloscope.
Normal Waveform of Engine Speed Senor Signal
Oscilloscope
06 RT21060200
OK Go to step 9
NG
3 Check engine speed sensor connector

b. Disconnect engine speed sensor connector E-016.
c. Check engine speed sensor connector.
NG Repair or replace engine speed sensor

connector
OK
4 Check installation of engine speed sensor
a. Remove engine speed sensor.

b. Check and clean engine speed sensor and installation area, and check for damage, foreign matter or
excessive movement, etc. that cause signal incorrectness.
NG Clean or replace engine speed sensor
OK

5 Check resistance of engine speed sensor
a. Check resistance between engine speed sensor

terminals 1 and 2.
+ -
Normal resistance: 860 Ω ± 20% (at normal temperature) 3 2 1
NG Replace engine speed sensor
RT21060210
OK
06
6 Check engine speed sensor circuit

b. Check wire harness between engine speed sensor
+ -
Condition E-016
E-016 (1) - E-035
(32)
E-016 (2) - E-035 25 26 27 28 29 30 31 32 33 34 35 36
(33) 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12
Check for Short
Condition
RT21065042
E-016 (1) or
E-035 (32) - Body
ground
E-016 (1) or
E-035 (32) -
Battery positive
E-016 (2) or
E-035 (33) - Body
ground
E-016 (2) or
E-035 (33) -
Battery positive


(engine speed sensor - ECM)
OK
7 Install a normal engine speed sensor and observe signal waveform
a. Install a normal engine speed sensor.

b. Connect engine speed sensor connector.
c. Turn ignition switch to ON, start the engine and observe the signal waveform of the engine speed sensor
with an oscilloscope.
OK Replace engine speed sensor

06
NG
8 Check flywheel gear ring
a. Turn crankshaft, and check crankshaft and flywheel gear ring for damage and foreign matter, etc. that
cause signal incorrectness.
NG Clear off debris and clean flywheel gear

ring. Replace flywheel if necessary 
(See page 07-42)
OK
9 Check for DTCs

NG Replace ECM
OK

been repaired.

DTC P0327-00 Knock Sensor 1 Circ. Low Input
DTC P0328-00 Knock Sensor 1 Circ. High Input
06

KNOCK
SENSOR
E-005
1 2
WY
GY
E-007
1 2
E-038
WY
06 GY
1-26 1-25
ECM-1
E-035
ECM-2
E-033
2-63 2-64 1-47 1-48
Br
Br
B
Br
B
E-026 E-028
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
B
E-033
B
42 38 34 30 25 20 15 10 5
41 37 33 29 24 19 14 9 4
E-007
1 2 3 28 23 18 13 8 3
40 36 32 B
27 22 17 12 7 2
E-005 39 35 31 26 21 16 11 6 1
B
ET21065011

DTC Detection
Conditions
Knock Sensor 1 Circ.
P0327-00  Knock sensor
Low Input
Engine running  Wire harness or connector
Knock Sensor 1 Circ.
P0328-00  ECM
High Input

procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK
2 Check knock sensor connector
a. Disconnect knock sensor connector E-005.

b. Check knock sensor connector.
RT21060330

OK
3 Check installation of knock sensor
a. Remove knock sensor.

b. Check installation area of knock sensor, and check for damage, foreign matter and excessive movement,
etc. that cause signal incorrectness.
NG Clean installation area or replace knock

sensor
OK
06
4 Check resistance of knock sensor
a. Check resistance between knock sensor terminals 1 and 2.

OK: 4.9 ± 20% MΩ (at normal temperature)
NG Replace knock sensor
OK
5 Check knock sensor signal circuit
a. Disconnect ECM wire harness connector E-035.

b. Check wire harness between terminals of connector E-035
and connector E-005.
+ -
Specified E-005
Condition
E-035 (26) - E-005 (1) Continuity
E-035 (25) - E-005 (2) Continuity 37 38 39 40 41 42 43 44 45 46 47 48
25 26 27 28 29 30 31 32 33 34 35 36
Check for Short
13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12
Specified
Condition
E-035 (26) or E-005 (1) - Body ground No continuity
E-035
E-035 (26) or E-005 (1) - Battery RT21065043
No continuity
positive
E-035 (25) or E-005 (2) - Battery
No continuity
positive
NG Replace wire harness or connector (knock

sensor - ECM)

OK
6 Check knock sensor signal
a. Install knock sensor.

b. Slightly strike around the knock sensor with a rubber hammer, and measure if voltage is generated
between the 2 terminals of knock sensor with multimeter at the same time.
NG Replace knock sensor
OK
7 Check for DTCs 06

NG Replace ECM
OK

been repaired.

DTC P0341-00 Camshaft Pos. Sensor Circ. Range/Performance
DTC P0346-00 Camshaft Pos. Sensor Circ. Range/Performance (Bank2)
ECM-1
E-035
ECM-2
E-033
1-34 1-29 1-31 1-41 2-63 2-64 1-47 1-48
06
WR
LR
Br
Br
Br
B
B
E-038
24 25 27 26
E-007
Br
B
WR
LR
LR
Br
Br
W
3 2 1 3 2 1
E-026 E-028
CAMSHAFT CAMSHAFT
POSITION POSITION
SENSOR SENSOR
(INTAKE) (EXHAUST)
E-020 E-015
42 38 34 30 25 20 15 10 5
3 2 1 3 2 1
41 37 33 29 24 19 14 9 4
E-007
28 23 18 13 8 3
E-020 E-015 40 36 32 B
27 22 17 12 7 2
B B
39 35 31 26 21 16 11 6 1
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
E-035
E-033 B
ET21065012
B

DTC Detection
Conditions
Camshaft Pos. Sensor  Camshaft position sensor (intake)
 Camshaft position sensor (exhaust)
Performance
Engine running  Camshaft
Camshaft Pos. Sensor
Performance (Bank2)  ECM

06
procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check camshaft position sensor signal waveform
a. Turn ignition switch to ON, start the engine and observe the signal waveform of camshaft position sensor
Normal Waveform
Oscilloscope
2.00 V 10.0 ms
06 RT21060230
OK Go to step 10
NG
3 Check camshaft position sensor connector

b. Disconnect camshaft position sensor connectors E-020 and E-015.
c. Check camshaft position sensor connector.
NG Repair or replace camshaft position

sensor connector
OK

4 Check camshaft position sensor power supply voltage

b. Check voltage between terminal 3 of camshaft position
sensor connector E-020 or E-015 and body ground.
V
Condition
E-020 (3) or
E-015 (3) - Body Ignition switch ON 5V 3 2 1
ground E-015
E-020
OK Go to step 6
06
RT21065044
NG
5 Check camshaft position sensor power supply circuit

c. Check wire harness between camshaft position sensor
connector terminals and ECM connector terminals. 3 2 1
+ -
E-020
Condition
E-020 (3) - E-035
(34)
25 26 27 28 29 30 31 32 33 34 35 36
E-015 (3) - E-035 13 14 15 16 17 18 19 20 21 22 23 24
Always Continuity
(34) 1 2 3 4 5 6 7 8 9 10 11 12
Check for Short

E-020 (3), E-015
(3) or E-035 (34) - Always No continuity
Body ground
E-020 (3), E-015
Battery positive

connector (camshaft position sensor -
ECM)

OK
Replace ECM
6 Check camshaft position sensor signal circuit and ground circuit
a. Check wire harness between camshaft position sensor

Check for Open
3 2 1
Condition E-015
E-020
06 E-020 (2) - E-035
(29)
E-015 (2) - E-035
(41)
25 26 27 28 29 30 31 32 33 34 35 36
E-020 (1), E-015 13 14 15 16 17 18 19 20 21 22 23 24
(1) - E-035 (31) 1 2 3 4 5 6 7 8 9 10 11 12
Check for Short

E-020 (2) or
E-035 (29) - Body
ground
E-020 (2) or
E-035 (29) -
Battery positive
E-015 (2) or
E-035 (41) - Body
ground
E-015 (2) or
E-035 (41) -
Battery positive
E-020 (1), E-015
(1) or E-035 (31) -
Body ground
E-020 (1), E-015
(1) or E-035 (31) -
Battery positive

(camshaft position sensor - ECM)
OK

7 Check installation of camshaft position sensor
a. Remove camshaft position sensor.

b. Check and clean camshaft position sensor and installation area, and check for damage, foreign matter and
NG Clean installation area or replace

camshaft position sensor
OK
8 Check camshaft gear ring
a. Check camshaft gear ring for damage and foreign matter (such as debris), etc. that cause signal
06
incorrectness.
NG Clear off debris and clean camshaft gear

ring or replace camshaft
OK
9 Install a normal camshaft position sensor and observe signal waveform
a. Install a normal camshaft position sensor.

b. Connect camshaft position sensor connector.
c. Turn ignition switch to ON, start the engine and observe the signal waveform of camshaft position sensor
OK Replace camshaft position sensor
NG
10 Check for DTCs

NG Replace ECM
OK

been repaired.

DTC P0420-00 Catalyst System, Bank1 Efficiency Below Threshold
DTC Detection
Conditions
 Three-way catalytic converter
Catalyst System,  Leakage in exhaust system
P0420-00 Bank1 Efficiency Engine running  Upstream oxygen sensor
Below Threshold  Downstream oxygen sensor
 ECM

06  Turn ignition switch to LOCK.
procedure - Step 1.
Diagnosis Procedure
1 Check for any other DTCs output (in addition to DTC P0420-00)
a. Connect X-431 3G diagnostic tester to Data Link Connector (DLC).

b. Turn ignition switch to ON. Start the engine and warm it up to normal operating temperature, and then
select Read Code.
Display (DTC Output) Proceed to

DTC P0420-00 A
DTC P0420-00 and other DTCs B
B Go to DTC chart, and perform

troubleshooting for other DTCs first

2 Read datastream
a. Read datastream using diagnostic tester.

b. Check datastream below.
Item OK (Idling) If it is NG, proceed to

Quickly fluctuates between 0.1 to
Upstream Oxygen Sensor Voltage A
0.9 V
Downstream Oxygen Sensor
Fluctuates slightly at about 0.45 V B
Voltage
Average Injection Pulse Width 1.5 - 2.9 ms C
A Replace upstream oxygen sensor

06
C Check injector, fuel pressure and other
causes for abnormal injection pulse width
3 Check exhaust system
a. Turn ignition switch to ON and start the engine.

b. Check exhaust system for leakage.
NG Repair or replace related exhaust system

components
OK
4 Check downstream oxygen sensor
OK
Replace three-way catalytic converter, and go to step 5

5 Check for DTCs

NG Replace ECM
OK

06 been repaired.

Evaporative Emiss. System Purge Control Valve Circ.

DTC P0444-00
Open
Evaporative Emission System Purge Control Valve

DTC P0458-00
Circuit Low
Evaporative Emission System Purge Control Valve

DTC P0459-00
Circuit High
06

IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
10A 10A RELAY BOX
E-069
EF40 EF27 E-076
10A E-023
10A
06
A4 A2 F14 A6 C9
RL
R
1
CANISTER
SOLENOID
VALVE
E-024
2
RL
Br
E-026
R
R
L
B
L
E-007
11 E-038
E-028
Br
Br
L
2-35 2-20 2-5 2-15 2-16 1-30 1-48 1-47 2-64 2-63
ECM-1
E-035
ECM-2
E-033

42 38 34 30 25 20 15 10 5
1 2 41 37 33 29 24 19 14 9 4
E-007
40 36 32 B
E-024 27 22 17 12 7 2
E-069 E-076 E-023 B 39 35 31 26 21 16 11 6 1
W Gr L
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
E-033
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
B
ET21065013

DTC Detection
Condition
Evaporative Emiss.
P0444-00 System Purge Control
Valve Circ. Open
Evaporative Emission  Canister solenoid valve
P0458-00 System Purge Control Engine running  Wire harness or connector
Valve Circuit Low  ECM
Evaporative Emission
P0459-00 System Purge Control
Valve Circuit High

Confirm that battery voltage is over 12 V before performing the following procedures. 06
 If the DTC is detected, the malfunction indicated by the DTC is current. Go to the diagnosis procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check canister solenoid valve connector
a. Disconnect canister solenoid valve connector E-024.

b. Check canister solenoid valve connector.
RT21060240
OK
06
3 Check canister solenoid valve power supply voltage

b. Measure voltage between canister solenoid valve
connector terminal and body ground.
V
Condition
E-024 (1) - Body
ground
1 2
E-024
OK Go to step 5
RT21065047
NG

4 Check canister solenoid valve power supply circuit

connector E-023.
+ -
d. Check wire harness between canister solenoid valve
relay box connector terminals. 1 2
Condition
C1 C2 C3 C4 C5
E-024 (1) -
E-023 (C9)
Always Continuity C6 C7 C8 C9 C10 06
E-023
Check for Short

Condition
E-024 (1) or
Body ground
E-024 (1) or
Battery positive

connector (canister solenoid valve -
OK

5 Check canister solenoid valve control circuit

b. Check wire harness between canister solenoid valve
1 2
Check for Open
+ -
E-024
Condition
E-024 (2) - E-035
Always Continuity
(30)
37 38 39 40 41 42 43 44 45 46 47 48
Check for Short 25 26 27 28 29 30 31 32 33 34 35 36

13 14 15 16 17 18 19 20 21 22 23 24
06 Multimeter
Condition
Specified 1 2 3 4 5 6 7 8 9 10 11 12
E-024 (2) or
E-035 (30) - E-035
Body ground RT21065049
E-024 (2) or
E-035 (30) -
Battery positive

connector (canister solenoid valve - ECM)
OK
6 Check canister solenoid valve
a. Check resistance of canister solenoid valve.
Multimeter + -
2 1
Specified Condition
Connection
1-2 26 ± 4 Ω (20°C)
b. With battery voltage applied between terminals 1 and 2,

the valve should open when air is sucked into the valve.
With battery voltage not applied, the valve should close
when air is sucked into the valve.
RT21090050
NG Replace canister solenoid valve
OK
7 Check for DTCs


NG Replace ECM
OK

been repaired.
06

DTC P0480-00 Cooling Fan 1 Control Circuit
DTC P0481-00 Cooling Fan 2 Control Circuit
DTC P0691-00 Cooling Fan 1 Control Circuit Low
06

BATTERY
IGNITION SWITCH
ON OR START
85 87
ECM
MAIN 86 87 ENGINE
RELAY FAN COMPARTMENT
EF17 EF19 86 30 RELAY FUSE AND
10A 10A RELAY BOX
85 30 E-069
EF40 EF38 E-076
MF02 E-059
10A 7.5A
60A
06
A4 A2 F14 A6 A8 F21 F22 2
RL
RL
R
R
B
1 VOTAGE 3
REGULATOR
B
INPUT
MICROPR
E-078 OCESSOR
OUTPUT E-051
M
BY
RL
Br
R
L
FAN CONTROLLER
E-046
E-028 E-026
Br
Br
2-35 2-20 2-5 2-15 2-16 1-48 1-47 2-56 2-64 B 2-63
ECM-1
E-035
ECM-2
E-033
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 2

A1 A2 A3 A4 A5
1 2 3
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 A6 A7 A8 A9 A10
E-069 E-046
E-076 E-059
W Gr
Gr
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
E-033
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
B
ET21065014

DTC Detection
Condition
Cooling Fan 1 Control
P0480-00  Cooling fan relay
Circuit
 Cooling fan controller
P0481-00 Ignition switch ON  Fuse
Circuit
P0691-00  ECM
Circuit Low

06  Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC).
CAUTION
Diagnosis Procedure


ground point
OK

2 Check cooling fan controller connector
a. Disconnect cooling fan controller connector E-046.

b. Check cooling fan controller connector.
OK
3 Check cooling fan fuse and relay
a. Unplug cooling fan fuse and relay from engine

compartment fuse and relay box.
+ - 06
b. Check if fuse is normal.
87 86
c. Check cooling fan relay.
Multimeter
Specified Condition
Connection
30 85
30 - 87 No continuity
Continuity
30 - 87 (when battery voltage is applied 87
86
85
NG Replace fuse or relay
30 RT21060250
OK

4 Check cooling fan relay circuit voltage
a. Check terminal voltage of cooling fan relay (engine

compartment fuse and relay box side).
Condition V
Terminal 87 -
Always 11 to 14 V
Body ground
Terminal 86 -
Body ground
Terminal 85 -
Always 0V
Body ground
06
87
85 86
30
NG Check engine compartment fuse and relay

box, repair or replace wire harness or
connector (fan relay - battery)
RT21060260
OK
5 Check wire harness and connector
a. Disconnect fuse and relay box connector E-059.

c. Check wire harness between fan controller connector
and ECM connector, engine compartment fuse and relay 1 2 3
box connector and body ground. + -
E-046
Check for Open
Specified
Condition
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
E-033 (56) - E-046 (2) Continuity 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Check for Short
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Specified
Condition
E-033 (56) or E-046 (2) - Body ground No continuity E-033
RT21065050
E-033 (56) or E-046 (2) -
No continuity
Battery positive

Check for Open
Specified
Condition
E-059 (2) - E-046 (1) Continuity + -
E-046 (3) - Body ground Continuity 2
Check for Short

E-059
Specified
Condition
E-059 (2) or E-046 (1) - 1 2 3
No continuity
Battery positive
06
E-046
NG Repair or replace wire harness or RT21065051
connector
OK
Replace cooling fan controller, and go to step 6
6 Check for DTCs

NG Replace ECM
OK

been repaired.

DTC P0560-00 System Voltage Malfunction
DTC P0562-00 System Voltage Low Voltage
DTC P0563-00 System Voltage High Voltage
06

IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
10A 10A RELAY BOX
E-069
EF40 E-076
10A
06
A4 A2 F14 A6
R
E-026
B
RL
Br
R
L
E-028
Br
Br
2-35 2-20 2-5 2-15 2-16 1-48 1-47 2-64 2-63

ECM-1
E-035
ECM-2
E-033
37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
25 26 27 28 29 30 31 32 33 34 35 36
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
B
E-033
B
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1

A1 A2 A3 A4 A5
E-076 F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
A6 A7 A8 A9 A10
Gr
E-069
W ET21065015

DTC Detection
Condition
System Voltage
P0560-00  Fuse
Malfunction
System Voltage Low
P0562-00 Ignition switch ON  Battery
Voltage
 Battery terminal
System Voltage High
P0563-00  ECM
Voltage

CAUTION
Diagnosis Procedure
1 Check battery
a. Check if battery voltage is normal.
NG Recharge or replace battery
OK
2 Check battery terminals
a. Check if battery terminals are loose or corroded.
NG Tighten or replace battery terminals
OK



ground point
OK
4 Check ECM connector
a. Disconnect ECM connector E-033 and E-035.

b. Check ECM connector.
06
NG Repair or replace ECM connector
OK
5 Check ECM power supply voltage (battery voltage)
a. Measure voltage between ECM connector E-033 terminal

and body ground.
Condition V
E-033 (20) -
Always 11 to 14 V
Body ground
OK Go to step 8
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065052
NG

6 Check ECM fuse
a. Unplug ECM fuse EF19 (10 A) from engine compartment fuse and relay box.
b. Check resistance of fuse EF19.
NG Replace ECM fuse
OK

06 connector E-076.
b. Check wire harness between connector terminals. A1 A2 A3 A4 A5
Check for Open A6 A7 A8 A9 A10

+ -
Specified E-076
Condition
E-033 (20) - E-076 (A2) Continuity
Check for Short 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Specified 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Condition 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033 (20) or E-076 (A2) -

No continuity
Body ground
E-033
E-033 (20) or E-076 (A2) -
No continuity RT21065053
Battery positive

connector
OK

8 Check ECM power supply voltage (ignition switch voltage)
a. Connect engine compartment fuse and relay box

connector E-076.
c. Check voltage between terminals of ECM connector  V
+ -
E-033.
Condition
E-033 (35) -
E-033 (63) or Ignition switch ON 11 to 14 V 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
E-033 (64) 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
OK Go to step 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
06
E-033
RT21065054
NG
9 Check ECM fuse
a. Unplug fuse EF17 (10 A) from engine compartment fuse and relay box.
b. Check resistance of fuse EF17.
NG Replace fuse
OK


connector E-076.
b. Check wire harness between ECM connector terminals A1 A2 A3 A4 A5
and engine compartment fuse and relay box connector A6 A7 A8 A9 A10
terminals. + -
Specified
Condition
E-033 (35) - E-076 (A4) Continuity 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Check for Short 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Specified
Condition
06 E-033 (35) or E-076 (A4) -
No continuity E-033
Body ground RT21065055
E-033 (35) or E-076 (A4) -

No continuity
Battery positive

connector
OK
11 Check ignition switch assembly (See page 15-67)
NG Replace ignition switch assembly
OK
and relay box - ignition switch)
12 Check for DTCs

NG Replace ECM
OK

been repaired.

DTC P0627-00 Fuel Pump "A" Control Circuit/Open
DTC P0628-00 Fuel Pump "A" Control Circuit Low
DTC P0629-00 Fuel Pump "A" Control Circuit High
06

BATTERY
IGNITION SWITCH
ON OR START
85 87
ECM
MAIN 1 5 ENGINE
FUEL
RELAY COMPARTMENT
PUMP
RELAY
10A 10A RELAY BOX
2 3 E-069
EF40 EF38 E-076
EF35 E-073
10A 7.5A
15A
06
A4 A2 F14 A6 A8 F6 F7 B6
R
RL
RL
R
E-070
13 B-048
R
FUEL PUMP MOTOR

RL
Br
E-028
R
R
L
Br
Br
M B-038
4
B
B-036 E-026
B
2-35 2-20 2-5 2-15 2-16 2-41 2-64 2-63 1-48 1-47
ECM-1
E-035
ECM-2
E-033
A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 1 2 3 4 5 6 7 8 9 10
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 1 2 3 4
11 12 13 14 15 16 17 18 19 20 21 22
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 A6 A7 A8 A9 A10 B6 B7 B8 B9 B10 B-038
E-070 B
E-069 E-076 E-073 W
W Gr Y
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
E-033
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
B
ET21065016

DTC Detection
Condition
Fuel Pump "A" Control
P0627-00  Fuel pump relay
Circuit/Open
Fuel Pump "A" Control Ignition switch ON
P0628-00  ECM
Circuit Low Engine running
 Engine compartment fuse and relay
Fuel Pump "A" Control box
P0629-00
Circuit High

 Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC). 06
CAUTION
Diagnosis Procedure


ground point
OK

2 Check fuel pump relay
a. Unplug fuel pump relay from engine compartment fuse

and relay box.
+ -
b. Check fuel pump relay terminals.
3 2
Multimeter
Specified Condition
Connection
3-5 No continuity
Continuity 5 1
3-5 (when battery voltage is applied
1
06 NG Replace fuel pump relay
5
3
2
RT21060270
OK
3 Check fuel pump relay control circuit

connector E-069.
b. Disconnect ECM connector E-033. F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
c. Check wire harness between connector terminals. F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
+ -
Specified
Condition
E-033 (41) - E-069 (F7) Continuity
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Check for Short 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Specified
Condition
E-033 (41) or E-069 (F7) -
No continuity
Body ground E-033
RT21065056
E-033 (41) or E-069 (F7) -
No continuity
Battery positive

connector (engine compartment fuse and
relay box - ECM)
OK

4 Check fuel pump relay terminal voltage

b. Measure voltage between terminal of fuel pump relay and
body ground.
V
Condition
Fuel pump relay
2 1
5
3
terminal 1 (engine
compartment fuse
and relay box
side) - Body
ground
06
OK Go to step 6
RT21060280
NG
5 Check main relay and fuse EF38
NG Replace main relay or fuse
OK
6 Check for DTCs

NG Replace ECM
OK

been repaired.

DTC P0645-00 A/C Clutch Relay Circuit
DTC P0646-00 A/C Clutch Relay Control Circuit Low
DTC P0647-00 A/C Clutch Relay Control Circuit High
06

BATTERY
IGNITION SWITCH
ON OR START
85 87
ECM
MAIN 1 5 A/C ENGINE
RELAY COMPRE- COMPARTMENT
EF17 EF19 86 30 SSOR FUSE AND
10A 10A CLUTCH RELAY BOX
2 3 RELAY E-069
EF40 E-076
EF10 E-023
10A
10A
06
A4 A2 F14 A6 F1 C1
R
R
1
A/C
COMPRESSOR
E-002
2
LG
RL
Br
E-028
R
R
L
Br
Br
B
E-019
E-026
B
MT CVT
2-35 2-20 2-5 2-15 2-16 2-42 2-58 2-64 2-63 1-48 1-47
ECM-1
E-035
ECM-2
E-033

2 1
E-069 E-076 E-023 E-002

W Gr L B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
E-033
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
B
ET21065017

DTC Detection
Condition
A/C Clutch Relay
P0645-00
Circuit
 A/C compressor relay
A/C Clutch Relay Ignition switch ON
P0646-00  Wire harness or connector
Control Circuit Low Engine running
 ECM
A/C Clutch Relay
P0647-00
Control Circuit High

CAUTION
Diagnosis Procedure


ground point
OK

2 Check A/C compressor relay
a. Unplug A/C compressor relay from engine compartment

fuse and relay box.
+ -
b. Check A/C compressor relay terminals.
3 2
Multimeter
Specified Condition
Connection
3-5 No continuity
Continuity 5 1
3-5 (when battery voltage is applied
1
NG Replace A/C compressor relay 06
5
3
2
RT21060270
OK
3 Check A/C compressor relay control circuit

connector E-069.
c. Check wire harness between ECM connector terminals F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
and engine compartment fuse and relay box connector + -

E-069
terminals.
Check for Open
Condition
Connection Condition 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
E-033 (42) (MT) 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
or E-033 (58)
(CVT) - E-069
(F1)
E-033
RT21065057

Check for Short
Condition
E-033 (42) (MT)
or E-033 (58)
(CVT) or E-069 Always No continuity
(F1) - Body
ground
E-033 (42) (MT)
or E-033 (58)
(CVT) or E-069 Always No continuity
(F1) - Battery
positive
06 NG Repair or replace wire harness or

connector (ECM - engine compartment
fuse and relay box)
OK
4 Check for DTCs

NG Replace ECM
OK

been repaired.

DTC P0688-00 EMC/PCM Power Relay Sense Circuit Open
IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
06
10A 10A RELAY BOX
E-069
EF40 E-076
10A
A4 A2 F14 A6
R
E-026
B
RL
Br
R
L
E-028
Br
Br
2-35 2-20 2-5 2-15 2-16 1-48 1-47 2-64 2-63

ECM-1
E-035
ECM-2
E-033
37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
25 26 27 28 29 30 31 32 33 34 35 36
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
B
E-033
B
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1

A1 A2 A3 A4 A5
E-076 F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
A6 A7 A8 A9 A10
Gr
E-069
W ET21065015

DTC Detection
Condition
EMC/PCM Power  Main Relay

P0688-00 Relay Sense Circuit Ignition switch ON  Wire harness or connector
Open  ECM

CAUTION
Diagnosis Procedure


ground point
OK

2 Check main relay and fuse
a. Unplug main relay and fuse EF40 from engine

compartment fuse and relay box.
+ -
b. Check if fuse EF40 is normal.
c. Check for continuity between terminals of main relay. 87 85
Multimeter
Specified Condition
Connection
30 - 87 No continuity 30 86
Continuity
30 - 87 (when battery voltage is applied 87
86
85
06
NG Replace main relay
30
RT21060020
OK
3 Check main relay circuit voltage
a. Measure voltage between terminals of main relay (engine

compartment fuse and relay box side) and body ground.
Condition V
Main relay
terminals 87 and
85 (engine
compartment fuse Always 11 to 14 V
and relay box 30
86 85
side) - Body
87
ground

connector (main relay - battery)
RT21060030
OK

a. Disconnect fuse and relay box connectors E-069 and 

E-076.
c. Check wire harness between connector terminals. F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
+ -
Specified
Condition
E-033 (5) - E-069 (F14) Continuity
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Check for Short 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
06 Multimeter Connection
Specified
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Condition
E-033 (5) or E-069 (F14) -
No continuity
Body ground E-033
RT21065058
E-033 (5) or E-069 (F14) -
No continuity
Battery positive
Check for Open
Specified
Multimeter Connection A1 A2 A3 A4 A5
Condition
A6 A7 A8 A9 A10
E-033 (15) - E-076 (A6) Continuity + -
E-076
E-033 (16) - E-076 (A6) Continuity
Check for Short
Specified
Multimeter Connection 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Condition 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
E-033 (15, 16) or E-076 (A6) -
No continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Body ground
E-033 (15, 16) or E-076 (A6) -
No continuity
Battery positive
E-033
RT21065059

connector
OK
5 Check for DTCs

NG Replace ECM

OK

been repaired.
06

Internal Contr. Module Random Access Memory (RAM)

DTC P0604-00
Error
DTC P0605-00 Internal Contr. Module ROM Test Error
DTC Detection
Condition
Internal Contr. Module
P0604-00 Random Access
Memory (RAM) Error  Wire harness or connector
Ignition switch ON
 ECM
Internal Contr. Module
P0605-00
ROM Test Error
06
CAUTION
Diagnosis Procedure


ground point
OK

b. Check if connector is normal.

OK
Replace ECM
06

DTC P1619-00 ECM Not Programmed (Virgin State)
DTC Detection
Condition
ECM Not Programmed  Wire harness or connector
P1619-00 Ignition switch ON
(Virgin State)  ECM

06  Use X-431 3G diagnostic tester to record and clear the DTCs stored in the ECM.
CAUTION
Diagnosis Procedure


ground point
OK

b. Check if connector is normal.
OK

3 Use X-431 3G diagnostic tester to match ECM (See page 34-7), and check for DTCs

NG Replace ECM
OK

been repaired. 06

A/C Refrigerant Pressure Sensor "A" Circuit Range/

DTC P0531-00
Performance
ECM-1
E-035
ECM-2
E-033
2-19 2-24 2-47 2-63 2-64 1-47 1-48
06
WL
LG
YL
Br
Br
B
Br
B
3 2 1
E-026 E-028
A/C
PRESSURE
SENSOR
E-041
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
E-033 B
B
3 2 1
E-041
B
ET21065018

DTC Detection
Condition
A/C Refrigerant  A/C pressure sensor
Pressure Sensor "A"
P0531-00 Ignition switch ON  Wire harness or connector
Circuit Range/
Performance  ECM

06
CAUTION
Diagnosis Procedure


ground point
OK
2 Check A/C pressure sensor connector
a. Disconnect A/C pressure sensor connector E-041.
RT21060290

b. Check A/C pressure sensor connector.
OK
3 Check A/C pressure sensor power supply voltage

b. Check voltage between A/C pressure sensor connector
terminal and body ground.
V
Condition
06 E-041 (3) - Body
Ignition switch ON 5V 3 2 1
ground
E-041
OK Go to step 5
RT21065060
NG
4 Check A/C pressure sensor power supply circuit

c. Check wire harness between connector terminals.
Check for Open + -
3 2 1

Condition
E-041 (3) -
Always Continuity
E-033 (19)
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Check for Short 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Condition
E-041 (3) or
RT21065061
ground
E-041 (3) or
Battery positive


connector (A/C pressure sensor - ECM)
OK
5 Check A/C pressure sensor signal circuit and ground circuit

b. Check wire harness between A/C pressure sensor
+ -

Condition
Connection Condition 06
E-041 (2) -
Always Continuity
E-033 (24)
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
E-041 (1) -
E-033 (47) 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Check for Short
Condition
RT21065062
E-041 (2) or
ground
E-041 (2) or
Battery positive
E-041 (1) or
ground
E-041 (1) or
Battery positive

connector (A/C pressure sensor - ECM)
OK
6 Replace A/C pressure sensor, and check for DTCs

NG Replace ECM

OK

been repaired.
06

DTC U0101-87 Lost Communication With TCM (CVT only)
ECM-1
E-035
ECM-2
CAN H1 CAN L1 E-033
2-1 2-17 2-63 2-64 1-47 1-48
06
OB
O
Br
Br
B
Br
B
E-026 E-028
OB
O
41 42
CAN H1 CAN L1 TCU
E-030
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
E-033 B
B
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
E-030
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B
ET21065019

DTC Detection
Condition
 CAN line or connector
Lost Communication Ignition switch ON
U0101-87  ECM
With TCM (CVT only) Engine running
 TCM

CAUTION
Diagnosis Procedure


ground point
OK
2 Check ECM connector and TCM connector

b. Disconnect TCU connector E-030.
c. Check if connectors are normal.
OK

3 Check CAN line
a. Check CAN line.

Check for Open
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
Specified 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Condition + -
E-030
E-033 (1) - E-030 (41) Continuity
E-033 (17) - E-030 (42) Continuity
Check for Short

49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Specified 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Condition 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
06
E-033 (1) or E-030 (41) - Battery
No continuity
positive E-033
RT21065063
E-033 (17) or E-030 (42) - Body
No continuity
ground
E-033 (17) or E-030 (42)- Battery
No continuity
positive
NG Repair or replace CAN line
OK
4 Replace ECM, and check for DTCs

c. Check if DTC U0101-87 still exists.
NG Replace TCU
OK

been repaired.

DTC U0129-87 Lost Communication With BSM
ECM-1
E-035
ECM-2
CAN H1 CAN L1 E-033
2-1 2-17 2-63 2-64 1-47 1-48
06
OB
O
Br
Br
B
Br
B
E-026 E-028
OB
O
26 14
ABS
CAN H1 CAN L1
CONTROL
MODULE
E-085
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
E-033 B
B
13 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-085
B
ET21065020

DTC Detection
Condition
U0129-87  ECM
With BSM Engine running
 ABS

 Start the engine and warm it up to normal operating temperature, and then select Read Code. 06
CAUTION
Diagnosis Procedure


ground point
OK
2 Check ECM connector and ABS connector

b. Disconnect ABS connector E-085.
OK

3 Check CAN line
a. Check CAN line.

Check for Open 12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
Specified
Condition + - 37 36 35 34 33 32 31 30 29 28 27 26
E-033 (1) - E-085 (26) Continuity E-085
E-033 (17) - E-085 (14) Continuity
Check for Short

49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Specified 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Condition 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
06 E-033 (1) or E-085 (26) - Body ground No continuity

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033 (1) or E-085 (26) - Battery

No continuity
positive E-033
RT21065064
E-033 (17) or E-085 (14) - Body
No continuity
ground
E-033 (17) or E-085 (14) - Battery
No continuity
positive
OK

NG Replace ABS control module
OK

been repaired.

DTC U0140-87 Lost Communication With BCM
ECM-1
E-035
ECM-2
CAN H1 CAN L1 E-033
2-1 2-17 2-63 2-64 1-47 1-48
06
OB
O
Br
Br
B
B
E-027 9 10
I-034
Br
B
E-026 E-028
OB
O
A15 A14
CAN H1 CAN L1
BCM(A)
I-005
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
E-033 B
B
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16
I-005 E-027
L W
ET21065021

DTC Detection
Condition
U0140-87  ECM
With BCM Engine running
 BCM

06  Start the engine and warm it up to normal operating temperature, and then select Read Code.
CAUTION
Diagnosis Procedure


ground point
OK
2 Check ECM connector and BCM connector

b. Disconnect BCM connector I-005.
NG Repair or replace connectors
OK

3 Check CAN line
a. Check CAN line.

Check for Open
Specified
Condition + -
E-033 (1) - I-005 (A15) Continuity A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32

E-033 (17) - I-005 (A14) Continuity I-005
Check for Short
Specified 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Condition 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
E-033 (1) or I-005 (A15) - Body

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 06
No continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
ground
E-033 (1) or I-005 (A15) - Battery
No continuity
positive E-033 RT21065065
E-033 (17) or I-005 (A14) - Body

No continuity
ground
E-033 (17) or I-005 (A14) - Battery
No continuity
positive
OK

NG Replace BCM
OK

been repaired.

DTC U0155-87 Lost Communication With ICM
ECM-1
E-035
ECM-2
CAN H1 CAN L1 E-033
2-1 2-17 2-63 2-64 1-47 1-48
OB
O
06
E-027 9 10
I-034
Br
Br
B
B
A15 A14
CAN H1 CAN L1
BCM(A)
Br
B
I-005
CAN H2 CAN L2
A31 A30
E-026 E-028
OB
O
30 29
CAN H2 CAN L2 INSTRUMENT
CLUSTER
I-015
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
E-033 B
B
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-015
I-005 E-027 L
L W
ET21065022

DTC Detection
Condition
Lost Communication Ignition switch ON  ECM
U0155-87
With ICM Engine running  ICM
 BCM

CAUTION
Diagnosis Procedure


ground point
OK
2 Check ECM connector, instrument cluster connector and BCM connector

b. Disconnect instrument cluster connector I-015.
c. Disconnect BCM connector I-005.
d. Check if connectors are normal.
OK

3 Check CAN line (ECM - BCM)
a. Check CAN line.

Check for Open
Specified
Condition + -

E-033 (17) - I-005 (A14) Continuity I-005
Check for Short
Specified 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Condition 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
06 E-033 (1) or I-005 (A15) - Body

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
No continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
ground
E-033 (1) or I-005 (A15) - Battery
No continuity
E-033 (17) or I-005 (A14) - Body

No continuity
ground
E-033 (17) or I-005 (A14) - Battery
No continuity
positive
OK

4 Check CAN line (BCM - ICM)
a. Check CAN line.

Check for Open
Specified
Condition + -
I-015 (30) - I-005 (A31) Continuity

I-015 (29) - I-005 (A30) Continuity A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32

Check for Short
I-005
Specified
Condition
I-015 (30) or I-005 (A31) - Body
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 06
No continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
ground I-015
I-015 (30) or I-005 (A31) - Battery
No continuity
positive RT21065066
I-015 (29) or I-005 (A30) - Body

No continuity
ground
I-015 (29) or I-005 (A30) - Battery
No continuity
positive
OK

NG Check or replace BCM and ICM
OK

been repaired.

DTC U0164-87 Lost Communication With CLM
ECM-1
E-035
ECM-2
CAN H1 CAN L1 E-033
2-1 2-17 2-63 2-64 1-47 1-48
OB
O
06 E-027 9 10
I-034
Br
Br
B
B
A15 A14
CAN H1 CAN L1
BCM(A)
I-005
CAN H2 CAN L2
A31 A30
Br
B
OB
O
I-039
K-007 13 14 E-026 E-028
PW
GB
13 14
CAN H2 CAN L2 HVAC
CONTROL
PANEL
K-012
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
E-033 B
B
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 I-005 1 2 3 4
1 2 3 4 5 6 7 8
L 5 6 7 8 9 K-007
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 9 10 11 12 13 14 15
10 11 12 13 14 W
15 16 17 18 19
E-027 20 21 22
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 K-012 W
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 W
ET21065023

DTC Detection
Condition
Lost Communication Ignition switch ON  ECM
U0164-87
With CLM Engine running  CLM (A/C control module)
 BCM

CAUTION
Diagnosis Procedure


ground point
OK
2 Check ECM connector, A/C control panel connector and BCM connector

b. Disconnect A/C control panel connector K-012.
c. Disconnect BCM connector I-005.
d. Check if connectors are normal.
OK

3 Check CAN line (ECM - BCM)
a. Check CAN line.

Check for Open
Specified
Condition + -

E-033 (17) - I-005 (A14) Continuity I-005
Check for Short
Specified 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Condition 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
06 E-033 (1) or I-005 (A15) - Body

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
No continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
ground
E-033 (1) or I-005 (A15) - Battery
No continuity
E-033 (17) or I-005 (A14) - Body

No continuity
ground
E-033 (17) or I-005 (A14) - Battery
No continuity
positive
OK

4 Check CAN line (BCM - A/C control panel)
a. Check CAN line.

Check for Open
Specified
Condition + -
K-012 (13) - I-005 (A31) Continuity

K-012 (14) - I-005 (A30) Continuity A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32

Check for Short
I-005
Specified
Condition
K-012 (13) or I-005 (A31) - Body
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 06
No continuity 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
ground K-012
K-012 (13) or I-005 (A31) - Battery
No continuity
positive RT21065067
K-012 (14) or I-005 (A30) - Body

No continuity
ground
K-012 (14) or I-005 (A30) - Battery
No continuity
positive
OK

NG Check or replace BCM and A/C control

panel
OK

been repaired.

DTC U0167-87 Lost Communication With IMMO
ECM-1
E-035
ECM-2
CAN H1 CAN L1 E-033
2-1 2-17 2-63 2-64 1-47 1-48
06
OB
O
Br
Br
B
B
E-027 9 10
I-034
Br
B
E-026 E-028
OB
O
8 6
IMMOBILIZER
CAN H1 CAN L1
CONTROL
MODULE
I-018
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
E-033 B
B
1 2 3 4 5 6 7 8 1 3 5 7
9 10 11 12 13 14 15 2 4 6 8
I-018
E-027 B
W
ET21065024

DTC Detection
Condition
Lost Communication
U0167-87 Ignition switch ON  ECM
With IMMO
 Engine immobilizer module

 Select Read Code. 06
CAUTION
Diagnosis Procedure


ground point
OK
2 Check ECM connector and engine immobilizer module connector

b. Disconnect engine immobilizer module connector I-018.
OK

3 Check CAN line (ECM - engine immobilizer module)
a. Check CAN line.

Check for Open
Specified 1 3 5 7
Multimeter Connection 2 4 6 8
Condition + -
I-018
E-033 (1) - I-018 (8) Continuity
E-033 (17) - I-018 (6) Continuity
Check for Short

49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Specified 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Condition 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
06 E-033 (1) or I-018 (8) - Body ground No continuity

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033 (1) or I-018 (8) - Battery positive No continuity

E-033 (17) or I-018 (6) - Body ground No continuity E-033
RT21065068
E-033 (17) or I-018 (6) - Battery
No continuity
positive
OK

NG Replace engine immobilizer module
OK

been repaired.

DTC P000A-00 "A" Camshaft Position Slow Response
DTC P000B-00 "B" Camshaft Position Slow Response
DTC Detection
Condition
"A" Camshaft Position  Camshaft phaser
P000A-00
Slow Response Ignition switch ON  VVT control valve
"B" Camshaft Position Engine running  Wire harness or connector
P000B-00
Slow Response  ECM

06
CAUTION
Diagnosis Procedure


ground point
OK

2 Check VVT control valve connector
a. Disconnect intake VVT control valve connector E-006.
RT21070520
b. Disconnect exhaust VVT control valve connector E-008.

06 c. Check VVT control valve connectors.
RT21070530
OK
3 Check intake/exhaust camshaft phaser
a. Check if intake/exhaust camshaft phaser is blocked or stuck.
NG Replace intake/exhaust camshaft phaser
OK
4 Check intake/exhaust VVT control valve

b. Remove intake/exhaust VVT control valves. + -
c. Check intake/exhaust VVT control valves.
1 2
Specified
Condition
Terminal 1 - Terminal 2 8Ω
d. When battery voltage is applied between terminals 1 and

2, control valve should move quickly. RT21060211
NG Replace intake/exhaust VVT control valve

OK
5 Check for DTCs

c. Check if DTC P000A-00 or P000B-00 still exists.
NG Replace ECM
OK
System is operating normally. 06

been repaired.

DTC P0010-00 "A" Camshaft Position Actuator Circuit/Open
DTC P0013-00 "B" Camshaft Position Actuator Circuit/Open
IGNITION SWITCH
BATTERY
ON OR START
85 87
ECM
MAIN ENGINE
RELAY COMPARTMENT
06 EF17
10A
EF19
10A
86 30 FUSE AND
RELAY BOX
E-069
EF40 EF08 E-076
10A E-023
15A
A4 A2 F14 A6 C3
RL
R
RL
RL
1 1
VARIABLE VARIABLE
CAMSHAFT CAMSHAFT
TIMING TIMING
(INTAKE) (EXHAUST)
RL
Br
2 2
R
E-006
L
E-008
GR
RL
E-007
20 19 E-038
GR
RL
2-35 2-20 2-5 2-15 2-16 1-7 1-5

ECM-1
E-035
ECM-2
E-033
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 A1 A2 A3 A4 A5 C1 C2 C3 C4 C5 2 1 42 38 34 30 25 20 15 10 5
41 37 33 29 24 19 14 9 4
E-007
E-006 40 36 32 B
27 22 17 12 7 2
E-069 B
E-076 E-023 39 35 31 26 21 16 11 6 1
W E-008
Gr L B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 25 26 27 28 29 30 31 32 33 34 35 36
E-033
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-035
B
ET21065025

DTC Detection
Condition
"A" Camshaft Position
P0010-00  VVT control valve
Actuator Circuit/Open Ignition switch ON
"B" Camshaft Position Engine running
P0013-00  ECM
Actuator Circuit/Open

CAUTION
Diagnosis Procedure


ground point
OK
RT21070520


c. Check VVT control valve connectors.
RT21070530
OK
3 Check VVT control valve power supply voltage

06
b. Check voltage between connector terminals and body
ground.
V
Condition
E-006 (1) - Body 2 1
ground
Ignition switch ON 11 to 14 V E-006
E-008 (1) - Body E-008
ground
OK Go to step 5
RT21065070
NG

4 Check VVT control valve power supply circuit and fuse EF08

b. Check if fuse EF08 is normal.
connector E-023.
+ -
d. Check wire harness between connector terminals.
Check for Open
2 1
Condition E-006
E-006 (1) - E-023
(C3) C1 C2 C3 C4 C5
Always Continuity
E-008 (1) - E-023 C6 C7 C8 C9 C10 06
(C3)
E-023
Check for Short
RT21065071
Condition
E-006 (1), E-008
(1) or E-023 (C3) - Always No continuity
Body ground
E-006 (1), E-008
(1) or E-023 (C3) - Always No continuity
Battery positive

connector (VVT control valve - engine
OK

5 Check VVT control valve control circuit

b. Check wire harness between connector terminals.
Check for Open
2 1
Condition E-006
E-006 (2) - E-035
(7)
Always Continuity
E-008 (2) - E-035 37 38 39 40 41 42 43 44 45 46 47 48
(5) 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
Check for Short
06 1 2 3 4 5 6 7 8 9 10 11 12
Condition
E-006 (2) or E-035
RT21065072
ground
E-006 (2) or
Battery positive
E-008 (2) or
ground
E-008 (2) or
Battery positive

connector (VVT control valve - ECM)
OK
6 Check intake/exhaust VVT control valve
a. Remove intake/exhaust VVT control valves.

b. Check intake/exhaust VVT control valves. + -
Specified
Condition 1 2
Terminal 1 - Terminal 2 8Ω
c. When battery voltage is applied between terminals 1 and

2, control valve should move quickly.
RT21060211
NG Replace intake/exhaust VVT control valve
OK

7 Check for DTCs

NG Replace ECM
OK

been repaired.
06

DTC P0012-00 "A" Camshaft Position - Timing Over-Retarded
DTC P0015-00 "B" Camshaft Position - Timing Over-Retarded
DTC Detection
Condition
"A" Camshaft Position -
P0012-00  Camshaft phaser
Timing Over-Retarded Ignition switch ON
"B" Camshaft Position - Engine running
P0015-00  ECM
Timing Over-Retarded

06 Confirm that battery voltage is over 12 V before performing the following procedures.
CAUTION
Diagnosis Procedure


ground point
OK

RT21070520

c. Check VVT control valve connectors.
06
RT21070530
OK
3 Check intake/exhaust camshaft phaser
a. Check if intake/exhaust camshaft phaser is blocked or stuck.
NG Replace intake/exhaust camshaft phaser
OK
4 Check for DTCs

NG Replace ECM
OK

been repaired.

Crankshaft Position-Camshaft Position Correlation

DTC P0016-00
Bank 1 Sensor A
Crankshaft Position-Camshaft Position Correlation

DTC P0018-00
Bank 2 Sensor A
ECM-1
E-035
ECM-2
E-033
1-32 1-33 1-34 1-29 1-31 1-41 2-63 2-64 1-47 1-48
06
WR
LR
Br
W
GW
WR
Br
Br
B
B
E-038
24 25 27 26
29 28 E-038 E-007
E-007
GW
WR
Br
B
WR
LR
LR
Br
Br
W
1 2 3 2 1 3 2 1
E-026 E-028
ENGINE
S
SPEED
SENSOR
N E-016
CAMSHAFT CAMSHAFT
POSITION POSITION
SENSOR SENSOR
(INTAKE) (EXHAUST)
E-020 E-015
42 38 34 30 25 20 15 10 5
3 2 1 3 2 1
41 37 33 29 24 19 14 9 4
E-007
28 23 18 13 8 3
E-020 E-015 40 36 32 B
27 22 17 12 7 2
B B
39 35 31 26 21 16 11 6 1
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
E-035
E-033 B
ET21065026
B

DTC Detection
Condition
Crankshaft Position-
Camshaft Position  Camshaft position sensor
P0016-00  Crankshaft position sensor
Correlation Bank 1
Sensor A Ignition switch ON  Wire harness or connector
Crankshaft Position- Engine running  Flywheel gear ring
Camshaft Position  Camshaft gear ring
P0018-00
Correlation Bank 2  ECM
Sensor A

 Turn ignition switch to LOCK. 06
CAUTION
Diagnosis Procedure


ground point
OK

2 Check camshaft position sensor signal waveform
a. Turn ignition switch to ON, start the engine and observe the signal waveform of camshaft position sensor
Normal Waveform
Oscilloscope
2.00 V 10.0 ms
06 RT21060230
OK Go to step 8
NG
3 Check camshaft position sensor connector
a. Disconnect intake camshaft position sensor connector

E-020 (1). 2
b. Disconnect exhaust camshaft position sensor connector

E-015 (2).
c. Check camshaft position sensor connectors.
1
RT21060351
OK

4 Check camshaft position sensor power supply voltage

b. Check voltage between terminal 3 of camshaft position
sensor connector E-020 or E-015 and body ground.
V
Condition
E-020 (3) or
E-015 (3) - Body Ignition switch ON 5V 3 2 1
ground E-015
E-020
OK Go to step 6
06
RT21065044
NG
5 Check camshaft position sensor power supply circuit

c. Check wire harness between camshaft position sensor
connector terminals and ECM connector terminals. 3 2 1
+ -
E-020
Condition
E-020 (3) - E-035
(34)
25 26 27 28 29 30 31 32 33 34 35 36
E-015 (3) - E-035 13 14 15 16 17 18 19 20 21 22 23 24
Always Continuity
(34) 1 2 3 4 5 6 7 8 9 10 11 12
Check for Short

E-020 (3), E-015
Body ground
E-020 (3), E-015
Battery positive

connector (camshaft position sensor -
ECM)

OK
Replace ECM
6 Check camshaft position sensor signal circuit and ground circuit
a. Check wire harness between camshaft position sensor

Check for Open
3 2 1
Condition E-015
E-020
06 E-020 (2) - E-035

(29)
E-015 (2) - E-035
(41)
25 26 27 28 29 30 31 32 33 34 35 36
E-020 (1), E-015 13 14 15 16 17 18 19 20 21 22 23 24
(1) - E-035 (31) 1 2 3 4 5 6 7 8 9 10 11 12
Check for Short

E-020 (2) or
E-035 (29) - Body
ground
E-020 (2) or
E-035 (29) -
Battery positive
E-015 (2) or
E-035 (41) - Body
ground
E-015 (2) or
E-035 (41) -
Battery positive
E-020 (1), E-015
(1) or E-035 (31) -
Body ground
E-020 (1), E-015
(1) or E-035 (31) -
Battery positive

(camshaft position sensor - ECM)
OK

7 Check camshaft position sensor
a. Remove camshaft position sensor.

b. Check and clean camshaft position sensor and installation area, and check for damage, foreign matter and
NG Clean installation area or replace

camshaft position sensor
OK
Replace ECM
06
8 Check engine speed sensor signal waveform
a. Turn ignition switch to ON, start the engine and observe the signal waveform of engine speed sensor with
an oscilloscope.
Normal Waveform of Engine Speed Senor Signal
Oscilloscope
RT21060200
OK Go to step 15
NG
9 Check engine speed sensor connector

b. Disconnect engine speed sensor connector E-016.
c. Check engine speed sensor connector.
NG Repair or replace engine speed sensor

connector
OK

10 Check installation of engine speed sensor
a. Remove engine speed sensor.

b. Check and clean engine speed sensor and installation area, and check for damage, foreign matter or
NG Clean or replace engine speed sensor
OK
11 Check resistance of engine speed sensor
a. Check resistance between engine speed sensor

06 terminals 1 and 2.
+ -
Normal resistance: 860 Ω ± 20% (at normal temperature) 3 2 1
NG Replace engine speed sensor
RT21060210
OK
12 Check engine speed sensor circuit

b. Check wire harness between engine speed sensor
+ -
Condition E-016
E-016 (1) - E-035
(32)
E-016 (2) - E-035 25 26 27 28 29 30 31 32 33 34 35 36
(33) 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12
E-035
RT21065042

Check for Short
Condition
E-016 (1) or
E-035 (32) - Body
ground
E-016 (1) or
E-035 (32) -
Battery positive
E-016 (2) or
E-035 (33) - Body
ground
E-016 (2) or
E-035 (33) - 06
Battery positive

(engine speed sensor - ECM)
OK
13 Check crankshaft and flywheel gear ring
a. Rotate crankshaft, and check crankshaft and flywheel gear ring for damage, foreign matter, etc. that cause
signal incorrectness.
NG Clear off debris and clean flywheel gear

ring. Replace flywheel if necessary (See
page 07-42)
OK
14 Check engine timing
a. Check for timing deviation.
NG Correct engine timing
OK

15 Check for DTCs

NG Replace ECM
OK

been repaired.
06

Engine Problem Symptom Diagnosis

Perform primary inspection first before performing malfunction diagnosis procedures:

1. Confirm that engine malfunction indicator operates normally;
2. Using diagnostic tester, check that no error messages are recorded;
3. Confirm that malfunction complained by customer is present, and confirm the condition under which the
malfunction occurs.
Then, perform appearance inspection:

1. Check fuel line for leakage;
2. Check if vacuum line is broken or twisted, and if connection is correct;
3. Check intake line for blockage, air leakage, crush or damage;
4. Check if high-voltage cable of ignition system is broken or deteriorated, and if ignition sequence is correct;
5. Check if wire harness ground points are clean and secure;
6. Check each sensor or actuator connector for looseness or poor contact. 06
HINT:
If above conditions exist, repair the trouble areas first. Otherwise, it will affect the repair work for the following
trouble diagnosis.
Diagnostic Help
1. Confirm that there are no trouble records for engine;
2. Confirm that complained trouble symptoms are present;
3. There are no abnormal conditions after performing the inspection according to above procedures;
4. During servicing, do not ignore vehicle maintenance condition, cylinder pressure, mechanical ignition
timing and fuel condition, etc. that can affect the system;
5. Replace ECM, and perform a test. If the trouble can be eliminated, the trouble area is in ECM; if the trouble
symptom still exists, reuse the original ECM, repeat the procedures, and perform service again.
Problem Symptoms Table
Symptom Suspected Area See page

Battery
Engine does not crank or cranks slowly Starter motor
06-212
while starting Wire harness or ignition switch
Engine mechanical
No fuel in tank
Fuel pump
Engine cranks normally but cannot start
Engine speed sensor 06-214
successfully while starting
Ignition coil
Engine mechanical
Water in fuel
Fuel pump
Difficult to start with hot engine Coolant temperature sensor 06-216
Fuel pressure regulator
Ignition coil


Water in fuel
Fuel pump
Coolant temperature sensor
Difficult to start with cold engine Injector 06-218
Ignition coil
Throttle
Engine mechanical
Water in fuel
Fuel pump
06
Injector
Engine speed is normal, but it is difficult to Ignition coil

06-220
start at anytime Throttle
Intake pipe
Ignition timing
Spark plug
Engine mechanical
Water in fuel
Injector
Spark plug
Engine starts normally, but idles roughly at
Throttle 06-223
anytime
Intake pipe
Ignition timing
Engine mechanical
Water in fuel
Engine starts normally, but idles roughly Spark plug
06-225
during warming up Throttle
Intake pipe
Engine mechanical
Water in fuel
Engine starts normally, but idles roughly Spark plug
06-227
after warming up Throttle body
Intake pipe
Engine mechanical


Engine starts normally, but idles roughly or Air conditioning system
stalls with part load (for example, A/C is 06-229
ON) Injector
Throttle
Engine starts normally, but idle speed is too Vacuum pipe

06-231
high Coolant temperature sensor
Ignition timing
Water in fuel
Air flow meter and throttle position sensor
Spark plug
Low engine speed or stalls when Throttle

06-233
06
accelerating Intake pipe
Injector
Ignition timing
Exhaust pipe
Water in fuel
Spark plug
Slow response when accelerating Throttle inlet pipe 06-236
Injector
Ignition timing
Exhaust pipe
Water in fuel
Spark plug
Ignition coil
Lack of power and poor performance when
Throttle 06-239
accelerating
Intake pipe
Injector
Ignition timing
Exhaust pipe

Engine does not crank or cranks slowly while starting
Diagnosis Procedure
1 Check voltage between two battery posts when engine starts
OK: Voltage is 8 to 12 V.
NG Replace battery
OK
06 2 Check voltage of positive post of starter motor
a. The ignition switch remains in START position and check voltage of positive post of starter motor.
OK: Voltage is 8 to 12 V.
NG Repair or replace wire harness
OK
3 Check operation of starter motor
a. Remove starter motor.

b. Check if there is an open circuit or if it is stuck due to poor lubrication.
NG Repair or replace starter
OK
4 Check engine lubricant and gear oil
a. If malfunction only occurs in winter, Check if starter motor resistance is too strong because of improper
engine lubricant and gear oil selection.
NG Replace lubricant with appropriate

number
OK
5 Check engine internal mechanical resistance
a. Check if engine internal mechanical resistance is too strong, causing starter motor not to run or run slowly.
NG Check and repair engine internal

resistance

OK
Go to Diagnostic Help
06

Engine cranks normally but cannot start successfully while starting
Diagnosis Procedure
1 Check fuel pressure
a. Using a fuel pressure gauge, check fuel pressure (See page 08-11).
Standard Fuel Pressure
Condition Fuel System Pressure (kPa)

Key ON 400
Engine Idling 400
06 Key LOCK 400
NG Repair or replace fuel system
OK
2 Using diagnostic tester, observe if any speed signal is output
a. Connect diagnostic tester, start the engine and select Read Datastream.
b. Observe if any speed signal is output.
NG Check and repair crankshaft position

sensor wire harness
OK
3 Check spark
a. Remove ignition coil and spark plug of one cylinder, and ground spark plug housing. Start the engine, and
check if spark is generated.
OK: Spark is generated.
NG Check and repair ignition system
OK
4 Check pressure of cylinder
a. Measure compression of misfiring cylinder (See page 07-20).

compression
OK

5 Check ECM power supply and ground

b. Turn ignition switch to ON and check ECM connector
terminals.
V
Condition
E-033 (35, 20) -
E-033 (63 or 64)
NG Repair or replace related wire harness 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
06
E-033
RT21065069
OK

Difficult to start with hot engine
Diagnosis Procedure

Key ON 400
Engine Idling 400
06 Key LOCK 400
OK
2 Check spark
OK
Disconnect coolant temperature sensor connector, start engine and observe if engine starts
3 successfully at this time
OK Check and repair wire harness or replace

sensor
NG
4 Check fuel pressure regulator
NG Replace fuel pressure regulator
OK

5 Check fuel condition
a. Observe if trouble occurs just after fuel is filled.
NG Replace fuel
OK

terminals.
V
06
Condition
E-033 (35, 20) -
E-033 (63 or 64)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065069
OK

Difficult to start with cold engine
Diagnosis Procedure

Key ON 400
Engine Idling 400
06 Key LOCK 400
OK
2 Check spark
OK

sensor
NG
4 Depress accelerator pedal slightly, and observe if it is easy to start
OK Clean throttle
NG

5 Check injector for leakage or blockage
NG Clean or replace injector
OK
NG Replace fuel
OK 06

compression
OK

terminals.
V
Condition
E-033 (35, 20) -
E-033 (63 or 64)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065069
OK

Engine speed is normal, but it is difficult to start at anytime
Diagnosis Procedure
1 Check air filter for blockage, and intake pipe for air leakage
NG Check and repair intake system
OK

06

Key ON 400
Engine Idling 400
Key LOCK 400
OK
3 Check spark plug
a. Check spark plug of each cylinder, and observe if the type and gap are as specified.
NG Replace spark plug
OK
4 Check spark
OK


sensor
NG
6 Depress accelerator pedal slightly, and observe if it is easy to start
OK Clean throttle
NG 06
OK
NG Replace fuel
OK

compression
OK
10 Check engine ignition sequence and ignition timing
a. Check if engine ignition sequence and ignition timing are as specified.
NG Check and repair ignition timing
OK


terminals.
V
Condition
E-033 (35, 20) -
E-033 (63 or 64)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
06 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065069
OK

Engine starts normally, but idles roughly at anytime
Diagnosis Procedure
OK
2 Check if throttle is stuck

06
NG Repair or replace throttle
OK
3 Check spark plug
OK
4 Check throttle for carbon deposits
NG Clean throttle
OK
OK
NG Replace fuel
OK


compression
OK
06 NG Check and repair ignition timing
OK

terminals.
V
Condition
E-033 (35, 20) -
E-033 (63 or 64)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065069
OK

Engine starts normally, but idles roughly during warming up
Diagnosis Procedure
OK
2 Check spark plug

06
OK
NG Clean throttle
OK
Unplug coolant temperature sensor connector, start engine and observe if engine idles
4 normally during warming up

sensor
NG
OK
NG Replace fuel

OK

compression
OK

06 a. Disconnect ECM connector E-033.
terminals.
V
Condition
E-033 (35, 20) -
E-033 (63 or 64)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065069
OK

Engine starts normally, but idles roughly after warming up
Diagnosis Procedure
OK
2 Check spark plug

06
OK
NG Clean throttle
OK
Unplug coolant temperature sensor connector, start engine and observe if engine idles
4 normally during warming up

sensor
NG
OK
NG Replace fuel

OK

compression
OK

06 a. Disconnect ECM connector E-033.
terminals.
V
Condition
E-033 (35, 20) -
E-033 (63 or 64)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065069
OK

Engine starts normally, but idles roughly or stalls with part load (for example,
A/C is ON)
Diagnosis Procedure
NG Clean throttle
OK
Observe if engine output increases when A/C is turned on. This means that observe 06
2 changes of ignition advance angle, injection pulse width and intake air volume using
diagnostic tester
OK Go to step 4
NG
Connect ECM adapter, and disconnect pin cable of ECM corresponding terminal. Check if
3 wire harness side is HIGH-level signal with A/C ON
NG Check and repair A/C system
OK
Check if A/C system pressure, compressor magnetic clutch and A/C compressor pump are
4 normal
NG Check and repair A/C system
OK
OK


terminals.
V
Condition
E-033 (35, 20) -
E-033 (63 or 64)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
06 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065069
OK

Engine starts normally, but idle speed is too high
Diagnosis Procedure
1 Check if accelerator pedal is stuck
NG Adjust or replace accelerator pedal
OK
2 Check intake system and connected vacuum pipe for air leakage
06
OK
NG Clean throttle
OK
Disconnect coolant temperature sensor connector, start engine and observe if engine idles
4 normally at this time

sensor
NG
5 Check engine ignition timing
a. Check if engine ignition timing is as specified.
OK


terminals.
V
Condition
E-033 (35, 20) -
E-033 (63 or 64)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
06 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065069
OK

Low engine speed or stalls when accelerating
Diagnosis Procedure
OK

06

Key ON 400
Engine Idling 400
Key LOCK 400
OK
3 Check spark plug
OK
NG Clean throttle
OK
5 Check air flow meter and throttle position sensor and wire harness
NG Check and repair wire harness or replace

sensor

OK
OK

06 NG Replace fuel
OK
OK
a. Check exhaust system for leakage or blockage.

components
OK


terminals.
V
Condition
E-033 (35, 20) -
E-033 (63 or 64)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
06
E-033
RT21065069
OK

Slow response when accelerating
Diagnosis Procedure
OK

06

Key ON 400
Engine Idling 400
Key LOCK 400
OK
3 Check spark plug
OK
NG Clean throttle
OK

sensor

OK
OK
NG Replace fuel
06
OK
OK

components
OK


terminals.
V
Condition
E-033 (35, 20) -
E-033 (63 or 64)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
06 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065069
OK

Lack of power and poor performance when accelerating
Diagnosis Procedure
Check if malfunctions that clutch slipping, low tire inflation pressure, brake dragging,
1 incorrect tire size, and incorrect four-wheel alignment are present
NG Check and repair malfunctioning

component
OK
2 Check air filter for blockage, and intake pipe for air leakage 06
OK

Key ON 400
Engine Idling 400
Key LOCK 400
OK
4 Check spark plug
OK
5 Check spark

OK
NG Clean throttle
OK
06
sensor
OK
OK
NG Replace fuel
OK
OK

components

OK

terminals.
V
Condition
E-033 (35, 20) -
E-033 (63 or 64)
NG Repair or replace related wire harness 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
64
48
06
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
RT21065069
OK

ON-VEHICLE SERVICE
Intake/Exhaust VVT Control Valve

Description
There are two VVT control valves, which are located on intake side and exhaust side respectively.
Operation
ECM controls the VVT control valve depending on the engine condition, changes the flowing direction of oil in
the phasers to advance or retard intake/exhaust camshaft, thus changing the timing of intake valve and
exhaust valve.
Removal
06 Use the same procedures of removal for exhaust VVT control valve and intake VVT control valve. The
procedures listed below are for the intake VVT control valve.
1. Turn off all electrical equipment and ignition switch.
2. Disconnect negative battery cable.
3. Remove engine trim cover.
4. Remove intake VVT control valve.
a. Disconnect intake VVT control valve connector.
RT21070520
b. Remove intake VVT control valve fixing bolt and

intake VVT control valve.
(Tightening torque: 8 ± 2 N·m)
RT21060310
Installation
Installation is in the reverse order of removal.

Coolant Temperature Sensor

Description
The coolant temperature sensor is a negative temperature coefficient sensor, which is installed into the
mounting hole in thermostat holder.
Operation
The coolant temperature sensor provides an input signal for Engine Control Module (ECM). As temperature
increases, the resistance of sensor decreases. As coolant temperature changes, resistance of coolant
temperature sensor varies accordingly, resulting in a change in voltage of coolant temperature sensor signal
circuit. The ECM uses input signal to control air-fuel mixture, ignition timing, A/C compressor and radiator fan
on/off timing.
Removal
1. Turn off all electrical equipment and ignition switch. 06
3. Drain coolant (See page 12-13).
WARNING
 Make sure engine is in low temperature before operating cooling system. Never open the expansion tank
cover and remove the drain cock plug when engine is operating or cooling system is in high temperature.
High-pressurized hot engine coolant and steam may flow out and cause serious injury.

5. Remove coolant temperature sensor.
a. Disconnect coolant temperature sensor connector
and remove coolant temperature sensor.
(Tightening torque: 11 - 16 N·m)
RT21060320
WARNING
 Remove the coolant temperature sensor when engine cools down to avoid scalding injury.

Installation
CAUTION
 Perform sealing with anaerobic seal gum.

 Confirm that the sensor is tightened fully during installation.
 After installing engine coolant temperature sensor, add coolant and check coolant level.
06

Knock Sensor
Description
The knock sensor is installed on cylinder block, and used to detect engine vibration caused by detonation.
Operation
The sensitive element of knock sensor is a piezoelectric ceramic. Vibration of engine cylinder block is
transferred to the piezoelectric ceramic through a mass block in knock sensor. Due to the pressure generated
by vibration of mass block, the piezoelectric ceramic generates a voltage at both electrode faces, and
converts the vibration signal to an AC voltage signal to output it. As intensity of vibration increases, knock
sensor output voltage increases accordingly.
Because frequency of vibration signal caused by engine knocking is far more than that of normal engine
vibration signal, Engine Control Module (ECM) can distinguish between knock or non-knock signals by
processing these signals from knock sensor.
06
Removal
4. Remove knock sensor.
a. Disconnect knock sensor connector, and move away
the knock sensor cable from bracket.
RT21060330
b. Remove intake manifold assembly (See page 10-24).

c. Remove knock sensor fixing bolt and knock sensor.
RT21060340

Installation
CAUTION
 Never allow any kinds of gasket and washer between sensor and engine block. Only the metal part of
sensor can contact with the engine block directly.
 DO NOT apply lubricant, grease or seal gum when installing knock sensor. Keep engine block clean and
dry, and never allow any foreign matter (such as oil) on the installation area of knock sensor.
 Never tap knock sensor when installing it.
06

Oxygen Sensor
Description
This vehicle is equipped with two oxygen sensors (upstream oxygen sensor and downstream oxygen sensor).
Oxygen sensors continually monitor the oxygen concentration in exhaust gas.
Operation
The oxygen sensor generates voltage depending on the oxygen content in exhaust gas. The sensor
generates low voltage when oxygen content is high, and high voltage when oxygen content is low. Therefore,
the sensor acts as a rich-lean switch.
The oxygen sensor is equipped with a heating element that keeps sensor at proper operating temperature
under all operating conditions.
Upstream Oxygen Sensor

The input signal from upstream heated oxygen sensor informs Engine Control Module (ECM) of the oxygen 06
content in exhaust gas. Based on this input signal, Engine Control Module (ECM) adjusts air-fuel ratio finely
by adjusting injector pulse width.

The downstream heated oxygen sensor signal is used to detect the catalytic converter deterioration. As
converter deteriorates, the signal from downstream oxygen sensor begins to match upstream oxygen sensor
signal except for a slight time delay. By comparing the signal from upstream heated oxygen sensor to the
signal from downstream oxygen sensor, Engine Control Module (ECM) calculates the efficiency of catalytic
converter.
Removal & Installation - Upstream Oxygen Sensor

(See page 09-13)
Removal & Installation - Downstream Oxygen Sensor

(See page 09-15)

Camshaft Position Sensor

Description
This vehicle is equipped with an intake camshaft position sensor and an exhaust camshaft position sensor,
which are installed on cylinder head cover.
Operation
The camshaft position sensor is a Hall type sensor and a sensor plate is installed on camshaft. When the
sensor plate is in high teeth, the applicable circuit output is low; when the sensor plate is in missing teeth, the
applicable circuit output is high. As a result, the crankshaft phase information is provided to Engine Control
Module (ECM) so that the compression top dead center and exhaust top dead center of crankshaft can be
distinguished.
Removal
06 1. Turn off all electrical equipment and ignition switch.
4. Remove camshaft position sensor.
a. Disconnect intake camshaft position sensor connector
(1) and exhaust camshaft position sensor connector 2
(2).
4
b. Remove intake camshaft position sensor fixing bolt (3)
and exhaust camshaft position sensor fixing bolt (4). 
(Tightening torque: 8 ± 0.5 N·m)
1
RT21060350
c. Remove intake camshaft position sensor and exhaust camshaft position sensor.
Installation
CAUTION
 The sensor should be pressed into mounting hole. Never use tools (such as a hammer) to strike the
sensor into mounting hole forcibly.

Engine Speed Sensor

Description
The engine speed sensor is installed on clutch case, against flywheel teeth. It is used to detect the speed and
position of crankshaft.
Operation
The engine speed sensor operates by using magnetoelectric effect. When crankshaft rotates, it drives
flywheel to rotate. The flywheel teeth will cut the magnetic line of sensor, and change of magnetic flux causes
both ends of sensor coil to generate output voltage with a certain frequency that is sent to Engine Control
Module (ECM). And the output signal can indicate the speed and position of crankshaft.
Removal
2. Disconnect negative battery cable. 06
4. Remove engine speed sensor.
a. Disconnect engine speed sensor connector (arrow),
and move away the engine speed sensor cable from
bracket.
RT21060360
b. Remove engine speed sensor fixing bolt and engine

speed sensor.
RT21060370
Installation
CAUTION
 Press in the engine speed sensor rather than tap when installing it.

Air Flow Meter

Description
The air flow meter is installed on the air inlet pipe behind air filter, which is used to measure mass of air
passing through.
Operation
When there is no mass flow, the electrical axle maintains a balance. The control circuit outputs a certain
heating current to hot-wire resistance RH. When there is mass flow, the electrical axle is out of balance due to
change of RH resistance (cooling of RH resulting from surrounding air absorbing RH's heat). The current
passing through hot-wire resistance IH must increase to keep hot-wire resistance and temperature difference
of air sucked invariant and at a fixed value. Therefore, hot-wire current IH is function of air mass flow.
Removal & Installation

06 (See page 10-13)

Ignition Coil
Description
The ignition coil converts the low voltage of primary winding into the high voltage of secondary winding, and
discharges spark plug electrode to produce sparks which will ignite the combustible air-fuel mixture in
cylinder.
Operation
An ignition coil consists of primary winding, secondary winding, iron core and housing etc. The primary and
secondary windings form an induced circuit. An instant induced voltage generated by turning primary circuit
switch on and off and an instant high voltage generated by secondary circuit will cause spark plugs to
discharge, thus igniting the combustible air-fuel mixture. The primary winding will recharge when its ground
passage is on through an Engine Control Module (ECM) signal. If Engine Control Module (ECM) cuts off the
control signal to primary winding circuit, it will stop charging and a high voltage will be induced in the
secondary winding.
06
(See page 14-10)

Electric Fuel Pump

Description
The electric fuel pump consists of DC motor, vane pump and end cover (integrated with check valve, pressure
regulator and anti-electromagnetic interference element) etc. The pump and motor are installed coaxially, and
sealed in the same housing. Fuel is filled around the pump and motor in the housing and used for heat
dissipation and lubrication.
Operation
The battery supplies power to electric fuel pump via electric fuel pump relay, which can turn on electric fuel
pump circuit only when starting and engine running. When engine stops running because of an accident, the
fuel pump stops running automatically. The maximum pressure at electric fuel pump outlet is adjusted by
pressure regulator to keep the whole fuel system pressure at 400 kPa.
06 Removal & Installation

(See page 08-14)

Fuel Injector
Description
The fuel injector is located on the cylinder head near to intake valve, and the nozzle end is located directly
above the intake port.
Operation
The Engine Control Module (ECM) sends electric pulse to injector coil, forming magnetic field force. When
magnetic field force increases enough to overcome the resultant force from return spring pressure, needle
gravity and friction force, the needle begins to rise up and injector starts to inject fuel. The pressure of return
spring forces the needle to close again when injection pulse stops.

(See page 08-26)
06

Electronic Throttle Assembly

Description
The electronic throttle assembly is located on intake manifold assembly.
Operation
The electronic throttle assembly is a critical part for engine intake system. Its main function is to adjust intake
passage area according to driver's driving intention, and control intake air volume to meet the intake
requirement for engine in different operating conditions, and send back the position signals of throttle valve
plate to control unit to achieve accurate control. The throttle valve plate will stop at the limp home position
(NLP) determined in a mechanical way when a malfunction occurs.
The electronic throttle assembly consists of four parts: drive module, train module, executive module and
feedback module, and all components are integrated into the same throttle valve housing.
06 Removal & Installation

(See page 10-20)

Canister Solenoid Valve

Description
The canister solenoid valve opens when power is on, and closes when power is off.
Operation
The canister solenoid valve consists of solenoid coil, magnet armature, valve, etc. The air volume through
canister solenoid valve depends on electric pulse duty ratio that outputs from Engine Control Module (ECM)
and pressure difference between canister inlet and outlet. When there is no electric pulse, the canister
solenoid valve closes.

(See page 09-7)
06

Engine Control Module (ECM)

Description
The Engine Control Module (ECM), mounted on the lower right side of engine compartment rain gutter front
end panel assembly, can be removed only as a unit for replacement.
Operation
The Engine Control Module (ECM) is a pre-programmed microprocessor digital computer, which is used to
adjust ignition timing, air-fuel ratio, emission control, speed control, A/C compressor and idle speed etc. The
Engine Control Module (ECM) enables the program to suit ever-changing operation conditions.
Removal
06 3. Remove front wiper arm assembly (See page 36-24).
4. Remove front windshield lower garnish assembly (See page 48-39).
5. Remove Engine Control Module (ECM).
a. Remove ECM connector protection cover bolts.
RT21060380
b. For MT model, disconnect 2 ECM connectors (1).

For CVT model, disconnect 2 ECM connector (1) and
TCU connector (2). 1
RT21060390
c. Remove ECM bracket fixing nuts (arrow).

RT21060400

d. Remove the Engine Control Module (ECM) from

bracket.
RT21060410
Installation
CAUTION
06
 Pay attention to static electricity protection when installing.
 Take care to protect connector pins.
 To prevent water droplets from accumulating on connector joint, face it down.

- MEMO -

GENERAL INFORMATION 07-3 Crankshaft Rear Oil Seal 07-44
Description 07-3 Removal 07-44
Operation 07-3 Installation 07-45
Specifications 07-3 Cylinder Head Cover 07-46
Tools 07-12 Removal 07-46
Installation 07-47
Camshaft 07-49
Engine Performance Diagnosis 07-19
Description 07-49
Inspection 07-20
Removal 07-50
ON-VEHICLE SERVICE 07-23 Inspection 07-53
Accessory Drive Belt 07-23 Installation 07-54
Description 07-23 Cylinder Head 07-55
Removal 07-24 Description 07-55 07
Inspection 07-24 Removal 07-56
Installation 07-25 Disassembly 07-57
Adjustment 07-25 Inspection 07-58
Idler Pulley Assembly 07-26 Assembly 07-61
Removal 07-26 Installation 07-63
Inspection 07-26 Engine Mounting Assembly 07-64
Installation 07-26 Removal & Installation - 
Belt Tensioner Assembly 07-27 Rear Mounting Assembly 07-64
Removal 07-27 Removal & Installation - 
Front Mounting Assembly 07-66
Inspection 07-27
Installation 07-27
Left Mounting Assembly 07-67
Engine Timing Belt 07-28
Description 07-28
Right Mounting Assembly 07-68
Removal 07-29
Inspection 07-31 ENGINE UNIT REPAIR 07-70
Installation 07-32 Engine Assembly 07-70
Camshaft Oil Seal 07-36 Removal 07-70
Installation 07-38 Engine Block 07-78
Crankshaft Front Oil Seal 07-39 Description 07-78
Removal 07-39 Disassembly 07-80
Installation 07-40 Inspection 07-86
Flywheel 07-42 Selection of Bearing Shell 07-93
Removal 07-42 Selection of Connecting Rod 
Inspection 07-42 Bearing Shell 07-94
Installation 07-43 Assembly 07-94

07

07 - SQR484F ENGINE MECHANICAL
GENERAL INFORMATION
Description
SQR484F engine has the following features:
 Vertical and water-cooled type
 In-line DOHC with 4 cylinders
 Four valves per cylinder
 DVVT
 Aluminum cylinder head
 Aluminum cylinder block
 Aluminum crankshaft frame
Operation
SQR484F engine adopts vertical, in-line 4-cylinder, water-cooled, 4-stroke, four valves per cylinder, DOHC,
DVVT, electronic controlled sequential multiport fuel injection and natural aspiration. The engine is made of 07
whole aluminum and adopts electronic controlled coil double ignition system.
Aluminum oil pan is fixed to the bottom of crankshaft frame with bolts. Aluminum cylinder head is fixed on the
cylinder block with bolts. Camshafts are installed in the cylinder head. Power output from the crankshaft drives
the camshaft to rotate by crankshaft timing pulley and timing belt to make the camshaft interact with valve
hydraulic lifter to open and close. Piston assembly is an aluminum piston with cast iron connecting rod. This
engine has reliable structure and good performance.
Specifications
SQR484F Engine Specifications
Item Specification
Vertical, in-line 4-cylinder, water-cooled, 4-stroke, DOHC, electronic
Engine Type
controlled sequential multiport fuel injection, Variable Valve Timing (VVT)
Engine Model SQR484F
Valve Number Per Cylinder 4
Cylinder Diameter (mm) 83.5
Piston Stroke (mm) 90
Displacement (L) 1.971
Compression Ratio 10:1
Combustion Chamber Type Pentroof type
Fuel Supply Type Electronic controlled sequential multiport fuel injection
Ignition Type Electrical control
Ignition Sequence 1-3-4-2
Idle Speed (r/min) 750 ± 50
Rated Power (kW) 102
Rated Power Speed (r/min) 5750
Max. Torque (N·m) 182
Max. Torque Speed (r/min) 4300 - 4500

Item Specification
Max. Permissible Speed (r/min) 5800
Min. Fuel Consumption Rate 
250
(g/kW·h)
Oil and Fuel Consumption
≤ 0.15
Percentage
Fuel Octane Number (Not Less
Unleaded gasoline, octane number 93
Than)
In Summer SAE 10W-40 (SM grade or higher)
Oil Octane Number
In Winter SAE 5W-40 (SM grade or higher)
Oil Capacity (L) 3.9 ± 0.5
Crankshaft Rotation Direction Counterclockwise (viewed from cross section of engine flywheel)
Starting Type Electrical starting
07 Cooling Type Forced circulation type antifreeze cooling
Lubrication Type Compound type (pressure, splash lubrication)
Fuel Pressure (bar) 4
Cylinder Compression
Pressure (bar) 10 - 13.5
(180 ~ 250) r/min
Higher than 150 kPa
Low Idling Speed (700 ± 50 r/min)
Higher than 360 kPa
Oil Pressure (kPa) High Idle Speed (2000 r/min)
Higher than 470 kPa
High Speed (4000 r/min)
Thermostat Operation Open Temperature 87 ± 2

Temperature (°C) Full Open Temperature 102
Net Weight (kg) 148
Boundary Dimension (Length ×
641 × 613 × 644
Width × Height) (mm)
With atmospheric temperature at -25°C, engine can start smoothly within
30 seconds without taking special measures. Starting test shows that
Starting Performance
staring can be performed 3 times consecutively. If it fails to start once,
perform starting again after 2 minutes.

Engine Mechanical Specifications
Item Specification
Intake Cam 37.65
Cam Height (mm)
Exhaust Cam 37.06
Camshaft Journal Intake 23.947 - 23.960

Camshaft
Diameter (mm) Exhaust 23.947 - 23.960
Camshaft Axial Intake 0.15 - 0.20

Clearance (mm) Exhaust 0.15 - 0.20
Lower Surface Flatness (mm) 0.04
Cylinder Head Overall Height (mm) 139.83 ± 0.335
Intake Valve 0.9
Valve Head Margin
Thickness (mm)
07
Exhaust Valve 0.7
Valve Stem Diameter Intake Valve 5.98 ± 0.008

(mm) Exhaust Valve 5.96 ± 0.008
Intake Valve 2.263
Grommet Width (mm)
Exhaust Valve 2.828
Valve
Clearance Between Intake Valve 0.012 - 0.043
Valve Stem and Guide
(mm) Exhaust Valve 0.032 - 0.063
Intake Valve 90 - 90.5

Grommet Cone Angle (°)
Exhaust Valve 90 - 90.5
Intake Valve 107.998
Height (mm)
Exhaust Valve 106.318
Free Height (mm) 47.7
Valve Spring
Operating Preload/Operating Height 260 ± 11 N/41 mm
Valve Guide Length (mm) 38 ± 0.25
Inner Diameter (mm) 6 - 6.015
Valve Guide Outer Diameter (mm) 11.040 - 11.051
Depression Depth (mm) 16 ± 0.3
Valve Stem Protrusion Amount (mm) 31.497 - 31.515
Piston Piston Skirt Diameter (mm) 83.455 ± 0.009
Side Clearance (mm)
Second Ring 0.025 - 0.070
End Gap (mm)
Piston Ring Second Ring 0.4 - 0.6
-0.01
First Ring 1.2 -0.05
-0.006
Height (mm) Second Ring 1.5 -0.050
Oil Ring 2.5

Item Specification
+0.06
First Ring 1.2 +0.05
+0.04
Piston Ring Groove Height (mm) Second Ring 1.5 +0.02
+0.05
Oil Ring 25 +0.01
0
0
Piston Pin Length (mm) 60 -0.5
+0.010
Piston Pin Hole Diameter (mm) 21 +0.006
Axial Clearance (mm) 0.070 - 0.265
Radial Clearance (mm) 0.021 - 0.059
0
Coaxially (mm) 0.04
Crankshaft Cylindricity (mm) 0.007
07 Roundness (mm) 0.004
0
Diameter (mm) 47.9 -0.016
Connecting Rod Journal Parallelism to Main
0.008
Journal
Overall Height (mm) 293
Bore Roundness (mm) 0.008
Cylinder Block Cylindricity (mm) 0.01
Upper Surface Flatness (mm) 0.04
Connecting Rod Big End Radial Clearance (mm) 0.021 - 0.056
Connecting Rod
Big End Axial Clearance (mm) 0.15 - 0.40

Engine Torque Specifications

Accessory Drive Belt Upper Idler Pulley Assembly
40 + 5
Fixing Bolt
Accessory Drive Belt Lower Idler Pulley Assembly
40 + 5
Fixing Bolt
Accessory Drive Belt Tensioner Assembly Fixing Bolt 40 + 5
Timing Belt Front Cover Upper Body Fixing Bolt 7
1st step: 25 ± 5
Crankshaft Pulley Fixing Bolt
2nd step: 30° ± 5°
Timing Belt Front Cover Lower Body Fixing Bolt 7
Plug for Installing Crankshaft Timing Tool on Bottom
40 + 5
of Engine Block
Timing Belt Tensioner Fixing Bolt 20 + 5
07
Exhaust Phaser Cover 30
Exhaust Camshaft Phaser Assembly Fixing Bolt 120 ± 5
Intake Phaser Cover 30
Intake Camshaft Phaser Assembly Fixing Bolt 120 ± 5
1st step: 130 ± 10
Crankshaft Timing Pulley Fixing Bolt
2nd step: 65° ± 5°
1st step: 35 ± 5
Flywheel Fixing Bolt
2nd step: 45° ± 5°
Engine Wire Harness Assembly Fixing Bolt 7±1
Intake Camshaft Position Sensor Fixing Bolt 8 ± 0.5
Exhaust Camshaft Position Sensor Fixing Bolt 8 ± 0.5
Cylinder Head Cover Fixing Bolt 8+3
Timing Belt Rear Cover Fixing Screw 5+2
Camshaft First Bearing Cap Fixing Bolt 8+3
Camshaft Bearing Cap Fixing Bolt 8+3
1st step: 45 ± 5
Cylinder Head Fixing Bolt
2nd step: 180° ± 10°
(for MT Model)
Rear Mounting Cushion Assembly Fixing Nut (for MT
70 ± 5
Model)
Assembly (for MT Model)
55 ± 5


(for CVT Model)
Assembly (for CVT Model)
80 ± 6
70 ± 5
Locking Nut for Through Bolt Between Front
Mounting Cushion Assembly and Front Mounting 70 ± 5
Bracket
Coupling Bolt Between Front Mounting Bracket and
07 Transmission Case
55 ± 5
Locking Nut for Through Bolt Between Left Mounting

Cushion Assembly and Left Mounting Bracket (for 105 ± 10
MT Model)
90 ± 5
Assembly and Body (for MT Model)
80 ± 6
Left Mounting Cushion Assembly Locking Nut (for
80 ± 6
CVT Model)
70 ± 5
Assembly and Body (for CVT Model)
80 ± 6
Coupling Bolt Between Left Mounting Bracket and
80 ± 6
Coupling Bolt and Nut Between Right Mounting
80 ± 6
Cushion Assembly and Right Mounting Bracket
70 ± 5
Assembly and Body
Right Mounting Cushion Assembly Fixing Bolt 55 ± 5
23 ± 2
50 ± 5
Coupling Nut Between Shift Cable and Shift Arm (for
18 ± 2
CVT Model)
Coupling Plug Between Pipe II Assembly and Clutch
16 ± 2
Release Cylinder
Bracket II Fixing Bolt 15 ± 2


Bracket I Fixing Bolt 15 ± 2
Transmission Ground Wire Fixing Bolt 15 ± 2
High Pressure Pipe Hollow Bolt 45 ± 5
Fixing Bolt Between A/C High/Low Pressure Line
25 ± 2.5
and Compressor Assembly
Battery Wire Harness Fixing Nut 7±1
Knock Sensor Inner Torx Fixing Bolt 20 ± 5
Small Circulation Metal Tube Fixing Bolt 20 ± 5
Engine Accessory Bracket Fixing Bolt 40 + 5
Power Steering Pump Bracket Fixing Bolt 30 + 5
Oil Cooler Bracket Fixing Bolt 40 + 5
Trim Cover Rear Right Bracket Fixing Bolt 7±1 07
Oil Deflector Assembly Fixing Bolt 8±3
1st step: 25 ± 3
Connecting Rod Bearing Cap Fixing Bolt
2nd step: 90° ± 5°
Crankshaft Frame Fixing Bolt 20 + 3
1st step: 45 ± 5
Main Bearing Cap Fixing Bolt
2nd step: 180° ± 10°

Lubrication Areas during Engine Assembly
Lubrication Area Note

Piston Pin SM10W-40
Piston Ring SM10W-40
Piston SM10W-40
Cylinder Bore SM10W-40
Main Bearing Shell and Crankshaft Main Journal SM10W-40
Crankshaft Thrust Washer (Oil Groove Side) SM10W-40
Connecting Rod Bearing Cap Bolt Head and Thread
SM10W-40
Part
Connecting Rod Bearing Shell and Crankshaft
SM10W-40
Connecting Rod Journal
07 Main Bearing Cap Bolt Head SM10W-40

Crankshaft Front Oil Seal Lip and Crankshaft Oil
SM10W-40
Seal Journal
Crankshaft Rear Oil Seal Lip and Crankshaft Oil Seal
SM10W-40
Journal
Valve Guide Hole SM10W-40
Valve Stem SM10W-40
Camshaft Cam and Journal SM10W-40
Hydraulic Lifter SM10W-40
Hydraulic Lifter Hole, Valve Rocker Arm SM10W-40
Valve Small End, Valve Rocker Arm Head SM10W-40
Valve Retainer Hole (Cylinder Head Assembly) SM10W-40
Valve Guide or Guide Bottom Hole (Cylinder Head) SM10W-40
Camshaft Oil Seal Lip and Camshaft Journal SM10W-40
Oil Filter Gasket Surface SM10W-40
All engine lubricants should be 5W-40 (for winter)/10W-40 (for summer) SM grade or higher.

Areas with Seal Gum Applied during Engine Assembly
Area with Seal Gum Applied Seal Gum Type

Cylinder Block Bowl Plug Loctite 747
Cylinder Block Main Oil Passage Plug Loctite 5910

Joint Surface Between Crankshaft Frame and
Loctite 518
Cylinder Block
Crankshaft Frame and Oil Pan Loctite 5910
Cylinder Head Bowl Plug Loctite 11747

Cylinder Head Oil Passage Plug Loctite 577
First Bearing Cap Bottom Plate Loctite 574
Coolant Temperature Sensor Loctite 243
Oil Pressure Sensor Loctite 577 07

Camshaft Variable Valve Timing Control Valve Loctite 243
Oil Deflector Bolt Loctite 243
Oil Pump Mounting Bolt Loctite 5910

Timing Gear Rear Cover Fixing Screw Loctite 243

Tools
Special Tools
Crankshaft Front Oil Seal Guide Tool
RCH0000049
07 Crankshaft Front Oil Seal Installer
RCH0000067
Camshaft Oil Seal Installer
RCH0000017
Valve Spring Compression Adapter
RCH0000050
Valve Spring Compressor
RCH0000028

Crankshaft Rear Oil Seal Installer
RCH0000031
Valve Oil Seal Installer
RCH0000034 07
Valve Oil Seal Guide Sleeve
RCH0000035
RCH0000018
Valve Oil Seal Remover
RCH0000037

Valve Cotter Installer
RCH0000029
Flywheel Holding Tool
07 RCH0000040
Oil Filter Remover
RCH0000054
Camshaft Timing Tool
RCH0000033
Crankshaft Timing Tool
RCH0000027

General Tools
Piston Installer
RCH0000039
20
10
30
0
40
90
50
80
60
70
07
RCH0000023
1.5
50
1.0
5
0
Outer Diameter Micrometer 0.01mm
50 75mm
RCH0000064
Vernier Caliper
RCH0000019
Precision Ruler
RCH0000063

Feeler Gauge
RCH0000060
Cylinder Gauge
07 RCH0000065
Caliper Gauge
RCH0000069
Digital Multimeter
RCH0000002
Flexional Magnetic Rod
RCH0000042

Engine Hoist
RCH0000043
Engine Equalizer
RCH0000026 07
RCH0000005
Fuel System Pressure Tester
RCH0000048
RCH0000044

Engine Service Platform
RCH0000057
07

DIAGNOSIS & TESTING

Engine Performance Diagnosis
HINT:
 Use the table below to help determine the cause of the problem. Check each suspected area in sequence.
 Repair or replace the faulty components, or adjust as necessary.

Engine oil (oil level high or low, oil lean or
13-11
rich)
Cam 07-49
Valve mechanism noise
Valve spring seat (excessive runout) 07-57
Valve (excessive clearance between valve
07-60
and guide)
Engine oil (low pressure) 13-10
07
Engine oil (lean) 13-11
Connecting rod bearing cap (loose fixing
07-98
nut)
Connecting rod noise
Connecting rod (misaligned) 07-97
Connecting rod bearing shell (excessive
07-91
radial clearance)
Connecting rod journal (out-of roundness) 07-91
Engine oil (low pressure) 13-10
Engine oil (lean) 13-11
Main bearing shell (excessive clearance) 07-90
Main bearing noise Crankshaft axial clearance (excessive) 07-90
Crankshaft journal (out-of roundness or
07-89
worn)
Flywheel or clutch (loose) 07-42
Piston ring (worn, scratched or damaged) 07-84
Piston ring groove (fouled) 07-87
Oil loss or spark plug blockage Valve oil seal (worn or damaged) 07-57
Valve (excessive clearance between valve
07-60
and guide)

Inspection
1. Check coolant (See page 12-12).
2. Check engine oil (See page 13-9).
3. Check battery (See page 16-7).
4. Check air filter.
a. Remove the air filter element.
b. Visually check that there is no dirt, blockage or damage in the air filter element.
HINT:
 If there is any dirt or blockage in the air filter element, clean it with compressed air.
 If any dirt or blockage remains even after cleaning the air filter element with compressed air, replace it.
5. Check spark plugs (See page 14-12).
6. Test cylinder compression pressure.
 Cylinder pressure is the main index to judge engine operation and also can be used to judge definitely
whether some system of engine operates well or not. Therefore, it is necessary to perform the
measurement of cylinder pressure when servicing the engine.
07
 Ensure that battery is fully charged and the engine starter is in good operating condition. Otherwise the
indicated compression pressure used for diagnosis may be invalid.
CAUTION
 Recommended compression pressure is only used as a guide for diagnosing engine malfunction.
 Never determine causes of low pressure by disassembling engine unless there are some malfunctions.
Measurement Procedures
CAUTION
 Select cylinder pressure gauge with accurate reading and reset it to zero. Otherwise it will affect
accuracy of reading.
a. Turn off all the electrical equipment and ignition switch.

b. Remove the engine trim cover assembly (See page 10-10).
c. Move away the high-voltage cables for each cylinder.
 Remove the clamp (arrow) from crankcase
ventilation hose, and disconnect the connection
between crankcase ventilation hose and cylinder
head cover.
 Move away the crankcase ventilation hose.
 Loosen the high-voltage cables (1) in order, pull
them upward from spark plug holes, and move
them to one side.
1
RT21140110
CAUTION
 Be careful not to damage high-voltage cables when pulling them upward.

d. Disconnect all fuel injector connectors.

e. Remove the spark plug (See page 14-12).
f. Slowly screw the cylinder pressure gauge joint
vertically into the spark plug hole. Do not tighten it
excessively to prevent difficult removal.
RT21070010
CAUTION
 DO NOT screw cylinder pressure gauge excessively to prevent difficult removal.

07
g. With transmission in neutral position, release the accelerator pedal fully, then start the engine and keep
it racing for 3 to 5 seconds to record the measured pressure value.
h. Press the bleeder button of cylinder pressure gauge to reset it to zero. Measure three times in the same
way and take the average.
Standard value for cylinder pressure: 10 - 13.5 bar
CAUTION
 During measurement, do not turn ignition switch to "START" for more than 10 seconds. Otherwise the
engine may be damaged.
 Ensure that battery is fully charged when cranking engine. Correct cylinder pressure can be measured
only when engine is running at 180 - 250 r/min.
 Use the same method to measure pressure of other cylinders.
Cylinder Pressure Value Judgement

 Correct cylinder pressure
Standard cylinder pressure value is between 10 and 13.5 bar and will drop slightly with the using of
engine. But the lowest value cannot be below 9 bar and the pressure difference between each
cylinder should not be above 3 bar.
 If cylinder pressure of engine is lower than the standard value, it indicates that cylinder pressure is
insufficient. Add a small amount of engine oil through spark plug hole and perform measurement
again.
If pressure increases after adding oil, the piston ring or cylinder bore may be worn or damaged.
If pressure remains low, the valve may be stuck or not properly installed or there is air leakage from
cylinder head gasket.
i. Install the spark plug (See page 14-12).
j. Connect all fuel injector connectors (See page 08-26).
k. Install the high-voltage cables.

7. Test cylinder head gasket.

Cylinder head gasket leakage may be present between adjacent cylinders, between cylinder and adjacent
water jacket or from an oil passage to the external of engine.
 Possible indications of cylinder head gasket leakage between adjacent cylinders are as follows:
- Engine power loss
- Engine stall
- Low fuel economy
 Possible indications of cylinder head gasket leakage between cylinder and adjacent water jacket are as
follows:
- Engine overheat
- Coolant loss
- Excessive steam (white smoke) emitted from exhaust system
- Coolant foaming
07

ON-VEHICLE SERVICE
Accessory Drive Belt
Description
07
1
4
7
RT21070020
1 - Alternator 2 - Upper Idler Pulley

3 - A/C Compressor 4 - Lower Idler Pulley
5 - Accessory Drive Belt 6 - Power Steering Pump Pulley
7 - Crankshaft Pulley 8 - Accessory Drive Belt Tensioner

Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents when repairing.

 Try to prevent body paint surface from being scratched during removal and installation.
1. Turn off all the electrical equipment and ignition switch.

2. Disconnect the negative battery cable.
3. Remove the engine trim cover assembly (See page 10-10).
4. Remove the engine lower right protector assembly (See page 48-29).
5. Remove the accessory drive belt.
a. Put the 15# open wrench (or socket) through area between engine and right side rail, and clamp the
tensioner pulley bolt.
07 b. Rotate the open wrench counterclockwise firmly in the
direction of arrow as show in the illustration. Loosen
the accessory drive belt (1) after it is loosened.
RT21160060
c. Carefully remove the accessory drive belt.
Inspection
1. Check belt surface for pilling, oiliness and deterioration, etc. If any of the defects is found, replace the
accessory drive belt.
2. Check the Internal and edge of belt for damage, wear, foreign matter and cracks, etc. If any of the defects
is found, replace the accessory drive belt.
HINT:
 Cracks on the rib side of accessory drive belt are
considered acceptable. If the accessory drive belt has
chunks missing from ribs, it should be replaced.
 After installing the accessory drive belt, check that it
fits properly in the ribbed grooves. Check that the belt
has not slipped out of grooves on the bottom of the
crankshaft pulley by hand.
Right Wrong Wrong

RT21070030

Installation
CAUTION
 Before installation, Remove oil and foreign matter from accessory drive belt.
 After installing accessory drive belt, turn crankshaft 2 turns with a wrench to make sure to install
accessory drive belt in place, and not interfere with other components.
Adjustment
1. Check the tension of accessory drive belt.
a. Turn the crankshaft pulley 2 turns. Distribute the belt tension between each pulley evenly.
b. Apply 100 N of force to center part of the belt between
alternator pulley and tensioner with your thumb. 100 N 5 ~ 6 mm
Check that the displacement of belt should be within 
5 - 6 mm. If the displacement is too large or too small, 07
adjust or repair.
RT21070040

Idler Pulley Assembly

Removal
CAUTION


5. Remove the accessory drive belt (See page 07-24).
07 6. Remove the idler pulley assembly.
a. Remove the fixing bolt (1) from upper idler pulley
assembly, and remove the upper idler pulley
assembly. 1
(Tightening torque: 40 + 5 N·m)
b. Remove the fixing bolt (2) from lower idler pulley
assembly, and remove the lower idler pulley
assembly.
(Tightening torque: 40 + 5 N·m) 2
RT21070050
Inspection
1. Rotate idler pulley assembly by hands and check if the rotation is smooth and if abnormal noise occurs.
2. Wiggle idler pulley assembly in the axial and radial direction to check the bearing for looseness.
3. Check if there is damage on idler pulley assembly operating surface.
Installation
CAUTION
 After installation, turn crankshaft with a wrench to run accessory drive belt several circles, and check if
crankshaft turns smoothly and belt runs well. If it does not turn smoothly, reinstall the accessory drive
belt.
 Make sure to install accessory drive belt in place, and not interfere with other components.

Belt Tensioner Assembly

Removal
CAUTION


5. Remove the belt tensioner assembly.
a. Remove the fixing bolt from belt tensioner assembly, 07
and remove the belt tensioner assembly (1).
RT21070060
Inspection
1. Rotate tensioner assembly by hands and check if the rotation is smooth and if abnormal noise occurs.
2. Wiggle tensioner assembly in the axial and radial direction to check the bearing for looseness.
3. Check if there is damage on tensioner assembly operating surface.
Installation
CAUTION
 After installation, turn crankshaft with a wrench to run accessory drive belt several circles, and check if
crankshaft turns smoothly and belt runs well. If it does not turn smoothly, reinstall the accessory drive
belt.
 Make sure to install accessory drive belt in place, and not interfere with other components.

Engine Timing Belt

Description
1
4
3 2
6 5
07
×6
9
5/8
13
13
10
B
3159
11
12
14
15
×5
20
×5
16
17
19
18
×6
RT21070070
1 - Engine Assembly 2 - Timing Belt Rear Cover

3 - Intake Camshaft Phaser Assembly 4 - Exhaust Camshaft Phaser Assembly
5 - Exhaust Camshaft Phaser Assembly Fixing Bolt 6 - Exhaust Phaser Cover
7 - Intake Phaser Cover 8 - Intake Camshaft Phaser Assembly Fixing Bolt
9 - Contacting Idler Pulley 10 - Timing Belt Front Cover Upper Body
11 - Timing Belt 12 - Timing Belt Idler Pulley
13 - Timing Belt Tensioner 14 - Crankshaft Timing Pulley
15 - Camshaft Timing Pulley Fixing Bolt Washer 16 - Timing Belt Front Cover Lower Body
17 - Timing Belt Front Cover Lower Body Gasket 18 - Water Pump Assembly
19 - Water Pump Assembly Gasket 20 - Semi-circle Key

Removal
CAUTION


6. Remove the belt tensioner assembly (See page 07-27).
7. Use an engine equalizer to hang the engine right lifting eye.
8. Remove the engine right mounting (See page 07-68). 07
9. Remove the timing belt front cover.
a. Loosen and remove 5 fixing bolts (arrow) from timing
belt front cover upper body, and remove the timing
belt front cover upper body (1). 1
(Tightening torque: 7 N·m)
RT21070080
b. Loosen and remove 6 fixing bolts (arrow) from

crankshaft pulley, and remove the crankshaft pulley 2
1
(1). 
(Tightening torque: 1st step: tighten to 25 ± 5 N·m;
2nd step: retighten by 30° ± 5°)
HINT:
Shift the transmission into 5th gear (for MT model) or
D position (for CVT model) when loosening the
crankshaft timing gear fixing bolt to engage the
crankshaft and propeller shaft. Another technician RT21070090
depresses the brake pedal, which can lock the
crankshaft by mechanical gear train.
c. Loosen and remove the fixing bolt from accessory

2
drive belt lower idler pulley assembly, and remove the
accessory drive belt lower idler pulley assembly (1). 
d. Loosen and remove 6 fixing bolts (arrow) from timing
belt front cover lower body, and remove the timing belt
front cover lower body (2). 1
RT21070100

10.Remove the timing belt.

a. Remove the cylinder head cover (See page 07-46).
b. Turn the camshaft, install the camshaft timing tool (1),
tighten the fixing bolts (arrow), and lock the exhaust 2
camshaft (2) and intake camshaft (3).
481H EX
481H IN
3
RT21070110
CAUTION
 After installing camshaft locking special tool, the crankshaft will be in the timing position, the camshaft
07 timing tool can be installed at this time.
c. Remove the plug (arrow) for installing crankshaft

timing tool from the bottom of engine block. 
RT21070120
d. Carefully screw in the crankshaft timing tool (arrow)

until the crankshaft is stuck completely.
RT21070130
CAUTION
 This operation needs patience, and exercise extreme care not to damage the crankshaft.
 When crankshaft is stuck completely, pistons in 4 cylinders of engine are at the same level.

e. Remove the fixing bolt (arrow) from timing belt

tensioner, and remove the timing belt tensioner
assembly (1).
f. Remove the timing belt (2).
RT21070140
Inspection 07
1. Check timing belt.
CAUTION
 Check timing belt carefully before installation, and replace it to prevent any of the following symptoms.
If the timing belt has the following conditions, replace it.

a. There are cracks on the back of belt: as shown in the
illustration (1).
b. There are cracks at the bottom or cord fabric layer of
1
belt: as shown in the illustration (2), (3) and (5).
c. Belt worn: as shown in the illustration (6).
d. Belt teeth missing and damaged: as shown in the 2
illustration (4) and (6).
4
3
6
RT21070150
CAUTION
 Check timing belt carefully before installation. If any of above conditions occurs, replace the timing belt.

2. Check timing belt tensioner assembly.

a. Rotate timing belt tensioner by hands and check if the
rotation is smooth and if abnormal noise occurs.
b. Wiggle timing belt tensioner in the axial and radial
direction to check if there is slackness. 5/8
c. Check if there is damage on the timing belt tensioner
13
surface. 31
59
B
RT21070160
Installation
1. Loosen the exhaust camshaft phaser assembly.
a. While holding the hexagon surface on exhaust
camshaft with an open wrench, loosen the exhaust
07 phaser cover (1) with a torque wrench in the direction
of arrow as shown in the illustration. 
(Tightening torque: 30 N·m) 1
b. Remove the exhaust phaser cover.
RT21070170
c. While holding the hexagon surface on exhaust

camshaft with an open wrench, loosen the fixing bolt
of exhaust camshaft phaser assembly (1) with a
torque wrench in the direction of arrow as shown in
the illustration.  1
RT21070171
CAUTION
 Loosen exhaust camshaft phaser assembly without removing it.

2. Loosen the intake camshaft phaser assembly.

a. While holding the hexagon surface on intake camshaft
with an open wrench, loosen the intake phaser cover
(1) with the monkey wrench in the direction of arrow
as shown in the illustration. 
b. Remove the intake phaser cover.
1
RT21070180
c. While holding the hexagon surface on intake camshaft

with an open wrench, loosen the fixing bolt of intake
camshaft phaser assembly (1) with a torque wrench in
the direction of arrow as shown in the illustration. 
(Tightening torque: 120 ± 5 N·m) 1 07
RT21070181
CAUTION
 Loosen intake camshaft phaser assembly without removing it.
3. Install the timing belt.

HINT:
Install the timing belt and be sure that the exhaust 1 2
camshaft phaser assembly (1), intake camshaft phaser
assembly (2), crankshaft timing belt pulley (7) and
coolant pump pulley (6) are at inside of timing belt tooth.
4
Also, the timing belt tensioner (5), contacting idler pulley 3
(3) and timing belt idler pulley (4) are at outside of tooth.
6
5
RT21070190
4. Install the timing belt tensioner.

a. Install the fixing bolt to timing belt tensioner by hand, and do not tighten the fixing bolt of timing belt
tensioner.

b. Using a suitable inner hexagon wrench, adjust the

tensioner adjuster in the adjustment direction (1) of
1
timing belt tensioner, and also tighten the fixing bolt
with a wrench until the timing belt tensioner needle (2)
and timing notch mark (3) of base are aligned. 5/8
13
HINT: 31
59
B
After marks of tensioner are aligned, return to an 2

angle after rotating by 5° - 10°, then align the marks 3
again.
RT21070200
5. Tighten the timing belt tensioner fixing bolt (arrow).

07
RT21070210
6. Tighten the intake camshaft phaser assembly (1) fixing

bolt.
RT21070220
7. Tighten the exhaust camshaft phaser assembly (1) fixing

bolt.
RT21070221
8. Remove the camshaft locking special tool.

9. Remove the crankshaft timing tool, and install the plug.

CAUTION
 Rotate the crankshaft 2 turns, and check the tension of timing belt tensioner. The tension of timing belt is
375 - 483 N. If alignment marks of timing belt tensioner are not aligned, loosen the tensioner fixing bolt,
and adjust the tensioner again.
 In order to ensure the usage life of timing belt, it is necessary to perform timing belt self-adjustment
operation.
10.Perform timing belt self-adjustment.

a. Turn the crankshaft to run timing belt several circles smoothly.
b. Install the camshaft locking special tool.
c. Install the crankshaft timing tool.
d. Loosen the fixing bolts of exhaust/intake camshaft phaser assembly, so that the timing belt returns to
natural state.
e. Tighten the exhaust/intake camshaft phaser assembly fixing bolt. 07
f. Remove the camshaft locking special tool.
g. Remove the crankshaft timing tool.
11. Tighten the intake/exhaust phaser covers.
12.Other installation procedures are in the reverse order of removal.

Camshaft Oil Seal

Removal
CAUTION


07 6. Remove the belt tensioner assembly (See page 07-27).
8. Remove the engine right mounting (See page 07-68).
9. Remove the engine timing belt (See page 07-28).
10.Remove the exhaust camshaft phaser assembly.
phaser cover (1) with a torque wrench in the direction
of arrow as shown in the illustration, and remove the
exhaust phaser cover.  1
RT21070170
b. While holding the hexagon surface on exhaust

the illustration, and remove the exhaust camshaft 1
phaser assembly. 
RT21070171

11. Remove the intake camshaft phaser assembly.

with an open wrench, loosen the intake phaser cover
(1) with the monkey wrench in the direction of arrow
as shown in the illustration, and remove the intake
phaser cover.
1
RT21070180
b. While holding the hexagon surface on intake camshaft

the direction of arrow as shown in the illustration, and
remove the intake camshaft phaser assembly. 
1 07
RT21070181
12.Remove the camshaft oil seal.

a. Using a flat tip screwdriver wrapped with tape, pry out
the exhaust camshaft oil seal (1) and intake camshaft
oil seal (2) carefully.
1
2
RT21070230
CAUTION
 Be careful not to damage the oil seal retainer and surface of camshaft when removing camshaft oil seal.

Installation
CAUTION
 Remove the dirt on oil seal retainer and apply a coat of engine oil to the oil seal retainer and oil seal lip
before installation.
 Be sure to prevent the lip of camshaft oil seal from being scratched during installation. If it is damaged,
replace immediately.
1. Install the camshaft oil seal.

HINT:
 Use the same installation procedures for the exhaust camshaft oil seal and intake camshaft oil seal.
 Procedures listed below are for intake camshaft oil seal.
a. Using a special tool (camshaft oil seal installer) (1),
install the intake camshaft oil seal (2) to intake
07 camshaft (3).
3
2
RT21070240
2. Other installation procedures are in the reverse order of removal.

Crankshaft Front Oil Seal

Removal
CAUTION


6. Remove the belt tensioner assembly (See page 07-27). 07
8. Remove the engine right mounting (See page 07-68).
10.Remove the crankshaft timing pulley.
a. Loosen the crankshaft timing pulley fixing bolt (arrow).
HINT:
Shift the transmission into 5th gear (for MT model) or
D position (for CVT model) when loosening the
crankshaft timing gear fixing bolt to engage the
crankshaft and propeller shaft. Another technician
depresses the brake pedal, which can lock the
crankshaft by mechanical gear train. RT21070250
b. Remove the timing pulley fixing bolt (1), washer (2),

crankshaft timing pulley (3), lining (4) and semi-circle
key (5) in order. 4
3 2
RT21070260
CAUTION
 Semi-circle key is small, so it is easy to be ignored. During installation, pay thorough attention not to
forget to install.

11. Remove the crankshaft front oil seal.

a. Using a flat tip screwdriver wrapped with tape, pry out
the crankshaft front oil seal (1) carefully.
RT21070270
CAUTION
 Be careful not to damage the oil seal retainer and surface of crankshaft when removing crankshaft front
oil seal.
07
Installation
CAUTION
 Apply a coat of engine oil to crankshaft front oil seal guide tool before installing the new oil seal.
 Remove the dirt on oil seal retainer and apply a coat of engine oil to oil seal retainer and oil seal lip
 Be sure to prevent the lip of crankshaft front oil seal from being scratched during installation. If it is
damaged, replace immediately.
1. Remove the dirt around the crankshaft front oil seal

retainer and on its inner wall.
4
2. Install the crankshaft front oil seal guide tool (3) to the 3 2
crankshaft (4). 1
3. Install the new oil seal (2) to the crankshaft front oil seal
guide tool, and install the new oil seal to the oil seal
retainer completely with a crankshaft front oil seal
installer (1).
RT21070280
4. Install the lining (4).

5. Using a brass bar, install the semi-circle key (5) in place.
4
HINT:
Protrusion height of semi-circle key should be 2.2 - 2.3 1
mm.
5
6. Install the crankshaft timing pulley (3), washer (2) and
bolt (1) in order. 3 2
RT21070260

7. Tighten the crankshaft timing pulley fixing bolt (arrow).

(Tightening torque: 1st step: tighten to 130 ± 10 N·m; 2nd
step: retighten by 65° ± 5°)
RT21070250
07

Flywheel
Removal
CAUTION


3. Remove the transmission assembly (See page 17-21 for MT model, See page 18-130 for CVT model).
4. Remove the clutch assembly (See page 19-14).
5. Remove the flywheel.
07 a. As shown in the illustration, install the flywheel holding
tool (1) to hold the flywheel securely.
b. Remove 6 fixing bolts (arrow) from flywheel, and 1
remove the flywheel.
RT21070290
WARNING
 Pay special attention to safety during operation, do not remove all flywheel fixing bolts without any
auxiliary measures.
 If necessary, other operators will be required to assist.
CAUTION
 Flywheel fixing bolts must be disposed after removal. Never reuse them.
Inspection
1. Check if crankshaft position signal gear is distorted or deformed. If damaged, replace the flywheel. Clean
the signal gear before installation.
2. Check if starter drive gear ring is worn. If excessively worn, replace the flywheel.
3. Check contact surface of clutch lining. If the contact surface is damaged or excessively worn, replace the
flywheel with a new one.

4. Measure flywheel end surface runout with the dial

indicator. If measured value exceeds the limit, replace the
flywheel with a new one.
Limit for end surface runout: 0.2 mm
RT21070291
Installation
WARNING
 Never reuse flywheel fixing bolts after removal.

 Make sure to use new flywheel fixing bolts with seal gum before installation. 07
CAUTION
 Six bolt holes on the flywheel have asymmetrical positions. There is a matchmark hole on flywheel. The
mark hole is located right above when 1st cylinder of engine is at the top dead center and flywheel fixing
bolts are aligned with bolt holes of crankshaft.
Installation procedures are in the reverse order of removal, and pay attention to the followings:
1. Align the flywheel installation hole with the crankshaft positioning journal and then push lightly during
assembly. Do not tap the flywheel with a hammer.
2. Replace the flywheel fixing bolts with precoated seal gum with new ones.
3. Install the flywheel fixing bolts (arrow), and then hold the
flywheel securely with the flywheel holding tool (1).
Tighten the flywheel fixing bolts. 1
step: retighten by 45° ± 5°)
RT21070290

Crankshaft Rear Oil Seal

Removal
CAUTION


3. Remove the transmission assembly (See page 17-21 for MT model, See page 18-130 for CVT model).
4. Remove the clutch assembly (See page 19-14).
5. Remove the flywheel (See page 07-42).
07 6. Remove the crankshaft rear oil seal.
a. Using a screwdriver with the tip wrapped with tape,
remove the crankshaft rear oil seal (1).
1
RT21070300
CAUTION
 Be careful not to damage surrounding parts and oil seal retainer when removing oil seal.
 Be careful not to damage oil pan gasket when removing rear oil seal bracket.

Installation
CAUTION
 Be sure to clean the dirt around oil seal retainer and on the inner wall before installation.
 Check oil seal for damage before installation. If there is any damaged, replace it.
 Be sure to prevent the lip of crankshaft rear oil seal from being scratched during installation.
 Be careful not to damage oil seal retainer during installation.
1. Replace the new crankshaft rear oil seal.

2. Using the crankshaft rear oil seal installer (1), install the
oil seal (2) with the part number side facing outward. 2
1
HINT:
Apply a coat of engine oil to the rear oil seal lip or
crankshaft rear oil seal journal.
07
RT21070301

Cylinder Head Cover

Removal
CAUTION
 Blow dirt and debris away from upper surface of cylinder head cover with compressed air.
 Be sure to wear necessary safety equipment when repairing to prevent accidents.

4. Remove the cylinder head cover.
07 a. Remove the engine wire harness assembly fixing bolt (arrow).
b. Remove the connecting clip (1) between engine wire
harness assembly and cylinder head cover. 3
c. Rotate the fuel tank cap (2) counterclockwise to 2
remove it.
1
d. Remove the clamp (3) and disconnect the connection
between crankcase ventilation hose and cylinder
head cover.
RT21070310
e. Remove the high-voltage cables (See page 14-8).

f. Disconnect the intake camshaft position sensor
2
connector (1) and exhaust camshaft position sensor
connector (2).
1
RT21070320
g. Remove the fixing bolt (1) from intake camshaft

position sensor and remove the intake camshaft 4
position sensor (2) from cylinder head cover. 
3
h. Remove the fixing bolt (3) from exhaust camshaft
position sensor and remove the exhaust camshaft
position sensor (4) from cylinder head cover. 
(Tightening torque: 8 ± 0.5 N·m) 1
2
RT21070330

i. Remove 12 fixing bolts from cylinder head cover in the

order shown in the illustration. 1 5 8 4
12 11 10 9
2 6 7 3
RT21070340
j. Remove the cylinder head cover gasket (arrow) from

cylinder head cover.
07
RT21070350
5. Remove the trim cover rear right bracket and rear left bracket from cylinder head cover.
Installation
1. Remove the residue of seal gum on camshaft 1st bearing cap and cylinder head cover with a scraper.
2. Replace the cylinder head cover gasket.
3. Install the cylinder head cover gasket into the groove of
cylinder head cover.
HINT:
Before installing cylinder head cover gasket, apply seal
gum to the cylinder head cover groove in the areas as
shown in the illustration. Avoid gasket falling out from
groove during installation.
RT21070360
4. Apply seal gum to connecting part of camshaft 1st

bearing cap and cylinder head cover in the oval areas as
shown in the illustration.
RT21070370

5. Install the cylinder head cover, and tighten the cylinder

head cover fixing bolts to the specified torque in 12 8 5 9
sequence shown in the illustration.
HINT:
First screw the bolts in order until they press against the 1 2 3 4
cylinder head and fit closely with cylinder head, then
tighten them again to the specified torque in order.
11 7 6 10
RT21070380
6. Other Installation procedures are in the reverse order of removal.
07

Camshaft
Description
×4
1 3 4
5
2 ×8
6
9 ×8
8 7 17
11 10 18
07
16
×4 19
×4 ×4
15 20
13 ×4
12 14
RT21070390

1 - Exhaust VVT Control Valve 2 - Camshaft 1st Bearing Cap

3 - Camshaft 1st Bearing Cap Fixing Bolt 4 - Intake VVT Control Valve
5 - Exhaust Camshaft Bearing Cap 6 - Exhaust Camshaft Bearing Cap Fixing Bolt
7 - Exhaust Camshaft 8 - Exhaust Camshaft Oil Seal
9 - Exhaust Camshaft Phaser Assembly 10 - Exhaust Camshaft Phaser Assembly Fixing Bolt
11 - Exhaust Phaser Cover 12 - Intake Phaser Cover
13 - Intake Camshaft Phaser Assembly Fixing Bolt 14 - Intake Camshaft Phaser Assembly
15 - Intake Camshaft Oil Seal 16 - Intake Camshaft
17 - Intake Camshaft Bearing Cap Fixing Bolt 18 - Intake Camshaft Bearing Cap
19 - Hydraulic Lifter 20 - Rocker Arm
Removal
07
CAUTION
 Blow dirt and debris away from the upper surface of cylinder head cover with compressed air.

4. Remove the high-voltage cables (See page 14-8).
6. Remove the cylinder head cover assembly (See page 07-46).
7. Remove the intake/exhaust VVT control valve (See page 06-242).
9. Remove the exhaust camshaft phaser assembly.
phaser cover (1) with a torque wrench in the direction
of arrow as shown in the illustration, and remove the
exhaust phaser cover. 1
RT21070170

b. While holding the hexagon surface on exhaust

the illustration, and remove the exhaust camshaft 1
phaser assembly. 
RT21070171
10.Remove the intake camshaft phaser assembly.

with an monkey wrench, loosen the intake phaser
cover (1) with the open wrench in the direction of
arrow as shown in the illustration, and remove the
intake phaser cover.
07
1
RT21070180
b. While holding the hexagon surface on intake camshaft

remove the intake camshaft phaser assembly. 1
RT21070181
11. Remove the timing belt rear cover.

a. Remove the timing belt idler pulley fixing bolt (arrow)
and remove the timing belt idler pulley. 
RT21070400

b. Remove 6 timing belt rear cover fixing screws (arrow)

and remove the timing belt rear cover. 
RT21070410
12.Remove the camshaft.

a. Remove 4 camshaft 1st bearing cap fixing bolts in the
1
order shown in the illustration and remove the
camshaft 1st bearing cap (arrow).
07 4
2
RT21070420
b. Remove the intake/exhaust camshaft bearing cap

fixing bolts separately in the order shown in the
illustration, and place the romoved camshaft bearing
2 6 8 4
caps in order.  E1 E2 E3 E4
(Tightening torque: 8 + 3 N·m) 1 5 7 3
HINT:
During removal, tighten the fixing bolts in steps in the I1
2
I2
6
I3
8
I4
4
order shown in the illustration. 1 5 7 3
RT21070430
c. Remove the intake camshaft and exhaust camshaft.

d. Remove the intake camshaft oil seal and exhaust camshaft oil seal separately.
13. Remove the rocker arm and hydraulic lifter.
a. Remove the rocker arm with hydraulic lifter assembly
(1) in the direction of arrow as shown in the
illustration.
RT21070440

b. Remove the snap spring (1) in the direction of arrow

as shown in the illustration, and separate the rocker
arm and hydraulic lifter.
RT21070450
Inspection
1. Check camshaft.
a. Check appearance.
 Check if there are scratches on camshaft bearing and cam surface. If there are scratches, repair or
replace camshaft.
 Check if there are leaking holes and cracks on camshaft bearing cap. If there are leaking holes or
07
cracks, replace camshaft.
b. Check camshaft journal diameter.
Measure camshaft journal diameter with the outer
diameter micrometer.
Specification
Measurement Item
(mm)
Intake Camshaft Journal 23.947 - 23.960
Exhaust Camshaft Journal 23.947 - 23.960
If camshaft journal diameter is not within the specified RT21070460
range, replace camshaft.

c. Check cam lift.
Measure cam lift with the outer diameter micrometer
as shown in the illustration.
Specification
Measurement Item
(mm)
Intake Camshaft Journal 37.65
Exhaust Camshaft Journal 37.06
If camshaft cam lift is not within the specified range, RT21070470
replace camshaft.
d. Check camshaft axial clearance.
 Reinstall the camshaft.
 Keep measuring rod of dial indicator contacting
with front end of camshaft. Turn the dial of dial
indicator to reset it to zero.
 Push camshaft forward and backward gently (do
70
80
60
not rotate camshaft) and read the value from dial

90
50
0
40
10
indicator.
30
20
RT21070480

Specification
Measurement Item
(mm)
Intake Camshaft Axial Clearance 0.15 - 0.20
Exhaust Camshaft Axial Clearance 0.15 - 0.20
If camshaft axial clearance is not within the specified

range, replace camshaft.
Installation
1. Clean the intake camshaft, exhaust camshaft, and camshaft bearing caps.
2. Apply seal gum to the bottom of camshaft 1st bearing cap
evenly as shown in the illustration.
07
RT21070490
CAUTION
 Pay attention not to apply seal gum into the oil hole.
3. First screw the camshaft bearing cap fixing bolts by hand without tightening.
4. Tighten the camshaft bearing cap fixing bolts in the order
11
7 3 1 5
E1 E2 E3 E4
8 4 2 6
9
10
7 3 1 5
I1 I2 I3 I4
8 4 2 6
12 RT21070500
5. Install the camshaft oil seals (See page 07-38).


Cylinder Head
Description
1
2
4
5 ×10
7
6
8 ×10
×8
9
07
×10
10
11
13 12
RT21070510
1 - Valve Cotter 2 - Valve Spring Upper Seat

3 - Valve Spring 4 - Valve Oil Seal
5 - Valve Spring Lower Seat 6 - Valve Guide
7 - Cylinder Head Fixing Bolt 8 - Cylinder Head Fixing Bolt Washer
9 - Cylinder Head 10 - Stud
11 - Cylinder Gasket 12 - Exhaust Valve
13 - Intake Valve

Removal
1. Release fuel system pressure (See page 08-10).
4. Drain the coolant (See page 12-13).
6. Remove the spark plugs (See page 14-12).
7. Remove the ignition coil (See page 14-10).
8. Remove the thermostat (See page 12-19).
9. Remove the thermostat seat (See page 12-22).
10.Remove the fuel rail injector assembly (See page 08-26).
11. Remove the exhaust manifold assembly (See page 11-7).
12.Disconnect the intake VVT control vavle connector
(arrow).
07
RT21070520
13.Disconnect the exhaust VVT control vavle connector

(arrow).
RT21070530
14.Remove the electronic throttle assembly (See page 10-20).

15.Remove the intake manifold assembly (See page 10-24).
16.Remove the accessory drive belt (See page 07-23).
17.Use an engine equalizer to hang the engine.
18.Remove the engine timing belt (See page 07-28).
19.Remove the cylinder head cover (See page 07-46).
20.Remove the exhaust camshaft phaser assembly (See page 07-50).
21.Remove the intake camshaft phaser assembly (See page 07-51).
22.Remove the timing belt rear cover (See page 07-51).

23.Rotate intake/exhaust camshafts to a proper position with

an appropriate wrench, and remove the cylinder head 3 7 10 6 2
fixing bolts in the sequence from (1) to (10) shown in the
illustration.
4 8 9 5 1
RT21070540
CAUTION
 Failure to follow the sequence to remove cylinder head bolts will cause cylinder head deformation.
24.Remove the cylinder head and cylinder head gasket.

07
CAUTION
 Replace the used gasket with a new one.
Disassembly
1. Remove the camshaft (See page 07-52).
2. Remove the rocker arm and hydraulic lifter (See page 07-52).
3. Using a special tool (valve spring compressor) (1),
compress the valve spring and remove the valve cotter 1
(2) with a flexional magnetic rod.
RT21070550

4. Remove the valve spring upper seat (1), valve spring (2)
and valve (3) from cylinder head. 1
RT21070560
07 5. Using a valve oil seal remover (1), remove the valve oil
seal (2).
2
1
RT21070570
6. Using a flexional magnetic rod, remove the valve spring lower seat.
Inspection
1. Check cylinder head.
a. Check appearance.
 Check if there are scratches on the camshaft bearing journal.
 Remove carbon deposits and varnish inside valve guide with the valve guide cleaner.
 Make sure that valve cotter can move and rotate in cylinder bore freely.
b. Check cylinder head flatness.
Using a precision ruler and feeler gauge, check
cylinder head flatness. Cylinder head flatness must be
within 0.04 mm.
Specification
Measurement Item
(mm)
Cylinder Head Flatness 0.04
If cylinder head flatness is not within the specified RT21070580

range, repair or replace cylinder head.

c. Check cylinder head height.

Using a precision ruler, measure cylinder head height.
Specification
Measurement Item
(mm)
a
Cylinder Head Height 97
If cylinder head height is not within the specified

range, replace cylinder head.
RT21070581
CAUTION
 During replacement, cylinder head should be fully equipped with valves, oil seals, springs, spring seats,
cotters, hydraulic lifters and camshafts.
07
2. Check valve spring.
Using a vernier caliper, measure free length of valve
spring and length of valve spring with the pre-pressure
between 249 N and 271 N.
Specification
Measurement Item
(mm)
Valve Spring Free Length 47.70
Valve Spring Length under
41 RT21070582
Pre-pressure
If valve spring length is not within the specified range,

replace valve spring.
3. Check valve.
a. Clean valve.
 Using a scraper, remove the carbon deposited on
valve head
 Using a wire brush, clean the valve thoroughly.
RT21070583
b. Check valve height.

Using a micrometer, measure valve height.
Specification
Measurement Item
(mm) Total Height
Intake Valve Height 107.998
Exhaust Valve Height 106.318
If height is less than specified value, replace the

valve. RT21070584

c. Check valve head.

 Measure valve head thickness "a" and record.
 Check if the contacting area of grommet is even
and if grommet is located at the center of valve
inclined plane, and measure grommet width "b".
b
Specification
Measurement Item
(mm) a
Intake Valve Head Thickness 0.9

RT21070585
Exhaust Valve Head Thickness 0.7
Intake Valve Grommet Width 2.263
Exhaust Valve Grommet Width 2.828
If it is not within the specified range, replace valve.

d. Check valve stem diameter.
07 Using a micrometer, measure valve stem diameter.
Specification
Measurement Item
(mm)
Intake Valve Stem Diameter 5.98 ± 0.008
Exhaust Valve Stem Diameter 5.96 ± 0.008
If valve stem diameter is not within the specified

range, check the clearance between valve stem and RT21070586
valve guide.
e. Check clearance between valve and valve guide.
Using a caliper gauge, measure the inside diameter of
valve guide.
Specification
Measurement Item
(mm)
Valve Guide Inner Diameter 6 - 6.015
Clearance between valve and valve guide = Valve

guide inner diameter - Valve stem diameter RT21070587
Specification
Measurement Item
(mm)
Clearance Between Intake Valve and
0.012 - 0.043
Guide
Clearance Between Exhaust Valve
0.032 - 0.063
and Guide
If clearance is not within the specified range, replace

valve or valve guide.

4. Check valve stem protrusion amount.

a. Using a vernier caliper, measure distance "a" (valve
stem protrusion amount) between valve stem end
surface and valve spring seat end surface.
a
Specification
Measurement Item
(mm)
Intake Valve Stem Protrusion 31.497 - 31.515
Exhaust Valve Stem Protrusion 31.497 - 31.515
If valve stem protrusion is not within the specified RT21070588

range, replace valve.
Assembly
CAUTION
 Soak new valve oil seal in oil for several minutes before installation.
07
 Check if valve spring lower seat is installed properly before installing valve spring.
 Variable pitch valve spring is used, which must be installed with the painted side facing the valve spring
lower seat.
HINT:
Clean all components to be assembled thoroughly before assembly.
1. Install the valve (1) into the cylinder head.
HINT: 5
 Distinguish intake valves and exhaust valves during
installation. 4
 Apply a light coat of engine oil to the valve stem end
when assembling the valve. 3
2. Install the new valve spring lower seat (2) if necessary. 2
HINT:
Bottom of valve spring lower seat should face the
cylinder head.
3. Install the valve oil seal.
HINT:
Apply a light coat of engine oil to the installation surface
of valve oil seal end when assembling the valve oil seal.
a. Install the valve oil seal guide sleeve (3) to the valve
stem. 1
b. Install the valve oil seal (4) to the valve oil seal guide
sleeve. RT21070589
c. Tap the valve oil seal installer lightly with a rubber
hammer to install the valve oil seal in place.

4. Install the valve cotter (1) to the valve cotter installer (2).
2
1
RT21070590
5. Install the valve spring (1) and valve spring upper seat
(2).
6. Using a valve spring compressor, compress the valve 3
spring and install the valve cotter (3) in place.
2
07 1
RT21070591
7. Tap valve cotter lightly with a rubber hammer to make sure the cotter is installed in place after assembly.

Installation
CAUTION
 Remove residual seal gum and oil on cylinder head and cylinder block.
 Replace cylinder head gasket.
 Check that cylinder head gasket is neat and clean without any chips and scratches. The side stamped
with part number of cylinder gasket should face upward.
 Install cylinder gasket to flat surface of cylinder block with a dowel pin.
 Clean the joint surface between cylinder head and combustion chamber, together with the flat surface of
cylinder block top and thread hole. There should be no accumulated oil at the bottom of cylinder block
thread hole.
 During installation, piston should not be located at the top dead center, in order to prevent it from being
impacted by the opening valve when installing rocker arm.
 Install cylinder head bolt washer with the chamfering surface facing upward and the flat side facing
cylinder head.
07
1. Make sure to tighten the cylinder head fixing bolts in the
sequence from (1) to (10) shown in the illustration: 8 4 1 5 9
a. Apply a small amount of oil to the bolt head and root.
b. Install the bolts and tighten them in place by hands.
c. Tighten the cylinder head fixing bolts in the following
procedures:
1st step: Tighten the bolts to 45 ± 5 N·m in the
sequence from (1) to (10) shown in the illustration.
7 3 2 6 10
2nd step: Rotate the bolts clockwise by 180° ± 10° in
RT21070592
tightening sequence.
CAUTION
 Check cylinder head fixing bolts before installation. If they are damaged, replace immediately.
 Be sure to tighten cylinder head bolts by following the operating procedures above strictly to achieve the
technology standard for vehicle usage.

Engine Mounting Assembly

Removal & Installation - Rear Mounting Assembly
CAUTION


3. Support the transmission with a transmission carrier.
4. Remove the engine rear mounting cushion assembly (for MT model).
a. Remove 2 coupling bolt (arrow) between rear
07 mounting cushion assembly and front sub frame
welding assembly.
(Tightening torque: 70 ± 5 N·m) 1
b. Remove the fixing nut (1) from rear mounting cushion
assembly.
RT21070600
c. Remove the locking nut (1) for through bolt between

rear mounting bracket and rear mounting cushion
assembly, and remove the through bolt (2).
1 2
RT21070610
d. Remove the engine rear mounting cushion assembly.

5. Remove the engine rear mounting bracket (for MT model).
a. Remove 3 coupling bolts (arrow) between rear
mounting bracket and transmission case.
RT21070620
b. Remove the engine rear mounting bracket from transmission case.

6. Remove the engine rear mounting cushion assembly (for CVT model).
mounting cushion assembly and front sub frame
RT21070621
b. Remove the locking nut (1) for through bolt between

rear mounting bracket and rear mounting cushion
assembly, and remove the through bolt (2).
07
1 2
RT21070622
c. Remove the engine rear mounting cushion assembly.

7. Remove the engine rear mounting bracket (for CVT model).
RT21070623
b. Remove the engine rear mounting bracket from transmission case.

8. Installation is in the reverse order of removal.

Removal & Installation - Front Mounting Assembly
CAUTION


3. Remove the engine lower protector assembly (See page 48-29).
4. Support the transmission with a transmission carrier.
5. Remove the engine front mounting cushion assembly.
a. Remove 2 coupling bolts (arrow) between front
mounting cushion assembly and side rail welding
07 assembly.
RT21070630
b. Remove the locking nut (arrow) for through bolt

between front mounting cushion assembly and front
mounting bracket, and remove the through bolt.
RT21070640
c. Remove the engine front mounting cushion assembly.

6. Remove the engine front mounting bracket.
RT21070650
b. Remove the engine front mounting bracket from transmission case.


Removal & Installation - Left Mounting Assembly
CAUTION


3. Use an engine equalizer to hang the engine.
4. Remove the air filter assembly and its bracket (See page 10-17).
5. Remove the battery (See page 16-7).
6. Remove the battery tray and tray bracket (See page 16-9).
7. Remove the engine left mounting cushion assembly (for MT model).
a. Remove the locking nut (1) for through bolt between 07
left mounting cushion assembly and left mounting
bracket, and remove the through bolt (2).
b. Remove 4 coupling bolts (arrow) between left
mounting cushion assembly and body.
(Tightening torque: 70 ± 5 N·m) 1 2
RT21070660
c. Remove the left mounting cushion assembly.

8. Remove the engine left mounting bracket (for MT model).
a. Remove 3 fixing nuts (arrow) between left mounting
bracket and transmission case.
RT21070670
b. Remove the left mounting bracket.

9. Remove the engine left mounting cushion assembly (for CVT model).
a. Remove the locking nut (1) from left mounting cushion
assembly.
b. Remove 4 coupling bolts (arrow) between left
RT21070671
c. Remove the left mounting cushion assembly.

10.Remove the engine left mounting bracket (for CVT model).
a. Remove 2 fixing nuts (arrow) between left mounting
07 (Tightening torque: 80 ± 6 N·m) 1
b. Remove the coupling bolt (1) between left mounting
RT21070672
c. Remove the left mounting bracket.

Removal & Installation - Right Mounting Assembly
CAUTION


6. Remove the engine right mounting cushion assembly.

a. Remove 2 fixing bolts (arrow) from expansion tank

and move the expansion tank to one side.
RT21070680
b. Remove the coupling bolt (1) and 2 coupling nuts (2)

between right mounting cushion assembly and right
1
mounting bracket.
c. Remove 3 coupling bolts (arrow) between right
2 07
RT21070690
d. Remove the engine right mounting bracket.

7. Remove the engine right mounting bracket.
a. Remove 3 fixing bolts (arrow) from right mounting
cushion assembly.
RT21070691
b. Remove the engine right mounting bracket assembly.


ENGINE UNIT REPAIR

Engine Assembly
Removal
CAUTION
 Remove engine and transmission as an assembly.

 Install protector to prevent the body from being scratched.
 Block inlet of intake pipe after removing air filter and engine trim cover to prevent foreign matter from
entering. Otherwise the foreign matter will block intake passage when starting, which may cause serious
damage to engine.
07 1. Remove the engine trim cover assembly (See page 10-10).

2. Remove the trim cover rear left bracket (See page 10-12).
6. Drain the engine oil (See page 13-11).
7. Drain the transmission oil (See page 17-14 for MT model, See page 18-110 for CVT model).
8. Drain the brake fluid (See page 26-13).
10.Drain the steering fluid (w/ hydraulic assist steering) (See page 29-7).
11. Recover the refrigerant (See page 31-66).
12.Remove the hood assembly (See page 47-11).
13.Remove the battery (See page 16-7).
14.Remove the battery tray and tray bracket (See page 16-9).
15.Remove the air induction pipe assembly (See page 10-16).
16.Remove the air filter assembly and its bracket (See page 10-17).
17.Remove the exhaust manifold assembly (See page 11-7).
18.Remove the brake fluid reservoir (See page 26-14).
19.Remove the front wheel (See page 24-9).
20.Remove the engine lower protector assembly (See page 48-29).
21.Remove the drive shaft (See page 20-5).
22.Disconnect the connection between precatalytic converter assembly and cylinder block.
a. Remove 2 coupling bolts (1) on left side and the
coupling bolt (2) on right side between precatalytic
converter assembly bracket and cylinder block
(Tightening torque for coupling bolt on left side:  2
1
23 ± 2 N·m; Tightening torque for coupling bolt on
right side: 50 ± 5 N·m).
RT21110100

23.Disconnect the engine inlet hose.

a. Loosen the elastic clamp (arrow) and disconnect the
connection between engine inlet hose and radiator
assembly.
RT21070700
24.Move away the expansion tank.

a. Loosen the elastic clamp (1) and disconnect the
connection between expansion tank and engine
discharge hose I.
b. Loosen the elastic clamp (2) and disconnect the 07
connection between expansion tank and expansion 1
tank outlet hose.
c. Remove 2 fixing bolts (arrow) from expansion tank.
2
RT21070710
d. Take out the expansion tank from expansion tank bracket, and move the expansion tank to one side.
25.Disconnect the connection between hose and heater core.
connection between heater inlet hose and heater
core.
1
b. Loosen the elastic clamp (2) and disconnect the
connection between heater outlet hose and heater 2
core.
RT21070711
26.Disconnect the connection between vacuum pipe and vacuum booster.

a. Move the vacuum pipe away from vacuum booster in
the direction of arrow as shown in the illustration.
RT21070720

27.Disconnect the coupling joint (arrow) between delivery

pipe and fuel rail.
RT21070730
28.Move away the fuel vapor hose III assembly.

a. Disengage the elastic clamp (arrow) and disconnect
the connection between fuel vapor hose III assembly
and charcoal canister.
07
RT21070740
b. Move the fuel vapor hose III assembly to one side.

29.Move away the engine outlet hose.
a. Loosen the engine outlet hose elastic clamp (arrow),
and disconnect the connection between engine inlet
hose and thermostat housing.
RT21120090
b. Move the engine outlet hose to one side.

HINT:
As for MT model, it is necessary to move away the back-up light switch wire harness clamp before
moving away the engine outlet hose.
30.Move away the gear select and shift cable (for MT model).
a. Remove the cotter pins (arrow) connecting gear select
and shift cable and transmission gear shift control
mechanism.
RT21070750

b. Remove the flexible shaft clamps (arrow) from gear

select and shift cable.
RT21070760
c. Move away the gear select and shift cable from flexible shaft bracket.
31.Move away the gear shift cable (for CVT model).
a. Remove the coupling nut (arrow) between gear shift
cable and gear shift arm, and disconnect the gear shift
cable from gear shift arm.
RT21070761
b. Push 2 locating claws on gear shift cable (1) in the

direction of arrow as shown in the illustration, and
disengage the gear shift cable from transmission gear
shift cable bracket (2). 2
RT21070762
32.Disconnect the connection of clutch hydraulic line (for MT model).

a. Loosen the coupling plug (arrow) and disconnect the
connection between clutch release cylinder pipe II
assembly and clutch release cylinder.
RT21070770

b. Remove the fixing bolt (arrow) and move away the

bracket II from transmission.
RT21070780
c. Remove the fixing bolt (arrow) and move away the

bracket I from transmission.
07
RT21070781
33.Move away the transmission ground wire.

a. Remove the transmission ground wire fixing bolt
(arrow) and move away the transmission ground wire
(for MT model).
RT21070790
b. Remove the transmission ground wire fixing bolt

(arrow) and move away the transmission ground wire
(for CVT model).
RT21070791

34.Disconnect the steering pump line (w/ hydraulic assist steering).

a. Remove the hollow bolt (arrow) from high pressure
pipe and move away the steering pump line from
steering pump.
RT21070792
35.Disconnect the A/C line.

a. Remove 2 fixing bolts (arrow) between A/C high/low
pressure line and compressor assembly, and
disengage the A/C high/low pressure line from
compressor assembly. 07
RT21310860
36.Disconnect the engine wire harness.

a. Disconnect the engine wire harness connector (arrow)
and move the engine wire harness away from the wire
harness clip (1).
RT21070800
b. Remove the battery wire harness ground wire fixing

bolt (arrow) and move away the battery wire harness
ground wire.
RT21070810

c. Open the fuse and relay box cover, remove the

battery wire harness fixing nut (arrow), and disconnect
the connection between battery wire harness and fuse
and relay box.
RT21070820
d. Remove the fuse and relay box and disconnect 2 engine wire harness connectors.
37.Disconnect the CVT connector (for CVT model).
a. Disconnect the second shaft pressure sensor (1).
b. Disconnect the second shaft speed sensor (2).
07 1
RT21070830
c. Disconnect the connector B (1).

d. Disconnect the connector A (2).
e. Disconnect the clutch speed sensor (3).
3
f. Disconnect the primary shaft speed sensor (4). 2
4
1
RT21070840
g. Disconnect the primary shaft pressure sensor (arrow).
RT21070850
38.Use an engine equalizer to hang the engine.

39.Remove the engine rear mounting assembly (See page 07-64).
40.Remove the engine front mounting assembly (See page 07-66).
41.Remove the engine equalizer and use an engine hoist to hang the lifting eyes on both sides of the engine.
42.Remove the engine left mounting cushion assembly (See page 07-67).

43.Remove the engine right mounting cushion assembly (See page 07-68).
44.Confirm that all the components are disconnected from engine.
45.Hang the engine with transmission out of engine compartment.
46.Remove the engine wire harness and battery wire harness from engine.
47.Separate the engine and the transmission.
48.Install the engine on the engine service platform.
Installation
07

Engine Block
Description
07
4 5
RT21070860
1 - Cylinder Head Gasket 2 - Cylinder Block

3 - Crankshaft Main Bearing Upper Shell 4 - Thrust Washer
5 - Crankshaft 6 - Crankshaft Main Bearing Lower Shell
7 - Crankshaft Frame

1
2
07
3 8
10
4
11
5
12
RT21070870
1 - Piston 2 - Piston Pin (Semi-floating)

3 - Connecting Rod 4 - Connecting Rod Bearing Upper Shell
5 - Connecting Rod Bearing Lower Shell 6 - Connecting Rod Bearing Cap
7 - Connecting Rod Fixing Bolt 8 - First Compression Ring
9 - Second Compression Ring 10 - Upper Rail
11 - Oil Ring Expander 12 - Lower Rail

Disassembly
1. Remove the engine assembly and install the engine on engine service platform (See page 07-70).
5. Remove the thermostat seat (See page 12-22).
6. Remove the oil dipstick (See page 13-15).
7. Remove the intake manifold (See page 10-24).
8. Remove the alternator (See page 16-10).
9. Remove the accessory drive belt lower idler pulley (See page 07-26).
10.Remove the compressor assembly (See page 31-99).
11. Remove the engine right mounting bracket.
a. Remove 3 fixing bolts (arrow) from right mounting
bracket.
07
RT21070691
b. Remove the engine right mounting bracket.

12.Move away the knock sensor connector (arrow) from
knock sensor bracket.
RT21070880
13.Remove the knock sensor.

a. Remove the knock senor inner hexagon bolt (1).
b. Remove the knock sensor cable fixing band (arrow)
from small circulation metal tube, and remove the 2
knock sensor. 1
14.Remove the small circulation metal tube.
a. Remove the small circulation metal tube fixing bolt (2).
RT21070890
b. Remove the small circulation metal tube from engine.

CAUTION
 There will be residue of coolant in the engine. If coolant gets on your skin, wash off with water
immediately.
ENVIRONMENTAL PROTECTION
 There will be residue of coolant in the engine. Wasted coolant should be handled according to local
environmental regulations.
15.Remove the engine accessory bracket.

a. Remove 4 fixing bolts from engine accessory bracket.
b. Remove the engine accessory bracket.
07
RT21070900
16.Remove the power steering pump with bracket assembly.

a. Remove 3 fixing bolts (arrow) from power steering
pump, and remove the steering pump with bracket
assembly.
RT21070910
17.Remove the oil filter (See page 13-13).

18.Remove the oil cooler bracket with oil pressure switch
assembly and intake manifold lower bracket.
a. Remove 4 fixing bolts (arrow) from oil cooler bracket. 
b. Remove the oil cooler bracket with oil pressure switch 3
assembly (1). 2
c. Remove the intake manifold lower bracket fixing bolt
(2) and remove the intake manifold lower bracket (3). 1
RT21070920

19.Remove the trim cover rear right bracket.

a. Remove 2 fixing bolts (arrow) from trim cover rear
right bracket. 
RT21100070
b. Remove the trim cover rear right bracket.

20.Fix the flywheel with a flywheel holding tool (arrow).
07
RT21070921
21.Remove the crankshaft pulley bolt (arrow), and remove

the crankshaft pulley (1).
step: rotate for 30° ± 5°)
1
RT21070930
22.Remove the cylinder head cover (See page 07-46).

23.Remove the timing belt (See page 07-28).
24.Remove the water pump (See page 12-31).
25.Remove the crankshaft timing pulley.
a. Loosen the crankshaft timing pulley fixing bolt (arrow).
2nd step: retighten for 30° ± 5°)
RT21070250

b. Take out timing pulley fixing bolt (1), washer (2),

crankshaft timing pulley (3), lining (4) and semi-circle
key (5). 4
3 2
RT21070260
CAUTION
 Semi-circle key is small, so it is easy to be ignored. During installation, pay thorough attention not to
forget to install.
07
26.Remove the clutch assembly (See page 19-14).
27.Remove the flywheel assembly (See page 07-42).
28.Remove the cylinder head (See page 07-55).
29.Remove the oil pan (See page 13-20).
30.Remove the oil strainer (See page 13-23).
31.Remove the oil pump assembly (See page 13-24).
32.Remove the crankshaft rear oil seal (See page 07-44).
33.Remove the oil deflector assembly.
a. Remove 7 fixing bolts (arrow) from oil deflector
assembly. 
RT21070940
b. Remove the oil deflector assembly.

34.Remove the piston connecting rod assembly.
a. Using a ridge reamer or equivalent, remove all carbon
from the top of cylinder.
b. Remove the connecting rod bearing cap fixing bolts
(arrow), and remove the connecting rod bearing cap.
RT21070950

c. Using a hammer handle (1), push the piston

connecting rod assembly (2) out of the top of cylinder.
1
RT21070960
35.Remove the connecting rod bearing.

a. Remove the connecting rod bearing (arrow).
HINT:
Arrange the removed parts in the correct order.
07
RT21070970
CAUTION
 Be careful not to scratch the cylinder wall during operation.

 Attach a label with the corresponding number to each piston connecting rod assembly to prevent
incorrect installation.
36.Remove the piston ring.

a. Using a piston ring remover (1), remove 2 2
compression rings (2).
RT21070980
CAUTION
 Before removing the piston ring, check the piston ring side clearance. If it is necessary to be reused, be
sure to mark the piston ring position.
b. Remove the oil ring rail and expander by hands.

37.Remove the piston.
Piston pin is semi-floating and cannot be assembled by general process after removal, so it is not
allowable to be removed in service. If there are abnormal noises caused by improper piston pin clearance,
replace the piston connecting rod assembly.

38.Remove the crankshaft.

4 8 9 5 1
a. Evenly loosen and remove 10 crankshaft frame fixing
bolts in the order shown in the illustration. 
3 7 10 6 2
RT21070990
b. Evenly loosen and remove 10 crankshaft main

4 8 9 5 1
bearing cap fixing bolts in the order shown in the
illustration. 
07
3 7 10 6 2
RT21071000
c. Remove the crankshaft frame.

HINT:
If it is difficult to remove the crankshaft frame due to seal gum, tap it gently with a rubber hammer to
make it loose. Be sure not to damage surrounding components.
d. Take out the crankshaft.
CAUTION
 Take care when removing crankshaft, as it is heavy. If necessary, ask other operators to assist.
 Take particular care when removing crankshaft. Avoid scratching the contact surface of crankshaft and
bearing shell.
39.Remove the crankshaft thrust washer.

a. Remove the crankshaft thrust washers (arrow) from 1
cylinder block.
RT21071010

40.Remove the crankshaft main bearing shell.

a. Slightly push the crankshaft main bearing upper shell
(1) in the direction of arrow and remove it carefully.
HINT: 1
 Remove other crankshaft main bearing upper
shells from the cylinder block in the same way.
 Remove the crankshaft main bearing lower shells
from the crankshaft frame in the same way.
 Pay attention to the notch position. Push out the
bearing shell carefully as shown in the illustration. RT21071020
It is difficult to push out the bearing shell and the
parts may be damaged if pushing in the opposite
direction.
Inspection
1. Check cylinder block.
Clean engine block thoroughly and check all hole passages for leakage.
07
Check engine block and cylinder bore for cracks.
Check bottom surface of engine block for cracks.
CAUTION
 DO NOT wash the cylinder at high temperature. Otherwise the cylinder liner will stick out beyond the
engine block.
2. Check flatness of engine block upper surface.

a. Clean the engine block upper surface.
b. Using a precision ruler and feeler gauge, measure the
flatness of engine block upper surface.
Specification
Measurement Item
(mm)
Engine Block Upper Surface Flatness 0.04
It is not allowed to grind the block upper surface. If the

flatness of engine block upper surface exceeds the
limit, replace the engine block.
RT21071030
3. Check cylinder.
a. Cylinder cylindricity and roundness calculation method (for general measurement):
Thrust direction - perpendicular to the axis of crankshaft; Axial direction: Parallel with the axis of
crankshaft
Cylindricity calculation method
Cylindricity is half of the diameter difference measured in the same direction.
Cylindricity in thrust direction = (maximum diameter measured at A, B and C in thrust direction -
minimum diameter measured at A, B and C in thrust direction)/2
Cylindricity in axial direction = (maximum bore diameter measured at A, B and C in axial direction -
minimum bore diameter measured at A, B and C in axial direction)/2
Compare the maximum value measured at the 2 directions with the standard cylinder cylindricity.
Roundness calculation method

Roundness error is half of the diameter difference measured at the same section.
Roundness of Section A = (maximum bore diameter measured in thrust direction and axial direction at
point A - minimum bore diameter measured in thrust direction and axial direction at point A)/2
Roundness of Section B = (maximum bore diameter measured in thrust direction and axial direction at
point B - minimum bore diameter measured in thrust direction and axial direction at point B)/2
Roundness of Section C = (maximum bore diameter measured in thrust direction and axial direction at
point C - minimum bore diameter measured in thrust direction and axial direction at point B)/2
Compare maximum value roundness measured at A, B and C with the standard cylinder roundness.
b. Check cylindricity of cylinder.
Using a cylinder gauge, measure the cylinder bore at
positions A, B and C in the thrust and axial directions.
Specification
Measurement Item
(mm)
Cylinder Cylindricity 0.01
Cylinder Roundness 0.008
07
If the cylindricity or roundness value measured at
positions A, B and C exceeds the specified value,
Thrust Direction
replace the engine block.
Front
Axial Direction
A 12 mm
B
Center
C
12 mm
RT21071040
4. Check piston.
a. Using a scraper, remove the carbon deposits on the
top of piston.
RT21071050
b. Using a piston ring, remove the carbon deposits in the

piston ring groove.
RT21071060

c. Using a brush and solvent, thoroughly clean the

piston.
RT21071070
CAUTION
 DO NOT use a wire brush to clean.
07 d. Measure the piston diameter with a micrometer at the

position that is approximately 11 mm under the piston
skirt in the vertical direction of piston pin.
Specification
Measurement Item
(mm)
Piston Diameter 83.455 ± 0.009
11 mm
If piston diameter is not within the specified range,
replace the piston connecting rod assembly.
RT21071080
5. Check clearance between piston ring and ring groove

side.
Using a feeler gauge, measure the clearance between
new piston ring and ring groove side.
Specification
Measurement Item
(mm)
Piston Ring Side First Ring 0.04 - 0.08

Clearance Second Ring 0.025 - 0.070
RT21071090
If piston ring side clearance is not within the specified

range, replace the piston connecting rod assembly.

6. Check piston ring end gap.

a. Using a piston, push the piston ring from the top of
cylinder to a place that is 45 mm from the top of
cylinder bore.
b. Using a feeler gauge, measure the end gap.
Specification
Measurement Item
(mm)
45 mm
Piston Ring End First Ring 0.2 - 0.4
Gap Second Ring 0.4 - 0.6
If piston ring end gap is not within the specified range,

replace the piston ring with a new one.
If end gap is still not within the specified range after
replacement, replace the engine block.
07
RT21071100
7. Check diameter of crankshaft main journal.

a. Using a micrometer, measure the main journal
diameter. Measure again after rotating the crankshaft
for 90°.
Specification
Measurement Item
(mm)
0
Crankshaft Main Journal Diameter 54 -0.019
If crankshaft main journal diameter is not within the RT21071110

specified range, replace the main bearing shells with
new ones, and check radial clearance of crankshaft
(See page 07-90).
If radial clearance of the main bearing shell is still not
within the specified range after replacement, replace
the crankshaft.
b. Calculate the crankshaft cylindricity by measured values (measured area is shown in the illustration).
Roundness calculation method (for general measurement):
Measure the diameter twice on the same cross section, and the roundness is half of the difference
between maximum and minimum values.
Roundness = (maximum diameter - minimum diameter)/2
As shown in the illustration, measure the diameter twice in different directions on two cross sections
separately to obtain four values. The cylindricity is the half of the difference between maximum and
minimum values among the four values.
Cylindricity = (maximum diameter - minimum diameter)/2

Cylindricity 0.007
Roundness 0.04

If roundness or cylindricity of crankshaft main journal exceeds the specified value, replace the
crankshaft.
8. Check crankshaft radial clearance.
a. Clean the crankshaft main journals and main bearing shells.
b. Install the crankshaft. Place the plastic feeler gauge
(1) on the crankshaft main journal, and make it
parallel to the crankshaft center axis and cover the
installation width range of main bearing cap
completely.
RT21071120
c. Install the crankshaft frame and tighten the main bearing cap fixing bolts to the specified torque in order.
07 d. Remove the crankshaft frame. Using the feeler gauge,
measure the widest part of compressed feeler gauge.
The measured value is the crankshaft radial
clearance.
Specification
Measurement Item
(mm)
Crankshaft Radial Clearance 0.021 - 0.059
If crankshaft radial clearance is not within the

RT21071130
specified range, install new main bearing shell.
Replace the crankshaft if necessary.
CAUTION
 Replace bearing shells in pairs.
For selection of main bearing shell (See page 07-93).

9. Check the crankshaft axial clearance.
a. Clean the crankshaft main journals and main bearing
shells.
b. Install the crankshaft frame and tighten the main
bearing cap fixing bolts to the specified torque in
order.
c. Push the crankshaft forward and backward and read
the value from the dial indicator.
Specification
Measurement Item
(mm) RT21071140
Crankshaft Axial Clearance 0.070 - 0.265
If crankshaft axial clearance is not within the specified

range, replace the thrust washer as a set.

10.Check the crankshaft coaxiality.

a. Install the crankshaft onto the inspection table and
keep it level.
b. Rotate the crankshaft slowly and read the maximum
change value from the dial indicator.
(Reading from the dial indicator)/2 is the coaxiality of
the crankshaft.
Specification
Measurement Item
(mm)
Coaxiality of Crankshaft 0.04 RT21071150
If radial runout is not at the specified range, replace

the crankshaft.
11. Check diameter of crankshaft connecting rod journal.

Using an outer diameter micrometer, measure the
diameter of crankshaft connecting rod journal. 07
Specification
Measurement Item
(mm)
Crankshaft Connecting Rod Journal 0
47.9 -0.016
Diameter
If connecting rod journal diameter is not within the RT21071160

specified range, replace the connecting rod bearing
shells with new ones, and check the radial clearance of
connecting rod bearing shell.
If radial clearance of connecting rod bearing shell is still
not within the specified range after replacement, replace
the crankshaft.
For selection of connecting rod bearing shell (See page
07-93).
12.Check radial clearance of crankshaft connecting rod bearing shell.
a. Clean connecting rod journals and connecting rod bearing shells.
b. Place a feeler gauge (arrow) on the connecting rod
journal as shown in the illustration.
RT21071170
c. Install the connecting rod bearing caps, and tighten the connecting rod bearing cap fixing bolts to 
20 + 5 N·m.
CAUTION
 DO NOT turn the crankshaft during installation.

d. Remove the connecting rod bearing caps.

e. Using the gauge scale of feeler gauge, measure the
widest part of the compressed feeler gauge to obtain
the radial clearance of connecting rod bearing shell as
Specification
Measurement Item
(mm)
Connecting Rod Bearing Shell Radial 1
0.021 - 0.056
Clearance
RT21071180
If radial clearance of connecting rod bearing shell is
not within the specified range, replace the connecting
rod bearing shell. Replace the crankshaft if necessary.
13.Check connecting rod big end axial clearance.
a. Install the connecting rod bearing caps, and tighten
the connecting rod bearing cap fixing bolts to the
07 specified torque. 1
b. Install a dial indicator (2) with its measuring rod
contacting the side of connecting rod cap (1).
c. Turn the dial of dial indicator to reset it to zero.
d. Push the connecting rod forward and backward (do
not move the crankshaft forward and backward) and 2
read the value on the dial indicator.
RT21071190
Specification
Measurement Item
(mm)
Connecting Rod Big End Axial
0.15 - 0.40
Clearance
If the axial clearance of connecting rod big end is not

within the specified range, replace the piston
connecting rod assembly.

Selection of Bearing Shell

Selection of main bearing shell
1. Selection of crankshaft main bearing upper shell.
Related letter marks are available on the cylinder block
(consisting of "A" and "B"). Such as "BBBBA" in the
illustration, each letter from left to right is for one type of XXXXXX
crankshaft bearing upper shell. The first letter "B" is for XXXXXXX
the upper shell type of crankshaft main bearing first BB BBA
journal, and so on; the fifth letter "A" is for the upper shell 201 NA
type of crankshaft main bearing fifth journal.
Cylinder Block
Name Color RT21071191
Mark
Main Bearing Red A

Upper Shell Blue B
07
2. Selection of crankshaft main bearing lower shell.
Related marks are available on the first balancer at the
front end of crankshaft (consisting of "A" and "B"). Such 1221 13F14
as "AAABB" on the first crankshaft front end balancer AAABB
shown in the illustration, the first letter "A" is for the lower
shell type of crankshaft main bearing first journal, and so
on; the fifth letter "B" is for the lower shell type of AAABB
crankshaft main bearing fifth journal.
Cylinder Block
Mark
Main Bearing Red A

Lower Shell Blue B
3. Precautions for crankshaft main bearing shell assembly:

a. There is shell groove and oil hole on the main bearing upper shell, and the oil hole should be aligned
with that on the engine block, but the main bearing lower shell has no oil hole.
b. Apply a coat of engine oil to the inner surface of main bearing shell before installation. The back side of
bearing shell should be clean without any oil or foreign matter during assembly.

Selection of Connecting Rod Bearing Shell

1. Selection of connecting rod bearing upper shell.
Connecting rod bearing upper shells are divided into red
shells and blue shells. Related marks are available on
the connecting rod. Select related connecting rod bearing
shell according to the marks.
481HK
As shown in the illustration, among the mark "130523 B"
130523 B
on the connecting rod, "B" indicates blue shell.
Connecting Rod
Name Color
Mark RT21071193
Connecting Rod Red A

Bearing Upper
Shell Blue B
2. Selection of connecting rod bearing lower shell.

07 Related digital marks are available on the first balancer at 1221
the front end of crankshaft (consisting of "1" and "2"). 1221 13F14
Such as "1221" on the first crankshaft front end balancer AAABB
shown in the illustration, the first digit "1" is for the lower
shell type of the 1st cylinder piston connecting rod, and
so on; the fourth digit "1" is for the lower shell type of the
fourth cylinder piston connecting rod.
Connecting Rod
Mark
Connecting Rod Red 1
Bearing Lower
Shell Blue 2
3. Precautions for connecting rod bearing shell assembly:

a. The connecting rod upper and lower bearing shells without oil grooves are universal, but one of the
connecting rod bearing shells has oil hole.
b. It is necessary to use a set of connecting rod bearing shells that are provided by the same
manufacturer on the same engine.
c. Apply a coat of engine oil to the inner surface of the connecting rod bearing shell before installation.
The back side of bearing shell should be clean without any oil or foreign matter during assembly.
Assembly
1. Install the crankshaft main bearing shell.
CAUTION
 Apply a coat of engine oil to the inner surface of main bearing shell before installation.

a. Carefully install the crankshaft bearing uppe shell (1)

in the direction of arrow, and the notch of each main
bearing upper shell should be aligned with the 1
cylinder block. The oil passage hole (2) on crankshaft
main bearing should be aligned with the passage hole
on cylinder block after installation.
HINT:
Install the crankshaft main bearing lower shells to the 2
crankshaft frame in the same way,and the notch of
each main bearing lower shell should be aligned with RT21071200
the crankshaft frame.
2. Install the crankshaft thrust washer.
a. Clean the crankshaft thrust washers and cylinder block inner wall before installation.
b. Apply a coat of engine oil to the crankshaft thrust washers.
c. There are 2 crankshaft thrust washers on the cylinder, which are installed on the front and rear sides of
thrust surface (both sides of 3rd bearing) respectively.
d. As shown in the illustration, the two grooves on one 07
side of crankshaft thrust washers (1) face outward
1
while the other side without groove is jointed with the
cylinder block inside wall.
RT21071010
3. Install the crankshaft.

a. Apply seal gum to the installation surface of frame
RT21071210

CAUTION
 DO NOT apply seal gum into the bearing shell installation area when applying seal gum.
 Seal gum should not be applied too thick. Avoid seal gum entering bearing shell installation area due to
compressing.
b. Place the crankshaft on the cylinder block carefully.

c. Install the crankshaft main bearing cap fixing bolts in
7 3 2 6 10
place by hand, and tighten 10 crankshaft main
bearing cap fixing bolts in the order shown in the
illustration.
07 8 4 1 5 9
RT21071211
d. Evenly tighten 10 crankshaft frame fixing bolts in the

7 3 2 6 10
order shown in the illustration. 
8 4 1 5 9
RT21071220
4. Install the piston ring.

a. The first compression ring is rectangular ring (1), the
second compression ring is conical ring (2), and the
oil ring is steel band combination ring. Apply a small
amount of engine lubricant to the piston ring groove
1
and piston. Note that the side with words for first
2
compression ring should face upward and the outer
cutting of second compression ring should face
downward. 3
b. The oil ring is steel band combination oil ring and 4
composed of upper rail (3), lower rail (5) and
5
expander (4). When installing the oil ring, first install
the expander into the oil groove, then install the two Openings of Each Ring：
rails with the two rails opening of steel band Lower Rail
combination oil ring staggered by 90° from the First Compression Second Compression
expander closed gap, and the upper and lower rails Ring Ring
180°. Then install the second compression ring, and Front Rear
install the first compression ring finally with the two Expander
compression rings staggered by 120° from the upper
rail opening. The piston ring should rotate in the ring Upper Rail
groove freely without any stuck condition.

RT21071230

c. Rotate the piston ring several turns after applying engine oil to the piston ring groove, and note that the
position of ring notch should be the same with that described above; clean the crankshaft connecting
rod journal and cylinder bore with a non-woven fabric cloth.
5. Install the connecting rod bearing shell.
CAUTION
 Apply a coat of engine oil to the inner surface of connecting rod bearing shell before installation.
 Back side of connecting rod bearing shell should be clean without any oil or foreign matter during
assembly.
a. Carefully install the connecting rod bearing upper

shell (1) in the direction of arrow, and keep the groove 1
opening of each connecting rod bearing upper shell
face the piston and connecting rod assembly.
07
RT21071240
b. Carefully install the connecting rod bearing lower shell

(1) in the direction of arrow, and keep the groove
opening of each connecting rod bearing lower shell
face the connecting rod bearing cap.
1
RT21071250
6. Install the piston connecting rod assembly.

a. Rotate the crankshaft to the top dead center of 1st and 4th cylinder.
b. Apply a coat of engine oil to the piston surface and cylinder inside wall.
c. As shown in the illustration, install the piston
connecting rod assembly to the cylinder with the
piston installer (1).
1
RT21071260

CAUTION
 Pay attention to the front marks of piston and connecting rod during assembly without being reversed.
Install them with the side stamped with letter "481HK" on the connecting rod and piston top arrow facing
toward timing belt side as shown in the illustration.
481HK
481HK
07 RT21071270
7. Install the connecting rod bearing cap.

HINT:
The direction of the number on one side of connecting
rod is the same as that of the number on the connecting
rod bearing cap. These numbers are cylinder numbers
481HK
indicating at which cylinder are located. For example, 3
number 3 indicates that the mounting position is at No.3
3
cylinder.
RT21071280
a. Install the connecting rod bearing cap in place, and

screw the connecting rod bearing cap fixing bolts
(arrow) by hands, then tighten the connecting rod
bearing cap fixing bolts in two steps.
RT21070950
CAUTION
 Apply a small amount of engine lubricant to the connecting rod, connecting rod bearing cap and thread
joint surface.
8. Other assembly is in the reverse order of disassembly.

GENERAL INFORMATION 08-3 Electric Fuel Pump Assembly 08-14
Description 08-3 On-vehicle Inspection 08-14
Specifications 08-4 Removal 08-15
Tools 08-5 Installation 08-17
Fuel Supply System Line Connection  Filler Tube Assembly 08-18
Diagram 08-6 Removal 08-18
Circuit Diagram 08-7 Installation 08-20
Fuel Tank 08-21
Removal 08-21
Problem Symptoms Table 08-9
Installation 08-25
Fuel System Pressure Release 08-10
Fuel Rail Injector Assembly 08-26
Fuel Supply System Pressure Test 08-11
Removal 08-26
Fuel Filter Assembly 08-12 Installation 08-27
Removal 08-12 08
Installation 08-13

08

08 - SQR484F FUEL SUPPLY SYSTEM
GENERAL INFORMATION
Description
2
5
×3
3
6
×5
7 08
8
11 9
10
13
14
12
17 15
16
RT21080010

1 - Fuel Pump Pressure Cap 2 - Electric Fuel Pump Assembly

3 - Fuel Tank Seal Ring 4 - Fuel Level Sensor
5 - Fuel Tank Cap Assembly 6 - Filler Tube Assembly
7 - Fuel Breather Hose 8 - Fuel Filler Hose
9 - Fuel Tank 10 - Inlet Pipe I
11 - Inlet and Return Pipe Assembly 12 - Fuel Filter Assembly
13 - Fuel Tank Fixing Strap I 14 - Fuel Tank Fixing Strap II
15 - Fuel Tank Fixing Strap III 16 - Inlet Pipe II
17 - Fuel Rail Injector Assembly
Engine fuel supply system provides a certain amount and concentration of combustible air-fuel mixture and
supplies it to cylinders according to the requirements under various operating conditions of engine. Fuel
supply system consists of fuel tank assembly, electric fuel pump assembly, fuel filter assembly, delivery pipe,
fuel rail and injectors, and is used for fuel storage, filtration, delivery and injection.
08 Function of fuel supply system is to provide gasoline with sufficient pressure to fuel injectors by using electric
fuel pump assembly, and the injector injects a certain amount of gasoline to the top of intake valve in intake
manifold in accordance with control signals from ECM.
Specifications

Fuel Filter Ground Wire Fixing Nut 7±1
Fuel Filter Bracket Fixing Screw 3.5 ± 0.5
Fuel Tank Pressure Cap 75 ± 5
Coupling Bolt Between Filler Tube Assembly and
22 ± 2
Body
Filler Tube Assembly Fixing Nut 7±1
Fuel Tank Fixing Strap Fixing Bolt 25 ± 3
Fuel Level Sensor Fixing Screw 5±1
Fuel Rail Fixing Bolt 8+3
Worm Clamp 3.5 ± 0.5


Tools
Special Tool
Fuel Tank Pressure Cap Remover
RCH0000004
General Tools
08
Digital Multimeter
RCH0000002
Fuel System Pressure Tester
RCH0000048
RCH0000005

Fuel Supply System Line Connection Diagram
3 4
2 1
08
RT21080020
1 - Electric Fuel Pump Assembly 2 - Electric Fuel Pump Assembly Pressure Regulator
3 - Fuel Filter Assembly 4 - Inlet and Return Pipe Assembly
5 - Fuel Rail Injector Assembly
When engine operates properly, electric fuel pump assembly (1) sucks fuel from fuel tank and filters it through
fuel filter assembly (3), and then deliveries it to inlet and return pipe assembly (4). Some fuel enters fuel rail
(5) and is supplied to injector. Some fuel flows back to electric fuel pump assembly pressure regulator (2)
directly. When fuel supply system pressure is high, diaphragm spring in the regulator is jacked up by pressure,
then valve opens and fuel flows out from the regulator. When pressure reaches normal value, the regulator
shuts off and fuel stops flowing out. Finally, system pressure reaches a steady state.

Circuit Diagram
Fuel Supply System (Page 1 of 2)
IGNITION SWITCH BATTERY

ON OR START
INSTRUMENT
PANEL
RF06 RF23 FUSE AND
10A 10A RELAY BOX 30 85 85 30
I-007 ENGINE
FUEL EF19 ECM
6 23 COMPARTMENT
PUMP MAIN
10A FUSE AND
RELAY RELAY
RELAY BOX
87 86 86 87
E-069
R
E-076
P
E-023
EF38 EF40 EF08 E-073
EF35
7.5A 10A 15A
15A
13 11
INSTRUMENT
CLUSTER
B6 F7 F6 A8 A2 F14 A6 C3
08
RL
RL
R
I-015
3 5 21 A
R
VB
Br
B
E-070
12 13 B-048
BY
RL
Br
R
I-006 B-003
R
I-003
VB
1 3 FUEL
PUMP
Q 41 20 5 15 16
M MOTOR
B-038
ECM
E-033
2 4
Br
B-032 B-036
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 C1 C2 C3 C4 C5

1 2 3 4
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 A6 A7 A8 A9 A10 B6 B7 B8 B9 B10 C6 C7 C8 C9 C10
B-038
B
E-069 E-076 E-073 E-023
W Gr Y L
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
27 25 26 I-007
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
87 B
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 85 86 86 86
87 30 87 30
E-033 30 85 85
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10
E-070
11 12 13 14 15 16 17 18 19 20 21 22 W
10 9 8 7 6 5 4 3 2 1
I-006
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-015 22 21 20 19 18 17 16 15 14 13 12 11
W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 L
ET21080010

Fuel Supply System (Page 2 of 2)
A
RL
RL
RL
RL
RL
1 1 1 1
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4
E-010 E-011 E-012 E-013
08 2 2 2 2
GBr
GW
GR
GB
E-007
15 14 13 12 E-038
GBr
GW
GR
GB
4 3 8 10
ECM
E-035
42 38 34 30 25 20 15 10 5
41 37 33 29 24 19 14 9 4
28 23 18 13 8 3 37 38 39 40 41 42 43 44 45 46 47 48
40 36 32
27 22 17 12 7 2
25 26 27 28 29 30 31 32 33 34 35 36
39 35 31 26 21 16 11 6 1
13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12
E-007
B
E-035
1 2 1 2 1 2 1 2 B
E-010 E-011 E-012 E-013

B B B B
ET21080020

DIAGNOSIS & TESTING

HINT:
Use the table below to help determine the cause of problem symptoms. Check each suspected area in
sequence. Repair or replace the faulty components, or adjust as necessary.

Fuel filter assembly (blocked) 08-12
Fuel pressure in fuel supply system is too
low Electric fuel pump assembly (strainer
08-14
blocked)
Fuel pressure in fuel supply system is too Fuel injector (clogged) 08-26
high Electric fuel pump assembly 08-14
Low fuel level -
Electric fuel pump assembly has loud
Electric fuel pump assembly relay -
operating noise and operates delay 08
Electric fuel pump assembly 08-14
Fuel filter assembly (blocked) 08-12
Fuel injector 08-26
Injector is clogged and leaks
Poor fuel quality -
Excessive foreign matter in fuel tank -
Fuel supply system line (broken) -
Fuel injector (short in coil) 08-26
Injector does not work
Electric fuel pump assembly (damaged) 08-14
Wire harness -

Fuel System Pressure Release

WARNING
 When engine is not operating, fuel pressure in fuel supply system is still high. Before repairing or
disconnecting fuel line or fuel supply system components, it is necessary to release the fuel supply
system pressure to prevent fuel from spraying out accidentally. Failure to follow these instructions may
result in serious personal injury or death.
Perform the following procedures to release fuel pressure in fuel supply system:
1. Recognize and remove electric fuel pump assembly relay from engine compartment fuse and relay box.
08
ERL Y08 ERL Y07 ERL Y06 ERL Y05 ERL Y04 ERL Y03 ERL Y02 ERL Y01
Fuel relay IGN2 relay Backup light A/C Horn relay Front fog Low beam High beam
relay compressor light relay relay relay
(CVT model)
EF20 10A
EF19 10A
EF18 15A
EF17 10A
EF15 15A
EF10 10A
EF08 15A
EF07 15A
EF05 15A
EF04 20A
EF03 20A
EF02 20A
EF01 20A
EF16
EF14
EF13
EF12
EF11
EF09
EF06
EF40 10A
EF39 10A
EF387.5A
EF37 10A
EF36 10A
EF35 15A
EF34 20A
EF30 10A
EF29 10A
EF28 10A
EF27 10A
EF26 10A
EF25 15A
EF33
EF32
EF31
EF24
EF23
EF22
EF21
ERL Y13 ERL Y12 ERL Y11 ERL Y10 ERL Y09
ACC relay TCU relay Main relay ING1 relay Start relay
(CVT model)
EF48 EF47 EF46 EF45 EF44 EF43 EF42 EF41

20A 25A 20A 20A 30A
ERL Y16 Fuse

ERL Y15
puller ERL Y14
Cooling fan relay Blower relay
RT21080030
2. Start and run engine until it stalls.

3. Restart engine until it does not run.
4. Turn ignition switch to LOCK.
6. Insert the electric fuel pump assembly relay into the original place.

Fuel Supply System Pressure Test


WARNING
 When operating fuel supply system, work area should be in good ventilation and keep fire sources or
open flames away from the work area, in which the fire extinguisher should be equipped.
 Before operating fuel supply system, please touch vehicle body to discharge static electricity; failure to
do so will cause a fire, even result in an explosion.
 Before removing and installing fuel pipes, release fuel supply system pressure.
08
CAUTION
 Make sure battery voltage is 11 - 12 V.

 Service life of fuel filter assembly should be within 30,000 km.
 Make sure fuel supply system lines are securely connected, preventing fuel supply system from leaking.

3. Disconnect the inlet hose connector and connect the fuel
supply system pressure tester to a position between inlet
hose and fuel rail.
Fuel Hose
RT21080040
4. Start engine and run it at idle, and then read the value on pressure tester.
Start engine and read the value while idling:
- Standard pressure at idle should be higher than 400 kPa.
- If measured pressure value is lower than 400 kPa, check fuel filter assembly for blockage.
Replace fuel filter assembly if necessary (See page 08-12).
- If measured pressure value is lower than 400 kPa and fuel filter assembly operates properly, check
electric fuel pump assembly. Replace as necessary.
- If measured pressure value is too high, it indicates that injector may be clogged or electric fuel pump
assembly pressure modulating valve may be malfunctioning.
Replace injector (See page 08-26) or electric fuel pump assembly (See page 08-14) if necessary.

ON-VEHICLE SERVICE
Fuel Filter Assembly
Removal
WARNING
 After performing procedures for fuel system pressure release, there still remains some pressure in fuel
line. When disconnecting fuel line, cover the joint with a piece of cloth or equivalent to prevent fuel from
spraying out.
 If fuel leakage occurs when operating fuel supply system, please handle the leaked fuel in time.
08
CAUTION
 DO NOT damage disconnected fuel system line or connectors. Cover line joints or connectors with
plastic bags or equivalent, preventing foreign matter from entering.
Disconnection way for all fuel pipe coupling joints in

following procedures is shown in the illustration.
RT21080050
1. Release fuel pressure in fuel supply system (See page 08-10).

4. Raise the vehicle to a proper height.

5. Remove the fuel filter assembly.

a. Remove the fuel filter ground wire fixing nut (1).
b. Disconnect the connecting joints (arrow) on both ends 1
of the fuel filter assembly.
c. Loosen the fuel filter bracket fixing screw (2).
(Tightening torque: 3.5 ± 0.5 N·m)
RT21080060
d. Remove the fuel filter assembly from fuel filter bracket.
CAUTION
 Cover both ends of fuel filter with plastic bags or equivalent to prevent foreign matter from entering.
08
 Removed fuel filter should be handled by the specialized department according to local laws and
regulations. Never discard it at will.
Installation
CAUTION
 Before connecting hose, check if there is any damage or foreign matter on the hose or joint.
 When installing, push in fuel pipe joint clip until a click sound is heard from coupling joint, then check that
fuel pipe joint clip is on the collar of fuel pipe joint. After installing pipe joint clip, check that fuel pipe joint
cannot be pulled out. Be careful not to damage the joint. If the clip is damaged, replace it.
 Turn ignition switch ON (without starting engine) to apply fuel pressure to fuel supply system, and then
check connections for leakage.

Electric Fuel Pump Assembly

1. Check electric fuel pump assembly fuel level sensor.
a. Using a flat tip screwdriver, pry up electric fuel pump
assembly protective cap, and disconnect electric fuel
pump assembly connector.
b. Using a digital multimeter, measure resistance of fuel + -
level sensor based on the fuel volume in fuel tank.

4 3 2 1
Fuel Level Multimeter
Specification (Ω)
Indicator Connection
Terminal 1 -
E 283 ± 4
Terminal 2 RT21080061
Terminal 1 -
Low Fuel Warning 189 ± 4
Terminal 2
Terminal 1 -
1/4 137 ± 5
08 Terminal 2
Terminal 1 -
1/2 89 ± 4
Terminal 2
Terminal 1 -
3/4 62 ± 3
Terminal 2
Terminal 1 -
F 40 ± 3
Terminal 2
If result is not as specified, replace the fuel level sensor.

2. Check electric fuel pump assembly operation.
a. Using a flat tip screwdriver, pry up electric fuel pump assembly protective cap.
b. Apply battery voltage to terminals 3 and 4. Check if electric fuel pump assembly operates in 10
seconds.
HINT:
 These tests must be finished within 10 seconds to
prevent coils from being burnt. -
+
 Leave electric fuel pump assembly as far as
possible from the battery.
 Always switch voltage on and off on battery side,
4 3 2 1
rather than electric fuel pump assembly side.
Multimeter Connection Specification

Battery positive (+) - Terminal 3 Fuel pump RT21080062
Battery negative (-) - Terminal 4 operates
If electric fuel pump assembly does not operate,

replace it.

Removal
WARNING
spraying out.
CAUTION

 Try to prevent body paint surface from being scratched during removal and installation. 08
 Operation staff should wear protective glasses and rubber gloves and avoid inhaling much fuel gas.
 Only use parts approved by Chery Automobile Co., Ltd. to replace electric fuel pump assembly.
 As electric fuel pump assembly radiates through fuel, low fuel level in fuel tank will directly shorten the
service life of electric fuel pump assembly.
 Keep electric fuel pump assembly and work area clean when replacing electric fuel pump assembly,
otherwise the electric fuel pump assembly element will be clogged.
 Keep fuel tank and line clean, and replace fuel filter assembly if electric fuel pump assembly has been
replaced.
Disconnection way for all coupling joints in the following

procedures is as shown in the illustration.
RT21080050

4. Open the fuel tank cap assembly and release fuel vapor from fuel tank.
5. Remove the rear right seat (See page 46-25).

6. Remove the electric fuel pump assembly.

a. Using a flat tip screwdriver (1), pry up the electric fuel
pump assembly protective cap (2).
2
RT21080070
b. Disconnect the electric fuel pump assembly connector

(arrow).
c. Disconnect the coupling joint (1) between electric fuel
pump assembly and inlet pipe I assembly.
d. Disconnect the coupling joint (2) between electric fuel
pump assembly and inlet and return pipe assembly.
08 1
2
RT21080080
CAUTION
 Before disconnecting the joint, remove all dirt and foreign matter from electric fuel pump assembly
pressure cap.
 DO NOT forcefully bend or twist delivery pipe.
e. Using special tool (fuel tank pressure cap remover),

remove the fuel tank pressure cap as shown in the
illustration.
RT21080090
f. Pull up the electric fuel pump assembly from fuel tank

and disconnect the fuel level sensor connector
(arrow).
RT21080100

CAUTION
 Operate carefully when pulling the electric fuel pump assembly out of fuel tank, preventing damaging
lines, wire harnesses and fuel level sensor.
 To keep fuel tank portion clean, cover it completely with a plastic bag or equivalent to prevent foreign
matter from entering.
 The electric fuel pump assembly can be put into a container and taken out of the cabin, thus preventing
fuel in the pump from dropping into the cabin.
g. Take the electric fuel pump assembly out of fuel tank.

7. Drain the fuel in the electric fuel pump assembly.
CAUTION
 Cover electric fuel pump assembly completely with a plastic bag or equivalent to prevent foreign matter
from entering.
 It is not allowed to perform running test for electric fuel pump assembly under dry or water condition. 08
Otherwise it will reduce its service life. In addition, DO NOT connect battery positive and negative poles
inversely.
Installation
CAUTION
 DO NOT connect the negative battery cable during installation. Work area should be in good ventilation
and keep fire sources or open flames away.
 To avoid damaging electric fuel pump assembly, align electric fuel pump assembly with installation
position of fuel tank and DO NOT run the electric fuel pump assembly without fuel in fuel tank.
 Before connecting hose, check if there is any damage or foreign matter on hose or joint.
 During installation, push in fuel pipe connector until a click sound is heard, then check that fuel pipe joint
clip is on the collar of fuel pipe joint. After installing the pipe joint clip, check that fuel pipe joint cannot be
pulled out. Be careful not to damage the joint. If the clip is damaged, replace it.

Filler Tube Assembly

Removal
WARNING
CAUTION

08

3. Remove the C-pillar lower right protector assembly (See page 49-23).
4. Remove the fuel filler door assembly.
a. Open the fuel filler door, turn the fuel tank cap in the
direction of arrow as shown in the illustration.
RT21080110
b. Remove the fuel tank cap assembly (1) from fuel filler
door hinge assembly.
c. Remove the fuel filler door outer cover plate (2) from
fuel filler door hinge assembly in the direction of arrow
1
2
RT21080120

d. Remove the fuel filler door cable from fuel filler door
hinge assembly in the direction of arrow as shown in
the illustration.
RT21080130
e. Remove the water-guide pipe from clamp slot (arrow)

under the wheel house.
08
RT21080140
f. Disengage the clips from fuel filler door hinge

assembly and remove the fuel filler door hinge
assembly.
RT21080150
5. Remove the filler tube assembly.

a. Loosen the worm clamp (1) and disconnect the
connection between fuel breather hose and filler tube
assembly.
(Tightening torque: 3.5 ± 0.5 N·m) 1
b. Loosen the worm clamp (2) and disconnect the 3
connection between fuel filler hose and filler tube
assembly.
c. Remove the coupling bolt (3) between filler tube
assembly and body. RT21080160
CAUTION
 Cover the joint with a plastic bag after disconnecting fuel breather hose and fuel filler hose, in order to
prevent foreign matter from entering fuel tank and fuel from evaporating or leaking.

d. Remove 3 fixing screws (arrow) from filler tube

assembly.
RT21080170
e. Remove the filler tube assembly.
Installation
08

Fuel Tank
Removal
WARNING
spraying out.
CAUTION
08
Disconnection way for all fuel pipe coupling joints in

following procedures is shown in the illustration.
RT21080050

4. Open the fuel filler door, rotate the fuel tank cap
assembly in the direction of arrow as shown in the
illustration and discharge fuel vapor in fuel tank.
RT21080110

5. Disconnect line and wire harness connections on electric fuel pump assembly side.
a. Remove the rear right seat (See page 46-25).
b. Using a flat tip screwdriver (1), pry up the electric fuel
pump assembly protective cap (2).
2
RT21080070
c. Disconnect the electric fuel pump assembly connector

(arrow).
d. Disconnect the coupling joint (1) between electric fuel
pump assembly and inlet pipe I assembly.
e. Disconnect the coupling joint (2) between electric fuel
08 pump assembly and inlet and return pipe assembly.
2 1
RT21080080
CAUTION
 Before disconnecting the joint, remove all dirt and foreign matter from electric fuel pump assembly
pressure cap.
6. Remove the fuel filter assembly (See page 08-12).

7. Remove the fuel tank.
a. Loosen the worm clamp (1) and disconnect the
connection between fuel breather hose and filler tube
assembly.
b. Loosen the worm clamp (2) and disconnect the
connection between fuel filler hose and filler tube
assembly.
RT21080180
CAUTION
 Cover the joint with a plastic bag after disconnecting fuel breather hose and fuel filler hose, in order to
prevent foreign matter from entering fuel tank and fuel from evaporating or leaking.

c. Pull out the fuel breather hose from the body

installation hole.
d. Disconnect the coupling joint (1) between inlet and
1
return pipe assembly and inlet pipe II assembly.
e. Move away the fuel vapor pipe III assembly (2) from
the pipe clamp on fuel tank.
2
RT21080190
CAUTION
 Before disconnecting the joint, remove any dirt and foreign matter from the retainer.
f. Disconnect the coupling joint (arrow) between fuel

vapor pipe I assembly and fuel vapor pipe of fuel tank.
08
RT21080200
g. Support the fuel tank with a transmission carrier.
RT21080210
h. Remove 4 fixing bolts (arrow) from fuel tank fixing

strips and remove the fuel tank fixing strips.
RT21080220
i. Slowly lower the transmission carrier to remove the fuel tank.

8. Remove the fuel pump pressure cap (1), electric fuel

pump assembly (2) and fuel tank seal ring (3) from fuel
tank. 1
RT21080230
9. Remove the fuel level sensor.

a. Remove 5 fixing screws (arrow) from fuel level sensor.
08 (Tightening torque: 5 ± 1 N·m)
RT21080240
b. Remove the fuel level sensor from fuel tank.
CAUTION
 DO NOT damage the float when taking out the fuel level sensor.
Fuel Tank Accessories Description

1. Fuel Vapor Valve
Function of Fuel Vapor Valve:
When fuel vapor is produced in fuel tank, the vapor will enter charcoal canister through fuel vapor valve (1)
by fuel vapor pipe (2). When vehicle body bumps or overturns, fuel vapor valve will automatically lock to
prevent fuel overflow.
2. Fuel Breather Pipe
Function of fuel breather pipe:
When filling fuel tank through fuel filler, fuel vapor will get out of fuel tank through fuel breather pipe (3).

3. Fuel Tank Cushion

Pay attention to installation positions of fuel tank 1
cushions (arrow). Incorrect installation will damage the
fuel tank or fuel pipe due to friction between fuel tank and 2
body.
3
RT21080250
Installation
1. Install the fuel level sensor.
a. Install the fuel level sensor into the fuel tank.
CAUTION
 DO NOT break the float when installing the fuel level sensor.
08
b. Align mark (1) on the fuel level sensor and mark (2) on
the fuel tank.
c. Install 5 fixing bolts (arrow) to the fuel level sensor.
2
RT21080251
CAUTION
 Fuel lines and ventilation pipes must be reinstalled to the original positions on fuel tank. Otherwise the
friction caused by body vibration will damage fuel lines and lead to fuel leakage.
 Before connecting hose, check if there is any damage or foreign matter on hose or joint.
 During installation, push in fuel pipe connector until a click sound is heard, then check that fuel pipe joint
clip is on the collar of fuel pipe joint. After installing the pipe joint clip, check that fuel pipe joint cannot be
pulled out. Be careful not to damage the joint. If the clip is damaged, replace it.

Fuel Rail Injector Assembly

Removal
WARNING
spraying out.
CAUTION
08
 DO NOT damage the disconnected fuel system line or connectors. Cover line joints or connectors with
 Injector is a part of high accuracy, featuring good anti-clogging, anti-pollution and atomization, so be
careful not to damage the injector during removal of fuel rail.
1. Release fuel pressure in fuel supply system (See page 08-10).

5. Remove the fuel rail injector assembly.
a. Disconnect the connectors (arrow) of 4 injectors
separately.
RT21080260
b. Move away the engine wire harness clips from fuel rail.

c. Disconnect the coupling joint (1) between delivery

pipe and fuel rail.
d. Loosen and remove 2 fixing bolts (arrow) from fuel 1
rail.
RT21080270
e. Remove the fuel rail and fuel rail injectors.

6. Remove the injector clamps and remove the injectors
(arrow) from fuel rail.
08
RT21080280
Inspection
1. Disconnect the injector connectors.
2. Measure resistance between 2 terminals (injector side) of
injector with a digital multimeter.
+ -
Multimeter Measurement 1 2
Specification (Ω)
Connection Temperature
Terminal 1 -
20°C 12
Terminal 2
RT21080290
Installation
CAUTION
 Install a new seal to the injector sealing surface.

 Before installing the injector, apply clean grease or gasoline to the O-ring sealing surface for easy
installation, preventing damage to the O-ring.

- MEMO -

GENERAL INFORMATION 09-3 Activated Charcoal Canister Assembly 09-9
Specifications 09-4 Installation 09-10
Tool 09-4 PCV Valve 09-11
Circuit Diagram 09-5 Removal 09-11
Inspection 09-11
Installation 09-12
Leakage Inspection 09-6
Upstream Oxygen Sensor 09-13
Activated Charcoal Canister Inspection 09-6
Removal 09-13
Fuel Tank Cap Assembly Inspection 09-6
Inspection 09-14
ON-VEHICLE SERVICE 09-7 Installation 09-14
Activated Charcoal Canister Solenoid  Downstream Oxygen Sensor 09-15
Valve and Bracket 09-7 Removal 09-15
Removal 09-7 Inspection 09-15
Inspection 09-8 Installation 09-15
Installation 09-8
09

09

09 - SQR484F EMISSION CONTROL SYSTEM
GENERAL INFORMATION
Description
4
2
3
MAX
09
MIN
RT21090010
1 - Fuel Tank Assembly 2 - Activated Charcoal Canister Solenoid Valve

3 - PCV Valve 4 - Activated Charcoal Canister Assembly
Emission control system recovers and burns fuel vapor to prevent the vapor in fuel tank from being
discharged into the atmosphere. It monitors the oxygen content in exhaust gas, so as to guarantee the
maximum efficiency of catalyst assembly in converting the HC, CO and NOx in exhaust gas.
Activated charcoal canister assembly plays an important role in the emission control system. The activated
charcoal canister assembly can be used to absorb and filter moisture and fuel vapor. Fresh air enters the
bottom of activated charcoal canister assembly while fuel vapor enters the top of activated charcoal canister
through pipe. When engine stops operating, the fuel vapor and fresh air will be stored in the activated
charcoal canister assembly. When canister solenoid valve opens, the fuel vapor will enter intake manifold to
burn.

Oxygen sensor consists of upstream oxygen sensor and downstream oxygen sensor. Upstream oxygen
sensor is installed on the upper part of precatalytic converter assembly, and downstream oxygen sensor is
installed on the lower part of precatalytic converter assembly. The oxygen sensor can detect the oxygen
content in exhaust gas, and determine whether combustible air-fuel mixture is completely burnt out or not, so
as to guarantee the maximum efficiency of catalyst assembly in converting the HC, CO and NOx in exhaust
gas.
Specifications

7±1
Fixing Bolt
Coupling Bolt Between Activated Charcoal Canister
7±1
Assembly and Body
09
Tool
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Emission Control System
BATTERY
85 30
ECM
MAIN ENGINE
RELAY COMPARTMENT
EF19 86 87 FUSE AND
10A RELAY BOX
E-069
EF40 EF39 EF27 E-076
E-023
10A 10A 10A
A2 F14 A6 A7 C9
R
RL
09
R
R 1
1 4 4 CANISTER
1
REAR FRONT SOLENOID
OXYGEN OXYGEN VALVE
RL
Br
SENSOR SENSOR 2 E-024

E-043 E-084
2 3 2 3
L
E-007
11
WG
GW
E-038
GL
RL
YL
YL
2-20 2-5 2-15 2-16 2-43 2-21 2-48 1-16 1-40 1-9 1-30
ECM
E-033
E-035
42 38 34 30 25 20 15 10 5
A1 A2 A3 A4 A5 C1 C2 C3 C4 C5 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
41 37 33 29 24 19 14 9 4
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 28 23 18 13 8 3
A6 A7 A8 A9 A10 C6 C7 C8 C9 C10 40 36 32
27 22 17 12 7 2
E-069 39 35 31 26 21 16 11 6 1
E-076 E-023
E-024 W 1 2 3 4
Gr L 1 2
B E-007
E-043 E-084
B B B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12
E-033 E-035
B B ET21090010

DIAGNOSIS & TESTING

Leakage Inspection
Visually check that hoses, connections and gaskets have no cracks, leaks or damage.
CAUTION
 Removal of engine oil dipstick, filler cap, PCV hose and other components or other problems in them
may cause engine to run improperly.
 Air suction caused by disconnections, looseness or cracks in intake system pipes related with throttle
assembly will result in engine failure or abnormal operation. Replace parts as necessary.
Activated Charcoal Canister Inspection

1. Close port C and blow compressed air into port A, check
that air flows from port B. If result is not as specified, B
replace canister. C
2. Close port C and blow compressed air into port B, check
A
09 that air flows from port A. If result is not as specified,
replace canister.
RT21090020
Fuel Tank Cap Assembly Inspection

1. Visually check that fuel tank cap assembly is not
deformed or damaged.
2. If result is not as specified, replace fuel tank cap
assembly.

ON-VEHICLE SERVICE
Activated Charcoal Canister Solenoid Valve and Bracket
Removal
CAUTION

 Before removal, mark fuel vapor pipe III assembly and outlet hose to avoid confusion.

4. Remove the activated charcoal canister solenoid valve.
a. Disconnect the canister solenoid valve connector
(arrow). 09
b. Disengage the clamps (1) and disconnect both ends
of canister solenoid valve from the hose.
RT21090030
CAUTION
 Positioning distance from hose end to clamp is 3 - 5 mm.
c. Remove the canister solenoid valve from the bracket.

5. Remove the activated charcoal canister solenoid valve bracket.
a. Remove 2 fixing bolts (arrow) from the activated
charcoal canister solenoid valve bracket, and remove
the activated charcoal canister solenoid valve bracket.
RT21090040

Inspection
Measure resistance between 2 pins of canister solenoid with
a digital multimeter.
+ -
2 1
Multimeter Measurement
Specification (Ω)
Connection Temperature
Terminal 1 -
20°C 26 ± 4
Terminal 2
RT21090050
Installation
09

Activated Charcoal Canister Assembly

Removal
CAUTION

 Before removal, mark fuel vapor pipe II, fuel vapor pipe I and charcoal canister breather pipe to avoid
confusion.

3. Raise the vehicle to the proper position.
4. Remove the activated charcoal canister assembly.
a. Pull out the charcoal canister breather pipe (1) from
body hole. 1
b. Remove the coupling bolt (arrow) between activated
charcoal canister assembly and body
09
c. Remove the activated charcoal canister assembly
from body bracket in the direction of arrow as shown
in the illustration.
RT21090060
d. Loosen the elastic clamps (arrow), disconnect the

connection between hose and activated charcoal
canister assembly, and remove the activated charcoal
canister assembly.
e. Loosen the elastic clamp (1), remove the charcoal
1
canister breather pipe from activated charcoal
canister assembly.
RT21090070
CAUTION
 Positioning distance from hose end to elastic clamp is 3 - 5 mm.

f. Remove the fixing nut (arrow), separate the activated

charcoal canister assembly and activated charcoal
canister protection box.
RT21090080
 Unneeded activated charcoal canister assembly should be handled by the specialized department
according to local laws and regulations. Never discard it at will.
Installation
09

PCV Valve
Removal
CAUTION


4. Remove the PCV valve.
a. Take out the pipe assembly with PCV valve assembly
from PCV valve rubber boot in the direction of arrow
09
RT21090090
b. Remove the PCV valve (1) from line assembly.

c. Remove the PCV valve rubber boot (2) from T-joint.
RT21090100
Inspection
1. Install a clean hose to PCV valve.
2. Check PCV valve operation.
a. Blow air into the T-joint side, and check that air flows smoothly.
WARNING
 DO NOT suck air through valve. Petroleum substances inside the valve are hazardous to your health.
b. Blow air into intake manifold side, and check that air flows difficultly.
If result is not as specified, replace PCV valve.
3. Remove the clean hose from PCV valve.

Installation
CAUTION
 Press PCV valve rubber boot into T-joint, then press in the PCV valve.
 End surface of PCV valve larger diameter is flush with end surface of PCV valve rubber boot.
09

Upstream Oxygen Sensor

Removal
WARNING
 Temperature of exhaust system is very high when engine is running. Before removal and installation, you
must make sure that the engine has stopped running; otherwise there is a risk of scald injury.

4. Remove the upstream oxygen sensor.
a. Remove and disconnect the upstream oxygen sensor
connector (arrow) from bracket.
09
RT21090110
b. Remove 4 fixing bolts (arrow) from exhaust manifold

heat insulator, and remove the exhaust manifold heat
insulator.
RT21110020
c. Remove the upstream oxygen sensor (arrow) from

precatalytic converter assembly.
RT21090130

Inspection
1. Measure resistance of upstream oxygen sensor with a
digital multimeter.
+ -
Multimeter Specified D C B A
Condition
Pin C - Pin D 20°C 7 - 11 Ω
Pin A - Pin B
Pin A - Pin C
Pin A - Pin D Always No continuity RT21090140
Pin B - Pin C
Pin B - Pin D
If result is not as specified, replace upstream oxygen sensor.
Installation
09


Removal
WARNING
 Temperature of exhaust system is very high when engine is running. Before removal and installation, you
must make sure that the engine has stopped running; otherwise there is a risk of scald injury.

3. Raise the vehicle to the proper position.
4. Remove the downstream oxygen sensor.
a. Remove and disconnect the downstream oxygen
sensor connector (1) from bracket.
b. Remove the downstream oxygen sensor (arrow) from
precatalytic converter assembly.
09
RT21090150
Inspection
1. Measure resistance of downstream oxygen sensor with a
digital multimeter.
+ -
Multimeter Specified D C B A
Condition
Pin C - Pin D 20°C 7 - 11 Ω
Pin A - Pin B
Pin A - Pin C
Pin A - Pin D Always No continuity RT21090140
Pin B - Pin C
Pin B - Pin D
If result is not as specified, replace downstream oxygen sensor.
Installation

- MEMO -

GENERAL INFORMATION 10-3 Air Induction Pipe Assembly 10-16
Tools 10-4 Air Filter Assembly & Bracket 10-17
Installation 10-19
Electronic Throttle Assembly 10-20
On-vehicle Inspection 10-20
ON-VEHICLE SERVICE 10-10 Removal 10-20
Engine Trim Cover Assembly &  Inspection 10-22
Bracket 10-10 Cleaning 10-22
Installation 10-12 Intake Manifold Assembly 10-24
Hot Wire Air Flow Meter 10-13 Removal 10-24
Installation 10-13 Installation 10-26
Air Filter Element 10-14 Electronic Accelerator Pedal 10-27
Removal 10-14 Removal 10-27 10

10

10 - SQR484F INTAKE SYSTEM
GENERAL INFORMATION
Description
3 4
2 ×2
×2
5
×2
6
×3
9
10 8
7 10
×4
11
12
14 ×9
13
15
RT21100010
1 - Engine Trim Cover Assembly 2 - Rear Intake Hose

3 - Hot Wire Air Flow Meter 4 - Air Filter Upper Housing
5 - Air Filter Element 6 - Air Filter Lower Housing
7 - Air Filter Assembly Bracket 8 - Air Induction Pipe Assembly
9 - Worm Clamp 10 - Front Intake Hose
11 - Electronic Throttle Assembly 12 - Electronic Throttle Assembly Gasket
13 - Intake Manifold Assembly 14 - Intake Manifold Gasket
15 - Intake Manifold Assembly Lower Bracket

Intake system mainly consists of air induction pipe, air filter assembly, hot wire air flow meter, intake hose,
electronic throttle assembly and intake manifold assembly, etc.
Intake system uses air filter to filter particles and dust in air. The air filtered flows into intake manifold through
electronic throttle assembly and mixes with fuel at the end of intake manifold assembly port to form flammable
gas mixture, which is transmitted to each cylinder uniformly to coordinate with engine operation.
Electronic throttle assembly is a critical part for engine intake system. Its main function is to adjust the intake
passage area according to driver's driving intention. It controls intake air volume to meet intake requirement of
engine in different operating conditions, and sends back position signals of throttle valve plate to control unit
to achieve accurate control.
Specifications

Trim Cover Front Bracket Fixing Bolt 7±1
Trim Cover Rear Left Bracket Fixing Bolt 7±1
Coupling Screw between Air Filter Upper Housing
1.3 ± 0.2
and Lower Housing
10 Air Induction Pipe Assembly Fixing Bolt 7±1

Air Filter Assembly Left Fixing Bolt 7±1
Air Filter Assembly Right Fixing Bolt 7±1
Hot Wire Air Flow Meter Fixing Bolt 4.5 ± 0.5
Air Filter Assembly Bracket Fixing Bolt 7±1
Electronic Throttle Assembly Fixing Bolt 8±3
Intake Manifold Bracket Fixing Bolt 18 ± 2
Oil Dipstick Fixing Bolt 8±3
Engine Wire Harness Fixing Bolt 8±3
Intake Manifold Assembly Fixing Nut 8±3
Electronic Accelerator Pedal Fixing Bolt 10 ± 2
Worm Clamp 5 ± 0.5
Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001

General Tools
Digital Multimeter
RCH0000002
Precision Ruler
RCH0000063
10
Feeler Gauge
RCH0000060

Circuit Diagram
Intake System (Page 1 of 3)
BATTERY
85 30
ECM
MAIN ENGINE
RELAY COMPARTMENT
EF19 86 87 FUSE AND
10A RELAY BOX
E-069
EF40 EF08 EF27 E-076
10A 15A 10A E-023
A2 F14 A6 C3 C9
RL
RL
R
RL
RL
10 1
VARIABLE
1
VARIABLE
3 1 2 4 5
CAMSHAFT CAMSHAFT
TIMING TIMING
(INTAKE)
RL
(EXHAUST)
Br
AIR FLOW METER

R
2 E-006 2
LG
LG
E-008
LR
LY
E-017
GR
RL
E-007
20 19 16 23 18 17
E-038
GR
LG
LG
RL
LR
LR
2-20 2-5 2-15 2-16 1-7 1-5 1-38 1-21 1-27 1-45
ECM
E-033
E-035
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 42 38 34 30 25 20 15 10 5

A1 A2 A3 A4 A5 C1 C2 C3 C4 C5
41 37 33 29 24 19 14 9 4
A6 A7 A8 A9 A10 C6 C7 C8 C9 C10 F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 28 23 18 13 8 3
40 36 32
27 22 17 12 7 2
E-076 E-069 39 35 31 26 21 16 11 6 1
E-023
Gr 1 2 3 4 5 E-017 W
L
B
E-007
2 1 E-008 2 1 E-006
B
B B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
E-035
E-033 B ET21100010
B

ECM
E-035
32 33 37 20 34 29 31 41
WR
LG
LR
GW
WB
Br
W
Y
E-038
29 28 9 10 24 25 27 26
E-007
10
LG
GW
WR
WR
LR
LR
Br
Br
1 2 2 1 3 2 1 3 W 2 1
COOLANT CAMSHAFT CAMSHAFT
ENGINE TEMPERATURE POSITION POSITION
S
SPEED SENSOR` SENSOR SENSOR
SENSOR E-021
(INTAKE) (EXHAUST)
N E-016
E-020 E-015
1 2 42 38 34 30 25 20 15 10 5
1 2 3
37 38 39 40 41 42 43 44 45 46 47 48
41 37 33 29 24 19 14 9 4
E-021 28 23 18 13 8 3
40 36 32 25 26 27 28 29 30 31 32 33 34 35 36
E-016 L 27 22 17 12 7 2
B 39 35 31 26 21 16 11 6 13 14 15 16 17 18 19 20 21 22 23 24
1
1 2 3 4 5 6 7 8 9 10 11 12
3 2 1 3 2 1
E-007
E-020 E-015 B
B B
E-035
B
ET21100020

ELECTRONIC ELECTRONIC
ACCELERATOR THROTTLE
PEDAL M
E-009
B-053
2 3 1 5 6 4
1 4 2 5 3 6
WG
WR
WR
WL
RG
WL
YR
RB
LR
RL
RL
L
B-054 E-007
5 8 6 12 7 4 3 6 4 7 5 8
E-029 E-038
10
RG
WL
RB
RL
RL
R
WR
WR
WR
RL
RL
LR
LY
2-59 2-36 2-30 2-32 2-7 2-37 2-45 1-23 1-11 1-22 1-14 1-43 1-13
ECM
E-033
E-035
42 38 34 30 25 20 15 10 5
1 2 3
1 2 3 4 5 6
11 10 9 8 7 6 5 4 3 2 1 41 37 33 29 24 19 14 9 4
4 5 6 28 23 18 13 8 3
22 21 20 19 18 17 16 15 14 13 12 40 36 32
27 22 17 12 7 2
B-053
E-029 E-009 39 35 31 26 21 16 11 6 1
B
W B
E-007
B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
37 38 39 40 41 42 43 44 45 46 47 48
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
25 26 27 28 29 30 31 32 33 34 35 36
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12
E-035
E-033
B ET21100030
B

DIAGNOSIS & TESTING

HINT:

Engine trim cover assembly (broken,
10-10
leaked)
Electronic throttle assembly (dirty) 10-20
Intake manifold assembly (broken, leaked) 10-24
Activated charcoal canister solenoid valve
Engine idles roughly 09-7
(remains open)
Hot wire air flow meter 10-13
Throttle gasket (damaged) 10-20
Fuel rail injector assembly (installed
08-26
incorrectly)
10
Engine trim cover assembly (broken,
10-10
leaked)
Air filter (broken, leaked) 10-17
Intake system leaks Intake manifold assembly (broken, leaked) 10-24

Electronic throttle assembly 10-20
Crankcase vent tube -
Intake line or component connection -
Air filter element (damaged, blocked) 10-17
Intake system blocked Engine trim cover assembly (blocked) 10-10
Intake line (blocked) -

ON-VEHICLE SERVICE
Engine Trim Cover Assembly & Bracket
Removal
CAUTION


3. Remove the engine trim cover assembly.
a. Loosen the worm clamp (arrow) and disconnect the
connection between rear intake hose and hot wire air
flow meter. 
10
RT21100020
b. Loosen the worm clamp (arrow) and disconnect the

connection between front intake hose and engine trim
cover assembly. 
RT21100030
c. Remove the engine trim cover assembly from the

bracket.
RT21100040

CAUTION
 Cover front intake hose with a plastic bag after removing engine trim cover assembly to prevent foreign
matter entering front intake hose.
4. Remove the rear intake hose.

a. Loosen the worm clamp (arrow) and remove the rear
intake hose from the engine trim cover assembly. 
RT21100050
5. Remove the trim cover front bracket.

a. Remove the trim cover front bracket fixing bolt
(arrow), and remove the trim cover front bracket.
10
RT21100060
6. Remove the trim cover rear right bracket.

a. Remove the exhaust manifold heat insulator.
b. Remove 2 fixing bolts (arrow) from the trim cover rear
right bracket, and remove the trim cover rear right
bracket.
RT21100070

7. Remove the trim cover rear left bracket.

a. Remove 2 fixing bolts (arrow) from the trim cover rear
left bracket, and remove the trim cover rear left
bracket.
RT21100080
Installation
10

Hot Wire Air Flow Meter

Removal
CAUTION


4. Remove the hot wire air flow meter.
a. Disconnect the hot wire air flow meter connector (1).
b. Remove 2 fixing bolts (arrow) from the hot wire air
flow meter. 
1
10
RT21100081
c. Remove the hot wire air flow meter.
Installation

Air Filter Element

Removal
CAUTION


3. Remove the air filter element.
flow meter.
b. Disconnect the hot wire air flow meter connector (1).
10
RT21100090
c. Move the inlet pipe II assembly (1) and fuel vapor tube
III assembly (2) from the pipe clamp on the air filter
upper housing. 1
RT21100100
d. Remove 2 coupling screws (arrow) between air filter

upper housing and lower housing. 
RT21100110
e. Remove the air filter upper housing.

f. Take out the air filter element.
RT21100120
Installation
1. Clean air filter upper housing and lower housing.
2. Install a new air filter element.
 Unneeded air filter element should be handled by the specialized department according to local laws and
10

Air Induction Pipe Assembly

Removal
CAUTION


3. Remove the air induction pipe assembly.
a. Remove 2 fixing bolts (arrow) from the air induction
pipe assembly. 
10
RT21100130
b. Remove the air induction pipe assembly from the air filter assembly.
Installation

Air Filter Assembly & Bracket

Removal
CAUTION


3. Remove the air induction pipe assembly.
a. Remove 2 fixing bolts (arrow) from the air induction
pipe assembly.
10
RT21100130
b. Remove the air induction pipe assembly.

4. Remove the air filter assembly.
flow meter.
b. Disconnect the hot wire air flow meter connector (1).
RT21100090
c. Move the inlet pipe II assembly (1) and canister

solenoid valve inlet pipe (2) from the bracket on air
filter upper housing. 1
RT21100100

d. Remove the air filter assembly left fixing bolt (arrow). 

RT21100140
e. Remove the air filter assembly right fixing bolt (arrow).

RT21100150
10
f. Remove the air filter assembly from the bracket.
HINT:
Make sure that connection between wire harness and air filter assembly is disconnected.
5. Remove the hot wire air flow meter.
a. Remove 2 fixing bolts (arrow) from the hot wire air
flow meter. 
RT21100160
b. Remove the hot wire air flow meter from the air filter assembly.

6. Remove the air filter assembly bracket.

a. Disconnect 3 wire harness clips from the air filter assembly bracket.
b. Remove 3 fixing bolts (arrow) from the air filter
assembly bracket. 
RT21100170
c. Remove the air filter assembly bracket.
Installation
10

Electronic Throttle Assembly

1. Check the electronic throttle assembly.
a. When power is off, the throttle valve plate should be in
NLP position. If you flip the valve plate by hand, it can Datastream
rotate smoothly. If sticking occurs, which indicates Datastream name Value Unit
internal components may be damaged, replace the lambda controller output 1.00
electronic throttle assembly.

b. Connect X-431 3G diagnostic tester to Data Link sensor voltage from throttle potentiometer 2 4.22 V
Connector (DLC). additive correction of the mixture adaptation 0.00 %
c. Turn ignition switch ON and turn on X-431 3G diagnostic Voltage PWG potentiometer 2 0.38 V
tester. Doubled PWG potentiometer-2 voltage 0.75 V
d. Read data flow on X-431 3G diagnostic tester. RT21100171
 Release accelerator pedal.
Data Flow Name Specification (V)

Throttle potentiometer 1 signal voltage 0.78
Throttle potentiometer 2 signal voltage 4.22
10  Depress accelerator pedal.

Datastream
Data Flow Name Specification (V) Datastream name Value Unit
Lambda controller output 1.00
Throttle potentiometer 1 signal voltage 4.29 multiplicative correction of the mixture adaptation 1.03
Throttle potentiometer 2 signal voltage 0.71 sensor voltage from throttle potentiometer 2 0.71 V
additive correction of the mixture adaptation 0.00 %
If result is not as specified, check wire harness, ECM or Voltage PWG potentiometer 1 4.60 V
replace electronic throttle assembly. Voltage PWG potentiometer 2 2.30 V
Doubled PWG potentiometer-2 voltage 4.61 V
RT21100172
Removal
CAUTION
 Temperature of hood is very high when engine is running. Before removal, make sure engine has
stopped running and hood has cooled down, otherwise, there is a risk of scald injury.

4. Remove the electronic throttle assembly.


connection between front inlet hose and electronic
throttle assembly. 
RT21100180
b. Disconnect the electronic throttle assembly connector

(arrow).
c. Loosen the elastic clamp, and disconnect the connection
between throttle body preheat water intake hose (1) and
2
electronic throttle assembly.
d. Loosen the hose clamp, and disconnect the connection 1
between throttle body preheat water outlet hose (2)
and electronic throttle assembly.
RT21100190
10
CAUTION
 After disconnecting throttle body preheat water inlet hose and outlet hose, cover the hoses with wooden
corks or equivalent to prevent coolant in hoses from flowing out.
 If your body contacts coolant accidentally, clean it with water immediately. If it is serious, please go to
hospital.
 DO NOT allow engine coolant enter electronic throttle assembly. If the coolant enters, wipe them with a
clean cotton yarn immediately.
 Wasted coolant should be handled by the specialized department according to local laws and
e. Remove 4 fixing bolts (arrow) from the electronic

throttle assembly. 
RT21100200
f. Remove the electronic throttle assembly and its gasket.

Inspection
1. Check electronic throttle assembly gasket.
Check electronic throttle assembly gasket for worn or
bent. If there is worn or bent, replace electronic throttle
assembly gasket.
RT21100210
2. Check electronic throttle.

Measure electronic throttle resistance according to the
table below.
+ -
Tester Specified 3 2 1
Adjustment 6 5 4
Terminal 3 - Normal
1.067 kΩ
10 Resistance
between terminal
6 and terminal 2 RT21100211
Terminal 2 throttle opens;
Rotate throttle
Terminal 6 - resistance
Terminal 3 between terminal
6 and terminal 3
decreases as
throttle opens.
Resistance
between terminal
5 and terminal 2
Terminal 2 throttle opens;
Rotate throttle
Terminal 5 - resistance
5 and terminal 3
increases as
throttle opens.
Cleaning
Cleaning tool
1. Thin stick: used to support throttle valve plate for cleaning the carbon deposited on contact wall between
valve plate and throttle. Please use plastic, wooden or bamboo thin stick. Do not use metal thin stick,
avoiding scratching or deforming the valve plate.
2. Clean cloth or paper towel

Cleaning Process
1. Remove throttle body, and make the valve plate face
upward in free condition. Avoid cleaner flowing into
electronic element through valve plate shaft, resulting in
functional failure.
2. Start to clean when it is as shown in the illustration.
RT21100220
WARNING
 Cleaner is a kind of flammable and corrosive fluid. Follow safety cautions to prevent accidents, and avoid
skin contacting with the cleaner.
3. Apply appropriate amount of cleaner to the inner wall of throttle valve body, and remove the carbon with a
clean cloth.
4. Support the throttle valve plate with thin stick, and clean
the carbon on valve plate and throttle valve body inner
10
wall.
RT21100221
5. Turn over the throttle 180°, and perform cleaning with the same procedures as above. Repeat several
times until it is clean.
6. Push the valve plate by hand, and check if valve plate rotates smoothly. If it is stuck, clean the valve plate
again following the cleaning procedures.
7. After cleaning, wipe off cleaner in throttle valve body with absorbent paper.
Installation
CAUTION
 Clean fitting surface of electronic throttle assembly.

 Perform throttle self-learning procedures after installation (See page 06-19). After self-learning completed,
start vehicle and observe if it operates properly.
 Check and add engine coolant.

Intake Manifold Assembly

Removal
CAUTION
 Temperature of hood is very high when engine is running. Before removal, make sure engine has
stopped running and hood has cooled down, otherwise, there is a risk of scald injury.

5. Remove the fuel rail injector assembly (See page 08-26).
6. Remove the electrical throttle assembly (See page 10-20).
7. Remove the trim cover front bracket (See page 10-11).
8. Remove the intake manifold assembly.
10 a. Pull out the line assembly with PCV valve assembly
from the PCV valve rubber boot in the direction of
arrow as shown in the illustration.
RT21100230

connection between vacuum booster hose and intake
manifold assembly. 1
c. Loosen the elastic clamp (2) and disconnect the 2
connection between canister solenoid valve outlet
hose and intake manifold assembly.
d. Remove the intake manifold bracket fixing bolt
(arrow). 
RT21100240

e. Remove the fixing bolt (1) of oil dipstick on intake

manifold assembly.
1
f. Disconnect the starter field wire harness connector
(2).
2
RT21100250
g. Remove the fixing bolt (arrow) of the engine wire

harness on cylinder head cover. 
RT21100260
10
h. Remove 9 fixing nuts (arrow) from the intake manifold
assembly.
RT21100270
i. Move the engine wire harness away, and remove the intake manifold assembly.
HINT:
While removing the intake manifold assembly, disconnect the intake camshaft variable timing control valve
connector, knock sensor connector, back-up light switch and back-up light switch wire harness clip (for MT
model).
9. Disconnect the coupling joint (arrow) between line
assembly and intake manifold assembly, and remove the
line assembly (1) from the intake manifold assembly.
1
RT21100280

Inspection
1. Clean and check the fitting surface between intake manifold assembly and cylinder head.
2. Measure the surface warpage of cylinder head intake
side with precision ruler and feeler gauge diagonally as
shown in the illustration. If surface warpage is more than
0.04 mm, replace the cylinder head.
RT21100290
Installation
CAUTION
 Clean the inner wall of intake manifold assembly and the fitting surface.
 Replace intake manifold gasket.
10

Electronic Accelerator Pedal

Removal
CAUTION


3. Remove the electronic accelerator pedal.
a. Disconnect the electronic accelerator pedal connector
(1).
b. Remove 3 fixing bolts (arrow) from the electronic 1
accelerator pedal.
10
RT21100300
c. Remove the electronic accelerator pedal.
Installation

- MEMO -

GENERAL INFORMATION 11-3 Precatalytic Converter Assembly 11-10
Tools 11-5 Main Catalytic Converter Assembly 11-13
Removal 11-13
Installation 11-14
Center Pipe Assembly 11-15
Exhaust System Gas Leakage 
Removal 11-15
Inspection 11-6
Installation 11-16
ON-VEHICLE SERVICE 11-7 Muffler Assembly 11-17
Exhaust Manifold Assembly 11-7 Removal 11-17
Inspection 11-8
Installation 11-9
11

11

11 - SQR484F EXHAUST SYSTEM
GENERAL INFORMATION
Description
×4
2
1
3
×4
7
×3
8
11
9
10
11
13
14
12
15
×2
16
×2
17
RT21110010

1 - Exhaust Manifold Assembly Gasket 2 - Exhaust Manifold Assembly

3 - Exhaust Manifold Heat Insulator 4 - Precatalytic Converter Assembly Gasket
5 - Upstream Oxygen Sensor 6 - Precatalytic Converter Assembly
7 - Downstream Oxygen Sensor 8 - Gasket
9 - Diamond Shaped Hanger Block 10 - Main Catalytic Converter Assembly
11 - Center Pipe Assembly 12 - Spring Bolt
13 - Sphere Flange Grommet 14 - Muffler Assembly Heat Insulator I
15 - Muffler Assembly Heat Insulator II 16 - Hanger Block III Assembly
17 - Muffler Assembly
Exhaust system is used to control the engine exhaust, reducing vehicle emissions by precatalytic converter
and main catalytic converter, and eliminating exhaust noise by muffler. When exhaust system discharges
exhaust gas, the oxygen sensor monitors oxygen content in the exhaust gas. The engine control module
adjusts the air-fuel ratio of flammable gas mixture to control vehicle emissions and achieve optimal fuel
economy according to feedback signals of the oxygen sensor and combining with other sensor signals.
Specifications
11 Description Torque (N·m)
Coupling Nut Between Exhaust Manifold Assembly
50 ± 5
and Precatalytic Converter Assembly
Exhaust Manifold Assembly Fixing Nut 23 ± 2
Coupling Nut Between Precatalytic Converter Upper
Body Assembly and Precatalytic Converter Lower 50 ± 5
Body Assembly
23 ± 2
50 ± 5
Coupling Nut Between Precatalytic Converter Lower
Body Assembly and Main Catalytic Converter 50 ± 5
Assembly
Coupling Nut Between Main Catalytic Converter
50 ± 5
Assembly and Center Pipe Assembly
Coupling Spring Bolt Between Center Pipe Assembly
50 ± 5
and Muffler Assembly
Muffler Assembly Left Hanger Block III Assembly
50 ± 5
Fixing Bolt
Muffler Assembly Right Hanger Block III Assembly
50 ± 5
Fixing Bolt

Tools
General Tools
Precision Ruler
RCH0000063
Feeler Gauge
RCH0000060
11

DIAGNOSIS & TESTING

HINT:

Exhaust pipe (loose connection) -
Precatalytic converter assembly (damaged
11-10
or leaked)
Main catalytic converter assembly
11-13
Excessive exhaust noise (damaged or leaked)
Center pipe assembly (damaged or leaked) 11-15
Muffler assembly (damaged or leaked) 11-17
Exhaust manifold assembly (broken or
11-7
leaked)
Precatalytic converter assembly (blocked) 11-10
Main catalytic converter assembly
11-13
11 Excessive exhaust temperature (blocked)
Incorrect ignition timing in ignition system -
Inadequate gas mixture combustion -
Exhaust pipe gasket (damaged) -
Exhaust pipe leakage
Exhaust pipe (damaged) -
Exhaust System Gas Leakage Inspection

Method to check gas leakage in exhaust system joints:
Warm up engine for a while, and check for gas leakage in the exhaust system joints. A certain amount of gas
leakage at the exhaust pipe joint is allowed, but gas leakage at the joint between exhaust manifold and
cylinder head is prohibited. The judging standard is that engine does not shudder and no "poof" sound can be
heard at the joints.

ON-VEHICLE SERVICE
Exhaust Manifold Assembly
Removal
WARNING
 The temperature of exhaust system is very high when engine is running. Before removal, make sure that
engine has stopped running, otherwise, there is a risk of scald injury.
CAUTION


4. Remove the exhaust manifold heat insulator. 11
a. Remove 4 fixing bolts (arrow) from the exhaust
manifold heat insulator.
RT21110020
b. Remove the exhaust manifold heat insulator.

5. Remove the exhaust manifold assembly.
a. Remove 4 coupling nuts (arrow), disconnect the
connection between exhaust manifold assembly and
precatalytic converter assembly, and take off the
gasket in the connecting part.
RT21110030

b. Remove 8 fixing nuts (arrow) from the exhaust

manifold assembly.
RT21110040
c. Remove the exhaust manifold assembly, and remove the gasket from the exhaust manifold assembly.
Inspection
1. Measure warpage on the surface of exhaust manifold
assembly with a precision ruler and a feeler gauge. If
warpage on the surface is greater than 0.5 mm, replace
it.
11 RT21110050
2. Measure warpage on the surface of cylinder head

exhaust side with a precision ruler and a feeler gauge. If
warpage on the surface is greater than 0.04 mm, replace
it.
RT21110060
3. Check that there are no scratches and roughness on

exhaust manifold gasket. Otherwise, replace it.
RT21110070

Installation
CAUTION
 When installation is completed, check that there is no exhaust gas leakage between exhaust manifold
assembly and cylinder head, precatalytic converter assembly.
11

Precatalytic Converter Assembly

Removal
WARNING
CAUTION


4. Remove the precatalytic converter assembly.
a. Take off and disconnect the upstream oxygen sensor
11 connector (arrow) from the bracket.
RT21090110
b. Remove 4 fixing bolts (arrow) from the exhaust

manifold heat insulator, and remove the exhaust
manifold heat insulator.
RT21110020

c. Remove 4 coupling nuts (arrow), disconnect the

connection between exhaust manifold assembly and
precatalytic converter assembly, and take off the
gasket in the connecting part.
RT21110030
d. Take off and disconnect the downstream oxygen

sensor connector (arrow) from the bracket.
RT21110031
e. Remove 2 coupling nuts (arrow) between precatalytic

converter upper body assembly and precatalytic 11
converter lower body assembly.
RT21110090
f. Remove 2 left coupling bolts (1) and right coupling

bolt (2) between precatalytic converter assembly
bracket and cylinder block.
(Tightening torque for left coupling bolt: 23 ± 2 N·m) 2
1
(Tightening torque for right coupling bolt: 50 ± 5 N·m)
RT21110100

g. Remove the precatalytic converter upper body assembly.

h. Remove 2 coupling nuts (1) between precatalytic
converter lower body assembly and main catalytic
converter assembly.
i. Remove the diamond shaped hanger block (arrow)

between precatalytic converter lower body assembly
and body hook.
RT21110110
j. Remove the precatalytic converter lower body assembly.

5. Remove the upstream oxygen sensor (1) and downstream
oxygen sensor (2) from the precatalytic converter upper
body assembly. 1
RT21110120
11
Installation
CAUTION
 If gasket is damaged, replace it, and remove foreign matter on joints and threads.
 If there are any cracks or leakage in precatalytic converter assembly, replace as necessary.
 Check for exhaust gas leaks. If gas leaks, tighten defective area to prevent leaking. Replace damaged
parts as necessary.
 Check that there is no exhaust gas leakage in upstream oxygen sensor connection.
 Check that there is no exhaust gas leakage in downstream oxygen sensor connection.

Main Catalytic Converter Assembly

Removal
WARNING
CAUTION


4. Remove the main catalytic converter assembly.
connection between main catalytic converter assembly
and precatalytic converter lower body assembly, and
11
take off the gasket in the connecting part.
RT21110130
b. Remove 2 coupling nuts (arrow), disconnect the

and center pipe assembly, and take off the gasket in
the connecting part.
RT21110140
c. Remove the main catalytic converter assembly.

Installation
CAUTION
 If there are any cracks or leakage in main catalytic converter assembly, replace as necessary.
 Keep sufficient distance between main catalytic converter assembly and body during installation.
parts as necessary.
11

Center Pipe Assembly

Removal
WARNING
engine has stopped running; otherwise, there is a risk of scald injury.
CAUTION
 When removing center pipe assembly, an assistant is needed to hold center pipe assembly. Prevent
center pipe assembly from dropping to cause accidents during operation.

4. Remove the center pipe assembly. 11
and center pipe assembly, and take off the gasket in
RT21110140
b. Remove 2 spring bolts (arrow), disconnect the

connection between center pipe assembly and muffler
assembly, and take off the sphere flange grommet in
RT21110150

c. Detach the diamond shaped hanger block (arrow)

between center pipe assembly and body hook.
RT21110160
d. Remove the center pipe assembly.
Installation
CAUTION
 If sphere flange grommet is damaged, replace it, and remove foreign matter on joints and threads.
 If there are cracks or leaks, replace the damaged parts.
 During installation, check that exhaust system components do not contact with muffler heat insulator I or
vehicle underbody. Make sure that clearance between exhaust system components and muffler heat
11 insulator I or vehicle underbody is more than 25 mm.
parts as necessary.

Muffler Assembly
Removal
WARNING
CAUTION
 When removing center pipe assembly, an assistant is needed to hold muffler assembly. Prevent muffler
assembly from dropping to cause accidents during operation.

4. Remove the muffler assembly. 11
a. Remove 2 spring bolts (arrow), disconnect the
connection between muffler assembly and center pipe
assembly, and take off the sphere flange grommet in
RT21110150
b. Detach the diamond shaped hanger block (1)

between left side of muffler assembly and body hook.
c. Detach the hanger block III (2) between left side of
muffler assembly and body hook. 2
RT21110170

d. Detach the diamond shaped hanger block (1)

between right side of muffler assembly and body
hook.
2
e. Detach the hanger block III assembly (2) between
right side of muffler assembly and body hook.
1
RT21110180
f. Remove the muffler assembly.

5. Remove the hanger block III assembly.
a. Remove 2 fixing bolts (arrow) from hanger block III
assembly on the left side of muffler assembly.
b. Remove the hanger block III assembly from the left
side of muffler assembly.
RT21110190
11
c. Remove 2 fixing bolts (arrow) from hanger block III
assembly on the right side of muffler assembly.
d. Remove the hanger block III assembly from the right
side of muffler assembly.
RT21110200
6. Remove the muffler assembly heat insulator.

a. Remove 4 clamping pieces (1) from the muffler
assembly heat insulator I, and remove the muffler
assembly heat insulator I.
b. Remove 4 clamping pieces (2) from the muffler
1
assembly heat insulator II, and remove the muffler 2
assembly heat insulator II.
RT21110210

Installation
CAUTION
 If sphere flange grommet is damaged, replace it, and remove foreign matter on joints and threads.
 If there are cracks or leaks, replace the damaged parts.
 During installation, make sure that clearance between tailpipe of muffler pipe and bumper on the rear
body is more than 30 mm.
parts as necessary.
11

- MEMO -

GENERAL INFORMATION 12-3 Thermostat 12-19
Specifications 12-5 Inspection 12-20
Cooling System Operation Flowchart 12-7 Thermostat Seat 12-22
Installation 12-24
Fan Controller 12-25
Removal 12-25
Cooling System Leakage Test 12-11
Installation 12-25
Coolant Concentration Test 12-12
Cooling Fan Assembly 12-26
ON-VEHICLE SERVICE 12-13 On-vehicle Inspection 12-26
Coolant Replacement 12-13 Removal 12-26
Coolant Draining 12-13 Installation 12-28
Coolant Adding 12-14 Radiator Assembly 12-29
Tank Upper Crossmember Assembly 12-16 Removal 12-29
Installation 12-17 Water Pump Assembly 12-31
Expansion Tank 12-18 Removal 12-31
12

12

12 - SQR484F COOLING SYSTEM
GENERAL INFORMATION
Description
1
2
×2
35
33 34
×4
32 4
36
5
×4
31
7
37
30 8 10
6
26 24 ×2
27 23 22
25 ×6
28 ×4 12
21
9
29
×4 17
11
18
20
12
19
13
15
16
14
RT21120010

1 - Expansion Tank 2 - Radiator Discharge Hose

3 - Expansion Tank Outlet Hose 4 - Discharge Pipe I
5 - Discharge Steel Pipe 6 - Engine Discharge Hose
7 - Engine Inlet Pipe 8 - Engine Inlet Pipe (for CVT Model)
9 - Throttle Body Glow Outlet Hose 10 - Water Pump Assembly
11 - Water Pump Assembly Gasket 12 - Small Circulation Metal Tube
13 - Small Circulation Outlet Hose 14 - Heater Outlet Pipe
15 - Oil Cooler Outlet Hose 16 - Oil Cooler Inlet Hose I
17 - Oil Cooler 18 - Oil Cooler Inlet Hose II
19 - T-joint 20 - Throttle Body Glow Inlet Hose
21 - Heater Inlet Pipe 22 - Thermostat Seat Gasket
23 - Thermostat Seat 24 - Coolant Temperature Sensor
25 - Thermostat 26 - Thermostat Housing
27 - Engine Outlet Hose 28 - Engine Outlet Hose (for CVT Model)
29 - Oil Cooler Assembly (for CVT Model) 30 - Rubber Cushion
31 - Radiator Assembly 32 - Bush Rubber
33 - Radiator Left Tension Plate 34 - Tank Upper Crossmember Assembly
35 - Radiator Right Tension Plate 36 - Cooling Fan Assembly
12 37 - Fan Controller
Engine cooling system adjusts the engine operating temperature by the flow of coolant and makes engine
operate normally under various operating conditions.
Engine cooling system is a forced circulation system, which supplies circulation pressure for the system by
water pump and forces the coolant to circulate in the engine cylinder block, and distributes excessive heat to
the radiator by the flow of coolant, and radiates it to the air by the cooling fan. Also, the engine cooling system
provides heat to the heater core in the cabin to improve driving comfort.

Specifications

Coupling Bolt Between Air Induction Pipe Assembly
7±1
and Tank Upper Crossmember Assembly
Radiator Left Tension Plate Fixing Bolt 7±1
Radiator Right Tension Plate Fixing Bolt 7±1
Tank Upper Crossmember Assembly Fixing Bolt 7±1
7±1
Fixing Bolt
Thermostat Housing Fixing Bolt 8±3
Engine Ground Wire Fixing Bolt 7±1
Engine Speed Sensor Bracket Fixing Bolt 7±1
Thermostat Seat Fixing Bolt 8+3
Fan Controller Fixing Bolt 7 ± 1.5
Cooling Fan Assembly Fixing Bolt 7±1
Timing Belt Idler Pulley Fixing Bolt 40 + 5 12
Water Pump Assembly Fixing Bolt 8+3
Coolant Capacity
Item Capacity (L)

Cooling System 7.5

50% 50%
Coolant Freezing Point
Item Freezing Point Value (°C)

Coolant -35
Cooling System Test Pressure
Item Test Pressure (bar)

Cooling System (Test Pressure) 1.3 ± 0.2

Tools
General Tools
Digital Multimeter
RCH0000002
Cooling System Pressure Tester
RCH0000055
12
Freezing Point Tester
RCH0000007

Cooling System Operation Flowchart
2
1 5
14 15
17
16
8
19 18
13
12
20
12
11 10
RT21120020

1 - Expansion Tank 2 - Engine Discharge Hose

3 - Cylinder Block 4 - Heater Core
5 - Heating Inlet Pipe 6 - Heating Outlet Pipe
7 - Thermostat 8 - Engine Outlet Pipe
9 - Radiator 10 - Black Solid Arrow (Indicates High Temperature
Coolant)
11 - Hollow Arrow (Indicates Low Temperature 12 - Radiator Discharge Hose
Coolant)
13 - Engine Inlet Pipe 14 - Expansion Tank Outlet Hose
15 - Water Pump 16 - Small Circulation Metal Tube
17 - Electronic Throttle 18 - T-Tube
19 - Oil Cooler 20 - Transmission Oil Cooler Assembly (for CVT
Model)
Small circulation: when coolant temperature is below 82 ± 2°C, the thermostat closes. Coolant only circulates
inside the cylinder block, and warms up other engine parts where need heat. Water pump assembly circulates
the engine coolant through cylinder block, electronic throttle assembly, oil cooler assembly and cylinder head.
The coolant does not radiate heat through the radiator.
Large circulation: when coolant temperature is higher than 103 ± 1°C, the thermostat opens fully, and all the
coolant, which flows out of cylinder block, enters the radiator where coolant heat is lost. The heat-radiated
coolant returns to the cylinder block for circulation by water pump. Due to the heat lost in radiator, the engine
coolant temperature drops quickly to prevent engine from overheating.
12 For CVT model, coolant will enter the transmission oil cooler assembly under the large circulation, so that the
temperature of transmission oil in transmission decreases.
When engine operates properly, the cooling fan operates under the following conditions:
a. If engine coolant temperature sensor malfunctions, the cooling fan remains rotate when engine operates
properly;
b. When A/C compressor is operating, the cooling fan operates at low speed.
c. When A/C compressor is operating and receives request signal from the A/C pressure switch, the cooling
fan operates at high speed.
d. When coolant temperature is higher than 96°C, the cooling fan starts to operate at low speed;
e. When coolant temperature is higher than 102°C, the cooling fan starts to operate at high speed;
f. When coolant temperature is below 99°C, the cooling fan stops at high speed;
g. When coolant temperature is below 93°C, the cooling fan stops at low speed.

Circuit Diagram
Cooling System
BATTERY
85 30
ECM ENGINE
MAIN 85 30 COMPARTMENT
RELAY FUSE AND
FAN
EF19 RELAY BOX
86 87 RELAY
10A E-069
86 87 E-076
EF40 EF38 E-059
MF02
10A 7.5A
60A
A2 F14 A6 A8 F21 F22 2

RL
R
B
R
COOLANT
1 VOTAGE 3 TEMPERATURE
REGULATOR SENSOR
E-078 E-021
2
INPUT
MICROPR 2 1
OCESSOR
LG
OUTPUT
12
Y
RL
Br
E-051
E-007
BY
9 10 E-038
M
FAN CONTROLLER
LG
Y
E-046
2-20 2-5 2-15 2-16 2-56 1-37 1-20
ECM
E-033
E-035
2
42 38 34 30 25 20 15 10 5
A1 A2 A3 A4 A5 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 1 2 3
41 37 33 29 24 19 14 9 4
A6 A7 A8 A9 A10 F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 28 23 18 13 8 3
40 36 32 E-046
27 22 17 12 7 2
E-059 Gr
E-076 E-069 39 35 31 26 21 16 11 6 1
Gr W
E-021
E-007 1 2
L
B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12
E-033 E-035
ET21120010
B B

DIAGNOSIS & TESTING

HINT:

Coolant pipe (deteriorated and leaked) -
Expansion tank (leaked) 12-18
Radiator assembly (leaked) 12-29
Heater core assembly (leaked) 31-78
Thermostat (improperly sealed) 12-19
Insufficient coolant
Thermostat seat (cracked and damaged) 12-22
Water pump (bearing loose and leaked) 12-31
Engine cylinder head gasket (damaged) 07-55
Engine cylinder head (water jacket leaked) 07-55
Engine block (water jacket leaked) 07-78
Low coolant level 12-14
12 Air resistance exists in pipe -
Expansion tank cap (damaged) -
Fan controller 12-25
Engine overheating
Cooling fan assembly 12-26
Radiator assembly 12-29
Thermostat 12-19
Leakage in engine -
Unable to reach normal engine Cooling fan assembly (constantly
12-26
temperature operating)
Thermostat 12-19
Cooling fan does not operate or abnormal Cooling fan assembly 12-26
air speed Wire harness -
ECM (Engine Control Module) failure 06-256

Cooling System Leakage Test

WARNING
 Always make sure engine is cold before operating cooling system.

 Never open expansion tank cap or remove drain cock plug when engine is operating or cooling system
overheats. The overheated engine coolant and steam with high-pressure may flow out and cause
serious personal injury.
CAUTION
 When testing cooling system, please pressurize the system to specified pressure. Otherwise it may
damage system components.
 Before testing cooling system, do not perform operation until coolant temperature drops to normal level.
Otherwise it may cause scald.
Test Procedures
2. Check if coolant level is between "MAX" and "MIN" lines.
If coolant level is below "MIN" line, add coolant.
MAX
12
MIN
RT21120030
3. Connect the cooling system pressure tester to the

coolant pressure release cap opening (expansion tank
cap opening) and tighten it slowly.
10
5
SYSTEM
TEST 100 120
60
40
80
20
140
160
180
200
PS
RT21120040
CAUTION
 Make sure there is no leakage in the connecting part of coolant system pressure tester, in order to avoid
pressure leakage during test.

4. Pressurize the cooling system to 1.3 ± 0.2 bar with the cooling system pressure tester, and then observe
the pressure changes. If the system pressure does not drop within 2 minutes, it indicates there is no
leakage in the system. If the pressure changes greatly, it indicates that there is a leakage in the system;
find the leaking area and perform troubleshooting.
Coolant Concentration Test

CAUTION
 DO NOT mix different colors or types of coolant.

 Please select coolant which is suitable for local climate in different areas.
 Please read measured value at the scale line. In order to distinguish the scale line more clearly, drip a
drop of water on the glass of freezing point tester with a pipette, then the scale line can be clearly
distinguished via a "waterline".
Test Procedures
1. As shown in the illustration, drip a drop of coolant on the
glass of freezing point tester with a pipette, and then
observe the freezing point value of coolant.
12
RT21120050
2. As shown in the illustration, observe the scale 3 of

freezing point tester to read the ethylene glycol coolant
freezing point value. The freezing point value must be
ETHYLENE
PROPYLENE GLYCOL
GLYCOL -50
2 1.40
kept at -35°C or lower.

-50
1.35
-40 -40
1 1.30 3
GOOD
-30 -30
1.25
FAIR
-20 1.20 -20

RECHARGE
1.15
-10 BATTERY -10
ELECTROLYTE 1.10 d 20
20
0( C)
O
WATERLINE 0( C)
O
ANTIFREEZE
RT21120060
If the freezing point is beyond the specified value, replace the coolant.
HINT:
Scale 1 is used to measure the freezing point value of propylene glycol coolant, and scale 2 is used to
measure the battery electrolyte concentration.

ON-VEHICLE SERVICE
Coolant Replacement
Coolant Draining
WARNING

hospital.
CAUTION


12
3. Remove the expansion tank cap when the engine temperature and radiator temperature are low.
4. Remove the engine lower left protector (See page 48-29).
5. Put a coolant collector under the vehicle, rotate the
radiator drain cock plug (arrow) and drain the coolant in
the radiator and expansion tank.
HINT:
Put a drainage device or similar tool at the radiator outlet,
so that the coolant can flow into the collector smoothly.
RT21120070
6. After the coolant stops flowing, retighten the radiator drain cock plug.
CAUTION
 Tighten the drain cock plug to prevent leakage.
 Wasted coolant should be handled by the specialized department according to local laws and

Coolant Adding
Only use coolant that meets Chery specifications.
Coolant Capacity
Item Capacity (L)

Cooling System 7.5

50% 50%
WARNING
 If it is necessary to add coolant when engine is hot, loosen expansion tank cap slightly first to release
internal pressure and loosen the cap completely after waiting for a while, and then add coolant.
hospital.
CAUTION
12
 DO NOT use inferior coolant.
 DO NOT mix different colors or types of coolant.
 Be careful when adding coolant; avoid spilling coolant on any area of engine.
1. Open the expansion tank cap and add coolant until the
coolant level reaches the "MAX" line.
MAX
MIN
RT21120030
2. Tighten the expansion tank cap, start and run the engine. Maintain the engine speed between 2000 and
2500 rpm to warm up the engine until the cooling fan operates.

CAUTION
 If there is no coolant in expansion tank after the engine just starts, perform the followings:
- Stop engine;
- Wait until coolant cools down;
- Add coolant to "MAX" line on expansion tank.
 Run the engine at 2500 rpm until the coolant level becomes stable.
3. Stop the engine and wait until the coolant temperature drops to the ambient temperature. Check that the
coolant level is between "MAX" and "MIN" lines. If the coolant level is below the "MIN" line, repeat all
above procedures. If the coolant level is above the "MAX" line, drain the coolant until the level is between
"MAX" and "MIN" lines.
12

Tank Upper Crossmember Assembly

Removal
WARNING
 Perform removal procedures with engine compartment at low temperature after cooling fan stops
completely, otherwise rotating cooling fan or hot components of engine compartment may cause serious
injury.
CAUTION


4. Remove the radiator grille assembly (See page 48-8).
5. Remove the water tank upper crossmember trim board (See page 48-10).
6. Remove the engine hood lock assembly (See page 37-39).
12 7. Move away the hood lock cable from tank upper crossmember assembly.
8. Remove the tank upper crossmember assembly.
a. Press the clips on both sides of engine compartment
contact switch in the direction of arrow as shown in
the illustration, and remove the engine compartment
contact switch from tank upper crossmember
assembly.
RT21120031
b. Disconnect the connector (arrow) from engine

compartment contact switch, and remove the engine
compartment contact switch.
RT21120032

c. Remove 2 coupling bolts (arrow) between air

induction pipe assembly and tank upper crossmember
assembly.
RT21120036
d. Remove 2 fixing bolts (arrow) from radiator left tension

plate, and remove the radiator left tension plate.
RT21120033
e. Remove 2 fixing bolts (arrow) from radiator right

tension plate, and remove the radiator right tension
plate.
RT21120034
f. Remove 4 fixing bolts (arrow) from tank upper

crossmember assembly.
RT21120035
g. Remove the tank upper crossmember assembly.
Installation

Expansion Tank
Removal
WARNING

hospital.
CAUTION


3. Remove the expansion tank.
12 a. Loosen the elastic clamp (1) and disconnect the
connection between expansion tank and discharge
pipe I.
connection between expansion tank and discharge 1
pipe II.
3
connection between expansion tank and expansion
tank outlet hose.
d. Remove 2 fixing bolts (arrow) from expansion tank. RT21120080
e. Remove the expansion tank from expansion tank bracket.
Installation
CAUTION
 Check that coolant has been added to the specified level after installation.

Thermostat
Removal
WARNING

hospital.
CAUTION


4. Remove the air induction pipe assembly (See page 10-16). 12
6. Remove the canister solenoid valve bracket.
a. Move away the canister solenoid valve from the bracket.
b. Remove 2 fixing bolts (arrow) from activated charcoal
canister solenoid valve bracket, and remove the
activated charcoal canister solenoid valve bracket.
RT21090040
7. Remove the thermostat housing.

connection between engine outlet hose and
thermostat housing.
RT21120090

b. Remove 4 fixing bolts (arrow) from thermostat

housing.
RT21120100
c. Remove the thermostat housing.

8. Remove the thermostat.
a. Take out the thermostat (arrow) from thermostat seat.
RT21120110
12 Inspection
1. As show in the illustration, check if the protrusion (2) of
thermostat grommet and chock (1) of thermostat are
1
installed at an angle of 180°.
If the result is not as specified, adjust the thermostat
grommet to the specified position or replace the
thermostat with a new one.
2
RT21120120
2. Check the opening temperature and maximum lift of

thermostat.
HINT:
Valve opening temperature is engraved in the thermostat.
B
87 C
0
3
87 0
RT21120130

a. Soak the thermostat in water, heat the water gradually

and perform inspection.
 Opening temperature of thermostat is 82 ± 2°C.
 Maximum lift of thermostat is no less than 8 mm.
 Temperature is 103 ± 1°C when thermostat opens
fully.
RT21120140
b. Check that the thermostat closes when temperature is low (5°C lower than the opening temperature).
c. If above conditions are not met, replace the thermostat.
Installation
CAUTION
 As shown in the illustration, align the protrusion (1) of thermostat grommet and groove (2) of thermostat
seat during installation.
12
2
1
RT21120150

Thermostat Seat
Removal
WARNING

overheats. The engine coolant and steam with high-pressure and overheat may flow out and cause
hospital.
CAUTION


12 4. Remove the air filter assembly and bracket (See page 10-17).
8. Remove the thermostat seat.
a. Disconnect the coolant temperature sensor connector
(arrow).
b. Loosen the elastic clamp (1) and disconnect the 1
connection between thermostat seat and engine
discharge hose.
connection between thermostat seat and heater inlet 3
pipe.
d. Loosen the elastic clamp (3) and disconnect the
connection between oil cooling pipe assembly I and RT21120160
thermostat seat.
e. Remove the fixing bolt (1) from engine ground wire,

and disconnect the engine wire harness.
f. Remove the fixing bolt (2) from engine speed sensor
bracket. 2
RT21120170

g. Loosen the elastic clamp (arrow) and disconnect the

connection between small circulation outlet hose and
thermostat seat.
RT21120180
h. Remove 4 fixing bolts (arrow) from thermostat seat.

RT21120190
i. Remove the thermostat seat and thermostat seat gasket.

9. Remove the coolant temperature sensor (arrow) from the
thermostat seat.
(Tightening torque: 11 - 16 N·m) 12
RT21120200

Installation
CAUTION
 Replace thermostat seat gasket with a new one during installation, and the removed gasket cannot be
reused.
12

Fan Controller
Removal
WARNING
injury.
CAUTION


4. Remove the fan controller.
a. Disconnect the fan controller connectors (arrow).
12
RT21120210
b. Remove 2 fixing bolts (arrow) from fan controller.

RT21120220
c. Remove the fan controller from cooling fan assembly.
Installation

Cooling Fan Assembly

1. Apply battery voltage to the specified connector terminals
-
of cooling fan respectively according to the table below, +
and check that the cooling fan operates smoothly when

applying battery voltage.
Multimeter Specified 3 2 1
Condition
Condition Condition
Battery positive
(+) - Terminal 1 Operates
Always
Battery negative smoothly RT21120221
(-) - Terminal 3
If result is not as specified, replace cooling fan assembly (See page 12-26).
Removal
WARNING
injury.
12
CAUTION


4. Remove the air induction pipe assembly (See page 10-16).
8. Remove the tank upper crossmember assembly (See page 12-16).
9. Remove the cooling fan assembly.

a. Disconnect the fan controller connector (arrow).
RT21120230
b. Remove the wire harness clips (arrow) from engine compartment contact switch, and move away the
engine compartment contact switch from cooling fan assembly.
c. Remove the fixing band (1) of engine outlet hose from
cooling fan assembly.
RT21120240
d. Remove 4 fixing bolts (arrow) from cooling fan

assembly. 12
RT21120250
e. Remove the cooling fan assembly from radiator assembly.

10.Remove the fan controller.
a. Disconnect the fan controller connector (1).
b. Remove 2 fixing bolts (arrow) from the fan controller,
and remove the fan controller from the cooling fan
assembly.
RT21120260

Installation
CAUTION
 Check that the coolant has been added to the specified level after installation.
12

Radiator Assembly
Removal
WARNING

hospital.
CAUTION


4. Remove the radiator grille assembly (See page 48-8). 12
7. Move away the hood lock cable from tank upper crossmember assembly.
8. Remove the tank upper crossmember assembly (See page 12-16).
10.Remove the cooling fan assembly (See page 12-26).
11. Remove the radiator assembly.
connection between engine outlet hose and radiator
assembly.
RT21120270


connection between radiator discharge hose and
radiator assembly.
connection between engine inlet pipe and radiator
assembly.
2
RT21120280
d. Remove the radiator.
Installation
12

Water Pump Assembly

Removal
WARNING

hospital.
CAUTION


4. Drain the coolant (See page 12-13). 12
7. Remove the engine right mounting assembly (See page 07-68).
9. Remove the water pump assembly.
a. Remove the fixing bolt (arrow) from timing belt idler
pulley, and remove the timing belt idler pulley.
RT21120290
b. Remove 6 fixing bolts (arrow) from water pump

assembly.
RT21120300

c. Remove the water pump assembly and gasket.
Inspection
1. Check water pump gasket.
Check water pump gasket for wear or bends. If wear or
bends are found, replace the gasket.
RT21120310
2. Check water pump assembly.

Check water pump assembly carefully. If any of the following occurs, replace the water pump assembly
immediately.
a. Contact surfaces of water pump assembly and cylinder block is uneven.
b. Impeller of water pump assembly is damaged.
c. Bearing of water pump assembly is loosened.
d. There is abnormal noise when water pump assembly is turning.
Installation
12
CAUTION
 Clean the installation surface of water pump assembly.

 If water pump is damaged, replace rather than attempt to repair it.
 Perform cooling system pressure test after adding coolant. check for leakage in the cooling system.

GENERAL INFORMATION 13-3 Oil Pressure Switch 13-16
Lubrication System Flowchart 13-7 Oil Cooler Assembly 13-18
Removal 13-18
Installation 13-19
Oil Pan 13-20
Engine Oil Level Inspection 13-9
Removal 13-20
Oil Pressure Inspection 13-10
Installation 13-22
ON-VEHICLE SERVICE 13-11 Oil Strainer 13-23
Engine Oil Replacement 13-11 Removal 13-23
Engine Oil Draining 13-11 Installation 13-23
Engine Oil Adding 13-12 Oil Pump Assembly 13-24
Oil Filter 13-13 Removal 13-24
Installation 13-14
Oil Dipstick Tube 13-15
Removal 13-15
Installation 13-15
13

13

13 - SQR484F LUBRICATION SYSTEM
GENERAL INFORMATION
Description
4
13
12 5
×4
13
×4
6
11 ×7
×2
10 8
×18
×6
RT21130010

1 - Engine Assembly 2 - Oil Dipstick

3 - Oil Dipstick Tube 4 - Oil Cooler Bracket Shim
5 - Oil Cooler Bracket 6 - Oil Cooler Assembly
7 - Oil Filter Joint 8 - Oil Strainer Filter
9 - Oil Pan 10 - Oil Strainer
11 - Oil Baffle Plate 12 - Oil Pump Assembly
13 - Oil Pump Assembly Gasket
The function of lubrication system is that crankshaft, when the engine is operating, drives oil pump to suck oil
from oil pan. The sucked oil is filtered by oil filter, then it flows to the friction surfaces of all drive parts through
oil passage and forms oil films between the friction surfaces to realize liquid friction, and finally returns to oil
pan, thus reducing the friction resistance of drive parts, power consumption and wear of part and increasing
the reliability and durability of engine operation.
WARNING
Prolonged and repeated contact with engine oil will result in the removal of natural oils from skin, leading to
dryness, irritation and dermatitis. In addition, the used engine oil contains potentially harmful contaminants,
which may cause skin cancer.
Precautions should be followed when replacing engine oil to minimize the risk of your skin making contact
with used engine oil.
 Wear protective clothing and gloves.
 Wash your skin thoroughly with soap and water, or use waterless hand cleaner to remove any used
engine oil.
13  Never use gasoline, thinners or solvents.

Specifications
System Pressures
Condition Pressure (bar)

Idling Speed (750 ± 50 r/min) Above 1.5 (oil temperature 90°C)
High Idling Speed (2000 r/min) Above 3.6 (oil temperature 90°C)
High Speed (4000 r/min) Above 4.7 (oil temperature 90°C)
Oil Specifications
Engine Type SQR484F

Oil Specifications

Drain Plug 35 ± 3
Oil Filter 25 ± 3
Coupling Bolt Between Oil Pan and Transmission
45 ± 5
Case
Fixing Bolt of Baffle Plate Between Oil Pan and
13
45 ± 5
Transmission Case
Oil Pressure Switch 20 ± 2
Oil Pan Fixing Bolt 11 ± 1
Oil Pan Baffle Plate Fixing Bolt 8+3
Oil Strainer Bracket Fixing Bolt 17 - 23
Oil Strainer Bracket Fixing Nut 17 - 23
Coupling Bolt Between Oil Strainer and Oil Pump 17 - 23
Oil Pump Fixing Bolt 8 - 11

Tools
Special Tools
Oil Pan Remover and Scraper
RCH0000056
Oil Filter Remover
RCH0000054
General Tool
13
Oil Pressure Tester
RCH0000006

Lubrication System Flowchart
11
13
10
7
9 8
RT21130020
1 - Oil Filler Cap 2 - Cylinder Head

3 - Oil Pressure Switch 4 - Oil Filter
5 - Cylinder Block 6 - Oil Pump
7 - Engine Oil 8 - Drain Plug
9 - Oil Strainer 10 - Oil Pan
11 - Crankshaft
Description
1. Solid arrow: indicates the flow of high-pressure lubricant.
2. Hollow arrow: indicates the flow of low-pressure lubricant.
3. Dark area: indicates the high-pressure lubricant.
4. Bright area: indicates the low-pressure lubricant.

DIAGNOSIS & TESTING

HINT:
Use the table below to help determine the cause of the problem symptoms. Check each suspected area in

Oil pan (dirty, leaked) 13-20
Oil strainer (mesh dirty, blocked) 13-23
Low pressure in lubrication system
Oil pump 13-24
Line (blocked) -
Engine oil (excessive oil filling capacity) 13-9
Oil filter (leaked) 13-13
Crankshaft front oil seal (damaged) 07-39
Crankshaft rear oil seal (damaged) 07-44
High oil consumption Oil pressure switch 13-16
Oil drain plug (leaked) -
Oil pan (leaked) 13-20
Each engine seal surface leakage -
13 Engine oil leakage -

Engine oil (insufficient oil, low oil viscosity) -
Oil filter (blocked) 13-13
Oil strainer (blocked) 13-23
Crankshaft front oil seal (damaged) 07-39
Crankshaft rear oil seal (damaged) 07-44
Oil pressure warning light comes on Oil pressure switch (damaged) 13-16
Instrument cluster (oil pressure warning
38-42
light)
Cylinder block (cracks occur in water
jacket, resulting in coolant leaking into the 07-78
oil pan, which will cause oil dilution)
Line (blocked) -
Engine oil (high oil viscosity, excessive oil
After cranking , clunking sound from engine -
filling capacity)
is heard
Cylinder block (oil passage blocked) 07-78

Engine Oil Level Inspection

HINT:
Check the oil level indicated by oil dipstick, when engine stops after it reaches operating temperature.
1. Park vehicle on level ground, stop the engine after warming up and wait for 5 minutes.
2. Open the engine hood and pull out the oil dipstick, and
wipe it clean with a piece of clean cloth.
RT21130030
CAUTION
 Please place a piece of cloth under the oil dipstick end to prevent the oil from splashing onto the engine
and body.
3. Reinsert the oil dipstick, check if oil level is proper.

4. Pull out the oil dipstick again, check if oil level is proper.
If engine oil level is low, check for leakage and add oil up to the full level mark.
a. If oil level is at or above the "MAX" mark, drain the
excessive engine oil.
13
b. If oil level is between "MIN" mark and "MAX" mark, it
shows that the oil level is proper.
c. If oil level is below the "MIN" mark, it is necessary to
add engine oil.
RT21130040
CAUTION
 When adding engine oil, the oil level should not be above the "MAX" mark.

Oil Pressure Inspection

Preconditions
WARNING
 DO NOT remove oil pressure switch until engine cools down.

 Prolonged and repeated contact with engine oil will be harmful to your skin. If engine oil spills on your
skin, wash it off immediately with water. In addition, the used engine oil contains potentially harmful
contaminants, which may cause skin cancer. Therefore, always take proper skin protection measures
when performing vehicle service.
1. Engine oil level is normal.

2. Oil filter is used within 5000 km.
3. Engine reaches the normal operating temperature.
Inspection
2. Disconnect the oil pressure switch connector (1) and
remove the oil pressure switch (2).
2
13
RT21130050
3. Screw the oil pressure tester into the thread hole of oil
pressure switch as shown in the illustration.
RT21130060
4. Start engine. When the engine inspection conditions are met, read the oil pressure values at low idling
speed, high idling speed and high speed respectively. If lubrication system pressure is low, clean the oil
pan and oil strainer mesh, and then test again. If lubrication system pressure is still low, it shows there is a
malfunction in the oil pump and the oil pump must be replaced.
Oil pressure at idling speed (700 ± 50 r/min): higher than 1.5 bar.
Oil pressure at high idling speed (2000 r/min): higher than 3.6 bar.
Oil pressure at high speed (4000 r/min): higher than 4.7 bar.
5. Install the oil pressure switch.
HINT:
Apply a small amount of seal gum to the threads when installing the oil pressure switch.
6. Connect the oil pressure switch connector and check the engine oil for leakage.
7. Install the engine lower right protector assembly.

ON-VEHICLE SERVICE
Engine Oil Replacement
Engine Oil Draining
WARNING
 DO NOT drain engine oil until engine cools down.


3. Open the oil filler cap.
a. Open the oil filler cap protector.
b. Rotate the oil filler cap counterclockwise to open it.
13
RT21130070
4. Unscrew the drain plug (arrow), and drain the oil into a
container.
RT21130080
WARNING
 Apply a certain pushing force to drain plug while loosening the plug by hand, and have the drain plug
attached to the thread tightly to prevent oil from overflowing in advance. Move away the hand quickly to
prevent burn by the oil with a certain temperature.

 Wasted engine oil should be handled by specialized department according to local laws and regulations.
Never discard it at will.
5. Wipe off the drain plug and tighten it.

Engine Oil Adding

Only use engine oil that meets Chery specifications
Engine Type SQR484F

Oil Specifications
CAUTION
 DO NOT use inferior engine oil.

 DO NOT mix different types of engine oil.
 Be careful not to spill engine oil on any part of the engine when adding the engine oil.
13 1. Add a proper amount of oil, and check that the oil level is
between "MIN" mark and "MAX" mark with oil dipstick.
RT21130040
2. Turn off the engine after running for 1 to 2 minutes, park vehicle on a level surface and wait for
approximately 5 minutes. Check if oil level is between "MIN" mark and "MAX" mark. Refill oil if necessary.
3. Check the vehicle for leakage after replacing oil.

Oil Filter
Removal
WARNING
 DO NOT remove oil filter until engine cools down.

CAUTION
 When repairing oil filter, use special oil filter installer to prevent oil filter from deforming.

5. Remove the oil filter.
a. Using the oil filter remover (1), remove the oil filter (2).
13
2
RT21130090
 The removed oil filter should be handled by specialized department according to local laws and

Installation
CAUTION
 Check oil filter bracket grommet for damages and cracks. If there are damages or cracks, replace the
grommet.
 Check and clean the installation surface of oil filter and oil filter bracket.
 Apply a layer of clean engine oil to new oil filter grommet.
 Slightly rotate oil filter in place by hand, and tighten oil filter until grommet contacts with oil filter bracket
base.
 Using a special tool to tighten oil filter.
13

Oil Dipstick Tube

Removal
CAUTION


4. Remove the oil dipstick tube with oil dipstick assembly.
a. Remove 2 oil dipstick tube fixing bolts (arrow).
RT21130091
b. Remove the oil dipstick tube with oil dipstick assembly from the engine block frame.
13
c. Separate the oil dipstick from the oil dipstick tube.
Installation
CAUTION
 Check oil dipstick tube grommet when installing, if damaged, replace with a new one.
 Apply a coat of engine oil to oil dipstick tube grommet when installing.

Oil Pressure Switch

WARNING
 DO NOT remove oil pressure switch until engine cools down.

Removal
4. Remove the oil pressure switch.
a. Disconnect the oil pressure switch connector (1) and
remove the oil pressure switch (2).
2
13 RT21130050
Inspection
CAUTION
 Before inspecting oil pressure switch, please make sure that oil level is proper and coolant temperature
is up to above 90°C, and that oil filter is used within 5000 km and electrical fan stops operating.
1. Use an oil pressure tester as shown in the illustration.
RT21130100

2. Install the oil pressure tester into the thread hole (4) of oil
1
pressure switch as shown in the illustration. 3
3. Install the oil pressure switch (2) onto the tester (1) and
connect the oil pressure switch connector.
4. Connect the oil pressure switch to the body.
+ -
5. Start engine and oil pressure warning light (3) comes on,
then observe the pressure reading on tester. If oil
pressure warning light still comes on when oil pressure is 4
higher than 75 kPa, replace the oil pressure switch. 2
RT21130110
Installation
1. Remove the oil and impurities on oil pressure switch and its thread hole.
2. Apply a small amount of seal gum to the threads when
installing the oil pressure switch as shown in the
illustration. a
Width of a: 3 mm
RT21130120
13

Oil Cooler Assembly

Removal
WARNING
 DO NOT disconnect oil cooler inlet hose and oil cooler outlet hose until engine is in low temperature.
Otherwise, overheated engine coolant and steam with high-pressure may flow out and cause serious
personal injury.
hospital.
 DO NOT remove oil filter and oil cooler assembly until engine cools down.

5. Remove the oil filter (See page 13-13).
6. Remove the oil cooler assembly.
connection between oil cooler outlet hose and oil
13 cooler assembly.
2

connection between oil cooler inlet hose and oil cooler
assembly.
c. Using an appropriate tool, loosen the oil filter joint
(arrow). 1
RT21130130
CAUTION
 After disconnecting oil cooler outlet hose and oil cooler inlet hose, cover the hoses with wooden corks or
equivalent to prevent coolant in hoses from flowing out.
d. Remove the oil filter joint (1) and oil cooler assembly
(2) in order.
RT21130140

Installation
CAUTION
 Clean installation surface of oil cooler assembly.

 Replace fuel filter.
 Add engine oil to specified level.
 Check and add engine coolant.
13

Oil Pan
Removal
WARNING
 DO NOT drain engine oil and remove oil pan until engine cools down.
when performing vehicle service. DO NOT remove oil filter until engine cools down.

 Wasted engine oil should be handled by specialized department according to local laws and regulations.
Never discard it at will.
5. Remove the oil pan.

a. Remove 2 baffle plate fixing bolts (arrow), and remove
13 the baffle plate (1) (for CVT model).
1
RT21130150
b. Remove 2 coupling bolts (arrow) between

transmission assembly and oil pan (for MT model).
RT21130160

c. Loosen and remove the oil pan fixing bolts in the order
19 12 8 4 1 5 9 13 20
shown in the illustration.
21
18
22
17 23
16 24
15 11 7 3 2 6 10 14 25 RT21130170
d. Pry off the oil pan at specific prying locations on the oil pan with oil pan remover and scraper and
remove it.
HINT:
Because the seal gum is sealed between oil pan and cylinder block, never use hard objects, such as a
hammer, to tap it during removal, but it can be tapped slowly from left and right with a rubber hammer.
CAUTION
 Be careful not to damage surrounding parts when removal.

 A transmission carrier can be used to support oil pan during removal, to prevent personal injury from
sudden dropping of oil pan.
6. Remove the residual seal gum on oil pan with oil pan
remover and scraper (1).
1 13
RT21130180
CAUTION
 After removing seal gum with oil pan scraper, clean the cylinder block installation surface, thread hole
and oil pan with appropriate cleaner.

Installation
CAUTION
 When applying seal gum, check the type and expiration date of seal gum.
 Remove impurities, iron chips and residue of seal gum on oil pan.
 Remove oil stain and residue of seal gum on cylinder block and thread hole of oil pan.
 Seal gum should not be applied too thick; otherwise, it will overflow into oil pan due to squeezing, which
will block oil strainer.
 DO NOT add engine oil until seal gum becomes dry after installing oil pan.
1. Uniformly apply seal gum to the oil pan installation

surface as shown in the illustration.
Recommended seal gum: Loctite 5910
RT21130190
CAUTION
13  Seal gum should be applied to inside of oil pan mounting bolt hole.
2. Pre-tighten the oil pan fixing bolts until it is enough for

19 12 8 4 1 5 9 13 20
press fit, and then tighten the oil pan fixing bolts in the
order shown in the illustration.
(Tightening torque: 15 + 3 N·m) 21
18
22
17 23
16 24
15 11 7 3 2 6 10 14 25 RT21130170

Oil Strainer
Removal
WARNING
 DO NOT drain engine oil until engine cools down.


4. Remove the oil pan (See page 13-20).
5. Remove the oil strainer.
a. Remove 2 fixing bolts (arrow) from the fuel strainer.
b. Remove the oil strainer (1) from the engine block
frame.
13
RT21130200
c. Remove the oil strainer and its gasket.
Installation
Installation is in the reverse order of removal. Pay attention to the following points during installation:
1. Clean the oil strainer mesh.
2. Replace the grommet.
 Oil strainer grommet (1)
 Oil pump and oil pan connecting pipe grommet (2) 1
 Oil filter and oil pan connecting pipe grommet (3)
RT21130210

Oil Pump Assembly

WARNING
 DO NOT remove oil filter until engine cools down.

Removal
4. Remove the front right wheel (See page 24-9).
5. Remove the engine accessory drive belt (See page 07-23).
7. Remove the crankshaft front oil seal (See page 07-39).
8. Remove the oil pump assembly.
a. Remove 4 fixing bolts (arrow) from the oil pump
assembly.
13
RT21130220
b. Using a proper tool (1), pry out the oil pump assembly
(2).
1
RT21130230

c. Remove the oil pump assembly (2) and oil pump

1 2
assembly grommet (1) in order.
RT21130240
 Wasted engine oil pump should be handled by specialized department according to local laws and
Installation
Installation is in the reverse order of removal. Pay attention to the following points during installation:
1. Replace the oil pump gasket and grommet.
2. Installation and alignment of oil pump:
 Align the plane (B) of oil pump assembly with plane
(A) of crankshaft as shown in the illustration.
A B
13
A B
RT21130250
 The relief valve (flange on the pump) (1) on oil pump

assembly is facing the outlet direction of cylinder
block frame, and the side with characters should face
upward.
 Apply a proper amount of seal gum to the bolt
mounting planes (arrow) before installing the oil pump
assembly fixing bolts.
1
RT21130260

- MEMO -

GENERAL INFORMATION 14-3 Removal 14-8
Description 14-3 Inspection 14-9
Specifications 14-4 Ignition Coil 14-10
Tool 14-4 Removal 14-10
Circuit Diagram 14-5 Inspection 14-11
Installation 14-11
Spark Plug 14-12
Removal 14-12
Service Precautions 14-7
Inspection 14-13
High-voltage Cable 14-8
14

14

14 - SQR484F IGNITION SYSTEM
GENERAL INFORMATION
Description
2
3
8
4
5
6
7
×4
MAX
14
MIN
RT21140010

1 - Cylinder 1 High-voltage Cable Assembly 2 - Cylinder 2 High-voltage Cable Assembly

3 - Cylinder 3 High-voltage Cable Assembly 4 - Cylinder 1 Spark Plug
5 - Cylinder 2 Spark Plug 6 - Cylinder 3 Spark Plug
7 - Cylinder 4 Spark Plug 8 - Cylinder 4 High-voltage Cable Assembly
9 - Ignition Coil
Operation
This model uses the distributorless ignition system which mainly consists of ignition coils, spark plugs, etc.
Ignition advance angle is controlled by Engine Control Module (ECM) directly.
Ignition coil consists of two primary windings, two secondary windings, iron core, housing, etc. When the
primary winding is connected to ground, it is charged. Once ECM cuts off the primary winding circuit, charging
stops, and at the same time, a high voltage is induced in the secondary winding to enable the spark plug to
discharge. This ignition system's difference from the ignition coil with distributor is that a spark plug is
connected to the ignition coil secondary winding at each end, which makes two spark plugs ignite
simultaneously. Two primary windings turn on/off alternately. Two secondary windings alternately discharge
accordingly.
Specifications

Spark Plug 30 ± 3
Ignition Coil Fixing Bolt 8+3
14 Spark Plug Specifications
Engine Type SQR484F

Spark Plug Type FR7DTC
Spark Plug Gap (mm) 0.8 - 0.9
Tool
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Ignition System
MT
BATTERY
85 30
ECM ENGINE
MAIN COMPARTMENT
RELAY FUSE AND
EF19 RELAY BOX
86 87
10A E-069
E-076
EF40 EF07 E-023
10A 15A
A2 F14 A6 C4
R
R
CYL1 CYL4 CYL3 CYL2

3
IGNITION
COIL
E-018
1 2
RL
Br
GGr
GBr
32 33
E-007
E-038 14
GGr
GBr
2-20 2-5 2-15 2-16 1-36 1-35
ECM
E-033
E-035
42 38 34 30 25 20 15 10 5
A1 A2 A3 A4 A5 C1 C2 C3 C4 C5 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
41 37 33 29 24 19 14 9 4
A6 A7 A8 A9 A10 C6 C7 C8 C9 C10 F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 28 23 18 13 8 3
40 36 32
27 22 17 12 7 2
E-076 E-023 E-069 39 35 31 26 21 16 11 6 1
Gr L W
E-018 E-007
1 2 3 4
B B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 25 26 27 28 29 30 31 32 33 34 35 36
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12
E-033 E-035
ET21140010
B B

DIAGNOSIS & TESTING

Ignition coil 14-10
Spark plug 14-12
Camshaft position sensor 06-248
Stall
Intake VVT control valve 06-242
Exhaust VVT control valve 06-242
Wire harness -
Ignition coil 14-10
Knock Knock sensor 06-245
ECM 06-256
Battery 16-7
Difficult to start Ignition coil 14-10
Spark plug 14-12
Spark plug 14-12
Engine speed sensor 06-249
Engine hesitation, power drop, unstable Intake VVT control valve 06-242
performance Exhaust VVT control valve 06-242
14 Camshaft position sensor 06-248
ECM 06-256
Spark plug 14-12
Rough, unstable idling or stall Ignition coil 14-10
ECM 06-256

Service Precautions
Visual inspection can reduce the unnecessary test and diagnostic time, so pay attention to the inspection of
the following items:
1. Check the lines and hoses for obvious looseness, and if they are disconnected or routed improperly.
2. Make sure battery connections are clean and firm.
3. Check if alternator wire and belt are installed correctly and securely.
4. Confirm that ignition coils are installed securely.
5. Check if engine wire harness connectors are inserted fully.
6. Check if all electrical connectors are installed correctly and securely.
7. Check the following electrical connections:
a. Engine speed sensor;
b. Oxygen sensor;
c. Intake pressure/temperature sensor;
d. Oil pressure switch;
e. Ignition coil;
f. Canister solenoid valve;
g. Camshaft position sensor;
h. Electronic throttle valve;
i. Intake VVT control valve;
j. Exhaust VVT control valve;
k. Fuel injector.
8. Check the routing of all vacuum hoses.
9. Confirm that the following vacuum hoses are connected securely without any leakage:
a. Canister solenoid valve;
b. Charcoal canister;
c. PCV valve; 14
d. Warm damper vacuum system;
e. Brake booster.
10.Check the fuel pump hose and wire connection to make sure they are connected securely.

ON-VEHICLE SERVICE
High-voltage Cable
Removal
CAUTION

 It is prohibited to use short circuit spark test to test ignition function during repair; otherwise it may cause
personal injury and damage the module.

4. Remove the high-voltage cable.
a. Disconnect the high-voltage cables (arrow) for each
cylinder in order from the ignition coil, and move the
high-voltage cable on the ignition coil side to one side.
14 RT21140020
b. Remove 3 high-voltage cable clips (arrow).

c. Loosen the high-voltage cables (1) in order and pull
them upward to remove them from the spark plug
holes.
1
RT21140030
d. Remove the high-voltage cable.
CAUTION
 Be careful not to damage the high-voltage cables when pulling them upward.

Inspection
Turn digital multimeter to ohm band, and measure resistance of high-voltage cables in the method shown in
the illustration.
If result is not as specified, replace the high-voltage cables.
Measurement Specification
Condition
Item (kΩ)
Cylinder 1
Normal
High-voltage 7.5 - 11.2
temperature
Cable
Cylinder 2
Normal
temperature
Cable RT21140040
Cylinder 3
Normal
temperature
Cable
Cylinder 4
Normal
High-voltage 4 - 6.5
temperature
Cable
Installation
CAUTION
 Install cylinder 1 to 4 high-voltage cables to spark plug hole and ignition coil in accordance with the
marks on high-voltage cables.
14

Ignition Coil
Removal
CAUTION


4. Remove the ignition coil.
a. Disconnect the ignition coil connector (1).
b. Disconnect the high-voltage cables (arrow) for each
cylinder, and put them aside.
RT21140050
c. Loosen and remove 4 fixing bolts (arrow) from the

14 ignition coil assembly.
RT21140060
d. Remove the ignition coil.

Inspection
1. Inspect resistance of ignition coil primary winding. 
Turn digital multimeter to ohm band, and check
+ -
resistance between terminals 1 and 3 or 1 and 4, 2 and 3 1 2 3 4
or 2 and 4. 
If result is not as specified, replace the ignition coil.
Multimeter
Condition Specification (Ω)
Connection
Terminal 1 - Normal
0.50 - 0.64
Terminal 3 or 4 temperature RT21140070
Terminal 2 - Normal
0.50 - 0.64
Terminal 3 or 4 temperature
2. Inspect resistance of ignition coil secondary winding.

Turn digital multimeter to ohm band, and check
resistance between the high-voltage posts 1 and 4, 2 and
3 of ignition coil secondary winding.
If result is not as specified, replace the ignition coil. 2 4
Multimeter Specification
Condition 3 1
Connection (kΩ)
Normal
Post 1 - Post 4 9.50 - 12.10
temperature RT21140080
Normal
Post 2 - Post 3 9.50 - 12.10
temperature
Installation
Installation is in the reverse order of removal. 14
CAUTION
 Make sure the connection between ignition coil and ignition coil high-voltage post, spark plug is reliable
during installation, or it may cause the high-voltage leakage, resulting in poor ignition.

Spark Plug
Removal
CAUTION

 DO NOT remove the spark plugs when the engine is hot; failure to do this may cause damage to the
spark plug thread holes on the cylinder head.
 Remove the high-voltage cables from the spark plugs in order, and mark them to prevent incorrect
installation.
 Before removal, remove the dirt and foreign matter around the spark plug holes to prevent them from
dropping into cylinders.
1. Turn off all the electrical equipment and ignition switch. Wait until the engine cools down.
4. Move away the high-voltage cables for each cylinder.
a. Remove the clamp (arrow) from the crankcase
ventilation hose, and disconnect the connection
between crankcase ventilation hose and valve
chamber cover.
b. Move away the crankcase ventilation hose.
14 c. Loosen the high-voltage cables (1) in order and pull
them upward to remove them from the spark plug
holes. 1
RT21140110
d. Move the high-voltage cable to one side.
CAUTION
 Be careful not to damage the high-voltage cables when pulling them upward.
5. Remove the spark plug.

a. Using a special spark plug socket wrench (1), loosen
the spark plug (2). 1
b. Remove the spark plug (2).

2
RT21140090

Inspection
Check the spark plug gap "a": 0.8 - 0.9 mm.
RT21140100
Installation
CAUTION
 Check the spark plug type to confirm if it is suitable.

 Please install spark plug with the special spark plug socket wrench, and never touch the spark plug
socket. DO NOT damage the normal spark plug gap.
1. Install 4 spark plugs respectively into the cylinder head mounting holes for pre-tightening, and then
retighten the spark plugs with a torque wrench. 
2. Other procedures are in the reverse order of removal.
14

- MEMO -

GENERAL INFORMATION 15-3 B1504-13 15-30
Description 15-3 B1506-00 15-37
Operation 15-6 B1507-00 15-41
Specifications 15-7 B1508-00 15-41
Tools 15-7 B1509-00 15-48
Circuit Diagram 15-8 B1510-00 15-52
B1514-00 15-56
Problem Symptoms Table 15-14 ON-VEHICLE SERVICE 15-64
Starter Relay Inspection 15-15 Starter 15-64
Precautions for Starting System 15-16 Removal 15-64
Diagnosis Procedure 15-17 Inspection 15-64
Problem Repair (No DTC) 15-19 Installation 15-66
Diagnostic Help 15-19 Ignition Starting Switch 
Intermittent DTC Troubleshooting 15-19 (w/o PEPS System) 15-67
Ground Inspection 15-20 Removal 15-67
Passive Entry & Passive Start (PEPS) Inspection 15-68
Controller Terminal List 15-20 Installation 15-68
Diagnostic Trouble Code (DTC) Chart 15-22 Engine Switch (w/ PEPS System) 15-69
B1500-13 15-23 Removal 15-69
B1501-13 15-23 Inspection 15-70
B1516-19 15-23 Installation 15-70
B1517-23 15-23 Passive Entry & Passive Start (PEPS)
B1502-13 15-30 Controller (w/ PEPS System) 15-71
B1503-13 15-30 Removal 15-71
Installation 15-71
15

15

15 - SQR484F STARTING SYSTEM
GENERAL INFORMATION
Description
w/o PEPS System
4
3
MAX
MIN
15
RT21150010
1 - Ignition Starting Switch 2 - Fuse and Relay Box

3 - Battery 4 - Starter
Starting system, equipped in the vehicle without Passive Entry & Passive Start (PEPS) system, consists of
battery, ignition switch and starter, etc.

w/ PEPS System
ENGINE
START
STOP
3
15 5 4
MAX
MIN
RT21150020
1 - Engine Switch 2 - Passive Entry & Passive Start (PEPS) Controller

3 - Fuse and Relay Box 4 - Battery
5 - Starter

Starting system, equipped in the vehicle with Passive Entry & Passive Start (PEPS) system, consists of PEPS
controller, engine switch, built-in low frequency antenna (3 antennas are equipped in vehicle to position where
the key is), anti-theft coil to back up starting, door handle sensor (built into front left/right door handle), back
door opener switch and smart key.
Passive Entry & Passive Start (PEPS) system has the following functions:
 Keyless entry function;
 Compatible general remote function;
 One-button keyless start function;
 Back door smart open function;
 Engine immobilizer function.
15

Operation
Engine Switch (w/ PEPS System)
Engine switch is located at the right side of instrument
cluster on instrument panel, the function of which is to
transform entire vehicle power state and control the starter.
There are 2 colors (amber and green) for LED indicator in
the engine switch. Driver can check current power mode and
if engine can start according to the illumination condition of
indicator.
RT21150030
Engine Switch Indicator Condition
Indicator Condition Description

 Engine switch is in OFF mode and brake pedal (for CVT
Indicator OFF model) or clutch pedal (for MT model) is released.
 Engine has been started.
Engine switch is in ACC or ON mode and brake pedal (for CVT
Indicator ON (Amber)
model) or clutch pedal (for MT model) is released.
For CVT model:
With shift lever in P or N position and brake pedal depressed,
press engine switch to start engine.
Indicator ON (Green)
For MT model:
With clutch pedal depressed, press engine switch to start
engine.
15
CAUTION
 For CVT model, if shift lever is in a position other than P when turning off the engine, the engine switch
will be turned to ACC mode, not to OFF.
Starter
The function of starter is to convert electrical energy from battery into mechanical energy so as to crank the
engine initially, and to disconnect the power transmission between starter and engine when the engine cranks
normally.
Starter consists of three parts: control mechanism, drive train mechanism and DC motor.
1. Control mechanism (solenoid switch): it controls the engagement and disengagement between starter
drive gear and engine flywheel gear and switches on/off the DC motor circuit; the solenoid switch can also
short out the ignition coil additional resistance when starting.
2. Drive train mechanism: it makes the starter drive gear get engaged with the flywheel gear when engine
starts and transmits the torque of starter to engine crankshaft; after the engine starts, the drive gear and
flywheel gear disengage automatically, so that the engine cannot drive the starter to run at a high speed in
reverse by flywheel, avoiding damage to the starter.
3. DC motor: it converts electrical energy from battery into electromagnetic moment.

Specifications

Starter Power Cable Nut 13 ± 1
Starter Fixing Bolt 35 ± 5
Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter 15
RCH0000002

Circuit Diagram
Starting System (Page 1 of 2)
MT
IGNITION SWITCH
BATTERY
START
30 86 ENGINE
COMPARTMENT
STARTER FUSE AND
RELAY RELAY BOX
87 85 E-022
E-067
EF41
E-069
30A
L1 F13 H5
R
RB
B
B 1
58 13
B M
15 S
M
STARTER
CONTROL
ECM
E-033
E-014
1 L2 L1 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 H8 H7 H6 H5 H4 H3 H2 H1
E-014 H16 H15 H14 H13 H12 H11 H10 H9

E-022 F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
B
W
E-067
E-069
W
W
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E-033
B
ET21150010

Starting System (Page 2 of 2)
CVT
BATTERY
30 86 ENGINE
COMPARTMENT
STARTER FUSE AND
RELAY RELAY BOX
87 85 E-022
E-067
EF41
E-069
30A
L1 F13 H5
R
RB
B
L
E-078
9
CONNECTOR A
(FOR CVT)
E-050
Y
10
YB
E-071
B 1 13 1 I-004
B M
BR
YB
S
STARTER J113 J110
15
M CONTROL
E-014 PEPS (J1)
I-029
L2 L1 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 H8 H7 H6 H5 H4 H3 H2 H1
H16 H15 H14 H13 H12 H11 H10 H9

E-022 F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
W
E-067
E-069
W
W
1 2 3 4 5 6 J108 J107 J106 J105 J104 J103 J102 J101

1 6 4 2 1 5 3
7 8 9 10 11 12 13 14
J116 J115 J114 J113 J112 J111 J110 J109
E-014 10 9 7 8
B I-029
E-071
Gr E-050
B
B
ET21150020

PEPS System (Page 1 of 4)
CVT

ON OR START
INSTRUMENT
PANEL FUSE
RF07 RF47 AND RELAY
BOX
7.5A 10A
I-007
I-031
7 E10
D1 YELLOW
D2 GREEN
D3 WHITE
ENGINE
SWITCH
R9
R8
R7
I-017
S1
S2
R3
R6
R2
R5
R1
R4
R
P
1 2 3 4 5 8
TO CAN
SYSTEM
GW
RW
WL
LW
R
L
OB
O
J111 J101 J211 J210 J213 J204 J203 J205 J106 J105
CAN H1 CAN L1
PEPS (J1/J2)
I-029
15 I-030
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
I-007 E1 E2 E3 E4 E5 E6 E7 E8
27 25 26 E13 E14 E15 E16
87
B E9 E10 E11 E12 E17 E18 E19 E20
85 86 86 86
87 30 87 30
30 85 85
I-031
W
J108 J107 J106 J105 J104 J103 J102 J101 J208 J207 J206 J205 J204 J203 J202 J201 1 2 3 4
J116 J115 J114 J113 J112 J111 J110 J109 J216 J215 J214 J213 J212 J211 J210 J209 5 6 7 8
I-029 I-030 I-017

Gr B W
ET21140020

CVT
BATTERY
ENGINE
EF15 EF48 EF43 COMPARTMENT
15A 20A 20A FUSE AND
RELAY BOX
85 30 85 30 85 30 E-065
IGN2 ACC IGN1 E-067
RELAY RELAY RELAY E-069
ERLY7 ERLY13 ERLY10 E-073
86 87 86 87 86 87 E-074
F4 F5 B1 F18 F17 I2 H6 H7 K1
B
B AM1 IG1 ACC AM2 IG2 ST2

240W 120W 120W 120W
RW
BW
LOCK IGNITION
W
R
E-078 E-078 E-078 R

ACC SWITCH
ON I-013
START
2 3 5
E-071
I-004 10 11 8 4 7 9
RW
BG
RY
RL
J104 J103 J102

15
PEPS (J1)
I-029
H8 H7 H6 H5 H4 H3 H2 H1 1 2 3 4 5 6
B1 B2 B3 B4 B5 K2 K1 I2 I1
E-073 7 8 9 10 11 12 13 14
H16 H15 H14 H13 H12 H11 H10 H9
B6 B7 B8 B9 B10 Y E-065 E-074
B Gr
E-067 E-071
W B
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 J108 J107 J106 J105 J104 J103 J102 J101 6 5 4
J116 J115 J114 J113 J112 J111 J110 J109 3 2 1
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
I-029 I-013
E-069
Gr Lg
W
ET21140030

CVT
PSE (J1/J2/J3)
I-029
I-030
B-056
J110 J113 J114 J107 J112 J301 J116 J201 J202
LW
RB
RB
YB
YB
L
I-004 I-034 I-035 15 B-012

1 13 14 3 16
E-071 E-027 B-059 T-004
YB
RL
LR
B
2
RB
RB
YB
BACK
DOOR
SWITCH
T-006
9 10 1 2 3 1 2
1
B
T-004
11 B-012
B
CONNECTOR A ABS CONTROL BRAKE SWITCH IMMOBILIZER COIL

E-050 MODULE B-052
E-085
B-017 I-037
15
6 5 4 3 2 1
6 4 2 1 5 3 13 12 11 10 9 8 7 6 5 4 3 2 1
14 13 12 11 10 9 8 7 2 1
10 9 7 8 24 23 22 21 20 19 18 17 16 15 14 E-085
4 3
B
I-004 E-050 38 37 36 35 34 33 32 31 30 29 28 27 26 25
B-052
W B
Lg
J108 J107 J106 J105 J104 J103 J102 J101 J208 J207 J206 J205 J204 J203 J202 J201 J304 J303 J302 J301 9 8 7 6 5 4 3 2 1
J116 J115 J114 J113 J112 J111 J110 J109 J216 J215 J214 J213 J212 J211 J210 J209 J308 J307 J306 J305 18 17 16 15 14 13 12 11 10
I-035
I-029 I-030 B-056
W
Gr B B
1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1
9 10 11 12 13 14 15 B-012 1 2 T-006 1 2
15 14 13 12 11 10 9
W B
I-034
W IMMOBILIZER COIL
ET21140040

CVT
PEPS (J2/J3)
I-030 B-056
J214 J206 J208 J207 J216 J215 J303 J302 J307 J306 J308 J304
RW
BG
BG
RY
LB
LY
G
I-035 I-006 B-040 B-061

13 14 16 15 12 9 18 10
B-059 B-003 F-007 H-002
GW
LW
W
RW
BG
BG
RY
LB
LY
G
1 2 1 2 1 2 2 1 2 1 1 2
LOW FREQUENCY LOW FREQUENCY LOW FREQUENCY LEFT HANDLE RIGHT HANDLE REAR BUMPER
ANTENNA 1 ANTENNA 2 ANTENNA 3 SENSOR SENSOR LOW FREQUENCY
I-043 B-024 B-035 F-003 H-004 ANTENNA
B-031
15
J208 J207 J206 J205 J204 J203 J202 J201 J304 J303 J302 J301
J308 J307 J306 J305 2 1 2 1 2 1 2 1
J216 J215 J214 J213 J212 J211 J210 J209
I-030 B-056 I-043 B-031 B-024 B-035

B B B B B B
10 9 8 7 6 5 4 3 2 1
9 8 7 6 5 4 3 2 1 2 1 2 1
22 21 20 19 18 17 16 15 14 13 12 11
18 17 16 15 14 13 12 11 10
I-035 I-006
W W F-003 H-004
B B
1 4 7 10 13 16 1 4 7 10 13 16
2 5 8 11 14 17 B-040 B-061
2 5 8 11 14 17
W W
3 6 9 12 15 18 3 6 9 12 15 18
ET21140050

DIAGNOSIS & TESTING

HINT:
Use the table below to help determine the cause of the problem. Check each suspected area in sequence.
Repair or replace the faulty components, or adjust as necessary.
Engine Switch Function Failure

Fuse 51-34
ACC relay 51-34
ING1 relay 51-34
ING2 relay 51-34
Power cannot be turned on Engine switch 15-6
Wire harness or connector -
Passive Entry & Passive Start (PEPS)
15-71
controller
Engine switch 15-6
Engine switch indicator does not come on
15-71
controller
Starter Failure
15
When ignition switch is turned to START, Battery (weak battery, poor contact of
16-7
solenoid switch makes a "clanking" sound battery cable)
and engine cannot start Starter 15-64
Battery (depleted) 16-7
Starter relay 51-34
Ignition switch 15-67
Engine switch 15-6
Starter does not run
Starter 15-64
15-71
controller
Battery (weak battery, internal fault) 16-7
Starter runs weakly
Starter 15-64
Starter (incorrect installation, internal fault) 15-64
Starter is racing
Flywheel ring gear (gear teeth broken) 07-42

Starter Relay Inspection

1. Remove the starter relay from engine compartment fuse
and relay box.
+ -
30
85
86
87
ERL Y09
Start relay
RT21150040
2. Check starter relay.

a. Using a digital multimeter, measure resistance according to the value(s) in the table below.
Standard Resistance
Multimeter Connection Specified Condition

30 - 87 10 kΩ or more
Below 1 Ω (when battery voltage is applied to
30 - 87
terminals 85 and 86)
If result is not as specified, replace the starter relay.
15

Precautions for Starting System

1. For models with PEPS system, shift the transmission to P or N before starting and firmly depress the clutch
pedal (for MT model) or brake pedal (for CVT model) until engine switch indicator illuminates in green.
2. For models without PEPS system, shift the transmission to neutral and apply parking brake before starting,
and depress the clutch pedal while starting.
3. For models with PEPS system, power supply mode (LOCK, ACC, ON) is always stored in vehicle. When
the battery cable is disconnected and reconnected, the power supply returns to the mode it was in before
the battery cable was disconnected. Be sure to turn engine switch off before disconnecting the cable from
battery terminal. Be careful if the power supply condition before the battery became depleted is not known.
4. Make sure that battery is fully charged to reduce the repeat operating time of starter.
After the battery is disconnected and reconnected, be sure to wait 10 seconds or more before engine start.
The engine may not start immediately after battery is reconnected.
5. Do not start engine for more than 5 seconds each time, the repeat starting time should be not less than 
10 - 15 seconds, and the consecutive starting is not allowed more than 3 times.
6. If starter cannot stop, turn off ignition switch immediately, or remove negative battery cable to find the
problem.
7. Check starter circuit frequently to make sure that each wire for starting system is connected securely and
in good insulation.
8. Generally, perform maintainable service for starter when servicing the vehicle. Also, the maintenance
interval can be shortened or extended properly depending on actual conditions.
9. Remove the negative battery cable before removing the starter.
15

Diagnosis Procedure
HINT:
Perform troubleshooting according to the procedures below.
1 Vehicle brought to workshop
NEXT
2 Customer problem analysis check
HINT:
In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions
should be discarded in order to make an accurate judgement. To clearly understand what the problem
symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time
the malfunction occurred.
NEXT
3 Check battery voltage
Standard voltage: 11 to 14 V
If voltage is below 11 V, recharge or replace the battery before proceeding to next step.
NEXT
4 Read DTCs
15
DTC
go to step 5
occurs
No 
go to step 7
DTC
5 Record DTCs, and clear DTCs
NEXT
6 Verify and duplicate problem: simulate problem occurring condition, and read DTCs again
DTC
For current DTC, go to step 8
occurs
No 
For history DTC, go to step 9
DTC

7 Problem repair (no DTC), then go to step 10
NEXT
8 Troubleshoot according to Diagnostic Trouble Code (DTC) chart, then go to step 10
NEXT
9 Troubleshoot according to Problem Symptoms Table, then go to step 10
NEXT
10 Confirm problem is repaired, and perform repair completion inspection
NEXT
11 End
15

Problem Repair (No DTC)

If PEPS system has problems, but no DTC is stored in PEPS system, this problem is called a problem without
DTC.
Symptom Suspected Area
Instrument cluster indicator does not come on or Instrument cluster indicator (broken)
remains on Wire harness (incorrectly connected)
Troubleshooting recommendation: check corresponding components according to problem symptom, and

troubleshoot following the vehicle repair manual.
Diagnostic Help
1. Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC), and make it
2. Confirm that malfunction is current, and carry out diagnostic test and repair procedures.
4. Visually check the related wire harness and connector.
5. Check and clean all wire harness connectors and grounds related to current DTC.
6. If multiple trouble codes were set, refer to the circuit diagrams to look for any common ground circuit or
power supply circuit applied to the DTC.

If malfunction is intermittent, perform the followings:
 Wiggle related wire harnesses and connectors and observe if signal is interrupted in the related circuit.
 If possible, try to duplicate the conditions under which the DTC was set. 15
 Look for the data that has changed or the DTC to be reset during the wiggle test.
 Check and clean all wire harness connectors and grounding parts related to the current DTC.
 Remove the PEPS controller from the malfunctioning vehicle and install it to a new vehicle and perform a
test. If DTC cannot be cleared, the PEPS controller is malfunctioning. If DTC can be cleared, reinstall the
PEPS controller to original vehicle.
 If multiple trouble codes were set, refer to the circuit diagrams to look for any common ground circuit or
 Refer to Technical Bulletin that is applied to the malfunction.

Ground Inspection
Groundings are very important to entire circuit system, which are normal or not can seriously affect the entire
circuit system. Ground points are often exposed to moisture, dirt and other corrosive environments. Corrosion
(rust) and oxidation may increase load resistance. This situation will seriously affect the normal operation of
the circuit. The operations to check the ground points are as follows:
sure all wire harnesses are clean, securely fastened and providing a good ground path.
Passive Entry & Passive Start (PEPS) Controller Terminal List
J1 J2 J3
15 J1 J2 J3
J101 J102 J103 J104 J105 J106 J107 J108 J301 J302 J303 J304
J201 J202 J203 J204 J205 J206 J207 J208
J109 J110 J111 J112 J113 J114 J115 J116 J305 J306 J307 J308
J209 J210 J211 J212 J213 J214 J215 J216
RT21150050
Connector J1 Terminal Definition
Terminal No. Terminal Definition Terminal No. Terminal Definition

J101 Battery Power Supply J109 Clutch Switch Signal
J102 IG1 Relay Drive (High) J110 Starter Relay Inspection
J103 ACC Relay Drive (High) J111 Ignition Signal
J104 IG2 Relay Drive (High) J112 -
J105 CAN-L J113 Starter Relay (High)
J106 CAN-H J114 Gear Position Signal


J107 Hard Wire Speed Signal J115 -
J108 - J116 GND

J201 Anti-theft Coil Positive J209 -
J202 Anti-theft Coil Negative J210 Engine Switch Ground
J203 Engine Switch Indicator (Green) J211 Engine Switch 1
J204 Engine Switch Backlight (White) J212 -
J205 Engine Switch Indicator (Amber) J213 Engine Switch 2
J206 Low Frequency Antenna 1 Negative J214 Low Frequency Antenna 1 Positive
J207 Low Frequency Antenna 2 Negative J215 Low Frequency Antenna 3 Negative
J208 Low Frequency Antenna 2 Positive J216 Low Frequency Antenna 3 Positive

J301 Back Door Unlock Signal J305 -
Front Left Door Handle Sensor (Low Front Right Door Handle Sensor
J302 J306
Frequency Antenna) Negative (Low Frequency Antenna) Negative
Front Left Door Handle Sensor (Low Front Right Door Handle Sensor
J303 J307
Frequency Antenna) Positive (Low Frequency Antenna) Positive
J304
Back Door Low Frequency Antenna
J308
Back Door Low Frequency Antenna 15
Negative Positive


B1500-13 Driver Door Outside LF Antenna Circuit Open
B1501-13 Passenger Door Outside LF Antenna Circuit Open
B1502-13 Front Internal LF Antenna Circuit Open
B1503-13 Middle Internal LF Antenna Circuit Open
B1504-13 Rear Internal LF Antenna Circuit Open
B1505-13 Bumper LF Antenna Circuit Open
B1506-00 Abnormality ON Switches of Engine Switch No Subtype Information
B1507-00 Abnormality in IG Circuit No Subtype Information
B1508-00 Abnormality in ACC Circuit No Subtype Information
B1509-00 Abnormality in Brake Signal No Subtype Information
B150A-00 Abnormality in Vehicle Speed Signal No Subtype Information
B150C-00 Clutch Switch Signal Error No Subtype Information
B150D-00 Abnormality on ESCL LCK_GND No Subtype Information
B150E-00 Abnormality on ESCL LCK_PS No Subtype Information
B150F-00 ESCL Anti-scanning No Subtype Information
B1510-00 Abnormality on Wheel Speed Signal No Subtype Information
B1511-00 Abnormality in ESCL Lock No Subtype Information
B1512-00 Abnormality in ESCL Unlock No Subtype Information
B1513-00 ESCL External Failure No Subtype Information
15 B1514-00 Abnormality on STAR Power Supply No Subtype Information

B1515-45 ROM for Checksum Failure
B1516-19 HSU Overload
B1517-23 HSU Switch Continuously Pressed Failure
U0073-88 Control Module Communication Bus Off
U0100-87 Lost Communication with EMS Missing Message
U0101-87 Lost Communication with TCM Missing Message
U0129-87 Lost Communication with BSM Missing Message
U0140-87 Lost Communication with BCM Missing Message
U0329-87 Lost Communication with ESCL Missing Message
U1300-55 Software Configuration Error Not Configured

DTC B1500-13 Driver Door Outside LF Antenna Circuit Open
DTC B1501-13 Passenger Door Outside LF Antenna Circuit Open
DTC B1516-19 HSU Overload
DTC B1517-23 HSU Switch Continuously Pressed Failure
15

CVT
PEPS (J3)
B-056
J303 J302 J307 J306
RW
BG
LB
LY
B-040 B-061
12 9 18 10
F-007 H-002
RW
BG
LB
LY
2 1 2 1
LEFT HANDLE RIGHT HANDLE

SENSOR SENSOR
F-003 H-004
15
1 4 7 10 13 16
1 4 7 10 13 16 B-040
B-061 2 5 8 11 14 17
2 5 8 11 14 17 W
W 3 6 9 12 15 18
3 6 9 12 15 18
J304 J303 J302 J301 2 1 2 1

J308 J307 J306 J305
B-056
F-003 H-004
B
B B
ET21140060

DTC Detection
Condition
Driver Door Outside LF
B1500-13
Antenna Circuit Open  Wire harness or connector damaged
Passenger Door  Outside low frequency antenna on
B1501-13 Outside LF Antenna driver side
Circuit Open Engine switch ON  Outside low frequency antenna on
B1516-19 HSU Overload passenger side
HSU Switch  Passive Entry & Passive Start (PEPS)
B1517-23 Continuously Pressed controller
Failure
CAUTION
 When performing electrical equipment diagnosis and test, always refer to the circuit diagram for related
circuit and component information.

Confirm that battery voltage is normal before performing the following procedures.
 Use X-431 3G diagnostic tester to record and clear the DTCs stored in the PEPS system.
 Turn ignition switch to LOCK and wait for a few seconds.
 Use X-431 3G diagnostic tester to select "Read Code".
 If DTC is detected, the malfunction indicated by the DTC is current. Go to the diagnosis procedure - Step 1. 15
Diagnosis Procedure

b. Disconnect the negative battery cable.
c. Disconnect the left handle sensor F-003 and right handle sensor H-004.
d. Disconnect the PEPS controller connector B-056.
e. Disconnect the front left door wire harness connector F-007 and body wire harness connector B-040.
f. Disconnect the front right door wire harness connector H-002 and body wire harness connector B-061.
g. Check if wire harnesses are worn, pierced, pinched or partially broken.
h. Look for broken, bent, protruded or corroded terminals.
i. Check that the related connector pins are in good condition.
NG Repair or replace related wire harness and

connector
OK

2 Check body wire harness and connector
a. Check the body wire harness and connector (outside low

frequency antenna on driver side).
Check for Open
Condition
J304 J303 J302 J301
B-056 (J303) -
Always Continuity J308 J307 J306 J305
B-040 (12)
B-056
B-056 (J302) -
Always Continuity
B-040 (9)
1 4 7 10 13 16
Check for Short 2 5 8 11 14 17
3 6 9 12 15 18
Condition B-040
B-056 (J303) or
RT21150210
B-040 (12) - Body Always No continuity
ground
B-056 (J302) or
ground
B-056 (J303) or
B-040 (12) - Always No continuity
Battery positive
B-056 (J302) or
Battery positive
15
b. Check the body wire harness and connector (outside low
frequency antenna on passenger side)
Check for Open
Condition
Connection Condition J304 J303 J302 J301
J308 J307 J306 J305
B-056 (J307) -
Always Continuity B-056
B-061 (18)
B-056 (J306) -
Always Continuity
B-061 (10)
1 4 7 10 13 16
2 5 8 11 14 17
Multimeter Specified B-061

Condition
B-056 (J307) or
RT21150230
B -061 (18) - Body Always No continuity
ground
B-056 (J306) or
ground

Condition
B-056 (J307) or
Battery positive
B-056 (J306) or
Battery positive
NG Repair or replace body wire harness and

connector
OK
3 Check front left door wire harness and connector
Check for Open
Condition
F-007 (12) - F-003 + - 1 2 3 3 2 1
Always Continuity 4 5 6 6 5 4
(2) 7 8 9 9 8 7
10 11 12 12 11 10
F-007 (9) - F-003 13 14 15 14 13
Always Continuity 15
(1) 16 17 18 18 17 16
Check for Short

F-007
Condition
Connection Condition 2 1
F-007 (12) or 15
F-003 (2) - Body Always No continuity F-003
ground
RT21150220
F-007 (9) or F-003
(1) - Body ground
F-007 (12) or
F-003 (2) - Always No continuity
Battery positive
F-007 (9) or F-003
(1) - Battery Always No continuity
positive
NG Repair or replace front left door wire

harness and connector
OK
4 Check front right door wire harness and connector

Check for Open
Condition
H-002 (18) - + -
H-004 (2) 4 5 6 6 5 4
7 8 9 9 8 7
H-002 (10) - 10 11 12 12 11 10
H-004 (1) 16 17 18 18 17 16
Check for Short

H-002
Condition
H-002 (18) or
H-004 (2) - Body Always No continuity
H-004
ground
RT21150240
H-002 (10) or
H-004 (1) - Body Always No continuity
ground
H-002 (18) or
H-004 (2) - Always No continuity
Battery positive
H-002 (10) or
H-004 (1) - Always No continuity
Battery positive
NG Repair or replace front right door wire

OK
15
5 Confirm DTCs
a. Connect related wire harness connectors.

b. Connect the negative battery cable.
c. Turn ignition switch ON.
d. Connect X-431 3G diagnostic tester to Data Link Connector (DLC) to check if any DTC is detected.
OK System operates normally
NG
6 Reconfirm DTCs after replacing front door handle sensor (built-in low frequency antenna)
a. Remove the front left door handle sensor (built-in low frequency antenna) (See page 37-56).
b. Remove the front right door handle sensor (built-in low frequency antenna).
c. Replace front left/right door handle sensors (built-in low frequency antenna) with new ones.
d. Connect X-431 3G diagnostic tester to Data Link Connector (DLC) again to check if any DTC is detected.

NG Repair or replace PEPS controller
OK
System operates normally
15

DTC B1502-13 Front Internal LF Antenna Circuit Open
DTC B1503-13 Middle Internal LF Antenna Circuit Open
DTC B1504-13 Rear Internal LF Antenna Circuit Open
15

CVT
PEPS (J2)
I-030
J214 J206 J208 J207 J216 J215
BG
RY
G
Y
I-035 I-006
13 14 16 15
B-059 B-003
W
BG
RY
G
1 2 1 2 1 2
LOW FREQUENCY LOW FREQUENCY LOW FREQUENCY

ANTENNA 1 ANTENNA 2 ANTENNA 3
I-043 B-024 B-035
15
9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 22 21 20 19 18 17 16 15 14 13 12 11
I-035 I-006
W W
J208 J207 J206 J205 J204 J203 J202 J201

2 1 2 1 2 1
J216 J215 J214 J213 J212 J211 J210 J209
I-030 I-043 B-024 B-035

B B B B
ET21140070

DTC Detection
Condition
Front Internal LF  Wire harness or connector damaged
B1502-13
Antenna Circuit Open  Front internal low frequency antenna
Middle Internal LF  Middle internal low frequency antenna
B1503-13 Engine switch ON
Antenna Circuit Open  Rear internal low frequency antenna
Rear Internal LF  Passive Entry & Passive Start (PEPS)
B1504-13
Antenna Circuit Open controller
CAUTION

 If DTC is detected, the malfunction indicated by the DTC is current. Go to the diagnosis procedure - Step 1.
Diagnosis Procedure
15

c. Disconnect the PEPS controller connector I-030.
d. Disconnect the front internal low frequency antenna connector I-043, middle internal low frequency
antenna connector B-024 and rear internal low frequency antenna connector B-035.
e. Disconnect the instrument panel wire harness connectors I-035 and I-006, and body wire harness
connectors B-059 and B-003.
f. Check if wire harnesses are worn, pierced, pinched or partially broken.
g. Look for broken, bent, protruded or corroded terminals.
h. Check that the related connector pins are in good condition.

connector
OK

2 Check instrument panel wire harness and connector
a. Check the instrument panel wire harness and connector

(front internal low frequency antenna).
Check for Open
Condition
J208 J207 J206 J205 J204 J203 J202 J201
I-030 (J214) -
Always Continuity J216 J215 J214 J213 J212 J211 J210 J209
I-043 (1)
I-030
I-030 (J206) -
Always Continuity
I-043 (2)
Check for Short 2 1
Multimeter Specified I-043

Condition
I-030 (J214) or
RT21150250
I-043 (1) - Body Always No continuity
ground
I-030 (J206) or
ground
I-030 (J214) or
I-043 (1) - Always No continuity
Battery positive
I-030 (J206) or
I-043 (2) - Battery Always No continuity
positive
15
b. Check the instrument panel wire harness and connector
(middle internal low frequency antenna).
Check for Open
Condition
J208 J207 J206 J205 J204 J203 J202 J201
I-030 (J208) -
I-035 (13)
I-030
I-030 (J207) -
Always Continuity
I-035 (14)
Check for Short 9 8 7 6 5 4 3 2 1

18 17 16 15 14 13 12 11 10
Condition I-035
I-030 (J208) or
RT21150260
ground
I-030 (J207) or
ground

Condition
I-030 (J208) or
Battery positive
I-030 (J207) or
Battery positive
c. Check the instrument panel wire harness and connector

(rear internal low frequency antenna).
Check for Open
Condition
J208 J207 J206 J205 J204 J203 J202 J201
I-030 (J216) -
I-006 (16)
I-030
I-030 (J215) -
Always Continuity
I-006 (15)
Check for Short 10 9 8 7 6 5 4 3 2 1

22 21 20 19 18 17 16 15 14 13 12 11
Condition I-006
I-030 (J216) or
RT21150270
ground
I-030 (J215) or
15 ground
I-030 (J216) or
Battery positive
I-030 (J215) or I
-006 (15) - Battery Always No continuity
positive
NG Repair or replace instrument panel wire

OK

a. Check the body wire harness and connector.

Check for Open
Condition 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B-059 (13) -
B-024 (1)
B-059 (14) -
Always Continuity
B-024 (2)
Check for Short

2 1
Condition
Connection Condition B-024
B-059 (13) or
RT21150271
ground
B-059 (14) or
ground
B-059 (13) or
Battery positive
B-059 (14) or
Battery positive
b. Check the body wire harness and connector. 15

Check for Open
Condition
B-003 (16) -
Always Continuity
B-035 (1) 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
B-003 (15) -
Always Continuity
B-035 (2) B-003
Check for Short

2 1
Condition
B-003 (16) or
RT21150280
ground
B-003 (15) or
ground

Condition
B-003 (16) or
Battery positive
B-003 (15) or
Battery positive

connector
OK
4 Confirm DTCs

NG
5 Replace low frequency antenna
15 a. Remove the low frequency antenna (See page 37-54).

b. Install new low frequency antenna.
c. Connect X-431 3G diagnostic tester to Data Link Connector (DLC) again to check if any DTC is detected.
OK

Abnormality ON Switches of Engine Switch No Subtype

DTC B1506-00
Information
CVT
D1 YELLOW
D2 GREEN
D3 WHITE
ENGINE
SWITCH
R9
R8
R7
I-017
S1
S2
R3
R6
R2
R5
R1
1 2 3 4 5 R4
8
GW
RW
WL
LW
R
L
J211 J210 J213 J204 J203 J205

15
PEPS (J2)
I-030
J208 J207 J206 J205 J204 J203 J202 J201 1 2 3 4

J216 J215 J214 J213 J212 J211 J210 J209 5 6 7 8
I-030 I-017
B W
ET21140080

DTC Detection
Condition
Abnormality ON  Wire harness or connector damaged

Switches of Engine  Engine switch
B1506-00 Engine switch ON
Switch No Subtype  Passive Entry & Passive Start (PEPS)
Information controller
CAUTION

Diagnosis Procedure
15 1 Check wire harness and connector

c. Disconnect the PEPS controller connector I-030.
d. Disconnect the engine switch connector I-017.
e. Check if wire harnesses are worn, pierced, pinched or partially broken.
f. Look for broken, bent, protruded or corroded terminals.
g. Check that the related connector pins are in good condition.

connector
OK

Check for Open
Condition
I-030 (J211) - + -
Always Continuity
I-017 (1)
I-030 (J210) - J208 J207 J206 J205 J204 J203 J202 J201
Always Continuity
I-017 (2) J216 J215 J214 J213 J212 J211 J210 J209
I-030
I-030 (J213) -
Always Continuity
I-017 (3)
I-030 (J204) -
Always Continuity 1 2 3 4
I-017 (4) 5 6 7 8
I-030 (J203) - I-017

Always Continuity
I-017 (5)
I-030 (J205) - RT21150290
Always Continuity
I-017 (8)
Check for Short
Condition
I-030 (J211) or
I-017 (1) - Body
ground/Battery
positive
I-030 (J210) or
I-017 (2) - Body
Always No continuity 15
ground/Battery
positive
I-030 (J213) or
I-017 (3) - Body
ground/Battery
positive
I-030 (J204) or
I-017 (4) - Body
ground/Battery
positive
I-030 (J203) or
I-017 (5) - Body
ground/Battery
positive
I-030 (J205) or
I-017 (8) - Body
ground/Battery
positive


OK
3 Check engine switch
a. Remove the engine switch (See page 15-69).

b. Check the engine switch (See page 15-70).
NG Repair or replace engine switch
OK
4 Confirm DTCs

OK
15

DTC B1507-00 Abnormality in IG Circuit No Subtype Information
DTC B1508-00 Abnormality in ACC Circuit No Subtype Information
BATTERY
ENGINE
RELAY BOX
85 30 85 30 85 30 E-065
IGN2 ACC IGN1 E-067
86 87 86 87 86 87 E-074
F4 F5 B1 F18 F17 I2 H6 H7 K1
B
AM1 IG1 ACC AM2 IG2 ST2

240W 120W 120W 120W
RW
BW
LOCK IGNITION
W
R
E-078 E-078 E-078 SWITCH

ACC
ON I-013
START
2 3 5
E-071
I-004 10 11 8 4 7 9
RW
BG
RY
RL
15
J104 J103 J102
PEPS (J1)
I-029
H8 H7 H6 H5 H4 H3 H2 H1 1 2 3 4 5 6
B1 B2 B3 B4 B5 K2 K1 I2 I1
E-073 7 8 9 10 11 12 13 14
H16 H15 H14 H13 H12 H11 H10 H9
B6 B7 B8 B9 B10 Y E-065 E-074
B Gr
E-067 E-071
W B
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 J108 J107 J106 J105 J104 J103 J102 J101 6 5 4
J116 J115 J114 J113 J112 J111 J110 J109 3 2 1
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
I-029 I-013
E-069
Gr Lg
W
ET21140030

DTC Detection
Condition
Abnormality in IG  Wire harness or connector damaged
B1507-00 Circuit No Subtype  Fuse
Information
 IGN1 relay
 IGN2 relay
Engine switch ON
Abnormality in ACC  ACC relay
B1508-00 Circuit No Subtype  Engine switch
Information
 Passive Entry & Passive Start (PEPS)
controller
CAUTION

15  If DTC is not detected, the malfunction indicated by the DTC is intermittent (See page 15-19).
Diagnosis Procedure
1 Check fuse and relay

c. Remove the fuses EF15 (15 A), EF48 (20 A) and EF43 (20 A) from engine compartment fuse and relay
box.
d. Remove the IGN1 relay, IGN2 relay and ACC relay from engine compartment fuse and relay box.
e. Check if fuses and relays are blown or damaged.
NG Repair or replace damaged fuses and

relays.
OK
2 Check engine compartment fuse and relay box ground
a. Check engine compartment fuse and relay box ground E-078 (See page 51-42).


ground point
OK
3 Check wire harness (battery - engine compartment fuse and relay box)
a. Remove the IGN1 relay, IGN2 relay and ACC relay from engine compartment fuse and relay box.
c. Turn the digital multimeter to DC voltage band to check if voltage output from the terminal 30 of relay is 
12 V.
NG Repair or replace wire harness (battery -

OK
4 Check engine compartment wire harness
a. Check the wire harness between engine compartment

fuse and relay box connector E-069 and engine
compartment wire harness connector E-071.
Check for Open
+ -
Condition
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
E-069 (F5) -
Always Continuity
E-071 (10)
15
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
E-069 (F17) - E-069

Always Continuity
E-071 (8)

7 8 9 10 11 12 13 14
Condition E-071
RT21150300
E-069 (F5) or
ground
E-069 (F17) or
ground
E-069 (F5) or
Battery positive
E-069 (F17) or
Battery positive

b. Check the wire harness between engine compartment

Check for Open
+ -
Condition
Connection Condition B1 B2 B3 B4 B5
E-073 (B1) - B6 B7 B8 B9 B10

Always Continuity
E-071 (11) E-073
Check for Short

1 2 3 4 5 6
Condition 7 8 9 10 11 12 13 14
E-071
E-073 (B1) or
ground RT21150310
E-073 (B1) or
Battery positive
c. Check the wire harness between engine compartment

Check for Open
+ -
Condition
E-074 (I2) - E-071 I2 I1
Always Continuity
(4) E-074
15 Check for Short

1 2 3 4 5 6
Condition 7 8 9 10 11 12 13 14
E-071
E-074 (I2) or
ground RT21150320
E-074 (I2) or
Battery positive

d. Check the wire harness between engine compartment

Check for Open
+ -
Condition
Connection Condition H8 H7 H6 H5 H4 H3 H2 H1
H16 H15 H14 H13 H12 H11 H10 H9

E-067 (H7) -
Always Continuity
E-071 (7) E-067
Check for Short

1 2 3 4 5 6
Condition 7 8 9 10 11 12 13 14
E-071
E-067 (H7) or
ground RT21150330
E-067 (H7) or
Battery positive
e. Check the wire harness between engine compartment

Check for Open
+ -
Condition
Connection Condition K2 K1
E-065 (K1) - E-065

Always Continuity
E-071 (9)
Check for Short 15

1 2 3 4 5 6
Multimeter Specified 7 8 9 10 11 12 13 14
Condition
E-071
E-065 (K1) or
ground RT21150340
E-065 (K1) or
Battery positive
NG Repair or replace engine compartment

wire harness
OK

5 Check instrument panel wire harness
a. Check the wire harness between instrument panel wire

harness connectors I-004 and I-029.
Check for Open
Condition 6 5 4 3 2 1
Connection Condition 14 13 12 11 10 9 8 7
I-004 (10) - I-029

Always Continuity
(J104) I-004
I-004 (8) - I-029

Always Continuity
(J103)
I-004 (7) - I-029
(J102)
J116 J115 J114 J113 J112 J111 J110 J109
Check for Short I-029
I-004 (10) or I-029
(J104) - Body
ground/Battery
positive
I-004 (8) or I-029
(J103) - Body
ground/Battery
positive
I-004 (7) or I-029
(J102) - Body
15 ground/Battery
positive
b. Check the wire harness between instrument panel wire

harness connectors I-004 and I-013.
Check for Open
Condition
6 5 4
I-004 (11) - I-013
Always Continuity 3 2 1
(5)
I-013
I-004 (4) - I-013
Always Continuity
(3)
I-004 (9) - I-013 6 5 4 3 2 1
Always Continuity
(2) 14 13 12 11 10 9 8 7
I-004
RT21150360

Check for Short
Condition
I-004 (11) or I-013
(5) - Body ground/ Always No continuity
Battery positive
I-004 (4) or I-013
Battery positive
I-004 (9) or I-013
Battery positive

harness
OK
6 Check engine switch
a. Remove the engine switch (See page 15-69).

b. Check the engine switch (See page 15-70).
NG Repair or replace engine switch
OK
15
7 Confirm DTCs

OK

DTC B1509-00 Abnormality in Brake Signal No Subtype Information
CVT
PEPS (J1)
I-029
J112
RB
I-035
16 B-059
RB
BRAKE SWITCH
B-052
15
J108 J107 J106 J105 J104 J103 J102 J101 9 8 7 6 5 4 3 2 1 2 1
18 17 16 15 14 13 12 11 10 4 3
J116 J115 J114 J113 J112 J111 J110 J109
I-035 B-052
I-029
W Lg
Gr
ET21140090

DTC Detection
Condition
 Wire harness or connector damaged
Abnormality in Brake
 Brake switch assembly
B1509-00 Signal No Subtype Engine switch ON
Information  Passive Entry & Passive Start (PEPS)
controller
CAUTION

Diagnosis Procedure

15
c. Disconnect the brake switch connector B-052 and PEPS controller connector I-029.
d. Disconnect the instrument panel wire harness connector I-035 and body wire harness connector B-059.

connector
OK

2 Check body wire harness
Check for Open
Condition
B-052 (3) - B-059 + -
Always Continuity
(16) 2 1
4 3
Check for Short
B-052
Condition
B-052 (3) or 1 2 3 4 5 6 7 8 9
B-059 (16) - Body Always No continuity 10 11 12 13 14 15 16 17 18
ground B-059
B-052 (3) or
NG Repair or replace body wire harness
OK
Check for Open
15 Connection
Condition
Condition
I-029 (J112) - + -
Always Continuity
I-035 (16)
J108 J107 J106 J105 J104 J103 J102 J101
Check for Short J116 J115 J114 J113 J112 J111 J110 J109

Condition
I-029 (J112) or 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
I-035
ground
I-029 (J112) or

harness
OK

4 Check brake switch assembly
a. Remove the brake switch assembly (See page 27-9).

b. Check the brake switch assembly. + -
Using ohm band of digital multimeter, check for continuity 1 2
3 4
between terminals of brake switch assembly according to
the table below.
Condition
Brake pedal
Terminal 1 -
depressed (switch Continuity RT21260300
Terminal 3
pin released)
Brake pedal
Terminal 2 -
depressed (switch No continuity
Terminal 4
pin released)
Brake pedal
Terminal 1 -
released (switch No continuity
Terminal 3
pin pushed)
Brake pedal
Terminal 2 -
released (switch Continuity
Terminal 4
pin pushed)
NG Replace brake switch assembly
OK
5 Confirm DTCs 15
OK

DTC B1510-00 Abnormality on Wheel Speed Signal No Subtype Information
CVT
PEPS (J1)
I-029
J107
LW
I-034
3 E-027
L
ABS CONTROL
MODULE
E-085
15
13 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 E-085
B
38 37 36 35 34 33 32 31 30 29 28 27 26 25
J108 J107 J106 J105 J104 J103 J102 J101 8 7 6 5 4 3 2 1

J116 J115 J114 J113 J112 J111 J110 J109 15 14 13 12 11 10 9
I-034
I-029 W
Gr
ET21140100

DTC Detection
Condition
Abnormality on Wheel
 ABS module
B1510-00 Speed Signal No Engine switch ON
Subtype Information  Passive Entry & Passive Start (PEPS)
controller
CAUTION

Diagnosis Procedure

15
c. Disconnect the ABS module connector E-085 and PEPS controller connector I-029.
d. Disconnect the instrument panel wire harness connector I-034 and engine compartment wire harness
connector E-027.

connector
OK

Check for Open
Condition
E-085 (2) - + -
Always Continuity
E-027 (3) 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
Check for Short

E-027
Condition
12 11 10 9 8 7 6 5 4 3 2
E-085 (2) or 13 1
24 23 22 21 20 19 18 17 16 15 14
38 25
ground 37 36 35 34 33 32 31 30 29 28 27 26
E-085 (2) or E-085


wire harness
OK
Check for Open

15 Multimeter Specified
Condition
I-034 (3) - I-029 + -
Always Continuity
(J107) 8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
Check for Short
I-034
Condition
I-034 (3) or I-029
(J107) - Body Always No continuity J108 J107 J106 J105 J104 J103 J102 J101
ground J116 J115 J114 J113 J112 J111 J110 J109
I-029
I-034 (3) or I-029
(J107) - Battery Always No continuity
positive RT21150400

harness
OK

4 Confirm DTCs

NG
5 Reconfirm DTCs after replacing ABS module
a. Remove the ABS module (See page 25-71).

b. Replace the ABS module.
OK
15

DTC B1514-00 Abnormality on STAR Power Supply No Subtype Information
CVT

BATTERY
ON OR START
INSTRUMENT
PANEL FUSE
30 86 ENGINE RF07 RF47 AND RELAY
COMPARTMENT BOX
STARTER FUSE AND 7.5A 10A
RELAY I-007
RELAY BOX
7 E10 I-031
87 85 E-022
E-067
EF41
E-069
30A
R
P
L1 F13 H5
R
RB
B
L
E-078
9
CONNECTOR A
(FOR CVT)
E-050
Y
10
YB
E-071
13 1 I-004
B 1
BR
YB
B M
15 S
M
STARTER
CONTROL J113 J110 J111 J101
E-014 PSE
CONNECTION
(J1)
I-029
L2 L1 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 H8 H7 H6 H5 H4 H3 H2 H1

1
H16 H15 H14 H13 H12 H11 H10 H9
E-014 E-022 F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
B W
E-067
E-069
W
W
1 2 3 4 5 6 J108 J107 J106 J105 J104 J103 J102 J101

E-071 I-029 6 4 2 1 5 3
E-050
7 8 9 10 11 12 13 14 B Gr B
J116 J115 J114 J113 J112 J111 J110 J109
10 9 7 8
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
E1 E2 E3 E4 E5 E6 E7 E8
I-007 E13 E14 E15 E16
27 25 26 E9 E10 E11 E12 E17 E18 E19 E20
87
B
85 86 86 86
87 30 87 30
30 85 85 I-031
W
ET21140110

DTC Detection
Condition
 Fuse
Abnormality on STAR
 Relay
B1514-00 Power Supply No Engine switch ON
Subtype Information  Connector A (for CVT model)
 Passive Entry & Passive Start (PEPS)
controller
CAUTION

Diagnosis Procedure
15
1 Check the fuses and relays

c. Remove the fuse EF41 (30 A) and starter relay from engine compartment fuse and relay box.
d. Remove the fuses RF07 (7.5 A) and RF47 (10 A) from instrument panel fuse and relay box.
e. Check if the fuses and relays are blown or damaged.
NG Repair or replace damaged fuses and

relays.
OK
2 Check engine compartment fuse and relay box ground
a. Check engine compartment fuse and relay box ground E-078 (See page 51-42).

ground point

OK
3 Check battery wire harness
a. Check if the voltage between starter power supply wire harness and battery negative is battery voltage.
b. Check if the voltage between engine compartment fuse and relay box power supply wire harness and
battery negative is battery voltage.
NG Repair or replace battery wire harness
OK
4 Check PEPS controller power supply voltage
a. Disconnect the PEPS controller connector I-029.

b. Check the voltage between terminal J101 of PEPS
controller connector I-029 and body ground.
Condition
I-029 (J101) -
Always 11 - 14 V
Body ground J108 J107 J106 J105 J104 J103 J102 J101
J116 J115 J114 J113 J112 J111 J110 J109
I-029
15
RT21150410

d. Check the voltage between terminal J111 of PEPS
controller connector I-029 and body ground.
Condition
I-029 (J111) -
Always 11 - 14 V J108 J107 J106 J105 J104 J103 J102 J101
Body ground
J116 J115 J114 J113 J112 J111 J110 J109
I-029
OK Go to step 6
RT21150420

NG
5 Check PEPS controller power supply circuit
a. Turn ignition switch off.

b. Disconnect the instrument panel fuse and relay box
connectors I-007 and I-031.
c. Check the wire harness between terminal E10 of
instrument panel fuse and relay box connector I-031 and
terminal J101 of PEPS controller connector I-029. + -
Check for Open
Condition E1 E2 E3 E4
E13 E14 E15 E16
E5 E6 E7 E8
Connection Condition E9 E10 E11 E12 E17 E18 E19 E20
I-031 (E10) -
Always Continuity I-031
I-029 (J101)
J116 J115 J114 J113 J112 J111 J110 J109

Condition I-029
I-031 (E10) or RT21150430
I-029 (J101) - Always No continuity
Body ground
I-031 (E10) or
I-029 (J101) - Always No continuity
Battery positive
d. Check the wire harness between terminal 7 of instrument

panel fuse and relay box connector I-007 and terminal 15
J111 of PEPS controller connector I-029.
Check for Open
+ -
J108 J107 J106 J105 J104 J103 J102 J101
Condition J116 J115 J114 J113 J112 J111 J110 J109
I-029
I-007 (7) - I-029
Always Continuity
(J111)
Check for Short 1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
Condition 27 25 26
Connection Condition 87
85 86 86 86
87 30 87 30
I-007 (7) or I-029 30 85 85
(J111) - Body Always No continuity I-007

ground RT21150440
I-007 (7) or I-029

(J111) - Battery Always No continuity
positive

NG Repair or replace related wire harness or

connector (instrument panel fuse and
relay box - PEPS controller)
OK
6 Check CVT connector A
a. Disconnect the CVT connector A (arrow).
RT21150451
b. Check the CVT connector A.
Gearshift Position Terminal No. Specified Condition

P 1 - 7, 9 - 10
R 7-8
N 2 - 7, 9 - 10 Continuity
D 3-7
L 4-7
15
NG Repair or replace CVT connector A
OK

7 Check wire harness (instrument panel - engine compartment)
a. Disconnect the engine compartment wire harness

connector E-067.
b. Check the wire harness between PEPS controller
connector I-029 and engine compartment fuse and relay
box connector E-067. + -
Check for Open H8 H7 H6 H5 H4 H3 H2 H1
H16 H15 H14 H13 H12 H11 H10 H9

Condition
I-029 (J110) -
Always Continuity
E-067 (H5)
J108 J107 J106 J105 J104 J103 J102 J101
Check for Short
J116 J115 J114 J113 J112 J111 J110 J109

Condition
I-029 (J110) or RT21150450
E-067 (H5) - Body Always No continuity
ground
I-029 (J110) or
E-067 (H5) - Always No continuity
Battery positive
c. Check the wire harness between PEPS controller

connector I-029 and CVT connector A E-050.
Check for Open
15
+ -
Condition
6 4 2 1 5 3
I-029 (J110) -
E-050 (9)
E-050
I-029 (J113) -
Always Continuity
E-050 (10)
J116 J115 J114 J113 J112 J111 J110 J109

Condition I-029
I-029 (J110) or
RT21150460
ground
I-029 (J113) or
ground
I-029 (J110) or
Battery positive
I-029 (J113) or
Battery positive

NG Repair or replace wire harness

(instrument panel - engine compartment)
OK
8 Check starter field wire harness
a. Disconnect the starter control connector E-014 and engine

compartment fuse and relay box connector E-022.
b. Check the starter field wire harness.
Check for Open
+ -
Condition
1
E-014 (1) - E-022
Always Continuity E-014
(L1)
Check for Short

L2 L1
Condition
E-014 (1) or
E-022 (L1) - Body Always No continuity
ground RT21150470
E-014 (1) or
E-022 (L1) - Always No continuity
Battery positive
15 NG Repair or replace starter field wire

harness
OK
9 Confirm DTCs

NG

10 Reconfirm DTCs after replacing starter
a. Remove the starter (See page 15-64).

b. Replace the starter.
OK
15

ON-VEHICLE SERVICE
Starter
Removal
CAUTION


4. Remove the intake manifold assembly (See page 10-24).
5. Remove the starter.
a. Move away the terminal cover, remove the starter
power cable nut (1) and disconnect the starter power
cable. 1
b. Remove 2 fixing bolts (arrow) from starter.
RT21150060
15 c. Remove the starter.
Inspection
1. Check starter clutch.
a. As shown in the illustration, rotate the clutch pinion
clockwise to check that it rotates smoothly. Rotate the
clutch pinion counterclockwise to check that it locks.
If result is not as specified, replace the starter.
Lock
Free
RT21150070

2. Check starter solenoid switch.

a. Check pull-in coil.
 Measure resistance between terminal 50 and
terminal C. Terminal 50
Terminal C
RT21150080
 Standard resistance should be below 2 Ω.

b. Check hold-in coil.
 Measure resistance between terminal 50 and
starter solenoid switch body.
Terminal 50 Switch Body
RT21150090
 Standard resistance should be below 2 Ω.

3. Check starter assembly. 15
CAUTION
 These tests must be performed within 3 to 5 seconds to avoid burning out coil.
 Secure the starter assembly in a vise. Jaws of the vise should be covered by aluminum plate or brass
plate; otherwise the starter assembly will be easily damaged when clamping it.
a. Perform pull-in test.

 Remove the nut, and disconnect the field coil lead
from terminal C. Terminal 50
 As shown in the illustration, connect battery to the

solenoid switch, and check that the starter clutch
pinion extends.
Terminal C
Body
- +
RT21150100
If the starter clutch pinion does not move, replace the starter assembly.

b. Perform hold-in test.

 Keep the starter clutch pinion extending and
Terminal 50
connections of battery mentioned above, and
disconnect the negative battery cable from
terminal C.
 Check that the starter clutch pinion remains
extended.
Terminal C
Body
- +
RT21150110
If the starter clutch pinion moves inward, replace the starter assembly.
c. Check if starter clutch pinion returns.
 Disconnect negative battery lead from the starter
Terminal 50
body. Check that the starter clutch pinion returns.
Terminal C
Body
- +
RT21150120
If the starter clutch pinion does not return, replace the starter assembly.
d. Check if starter rotates smoothly.
 Connect the field coil lead to terminal C, and
tighten it with a nut.
15  As shown in the illustration, connect battery to the
starter. Check that the starter rotates smoothly and
steadily when the starter clutch pinion is moving Terminal 30
outward. Terminal 50
- Body
+
RT21150130
CAUTION
 The lead to be connected should avoid the pinion side to prevent the lead from getting caught as the
pinion rotates.
If result is not as specified, replace the starter assembly.
Installation

Ignition Starting Switch (w/o PEPS System)

Removal
CAUTION

 Try to prevent vehicle protector from being scratched during removal and installation.

3. Remove the combination switch cover (See page 28-13).
4. Remove the ignition starting switch.
a. Move the wire harness connectors (arrow) away from
ignition starting switch.
RT21150140
b. Disconnect the ignition starting switch connector (1).

c. Remove the fixing screws (arrow) from ignition
starting switch.
1 15
RT21150150
d. Remove the ignition starting switch.

Inspection
1. Check for continuity of ignition starting switch.
Using ohm band of the digital multimeter, check for
continuity of ignition starting switch according to the table
+ -
below.
4 5 6
1 2 3
Multimeter Switch Specified
Connection Condition Condition
All terminals LOCK No continuity
Terminal 1 -
ACC Continuity
Terminal 3
RT21150160
Terminal 1 -
Terminal 2
Terminal 1 -
Terminal 3
ON Continuity
Terminal 2 -
Terminal 3
Terminal 5 -
Terminal 6
Terminal 1 -
Terminal 2
Terminal 4 -
Terminal 5
START Continuity
Terminal 4 -
Terminal 6
Terminal 5 -
Terminal 6
If result is not as specified, replace the ignition starting switch.

15
Installation

Engine Switch (w/ PEPS System)

Removal
CAUTION


4. Remove the engine switch.
a. Disconnect the engine switch connector (arrow).
RT21150170
b. Detach 2 claws on engine switch in the direction of

arrow as shown in the illustration, and remove the
engine switch.
15
RT21150180

Inspection
1. Check for continuity of engine switch.
Using ohm band of the digital multimeter, check for
continuity of engine switch according to the table below.
+ -
Multimeter Switch Specified 5 6 7 8

1 2 3 4
Terminal 1 -
Not pushed No continuity
Terminal 2
ENGINE
START
Terminal 3 - STOP
Not pushed No continuity
Terminal 2
RT21150190
Terminal 1 -
Pushed Continuity
Terminal 2
Terminal 3 -
Pushed Continuity
Terminal 2
If result is not as specified, replace the engine switch.

2. Check engine switch indicator illumination.
Apply battery voltage between terminals of engine
+ -
switch, check engine switch indicator illumination.
HINT:
 If positive (+) lead and negative (-) lead are connected 5 6 7 8
1 2 3 4
incorrectly, the engine switch indicator does not come

on.
 When battery voltage is too low, the engine switch
ENGINE
indicator does not come on. START
STOP
Measurement Specified
Condition Condition
15 Battery positive
(+) → Terminal 4 Come on
Always
Battery negative (stamping word)
(-) → Terminal 2
Battery positive
(+) → Terminal 5
Always Come on (amber)
Battery negative
(-) → Terminal 2
Battery positive
(+) → Terminal 8
Battery negative Always Come on (green)
(-) → Terminal 2
If result is not as specified, replace the engine switch
Installation

Passive Entry & Passive Start (PEPS) Controller (w/ PEPS System)
Removal
CAUTION


3. Remove the glove box assembly (See page 45-17).
4. Remove the PEPS controller.
a. Disconnect the PEPS controller connectors (1).
b. Remove 2 fixing nuts (arrow) from PEPS controller
bracket.
RT21450480
c. Remove the PEPS controller with bracket from engine crossmember.
CAUTION
 DO NOT separate PEPS controller and bracket if not as necessary. DO NOT separate them over and 15
over again if it is necessary to separate, to avoid damage to claws of PEPS controller.
Installation
CAUTION
 It is necessary to match the PEPS controller after replacing it (See page 15-71).
 With PEPS controller not matched, do not carelessly turn on and off the power, as the non-matched
PEPS controller has 50 chances to turn the power from off to ignition state, PEPS controller will not be
used once more than 50 times.

- MEMO -

GENERAL INFORMATION 16-3 ON-VEHICLE SERVICE 16-7
Description 16-3 Battery 16-7
Alternator Operation 16-4 Inspection 16-7
Tool 16-4 Installation 16-8
Circuit Diagram 16-5 Battery Tray and Tray Bracket 16-9
Removal 16-9
Installation 16-9
Alternator 16-10
Charging System Charging Voltage 
Removal 16-10
Inspection 16-6
Installation 16-11
16

16

16 - SQR484F CHARGING SYSTEM
GENERAL INFORMATION
Description
4
1
MAX
MIN
16
RT21160010
1 - Alternator 2 - ECM
3 - Battery 4 - Fuse and Relay Box
Alternator is a key component of the charging system. It is a device that converts mechanical energy into
electrical energy and generates DC voltage through a rectifying circuit, as one of main power sources of the
vehicle. The alternator operates as a complete assembly. If alternator fails for any reason, the entire unit must
be replaced.

Alternator Operation
Alternator is a silicon rectifying alternator, which mainly consists of rotor, stator and rectifier.
When direct current flows to the rotor winding, rotor claw establishes magnetic field to produce alternating
induced electromotive force. The stator is installed on the outside of the rotor, and it is secured together with
the front and rear end covers of alternator. When the alternator rotor is rotated by drive belt, magnetic pole
lines cut the stator winding, causing a change in the magnetic flux of the stator winding; thus, the stator
winding generates alternating induced electromotive force, producing alternating current. The three-phase
alternating current generated by alternator is converted to direct current from alternating current by rectifier,
and the direct current is transmitted to the vehicle electrical system and battery.
Specifications

Battery Pressure Plate Fixing Nut 7±1
Coupling Bolt Between Battery Pressure Plate and
7±1
Tank Upper Crossmember
Coupling Bolt Between Battery Tray and Air Filter
7 ± 1.5
Bracket
Battery Tray Fixing Bolt 20 ± 2
Battery Tray Bracket Fixing Bolt 20 ± 2
Alternator Output Cable Fixing Nut 18 - 22
Alternator Fixing Bolt 20 + 5
Battery Specification
Engine Type Battery Type Specification

SQR484F 6-QW-70QR 12 V, 70 Ah, CCA (SAE) 560 A
16
Tool
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Charging System
IGNITION SWITCH
BATTERY
ON OR START
INSTRUMENT ENGINE
POWER PANEL
MF07 RF06 EF29 COMPARTMENT
FUSE BOX FUSE AND
150A RELAY BOX FUSE AND
10A 10A
RELAY BOX
I-007
E-023
6 C7
P
13
INSTRUMENT
CLUSTER
I-015
16
R
I-034
6
E-027
BY
V
22 E-038
E-007
B
V
ALTERNATOR
E-003 16
2
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 2 3 4 5 6 7 8
1 2 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15
E-003
I-015
B
L E-027
W
1 2 3 4 5 6 7 8 9 10 11 12
42 38 34 30 25 20 15 10 5
13 14 15 16 17 18 19 20 21 22 23 24
C1 C2 C3 C4 C5 41 37 33 29 24 19 14 9 4
27 25 26 28 23 18 13 8 3
C6 C7 C8 C9 C10 87 40 36 32
27 22 17 12 7 2
85 86 86 86 39 35 31 26 21 16 11 6
87 30 87 30 1
E-023 30 85 85
L
I-007 E-007
B B
ET21160010

DIAGNOSIS & TESTING

Alternator 16-10
Charging system warning light comes on
Instrument cluster 38-42
after engine starts
Wire harness -
Fixing bolt (loose) 16-4
Noises are heard from alternator after Accessory drive belt (misaligned, loose or
07-23
engine starts fault)
Alternator 16-10
Charging System Charging Voltage Inspection

1. Leave vehicle under no load test condition and idle the engine. Measure battery voltage with digital
multimeter.
Standard voltage: 14.1 - 14.7 V
If result is not as specified, replace alternator (See page 16-10).
2. Leave vehicle under load test condition and idle the engine. Measure battery voltage with digital
multimeter.
Load test condition:
 Set headlight to high beam;
 Turn on blower and adjust blower speed to the highest;
 Turn on "A/C" switch;
 Turn cold and hot switch to adjust temperature of outlet to the highest.
Standard voltage: 14.1 - 14.7 V
If result is not as specified, replace alternator (See page 16-10).
16
CAUTION
 If charging system warning light comes on, the charging system may have a malfunction.
 If noises are heard from alternator or generating capacity is extremely high or low, repair or replace the
alternator.

ON-VEHICLE SERVICE
Battery
Inspection
1. Check that battery terminals are not loose or corroded.
If battery terminals are corroded, clean them.
2. Check the battery for damage, deformation or leakage. If serious damage, deformation or leakage is
found, replace the battery.
3. Check the battery voltage.
Turn ignition switch to ON, and turn it off 20 to 30 seconds after turning on the headlights. This will
eliminate the surface charge on the battery. Measure battery voltage with digital multimeter.
Testing Temperature Specification

20°C 12 - 13 V
Removal
CAUTION


2. Remove the battery.
a. Loosen the negative battery cable locking nut, and
remove the negative (-) battery cable (1).
b. Open the battery positive terminal cover, loosen the
positive battery cable locking nut, and remove the 2 1
16
positive (+) battery cable (2).
RT21160020
c. Remove the battery pressure plate fixing nut (1).

d. Remove the coupling bolt (2) between battery
pressure plate and tank upper crossmember.
2 1
RT21160030

CAUTION
 Please be careful to prevent metal tools from contacting both electrodes of battery at the same time or
accidentally touching the positive electrode and vehicle body.
e. Remove the battery.
Installation
CAUTION
 Replace battery with a new one which conforms to the specifications.

 Used battery contains sulfuric acid and lead, so never discard it at will. Please dispose of it at a qualified
local waste treatment station.
16

Battery Tray and Tray Bracket

Removal
CAUTION


3. Remove the battery tray.
a. Remove 2 coupling bolts (1) between battery tray and 1
air filter bracket.
b. Remove 6 fixing bolts (2) from the battery tray.
2
RT21160040
c. Remove the battery tray.

4. Remove the battery tray bracket.
a. Remove 4 fixing bolts (arrow) from the battery tray
bracket.
16
RT21160050
b. Remove 2 battery tray brackets.
Installation

Alternator
Removal
CAUTION


5. Loosen the accessory drive belt.
a. Put 15# open wrench (or socket) between engine and
right side-member, and tighten the tensioner pulley
bolt.
b. Rotate open wrench counterclockwise firmly indicated
by the arrow shown in the illustration. Loosen the
accessory drive belt (1) after it is slack. 1
RT21160060
6. Remove the alternator.

a. Move away the terminal cap, remove the fixing nut (1)
from alternator output cable, and move away the
alternator output cable.
1
b. Disconnect the alternator connector (2).
16
2
RT21160070
c. Remove 2 fixing bolts (arrow) from the alternator.

RT21160080
d. Remove the alternator from alternator bracket.

Installation
16

- MEMO -

GENERAL INFORMATION 17-3 Disassembly 17-22
Description 17-3 Assembly 17-27
Specifications 17-8 Gear Shift Mechanism 17-33
Daily Maintenance 17-9 Disassembly 17-33
Tools 17-9 Assembly 17-34
Shift Fork 17-35
Disassembly 17-35
Inspection 17-37
Assembly 17-37
ON-VEHICLE SERVICE 17-14 Input Shaft 17-38
Transmission Oil 17-14 Disassembly 17-38
Replacement 17-14 Assembly 17-42
Differential Oil Seal 17-16 Inspection 17-47
Removal 17-16 Output Shaft 17-48
Select and Shift Cable 17-18 Assembly 17-52
Installation 17-19 Transmission External Accessory 17-57
Gear Shift Control Mechanism 17-20 Removal 17-57
Installation 17-20 Transmission Case 17-60
Transmission Assembly 17-21 Disassembly 17-60
Removal 17-21 Assembly 17-63
17

17

17 - QR525MHE TRANSMISSION
GENERAL INFORMATION
Description
Input Shaft
7 8
6
5
3
18
2
17
16
1
15
14
13
12
11 22
10
21
17
20
19
RT21170010

1 - Input Shaft Rear Bearing Snap Ring 2 - Input Shaft Rear Bearing
3 - 5th Synchronizer Gear Hub 4 - 5th Synchronizer Meshing Plate
5 - 5th Synchronizer Outer Race 6 - 5th Synchronizer Ring
7 - 5th Drive Gear 8 - 5th Gear Shaft Bushing
9 - 5th Needle Roller Bearing 10 - 4th Drive Gear
11 - 4th Needle Roller Bearing 12 - 4th Gear Gasket
13 - 4th Synchronizer Ring 14 - Snap Ring
15 - 3rd-4th Synchronizer Gear Hub 16 - 3rd-4th Synchronizer Meshing Key and Spring
17 - 3rd-4th Synchronizer Outer Race 18 - 3rd Synchronizer Ring
19 - 3rd Drive Gear 20 - 3rd Needle Roller Bearing
21 - Input Shaft 22 - Input Shaft Front Bearing
17

Output Shaft
4 5
3
1 2
9
8
10
10
10
12 11
13
13
17
16
14
15
13
17
RT21170020

1 - Output Shaft Rear Bearing 2 - Snap Ring

3 - 5th Driven Gear 4 - 4th Driven Gear
5 - Gear Shaft Bushing 6 - 3rd Driven Gear
7 - 2nd Driven Gear 8 - 2nd Needle Roller Bearing
9 - 1st-2nd Synchronizer Outer Race 10 - 2nd Synchronizer Ring Set
11 - Snap Ring 12 - 1st-2nd Synchronizer Gear Hub
13 - 1st Synchronizer Ring Set 14 - 1st Driven Gear
15 - 1st Needle Roller Bearing 16 - Output Shaft
17 - Output Shaft Front Bearing
17

Transmission and Clutch Cases
16
15
14
13 20
12
11
10
4
5
9
6
8 3
2
19
17 7
18
RT21170030
17
1 - Linear Bearing 2 - Differential Oil Seal
3 - Bearing Outer Race 4 - Bearing Outer Race
5 - Oil Deflector 6 - Input Shaft Oil Seal
7 - Clutch Case 8 - Oil Guide
9 - Transmission Case 10 - Washer
11 - Transmission Retaining Bolt 12 - Washer
13 - Drain Plug 14 - Bearing Outer Race
15 - Adjustment Washer 16 - Differential Oil Seal

Operation
This transmission has five forward gears and one reverse gear, which is achieved by three sets of
synchronizers and two shafts (input shaft and output shaft). All forward gears use conventional engagement,
and reverse gear uses a sliding idler gear device. 1st-2nd synchronizer is installed on the output shaft and
3rd-4th and 5th synchronizers are installed on the input shaft. The transmission will engage with its
corresponding gear hub separately when it is shifted to each different gear position, thus realizing the
transmission of power. Drive gear of final drive, which is on the output shaft, rotates driven gear of final drive
and differential assembly, thus propeller shaft is driven to turn wheels.
Specifications

Coupling Bolt Between Clutch Case and
25 ± 2
Transmission Case
Reverse Idler Gear Shaft Locating Bolt 40 ± 4
Coupling Bolt Between Gear Shift Mechanism and
25 ± 2
Transmission Case
Gear Shift Mechanism Locating Bolt 35 ± 5.25
Shift Shaft Locating Bolt 35 ± 5.25
Gear Shift Control Mechanism Fixing Bolt 23 ± 2
Drain/Retaining Plug 40 ± 6
Shift Arm Bracket Bolt 25 ± 2
Reverse Lock Mechanism Fixing Bolt 18 ± 2
Reverse Gear Fork Fixing Bolt 25 ± 2
Transmission Lower Coupling Bolt 50 ± 5
Transmission Upper Coupling Bolt 60 ± 5
Engine Side Coupling Bolt 60 ± 5
17
Transmission Gear Ratio Table
Gear Ratio Type

QR525MHE
Gear
Gear Gear Ratio
1st 3.583
2nd 2.053
3rd 1.379
4th 1.03
5th 0.821
Reverse 3.417
Final Drive 4.313
Speedometer 0.806

Daily Maintenance
Generally, it is not necessary to take special maintenance for transmission case. The commonest
maintenance is to change transmission oil. Gear lubricant for QR525MHE series transmission case must be
equivalent to GL-4 75W-90 grade or above. Applying incorrect lubricant will cause serious damage to the
transmission. Never use engine lubricant instead of transmission case lubricant. Please note that the lubricant
filling capacity is also strictly specified.
Filling method:
Park vehicle on service platform or lifter levelly without removing the transmission. Prepare a container to
recover used lubricant. Remove the transmission drain plug, and then drain the used lubricant completely. Be
sure to tighten the drain plug firmly after draining.
Loosen the retaining plug of transmission, add lubricant to QR525 transmission with a special filling device
until the lubricant is flowing out from the retaining plug, and then tighten the retaining plug.
Tools
Special Tools
Input Shaft Oil Seal Installer
RCH0000008
RCH0000009 17
Installer Joint
RCH0000010

Bearing Remover
RCH0000011
Punch
RCH0000015
Puller
RCH0000059
17

General Tools
RCH0000005
Engine Equalizer
RCH0000026
Hydraulic Press
RCH0000012
17

DIAGNOSIS & TESTING

HINT:

Oil level (too low) 17-14
Oil wrong grade 17-14
Gear (worn or damaged) -
Noise
Bearing (worn or damaged) -
Gear thrust position and clearance
-
improper
Drain plug -
Drain plug gasket -
Oil leakage Differential oil seal 17-16
Joint surface damaged and not trimmed in
-
time
Oil level (too low) 17-14
Hard shifting or impossible to shift
Synchronizer ring (worn or damaged) -
Shift key spring (worn or damaged) -
Detent ball spring -
Shift fork (worn) 17-35
Jumps out of gear
17 Bearing (worn or damaged) -
Lubricant contains metal impurities -
Insufficient lubrication or lubricant does not
Bearing irregular damaged -
conform to standard
Irregular bearing -
Insufficient lubrication at joint surface of
Release fork makes a "click" sound when release fork and hydraulic sub cylinder or
-
clutch pedal is depressed joint surface of release fork and ball joint
housing
Shift drive train (loose) -
No shift
Driver rocker arm (loose) -

CAUTION
 To guarantee the service quality of transmission, perform operations carefully and keep each component
of transmission clean.
 Select appropriate or special tools.
 Transmission can achieve a good operation condition only when strictly performing service according to
the technical requirements of assembly or adjustment.
Transmission Oil
Check transmission oil level.
1. Raise the vehicle with a lifter
WARNING
 Be sure to wear necessary safety equipment to prevent accidents.

 Check if safety lock of lifter is locked when performing vehicle lift repair and inspection.
2. Remove the transmission retaining plug and washer.

3. Check if oil level is at the opening of retaining plug.
Transmission oil type:

GL-4
Viscosity:
75W-90
Standard capacity:
2.2 L ± 0.1 L
CAUTION 17
 An excessively large or small amount of oil may affect proper functioning of transmission.
 After filling oil, run the vehicle, and then check the oil level.

ON-VEHICLE SERVICE
Transmission Oil
Replacement
CAUTION
 Replace transmission oil only when engine stops and transmission cools down.
 Before installation, replace drain/retaining plug washer with a new one.

3. Place a recovering container under the transmission drain hole.
4. Using a wrench, loosen the transmission retaining plug
(arrow).
RT21170040
5. Using a wrench, loosen the transmission filler plug

(arrow). Replace the drain plug washer and tighten the
drain plug after draining transmission oil.
17
RT21170050
6. Fill transmission oil.
CAUTION
 Only use transmission oil approved by Chery Automobile Co., Ltd.
a. Make sure that transmission drain plug has been tightened in place.

b. Using a filling tool, fill transmission oil to the

transmission filler until it overflows.
RT21170060
c. Replace the retaining plug washer and tighten the retaining plug after filling.
Transmission Oil Type
Model 1.5 L MT
Transmission Oil Type API GL-4, 75W-90
Filling Capacity 2.2 L ± 0.1 L
17

Differential Oil Seal

Removal
Use the same procedures for the right side and left side.
Procedures listed below are for the left side.
1. Raise the vehicle with a lifter.
WARNING
 Make sure to wear safety equipment to prevent accidents.

2. Drain transmission oil.

a. Remove the retaining plug and washer.
b. Remove the drain plug and washer, and drain the transmission oil.
 Drained transmission oil should be collected with a recovering tool.
c. Install the new washer and drain plug.

3. Remove the front left wheel (See page 24-9).
4. Remove the left drive shaft (See page 20-5).
5. Pull out the oil seal with a puller.
17
RT21170070
Installation
1. Apply an appropriate amount of transmission oil to the lip of new oil seal.
2. Using a special tool and a hammer, tap in the oil seal.
RT21170080

CAUTION
 DO NOT damage the oil seal during installation.
3. Fill transmission oil.

Other procedures are in the reverse order of removal.
17

Select and Shift Cable

Removal
4. Remove the air filter assembly (See page 10-17).
5. Disconnect the select and shift cable from the transmission.
a. Remove the cotter pins (arrow) connecting select and
shift cable with transmission gear shift mechanism.
RT21170090
b. Remove the flexible shaft clamps (arrow) and select

and shift cable.
RT21170100
6. Remove the auxiliary fascia console (See page 45-9).

7. Remove the fixing bolts between gear select and shift cable and body.
17 8. Disconnect the select and shift cable from gear shift control mechanism.
a. Remove the flexible shaft clamps and cotter pins
connecting select and shift cable with gear shift
control mechanism.
RT21170110
9. Remove the gear select and shift cable.

Installation
CAUTION
 DO NOT install the select and shift cable in reverse position during installation.
17

Gear Shift Control Mechanism

Removal
3. Remove the auxiliary fascia console (See page 45-9).
4. Remove the gear shift control mechanism.
a. Remove the flexible shaft clamps and cotter pins
connecting select and shift cable with gear shift
control mechanism.
RT21170110
b. Remove the fixing bolts from gear shift control

mechanism, and remove the gear shift control
mechanism.
RT21170130
Installation
17

Transmission Assembly
Removal
4. Remove the battery bracket (See page 16-9).
6. Drain transmission oil.
7. Remove the front wheels (See page 24-9).
8. Remove the drive shaft(See page 20-5).
10.Remove the flexible shaft clamps and cotter pins connecting select and shift cable with gear shift
mechanism.
11. Disconnect the back-up light switch connector, ground
wire and clutch line bracket II.
RT21170140
12.Remove the crankshaft position sensor.

a. Remove the fixing bolt from crankshaft position sensor, and remove the crankshaft position sensor.
13.Remove the left mounting (See page 07-67).
14.Remove the front mounting (See page 07-66).
15.Remove the rear mounting (See page 07-64).
16.Remove the clutch release cylinder from transmission (See page 19-12).
17.Remove the starter (See page 15-64). 17
18.Remove the transmission.
a. Support the transmission assembly with a
transmission carrier.
b. Remove the transmission lower coupling bolts, and
remove the seal plate.
RT21170150

c. Remove the transmission upper coupling bolts.

RT21170160
d. Remove the coupling bolts from engine side and pull

the transmission to separate it from the engine.
RT21170170
Disassembly
1. Remove the gear shift mechanism locating bolt.
a. Remove the gear shift mechanism locating bolt
(arrow) from transmission assembly.
17 RT21170180
2. Remove the back-up light switch.

a. Remove the back-up light switch (arrow) from
transmission assembly.
RT21170190

3. Remove the gear shift mechanism.

a. Remove the gear shift mechanism fixing bolts (arrow).
RT21170200
b. Remove the gear shift mechanism (1) in the direction

of arrow.
1
HINT:
Tap the protrusion part of gear shift mechanism case
side with a rubber hammer, as the seal gum makes
difficulty to remove gear shift mechanism.
RT21170210
4. Remove the shift shaft locating bolt.

a. Remove the shift shaft locating bolts (1) from
RT21170220
17
5. Remove the reverse idler gear shaft locating bolt.
a. Remove the reverse idler gear shaft locating bolt
(arrow) from transmission assembly.
RT21170230

6. Remove the transmission case.

a. Remove the clutch case fixing bolts (arrow) from
RT21170240
b. Remove the transmission case fixing bolts (arrow)

from transmission assembly.
RT21170250
c. Separate the transmission case and clutch case, and

remove the transmission case.
HINT:
Tap the protrusion part of transmission case side with
a rubber hammer or equivalent for easy removal, as
the seal gum makes difficulty to remove transmission
case.
RT21170260
17
7. Remove the reverse gear fork.
a. Remove the fixing bolts (arrow) from reverse gear
fork, and remove the reverse gear fork (1).
RT21170270

8. Remove the reverse gear shaft and reverse gear.

a. Remove the reverse gear shaft (1) and reverse gear
(2) together from clutch case.
RT21170280
9. Remove the input shaft rear washer.

a. Remove the input shaft rear washer (1) from input
shaft.
RT21170290
10.Remove the magnet.

a. Remove the magnet (1) from clutch case.
17
RT21170300

11. Remove the input shaft, output shaft and fork mechanism.
a. Remove the input shaft, output shaft and fork
mechanism (1) together from clutch case.
HINT:
Gently jiggle them during removal.
RT21170310
CAUTION
 Prevent input shaft spline from damaging input shaft front oil seal during removal.
 Prevent interference between output shaft bearing cage and differential big ring gear and avoid
damaging bearing cage during removal.
12.Remove the gear fork assembly.

a. Remove the shift fork assembly (1) from input shaft
and output shaft (2).
17 2
1
RT21170320

13.Remove the differential assembly.

a. Remove the differential assembly (1) from clutch
case.
1
RT21170330
Assembly
CAUTION
 Before assembling the components, wash them clean.

 Remove the seal gum residues from the case.
 Make sure the joint surface of case is free of oil, and uniformly apply seal gum.
 Make sure the joint surface of case and shift assembly is free of oil, and uniformly apply seal gum.
 Tighten bolts to the specified torque.
1. Install the differential assembly.

a. Apply transmission oil to the each slide part of
differential, and install the differential (1) to the clutch
case in the direction of arrow. 1
RT21170340
17
2. Install the shift fork assembly.

a. Install the shift fork assembly (1) to the input shaft and
output shaft (2).
2
1
RT21170320

3. Install the input shaft, output shaft and fork mechanism.

a. Apply transmission oil to each slide part of input shaft
and output shaft, and install the input shaft, output
shaft and fork mechanism (1) together to the clutch
case in the direction of arrow.
RT21170350
CAUTION
 Prevent input shaft spline from damaging input shaft front oil seal during installation.
4. Install the reverse idler gear and reverse gear.

a. Apply transmission oil to each slide part of reverse
gear and reverse gear shaft, and install the reverse
idler gear (1) and reverse gear (2) together to the
clutch case.
1
17
RT21170280
5. Install the reverse gear fork.

a. Install the reverse gear fork (1) to the clutch case, and
tighten the reverse gear fork fixing bolts (arrow).
RT21170270

6. Install the input shaft rear washer.

a. Apply an appropriate amount of transmission oil to the
input shaft rear washer, and put the input shaft rear
washer (1) onto the input shaft rear bearing.
1
RT21170290
CAUTION
 Evenly put the input shaft rear washer onto the input shaft rear bearing without the washer edge out of
the input shaft rear bearing.
7. Install the magnet.

a. Install the magnet (1) to the clutch case in the
direction of arrow.
RT21170360
8. Install the transmission case.

a. Install the transmission case to the clutch case.
17
RT21170370
CAUTION
 Remove the seal gum residues from the case.

 Make sure the joint surface of case is free of oil, and uniformly apply seal gum.

b. Install the transmission case fixing bolts (arrow) and

tighten them.
RT21170250
c. Install the clutch case fixing bolts (arrow) and tighten

them.
RT21170240
9. Install the reverse idler gear shaft locating bolt.

a. Install the reverse idler gear shaft locating bolt (arrow)
to the transmission case.
RT21170230
17
10.Install the gear shift mechanism.
a. Install the gear shift mechanism (1) to the
transmission case.
RT21170380
CAUTION
 Clean the engagement portion of shifter case and transmission case, and apply seal gum evenly.

b. Install the coupling bolts (arrow) between gear shift

mechanism and transmission case.
RT21170200
11. Install the gear shift mechanism locating bolt.

HINT:
Apply thread adhesive to thread before installation.
a. Install the gear shift mechanism locating bolt (arrow)
RT21170180
12.Install the back-up light switch.

HINT:
a. Install the back-up light switch (arrow) to the
transmission case.
17
RT21170190

13.Install the shift shaft locating bolt.

HINT:
a. Install the shift shaft locating bolts (1) to the
1
RT21171070
Installation
CAUTION
 After installation, add transmission oil and check the oil level.
17

Gear Shift Mechanism

Disassembly
1. Loosen the shift arm bracket bolts (A).
2. Remove the shift arm bracket (1). 1
3. Using snap spring calipers (2), remove the snap ring (3).
4. Loosen the fixing bolts (B) of reverse gear lock
B
mechanism. 4
5. Remove the reverse gear lock mechanism (4).
RT21170400
6. Tap out the dowel pin (2) with a punch (1).

1
7. Remove the shift arm (3) and plate (4).
2
3
RT21170410
17
8. Tap out the dowel pin (2) with a punch (1).
9. Remove the shift finger (3).
1 3
RT21170420

Assembly
Assembly is in the reverse order of disassembly.
CAUTION
 Tighten bolts to the specified torque.

 Replace damaged dowel pins.
17

Shift Fork
Disassembly
1. Remove the reverse gear fork.
a. Using snap spring calipers, remove the snap ring (1).
RT21170430
b. Remove the reverse gear fork (1) and return spring

(2).
1
RT21170440
17
2. Remove the 3rd-4th gear shift fork.
a. Using a punch (1), tap out the dowel pin (3) from 
3rd-4th gear shift shaft (2).
1
RT21170450

b. Separate the 3rd-4th gear shift fork (1) from the shift
shaft (2).
RT21170460
3. Remove the 1st-2nd gear shift fork.

a. Using a punch (1), tap out the dowel pin (3) from the
gear shift shaft (2).
1
3
RT21170470
b. Separate the 1st-2nd gear shift fork (1) from gear shift
shaft (2).
RT21170480
17
4. Remove the fork.
a. Using a punch (1), tap out the dowel pin (3) from gear
shift shaft (2).
1 3
RT21170490

b. Separate the fork (1) from the gear shift shaft (2).
RT21170500
Inspection
1. Check gear shift shaft for excessive wear or damage. Replace if it is damaged.
2. Check release fork for excessive wear or damage. Replace if it is damaged.
Assembly
CAUTION
 When installing dowel pin, if there is excessive wear or damage, replace with a new one.
17

Input Shaft
Disassembly
1. Remove the input shaft (See page 17-22).
2. Remove the 5th synchronizer outer race and 3rd-4th synchronizer outer race.
a. Remove the 5th synchronizer outer race (1) and 
3rd-4th synchronizer outer race (2) from input shaft.
1
RT21170510
3. Remove the input shaft rear bearing snap ring.

a. Using snap spring calipers, remove the input shaft
rear bearing snap ring.
RT21170520
4. Remove the input shaft rear bearing.

a. Using a special tool (1), secure the input shaft rear
bearing (2). 2
17
RT21170530
b. Using a hydraulic press (1), press the input shaft rear

bearing (3) out of input shaft (2) and remove the input
shaft rear bearing. 1
RT21170540

5. Remove the 5th drive gear and 5th synchronizer gear hub.
a. Using a special tool (1), secure the 5th drive gear (2).
RT21170550
b. Using a hydraulic press (1), press the 5th drive gear

and 5th synchronizer gear hub (3) out of input shaft 1
(2), and remove the 5th drive gear and 5th 2
synchronizer gear hub.
3
RT21170560
6. Remove the 5th needle roller bearing.

a. Remove the 5th needle roller bearing (1) from input
shaft.
RT21170570
17
7. Remove the 5th drive gear needle roller bearing bushing and 4th drive gear.
a. Install a special tool.
RT21170580

b. Using a hydraulic press (1), press the 5th drive gear

needle roller bearing bushing and 4th drive gear (3)
out of input shaft (2), and remove the 5th drive gear 1
needle roller bearing bushing and 4th drive gear.
2
RT21170590
8. Remove the 4th needle roller bearing.

a. Remove the 4th needle roller bearing (arrow) from
input shaft.
RT21170600
9. Remove the 3rd drive gear and 3rd-4th synchronizer gear hub.
a. Remove the synchronizer ring (arrow) from 3rd-4th
17 RT21170610
b. Using snap spring calipers (1), remove the snap ring

(2).
RT21170620

c. Using a special tool (1), secure the 3rd drive gear (2).
2
1
RT21170630
d. Using a hydraulic press (1), press the 3rd drive gear

and 3rd-4th synchronizer gear hub (3) out of input 1
shaft (2), and remove the 3rd drive gear and 3rd-4th
2
RT21170640
10.Remove the 3rd needle roller bearing.

a. Remove the 3rd needle roller bearing (1) from input
shaft.
RT21170650
17
11. Remove the input shaft front bearing.
a. Using a special tool (1), secure the input shaft front
bearing (2).
2
RT21170660

b. Using a hydraulic press (1), press the input shaft front

bearing (3) out of input shaft (2), and remove the input 1
shaft front bearing.
RT21170670
Assembly
1. Install the input shaft front bearing.
a. Using a hydraulic press (1), press the input shaft front
bearing (3) into input shaft (2). 1
RT21170680
CAUTION
 When pressing input shaft front bearing, make sure that pressure is applied to the bearing inner race as
the bearing may be damaged due to uneven force.
2. Install the 3rd needle roller bearing.

a. Apply transmission oil to the needle roller bearing (1),
17 and install it to the input shaft.
RT21170650

3. Install the 3rd drive gear.

a. Apply transmission oil to the 3rd drive gear (arrow),
and install it to the input shaft.
RT21170690
4. Install the 3rd synchronizer ring.

a. Apply transmission oil to the 3rd synchronizer ring
(arrow), and install it to the input shaft.
RT21170700
5. Install the 3rd-4th synchronizer gear.

a. Using a hydraulic press (3), press the 3rd-4th
synchronizer gear (1) into the input shaft. 3
2
1
17
RT21170710
CAUTION
 When pressing synchronizer gear, prevent the 3rd drive gear (2) from disengaging.

6. Install the 4th synchronizer ring.

a. Apply transmission oil to the 4th synchronizer ring
RT21170610
7. Install the 4th needle roller bearing.

a. Apply transmission oil to the 4th needle roller bearing
RT21170600
8. Install the 4th drive gear.

a. Apply transmission oil to the 4th drive gear (1), and
install it to the input shaft.
17
RT21170720
9. Install the 5th drive gear needle roller bearing bushing.

a. Using a hydraulic press (1), press the 5th drive gear
needle roller bearing bushing (2) into the input shaft.
1
RT21170730

10.Install the 5th needle roller bearing.

a. Apply transmission oil to the 5th needle roller bearing
(1), and install it to the input shaft.
RT21170570
11. Install the 5th drive gear and 5th synchronizer ring.
a. Apply transmission oil to the 5th drive gear (1) and 5th
synchronizer ring (2), and install them to the input
shaft.
2
RT21170740
12.Install the 5th synchronizer gear hub.

a. Using a hydraulic press (3), press the 5th synchronizer
3
gear (2) and 5th synchronizer gear hub (1) together into
the input shaft.
1 2 17
RT21170750
CAUTION
 When pressing synchronizer gear hub, prevent the 5th drive gear from disengaging.

13.Install the input shaft rear bearing.

a. Using a hydraulic press (1), press the input shaft rear
1
bearing (3) into the input shaft (2).
2
RT21170760
14.Install the 5th synchronizer outer race and 3rd-4th synchronizer outer race.
a. Apply transmission oil to the 5th synchronizer
meshing key and spring (1) and 3rd-4th synchronizer
meshing key and spring (2), and install them to the 1
synchronizer gear hubs.
RT21170770
b. Apply transmission oil to 5th synchronizer outer race

(1) and 3rd-4th synchronizer outer race (2), and install
1
them to the input shaft.
17 RT21170780
15.Install the input shaft rear bearing snap ring.

a. Using snap spring calipers, install the rear bearing
snap ring.
RT21170790

CAUTION
 Check gears on the input shaft for smooth rotation after installation.
 Check engagement of gears on the input shaft for looseness or sticking.
Inspection
1. Using a feeler gauge, measure clearance between 3rd
drive gear and synchronizer ring.
Standard value: 1.35 mm
Limit value: 1.100 - 1.600 mm
RT21173040
2. Using a feeler gauge, measure clearance between 4th

drive gear and synchronizer ring.
RT21173041
3. Using a feeler gauge, measure clearance between 2nd

drive gear and 3rd drive gear.
Limit value: 0.45 - 0.85 mm 17
RT21173042

Output Shaft
Disassembly
1. Remove the output shaft (See page 17-22).
2. Remove the output shaft rear bearing.
a. Using a special tool (1), secure the output shaft rear
bearing (2). 2
RT21170800
b. Using a hydraulic press (1), press the output shaft

1
rear bearing (3) out of output shaft (2), and remove
3
the output shaft rear bearing. 2
RT21170810
3. Remove the 5th driven gear and 4th driven gear.

a. Using snap spring calipers (1), remove the snap ring.
17
RT21170820
b. Using a special tool (1), secure the 5th and 4th driven
gear set (2).
2
RT21170830

c. Using a hydraulic press (1), press the 5th and 4th

driven gear set (3) out of output shaft (2), and remove 1
the 5th driven gear and 4th driven gear.
2
RT21170840
4. Remove the gear shaft bushing.

a. Remove the gear shaft bushing (1) from output shaft.
RT21170850
5. Remove the 2nd driven gear and 3rd driven gear.

a. Using a special tool (1), secure the 2nd driven gear
(2).
1 2
RT21170860
17
b. Using a hydraulic press (1), press the 2nd and 3rd
driven gears (3) out of output shaft (2), and remove
the 2nd driven gear and 3rd driven gear. 1
RT21170870

6. Remove the 2nd needle roller bearing.

a. Remove the 2nd needle roller bearing (1) from output
shaft.
RT21170880
7. Remove the 1st driven gear and 1st-2nd synchronizer gear hub.
a. Remove the 1st-2nd synchronizer ring set (2).
b. Remove the 1st-2nd synchronizer outer race (1).
2
RT21170890
c. Using snap spring calipers (1), remove the snap ring

(2).
17 RT21170900
d. Secure a special tool to the 1st driven gear.
RT21170910

e. Using a hydraulic press (1), press the 1st driven gear

1
and 1st-2nd synchronizer (3) out of output shaft (2),
and remove the 1st driven gear and 1st-2nd
synchronizer.
2
RT21170920
8. Remove the 1st needle roller bearing.

a. Remove the 1st needle roller bearing (1) from output
shaft.
RT21170930
9. Remove the output shaft front bearing.

a. Using a special tool (1), secure the output shaft front
bearing (2).
2
RT21170940
17
b. Using a hydraulic press (1), press the output shaft
front bearing (3) out of output shaft (2), and remove 1
the output shaft front bearing. 2
RT21170950

Assembly
1. Install the output shaft front bearing.
a. Using a hydraulic press (1), press the output shaft
front bearing (3) into the output shaft (2). 1
3 RT21170960
CAUTION
 When pressing the bearing, make sure that pressure is applied to bearing inner race as the bearing may
be damaged due to uneven force.
2. Install the 1st needle roller bearing.

a. Apply transmission oil to the 1st needle roller bearing
(1), and install it to the output shaft.
RT21170930
3. Install the 1st driven gear.

17 a. Apply transmission oil to the 1st driven gear (1), and
install it to the output shaft.
RT21170970

4. Install the 1st synchronizer ring set.

a. Apply transmission oil to the 1st synchronizer ring set
(arrow), and install it to the output shaft.
RT21170980
5. Install the 1st-2nd synchronizer gear hub and 1st driven gear.
a. Place the 1st-2nd synchronizer gear hub (1) in place,
and then press it into the output shaft with a hydraulic
press.
RT21170990
b. Using snap spring calipers (1), install the snap ring

(2).
RT21170900
17
6. Install the synchronizer ring set.
a. Apply transmission oil to the synchronizer ring set
RT21171000

7. Install the synchronizer outer race.

a. Apply transmission oil to the synchronizer outer race
RT21171010
8. Install the 2nd needle roller bearing.

a. Apply transmission oil to the 2nd needle roller bearing
RT21170880
9. Install the 2nd driven gear.

a. Apply transmission oil to the 2nd driven gear (1), and
install it to the output shaft.
17
RT21171020
10.Install the 3rd driven gear.

a. Using a hydraulic press, press the 3rd driven gear (1)
into the output shaft.
RT21171030

11. Install the gear shaft bushing.

a. Apply transmission oil to the gear shaft bushing (1),
and install it to the output shaft.
RT21170850
12.Install the 4th and 5th driven gears.

a. Using a special tool (1), secure the 4th and 5th driven
gears (2).
1
RT21171040
b. Using a hydraulic press (1), press the 4th and 5th

1
driven gears (3) into the output shaft (2).
2
RT21171050
17
c. Using snap spring calipers (1), install the snap ring.
RT21170820

13.Install the output shaft rear bearing.

a. Using a hydraulic press (1), press the output shaft
rear bearing (3) into the output shaft (2). 1
3
RT21171060
CAUTION
 Check gears on the output shaft for smooth rotation after installation.
 Check engagement of gears on the output shaft for looseness or sticking.
Inspection
1. Using a feeler gauge, measure clearance between 1st
driven gear and synchronizer ring.
RT21173051

driven gear and synchronizer ring.
17 Standard value: 1.54 mm
RT21173052

driven gear and 3rd driven gear.
RT21173053

Transmission External Accessory

Removal
1. Shift transmission to the neutral position.
2. Remove the shift shaft locating bolt.
a. Remove the shift shaft locating bolts (1) from
transmission case.
RT21171070
3. Remove the back-up light switch.

a. Remove the back-up light switch (arrow) from
transmission case.
RT21170190
4. Remove the gear shift mechanism locating bolt.

a. Remove the gear shift mechanism locating bolt
(arrow) from transmission case.
17
RT21170180
5. Remove the reverse idler gear shaft locating bolt.

a. Remove the reverse idler gear shaft locating bolt
(arrow) from transmission case.
RT21171080

Installation
1. Install the reverse idler gear shaft locating bolt.
a. Install the reverse idler gear shaft locating bolt (arrow)
RT21171080
2. Install the gear shift mechanism locating bolt.

HINT:
a. Install the gear shift mechanism locating bolt (arrow)
RT21170180
3. Install the back-up light switch.

HINT:
a. Install the back-up light switch (arrow) to the
RT21170190

4. Install the shift shaft locating bolt.

HINT:
a. Install the shift shaft locating bolts (1) to the
1
RT21171070
17

Transmission Case
Disassembly
CAUTION
 Use the same removal procedures for the differential bearing out race of transmission case and clutch
case and the oil seal.
 The oil seal cannot be reused. After removal, it must be replaced.
1. Remove the differential bearing outer race.

a. Secure the bearing outer race puller joint (1) to the
bearing outer race (2). 1
RT21171090
b. Install the puller (1) to the bearing outer race remover

(2), and pull out bearing outer race (3) with the puller.
17
RT21172000

2. Remove the drive shaft oil seal.

a. Using a flat tip screwdriver (1), pry out the drive shaft
oil seal (2).
RT21172010
3. Remove the input shaft oil seal.

a. Using a flat tip screwdriver (1), pry out the input shaft
oil seal (2).
RT21172020
4. Remove the output shaft bearing outer race.

a. Secure the output shaft end bearing outer race puller
joint (1) to the output shaft bearing outer race (2).
17
RT21172030

b. Install the puller (1) to bearing outer race remover (2).

c. Using the puller, pull out the output shaft bearing outer
race (3).
1
RT21172040
5. Remove the oil deflector.

a. Remove the oil deflector (1) from clutch case.
RT21172050
6. Remove the magnet.

17
a. Remove the magnet (1) from clutch case.
RT21172060

7. Remove the oil guide.

a. Remove the oil guide (1) from transmission case.
RT21172070
Assembly
1. Install the drive shaft oil seal.
a. Using a drive shaft oil seal installer (1), install the drive
shaft oil seal (2) to the transmission case (3).
RT21172080 17
CAUTION
 Apply a proper amount of transmission oil to the lip when installing the oil seal.
2. Install the oil deflector.

a. Install the oil deflector (1) to the clutch case.
RT21172090

3. Install the input shaft oil seal.

a. Using a input shaft oil seal installer (1), install the input
shaft oil seal (2) to the clutch case (3).
1
2
3
RT21173000
4. Install the differential bearing outer race.

a. Install the joint (1) to the bearing outer race (2), and
install the bearing outer race (2) to the case (3) with a
rubber hammer (4).
RT21173010
17
5. Install the magnet.
a. Install the magnet (1) to the clutch case.
RT21173020

6. Install the oil guide.

a. Install the oil guide (1) to the transmission case.
RT21173030
17

- MEMO -

QR019CHB CVT
GENERAL INFORMATION 18-3 P0848 18-68
Description 18-3 P0890 18-72
Precautions 18-7 P0891 18-72
Operation 18-7 P0900 18-77
Tools 18-13 P0902 18-77
Specifications 18-14 P0903 18-77
Circuit Diagram 18-15 P0928 18-82
Transmission Control Unit (TCU)  P0930 18-82
Pin-Out Table 18-20 P0931 18-82
P0938 18-89
P0939 18-89
Transmission Fluid Level and 
Quality Inspection 18-21 P0940 18-89
Gear Shift Cable Inspection and  P0960 18-93
Adjustment 18-21 P0962 18-93
Transmission Range Sensor  P0963 18-93
Inspection 18-22 P0964 18-98
Transmission Fluid Temperature  P0966 18-98
Sensor Inspection 18-23 P0967 18-98
Primary Shaft Speed Sensor  P0970 18-103
Inspection 18-23 P0971 18-103
Turbine/Secondary Shaft Speed  P2797 18-108
Sensor Inspection 18-24
P2798 18-108
Diagnostic Help 18-26 ON-VEHICLE SERVICE 18-110
Intermittent DTC Troubleshooting 18-27 Automatic Transmission Fluid 
Ground Inspection 18-27 (ATF) Replacement 18-110
Diagnostic Trouble Code (DTC)  Draining 18-110
Chart 18-27 Filling 18-110
Data Stream List 18-31 Inspection 18-111
Power Supply and Ground  Differential Oil Seal 18-112
Circuit Test 18-35 Removal 18-112
Power Supply Circuit Test 18-35 Installation 18-112 18
Ground Circuit Test 18-41 Transmission Fluid Cooler 18-113
P0705 18-44 Removal 18-113
P0715 18-48 Installation 18-113
P0716 18-48 Primary Shaft Speed Sensor 18-114
P0720 18-52 Removal 18-114
P0730 18-56 Secondary Shaft Speed Sensor 18-115
P0791 18-58 Removal 18-115
P0811 18-62 Turbine Speed Sensor 18-116
P081E 18-62 Removal 18-116
P0842 18-64 Primary Shaft Pressure Sensor 18-117
P0843 18-64 Removal 18-117

Secondary Shaft Pressure Sensor 18-118 Gear Shift Control Mechanism 18-125
Removal 18-118 Removal 18-125
Transmission Range Sensor 18-119 Gear Shift Cable 18-127
Valve Body Case 18-121 TCU 18-129
Valve Body 18-122 CVT Assembly 18-130
18

18 - QR019CHB CVT
GENERAL INFORMATION
QR019CHB CVT
Description
Continuous Variable Transmission (CVT) is a kind of continuous mechanical transmission. The most
difference between CVT and common gear-type transmission is that CVT uses two groups of pulleys for
driving instead of complex and heavy gear combined drive. It shifts speeds by changing the contact radius of
drive pulley and driven pulley.
CVT mainly consists of the following components:

 Torque converter
 Planetary gear system
 Drive and driven pulley system (transmission system)
 Steel belt (steel belt consists of two groups of metal rings and hundreds of metal plates)
 Oil pump
 Valve body
QR019CHB CVT features with:

 Automatic and manual modes.
 Electronic hydraulic control.
 At D gear, it realizes automatic continuous variable speeds; at M gear, it realizes manual 7-gear variable
speeds, providing users with dual driving fun.
 It can keep engine lowest speed at a certain vehicle speed.
 It can reduce vehicle emission and NVH (Noise, Vibration, Harshness).
 It can improve vehicle economy and reduce fuel consumption.
 Accelerator pedal responses rapidly when accelerating. Acceleration is gentle and smooth without impact.
18

18 - QR019CHB CVT
3 4
13
6
12
11
9
10
18
RT21180010
1 - Rear Case 2 - Drive Clutch

3 - Transmission Case 4 - Torque Converter
5 - Torque Converter Case 6 - Input Shaft
7 - Oil Pump Thrust Gasket 8 - Oil Pump
9 - Output Shaft 10 - Differential
11 - Steel Belt 12 - Output Pulley Shaft
13 - Input Pulley Shaft

18 - QR019CHB CVT
RT21180020
1 - Gear Shift Cable 2 - Gear Shift Lever Knob

3 - Gear Indicator Panel 4 - Gear Shift Control Mechanism 18
5 - Gear Shift Cable Dust Boot

18 - QR019CHB CVT
18
RT21180030
1 - Turbine Speed Sensor 2 - Secondary Shaft Speed Sensor

3 - Secondary Shaft Pressure Sensor 4 - Primary Shaft Speed Sensor
5 - Primary Shaft Pressure Sensor 6 - Transmission Range Sensor

18 - QR019CHB CVT
Precautions
1. During removal and installation, make sure that the gear shift lever is at "N" position.
2. When installing the gear shift arm and transmission range sensor, use a proper tool to fix them, and then
tighten bolts to the specified torque.
3. The components of transmission are of high precision, so take care in removal and installation and do not
scratch or damage any component.
4. When installing the oil seal, apply force evenly and do not cause deformation or damage of oil seal.
5. Keep transmission components clean when removing and installing transmission components to prevent
foreign matter from entering the transmission.
6. When installing the torque converter onto transmission, make sure that the oil pump drive slot is installed in
place; otherwise it will cause abnormal damage to the transmission.
7. When assembling engine and transmission, make sure that the four connecting bolts of engine flywheel
and torque converter are not ignored.
8. When assembling engine and transmission, make sure that all connecting bolts are installed correctly and
completely, and the torques meet the specifications.
9. When disassembling and assembling engine and transmission, make sure that the torque converter does
not drop down.
10.When assembling engine and transmission, make sure that the dust baffle is not ignored.
11. When replacing transmission sensors and oil seals, make sure that they are installed in place and bolt
torques meet the specifications.
12.Take measures to avoid foreign matter entering the transmission, when removing or installing the cooling
oil pipes and radiator. And check the fluid level and make sure that there is no leakage after installation.
Operation
Speed Ratio Change Principle
The CVT uses a metal belt and V-shape drive and driven pulleys with width-variable slot for the power
transition. The drive and driven pulleys consist of movable and fixed discs. The pulley close to the oil cylinder
could slide on the pulley shaft and the one on other side is fixed. The movable and fixed discs are of cone
structure. Their cones form a V-shape slot for engagement of the V-shape metal belt. It changes the working
radius of the engagement of the cones and V-shape metal belt to shift the speed by the axial movement of the
movable disc when working.
Right illustration shows the low speed ratio: Transmission
oil passage
1. Input pulley Low speed ratio
2. Output pulley
Low
pressure
1 oil 3
18
3. Input circle
V-belt
4. Output circle
2 4
Clamping
pressure oil
RT21180040

18 - QR019CHB CVT
Right illustration shows the high speed ratio:

Transmission
1. Input pulley oil passage
High
High speed ratio
pressure
2. Output pulley oil
1 3
3. Input circle
4. Output circle V-belt
2 4
Clamping
pressure oil
RT21180050
Torque Converter
The torque converter is used to keep stable start, reduce torsional vibration of transmission system and
prevent overload of the transmission system.
The torque converter could ensure stable start and even
acceleration of the vehicle. The hydraulic vibration 5
1 3 4
absorption could eliminate or reduce the impact and
2
dynamic load in the transmission system, extending the
service life of the components of the engine and
transmission system.
8 7 6
RT21180060
1 - Pump Wheel 2 - Turbine

3 - Front Case 4 - Bearing
5 - Guide Wheel and 6 - Clutch Assembly
One-way Clutch
7 - Welded Hub 8 - Drive Hub
Transmission Control Unit (TCU)

The transmission control unit (TCU) is installed on the
battery tray. It receives input signals of switches and sensors
18 and mainly controls the operation of the gear shifting and
locking solenoid. Transmission gears are regulated by the
electronic gear shift system. The TCU processes the input
signals and regulates transmission hydraulic system by
exploiting the information received.
RT21180070

18 - QR019CHB CVT
Electronic control system consists of the components below:

 Transmission control unit (TCU)
 Pressure control solenoid
 Torque converter solenoid
 Clutch control solenoid
 Gear shift lever locking solenoid
 Turbine speed sensor
 Primary shaft speed sensor
 Secondary shaft speed sensor
 Oil pressure sensor
 Transmission fluid temperature sensor
 Transmission range sensor
 Manual mode switch
Transmission Range Sensor

The transmission range sensor is located at the top of the
transmission. It is used to input the current gear signal into
the TCU, and the TCU will output the operation requirements
to control the clutch and transmission for gear shifting. The
engine can be started only when the gear shift lever is at
parking (P) and neutral (N) gear, thus avoiding misoperation.
RT21180080
Manual Mode Switch

No matter whether the vehicle is static or running, you could
push the gear shift lever to shift between "M" and "D" gear.
On the gear shift mechanism panel, there are two gears of
"+" and "-" at the "M" gear, they are also called manual 
shift-up and manual shift-down.
18
RT21180090
 M+: push the gear shift lever once to "M+" and the transmission will be increased one gear.
 M-: push the gear shift lever once to "M-" and the transmission will be reduced one gear.
 In the automatic mode, when the engine speed is too low, it will automatically shift down; and shift up when
the engine speed is high.
 In the manual mode, the driver should shift up the gear in advance based on the experience to prevent the
engine speed entering the red area of tachometer.

18 - QR019CHB CVT
Transmission Fluid Temperature Sensor

The transmission fluid temperature sensor is located in the
valve body. The sensor converts the transmission fluid
temperature signals into electronic signals and sends them
to the transmission control unit (TCU).
RT21180100
Primary Shaft Speed Sensor

The TCU calculates the primary shaft speed based on the
impulse signals. It is mainly used for the operations of torque
converter locking, clutch engagement and transmission
control.
RT21180110
Turbine/Secondary Shaft Speed Sensor

The TCU calculates the turbine and secondary shaft speeds
based on the impulse signals. It is mainly used for the
operations of torque converter locking, clutch engagement
and transmission control.
18 RT21180120
Fluid Pressure Sensor

The transmission fluid pressure sensor is used to monitor
the CVT pulley shaft pressure and send the signals to the
TCU.
RT21180130

18 - QR019CHB CVT
Oil Pressure Control Solenoid

The input and output pulley shaft oil pressure control
solenoids (1) and (2) are installed on the valve body. The
TCU receives accelerator pedal signals, gear signals and
speed signals, then the TCU sends the operation
requirements to start the oil pressure control solenoid for
changing speed ratio of the CVT.
1 2
RT21180140
Clutch Pressure Control Solenoid

The clutch pressure control solenoid (1) is installed on the
valve body. The TCU receives accelerator pedal signals,
gear signals and speed signals, then the TCU sends the
operation requirements to start the clutch pressure control
solenoid for changing clutch engagement.
RT21180150
Torque Converter Pressure Control Solenoid

The torque converter pressure control solenoid (1) is
installed on the valve body. The TCU receives accelerator
pedal signals, gear signals and speed signals, then the TCU
sends the operation requirements to start the torque
converter pressure control solenoid for locking the torque
1
converter.
RT21180160
18
Gear Shift Lock Solenoid
The gear shift lock solenoid (arrow) is installed in the
transmission gear shift control mechanism. Before moving
out of the "P" gear, the brake pedal should be fully
depressed and the ignition switch set to the "ON" position.
RT21180170

18 - QR019CHB CVT
Sport Mode Switch

The transmission is equipped with sport mode, which can be
switched on with the sport mode switch on the gear shift
indication panel.
R
S
RT21180180
System Control Logic
Turbine speed sensor TCU relay
Primary shaft speed sensor Torque converter solenoid
Input pulley shaft oil pressure

Secondary shaft speed sensor
control solenoid
TCU Output pulley shaft oil pressure

Oil temperature sensor
control solenoid
Transmission range sensor Clutch control solenoid
Mode select switch Gear shift lock solenoid
Oil pressure sensor
CAN
18
RT21180190

18 - QR019CHB CVT
Tools
Special Tools
Puller
RCH0000059
RCH0000009
General Tools
Engine Equalizer
RCH0000026
18
RCH0000005

18 - QR019CHB CVT
Specifications

Transmission Drain Bolt 29 - 34
Primary Shaft Speed Sensor Fixing Bolt 10 - 12
Secondary Shaft Speed Sensor Fixing Bolt 10 - 12
Turbine Speed Sensor Fixing Bolt 10 - 12
Primary Shaft Pressure Sensor 15 - 22
Secondary Shaft Pressure Sensor 15 - 22
Gear Shift Cable to Arm Nut 16 - 20
Valve Body Case Fixing Bolt 10 - 12
Transmission Range Sensor Fixing Bolt 10 - 12
Gear Shift Arm Fixing Nut 18 - 25
Gear Shift Control Mechanism Fixing Bolt 18 - 22
Gear Shift Cable Dust Boot Fixing Bolt 8 - 10
TCU Fixing Bolt 6-8
Transmission Ground Wire Harness Fixing Bolt 18 - 22
Engine to Upper Part of Transmission Bolt 75 - 85
Dust Baffle Fixing Bolt 45 - 55
Flywheel to Torque Converter Bolt 50 - 60
Transmission to Engine Front Bolt 75 - 85
Transmission to Engine Bolt 75 - 85
Valve Body Fixing Bolt 8 - 10
Transmission Fluid Cooler Fixing Bolt 22 - 28
18 General Specifications
Item Parameter
Model QR019CHB
Type CVT
Central Distance (mm) 204
Maximum Input Torque (N·m) 190
Final Drive Ratio 5.141
Pulley Speed Ratio Scope 0.44 - 2.39
Solenoid Quantity 4
Gear Shift Positions P, R, N, D, L, M (manual mode)
Fluid Type SP - III
Transmission Fluid Capacity (L) 8.0 ± 0.2

18 - QR019CHB CVT
Circuit Diagram
TCU (Page 1 of 5)
IGNITION SEITCH BATTERY

ON OR START
EF19 EF46
ENGINE
10A 20A COMPARTMENT
EF17 FUSE AND
85 30 RELAY BOX
10A
TCU E-069
RELAY E-076
ERLY12 E-066
86 87
A4 A2 F15 F16 J2
CLUTCH CONTROL SOLENOID
PRIMARY PRESSURE SOLENOID

SECONDARY CONTROL
TORQUE CONVENTER
PRESSURE SOLENOID
CONTROL SOLENOID
CONNECTOR B
OIL TEMP GND

OIL TEMP
E-052
RL
RL
R
L
6 10 4 9 3 5 1 2
R
R
A
WR
WR
GR
BY
RL
R
V
L
28 46 56 31 3 34 32 33 35 47 20 18
TCU
E-030

E-076 E-069 6 5 4 3 2 1 E-052
A6 A7 A8 A9 A10
Gr F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
W 10 9 8 7
Gr
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 J2 J1
E-030
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B E-066
B
ET21180010

18 - QR019CHB CVT
TCU (Page 2 of 5)
IGNITION SEITCH
ON OR START
INSTRUMENT
PANEL FUSE
RF02 AND RELAY
10A BOX A
I-007
2
RL
18 I-006
B-003
B-042
B
9 RL 10
GEAR LEVEL
COMMAND
GEAR SHIFT
B-004
1 2 3 5 7 6 8
RW
YR
GL
Lg
W
R
Y
R ILLUMINATION
A 15
E-029 B-054
B-054
17 18 19 10 21
E-029
RW
YR
GL
W
44 45 43 4 30
18 TCU
E-030
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11
E-030
12 13 14 15 16 17 18 19 20 21 22
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
B-054
W
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 10 9 8 7 6 5 4 3 2 1
11 10 9 8 B-004
27 25 26 I-007 22 21 20 19 18 17 16 15 14 13 12 11
7 6 5 4 3 2 1 W
87 B
85 86 86 86 I-006
87 30 87 30
30 85 85 W ET21180020

18 - QR019CHB CVT
TCU (Page 3 of 5)
IGNITION SEITCH
BATTERY
ON OR START
INSTRUMENT
PANEL FUSE EF30 85 30 ENGINE
RF03 AND RELAY 10A STARTER COMPARTMENT
10A BOX A FUSE AND
RELAY
I-007 85 30 RELAY BOX
3 86 87
REVERSE E-023
RELAY E-069
EF41
Y
ERLY6
30A E-022
86 87
12 I-004
F3 F2 C6 F13 H5 L1
E-071
Br
Y
L
TO BACK-UP
SWITCH
TO ST
SEL_PWR_FB
SEL_POS_DS
SEL_POS_D
SEL_POS_N
SEL_POS_P
REV_FB
E-078
10
TO PSE J1
CONNECTOR A 7 4 3 2 8 1
E-050
WR
BL
Gr
Br
R
B
B
R
TO PSE J1
Br
E-087
49 18 17 16 14 15
TCU 18
E-030
C1 C2 C3 C4 C5 E-023
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 L
C6 C7 C8 C9 C10
E-030
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B
L2 L1
6 4 2 1 5 3 E-050
B E-022
10 9 7 8
W
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 6 5 4 3 2 1

27 25 26 14 13 12 11 10 9 8 7
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
87
85 86 86 86
87 30 87 30 I-007 E-069 I-004
30 85 85
B W W ET21180030

18 - QR019CHB CVT
TCU (Page 4 of 5)
TCU
E-030
27 51 23 55 22 21 54 50 19 36 12 13 8 11 10
BGr
BGr
WR
WR
WR
GR
LW
RL
LB
LY
G
P
L
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
PRIMARY SHAFT CLUTCH SPEED SECONDARY SHAFT SECONDARY SHAFT PRIMARY SHAFT
SPEED SENSOR SENSOR SPEED SENSOR PRESSURE SENSOR PRESSURE SENSOR
E-083 E-049 E-079 E-080 E-054
18
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
E-030
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
E-083 E-049 E-079 E-080 E-054

B B B B W
ET21180040

18 - QR019CHB CVT
TCU (Page 5 of 5)
TCU
E-030
CAN H1 CAN L1
6 7 41 42 24 25 26
GW
OB
RB
TO CAN
SYSTEM
GW
RB
B
E-029
14 13
GW
OB
RB
B-054
O
RB
GW
3 4 25 23 1 17
BRAKE CAN H1 CAN L1 ECM-2
SWITCH
E-033
B-052 E-087
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
2 1
18
E-030 B-052
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B 4 3 Lg
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
11 10 9 8 7 6 5 4 3 2 1 E-029
E-033
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B 22 21 20 19 18 17 16 15 14 13 12 W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
ET21180050

18 - QR019CHB CVT
Transmission Control Unit (TCU) Pin-Out Table

Pin Circuit Identification Pin Circuit Identification
1 - 29 -
2 - 30 Shift Solenoid Lock
3 Solenoid Power Feedback 31 TCU Relay
4 - 32 Clutch Solenoid
5 Winter Mode Switch 33 Torque Converter Solenoid
6 Brake Switch 1 34 Output Pulley Oil Pressure Solenoid
7 Brake Switch 2 35 Input Pulley Oil Pressure Solenoid
Secondary Shaft Pressure Sensor
8 Primary Shaft Pressure Sensor Power 36
Power
Winter Mode Switch Illumination
10 Primary Shaft Pressure Sensor Ground 37
Ground
11 Primary Shaft Pressure Sensor Signal 38 -
12 39 -
Signal
13 40 -
Ground
14 Reverse Gear Switch 41 CAN High
15 P Gear Switch 42 CAN Low
16 Neutral Switch 43 Shift-Up Switch
17 D Gear Switch 44 Shift-Down Switch
18 Low Speed Gear Switch 45 Manual Mode Switch
19 Secondary Shaft Speed Sensor Ground 46 KL15
20 Oil Temperature Sensor Ground 47 Oil Temperature Sensor Signal
21 Turbine Speed Sensor Ground 48 P/N Signal Feedback
22 Turbine Speed Sensor Signal 49 Shift Position Power Feedback
18
23 Primary Shaft Speed Sensor Ground 50 Secondary Shaft Speed Sensor Signal
24 Ground 51 Primary Shaft Speed Sensor Signal
25 Ground 52 -
26 Ground 54 Secondary Shaft Speed Sensor Power
27 Primary Shaft Speed Sensor Power 55 Turbine Speed Sensor Power
28 KL15 56 Power Supply

18 - QR019CHB CVT
DIAGNOSIS & TESTING

Transmission Fluid Level and Quality Inspection
1. After the vehicle runs for 5 min, the temperature will reach the normal working conditions (ATF temperature
60 - 80°C, and the engine coolant temperature 80 - 100°C).
2. Park the vehicle on a flat ground and pull the parking brake lever.
3. Start up the engine to make it run at idle speed, and then fully depress the brake pedal and move the shift
lever for five times at each gear. Finally, place the lever at "P" or "N" position.
4. Pull out the automatic transmission fluid dipstick and
clean it with non-wool paper; then insert the dipstick into
the filling pipe as much as possible and then take out to
observe whether it reaches the "HOT" position.
RT21180200
5. Check the transmission fluid:

 If the fluid becomes brown, replace the automatic transmission fluid and check the vehicle for working
conditions.
 If the fluid becomes milk white or cloudy, or there is water in the fluid, replace the automatic transmission
fluid and check for the leaking location.
 If the fluid becomes black with a lot of powders and there is abnormal wear in the CVT, replace the
automatic transmission fluid and check the vehicle for normal working.
Gear Shift Cable Inspection and Adjustment

Shift the gear lever from "N" gear to other gears to check whether the lever can be shifted to other gears
smoothly and precisely, and also check whether the gear indicators can indicate the gear correctly.
If the gear indicators indicate incorrectly, adjust them as shown below:
1. Park the vehicle at a safe place and pull the parking brake lever.
2. Change the shift lever to the "N" position.
3. Turn off all the electrical devices and ignition switch. 18
5. Remove the battery, battery tray and tray bracket (See page 16-7).
6. Remove the connecting nut (3) of the gear shift cable (1)
and shift arm (2). Disconnect the gear shift cable from the
shift arm.
2 3
RT21180210

18 - QR019CHB CVT
7. Loosen the transmission range sensor fixing bolts, and

adjust the relative position of the transmission range
sensor and shift arm to make the holes of gear shift arm
(1) and transmission range sensor (2) coincident. 1
2
RT21180220
8. Use a proper tool to fix the gear shift arm and transmission range sensor, and then tighten the bolts to the
specified torque.
9. Start engine only when the gear lever is at the "P" or "N" gear.
CAUTION
 The ledge of the gear shift cable must be placed into the slot of shift arm.
Transmission Range Sensor Inspection

1. Turn off all the electrical devices and ignition switch.
3. Disconnect the transmission range sensor wire harness
connector.
RT21180230
18 4. Check for continuity between the terminals of transmission range sensor wire harness connector
according to the table below.
Gearshift Position Terminal Specified Condition

P 1 - 7, 9 - 10
R 7-8
N 2 - 7, 9 - 10 Continuity
D 3-7
L 4-7
If result is not as specified, replace the transmission range sensor.

18 - QR019CHB CVT
Transmission Fluid Temperature Sensor Inspection

2. Disconnect the transmission wire harness connector.
3. Check for resistance between the transmission wire
harness connector terminals 1 and 2.
RT21180240
Item Terminal Temperature (°C (°F)) Resistance (KΩ)

20 (68) 6.5
Gear Box 1-2
80 (176) 0.9
Primary Shaft Speed Sensor Inspection

2. Disconnect the primary shaft speed sensor connector.
3. Check for resistance between the terminals of primary
shaft speed sensor as shown in the table below at normal
temperature.
RT21180250
HINT:
The inner parts of the sensor are triode and capacitor, and will be affected greatly by the environment and
usage condition. Therefore, the actual measured value is within the specified value plus/minus 15% in the 18
table below.
Item Multimeter Connection Specified Condition

+ - (MΩ)
1 3 3.313
Primary Shaft Speed Sensor 3 1 6.56
1 2 1.649
3 2 11.56

18 - QR019CHB CVT
Turbine/Secondary Shaft Speed Sensor Inspection

2. Disconnect the turbine/secondary shaft speed sensor
connector.
RT21180260
RT21180270
3. Check for resistance between the terminals of turbine/secondary shaft speed sensor as shown in the table
below at normal temperature.
HINT:
The inner parts of the sensor are triode and capacitor, and will be affected greatly by the environment and
usage condition. Therefore, the actual measured value is within the specified value plus/minus 15% in the
table below.
Item Multimeter Connection Specified Condition

+ - (MΩ)
1 3 3.397
18 Turbine/Secondary Shaft Speed
3 1 6.79
Sensor
1 2 1.77
3 2 11.9

18 - QR019CHB CVT
Primary/Secondary Shaft Pressure Sensor Inspection

2. Disconnect the primary/secondary shaft pressure sensor
connector.
RT21180280
RT21180290
3. Check for resistance between the terminals of primary/secondary shaft pressure sensor as shown in the
table below at normal temperature.
HINT:
The inner parts of the sensor are triode and capacitor, and will be affected greatly by the environment and the
usage condition. Therefore, the actual measured value is within the specified value plus/minus 15% in the
table below.
Item Multimeter Connection Specified Condition (KΩ)
Primary/Secondary Shaft Pressure 1-3 45.77

Sensor 2-1 10.06
18

18 - QR019CHB CVT

HINT:
Symptoms Suspected Area See page
With power-on or ignited, P gear is not Brake switch or circuit 26-26

released after applying brake Gear shift lock solenoid -
Turbine speed sensor 18-116
High impact during static gear shifting Circuit or connector -
Solenoid -
Vehicle fails to move when D/R gear is
Gear shift cable and transmission shift arm
engaged, or engaged gear is different from 18-127
(assembled incorrectly)
gear shown in the instrument
Oil pressure switch 13-16
Variable speed anomaly, jumbled speed
shifting in driving; abnormal driving and Circuit or connector -
poor comfort
Speed sensor 06-249
Vehicle fails to run after gear is engaged, Transmission fluid pump -

but gear indication is normal Solenoid -
Vehicle fails to run when reverse gear is
Transmission planetary gear system -
engaged
Radiator oil pipes (incorrectly assembled,
12-29
Vehicle stalls when D/R gear is engaged bent or folded)
Locking clutch (abnormal) -
Abnormal noise of transmission in
Transmission fluid (insufficient) 18-110
acceleration
Reduced power and speed in high
Thermal protection of transmission -
speeding driving
18 Diagnostic Help
2. Confirm that the malfunction occurs, and perform diagnosis tests and repair procedures.
3. If diagnostic trouble code (DTC) cannot be deleted, it is a current malfunction.
4. Only use a digital multimeter to measure the voltage of electrical systems.
6. Visually check the related wire harnesses.
7. Inspect and clean all engine control module (ECM) grounds that are related to the latest DTC.
8. If multiple trouble codes were set, use the circuit diagrams and look for any common ground circuit or

18 - QR019CHB CVT

 Inspect the mounting areas of instrument cluster, wire harness or wire harness connector and so on for
damage, foreign matter, etc. that will cause incorrect signals.
Ground Inspection
(rust) and oxidation can increase load resistance. This situation will seriously affect the normal operation of
6. If several wire harnesses are crimped into one ground eyelet terminal, check if they are installed correctly.
Make sure all wire harnesses are clean, securely fastened and providing a good ground path.

P1700 Unexpected Interrupt
P0700 Transmission Control System (MIL Request)
P0701 Transmission Control System Performance
P0702 Transmission Control System Electrical
P0703 Brake Switch 'B' Circuit
18
P0705 Transmission Range Sensor 'A' Circuit (PRNDL Input)
P0706 Transmission Range Sensor 'A' Circuit Range (PRNDL Input)
P0707 Transmission Range Sensor 'A' Circuit Low (PRNDL Input)
P0708 Transmission Range Sensor 'A' Circuit High (PRNDL Input)
P0709 Transmission Range Sensor 'A' Circuit Intermittent (PRNDL Input)
P0715 Input/Turbine Speed Sensor Circuit
P0716 Input/Turbine Speed Sensor Circuit Range
P0717 Input/Turbine Speed Sensor Circuit No Signal
P0718 Input/Turbine Speed Sensor Circuit Intermittent
P0719 Brake Switch 'B' Circuit Low
P071A Transmission Sport Mode Switch Circuit

18 - QR019CHB CVT

P071B Transmission Sport Mode Switch Circuit Low
P071C Transmission Sport Mode Switch Circuit High
P071D Transmission Winter Mode Switch Circuit
P071E Transmission Winter Mode Switch Circuit Low
P071F Transmission Winter Mode Switch Circuit High
P0720 Output Speed Sensor Circuit
P0721 Output Speed Sensor Circuit Range/Performance
P0722 Output Speed Sensor Circuit No Signal
P0723 Output Speed Sensor Circuit Intermittent
P0724 Brake Switch 'B' Circuit High
P0725 Engine Speed Input Circuit
P0726 Engine Speed Input Circuit Range/Performance
P0727 Engine Speed Input Circuit No Signal
P0728 Engine Speed Input Circuit Intermittent
P0730 Incorrect Gear Ratio
P0740 Torque Converter Clutch Circuit Open
P0741 Torque Converter Clutch Circuit Performance
P0742 Torque Converter Clutch Circuit Stuck On
P0743 Torque Converter Clutch Circuit Electrical
P0744 Torque Converter Clutch Circuit Intermittent
P0745 Pressure Control Solenoid 'A'
P0746 Pressure Control Solenoid 'A' Stuck Off
P0747 Pressure Control Solenoid 'A' Stuck On
P0748 Pressure Control Solenoid 'A' Electrical
P0749 Pressure Control Solenoid 'A' Intermittent
18
P0775 Pressure Control Solenoid 'B'
P0776 Pressure Control Solenoid 'B' Stuck Off
P0777 Pressure Control Solenoid 'B' Stuck On
P0778 Pressure Control Solenoid 'B' Electrical
P0779 Pressure Control Solenoid 'B' Intermittent
P0791 Intermediate Shaft Speed Sensor 'A' Circuit
P0792 Intermediate Shaft Speed Sensor 'A' Circuit Range
P0793 Intermediate Shaft Speed Sensor 'A' Circuit No Signal
P0794 Intermediate Shaft Speed Sensor 'A' Circuit Intermittent
P0811 Drive Clutch 'A' Slippage
P0814 Transmission Range Display Circuit
P0815 Upshift Switch Circuit

18 - QR019CHB CVT

P0816 Downshift Switch Circuit
P0817 Starter Disable Circuit Open
P081A Starter Disable Circuit Low
P081B Starter Disable Circuit High
P081C Park Input Circuit
P081D Neutral Input Circuit
P081E Reverse Clutch 'B' Slippage
P0826 Up and Down Shift Switch Circuit
P0827 Up and Down Shift Switch Circuit Low
P0828 Up and Down Shift Switch Circuit High
P1811 Continuous Clutch Slippage
P0840 Transmission Fluid Pressure Sensor 'A' Circuit
P0841 Transmission Fluid Pressure Sensor 'A' Circuit Range
P0842 Transmission Fluid Pressure Sensor 'A' Circuit Low
P0843 Transmission Fluid Pressure Sensor 'A' Circuit High
P0844 Transmission Fluid Pressure Sensor 'A' Circuit Intermittent
P0845 Transmission Fluid Pressure Sensor 'B' Circuit
P0846 Transmission Fluid Pressure Sensor 'B' Circuit Range/Performance
P0847 Transmission Fluid Pressure Sensor 'B' Circuit Low
P0848 Transmission Fluid Pressure Sensor 'B' Circuit High
P0849 Transmission Fluid Pressure Sensor 'B' Circuit Intermittent
P0850 Park/Neutral Switch Input Circuit
P0851 Park/Neutral Switch Input Circuit Low
P0852 Park/Neutral Switch Input Circuit High
P0853 Drive Switch Input Circuit
18
P0854 Drive Switch Input Circuit Low
P0855 Drive Switch Input Circuit High
P0863 TCM Communication Circuit
P0864 TCM Communication Circuit Range
P0865 TCM Communication Circuit Low
P0866 TCM Communication Circuit High
P0867 Transmission Fluid Pressure
P0868 Transmission Fluid Pressure Low
P0869 Transmission Fluid Pressure High
P0880 TCM Power Input Signal
P0881 TCM Power Input Signal Range
P0882 TCM Power Input Signal Low

18 - QR019CHB CVT

P0883 TCM Power Input Signal High
P0884 TCM Power Input Signal Intermittent
P0885 TCM Power Relay Control Circuit Open
P0886 TCM Power Relay Control Circuit Low
P0887 TCM Power Relay Control Circuit High
P0888 TCM Power Relay Sense Circuit
P0889 TCM Power Relay Sense Circuit Range/Performance
P0890 TCM Power Relay Sense Circuit Low
P0891 TCM Power Relay Sense Circuit High
P0892 TCM Power Relay Sense Circuit Intermittent
P0894 Transmission Component Slipping
P0897 Transmission Fluid Deteriorated
P0900 Clutch Actuator Circuit Open
P0901 Clutch Actuator Circuit Range
P0902 Clutch Actuator Circuit Low
P0903 Clutch Actuator Circuit High
P0928 Gear Shift Lock Solenoid Control Circuit Open
P0929 Gear Shift Lock Solenoid Control Circuit Range
P0930 Gear Shift Lock Solenoid Control Circuit Low
P0931 Gear Shift Lock Solenoid Control Circuit High
P0932 Hydraulic Pressure Sensor Circuit
P0933 Hydraulic Pressure Sensor Range
P0934 Hydraulic Pressure Sensor Circuit Low
P0935 Hydraulic Pressure Sensor Circuit High
P0936 Hydraulic Pressure Sensor Circuit Intermittent
18
P0937 Hydraulic Oil Temperature Sensor Circuit
P0938 Hydraulic Oil Temperature Sensor Range
P0939 Hydraulic Oil Temperature Sensor Circuit Low
P0940 Hydraulic Oil Temperature Sensor Circuit High
P0941 Hydraulic Oil Temperature Sensor Circuit Intermittent
P0955 Auto Shift Manual Mode Circuit
P0956 Auto Shift Manual Mode Circuit Range/Performance
P0957 Auto Shift Manual Mode Circuit Low
P0958 Auto Shift Manual Mode Circuit High
P0959 Auto Shift Manual Mode Circuit Intermittent
P0960 Pressure Control Solenoid 'A' Control Circuit Open
P0961 Pressure Control Solenoid 'A' Control Circuit Range

18 - QR019CHB CVT

P0962 Pressure Control Solenoid 'A' Control Circuit Low
P0963 Pressure Control Solenoid 'A' Control Circuit High
P0964 Pressure Control Solenoid 'B' Control Circuit Open
P0965 Pressure Control Solenoid 'B' Control Circuit Range
P0966 Pressure Control Solenoid 'B' Control Circuit Low
P0967 Pressure Control Solenoid 'B' Control Circuit High
P0970 Pressure Control Solenoid 'C' Control Circuit Low
P0971 Pressure Control Solenoid 'C' Control Circuit High
P1900 Clutch Solenoid Control Circuit
P1928 Shift-Lock Solenoid Control Circuit
P1785 Power Relay Drive Circuit
P1745 Second Speed Sensor Plausible
P2797 Auxiliary Transmission Fluid Pump Performance
P2798 Auxiliary Transmission Fluid Pump Control Circuit Low
Data Stream List

By reading the "Data Stream List" on the diagnostic tester, the working state of the switches, sensors, and
actuators can be checked without removing any component. Before the fault diagnosis of the transmission
electrical control system, the observation and analysis of data is the first step in troubleshooting, this can
reduce the troubleshooting time.
WARNING
 The following table lists the data under normal conditions, only for reference. Do not determine the failure
just based on these standard values. Generally, compare a normal vehicle to the vehicle in diagnosis
under the same state to determine the data of diagnosis vehicle under current state is normal or not.
TCU (Transmission Control Unit) Configuration 18

Gear Data Stream Item Engine Idle Speed
Transmission engagement gear P gear
P Driver request 0.00%
Battery voltage 13.00 V
Transmission engagement gear Reverse
R Driver request 0.00%
Transmission engagement gear N gear
N Driver request 0.00%

18 - QR019CHB CVT

Transmission engagement gear D gear
D Driver request 0.00%
Transmission engagement gear Low speed gear
L Driver request 0.00%
Transmission engagement gear First gear
M-1 Driver request 0.00%
TCU (Transmission Control Unit ) Input Inspection

Transmission engagement gear P gear
Drive pulley pressure 1.9 Bar
Oil temperature 71°C
P Driven pulley pressure 10 Bar
Driver request 0.00%
Engine torque signal in CAN 5.00%
Engine coolant temperature 93.00°C
Transmission engagement gear Reverse
R Driven pulley pressure 10 Bar
18 Engine torque signal in CAN 11%
Transmission engagement gear N gear
N Driven pulley pressure 9.9 Bar
Engine torque signal in CAN 5%

18 - QR019CHB CVT

Transmission engagement gear D gear
D Driven pulley pressure 9.5 Bar
Engine torque signal in CAN 1.1%
Transmission engagement gear Low speed gear
L Driven pulley pressure 8.2 Bar
Engine coolant temperature 96°C
Transmission engagement gear First gear
M-1 Driven pulley pressure 9.2 Bar
TCU (Transmission Control Unit ) Output Inspection
Data Stream Item Engine Idle Speed

Clutch duty ratio 99.70% 18
TCC (torque converter clutch) duty ratio 0.00%
Drive pulley duty ratio 49.241%
Driven pulley duty ratio 76.135%
Transmission engagement gear (transmission
P gear
position)
Transmission engagement gear (transmission
Common code
working mode)
Transmission engagement gear (transmission fault) Non-default
Coolant temperature signal in CAN 93°C

18 - QR019CHB CVT
Dynamic Inspection

Multi-function switch position P gear
Engine speed 702.75 rpm
Turbine speed 702 rpm
Vehicle speed 0.00 km/h
Driver request 0.00 NM
Driven pulley pressure 10.076 Bar
Speed Inspection

Turbine speed 7.2 rpm
Drive pulley speed 0 rpm
Driven pulley speed 0 rpm
CAN Network

18 Driver request 0.00%
Driver request 0.00 NM
Torque converter status Unlock

18 - QR019CHB CVT
Power Supply and Ground Circuit Test

Power Supply Circuit Test
Power Supply Circuit
IGNITION SEITCH BATTERY

ON OR START
EF19 EF46
ENGINE
10A 20A COMPARTMENT
EF17 FUSE AND
85 30 RELAY BOX
10A
TCU E-069
RELAY E-076
ERLY12 E-066
86 87
A4 A2 F15 F16 J2
RL
RL
R
L
R
L
28 46 56 31 3
TCU
18
E-030

E-076 E-069
A6 A7 A8 A9 A10
Gr W
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 J2 J1
E-030
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B E-066
B
ET21180060

18 - QR019CHB CVT
Check TCU Power Circuit Value
Terminal No. Item Condition Value

28 Ignition Switch Ignition Switch ON Voltage (11 - 14 V)
46 Ignition Switch Ignition Switch ON Voltage (11 - 14 V)
56 Battery Power - Voltage (11 - 14 V)
DTC Confirmation Procedure:

Confirm that battery voltage is between 11 and 14 V before performing the following procedures.
 Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC), and make it
 Using X-431 3G diagnostic tester to record and clear the DTCs stored in the TCU.
 Turn ignition switch to ON, and then select "Read Code".
 If DTC is not detected, the malfunction indicated by the DTC is intermittent. Please refer to Intermittent
DTC Troubleshooting.
Diagnosis procedure
1 Check if TCU power fuse EF17, EF19 and EF46 are normal
NG Replace failed fuse
OK
18 2 Check if TCU relay 12 operates normally
NG Replace TCU relay 12
OK
Check if ignition switch to fuse box TCU fuse and relay circuit and battery to fuse box TCU
3 fuse and relay circuit are normal
NG Repair or replace failed circuit
OK

18 - QR019CHB CVT
4 Check engine wire harness
a. Turn ignition switch to LOCK and disconnect the negative

battery cable.
b. Disconnect the connector E-030.
c. Connect the negative battery cable. V
+ -
d. Check if the output voltage of the terminal 3, 28, 31, 46
and 56 of connector E-030 is normal.
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21180800
e. Check for continuity between terminal 3, 28, 31, 46 and

56 of connector E-030 and ground.
NG Replace engine wire harness

+ -
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
18
RT21180810
OK

18 - QR019CHB CVT
5 Check engine compartment fuse and relay box

battery cable.
b. Disconnect the connector E-066, E-069 and E-076.
c. Check if the output voltage of the terminal J2 of V
connector E-066 is normal. + -
J2 J1
E-066
RT21180820
d. Check if the terminal J2 of connector E-066 and ground is

conductive.
+ -
J2 J1
E-066
18
RT21180830

18 - QR019CHB CVT
e. Check if the output voltage of the terminal F18 of

connector E-069 is normal.
V
+ -
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
E-069
RT21180840
f. Check if the terminal F18 of connector E-069 and ground

is conductive.
+ -
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
E-069
RT21180850
g. Check if the output voltage of the terminal A2 and A4 of 18

V
+ -
A1 A2 A3 A4 A5
A6 A7 A8 A9 A10
E-076
RT21180860

18 - QR019CHB CVT
h. Check if the terminal A2 and A4 of connector E-076 and

ground is conductive.
NG Replace compartment fuse and relay box

+ -
A1 A2 A3 A4 A5
A6 A7 A8 A9 A10
E-076
RT21180870
OK
Replace TCU
18

18 - QR019CHB CVT
Ground Circuit Test

Ground Circuit
TCU
E-030
24 25 26
B
E-087
18
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
E-030
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B
ET21180070

18 - QR019CHB CVT

Diagnosis Procedure
1 Check ground for dirty or oxidized
NG Clean transmission ground contact point
OK
2 Check ground circuit for continuity

battery cable.
b. Disconnect the TCU connector E-030.
c. Check for continuity between the terminals 24, 25 and 26
+ -
of connector E-030 and ground E-087.

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
18 E-030
E-087
RT21180880
OK

18 - QR019CHB CVT
3 Check if there is voltage in ground circuit

battery cable.
b. Disconnect the TCU connector E-030.
+ -
d. Check if there is voltage between the terminals 24, 25
and 26 of TCU connector E-030 and ground.
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
NG Repair or replace failed circuit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21180890
OK
Replace TCU
18

18 - QR019CHB CVT
DTC P0705 Transmission Range Sensor 'A' Circuit (P-R-N-D-L Input)
SEL_PWR_FB
SEL_POS_DS
SEL_POS_D
SEL_POS_N
SEL_POS_P
CONNECTOR A
REV_FB
E-050
7 4 3 2 8 1
WR
BL
Gr
Br
R
B
49 18 17 16 14 15
TCU
E-030
18
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
6 4 2 1 5 3
E-030
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 10 9 7 8
B
E-050
B
ET21180080

18 - QR019CHB CVT
DTC Detection
DTC Code DTC Definition DTC Set Condition Possible Cause
Condition
 Transmission range
sensor failure
Transmission Range Start engine and If multiple TCU
 Gear signal circuit
P0705 Sensor 'A' Circuit  shift between  reading gear signals
short circuit to ground
(P-R-N-D-L Input) P-R-N-D-L gears exist (more than 1)
 TCU digital signal
circuit failure

Diagnosis Procedure
HINT:
After the fault is eliminated, verify DTC and symptom again.
1 Check wire harness connector

b. Disconnect the gear selector connector.
c. Check if the gear selector connector is dirty, oxidized, loose or damaged.
NG Repair fault
18
OK
2 Check transmission range sensor

c. Disconnect the transmission range sensor connector and shift the lever to each gear.
d. Check if the terminals of the transmission range sensor connector connects well (See page 18-119).
NG Replace transmission range sensor
OK

18 - QR019CHB CVT
3 Check wire harness connector U-010

battery cable.
b. Disconnect the wire harness connector E-030.
c. Check for continuity between the terminals 14, 15, 16, 17
+ -
and 18 of wire harness connector E-030 and ground.

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
E-087
RT21180900
OK
4 Check TCU wire harness

battery cable.
b. Disconnect the wire harness connectors E-030 and 
E-050.
+ -
c. Check for continuity between the terminals 14, 15, 16, 17
and 18 of wire harness connector E-030 and terminals of
1, 2, 3, 4 and 8 of connector E-050.
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
18 E-030
E-087
RT21180900
OK
5 Check for DTC
a. Using X-431 3G diagnostic tester, select Read Code.

b. Check if DTC P0705 still exists.
NG Replace TCU

18 - QR019CHB CVT
OK
System is normal
18

18 - QR019CHB CVT
QR019CHB CVT
DTC P0715 Input/Turbine Speed Sensor Circuit
DTC P0716 Input/Turbine Speed Sensor Circuit Range
TCU
E-030
55 WR 22 21
LY
1 2 3
CLUTCH SPEED
SENSOR
E-049
18
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
E-030 1 2 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B
E-049
B
ET21180090

18 - QR019CHB CVT
DTC Detection Warning Light

Condition Condition
Turbine speed  Incorrect
signal is higher installation of the
Input/Turbine Speed
P0715 than standard turbine speed
Sensor Circuit
Start engine and keep value within a sensor
it at following status for period  Signal circuit open
at least 10 seconds: or short circuit
idle speed or Difference
between engine  Turbine speed
accelerator not more
speed and sensor power
than 10%, at P or N
Input/Turbine Speed turbine speed circuit poor contact
P0716 gear, engine speed not
Sensor Circuit Range less than idle speed exceeds  Turbine speed
standard value sensor failure
and keep for  TCU signal circuit
900ms failure

Diagnosis Procedure
HINT:
1 Check wire harness connector 18

b. Disconnect the turbine speed sensor connector.
c. Check if the turbine speed sensor connector is dirty, oxidized, loose or damaged.
NG Repair fault
OK

18 - QR019CHB CVT

battery cable.
b. Disconnect the wire harness connectors E-030 and E-049.
+ -
of wire harness connector E-030 and terminals 3, 2 and 1
of connector E-049.
NG Replace engine compartment wire 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
harness 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
6 4 2 1 5 3
10 9 7 8
E-050
RT21180920
OK
3 Check if TCU wire harness connector E-030 and ground is conductive

battery cable.
+ -
of wire harness connector E-030 and ground.

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
18 E-030
RT21180930
OK

18 - QR019CHB CVT
4 Check if TCU wire harness connector E-030 is short to power

battery cable.
c. Check if the terminals 21, 22 and 55 of wire harness V
+ -
connector E-030 are short to power.

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21180940
OK
5 Check turbine speed sensor
a. Correctly install a new turbine speed sensor.

b. Check whether the system is normal.
NG Diagnosis complete
OK
6 Check for DTC

18
b. Check if DTC P0715 or P0716 still exists.
NG Replace TCU
OK
System is normal

18 - QR019CHB CVT
DTC P0720 Output Speed Sensor Circuit
DTC P1745 Second Speed Sensor Plausible
TCU
E-030
54 50 19
LW
O
Y
1 2 3
SECONDARY SHAFT
SPEED SENSOR
E-079
18
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
E-030
1 2 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B
E-079
B
ET21180100

18 - QR019CHB CVT
DTC Detection DTC Set

Condition Condition
Start engine and keep
it at following status for Output speed  Incorrect
at least 1 min: throttle signal is higher installation of the
Output Speed Sensor
P0720 opening not less than than the output speed
Circuit
10%, at D gear, engine allowable value sensor
speed higher than 800 within a period
 Signal circuit open
rpm
or short circuit
Difference  Output speed
Start engine and keep between output sensor power
it at following status for speed after circuit poor contact
at least 30 seconds: conversing
Second Speed Sensor  Output speed
P1745 throttle opening higher vehicle speed
Plausible sensor failure
than 10%, at D gear, signal and actual
vehicle speed higher measured speed  TCU signal circuit
than 10 km/h is higher than failure
limit

Diagnosis Procedure
HINT:
After the fault is eliminated, verify DTC and symptom again. 18

b. Disconnect the secondary speed sensor connector.
c. Check if the secondary speed sensor connector is dirty, oxidized, loose or damaged.
NG Repair fault
OK

18 - QR019CHB CVT

battery cable.
+ -
of connector E-079.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
1 2 3
E-079
RT21180950
OK
3 Check if TCU wire harness connector E-030 and ground is conductive

battery cable.
+ -

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
18 E-030
RT21180960
OK

18 - QR019CHB CVT

battery cable.
+ -

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21180970
OK
5 Check secondary shaft speed sensor
a. Correctly install a new secondary shaft speed sensor.

b. Using the X-431 3G diagnostic tester, check whether the system is normal.
OK
6 Check for DTC

18
NG Replace TCU
OK
System is normal

18 - QR019CHB CVT
DTC P0730 Incorrect Gear Ratio

Condition Condition
 Speed ratio control
valve body circuit
The absolute seized
Start engine and keep
value of
it at following status for  Solenoid wire
difference of
at least 1 min: throttle harness or
target speed
P0730 Incorrect Gear Ratio opening not less than connector open
ratio and actual
15%, at D gear, vehicle circuit or short
speed ratio is
speed not less than 18 circuit
higher than the
km/h  Auxiliary oil
standard value
pressure control
failure or too low

Diagnosis Procedure
HINT:
18 1 Carry out following preliminary checks
a. Engine wire harness (check for looseness, dirt and other fault)
b. Transmission sensor (check for damage, dirt and other fault)
c. Are all checks OK?
NG Repair fault
OK
2 Check transmission system
a. Use diagnostic tester to check the transmission system.

b. Is there any DTC except for P0730?

18 - QR019CHB CVT
NG Repair these DTCs fault
OK
3 Read data stream
a. Use the diagnostic tester to read the data related to engine and transmission system speed sensor for
abnormality.
b. Transmission system should be normal.
c. Is the check result normal?
NG Repair fault
OK
4 Check for DTC

c. Is DTC P0730 still present?
NG Replace solenoid and wire harness

assembly
OK
System is normal
18

18 - QR019CHB CVT
DTC P0791 Intermediate Shaft Speed Sensor 'A' Circuit
DTC P0792 Intermediate Shaft Speed Sensor 'A' Circuit Range
TCU
E-030
27 51 23
BGr
GR
LB
1 2 3
PRIMARY SHAFT
SPEED SENSOR
E-083
18
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
E-030 1 2 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B
E-083
B
ET21180110

18 - QR019CHB CVT

Condition Condition
Start engine and keep  Incorrect
it at following status for The input speed installation of the
Intermediate Shaft at least 1 min: throttle signal is higher input speed sensor
P0791 Speed Sensor 'A' opening not less than than the
Circuit 10%, at D gear, engine allowable value
or short circuit
speed higher than 800 within a period
rpm  Input speed sensor
power circuit poor
Start engine and keep contact
it at following status for
The input speed  Input speed sensor
Intermediate Shaft at least 10 seconds:
signal exceeds failure
P0792 Speed Sensor 'A' throttle opening not
the standard  TCU signal
Circuit Range less than 10%, at D
value treatment circuit
gear, engine speed
higher than 800 rpm failure

Diagnosis Procedure
HINT:
18

b. Disconnect the primary shaft speed sensor connector.
c. Check if the primary shaft speed sensor connector is dirty, oxidized, loose or damaged.
NG Repair fault
OK

18 - QR019CHB CVT

battery cable.
+ -
of connector E-083.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
1 2 3
E-083
RT21180980
OK
3 Check if TCU wire harness E-030 and ground is conductive

battery cable.
+ -

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
18 E-030
RT21180990
OK

18 - QR019CHB CVT

battery cable.
+ -

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21181000
OK
5 Check primary shaft speed sensor
a. Correctly install a new primary shaft speed sensor.

OK
6 Check for DTC

18
NG Replace TCU
OK
System is normal

18 - QR019CHB CVT
DTC P0811 Drive Clutch 'A' Slippage
DTC P081E Reverse Clutch 'B' Slippage
DTC P0894 Transmission Component Slipping

Condition Condition
Start engine and keep  Clutch control
Drive Clutch 'A' it at following status for valve core seized
P0811 High slippage
Slippage at least 30 seconds:  Clutch control
apply brake, at D gear speed of the
solenoid short
forward/ reverse
Start engine and keep circuit to the power
clutch input and
Reverse Clutch 'B' it at following status for output speed  Clutch friction plate
P811E
Slippage at least 30 seconds: serious wearing or
apply brake, at R gear sinter
Start engine and make  Solenoid circuit

The torque open circuit or
the operation as
converter locking short circuit
following: 20% - 50%
clutch is
throttle opening, at D  TCU torque
Transmission engaged for a
P0894 gear, vehicle speed converter locking
Component Slipping long time or high
higher than 30 km/h, control solenoid
slippage speed
constant driving time failure
exists after
not less than 30  Hydraulic control
engagement
seconds circuit fault

18  Using X-431 3G diagnostic tester to record and clear the DTCs stored in the TCU.

18 - QR019CHB CVT
Diagnosis Procedure
HINT:
1 Carry out following preliminary checks
a. Transmission sensor wire harnesses (check for looseness, dirt and other fault)
b. Transmission sensor (check for damage, dirt and other fault)
NG Repair fault
OK
a. Use diagnostic tester to check the transmission system.

b. Is there any DTC except for P0811, P081E, P0894?
OK
3 Read data stream
a. Use the diagnostic tester to read the data flow related to engine and transmission system for abnormality.
NG Diagnose abnormal data flow fault
OK
18
4 Check for DTC

c. Is DTC P0811, P081E or P0894 still present?

assembly
OK
System is normal

18 - QR019CHB CVT
DTC P0842 Transmission Fluid Pressure Sensor 'A' Circuit Low
DTC P0843 Transmission Fluid Pressure Sensor 'A' Circuit High
TCU
E-030
8 11 10
WR
L
G
1 2 3
PRIMARY SHAFT
PRESSURE SENSOR
E-054
18
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
E-030
1 2 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B
E-054
W
ET21180120

18 - QR019CHB CVT

Condition Condition
The transmission
fluid pressure
Transmission Fluid sensor 'A' oil
P0842 Pressure Sensor 'A' pressure is less
 Transmission fluid
Circuit Low than the
pressure sensor 'A'
allowable min
failure
Start engine and wait value
for at least 10 seconds The transmission or short circuit
fluid pressure
 TCU signal circuit
Transmission Fluid sensor 'A' oil
failure
P0843 Pressure Sensor 'A' pressure is more
Circuit High than the
allowable max
value

Diagnosis Procedure
HINT:
18

b. Disconnect the primary shaft pressure sensor connector.
c. Check if the primary shaft pressure sensor connector is dirty, oxidized, loose or damaged.
NG Repair fault
OK

18 - QR019CHB CVT

battery cable.
b. Disconnect the wire harness connectors E-030 and E-
054.
+ -
of connector E-054.
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
NG Repair failed circuit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
1 2 3
E-054
RT21181010
OK

battery cable.
+ -

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
18 E-030
RT21181020
OK

18 - QR019CHB CVT

battery cable.
+ -

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21181030
OK
5 Check primary shaft pressure sensor
a. Correctly install a new primary shaft pressure sensor.

OK
6 Check for DTC

18
NG Replace TCU
OK
System is normal

18 - QR019CHB CVT
DTC P0847 Transmission Fluid Pressure Sensor 'B' Circuit Low
DTC P0848 Transmission Fluid Pressure Sensor 'B' Circuit High
TCU
E-030
36 12 13
BGr
WR
RL
1 2 3
SECONDARY SHAFT
PRESSURE SENSOR
E-080
18
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
E-030
1 2 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B
E-080
B
ET21180130

18 - QR019CHB CVT

Condition Condition
The transmission
fluid pressure
Transmission Fluid sensor 'B' oil
P0847 Pressure Sensor 'B' pressure is less
 Transmission fluid
Circuit Low than the
pressure sensor 'B'
allowable min
failure
Start engine and wait value
for at least 10 seconds The transmission or short circuit
fluid pressure
 TCU signal circuit
Transmission Fluid sensor 'B' oil
failure
P0848 Pressure Sensor 'B' pressure is more
Circuit High than the
allowable max
value

Diagnosis Procedure
HINT:
18

b. Disconnect the secondary shaft pressure sensor connector.
c. Check if the secondary shaft pressure sensor connector is dirty, oxidized, loose or damaged.
NG Repair fault
OK

18 - QR019CHB CVT

battery cable.
c. Check for continuity between the terminals 12, 13, and
+ -
36 of wire harness connector E-030 and terminals 2, 3
and 1 of connector E-080.
NG Repair failed circuit 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
1 2 3
E-080
RT21181040
OK

battery cable.
+ -

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
18 E-030
RT21181050
OK

18 - QR019CHB CVT
4 Check if the TCU wire harness connector E-030 is short to power

battery cable.
c. Check if the terminals 12, 13, and 36 of wire harness V
+ -

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21181060
OK
5 Check secondary shaft pressure sensor
a. Correctly install a new secondary shaft pressure sensor.

OK
6 Check for DTC

18
NG Replace TCU
OK
System is normal

18 - QR019CHB CVT
DTC P0890 TCM Power Relay Sense Circuit Low
DTC P0891 TCM Power Relay Sense Circuit High
BATTERY
EF19 EF46
ENGINE
10A 20A COMPARTMENT
FUSE AND
85 30 RELAY BOX
TCU E-069
RELAY E-076
ERLY12 E-066
86 87
A2 F15 F16 J2
RL
RL
56 31 3
TCU
E-030
18
A1 A2 A3 A4 A5 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 J2 J1

E-076 E-069
A6 A7 A8 A9 A10
Gr F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
W E-066
B
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
E-030
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B
ET21180140

18 - QR019CHB CVT

Condition Condition
TCU power
command is
sent, solenoid
TCM Power Relay
P0890 output feedback
Sense Circuit Low
voltage is less
than the  Solenoid circuit
standard value open circuit or
Start engine and wait short circuit
for at least 10 seconds TCU power  TCU power relay
command is not failure
sent, solenoid
TCM Power Relay
P0891 output feedback
Sense Circuit High
voltage is higher
than the
standard value

Diagnosis Procedure
HINT:
18
1 Check if TCU power fuse EF19 and EF46 are normal
NG Replace failed fuse
OK
2 Check if battery to fuse box TCU fuse and relay circuit are normal
OK

18 - QR019CHB CVT
3 Check if TCU relay 12 operates normally
NG Repair TCU relay 12
OK
4 Check engine compartment fuse and relay box

battery cable.
b. Disconnect the connector E-066, E-069 and E-076.
+ -
d. Check if the output voltage of the terminals J2 of
J2 J1
E-066
RT21181070
e. Check if the output voltage of the terminals F16 of

V
+ -
18 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
E-069
RT21181080

18 - QR019CHB CVT
f. Check if the output voltage of the terminals A2 of

NG Replace fuse box V

+ -
A1 A2 A3 A4 A5
A6 A7 A8 A9 A10
E-076
RT21181090
OK

battery cable.
b. Disconnect the connectors E-030, E-066, E-069 and E-076.
c. Check for continuity between the terminal 3 of connector
+ -
E-030 and terminal J2 of connector E-066.
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
J2 J1
18
E-066
RT21181100

18 - QR019CHB CVT
d. Check for continuity between the terminal 31 of

connector E-030 and terminal F16 of connector E-069.
+ -
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
E-069
RT21181110
e. Check for continuity between terminal 56 of connector

E-030 and terminal A2 of connector E-076.
NG Replace engine compartment wire

harness + -
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
A1 A2 A3 A4 A5
A6 A7 A8 A9 A10
E-076
RT21181120
18 OK
6 Check for DTC

NG Replace TCU
OK
System is normal

18 - QR019CHB CVT
DTC P0900 Clutch Actuator Circuit Open
DTC P0902 Clutch Actuator Circuit Low
DTC P0903 Clutch Actuator Circuit High
18

18 - QR019CHB CVT
BATTERY
EF19 EF46
ENGINE
10A 20A COMPARTMENT
FUSE AND
85 30 RELAY BOX
TCU E-069
RELAY E-076
ERLY12 E-066
86 87
A2 F15 F16 J2
CLUTCH CONTROL SOLENOID

CONNECTOR B
RL
RL
E-052
4 9
R
WR
R
56 31 3 32
TCU
E-030
18

E-076 E-069
6 5 4 3 2 1 E-052
A6 A7 A8 A9 A10
Gr F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
W
10 9 8 7
Gr
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 J2 J1
E-030
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B E-066
B
ET21180150

18 - QR019CHB CVT

Condition Condition
The solenoid
output feedback
voltage is
Clutch Actuator Circuit normal, clutch
P0900
Open solenoid
feedback current
is less than the
standard value
When the
solenoid output  Solenoid circuit
feedback voltage open circuit or
Start engine and
Clutch Actuator Circuit is normal, clutch short circuit
P0902 engage D or R gear for
Low solenoid
at least 5 seconds  Clutch control
feedback current
is higher than the solenoid failure
standard value
When the
solenoid output
feedback voltage
Clutch Actuator Circuit is normal, clutch
P0903
High solenoid
feedback current
is less than the
standard value

 Turn ignition switch to LOCK and wait for a few seconds. 18
Diagnosis Procedure
HINT:

b. Disconnect the transmission wire harness connector.
c. Check if the transmission wire harness connector is dirty, oxidized, loose or damaged.

18 - QR019CHB CVT
NG Repair fault
OK

battery cable.
b. Disconnect the connectors E-052 and E-030.
c. Check for continuity between the terminal 4 and 9 of
+ -
connector E-052 and terminal 32 and 3 of connector E-030.

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
6 5 4 3 2 1
10 9 8 7
E-052
RT21181130
OK
3 Check for continuity between wire harness connector E-030 and ground

battery cable.
c. Check for continuity between the terminals 3 and 32 of
+ -
wire harness connector E-030 and ground.
18
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21181140
OK

18 - QR019CHB CVT
4 Check if transmission wire harness connector E-030 is short to power

battery cable.
c. Check if the terminals 3 and 32 of wire harness connector V
+ -
E-030 is short to power.

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21181150
OK
5 Check for DTC

b. Check if DTC P0900, P0902 or P0903 still exists.

assembly
OK
System is normal
18

18 - QR019CHB CVT
DTC P0928 Gear Shift Lock Solenoid Control Circuit Open
DTC P0930 Gear Shift Lock Solenoid Control Circuit Low
DTC P0931 Gear Shift Lock Solenoid Control Circuit High
18

18 - QR019CHB CVT
BATTERY
EF19 EF46
ENGINE
10A 20A COMPARTMENT
FUSE AND
85 30 RELAY BOX
TCU E-069
RELAY E-076
ERLY12 E-066
86 87
A2 F15 F16 J2
COMMAND
GEAR SHIFT
B-004
RL
RL
7 6
YR
R
R
15
E-029 B-054
B-054
21
E-029
R
YR
56 31 3 30
TCU
E-030
18
11 10 9 8 B-004
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
7 6 5 4 3 2 1 W
E-030
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
J2 J1 E-066
B
1 2 3 4 5 6 7 8 9 10 11
A1 A2 A3 A4 A5 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 12 13 14 15 16 17 18 19 20 21 22
E-076 E-069
A6 A7 A8 A9 A10
Gr F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
W
B-054
W
ET21180160

18 - QR019CHB CVT

Condition Condition
The solenoid
output feedback
voltage is
Gear Shift Lock
normal, gear
P0928 Solenoid Control
shifting solenoid
Circuit Open
feedback current
is less than the
standard value
When the
solenoid output
feedback voltage  Solenoid circuit
Gear Shift Lock Start engine, apply is normal, gear open circuit or
P0930 Solenoid Control brake and then shift shifting lock short circuit
Circuit Low from P gear to R gear solenoid  Gear shifting lock
feedback current solenoid failure
is higher than the
standard value
The solenoid
output feedback
voltage is
Gear Shift Lock
normal, gear
P0931 Solenoid Control
shifting solenoid
Circuit High
feedback current
is less than the
standard value

18
Diagnosis Procedure
HINT:

b. Disconnect the gear selector connector.
c. Check if the gear selector connector is dirty, oxidized, loose or damaged.

18 - QR019CHB CVT
NG Repair fault
OK

battery cable.
b. Disconnect the connectors E-029, E-030, E-066, E-069
and E-076.
+ -
c. Check for continuity between terminal 3 of connector
E-030 and terminal J2 of connector E-066.
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
J2 J1
E-066
RT21181100
d. Check for continuity between terminal 31 of connector

E-030 and terminal F16 of connector E-069.
+ -
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
18
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
E-069
RT21181110

18 - QR019CHB CVT
e. Check for continuity between terminal 56 of connector

E-030 and terminal A2 of connector E-069.
+ -
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
A1 A2 A3 A4 A5
A6 A7 A8 A9 A10
E-076
RT21181120
f. Check for continuity between terminals 3 and 30 of

connector E-030 and terminals 15 and 21 of connector
E-029.
NG Repair or replace failed circuit + -
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
E-029
RT21181160
18 OK

18 - QR019CHB CVT
3 Check body wire harness

battery cable.
b. Disconnect the wire harness connector B-054 and B-004.
c. Check for continuity between terminals 15 and 21 of
+ -
connector B-054 and terminals 6 and 7 of connector B-004.
NG Repair or replace failed circuit 1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22
B-054
11 10 9 8
7 6 5 4 3 2 1
B-004
RT21181170
OK
4 Check for continuity between transmission wire harness E-030 and ground

battery cable.
c. Check for continuity between terminal 30 of wire harness
+ -
connector E-030 and ground.

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030 18
RT21181180
OK

18 - QR019CHB CVT

battery cable.
+ -
d. Check if the terminal 30 of wire harness connector E-030
is short to power.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21181190
OK
6 Check for DTC

NG Replace gear shift mechanism
OK
System is normal
18

18 - QR019CHB CVT
DTC P0938 Hydraulic Oil Temperature Sensor Range
DTC P0939 Hydraulic Oil Temperature Sensor Circuit Low
DTC P0940 Hydraulic Oil Temperature Sensor Circuit High
CONNECTOR B
OIL TEMP GND

E-052
OIL TEMP
1 2
GR
47 20
TCU
E-030
18
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
E-030 6 5 4 3 2 1 E-052
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B
10 9 8 7
Gr
ET21180170

18 - QR019CHB CVT

Condition Condition
The CVT oil
temperature
Hydraulic Oil sensor voltage is
P0938 Temperature Sensor less than the
Range high oil
temperature
Standard value  CVT oil
The CVT oil temperature
temperature sensor failure
Hydraulic Oil Start engine and wait
sensor voltage is  Signal circuit open
P0939 Temperature Sensor for at least 3 seconds
less than the or short circuit
Circuit Low
standard min  TCU signal circuit
value failure
When the CVT
oil temperature
Hydraulic Oil
sensor voltage is
P0940 Temperature Sensor
higher than the
Circuit High
standard max
value

18
Diagnosis Procedure
HINT:

NG Repair fault
OK

18 - QR019CHB CVT

battery cable.
c. Check for continuity between terminals 20 and 47 of wire
+ -
harness connector E-030 and terminals 2 and 1 of
connector E-052.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
6 5 4 3 2 1
10 9 8 7
E-052
RT21181200
OK
3 Check for continuity between transmission wire harness connector E-030 and ground

battery cable.
+ -
harness connector E-030 and ground.

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030 18
RT21181210
OK

18 - QR019CHB CVT

battery cable.
c. Check if the terminals 20 and 47 of wire harness V
+ -

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21181220
OK
5 Check for DTC

NG Replace wire harness assembly
OK
System is normal
18

18 - QR019CHB CVT
QR019CHB CVT
DTC P0960 Pressure Control Solenoid 'A' Control Circuit Open
DTC P0962 Pressure Control Solenoid 'A' Control Circuit Low
DTC P0963 Pressure Control Solenoid 'A' Control Circuit High
18

18 - QR019CHB CVT
BATTERY
EF19 EF46
ENGINE
10A 20A COMPARTMENT
FUSE AND
85 30 RELAY BOX
TCU E-069
RELAY E-076
ERLY12 E-066
86 87
A2 F15 F16 J2
PRIMARY PRESSURE SOLENOID

CONNECTOR B
RL
RL
E-052
5 9
R
WR
R
56 31 3 35
TCU
E-030
18

E-076 E-069 6 5 4 3 2 1 E-052
A6 A7 A8 A9 A10
Gr F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
W Gr
10 9 8 7
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 J2 J1
E-030
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B E-066
B
ET21180180

18 - QR019CHB CVT

Condition Condition
The solenoid
output feedback
voltage is
Pressure Control normal, oil
P0960 Solenoid 'A' Control pressure control
Circuit Open solenoid 'A'
feedback current
is less than the
standard value
The solenoid
output feedback
voltage is  Solenoid circuit
normal, oil open circuit or
Pressure Control short circuit
Start engine and wait pressure control
P0962 Solenoid 'A' Control
for at least 3 seconds solenoid 'A'  Oil pressure
Circuit Low
feedback current control solenoid 'A'
is higher than the failure
standard max
value
The solenoid
output feedback
voltage is
P0963 Solenoid 'A' Control pressure control
Circuit High solenoid 'A'
feedback current
is less than the
standard value

communicate with vehicle electronic module by the data network. 18
Diagnosis Procedure
HINT:


18 - QR019CHB CVT
NG Repair fault
OK

battery cable.
E-030.
+ -
harness connector E-052 and terminals 35 and 3 of
connector E-030.
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
E-030
6 5 4 3 2 1
10 9 8 7
E-052
RT21181230
OK

battery cable.
18 harness connector E-030 and ground.
+ -

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21181240
OK

18 - QR019CHB CVT

battery cable.
c. Check if terminals 3 and 35 of wire harness connector  V
+ -

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21181250
OK
5 Check for DTC


assembly
OK
System is normal
18

18 - QR019CHB CVT
DTC P0964 Pressure Control Solenoid 'B' Control Circuit Open
DTC P0966 Pressure Control Solenoid 'B' Control Circuit Low
DTC P0967 Pressure Control Solenoid 'B' Control Circuit High
18

18 - QR019CHB CVT
BATTERY
EF19 EF46
ENGINE
10A 20A COMPARTMENT
FUSE AND
85 30 RELAY BOX
TCU E-069
RELAY E-076
ERLY12 E-066
86 87
A2 F15 F16 J2
SECONDARY CONTROL
PRESSURE SOLENOID
CONNECTOR B
RL
RL
E-052
10 6
R
WR
R
56 31 3 35
TCU
E-030
18

E-076 E-069 6 5 4 3 2 1 E-052
A6 A7 A8 A9 A10
Gr F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
W Gr
10 9 8 7
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 J2 J1
E-030
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B E-066
B
ET21180190

18 - QR019CHB CVT

Condition Condition
When the
solenoid output
feedback voltage
Pressure Control is normal, oil
P0964 Solenoid 'B' Control pressure control
Circuit Open solenoid B
feedback current
is less than the
standard value
The solenoid
output feedback
voltage is  Solenoid circuit
normal, oil open circuit or
Pressure Control short circuit
Start engine and wait pressure control
P0966 Solenoid 'B' Control
for at least 3 seconds solenoid B  Oil pressure
Circuit Low
feedback current control solenoid B
is higher than the failure
standard max
value
The solenoid
output feedback
voltage is
P0967 Solenoid 'B' Control pressure control
Circuit High solenoid B
feedback current
is less than the
standard value

18 communicate with vehicle electronic module by the data network.
Diagnosis Procedure
HINT:

b. Disconnect the wire harness connector.

18 - QR019CHB CVT
NG Repair fault
OK

battery cable.
E-030.
+ -
c. Check for continuity between the terminals 6 and 10 of
wire harness connector E-052 and terminals 34 and 3 of
connector E-030.
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
E-030
6 5 4 3 2 1
10 9 8 7
E-052
RT21181260
OK

battery cable.
+ -
18
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21181270
OK

18 - QR019CHB CVT

battery cable.
c. Check if terminals 3 and 34 of wire harness connector  V
+ -

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21181280
OK
5 Check for DTC


assembly
OK
System is normal
18

18 - QR019CHB CVT
DTC P0970 Pressure Control Solenoid 'C' Control Circuit Low
DTC P0971 Pressure Control Solenoid 'C' Control Circuit High
18

18 - QR019CHB CVT
BATTERY
EF19 EF46
ENGINE
10A 20A COMPARTMENT
FUSE AND
85 30 RELAY BOX
TCU E-069
RELAY E-076
ERLY12 E-066
86 87
A2 F15 F16 J2
CONNECTOR B
RL
RL
TORQUE CONVENTER
CONTROL SOLENOID
E-052
10 3
R
WR
R
56 31 3 33
TCU
E-030
18

E-076 E-069 6 5 4 3 2 1 E-052
Gr W
10 9 8 7
Gr
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 J2 J1
E-030
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B E-066
B
ET21180200

18 - QR019CHB CVT

Condition Condition
The solenoid
output feedback
voltage is
normal, oil
Pressure Control
pressure control
P0970 Solenoid 'C' Control
solenoid 'C'
Circuit Low
feedback current
is higher than the  Solenoid circuit
standard max open circuit or
Start engine and wait value short circuit
for at least 3 seconds  Oil pressure
The solenoid control solenoid 'C'
output feedback failure
voltage is
P0971 Solenoid 'C' Control pressure control
Circuit High solenoid 'C'
feedback current
is less than the
standard value

18
Diagnosis Procedure
HINT:

NG Repair fault
OK

18 - QR019CHB CVT

battery cable.
E-030.
+ -
c. Check for continuity between terminals 3 and 10 of
connector E-052 and terminals 33 and 3 of connector 
E-030.
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
E-030
6 5 4 3 2 1
10 9 8 7
E-052
RT21181290
OK

battery cable.
+ -

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
18 E-030
RT21181300
OK

18 - QR019CHB CVT

battery cable.
+ -
d. Check if the terminal 33 of wire harness connector E-030
is short to power.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21181310
OK
5 Check for DTC


assembly
OK
System is normal
18

18 - QR019CHB CVT
DTC P2797 Auxiliary Transmission Fluid Pump Performance
DTC P2798 Auxiliary Transmission Fluid Pump Control Circuit Low

Condition Condition
The difference of
the target oil
Auxiliary Transmission pressure and
P2797 Fluid Pump actual oil
Performance pressure is
higher than the
table value  Oil pressure
control valve core
Start engine and wait The difference of seized
for at least 10 seconds the target oil  Hydraulic system
pressure and pressure failure
Auxiliary Transmission actual oil
P2798 Fluid Pump Control pressure is
Circuit Low higher than table
value, and is
maintained for
over 700 ms

18
Diagnosis Procedure
HINT:
1 Carry out following preliminary checks
a. Transmission wire harness connector (check for looseness, dirt and other fault).
b. Transmission wire harness (check for damage, dirt and other fault).
NG Repair fault
OK

18 - QR019CHB CVT
a. Check the transmission system using the diagnostic tester.

b. Is there any DTC except for P2797 and P2798?
OK
3 Read data flow
a. Use diagnostic tester to read the data flow related to transmission system oil pressure sensor for
abnormality.
NG Repair fault
OK
4 Check for DTC

c. Is DTC P2797 or P2798 still present?

assembly
OK
18
System is normal

18 - QR019CHB CVT
ON-VEHICLE SERVICE
Automatic Transmission Fluid (ATF) Replacement
CAUTION
 Replace gasket after removing drain bolt every time.

 If automatic transmission fluid level is too low, add ATF until it reaches "HOT" position.
Draining
3. Place a collection vessel under the oil outlet of transmission.
4. Unscrew the drain bolt to drain ATF. After draining,
replace the drain bolt gasket and tighten the bolt.
RT21180300
Filling
1. Add new ATF along the oil dipstick pipe (filling quantity is
equal to that of the drained).
2. Start engine to make it run for 1 - 2 min.
3. Step on the brake pedal and move the shift lever at each
gear and place it to "N" or "P" position.
18
RT21180310

18 - QR019CHB CVT
Inspection
1. After the vehicle runs for 5 min, the temperature will reach the normal working conditions (ATF temperature
60 - 80°C, and the engine coolant temperature 80 - 100°C).
2. Park the vehicle on a flat ground and pull the parking brake lever.
3. Start engine to make it run at idle speed, and then fully depress the brake pedal and move the shift lever
for five times at each gear. Finally, place the lever at "P" or "N" position.
4. Pull out the automatic transmission fluid dipstick and
clean it with a piece of non-wool paper; then insert the
dipstick into the filling pipe as much as possible and then
take out to observe whether it reaches the "HOT"
position.
RT21180200
18

18 - QR019CHB CVT
Differential Oil Seal

Removal
CAUTION
 After the oil seal is removed, use a new one during installation.

3. Remove the axle shaft.
4. Using the special tool (1), remove the differential oil seal
(2).
HINT:
Do not damage the joint surface of the oil seal and
housing during removal. 2
RT21180320
Installation
1. Apply automatic transmission fluid on the inner ring of the oil seal.
2. Use the special tool (1) to install the differential oil seal
(2) to transmission (3).
2 3
1
18 RT21180330
CAUTION
 When installing the oil seal, apply force evenly and prevent the oil seal from deformation and damage.
 Keep the transmission fluid seal open and oil seal clean, to avoid foreign matter entering the transmission.
 Do not apply other sealant on the oil seal.
 Do not wear velutinous gloves when installation.
 After installing oil seal, make sure that the oil seal end surface and the transmission case are on the
same plane.
3. Other installation steps are in the reverse order of removal.

18 - QR019CHB CVT
Transmission Fluid Cooler

Removal
CAUTION
 Do not perform the following removal process with the engine running to avoid causing serious injury.

3. Remove the clamps and disconnect the cooling water
pipes.
RT21180340
4. Remove the clamps and disconnect the transmission

fluid pipes.
HINT:
Use appropriate tools to plug the transmission fluid pipes
after removing them to prevent transmission fluid
leakage.
RT21180350
5. Remove the transmission fluid cooler fixing bolts and

remove the transmission fluid cooler. 18
RT21180360
Installation
CAUTION
 Check if transmission fluid is in the normal position. If not, add transmission fluid.

18 - QR019CHB CVT
Primary Shaft Speed Sensor

Removal
4. Remove the air filter (See page 10-17).
5. Disconnect the primary shaft speed sensor wire harness connector.
6. Remove the fixing bolt (1) of the primary shaft speed
sensor and take out the primary shaft speed sensor (2). 
RT21180370
Installation
CAUTION
 Keep clean of sensor and contact surface between sensor and transmission, and avoid dust or impurity
entering the transmission.
 During installation, apply automatic transmission fluid on the O ring of the sensor.
18

18 - QR019CHB CVT
Secondary Shaft Speed Sensor

Removal
4. Disconnect the secondary shaft speed sensor wire
harness connector (arrow).
5. Remove the fixing bolt (1) of the secondary shaft speed
sensor and take out the secondary shaft speed sensor
(2).
1
2
RT21180380
Installation
CAUTION
18

18 - QR019CHB CVT
Turbine Speed Sensor

Removal
5. Disconnect the turbine speed sensor wire harness
connector (arrow).
6. Remove the fixing bolt (2) of the turbine speed sensor
and take out the turbine speed sensor (1). 
1
2
RT21180390
Installation
CAUTION
18

18 - QR019CHB CVT
Primary Shaft Pressure Sensor

Removal
4. Drain the automatic transmission fluid (See page 18-110).
5. Disconnect the wire harness connector of the primary
shaft pressure sensor.
RT21180400
6. Remove the primary shaft pressure sensor (1). 

RT21180410
Installation
CAUTION
 Keep clean of sensor and contact surface between sensor and transmission, and avoid dust or impurity 18
 Add automatic transmission fluid (See page 18-110).

18 - QR019CHB CVT

Removal
4. Disconnect the wire harness connector of the secondary
shaft pressure sensor (arrow).
RT21180420
5. Remove the secondary shaft pressure sensor (1).

RT21180430
Installation
CAUTION
18 entering the transmission.

18 - QR019CHB CVT
Transmission Range Sensor

Removal
CAUTION
 When removing and installing the transmission range sensor, make sure that the gear shift lever is at "N"
position.
1. Apply the parking brake.

5. Insert the mechanical key (3) in the emergency unlock
hole (2) and press the mechanical key to hold down the
emergency unlock switch, and move the shift lever (1) to
the N (neutral) position to release the shift lock. 1
3
R
S
2
RT21180440
6. Remove the gear shift cable (1) and arm (2) connecting
nut (3). 
2 3
RT21180450
18
7. Disconnect the transmission range sensor wire harness
connector (arrow).
RT21180460

18 - QR019CHB CVT
8. Remove the gear shift arm fixing nut (1).

(Tightening torque: 18 - 25 N·m) 2
9. Take out the gear shift arm spring gasket (2).
1
10.Take out the gear shift arm (3).
11. Remove the transmission range sensor fixing bolts 3
(arrow).  4
12.Take out the transmission range sensor (4).
RT21180470
Installation
CAUTION
 After the spring gasket of the gear shift arm is removed, use a new spring gasket during installation.
 During installation, align the hole of gear shift arm to the hole of transmission range sensor and fix them
with a proper tool.
 After installation, inspect the gear shift lever position. Adjust the gear shift cable as necessary.
18

18 - QR019CHB CVT
Valve Body Case

Removal
4. Drain the transmission fluid (See page 18-110).
5. Remove the valve body case fixing bolts and remove the
valve body case (1). 
HINT:
When removing the valve body, do not damage the joint
1
surface of the transmission case.
RT21180480
Installation
CAUTION
 Before installation, clear the sealant residues on the joint surface of the transmission case and clean it
up.
 Keep the installation parts clean and avoid foreign matter entering the transmission.
 During installation, apply sealant on the joint surface of the valve body case and transmission evenly.
 After adding fluid, inspect for fluid leakage.
18

18 - QR019CHB CVT
Valve Body
Removal
4. Disconnect the wire harness connector of the
transmission solenoid as shown in the illustration.
RT21180490
5. Use a proper tool to remove the transmission solenoid

wire harness assembly clamp.
RT21180500
6. Remove the transmission range sensor (See page 18-119).

8. Drain the transmission fluid (See page 18-110).
9. Remove the valve body case (See page 18-121).
18

18 - QR019CHB CVT
10.Remove the positioning plate fixing bolt (1).

11. Remove the positioning plate (2). ×19
12.Remove the valve body fixing bolts. 

RT21180510
13.Remove the valve body (1), steel ball (3) and drive lever
(2).
1
2
RT21180520
14.Remove the transmission fluid temperature sensor (1)

from the valve body.
15.Remove the wire harness bracket fixing bolt (2).
16.Remove the solenoid press plate fixing bolts.
2
18
1
RT21180530
17.Take out the solenoid and wire harness assembly.
Installation

18 - QR019CHB CVT
CAUTION
 Before installation, clear the sealant residues on the joint surface of the transmission case and clean it
up.
 Keep the installation parts clean and avoid foreign matter entering the transmission.
 During installation, apply automatic transmission fluid on the O ring of solenoid wire harness assembly.
 During installation, apply sealant on the joint surface of valve body case and transmission evenly.
 After adding fluid, inspect for fluid leakage.
18

18 - QR019CHB CVT
Gear Shift Control Mechanism

Removal
3
R
S
2
RT21180440
5. Remove the auxiliary fascia console assembly (See page 45-9).

6. Disconnect the gear shift control mechanism wire
harness connector (1).
RT21180550
7. Disconnect the transmission gear shift cable (1) from the

gear shift control mechanism (2).
2
1
18
RT21180560
8. Remove the gear shift control mechanism fixing bolts.

9. Take out the gear shift control mechanism (1).
RT21180570

18 - QR019CHB CVT
Installation
CAUTION
 After installation, inspect the gear shift lever for gear shift positions. Adjust the gear shift cable as
necessary (See page 18-21).
18

18 - QR019CHB CVT
Gear Shift Cable

Removal
CAUTION
 When removing and installing the gear shift cable, make sure that the gear shift lever is at "N" position.

3
R
S
2
RT21180440
5. Disconnect the transmission gear shift cable from the gear shift control mechanism (See page 18-125).
7. Remove the connecting nut (3) between the gear shift
cable (1) and arm (2). Disconnect the gear shift cable
from the shift arm. 
2 3
RT21180590 18
8. Remove the gear shift cable flexible shaft clamp.
RT21180600

18 - QR019CHB CVT
9. Remove the gear shift cable dust boot fixing bolts from
the vehicle body. 
RT21180610
10.Take out the gear shift cable.
Installation
CAUTION
necessary (See page 18-21).
18

18 - QR019CHB CVT
TCU
Removal
3. Remove the TCU and ECM connector protective cover.
4. Disconnect the TCU and ECM connector.
RT21180621
5. Remove the TCU mounting bracket.
RT21180620
6. Remove the TCU fixing bolts (arrow). 

18
RT21180630
Installation

18 - QR019CHB CVT
CVT Assembly
Removal
CAUTION
 In the removal and installation of transmission, make sure that the torque converter does not drop from
the transmission.
 Do not scratch or damage the parts in the removal and installation.

4. Drain the automatic transmission fluid (See page 18-110).
7. Remove the battery tray (See page 16-9).
8. Remove the starter (See page 15-64).
9. Remove the engine speed sensor (See page 06-249).
10.Disconnect the primary shaft pressure sensor wire
RT21180640
11. Disconnect the wire harness connectors on the

transmission:
18  Transmission range sensor connector;
 Transmission solenoid wire harness connector;
 Turbine speed sensor wire harness connector;
 Primary shaft speed sensor wire harness connector;
 Remove the transmission ground wire harness fixing
bolt;
RT21180650

18 - QR019CHB CVT
 Secondary shaft pressure sensor wire harness

connector;
RT21180660
 Secondary shaft speed sensor wire harness

connector.
RT21180670
12.Disconnect the connection of the gear shift cable on the transmission (See page 18-127).
13.Remove the transmission fluid coolant hose clamps
(arrow) and detach the hoses.
RT21180680
14.Use engine equalizer to fix the engine assembly.

15.Remove the engine front, rear and left mountings (See page 07-64). 18
16.Remove the bolts connected with the engine at the upper
part of the transmission. 
RT21180690
17.Raise the vehicle with a lifter.

18 - QR019CHB CVT
18.Remove the dust baffle fixing bolts, and take out the dust
baffle. 
RT21180700
19.Turn the crankshaft and turn the connecting bolt of

flywheel and torque converter to the middle section of U
slot to lock the crankshaft bolts. Remove 4 connecting
bolts of the flywheel and torque converter. 
HINT:
The crankshaft should rotate clockwise viewing from the
front of the engine.
RT21180710
20.Remove the axle shaft.

21.Use transmission carrier (1) to support the transmission
(2).
2
RT21180720
22.Remove the transmission and engine front connecting

18 bolt (1).
RT21180730

18 - QR019CHB CVT
23.Remove the transmission and engine connecting bolts

(arrow). 
RT21180740
24.Remove the engine rear mounting.

25.Use a proper tool (1) to separate the transmission (2)
from the engine.
RT21180750
26.Take out the transmission plate.

27.Remove the transmission.
RT21180760
Installation 18
CAUTION
 Turn crankshaft clockwise from the front of engine.

 When installing torque converter, temporarily tighten the bolts and then tighten them to the specified
torque.
 Keep transmission parts clean, and prevent foreign matter from entering into the transmission.
 Add automatic transmission fluid.
necessary.

- MEMO -

CLUTCH
GENERAL INFORMATION 19-3 Clutch Pedal 19-9
Specifications 19-5 Clutch Master Cylinder Assembly 19-10
Tools 19-6 Removal 19-10
Installation 19-11
Clutch Release Cylinder Assembly 19-12
Removal 19-12
Clutch Switch 19-8 Clutch Unit 19-14
Inspection 19-8 Inspection 19-14
Bleeding Hydraulic Clutch 19-16
19

19

19 - CLUTCH
GENERAL INFORMATION
CLUTCH
Description
4
9
8
6
RT21190010
1 - Clutch Switch 2 - Clutch Pedal Assembly

3 - Clutch Master Cylinder with Inlet Hose Assembly 4 - Pipe Assembly I
19
5 - Bracket I 6 - Hose Assembly
7 - Bracket II 8 - Pipe Assembly II
9 - Clutch Release Cylinder Assembly

19 - CLUTCH
×6
19
RT21190020
1 - Flywheel 2 - Clutch Driven Disc

3 - Clutch Pressure Plate 4 - Release Bearing
5 - Release Bearing Clip 6 - Clutch Release Fork
7 - Release Fork Ball Seat 8 - Dust Boot

19 - CLUTCH
Operation
Hydraulic clutch system mainly consists of clutch pedal, clutch master cylinder, clutch release cylinder, clutch
hydraulic line, etc. When depressing clutch pedal, clutch master cylinder generates pressure, and this
pressure is transmitted to integrated release bearing which is fitted with pressure plate diaphragm spring. As
external force is applied, release bearing presses the release finger of diaphragm spring inward until it
reaches the fulcrum. This operation makes pressure plate move backward, thus releasing clamping force
from clutch driven disc.
Clutch master cylinder consists of piston, cylinder block, push rod and hydraulic line. When depressing pedal,
push rod pushes the piston in master cylinder to discharge fluid in hydraulic line into release cylinder.
Specifications

Clutch Pedal Fixing Nut 25 ± 2
Pipe Assembly II Joint 16 ± 2
Clutch Release Cylinder Fixing Bolt 22 ± 2
Clutch Pressure Plate 25 ± 2
Clutch Driven Disc Specifications

Clutch Driven Disc Standard Thickness 7.6 ± 0.2
Minimum Rivet Depth 1.2
19

19 - CLUTCH
Tools
Special Tool
RCH0000018
General Tools
Vernier Caliper
RCH0000019
Digital Multimeter
RCH0000002
19

19 - CLUTCH
DIAGNOSIS & TESTING

HINT:
sequence. Repair or replace the faulty components, or adjust them as necessary.

Engine mounting (loose) 07-64
Clutch driven disc (oily) 19-14
Clutch driven disc (worn) 19-14
Clutch chatters Clutch driven disc torsion spring
19-14
(damaged)
Clutch driven disc (glazed) 19-14
Diaphragm spring (tip is out of alignment) 19-14
Clutch release bearing (worn, dirty or
19-14
damaged)
Clutch is noisy
Clutch driven disc torsion spring
19-14
(damaged)
Clutch slips Clutch driven disc (oily) 19-14
Clutch driven disc (worn) 19-14
Diaphragm spring (damaged) 19-14
Pressure plate (distorted) 19-14
Flywheel (distorted) -
Clutch driven disc (improperly installed) 19-14
Clutch driven disc runout (excessive) 19-14
Clutch does not disengage completely Clutch driven disc lining (broken) 19-14
Clutch driven disc (dirty or burned) 19-14
Clutch driven disc (oily) 19-14
19

19 - CLUTCH
ON-VEHICLE SERVICE
Clutch Switch
Removal
3. Remove the clutch switch.
a. Disconnect the clutch switch connector (1) and
remove the clutch switch (2).
1
2
RT21190060
Inspection
Check for continuity between terminals when clutch switch is
turned on or off.
+ -
Switch Condition Specified Condition 1 2
ON (not pushed) Continuity

OFF (pushed) No continuity
RT21190070
Installation
19

19 - CLUTCH
Clutch Pedal
Removal
3. Remove the clutch switch (See page 19-8).
4. Remove the clutch pedal.
a. Remove the fork retainer (1), pull out the center pin
(2) and disconnect the clutch master cylinder push rod
2
(3) from clutch pedal.
RT21190080
b. Remove 3 nuts (arrow) from clutch.

(Tightening torque for nut: 25 ± 2 N·m)
RT21190090
c. Remove the clutch pedal.
Installation
CAUTION
 Make sure to adjust clutch pedal to standard height before installation. 19

 Be sure to tighten nuts to specified torque.
 Check fluid level in reservoir after installation.

19 - CLUTCH
Clutch Master Cylinder Assembly

Removal
WARNING
 Brake fluid in master cylinder is harmful to your skin, be sure to wear protective gloves before operation.
 Once brake fluid contacts with your skin, wash it off with water immediately.
CAUTION
 Be careful when removing clutch master cylinder from engine compartment. Incorrect operation may
damage the hydraulic line, also cause clutch to separate improperly.
 DO NOT allow brake fluid to spray onto body surface. Brake fluid may damage the painted surfaces. If
any brake fluid is get onto the painted surfaces, wash it off with water immediately.

HINT:
Collect brake fluid with a container.
3. Loosen the elastic clamp and disconnect the master cylinder inlet hose.
4. Remove the clutch master cylinder.
a. Push the locating clip in the direction of arrow, and
pull out the pipe from clutch master cylinder.
RT21190100
19
b. Remove the fork retainer (1) and pull out the center
pin (2).
2
RT21190080

19 - CLUTCH
c. Remove 2 fixing nuts (arrow) from clutch master

cylinder.
RT21190110
Installation
CAUTION
 Add brake fluid to "MAX".

 Perform bleeding procedure for hydraulic clutch and check brake fluid for leakage after installation.
19

19 - CLUTCH
Clutch Release Cylinder Assembly

Removal
WARNING
 Brake fluid in release cylinder is harmful to your skin, be sure to wear protective gloves before operation.
CAUTION
 Collect brake fluid with a container while servicing.

 Make sure fluid level in reservoir is at "MAX" after replacing release cylinder.
 DO NOT allow brake fluid to spray onto body surface, or it will damage the painted surfaces. If any brake
fluid is get onto the painted surfaces, wash it off with water immediately.

HINT:
Collect brake fluid with a container.
3. Remove the clutch release cylinder.
a. Remove the pipe joint and pipe assembly II from
clutch release cylinder.
RT21190150
19 b. Remove the clutch release cylinder fixing bolts (arrow)

and then remove the clutch release cylinder.
RT21190160

19 - CLUTCH
Installation
CAUTION
 Add brake fluid to "MAX".

 Connect pipe joint of pipe assembly II to the clutch release cylinder assembly first, then tighten it after
installation.
 Be sure to align the push rod of clutch release cylinder assembly with hole in transmission case release
fork, and tighten bolts to specified torque.
 Perform bleeding procedure for hydraulic clutch and check system line for leakage after installation.
19

19 - CLUTCH
Clutch Unit
Removal
1. Remove the transmission assembly (See page 17-21).
2. Remove the clutch release bearing (1).
3. Remove the release fork (2) from clutch cover.
1
2
RT21190170
4. Remove the release fork ball seat (1).

5. Remove the release fork dust boot (2).
RT21190180
6. Remove the clutch pressure plate bolts.

7. Remove the clutch pressure plate and clutch driven disc. 1
3
6
5
4
2
RT21190190
19
Inspection
1. Check clutch driven disc.
a. Visually check clutch driven disc for dirt or glazing. Clean or replace clutch driven disc as necessary.
2. Use a vernier caliper to measure the thickness of clutch
driven disc.
Standard thickness: 7.6 ± 0.2 mm
Minimum rivet depth: 1.2 mm
If result is not as specified, replace clutch driven disc.
RT21190200

19 - CLUTCH
3. Check clutch release bearing assembly.

a. Visually check release bearing surface for dirt, glazing or damage. Clean or replace release bearing
assembly as necessary.
b. Check that bearing operates smoothly by rotating the
sliding part of bearing (the side contacting with clutch).
Replace release bearing assembly if necessary.
RT21190210
Installation
1. Insert a special tool into the clutch driven disc, and insert
it into the flywheel.
RT21190220
2. Install the clutch pressure plate and tighten the bolts.

1
3
6
5
4
2
RT21190190
19
3. Install the release fork ball seat (1).
4. Install the dust boot (2).
RT21190180

19 - CLUTCH
5. Install the release fork (2).

6. Install the release bearing (1).
1
2
RT21190170
Bleeding Hydraulic Clutch

WARNING
 Brake fluid is harmful to your skin, be sure to wear protective gloves before operation.
CAUTION
 Collect brake fluid with a container.

 DO NOT allow brake fluid to spray onto body surface. Brake fluid may damage the painted surfaces. If
any brake fluid is get onto the painted surfaces, wash it off with water immediately.
 Only use brake fluid recommended by Chery Automobile Co., Ltd, otherwise the lines may be subjected
to a severe corrosion.
 Brake fluid type should be DOT4.
HINT:
An assistant will be required to assist when bleeding hydraulic clutch.
2. Check the fluid level in brake master cylinder, add DOT4 brake fluid as necessary, and keep the cap open.
CAUTION
19
 Make sure that there is sufficient brake fluid in reservoir before bleeding.

4. Remove the discharge port protective cap and connect a
clear plastic hose to the bleeder screw, and submerge
the end of hose into the clear container which is full of
new brake fluid.
RT21190260

19 - CLUTCH
5. Release the discharge port (arrow).
RT21190270
6. Depress the clutch pedal until brake fluid is drained from discharge port.
7. Depress the clutch pedal and tighten the discharge port.
8. Depress the clutch pedal until there is pressure in the clutch system.
9. Depress the clutch pedal, then release the discharge port and bleed the fluid in brake master cylinder.
10.Repeat steps from 6 to 9 for several times, until there is no air in the hydraulic clutch system any more.
CAUTION
 Never drain brake fluid when bleeding hydraulic clutch.

 Make sure brake level is always at "MAX" during bleeding.
11. Tighten the discharge port, then remove the discharge hose and replace the discharge port dust cover.
12.Check the brake fluid level, add DOT4 brake fluid up to "MAX" as necessary, and then tighten the reservoir
cap.
13.Check clutch pedal stroke. If clutch pedal stroke is excessive, or the condition does not improve, it
indicates that some air is still kept in the system. Bleed the clutch again as necessary.
14.Test the vehicle again and make sure clutch operates normally and depressing feel is good.
19

- MEMO -

DRIVE SHAFT
GENERAL INFORMATION 20-3 Inner Ball Cage 20-8
Description 20-3 Disassembly 20-8
Operation 20-4 Inspection 20-9
Specifications 20-4 Assembly 20-10
Outer Ball Cage 20-11
ON-VEHICLE SERVICE 20-5
Disassembly 20-11
Drive Shaft Assembly 20-5
Inspection 20-12
Removal 20-5
Assembly 20-12
Installation 20-7
20

20

20 - DRIVE SHAFT
GENERAL INFORMATION
DRIVE SHAFT
Description
5
6
7
12
8 13
9
14
10
11
20
RT21200010

20 - DRIVE SHAFT
1 - Nut 2 - Outer Ball Cage

3 - Outer Dust Boot Clamp 4 - Outer Dust Boot
5 - Outer Dust Boot Clamp 6 - Right Drive Shaft
7 - Left Drive Shaft 8 - Inner Dust Boot Clamp
9 - Inner Dust Boot 10 - Inner Dust Boot Clamp
11 - Tripod 12 - Positioning Snap Spring
13 - Inner Ball Cage 14 - Set Ring
Operation
Drive shaft, which is a solid shaft, transmits torque between differential and drive wheels. Generally, the inner
end of drive shaft is connected with drive shaft gear by spline, and the outer end is connected to wheel hub.
The drive shaft transmits torque from differential to wheels, thus rotating the wheels to run vehicle.
Specifications

Drive Shaft Fixing Nut 300 ± 20
Coupling Nut Between Steering Knuckle and Control
180 ± 10
Arm Ball Pin
Coupling Bolt Between Front Left Wheel Speed
10 ± 1
Sensor and Front Left Steering Knuckle Assembly
20

20 - DRIVE SHAFT
ON-VEHICLE SERVICE
Drive Shaft Assembly
Removal
HINT:
 Use the same procedures for the right side and left side.
 Procedures listed below are for the left side.
3. Remove the front wheel (See page 24-9).
4. Drain the transmission oil (See page 17-14).
5. Remove the fixing nut from front axle left drive shaft.
a. Using a nut chisel and a hammer, loosen the staked
part of nut.
RT21220050
CAUTION
 Loosen the staked part of nut completely, otherwise it will damage the thread of drive shaft.
b. While applying brake, remove the drive shaft fixing

nut.
20
RT21220060

20 - DRIVE SHAFT
6. Remove the drive shaft.

a. Disengage the front left wheel speed sensor wire
harness and front left brake hose assembly (arrow)
from front left shock absorber assembly.
RT21230040
b. Remove the coupling bolt (arrow) between front left

wheel speed sensor and front left steering knuckle
assembly, and disengage the front left wheel speed
sensor carefully.
RT21220110
c. Remove the coupling nuts and coupling bolts between

front left steering knuckle and shock absorber.
RT21220150
d. Using a crowbar, pry out the drive shaft.
20
RT21200020

20 - DRIVE SHAFT
e. Remove the set ring.
RT21200030
Installation
CAUTION
 DO NOT damage the constant velocity universal joint dust boot.

 DO NOT use excessive force to pull the drive shaft to prevent the constant velocity universal joint from
dropping.
 Use crowbar carefully to prevent damage to oil seal.
 Adjust the wheel alignment if necessary.
20

20 - DRIVE SHAFT
Inner Ball Cage

Disassembly
HINT:
Use the same disassembly and assembly procedures for left and right drive shaft assemblies.
CAUTION
 DO NOT put matchmarks on the rotating surface of rotary drum.

 Operate carefully to prevent the dust boot from being damaged.
1. Remove the drive shaft assembly (See page 20-5).

2. Remove the inner ball cage dust boot clamp.
a. Using needle nose pliers, remove the inner ball cage
dust boot clamps.
RT21200040
3. Remove the inner ball cage.

a. Separate the dust boot from inner ball cage in the
direction of arrow.
20
RT21200051

20 - DRIVE SHAFT
b. Remove the inner ball cage in the direction of arrow,

and place it on a piece of clean cloth.
RT21200050
4. Remove the tripod.

a. Using snap spring calipers, remove the positioning
snap spring of tripod.
RT21200060
b. Put matchmarks on the tripod and drive shaft, and

remove the tripod.
Matchmark
RT21200070
5. Remove the dust boot.

a. Wrap tape on the spline of drive shaft, and remove the
dust boot.
20
7DSH
RT21200080
Inspection
1. Check if spline of drive shaft is in good condition. If it is deformed or damaged, replace it.
2. Check if dust boot is in good condition. If it is scratched or broken, replace it.
3. Check if positioning snap spring of tripod is deformed. If it is deformed, replace it.

20 - DRIVE SHAFT
Assembly
CAUTION
 Refill grease during assembly.

20

20 - DRIVE SHAFT
Outer Ball Cage

Disassembly
HINT:
Use the same disassembly and assembly procedures for left and right drive shaft assemblies.
1. Remove the drive shaft assembly (See page 20-5).
2. Remove the outer ball cage dust boot outer clamp.
a. Using a screwdriver, pry out the striker of outer ball
cage dust boot outer clamp and remove the outer ball
cage dust boot outer clamp.
RT21200090
3. Remove the outer ball cage dust boot inner clamp.

a. Using a screwdriver, pry out the striker of outer ball
cage dust boot inner clamp and remove the outer ball
cage dust boot inner clamp.
RT21200100
4. Remove the outer ball cage.

a. Slide the outer dust boot (1) carefully into the inner
ball cage side in the direction of arrow.
1
20
RT21200110
b. Put a matchmark (1) on the area with the same height

as drive shaft assembly (2) and edge of outer ball
cage (3) for correct installation. 1 2
RT21200120

20 - DRIVE SHAFT
c. Wrap the drive shaft assembly with a piece of cloth

and put it onto a vise. Secure the vise to prevent the 1
drive shaft assembly from shaking. Tap the outer ball
cage (1) forcibly with a hammer, and remove the outer
ball cage (1).
RT21200130
5. Remove the retaining ring (1).
RT21200140
6. Remove the outer ball cage dust boot.

a. Wrap tape on the spline of drive shaft, and remove the
dust boot.
7DSH
RT21200150
b. Remove the tape.
Inspection
1. Check if spline of drive shaft is in good condition. If it is deformed or damaged, replace it.
20 2. Check if dust boot is in good condition. If it is scratched or broken, replace it.
Assembly
CAUTION
 Refill grease during assembly.

 Install it with new clamps.

DIFFERENTIAL
Description 21-3 Installation 21-7
Operation 21-4 Differential Bearing 21-8
Differential Planetary Gear 21-9
Removal 21-9
Differential Gear Clearance Inspection 21-6
Installation 21-9
ON-VEHICLE SERVICE 21-7 Differential Parts Inspection 21-9
Driven Gear of Final Drive 21-7
21

21

21 - DIFFERENTIAL
GENERAL INFORMATION
DIFFERENTIAL
Description
1
2
3
×8
5
14
6
7
8
10
11
12
13 21
RT21210010

21 - DIFFERENTIAL
1 - Differential Tapered Roller Bearing Outer Race 2 - Differential Tapered Roller Bearing
3 - Driven Gear of Final Drive 4 - Differential Case
5 - Dowel Pin 6 - Speedometer Drive Gear
7 - Differential Tapered Roller Bearing 8 - Differential Tapered Roller Bearing Outer Race
9 - Planetary Gear Washer 10 - Planetary Gear
11 - Planetary Gear Shaft 12 - Drive Shaft Gear
13 - Drive Shaft Gear Washer
The differential case contains 2 drive shaft gears, planetary gear shaft and 2 planetary gears. The driven gear
of final drive is connected together with differential case by bolts. The planetary gear shaft, which is fixed on
differential case, drives the planetary gears to rotate when the differential operates, thus driving the drive shaft
gears to turn. The drive shaft gears are connected with drive shaft to transmit effort to wheels.
Operation
 When driving on a bumpy road or turning, the travel distance of outside wheels is longer than that of inside
wheels, so the speed of outside wheels is faster, which breaks the balance of vehicle drive train.
 The planetary gear mechanism in differential can transmit speed difference between outside and inside
wheels via drive shaft when turning. It forces the planetary gears to rotate, thus allowing the inside and
outside wheels to spin at two different speeds in order to balance the speed difference and keep the
vehicle moving smoothly.
 The final drive is a component to reduce the rotation speed and increase the torque of drive train.
Specifications

Final Drive Driven Gear Bolt 111 - 118
Clearance Specification
Description Acceptable Range (mm)

Clearance Between Differential Case and Planetary
0.025 - 0.150
Gear
21

21 - DIFFERENTIAL
Tools
Special Tools
Bearing Remover
RCH0000011
Punch
RCH0000015
General Tools
Hydraulic Press
RCH0000012
20
10
30
0
40
90
50
80

60
70
RCH0000023
21

21 - DIFFERENTIAL
DIAGNOSIS & TESTING

Differential Gear Clearance Inspection
Inspection Method
1. Remove the differential.
2. Check the clearance of differential drive shaft gear (2)
with the dial indicator (1).
1
2 RT21210020
Gear clearance: 0.025 - 0.150 mm
CAUTION
 If the clearance is not as specified, replace and adjust the drive shaft gear washer.
 After replacing the drive shaft gear washer, measure and adjust the clearance again to ensure that it is
as specified.
21

21 - DIFFERENTIAL
ON-VEHICLE SERVICE
Driven Gear of Final Drive
Removal
1. Remove the differential (See page 17-22).
2. Hold the differential in a vise.
3. Remove the final drive driven gear bolts.
RT21210030
Installation
CAUTION
 Apply seal gum to the bolts during installation.
21

21 - DIFFERENTIAL
Differential Bearing
Removal
2. Remove the differential bearing.
a. Using a hydraulic press (1), separate the bearing (2)
from the differential.
1
2
RT21210040
Installation
1. Install the differential bearing (1).
RT21210050
21

21 - DIFFERENTIAL
Differential Planetary Gear

Removal
2. Remove the differential planetary gear.
a. Tap out the dowel pin (2) with a punch (1).
1
RA19200060
b. Remove the planetary gear shaft (1), planetary gear

(2) and drive shaft gear (3).
1
3
2
RT21210070
Installation
CAUTION
 Adjust clearance until the gear clearances of both sides are the same during installation.
 The drive shaft gears and planetary gears should operate normally after tapping in the dowel pin.
Differential Parts Inspection

1. Clean all the components.
2. Check the following components for wear: 21
 Driven gear of final drive
 Planetary gear washer
 Drive shaft gear
 Planetary gear
 Planetary gear shaft
 Drive shaft gear washer

- MEMO -

AXLE
GENERAL INFORMATION 22-3 Installation 22-13
Description 22-3 Side Rail Welding Assembly 22-14
Front Sub Frame Welding Assembly 22-17
Removal 22-17
Installation 22-18
ON-VEHICLE SERVICE 22-9 Rear Hub Bearing Unit 22-19
Front Hub Assembly 22-9 Removal 22-19
Installation 22-11 Rear Sub Frame Assembly 22-20
Front Steering Knuckle 22-12 Removal 22-20
22

22

22 - AXLE
GENERAL INFORMATION
AXLE
Description
Front Axle
×2
×2
1
2
3
×2
13 4
14
×2
12
×2 5
×2
×2 ×2 7
8
6
11
10 ×2
9
×2
×2
RT21220010
22
1 - Front Right Connecting Rod Assembly 2 - Front Stabilizer Bar
3 - Front Stabilizer Bar Retainer 4 - Front Stabilizer Bar Rubber Bushing
5 - Front Left Connecting Rod Assembly 6 - Front Left Control Arm Assembly
7 - Front Control Arm Ball Pin Assembly Locking Nut 8 - Front control Arm Ball Pin Lock Pin
9 - Front Left Control Arm Ball Pin Assembly 10 - Front Rubber Bushing Assembly
11 - Side Rail Welding Assembly 12 - Front Sub Frame Welding Assembly
13 - Front Right Control Arm Assembly 14 - Front Right Control Arm Ball Pin Assembly

22 - AXLE
Rear Axle
9
6
×2
3
×2
×2
10 7
8
×2
11
4
12 13
14
RT21220020
1 - Rear Suspension Upper Right Swing Arm 2 - Rear Sub Frame Welding Assembly
Assembly
3 - Rear Suspension Upper Left Swing Arm 4 - Rear Left Connecting Rod Assembly
Assembly
5 - Rear Suspension Lower Left Swing Arm 6 - Rear Stabilizer Bar
Assembly
22 7 - Rear Stabilizer Bar Rubber Bushing 8 - Rear Stabilizer Bar Retainer
9 - Rear Right Connecting Rod Assembly 10 - Rear Suspension Lower Right Swing Arm
Assembly
11 - Rear Right Trailing Arm Assembly 12 - Rubber Bushing Assembly
13 - Rubber Cushion 14 - Rear Left Trailing Arm Assembly
Axles are connected to the integral body through suspension, and wheels are installed on both ends. The
function is to transmit the force in all directions between integral body and wheels.

22 - AXLE
Specifications

Front Drive Shaft Assembly Locking Nut 300 ± 20
Coupling Bolt Between Front Hub Assembly and
70 - 75
Front Steering Knuckle Assembly
Coupling Bolt Between Front Wheel Speed Sensor
10 ± 1
and Front Steering Knuckle Assembly
Locking Nut Between Steering Tie Rod Assembly
47 ± 3
120 ± 12
180 ± 10
180 ± 10
Coupling Bolt Between Engine Lower Protector
10 ± 1
70 ± 5
70 ± 5
70 ± 5
70 ± 5
80 ± 6
and Body
70 ± 5
and Front Mounting Cushion Assembly
70 ± 5
70 ± 5
Coupling Bolt Between Front Stabilizer Bar and Front
20 ± 3
22
Sub Frame Welding Assembly
120 ± 10
180 ± 10
180 ± 10

22 - AXLE

Coupling Nut Between Rear Hub Bearing Unit and
68 ± 5
Rear Brake Bottom Board Assembly
Assembly
Assembly
Assembly
Assembly
Coupling Bolt Between Rear Sub Frame Assembly
120 ± 10
and Body
Coupling Nut Between Rear Sub Frame Assembly
120 ± 10
and Body
Tools
Special Tool
Ball Pin Separator
RCH0000024
22

22 - AXLE
General Tools
20
10
30
0
40
90
50
80
60
70
RCH0000023
RCH0000005
Hydraulic Press
RCH0000012
Bearing Remover
RCH0000011
Engine Equalizer
22
RCH0000026

22 - AXLE
DIAGNOSIS & TESTING

HINT:

Tire (worn or improperly inflated) 24-7
Front wheel alignment (wrong) 23-50
Rear wheel alignment (wrong) 23-52
Pulls Front hub bearing (loose or worn) 22-9
Rear hub bearing (loose or worn) 22-19
Steering gear (misaligned or damaged) 29-23
Suspension component (worn) 23-12
Wheel (imbalanced) 24-10
Front shock absorber assembly (stuck or
23-12
damaged)
Front wheel shimmy Front wheel alignment (wrong) 23-50
Control arm assembly ball pin (stuck or
23-22
damaged)
Front hub bearing (loose or worn) 22-9
Wheel (imbalanced) 24-10
Rear shock absorber assembly (stuck or
Rear wheel shimmy 23-29
damaged)
Rear hub bearing (loose or worn) 22-19
Rear wheel alignment (wrong) 23-52
22

22 - AXLE
ON-VEHICLE SERVICE
Front Hub Assembly
Removal
WARNING

 Check if safety lock of lifter is locked when repairing chassis parts.
 It is not permitted to weld or modify bearing parts of wheel suspension and guide parts of wheel.
 When removing chassis parts, replace the self-locking nuts and rusted nuts for safety.
HINT:
2. Remove the front drive shaft assembly locking nut.
a. Using a nut chisel and a hammer, loosen the staked
part of nut.
RT21220050
CAUTION
 Loosen staked part of nut completely, otherwise it will damage the thread of drive shaft assembly.
b. Remove the front drive shaft assembly locking nut

(arrow) while applying the brakes securely.
22
RT21220060

22 - AXLE
3. Remove the front left brake caliper assembly (See page 26-28).
CAUTION
 Place front brake caliper assembly to a proper position after removal. Be careful not to extend front brake
hose excessively.
4. Remove the front left brake disc (See page 26-28).

5. Remove the front left hub assembly.
a. Remove 4 coupling bolts (arrow) between front left hub
assembly and front left steering knuckle assembly.
RT21220070
b. Remove the front left mudguard (arrow) and front left

hub assembly (1).
RT21220080
6. Remove the front left hub bearing.

a. Place front left hub assembly on a hydraulic press,
install bearing remover and adapter, and press out the
front left hub with hydraulic press.
22 RT21220090

22 - AXLE
b. Remove the front left hub bearing.
RT21220100
Installation
CAUTION
 Always tighten coupling bolts and nut to the specified torque.

 Check that hub assembly turns freely without sticking after installation.
22

22 - AXLE
Front Steering Knuckle

Removal
CAUTION

HINT:
2. Remove the front drive shaft assembly locking nut (See page 22-9).
3. Remove the front left brake caliper assembly (See page 26-28).
CAUTION
 Place front brake caliper assembly to a proper position after removal. Be careful not to extend front brake
hose excessively.
4. Remove the front left brake disc (See page 26-28).

5. Remove the front left hub assembly (See page 22-9).
6. Remove the front left mudguard (See page 22-9).
7. Remove the front left steering knuckle assembly.
a. Remove the coupling bolt (arrow) between front left
RT21220110
b. Remove the locking nut (arrow) between left steering

22 tie rod assembly ball pin and front left steering knuckle
assembly.
RT21220120

22 - AXLE
c. Install the ball pin separator (1), and tighten the ball
pin separator bolt with a wrench (2) to separate the
steering tie rod ball pin from the steering knuckle
assembly.
1 RT21220130
d. Remove the lock pin (arrow) and coupling nut (1)

between front left control arm assembly ball pin and
front left steering knuckle assembly.
RT21220140
e. Remove 2 coupling bolts and nuts (arrow) between

front left shock absorber assembly and front left
steering knuckle assembly.
RT21220150
f. Detach the left drive shaft and remove the front left steering knuckle assembly.
Installation
CAUTION
 Always tighten coupling bolts and nuts to the specified torque.

 Check and adjust front wheel alignment after installation.
22

22 - AXLE
Side Rail Welding Assembly

Removal
WARNING

 When removing side rail welding assembly, an engine equalizer needs to be used to support engine and
transmission assembly securely to prevent them from being damaged.
1. Remove the side rail welding assembly.

a. Using an engine equalizer, support the engine and transmission assembly securely.
b. Remove 2 coupling bolts (arrow) between engine
lower left protector assembly and side rail welding
assembly.
RT21220160
c. Remove 2 coupling bolts (arrow) between engine

lower right protector assembly and side rail welding
assembly.
RT21220170
d. Remove the coupling bolt and nut (arrow) between

rear mounting cushion assembly and rear mounting
bracket.
RT21220180

22 - AXLE
e. Remove the coupling bolt and nut (arrow) between

front mounting cushion assembly and front mounting
bracket.
RT21220190
f. Remove 2 coupling bolts (arrow) between side rail

welding assembly and body.
RT21220200
g. Remove 2 coupling bolts (arrow) between side rail

welding assembly and front mounting cushion
assembly.
RT21220210
h. Remove 2 coupling bolts and a nut (arrow) between

side rail welding assembly and rear mounting cushion
assembly.
RT21220220 22
i. Remove the side rail welding assembly.

22 - AXLE
Installation
CAUTION
22

22 - AXLE

Removal
WARNING

 When removing front sub frame welding assembly, an engine equalizer needs to be used to support
engine and transmission assembly securely to prevent them from being damaged.

2. Remove the front control arm assembly (See page 23-20).
3. Remove the front sub frame welding assembly.
a. Using an engine equalizer, support the engine and transmission assembly securely. Use the same
procedure to remove the right side.
b. Remove 2 coupling bolts (arrow) between front left
stabilizer bar and front sub frame welding assembly.
RT21220230
c. Remove 2 coupling bolts and a nut (arrow) between

assembly.
RT21220220
d. Remove 2 coupling bolts (arrow) between front sub

22
frame welding assembly and steering gear assembly.
RT21220240

22 - AXLE
e. Remove 2 coupling bolts (arrow) between upper part

of front sub frame welding assembly and body.
RT21220250
f. Remove 2 coupling bolts (arrow) between rear part of

front sub frame welding assembly and body.
RT21220260
g. Support the front sub frame welding assembly with a

transmission carrier and carefully remove it.
RT21220270
Installation
CAUTION
 Always tighten coupling bolts and nut to the specified torque.

 Check and adjust front wheel alignment after installation.
22

22 - AXLE
Rear Hub Bearing Unit

Removal
HINT:
1. Remove the rear left wheel (See page 24-9).
2. Remove the rear left brake caliper assembly (See page 26-41).
3. Remove the rear left brake disc (See page 26-41).
4. Remove the rear left hub bearing unit.
a. Remove the coupling bolt (arrow) between rear left
wheel speed sensor and rear left hub bearing unit,
and disengage the rear left wheel speed sensor.
RT21220300
b. Remove 4 coupling nuts (arrow) between rear left hub

bearing unit and rear left brake bottom board
assembly.
RT21220310
c. Slightly wiggle the rear left hub bearing unit and pull it
out.
RT21220320
22
Installation
CAUTION
 Always tighten coupling nuts to the specified torque.

 Make sure rear axle hub rotates smoothly and freely after installation.

22 - AXLE
Rear Sub Frame Assembly

Removal
WARNING

1. Remove the rear wheel (See page 24-9).

2. Remove the center exhaust pipe assembly (See page 11-15).
3. Remove the rear sub frame assembly.
a. Remove the coupling bolts and nuts (arrow) between
rear suspension upper left swing arm assembly and
rear sub frame assembly. Use the same procedure to
remove the right side. 
RT21220330
b. Remove the coupling bolt and nut (arrow) between

rear suspension lower left swing arm assembly and
rear sub frame assembly. Use the same procedure to
remove the right side. 
RT21220340
c. Remove 2 coupling bolts and 2 coupling nuts (arrow)

between rear sub frame assembly and body.
22
RT21220350
d. Remove the rear sub frame assembly.

22 - AXLE
Installation
CAUTION
 Always tighten the coupling bolts and nuts to the specified torque.
 Check and adjust the rear wheel alignment after installation.
22

- MEMO -

SUSPENSION
GENERAL INFORMATION 23-3 Rear Coil Spring 23-34
Rear Suspension Upper Swing 
DIAGNOSIS & TESTING 23-10 Arm Assembly 23-37
Problem Symptoms Table 23-10 Removal 23-37
Front Shock Absorber Assembly 23-12 Rear Suspension Lower Swing 
Arm Assembly 23-38
Removal 23-38
Removal 23-13
Disassembly 23-15 Installation 23-39
Rear Trailing Arm Assembly 23-40
Inspection 23-18
Removal 23-40
Assembly 23-18
Rear Stabilizer Bar Assembly 23-43
Disposal 23-19
Removal 23-43
Front Control Arm Assembly 23-20
Inspection 23-44
Removal 23-20
Installation 23-44
Installation 23-21
Rear Stabilizer Link Assembly 23-45
Front Control Arm Ball Pin Assembly 23-22
Removal 23-45
Removal 23-22
Inspection 23-45
Inspection 23-23
Installation 23-46
Installation 23-23
Front Stabilizer Bar Assembly 23-24 WHEEL ALIGNMENT 23-47
Removal 23-24 Description 23-47
Inspection 23-26 Specifications 23-47
Installation 23-26 Problem Symptoms Table 23-48
Front Stabilizer Link Assembly 23-27 Inspection before Wheel Alignment 23-48
Removal 23-27 Front Wheel Toe-in 23-49
Installation 23-28 Adjustment 23-50
Rear Shock Absorber Assembly 23-29 Front Wheel Camber, Kingpin 
Removal 23-30 Caster & Kingpin Inclination 23-51
Inspection 23-32 Rear Wheel Camber 23-52
Installation 23-32 Adjustment 23-52
Disposal 23-33 Rear Wheel Toe-in 23-53
Adjustment 23-53
23

23

23 - SUSPENSION
GENERAL INFORMATION
SUSPENSION
Description
Front Suspension
×2
×2
1
2
3
4
×2
15
16
5
×2
14 6
×2
×2
×2 ×2 9
8 7
11
13
12 ×2
10
×2
×2
RT21230010
23

23 - SUSPENSION
1 - Front Right Link Assembly 2 - Front Stabilizer Bar

3 - Front Stabilizer Clamp 4 - Front Stabilizer Bar Rubber Support
5 - Front Shock Absorber Assembly 6 - Front Left Link Assembly
7 - Front Steering Knuckle 8 - Front Control Arm Ball Pin Assembly Lock Pin
9 - Front Control Arm Ball Pin Assembly Lock Nut 10 - Front Left Control Arm Ball Pin Assembly
11 - Front Left Control Arm Assembly 12 - Bush Rubber
13 - Side Rail Welding Assembly 14 - Front Sub Frame Welding Assembly
15 - Front Right Control Arm Assembly 16 - Front Right Control Arm Ball Pin Assembly
This model uses Macpherson independent suspension for front suspension, whose height is non-adjustable.
It is equipped with cylindrical coil spring, double action telescopic shock absorber and lateral stabilizer. Front
suspension has driving and steering functions. The upper end of suspension is connected to body, and the
lower end is connected to front steering knuckle. Sub frame is connected to body with bolts, thus improving
driving stability and safety.
23

23 - SUSPENSION
Rear Suspension
20
2
9
6
×2
3
×2
×2
10 7
8
×2
11
4
15
5
16
12 13
19
17
14
18
RT21230020
1 - Rear Suspension Upper Right Swing Arm 2 - Rear Sub Frame Assembly
Assembly
3 - Rear Suspension Upper Left Swing Arm 4 - Rear Left Stabilizer Link Assembly
Assembly
5 - Rear Suspension Lower Left Swing Arm 6 - Rear Stabilizer Bar
Assembly
7 - Rear Stabilizer Bar Rubber Support 8 - Rear Stabilizer Clamp
9 - Rear Right Stabilizer Link Assembly 10 - Rear Suspension Lower Right Swing Arm 23
Assembly
11 - Rear Right Trailing Arm Assembly 12 - Bush Rubber
13 - Rubber Washer 14 - Rear Left Trailing Arm Assembly
15 - Rear Rubber Cushion Assembly 16 - Rear Buffer Block Assembly
17 - Rear Coil Spring Upper Cushion 18 - Rear Coil Spring
19 - Rear Left Shock Absorber Assembly 20 - Rear Right Shock Absorber Assembly

23 - SUSPENSION
This model uses trailing arm type independent suspension for rear suspension, whose height is non-adjustable.
It is equipped with cylindrical coil spring, double action telescopic shock absorber and lateral stabilizer. This
suspension features easy-removal and quick-installation, and driving stability and ride comfort have greatly
improved.
Specifications

Coupling Nut Between Front Stabilizer Link
45 ± 5
Assembly and Front Shock Absorber Assembly
180 ± 10
180 ± 10
60 ± 6
Assembly and Body
Front Shock Absorber Assembly Locking Nut 82 ± 5
120 ± 12
Coupling Bolt Between Front Part of Front Control
Assembly
Coupling Bolt Between Rear Part of Front Control
Assembly
Coupling Nut Between Front Control Arm Ball Pin
150 ± 10
Coupling Bolt Between Front Control Arm Ball Pin
150 ± 10
Coupling Nut Between Front Stabilizer Bar Assembly
45 ± 5
and Front Stabilizer Link Assembly
70 ± 5
70 ± 5
120 ± 10
180 ± 10
23 Frame Welding Assembly and Body

23 - SUSPENSION

180 ± 10
Coupling Bolt Between Front Stabilizer Bar
25 ± 3
Assembly and Front Sub Frame Welding Assembly
Coupling Bolt Between Lower Part of Rear Shock
45 ± 5
Absorber Assembly and Rear Trailing Arm Assembly
Coupling Nut Between Upper Part of Rear Shock
45 ± 5
Absorber Assembly and Body
45 ± 5
and Rear Suspension Lower Swing Arm Assembly
Coupling Bolt Between Rear Shock Absorber
Assembly
Assembly
Assembly
Assembly
Assembly
Coupling Bolt Between Rear Rubber Cushion
25 ± 5
Assembly and Body
Assembly
Assembly
Assembly
Assembly
23

23 - SUSPENSION

Coupling Bolt Between Rear Wheel Speed Sensor
23 ± 2
Fixing Bracket and Rear Trailing Arm Assembly
Coupling Bolt Between Parking Brake Cable Fixing
23 ± 2
23 ± 2
Coupling Bolt Between Rear Trailing Arm Assembly
120 ± 10
Coupling Nut Between Rear Trailing Arm Assembly
120 ± 10
45 ± 5
and Rear Stabilizer Bar Assembly
Rear Brake Line Fixing Plug 16 ± 2
Coupling Bolt Between Rear Stabilizer Bar Assembly
25 ± 3
and Body
Steering Wheel Locking Nut 35 ± 5
23

23 - SUSPENSION
Tools
Special Tool
Spring Compressor
RCH0000021
General Tools
RCH0000005
Engine Equalizer
RCH0000026
23

23 - SUSPENSION
DIAGNOSIS & TESTING

HINT:
Front Suspension

Front tire (worn or improperly inflated) 24-7
Front wheel alignment (incorrect) 23-50
Control arm ball pin assembly (loose) 23-22
Vehicle pulls Steering tie rod (loose or worn) 29-21
Front hub bearing (excessively worn) 22-9
Front suspension components (excessively
23-12
worn or deformed)
Vehicle (overloaded) -
Front coil spring (too soft) 23-15
Front shock absorber assembly (worn or
Droop 23-12
damaged)
Front suspension components (excessively
23-12
worn or deformed)
Front stabilizer bar assembly (bent or
23-24
Sways/pitches broken)
23-12
damaged)
Front wheel (out of balance) 24-7
23-12
damaged)
Wheel shimmy
Control arm ball pin assembly (loose) 23-22
Front hub bearing (excessively worn) 22-9
23
Front tire (improperly inflated) 24-7
Abnormal tire wear Front shock absorber assembly (worn or

23-12
deformed)
Front suspension components (worn or
23-12
deformed)

23 - SUSPENSION
Rear Suspension

Rear tire (worn or improperly inflated) 24-7
Rear wheel alignment (incorrect) 23-52
Vehicle pulls Rear hub bearing (excessively worn) 22-19
Rear suspension components (worn or
23-29
deformed)
Vehicle (overloaded) -
Rear coil spring (too soft) 23-34
Droop Rear shock absorber assembly (worn or

23-29
damaged)
Rear suspension components (excessively
23-29
worn or deformed)
Rear stabilizer bar (bent or broken) 23-43
Sways/pitches
Rear shock absorber assembly (worn or
23-29
deformed)
Rear wheel (out of balance) 24-10
Rear shock absorber assembly (worn or
Wheel shimmy 23-29
damaged)
Rear hub bearing (worn) 22-19
Rear tire (improperly inflated) 24-7
Abnormal tire wear Rear shock absorber assembly (worn or

23-29
deformed)
Rear suspension components (worn or
23-29
deformed)
23

23 - SUSPENSION
ON-VEHICLE SERVICE
Front Shock Absorber Assembly
9
3
5 10
11
7
RT21230030
23
1 - Front Shock Absorber Upper Cover 2 - Locking Nut
3 - Front Shock Absorber Cushion 4 - Connecting Bracket Assembly
5 - Bearing Washer 6 - Front Spring Upper Tray
7 - Dust Boot 8 - Front Buffer Block
9 - Front Coil Spring 10 - Front Spring Lower Cushion
11 - Front Shock Absorber Assembly Strut

23 - SUSPENSION
1. Check the front shock absorber assembly.
a. Park vehicle on level ground, and bounce the vehicle up and down, then check if vehicle shakes up and
down when body bounds. If vehicle shakes up and down consecutively, shock absorber assembly may
be damaged and should be replaced.
2. Check the front shock absorber assembly for leakage.
a. As shock absorber assembly operates frequently while driving vehicle, shock absorber fluid
temperature rises and oil gas is formed and adheres to dust boot. This is a normal phenomenon, and it
is not necessary to replace the shock absorber assembly.
b. Shock absorber is designed with a thin layer of oil film on surface of piston rod. While the shock
absorber is being compressed, the oil film will be scraped off by dust plate on shock absorber oil seal
and a small amount of oil will remain on the upper part of oil seal. Due to high oil permeability, oil
deposited on the upper part of oil seal spreads slowly from the upper part of shock absorber to lower
part of shock absorber, thus forming a thin coat of oil film. When any of following conditions occurs:
- Oil film is between dust boot and spring seat;
- Oil traces in circumferential direction are even.
- For above conditions, oil traces are formed through volatilization, so we can judge it as minor leaks.
This is a normal phenomenon, and it is not necessary to replace the shock absorber assembly.
c. If following conditions occur:
- Oil traces in circumferential direction are uneven;
- Oil traces reach lower connecting positions.
- Above conditions indicate that there may be leakage in shock absorber assembly, and it is
necessary to replace the shock absorber assembly.
d. If it is difficult to accurately judge shock absorber assembly for leakage from appearance. Perform road
test after wiping off oil on the surface of malfunctioning shock absorber. Under normal road conditions,
drive vehicle for 5 to 10 minutes and perform inspection. If there are oil traces at the shock absorber
assembly surface, it indicates oil leakage, and it is necessary to replace the shock absorber assembly.
Removal
WARNING

 Make sure that safety lock of lifter has been locked when removing and installing chassis parts.
 It is not permitted to weld or modify suspension bearing parts and guide parts.
 When removing and installing chassis parts, replace self-locking nuts and rusted nuts for safety.
 Operate carefully when removing and installing coil spring, preventing spring from jumping out and
causing personal injury.
HINT:
23
2. Remove the front left shock absorber assembly.

23 - SUSPENSION
a. Remove the coupling nut (arrow) between front left

stabilizer link assembly and front left shock absorber
assembly.
RT21230031
b. Disengage the front left wheel speed sensor wire

harness and front left brake hose assembly (arrow)
from the front left shock absorber assembly.
RT21230040
c. Remove 2 coupling bolts and nuts (arrow) between

front left shock absorber assembly and front left
steering knuckle assembly.
RT21230050
d. Remove 3 coupling nuts (arrow) between front left

shock absorber assembly and body.
RT21230060
23 e. Remove the front left shock absorber assembly with front coil spring.

23 - SUSPENSION
Disassembly
HINT:
1. Remove the front shock absorber cushion.
a. Remove the front cushion (arrow) from front left shock
absorber assembly.
RT21230070
2. Remove the front shock absorber upper cover.

a. Remove the front shock absorber upper cover (arrow)
RT21230080
3. Remove the locking nut from front shock absorber assembly.

a. Install the spring compressor (1), and tighten the end
lever of spring compressor with a wrench (2) to
compress the front coil spring. 1
RT21230090
WARNING
 When removing front coil spring, compress spring until locking nut can be rotated. DO NOT compress 23
the coil spring more than necessary, avoid damaging the spring and personal injury.

23 - SUSPENSION
b. Hold the end of front left shock absorber assembly

lever with an inner hexagon wrench, and then remove
the locking nut (arrow) from front left shock absorber
assembly with a fixing wrench.
RT21230100
4. Remove the connecting bracket assembly.

a. Remove the connecting bracket assembly (arrow)
from upper part of front left shock absorber assembly.
RT21230110
5. Remove the bearing washer.

a. Remove the bearing washer (arrow) from upper part
of front left shock absorber assembly.
RT21230120
6. Remove the front spring upper tray.

a. Remove the front spring upper tray (arrow) from upper
part of front left shock absorber assembly.
23
RT21230130

23 - SUSPENSION
7. Remove the dust boot.

a. Remove the dust boot (arrow) from upper part of front
left shock absorber assembly.
RT21230140
8. Remove the front coil spring.

a. Remove the front left coil spring (1) with spring
compressor (arrow) from front left shock absorber 1
assembly.
RT21230150
b. Slowly loosen the spring compressor, and carefully remove the front left coil spring.
9. Remove the front buffer block.
a. Detach and remove the front buffer block (arrow) from
front left shock absorber assembly.
RT21230160
10.Remove the front spring lower cushion.

a. Detach the front spring lower cushion (arrow) from
positioning hole at the lower end of front left shock
absorber assembly strut and remove it.
23
RT21230170

23 - SUSPENSION
Inspection
1. Check front shock absorber assembly.
Manual inspection:
a. Install the locking nut (1) to the upper end of front
shock absorber assembly strut, and then install the 2
T-wrench (2) or equivalent. 1
b. Compress and extend the front shock absorber

assembly strut several times by hands in the direction
of arrow as shown in the illustration. Check that there
is no abnormal resistance or unusual sound during
operation. If there is any abnormality, replace the front
shock absorber assembly with a new one.
RT21230180
2. Check the other components of front shock absorber assembly.

a. Check front shock absorber upper cover, front shock absorber cushion, bearing washer, dust boot, front
buffer block and front spring lower cushion for cracks, wear or deformation. Replace as necessary.
b. Check connecting bracket assembly and front spring upper tray for damage. Replace as necessary.
c. Check front coil spring for wear, cracks or deformation. Replace as necessary.
Assembly
CAUTION
 Make sure to align protrusion of front spring lower cushion and positioning hole at the lower end of front
shock absorber assembly strut during installation.
Installation
CAUTION

 Check wheel alignment after installation is completed. Adjust the wheel alignment to standard range as
necessary.
23

23 - SUSPENSION
Disposal
WARNING
 Shock absorber assembly contains nitrogen and oil, which are under negative pressure. Before handling,
be sure to wear goggles and release pressure inside the shock absorber assembly to avoid personal
injury.
1. Disposal of the front shock absorber assembly.

a. Extend the front shock absorber assembly strut fully, and clamp it in a vise at an angle.
b. Using a drill or equivalent, make a hole slowly at area
A shown in the illustration to discharge the gas in the
front shock absorber assembly.
RT21230190
CAUTION
 Gas discharged from shock absorber is colorless and harmless. Be careful when drilling, because metal
chips may fly out.
c. Handle the front shock absorber assembly properly after discharging the gas.
 Recycle disposed front shock absorber assembly according to local environmental regulations.
23

23 - SUSPENSION
Front Control Arm Assembly

Removal
CAUTION

HINT:
2. Remove the front left control arm assembly.
a. Remove the locking pin (arrow) and coupling nut (1)
front left steering knuckle.
RT21220140
CAUTION
 If it is difficult to remove control arm ball pin end from steering knuckle, disengage the ball pin by striking
the end of steering knuckle uniformly and slightly with a hammer or equivalent.
b. Remove the coupling bolt (arrow) between front part

of front left control arm assembly and front sub frame
23
RT21230200

23 - SUSPENSION
c. Remove the coupling bolt (arrow) between rear part of

front left control arm assembly and front sub frame
RT21230210
d. Remove the front left control arm assembly with ball pin.
Installation
CAUTION

 Make sure that ball pin rotates smoothly and is not stuck after installation.
necessary.
23

23 - SUSPENSION
Front Control Arm Ball Pin Assembly

Removal
CAUTION

HINT:
2. Remove the front left control arm ball pin assembly.
a. Remove the locking pin (arrow) and coupling nut (1)
front left steering knuckle.
RT21220140
CAUTION
 If it is difficult to remove control arm ball pin end from steering knuckle, disengage the ball pin by striking
the end of steering knuckle uniformly and slightly with a hammer or equivalent.
b. Remove 2 coupling nuts (arrow) between front left

control arm ball pin assembly and front left control arm
assembly.
23
RT21230220

23 - SUSPENSION
c. Remove the coupling bolt (arrow) between front left

control arm ball pin assembly and front left control arm
assembly.
RT21230230
d. Remove the front left control arm ball pin assembly.
Inspection
1. Check control arm ball pin assembly.
a. Check control arm assembly ball pin boot for wear, cracks, deformation, damage or grease leakage.
Replace as necessary.
b. Check if control arm assembly ball pin rotates smoothly. Replace as necessary.
Installation
CAUTION

 Make sure that ball pin rotates smoothly and is not stuck after installation.
necessary.
23

23 - SUSPENSION
Front Stabilizer Bar Assembly

Removal
CAUTION

 It is not permitted to weld or modify suspension bearing parts.
 When lowering front sub frame welding assembly, it needs to support engine and transmission assembly
securely with a engine equalizer to avoid damage.

2. Remove the precatalytic converter assembly (See page 11-10).
3. Remove the front control arm assembly (See page 23-20).
4. Remove the front stabilizer bar assembly.
a. Support the engine and transmission assembly securely with a engine equalizer.
b. Hold the lower end of front link assembly with an inner
hexagon wrench, remove the coupling nut (arrow)
between front stabilizer bar and front link assembly
with a fixing wrench and disengage the front link
assembly.
RT21230240
c. Remove 2 coupling bolts and nut (arrow) between

assembly.
RT21220220
d. Remove 2 coupling bolts (arrow) between front sub

23 frame welding assembly and steering gear assembly.
RT21220240

23 - SUSPENSION
e. Remove 2 coupling bolts (arrow) between upper part

of front sub frame welding assembly and body.
RT21220250
f. Remove 2 coupling bolts (arrow) between rear part of

front sub frame welding assembly and body.
RT21220260
g. Support the front sub frame welding assembly with

front stabilizer bar assembly with a transmission
carrier, and lower it carefully.
RT21220270
h. Remove the coupling bolts (arrow) between front

stabilizer bar assembly and front sub frame welding
assembly, and separate them.
RT21230235
23

23 - SUSPENSION
i. Detach the left and right fixing clamps (arrow) from

front stabilizer bar assembly.
RT21230250
j. Detach the left and right rubber supports (arrow) from

front stabilizer bar assembly.
RT21230260
Inspection
1. Check front stabilizer bar assembly.
a. Check front stabilizer bar assembly fixing clamps for wear, cracks, deformation or damage. Replace as
necessary.
b. Check front stabilizer bar assembly rubber supports for dirt, wear, cracks, deformation or damage.
Installation
CAUTION
23

23 - SUSPENSION
Front Stabilizer Link Assembly

SUSPENSION
Removal
CAUTION

HINT:
2. Remove the front left stabilizer link assembly.
a. Hold the lower end of front left stabilizer link assembly
with an inner hexagon wrench, and remove the
coupling nut (arrow) between front left stabilizer bar
assembly and front left stabilizer link assembly with a
fixing wrench.
RT21230240
b. Hold the upper end of front left stabilizer link assembly

with an inner hexagon wrench, and remove the
coupling nut (arrow) between front left stabilizer link
assembly and front left shock absorber assembly with
a fixing wrench.
RT21230031
c. Remove the front left stabilizer link assembly.
Inspection
1. Check front stabilizer link assembly. 23
a. Check front stabilizer link assembly bushes for wear, cracks, deformation, damage or grease leakage.
b. Check if the end of front stabilizer link assembly rotates smoothly. Replace as necessary.

23 - SUSPENSION
Installation
CAUTION
 Be sure to tighten coupling nuts to specified torque.

 Make sure that the end of front stabilizer link assembly rotates smoothly and is not stuck after installation.
23

23 - SUSPENSION
Rear Shock Absorber Assembly
RT21230270
1 - Rear Shock Absorber Assembly Fixing Nut 2 - Rear Shock Absorber Insulator Shim
3 - Rear Shock Absorber Upper Insulator 4 - Rear Shock Absorber Insulator Sleeve 23
5 - Rear Shock Absorber Lower Insulator 6 - Rear Shock Absorber Assembly

23 - SUSPENSION
Removal
CAUTION

HINT:
1. Remove the rear left shock absorber assembly.
a. Remove the coupling bolt and washer (arrow)
between lower part of rear left shock absorber
assembly and rear left trailing arm Assembly.
RT21230280
b. Lift up the rear floor carpet, remove the rear left shock
absorber assembly service hole cover.
RT21230290
c. Remove the coupling nut (arrow) between upper part

of rear left shock absorber assembly and body.
23
RT21230300

23 - SUSPENSION
d. Remove the rear left shock absorber insulator shim

(arrow).
RT21230310
e. Remove the rear left shock absorber upper insulator

(arrow).
RT21230320
f. Remove the rear left shock absorber insulator sleeve

(arrow).
RT21230330
g. Remove the rear left shock absorber lower insulator

(arrow).
RT21230340
23

23 - SUSPENSION
Inspection
1. Check rear shock absorber assembly.
Manual inspection:
a. Install the nut (1) to the upper end of rear shock absorber assembly strut, and then install the T-wrench
(2) or equivalent.
b. Compress and extend the rear shock absorber
assembly strut several times by hands in the direction
of arrow as shown in the illustration. Check that there 2
1
is no abnormal resistance or unusual sound during
operation. If there is any abnormality, replace the rear
shock absorber assembly with a new one.
RT21230350
2. Check the other components of rear shock absorber assembly.

a. Check rear shock absorber upper insulator and lower insulator for cracks, wear or deformation.
b. Check rear shock absorber insulator shim, rear shock absorber insulator sleeve for damage. Replace
as necessary.
Installation
CAUTION

 Bounce vehicle up and down several times to stabilize rear suspension after installation.
23

23 - SUSPENSION
Disposal
1. Disposal of the rear shock absorber assembly.
a. Extend the rear shock absorber assembly strut fully.
b. Using a drill, make a hole between A and B in the strut
as shown in the illustration to discharge the gas inside
the rear shock absorber assembly.
A B
RT21230360
CAUTION
 Be careful when drilling, because metal chips may fly about. Always perform operations with proper
safety equipment to avoid personal injury.
 The gas is colorless, odorless and nonpoisonous.
c. After discharging the gas inside the rear shock absorber assembly, handle the rear shock absorber
assembly properly.
 Recycle disposed rear shock absorber assembly according to local environmental regulations.
23

23 - SUSPENSION
Rear Coil Spring

Removal
CAUTION

HINT:
2. Remove the rear left coil spring.
a. Support the rear left suspension with a transmission carrier securely.
b. Remove the coupling nut (arrow) between lower part
of rear left stabilizer link assembly and rear
suspension lower left swing arm assembly.
RT21230370
c. Remove 2 coupling bolts (arrow) between rear left

shock absorber assembly fixing bracket and rear left
trailing arm assembly.
RT21230380

lower part of rear suspension lower left swing arm
23 assembly and rear left trailing arm assembly.
RT21230390

23 - SUSPENSION

lower part of rear suspension upper left swing arm
assembly and rear left trailing arm assembly.
RT21230400
f. Lower the transmission carrier slowly to the

appropriate height and take off the rear coil spring
(arrow) and rear spring upper cushion (1) carefully.
RT21230410
g. Detach the rear buffer block (arrow) from the body.
RT21230420
h. Remove the fixing bolt (arrow) and detach the rear

rubber cushion assembly (1) from body.
RT21230430
23

23 - SUSPENSION
Inspection
1. Check rear coil spring assembly.
a. Check rear coil spring for wear, cracks and permanent deformation due to excessive use. Replace as
necessary.
b. Check rear coil spring upper cushion, rear cushion and rear rubber cushion assembly for dirt, wear,
cracks, deformation or damage. Replace as necessary.
Installation
CAUTION

 After installation is completed, lower vehicle and bounce it up and down several times to stabilize the
suspension.
23

23 - SUSPENSION
Rear Suspension Upper Swing Arm Assembly

Removal
CAUTION

HINT:
2. Remove the rear suspension upper left swing arm assembly.
a. Remove the coupling bolt and nut (arrow) between
RT21230400

upper part of rear suspension upper left swing arm
assembly and rear sub frame assembly.
RT21220330
c. Remove the rear suspension upper left swing arm assembly.
Installation
Installation is in the reverse order of removal. 23
CAUTION

23 - SUSPENSION
Rear Suspension Lower Swing Arm Assembly

Removal
CAUTION

 When removing and installing chassis parts, replace self-locking nuts and the rusted nuts for safety.
HINT:
2. Remove the rear suspension lower left swing arm assembly.
a. Remove the coupling nut (arrow) between lower part
RT21230370
b. Remove 2 coupling bolts (arrow) between rear left

RT21230380
c. Remove the coupling bolt and nut (arrow) between

23
RT21230390

23 - SUSPENSION

upper part of rear suspension upper left swing arm
assembly and rear sub frame assembly.
RT21220340
e. Remove the rear suspension lower left swing arm assembly.
Installation
CAUTION

 Check and adjust wheel alignment after installation.
23

23 - SUSPENSION
Rear Trailing Arm Assembly

Removal
CAUTION

HINT:
4. Remove the rear left axle hub bearing unit (See page 22-19).
5. Remove the rear left trailing arm assembly.
a. Remove 2 coupling bolts (arrow) between rear left
RT21230380

RT21230390
23

23 - SUSPENSION
c. Remove the coupling bolt and nut (arrow) between

RT21230400
d. Remove 2 coupling bolts (arrow) between rear left

wheel speed sensor fixing bracket and rear left trailing
arm assembly.
RT21230440
e. Remove the coupling bolt (arrow) between parking

brake cable fixing bracket and rear left trailing arm
assembly.
RT21230450
f. Remove the coupling bolt (arrow) between rear left

brake line fixing bracket and rear left trailing arm
assembly.
RT21230460
23

23 - SUSPENSION
g. Remove the coupling bolt and nut (arrow) between

front part of rear left trailing arm assembly and
RT21230470
h. Remove the rear left trailing arm assembly.
Installation
CAUTION

 Check and adjust wheel alignment after installation.
23

23 - SUSPENSION
Rear Stabilizer Bar Assembly

Removal
CAUTION

1. Remove the rear stabilizer bar assembly.

a. Remove the coupling nut (arrow) between upper part
of rear left stabilizer link assembly and rear stabilizer
bar assembly. Use the same removal procedure for
the right side.
RT21230480
b. Remove the fixing clamp (arrow) from rear left brake

line and disconnect the brake pipe fixing plug (1). Use
the same removal procedure for the right side.
RT21230490
CAUTION
 DO NOT bend or damage brake tube.

 DO NOT allow any foreign matter such as dirt and dust to enter brake tube from the connecting parts.
 After removing brake line, take seal measures to prevent foreign matter from entering.
23

23 - SUSPENSION
c. Remove 2 coupling bolts (arrow) between left side of

rear stabilizer bar assembly and body. Use the same
removal procedure for the right side.
RT21230500
d. Remove the rear stabilizer bar fixing clamp (1), rear

stabilizer bar rubber support (2) and rear stabilizer bar
assembly (3).
3
RT21230510
Inspection
1. Check rear stabilizer bar assembly.
a. Check rear stabilizer bar assembly fixing clamps for wear, cracks, deformation or damage. Replace as
necessary.
b. Check rear stabilizer bar assembly rubber supports for dirt, wear, cracks, deformation or damage.
Installation
CAUTION
23

23 - SUSPENSION
Rear Stabilizer Link Assembly

Removal
CAUTION

HINT:
2. Remove the rear left stabilizer link assembly.
a. Remove the coupling nut (arrow) between lower part
RT21230370
b. Remove the coupling nut (arrow) between upper part

of rear left stabilizer link assembly and rear stabilizer
bar assembly.
RT21230480
c. Remove the rear left stabilizer link assembly.
Inspection
1. Check rear stabilizer link assembly. 23
a. Check rear stabilizer link assembly bushes for wear, cracks, deformation, damage or grease leakage.
b. Check if the end of rear stabilizer link assembly rotates smoothly. Replace as necessary.

23 - SUSPENSION
Installation
CAUTION
 Be sure to tighten coupling nuts to specified torque.

 Make sure that the end of rear stabilizer link assembly rotates smoothly and is not stuck after installation.
23

23 - SUSPENSION
WHEEL ALIGNMENT
Description
CAUTION
 Be sure to perform wheel alignment procedure according to operating instructions of four-wheel

alignment device.
 Periodic maintenance and service for four-wheel alignment device should be performed.
In general, the wheel alignment has following 6 parameters:

1. Check front wheel camber
2. Check front wheel toe-in
3. Check kingpin caster
4. Check kingpin inclination
5. Check rear wheel camber
6. Check rear wheel toe-in
If following components have been removed, installed or replaced, check and perform wheel alignment
procedures:
 Front control arm assembly
 Front control arm ball pin assembly
 Front steering knuckle
 Front shock absorber assembly
 Steering gear and steering tie rod
 Drive shaft
 Front sub frame welding assembly
 Rear suspension lower swing arm assembly
 Rear sub frame assembly
 Rear trailing arm assembly
Specifications
Specifications (parameters standard for four-wheel alignment)
Item Specified Value

Front Wheel Camber -10′ ± 45′
Front Front Wheel Toe-in 5′ ± 5′

Wheel Kingpin Inclination 11°30′ ± 60′
Kingpin Caster 2°50′ ± 60′ 23
Rear Rear Wheel Camber -12′ ± 30′
Wheel Rear Wheel Toe-in 10′ ± 10′
Sideways Sliding ≤ 3 m/km

23 - SUSPENSION

HINT:

Vehicle pulls
Wheel shimmy
Abnormal tire wear Front wheel alignment (incorrect) 23-50
Inspection before Wheel Alignment

1. Vehicle is in unloaded state.
2. Use a lifter to support and raise vehicle to proper height.
3. Check hub bearing for excessive clearance, and replace hub bearing as necessary.
4. Check suspension components, steering tie rod and ball pin for wear, deformation or damage. Replace the
malfunctioning part as necessary.
5. Check if shock absorber assembly operates normally.
6. Check if tire pressure is within the specified range and adjust it to specified pressure as necessary.
Standard Inflation Pressure of Cold Tire (kPa)
Item Front Wheel Rear Wheel Spare Tire

Tire (Unloaded) 230 230 250
7. Check the rim and tire.

a. Visually check rim and tire for scratches, wear or damage.
b. Perform wheel dynamic balance procedures (See page 24-10).
23

23 - SUSPENSION
Front Wheel Toe-in

Incorrect front wheel toe-in will cause wheel pull and abnormal tire wear. Check and adjust front wheel toe-in
as necessary.
Adjust the length of steering tie rod to the specified valve if front wheel toe-in is not within the tolerance due to
other reasons.
Specified Value for Front Wheel Toe-in

Front Wheel Toe-in 5′ ± 5′
Inspection
1. Perform inspection with four-wheel alignment device (perform inspection procedures referring to operating
instructions for four-wheel alignment device).
2. Manual check:
a. Park vehicle on level ground, check if front tire pressure is within the specified range and adjust it to
specified value as necessary.
b. Place marks on the center position in front of front
wheels, and measure distance A between marks with
a tape measure. B
c. Push vehicle to rotate wheels 180°, and measure
distance B between marks with tape measure when
the marks are turned to the rear of wheels.
d. Calculation method: front wheel toe-in = A - B ≤ 1 mm
A
RT21230520
23

23 - SUSPENSION
Adjustment
1. Make adjusting preparation for wheel alignment according to the requirement of tester.
2. Loosen the steering tie rod locking nut (1) and elastic
jacket snap ring (2), and turn the tie rod to adjust length
according to the requirement until front wheel toe-in
reaches the specified value.
2
1
RT21230530
3. Tighten the steering tie rod locking nut, reinstall the elastic jacket snap ring. Check if locking nut is
tightened in place and if jacket position is correct.
CAUTION
 If elasticity of elastic jacket snap ring is not enough, replace it.
4. After adjusting front wheel toe-in, check the steering wheel for eccentricity. If necessary, loosen the
steering wheel locking nut and adjust the steering wheel to horizontal position, and then tighten the
steering wheel locking nut to the specified torque.
23

23 - SUSPENSION
Front Wheel Camber, Kingpin Caster & Kingpin Inclination

1. Front wheel camber, kingpin caster and kingpin inclination can only be checked by using four-wheel
alignment device.
2. Front wheel camber, kingpin caster and kingpin inclination are assured by design structure and cannot be
adjusted. If measured value is not within the specified range, check if other components that connect to
steering knuckle are deformed or damaged. Also, check if connected part of steering knuckle is deformed
or damaged. If it is, replace the corresponding components.

Front Wheel Camber -10′ ± 45′
Kingpin Caster 2°50′ ± 60′
Kingpin Inclination 11°30′ ± 60′
23

23 - SUSPENSION
Rear Wheel Camber

Incorrect rear wheel camber will cause wheel pull and abnormal tire wear. Check and adjust rear wheel
camber as necessary.
If rear wheel camber is not within the tolerance due to other reasons, adjust the eccentric adjusting sleeve and
eccentric adjusting nut of coupling bolt between rear suspension lower swing arm assembly and rear sub
frame assembly to the specified valve.
If rear wheel camber is not as specified, check if rear suspension and wheels are damaged or deformed.
Replace the damaged or deformed components as necessary.

Rear Wheel Camber -12′ ± 30′
Adjustment
2. Loosen the coupling bolt (arrow) between rear
suspension lower swing arm assembly and rear sub
frame assembly, be careful that eccentric adjusting
sleeve and eccentric adjusting nut do not detach from
groove.
RT21220340
3. Rotate the eccentric adjusting sleeve and eccentric adjusting nut to adjust rear wheel camber to the
specified valve.
4. Tighten the coupling bolt between rear suspension lower swing arm assembly and rear sub frame
assembly to specified torque (adjusting method of left and right wheels is the same).
23

23 - SUSPENSION
Rear Wheel Toe-in

Incorrect rear wheel toe-in will cause wheel pull and abnormal tire wear. Check and adjust rear wheel toe-in
as necessary.
If rear wheel toe-in is not within the tolerance due to other reasons, adjust the eccentric adjusting sleeve and
eccentric adjusting nut of coupling bolt between rear trailing arm assembly and fixing bracket assembly to the
specified valve.
If rear wheel toe-in is not as specified, check if rear suspension and wheels are damaged or deformed.
Replace the damaged or deformed components as necessary.

Rear Wheel Toe-in 10′ ± 10′
Adjustment
2. Loosen the coupling bolts (arrow) between rear trailing
arm assembly and fixing bracket assembly, be careful
that eccentric adjusting sleeve and eccentric adjusting
nut do not detach from groove.
RT21230470
3. Rotate the eccentric adjusting sleeve and eccentric adjusting nut to adjust rear wheel toe-in to the
specified valve.
4. Tighten the coupling bolt between rear trailing arm assembly and fixing bracket assembly to the specified
torque (adjusting method of left and right wheels is the same).
23

- MEMO -

TIRE AND WHEEL
Precautions 24-3 Tire Replacement 24-7
Tire Identification 24-3 Wheel 24-9
Installation 24-9
Wheel Balance 24-10
Adjustment 24-10
Inspection 24-5
Tire Rotation 24-11
Description 24-11
Rotation Method 24-11
24

24

24 - TIRE AND WHEEL
GENERAL INFORMATION
TIRE AND WHEEL
Precautions
 Use tires only with the standard specification and type, because they have excellent reliability and skid
resistance. Non-standard tire may lead to vehicle malfunction, causing accident or even serious injury and
death.
 Contact surface of rim and tire should be cleaned before installing a new tire.
 When installing the wheel bolts, firstly, pre-tighten the bolts by hand, and then tighten them to the specified
torque with a torque wrench.
 Do not apply grease to the wheel bolts.
 Some bad driving habits will shorten the life of tire:
- Rapid acceleration
- Depress brake pedal suddenly and firmly
- High-speed driving
- Turn at excessive speed
- Striking curbs or other obstacles
- Tire pressure is too high or too low when driving vehicle
Tire Identification
 Letter and number code of tire type, size, load index and
speed level are stamped on the side wall of tire as shown
225/65 R17 102H
in the illustration. 225/65
R1
71
02
RT21240010
24

24 - TIRE AND WHEEL
Specifications

Tire Type
Tire Type 225/65 R17 102H
Rim Type
Rim Type 17 × 7 J
Tire Pressure Specifications of Cold Tire
Description Pressure (kPa)

Front Tire (Unloaded) 230
Rear Tire (Unloaded) 230
Spare Tire 250
24

24 - TIRE AND WHEEL
DIAGNOSIS & TESTING

HINT:

Wear on one side of tire Wheel alignment (wrong) 23-47
Wear on both sides of tire Tire pressure (insufficient) 24-4
Tire center wear Tire pressure (excessive) 24-4
Serrated wear Wheel alignment (wrong) 23-47
Severe wear of some area of tire Brake (too hard) -
Scratches on side wall of tire Sharp objects on road (scratched) 24-5
Tire pressure (incorrect) 24-4
Excessive tire noise
Tire (worn) 24-5
Inspection
CAUTION
 Be sure to refer to the instruction when installing non-standard tires and rims.
 Use tires only with the standard specification and type.
1. Check if tires are damaged or scratched as shown in the

illustration.
2. Check if rims are damaged or scratched as shown in the
illustration.
RT21240020
24

24 - TIRE AND WHEEL
3. Check if tires are worn abnormally as shown in the

illustration.
Wear on Both Sides Center Wear
Serrated Wear Wear on One Side

RT21240030
4. Check the tread wear indicators (arrow) as shown in the

illustration. When tires are worn to the indicating mark,
replace them.
RT21240040
5. Use tire pressure gauge to check if pressures of all tires (including spare tire) are normal. Inflate tires to
specified tire pressure as necessary.
6. Check the air cock for leakage.
24

24 - TIRE AND WHEEL
ON-VEHICLE SERVICE
Tire Replacement
WARNING
 Speed level of new replaced tire must meet the specified values for safe operation; otherwise the tire
may blow out.
1. Remove the wheel (See page 24-9).

2. Use a tire remover to remove the tires according to the instructions.
CAUTION
 Before installing air cock, check if air cock hole of wheel is smooth without any burrs, and apply glycerin
to air cock rubber surface or soak air cock in glycerin fluid, and then using a tool to pull or press locating
ring of air cock with force to pass it through the coke hole and install it into place (it is possible to use
soapy water instead of glycerin).
 Apply glycerin or soapy water around tire before assembling the tires.
 When there is "dark point" mark on rim, align static balance "light point" testing mark or dynamic balance
"light point" testing mark on tire with the "dark point" of rim.
 When there is no "dark point" mark on rim, align static balance testing mark or dynamic balance "light
point" testing mark on tire with the air cock.
3. The white dot on tire edge must be aligned with the air
cock on rim when installing the tires, as shown in the
illustration.
RT21240050
4. Adjust tire pressure to the specified value.
CAUTION
 Be sure to inflate tires as specified air pressure. The maximum air pressure cannot exceed 10% of rated
air pressure during inflating the tire.
 Replace using specified standard tire with the same size and type.
24

24 - TIRE AND WHEEL
5. Check the contact surfaces among air cock, tire and rim for leakage.
6. Using a dynamic balancer, adjust the wheel balance (See page 24-10).
7. Install the wheel (See page 24-9).
CAUTION
 Avoid scratching tires and rims when removing tires.

 Contact surface between tire and rim should be cleaned when installing tires.
24

24 - TIRE AND WHEEL
Wheel
Removal
1. Remove the wheel.
a. Stop the vehicle at a level ground and apply parking brake.
b. Using a tire wrench, loosen the wheel mounting bolts.
c. Firmly support and raise vehicle to a proper height.
d. Using a tire wrench, remove 5 wheel mounting bolts.
RT21240060
e. Remove the wheel.
Installation
1. Install the wheel.
a. Anticorrosion treatment is conducted on the contact surface between wheel and brake disc.
b. Install the wheel and pre-tighten the wheel mounting bolts by hand.
c. Using a torque wrench, tighten the wheel mounting
bolts evenly to the specified torque in the order shown
in the illustration.
1
3 4
5
2
RT21240070
CAUTION
 DO NOT attempt to repair wheels by striking, heating or welding.

 Replace wheel mounting bolts with the special wheel mounting bolts, rather than those with different
specifications or inferior quality.
 Be careful not to damage coating on wheel.
 To avoid damage to tire or over/under tightening the wheel mounting bolts, never use an impact wrench.
 DO NOT apply grease to wheel mounting bolts.
 To ensure wheel mounting bolts are tightened in place, wheel mounting nuts should be tightened after
24
driving 100 km at the first time.

24 - TIRE AND WHEEL
Wheel Balance
Adjustment
CAUTION
 Dynamic balancer must be calibrated before adjusting wheel balance.

 Remove impurities inside the tread pattern and original balance blocks to ensure wheel balance.
1. Remove the wheel (See page 24-9).

2. Adjust tire pressure to the specified value.
3. Install the wheel to balancer with balance block removed. Install the balance shaft with mounting surface of
wheel facing inward, choose a suitable taper body, and firmly lock the wheels using a locking device (align
the taper body with center hole, otherwise data may be incorrect).
4. Turn on power source of balancer, and input parameters such as the measured distance from rim to
balancer, rim width and rim diameter.
5. Put down the wheel protector, and proceed to balance test procedure automatically (start button should be
pushed for some balancers). When the measurement is completed, unbalanced weight for both sides of
tire will be displayed on the balancer automatically, and the wheel automatically brakes until it stops. Do
not open the protector before stopping. Failure to do this may lead to accident.
6. According to the measurement result, corresponding
balance blocks should be installed on the outside (1) and
inside (2) of rim edge as shown in the illustration.
2
RT21240080
7. Perform the test again after assembly is completed, until the balancer displays 0.
8. After dynamic balance is completed, remove the wheel.
CAUTION
 When installing balance blocks, the final assembly unbalanced degree should be less than 200 g·cm,
which means clamp type balance block of inside rim is 8 g and paste type balance blocks of outside rim
is 10 g.
24  DO NOT tap balance blocks forcibly when installing them in order to prevent balance blocks from
deforming.
 DO NOT reuse deformed balance blocks, replace as necessary.

24 - TIRE AND WHEEL
Tire Rotation
Description
Front and rear tires operate at different loads and perform different steering, driving and braking functions. For
these reasons, different wear rate is formed, causing irregular wear patterns. These effects can be reduced by
rotating the tires at regular time.
Advantages of tire rotation:
 Improving tread life
 Maintaining traction levels
 Maintaining smooth and quiet driveability
CAUTION
 Chery recommends you rotate your tires every 10000 km. However, the best suitable time for tire rotation
differs depending on driver's driving habits and road conditions.
Rotation Method
Perform tire rotation as shown in the illustration.
Front
RT21240090
24

- MEMO -

GENERAL INFORMATION 25-3 C0034-12 25-36
Description 25-3 C0034-13 25-36
Operation 25-4 C0034-29 25-36
Specifications 25-9 C0037-00 25-42
Tools 25-10 C0037-09 25-42
Circuit Diagram 25-11 C0037-11 25-42
C0037-12 25-42
C0037-13 25-42
C0037-29 25-42
Diagnosis Procedure 25-14
C003A-00 25-49
Problem Repair (No DTC) 25-16
C003A-09 25-49
DTC Confirmation Procedure 25-16
C003A-11 25-49
C003A-12 25-49
C003A-13 25-49
ABS Control Module Assembly 
C003A-29 25-49
Terminal List 25-18
C006B-00 25-56
Diagnostic Trouble Code (DTC) Chart 25-19
C1000-16 25-62
C0010-04 25-21
C1000-17 25-62
C0011-04 25-21
C1001-04 25-66
C0014-04 25-21
C1009-00 25-66
C0015-04 25-21
C0018-04 25-21 ON-VEHICLE SERVICE 25-70
C0019-04 25-21 ABS Bleeding 25-70
C001C-04 25-21 ABS Control Module Assembly 25-71
C001D-04 25-21 Removal 25-71
C1003-04 25-21 Disassembly 25-72
C1004-00 25-21 Assembly 25-73
C0020-04 25-26 Installation 25-73
C0031-00 25-30 Front Wheel Speed Sensor 25-74
C0031-09 25-30 Removal 25-74
C0031-11 25-30 Inspection 25-75
C0031-12 25-30 Installation 25-75
C0031-13 25-30 Rear Wheel Speed Sensor 25-76
C0031-29 25-30 Removal 25-76
C0034-00 25-36 Inspection 25-77
C0034-09 25-36 Installation 25-77
C0034-11 25-36
25

25

25 - BRAKE CONTROL SYSTEM
GENERAL INFORMATION
Description
3
5
RT21250010
1 - ABS Control Module Assembly 2 - Rear Right Wheel Speed Sensor

3 - Rear Left Wheel Speed Sensor 4 - Front Left Wheel Speed Sensor
5 - Front Right Wheel Speed Sensor
The brake control system equipped on this vehicle is ABS (Anti-lock Brake System) + EBD (Electronic Brake
Force Distribution). It mainly consists of the following components:
 ABS control module assembly (hydraulic control module and electronic control module)
 Wheel speed sensors (each wheel has one sensor)
The primary purpose of ABS is to prevent wheels from being locked during sudden braking. It has the
following effects: 25
1. Improve vehicle driving stability.
2. Improve vehicle steering ability.
3. Maintain optimal brake pressure.

4. Shorten brake distance effectively.
Operation
ABS Braking
1. If ABS system detects that the wheels may be locked when applying brake, the brake system will enter
ABS braking mode. During braking, ABS control module outputs signal from each wheel speed sensor to
each solenoid valve after analysis in order to adjust the fluid pressure in each line, to prevent the wheels
from being locked.
2. There are some operating symptoms of ABS that seem to be abnormal at first, but in fact they are normal.
The symptoms are as follows:
a. If the electronic control module is malfunctioning, fail-safe function will be activated, ABS system will
not operate and ABS warning light will come on.
b. After vehicle is power on or engine is started, short "buzz" sound can be heard, which is the ABS 
self-check sound, and this is normal.
c. Noise caused by the corresponding solenoid valve movement when EBD is involved in braking can be
heard, but this is normal.
d. Brake pedal may vibrate slightly and mechanical noise can be heard during ABS operation, but this is
normal.
e. Braking distance may be longer than that of vehicles without ABS when braking on rough, sandy, or
snow-covered roads.
ABS Control Mode
MC1 MC2
NO NO EME NO
NO
NC NC NC NC
FL RR RL FR
LPA LPA
RT21250020
25

Description Definition Description Definition

MC1 Brake Master Cylinder Circuit 1 LPA Low Pressure Accumulator
MC2 Brake Master Cylinder Circuit 2 FL Front Left Wheel
EME Return Pump RR Rear Right Wheel
NO Normal Open (Solenoid Valve) RL Rear Left Wheel
NC Normal Close (Solenoid Valve) FR Front Right Wheel
1. General Brake Operating Condition

For vehicles equipped with ABS, if brake pressure applied to wheels is not enough to lock the wheels, the
oil pressure generated by master cylinder will be transmitted to the wheel cylinder through normal open
valve, producing regular braking effect. When it is not necessary to continue braking, and if the driver
reduces the pressure to brake pedal, the brake fluid of each wheel returns to master cylinder and the brake
pressure decreases.
Solenoid Valve Powered Condition Solenoid Valve Condition

Normal Open Valve OFF OPEN
Normal Close Valve OFF CLOSE
MC1 MC2
NO NO NO NO
EME
NC NC NC NC
FL RR RL FR
LPA LPA
RT21250030
25

2. ABS Operating (Relief) Condition

For vehicles equipped with ABS, if brake pressure is applied excessively, the friction coefficient between
wheels and road will decrease, and the wheels will be decelerated earlier than vehicle, which could cause
the wheels to lock first. In this case, the ABS control module transmits command that reduces the wheel
pressure to hydraulic control module. In other words, the normal open valve cuts off oil passage and the oil
passage of normal close valve is open, in order to reduce the wheel cylinder pressure. At this time, the
brake fluid drained from wheel cylinder is temporarily stored in the low pressure accumulator. Then, the
brake fluid stored in low pressure accumulator returns to the master cylinder with the rotation of motor.

Normal Open Valve ON CLOSE
Normal Close Valve ON OPEN
MC1 MC2
NO NO NO NO
EME
NC NC NC NC
FL RR RL FR
LPA LPA
RT21250040
25

3. ABS Operating (Maintaining) Condition

When appropriate pressure is applied to the wheel cylinder, ABS system enters maintaining pressure
state. In other words, the normal open valve cuts off oil passage and the normal close valve also cuts off
the oil passage, the wheel cylinder pressure is maintained.

Normal Open Valve ON CLOSE
MC1 MC2
NO NO NO NO
EME
NC NC NC NC
FL RR RL FR
LPA LPA
RT21250050
25

4. ABS Operating (Boost) Condition

When ABS operates under relief pressure condition, if brake fluid is drained excessively or friction
coefficient between wheel and road surface increases, it needs to increase each wheel pressure. In this
case, the ABS control module transmits command that increases wheel pressure to the hydraulic control
module. In other words, the normal open valve opens oil passage and the normal close valve cuts off oil
passage, in order to increase the wheel cylinder pressure. Brake fluid stored in the low pressure
accumulator is supplied to each wheel cylinder through the master cylinder and normal open valve.

Normal Open Valve OFF OPEN
MC1 MC2
NO NO NO NO
EME
NC NC NC NC
FL RR RL FR
LPA LPA
RT21250060
ABS system operates circularly under relief, maintaining and boost pressure conditions until vehicle is
completely stopped, so the vehicle braking and steering performance will be guaranteed.
25

Specifications

Brake Pipe Coupling Plug 16 ± 2
23 ± 2
Fixing Bolt
23 ± 2
Fixing Nut
ABS Control Module Assembly Bottom Mounting Nut 8±2
Front Wheel Speed Sensor Fixing Bolt 10 ± 1
Rear Wheel Speed Sensor Fixing Bolt 10 ± 1
25

Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002
25

Circuit Diagram
Brake Control System (Page 1 of 3)
IGNITION SWITCH
BATTERY
ON OR START
ENGINE INSTRUMENT
COMPARTMENT PANEL
MF01 EF47 EF36 EF34 FUSE AND RF35 RF09 FUSE AND
40A 25A 10A 20A RELAY BOX 10A 7.5A RELAY BOX
I-007
E-074
B-060
I1 A10 E-076 F18 9
L
I-006
17
GR B-003
L
A
B
RL
R
TO CAN
SYSTEM
OB
O
1 25 28 26 14
CAN H1 CAN L1
ABS
CONTROL
MODULE
E-085
A1 A2 A3 A4 A5 I2 I1 10 9 8 7 6 5 4 3 2 1
F1 F2 F3 F4 F5 F6 F7
F11 F12 F13 F14 22 21 20 19 18 17 16 15 14 13 12 11
F8 F9 F10 F15 F16 F17 F18 A6 A7 A8 A9 A10
E-074
Gr I-006
E-076 W
B-060
Gr
W
1 2 3 4 5 6 7 8 9 10 11 12
12 11 10 9 8 7 6 5 4 3 2
25
13 1 13 14 15 16 17 18 19 20 21 22 23 24
24 23 22 21 20 19 18 17 16 15 14 27 25 26
87
38 37 36 35 34 33 32 31 30 29 28 27 26 25
85 86 86 86
87 30 87 30
30 85 85
E-085
B I-007
B ET21250010

GR
L 2 1
BRAKE STOP BRAKE

SWITCH LAMP SWITCH
SWITCH B-052
DEP-
RESSED RELEASED
4 3
GW
RB
13 14 B-054
E-029
GW
GW
RB
RB
RB
E-042
23 25 7 6
Br
ECM TCU B
E-033 E-030
30 13 38
ABS
CONTROL
MODULE
E-085
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 2 1
4 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
B-052
Lg
E-030
B
13 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 38 25
37 36 35 34 33 32 31 30 29 28 27 26
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 E-085
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11
25 12 13 14 15 16 17 18 19 20 21 22
B-054
E-033 W
B ET21250020

PSE
CONNECTION
I-029
J107
LW
I-034
3 E-027
L
2
ABS
CONTROL
MODULE
E-085
8 19 4 16 18 31 29 17
GW
WY
GR
GY
VB
Br
R
E-029
9 20 2 1 B-054
GW
GR
VB
2 1 2 1 1 2 1 2
FRONT LEFT FRONT RIGHT REAR LEFT REAR RIGHT

WHEEL SPEED WHEEL SPEED WHEEL SPEED WHEEL SPEED
SENSOR SENSOR SENSOR SENSOR
E-060 E-036 B-029 B-009
13 12 11 10 9 8 7 6 5 4 3 2 1
1 2 1 2
24 23 22 21 20 19 18 17 16 15 14 J108 J107 J106 J105 J104 J103 J102 J101
38 37 36 35 34 33 32 31 30 29 28 27 26 25 J116 J115 J114 J113 J112 J111 J110 J109
E-060 E-036 I-029

E-085 Gr
B B
B
8 7 6 5 4 3 2 1
2 1 2 1 11 10 9 8 7 6 5 4 3 2 1 15 14 13 12 11 10 9
B-009 B-029
22 21 20 19 18 17 16 15 14 13 12
I-034 25
B B E-029 W
W
ET21250030

DIAGNOSIS & TESTING

HINT:

ABS fuse 51-34
When turning ignition switch ON, ABS Wire harness or connector -

warning light does not come on ABS control module assembly 25-71
ABS fuse 51-34
ABS warning light remains on
ABS control module assembly 25-71
Wheel speed sensor (damaged, improper
25-74, 25-76
installed, foreign matter attached)
Hub ring gear (damaged, improper
-
installed, foreign matter attached)
ABS operation is abnormal
Brake line (blocked or leaked) -
ABS fuse 51-34
Communication with diagnostic tester Wire harness or connector -

cannot be performed X-431 3G diagnostic tester -
Diagnosis Procedure
HINT:
Use the following procedures to troubleshoot the Anti-lock Brake System (ABS).
NEXT

25
NEXT

3 Customer problem analysis
NEXT
4 Check and clear DTCs
NEXT
Confirm and duplicate malfunction: accelerate vehicle to 15 km/h or more, simulate

5 malfunction conditions and read DTCs again
DTC
occurs
No 
DTC
NEXT
NEXT
NEXT
9 Conduct test and confirm malfunction has repaired
NEXT
10 End
25

Problem Repair (No DTC)

If there is a problem in brake system, but no DTC is stored in ABS control module assembly, this problem is
called a problem without DTC. A problem without DTC is caused by basic brake system malfunction. For
example:
1. Brake fluid leakage (it may result in weak braking, brake pedal overtravel, or even ineffective braking).
2. Using inferior brake fluid (it can result in corrosion of brake line and ABS hydraulic regulating module
internal elements, or even ineffective braking).
3. Air in brake line (it may result in weak braking, or even ineffective braking).
4. Brake line blockage (it may result in hard braking, or even ineffective braking).
5. Excessive wear of brake disc (it may result in weak braking, brake pedal overtravel).
6. Brake booster malfunction (it may result in weak or hard braking, brake pedal overtravel, or even
ineffective braking).
7. Wrong brake line connection (it may result in braking performance decreasing, drift, long braking distance
etc.).
HINT:
 ABS interrupted due to no power supply or power supply abnormality will cause the ABS warning light
remains on without storing DTC.
 Troubleshooting method: check corresponding component according to the malfunction, repair or replace
as necessary.

 Using X-431 3G diagnostic tester to record and clear the DTCs stored in the ABS control module
assembly.
 Start engine, drive the vehicle at 20 km/h or more and perform road test with X-431 3G diagnostic tester
connected to Data Link Connector (DLC).
 Using X-431 3G diagnostic tester to select "Read Code".
25


 Wiggle related wire harnesses and connectors and observe if signal is interrupted in related circuit.
 Inspect the mounting areas of wheel speed sensor for damage, foreign matter, etc. that will cause incorrect
signals.
 Remove the ABS control module assembly from the malfunctioning vehicle and install it to a new vehicle
and perform a test. If DTC cannot be cleared, the ABS control module is malfunctioning. If DTC can be
cleared, reinstall the ABS control module assembly to original vehicle.
Ground Inspection
Groundings are very important to the proper operation of circuits. Groundings are often exposed to moisture,
dirt and other corrosive environments. Corrosion (rust) may increase load resistance. This situation may
change the way in which a circuit works.
Circuits are very sensitive to proper grounding. A loose or corroded ground can affect the control circuit.
The operations to check the ground points are as follows:
2. Check all contact surfaces for tarnish, dirt, rust, etc.
25

ABS Control Module Assembly Terminal List

1 Battery Power Supply (Pump Motor) 20 -
2 Wheel Speed Sensor Signal Output 21 -
3 - 22 -
Front Right Wheel Speed Sensor
4 23 -
Signal
5 - 24 -
6 - 25 Battery Power Supply (Valve Relay)
7 - 26 CAN H
Front Left Wheel Speed Sensor
8 27 -
Signal
9 - 28 Power Supply (Ignition Switch)
Rear Right Wheel Speed Sensor
10 - 29
Signal
11 - 30 Brake Light Switch Signal
Rear Left Wheel Speed Sensor
12 - 31
Power Supply
13 Ground 32 -
14 CAN L 33 -
15 - 34 -
Front Right Wheel Speed Sensor
16 35 -
Power Supply
Rear Right Wheel Speed Sensor
17 36 -
Power Supply
Rear Left Wheel Speed Sensor
18 37 -
Signal
Front Left Wheel Speed Sensor
19 38 Ground
Power Supply
25


C0010-04 Left Front Inlet Control
C0011-04 Left Front Outlet Control
C0014-04 Right Front Inlet Control
C0015-04 Right Front Outlet Control
C0018-04 Left Rear Inlet Control
C0019-04 Left Rear Outlet Control
C001C-04 Right Rear Inlet Control
C001D-04 Right Rear Outlet Control
C1003-04 Valve Relay
C1004-00 General Valve
C0020-04 ABS Pump Motor Control
C0031-00 Left Front Wheel Speed Sensor
C0034-00 Right Front Wheel Speed Sensor
C0037-00 Left Rear Wheel Speed Sensor
C003A-00 Right Rear Wheel Speed Sensor
C003A-12 Right Rear Wheel Speed Sensor 25
C006B-00 Stability System Active Too Long


C1000-16 ECU Voltage Supply
C1000-17 ECU Voltage Supply
C1001-04 ECU
C1009-00 ECU Hardware Related
25

DTC C0010-04 Left Front Inlet Control
DTC C0011-04 Left Front Outlet Control
DTC C0014-04 Right Front Inlet Control
DTC C0015-04 Right Front Outlet Control
DTC C0018-04 Left Rear Inlet Control
DTC C0019-04 Left Rear Outlet Control
DTC C001C-04 Right Rear Inlet Control
DTC C001D-04 Right Rear Outlet Control
DTC C1003-04 Valve Relay
DTC C1004-00 General Valve
25

BATTERY
ENGINE
COMPARTMENT
EF47 FUSE AND
25A RELAY BOX
E-074
I1
25
ABS
CONTROL
MODULE
E-085
Br
B
13 38
E-042
13 12 11 10 9 8 7 6 5 4 3 2 1 I2 I1
24 23 22 21 20 19 18 17 16 15 14
E-074
38 25
37 36 35 34 33 32 31 30 29 28 27 26 Gr
E-085
B
25
ET21250040

Self-diagnosis Detection Logic
DTC Detection
Conditions
These DTCs occur
C0010-04 Left Front Inlet Control
when any of the
Left Front Outlet following conditions is
C0011-04 met:
Control
1. Valve power supply
Right Front Inlet malfunction (power
C0014-04
Control supply is short to
Right Front Outlet ground or ground is  Valve relay power supply is abnormal.
C0015-04 open).
Control
 ABS control module assembly has
2. Solenoid valve poor ground connection.
C0018-04 Left Rear Inlet Control temperature is too
high (overheat  Fuse is malfunctioning.
Left Rear Outlet protection).  Solenoid valve is short to power
C0019-04
Control supply and ground, or ground is open.
3. Short in solenoid
Right Rear Inlet valves more than 5  System overheat protection.
C001C-04
Control (fuse).  ABS control module assembly is
Right Rear Outlet 4. Activate the damaged.
C001D-04 corresponsive
Control
solenoid valve, but
C1003-04 Valve Relay no feedback.
5. Solenoid valve itself
is malfunctioning.
C1004-00 General Valve 6. Valve set relay is
malfunctioning.
CAUTION
Diagnosis Procedure
1 Check for DTCs
a. Leave the vehicle for 5 minutes, clear and read the ABS control module assembly DTC again with X-431
3G diagnostic tester.
b. Refer to DTC Confirmation Procedure.
c. Check if the same DTC is output.
NO Problem indicated by DTC is intermittent

(system overheat protection)
25
YES

2 Check ABS fuse

c. Remove the ABS fuse EF-47 (25 A) from the engine compartment fuse and relay box.
d. Check if the fuse is blown.
NG Replace ABS fuse
OK
Use the circuit diagram as a guide to perform the following procedures:

 Disconnect the negative battery cable.
 Disconnect the ABS control module assembly connector E-085 and engine compartment fuse and relay
box connector E-074.
 Check if the wire harnesses are worn, pierced, pinched or partially broken.
 Check if related connector pins are in good condition.

connector
OK
4 Check wire harness and connector (ABS control module assembly - battery)
a. Connect the negative battery cable.

b. Turn ignition switch to LOCK.
c. Disconnect the ABS control module assembly connector
E-085. V
+ -
d. Using a digital multimeter, measure the voltage between
ABS control module assembly terminal 25 and body
ground to check if the power supply circuit is normal 12 11 10 9 8 7 6 5 4 3 2
13 1
according to the table below. 24 23 22 21 20 19 18 17 16 15 14
Standard Voltage 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Condition
E-085 (25) - Body

Always 9 to 16 V
ground
25
NG Repair or replace engine compartment RT21250200
wire harness and connector

OK
5 Check wire harness and connector (ABS control module assembly - body ground)

E-085.
+ -
d. Using a digital multimeter, check for continuity between
ABS control module assembly terminal 13, 38 and body
ground to check if the system ground circuit is normal 12 11 10 9 8 7 6 5 4 3 2
13 1
Standard Condition 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Condition
E-085 (13) - Body

Always Continuity
ground
E-085 (38) - Body
Always Continuity
ground RT21250210

OK
6 Reconfirm DTCs
a. Use X-431 3G diagnostic tester to clear the DTC.

b. Start the engine.
c. Drive the vehicle at 15 km/h or more, read the ABS control module assembly DTC again with X-431 3G
diagnostic tester.
d. Check if the same DTC is output.
NO System operates normally
YES
Replace ABS control module assembly
25

DTC C0020-04 ABS Pump Motor Control
BATTERY
MF01
40A
ABS
CONTROL
MODULE
E-085
Br
B
13 38
E-042
13 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
25 E-085
B
ET21250050

DTC Detection
Conditions
These DTCs occur
when any of the
following conditions is
met:
1. Pump motor
operates with
overload, and
temperature is too
high (over
protection).
2. Return pump  Fuse malfunction
monitor still cannot
detect the voltage  Pump motor has poor ground
signal after return connection
ABS Pump Motor  System overheat protection
C0020-04 pump motor relay
Control
operates for 60 ms.  Pump motor power supply is abnormal
3. Return pump  Pump motor relay malfunction.
monitor detects the  Pump motor malfunction
voltage for more
than 2.5 s when
return pump motor
relay does not
operate.
4. Return pump
monitor detects that
the voltage does not
drop when return
pump motor relay
stop operating.
CAUTION
Diagnosis Procedure
1 Check for DTCs
a. Leave the vehicle for 5 minutes, clear and read the ABS control module assembly DTC again with X-431
3G diagnostic tester.
c. Check if the same DTC is output. 25
NO Problem indicated by DTC is intermittent
(system overheat protection)

YES
2 Check ABS fuse

c. Remove the ABS fuse MF-01 (40 A) from the engine compartment fuse and relay box.
NG Replace ABS fuse
OK

 Disconnect the negative battery cable.
 Disconnect the ABS control module assembly connector E-085.
 Check if the wire harnesses are worn, pierced, pinched or partially broken.
 Check if related connector pins are in good condition.

OK

b. Turn ignition switch to LOCK.
E-085. V
+ -
d. Using a digital multimeter, measure the voltage between
ABS control module assembly terminal 1 and body
ground to check if the power supply circuit is normal 12 11 10 9 8 7 6 5 4 3 2
13 1
Standard Voltage 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Condition
25 E-085 (1) - Body

Always 9 to 16 V
ground
NG Repair or replace engine compartment RT21250220


OK

E-085.
+ -
ABS control module assembly terminal 13, 38 and body
13 1
Condition
E-085 (13) - Body

Always Continuity
ground
E-085 (38) - Body
Always Continuity
ground RT21250210

OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

Code C0031-00 Left Front Wheel Speed Sensor
25

IGNITION SWITCH
BATTERY
ON OR START
ENGINE
COMPARTMENT
MF01 EF47 EF36 EF34 FUSE AND
40A 25A 10A 20A RELAY BOX
E-074
I1 A10 E-076
RL
R
1 25 28
ABS
CONTROL
MODULE
E-085
8 19
Br
B
Br
R
13 38
2 1
FRONT LEFT E-042
WHEEL SPEED
SENSOR
E-060
13 12 11 10 9 8 7 6 5 4 3 2 1 A1 A2 A3 A4 A5 I2 I1 1 2
24 23 22 21 20 19 18 17 16 15 14
A6 A7 A8 A9 A10
38 25 E-074
37 36 35 34 33 32 31 30 29 28 27 26
Gr
E-076
Gr E-060
E-085
B B
25
ET21250060

DTC Detection
Conditions
 Wheel speed sensor signal wire is
Left Front Wheel These DTCs occur connecting with the power supply wire
C0031-00 when any of the in reverse.
Speed Sensor
following conditions is  Wheel speed sensor signal wire is
met: short to ground.
1. ABS control module  Wheel speed sensor line is open,
Left Front Wheel assembly detects
C0031-09 connector is loose or broken.
Speed Sensor that the wheel
speed sensor signal  Wheel speed sensor signal wire is
wire is short to short to power supply.
ground.  Wheel speed sensor power supply
Left Front Wheel
C0031-11 2. Wheel speed sensor wire is short to ground.
Speed Sensor
line is open.  Sensor head or plug pin is damaged.
3. ABS control module  Wheel speed sensor is interfered by
assembly detects magnetic field outside (wheel or axle is
Left Front Wheel that the wheel not demagnetized).
C0031-12
Speed Sensor speed sensor signal  Wheel speed sensor body is
wire is short to malfunctioning.
power supply.  Ring gear is not installed, has teeth
Left Front Wheel 4. ABS control module missing, dirty, demagnetized or off
C0031-13 assembly detects
Speed Sensor center.
that the wheel  Clearance between sensor and ring
speed sensor power gear is excessive.
supply wire is short
to ground.  Number of ring gear teeth is wrong.
Left Front Wheel
C0031-29
Speed Sensor 5. Wheel speed sensor  Tire size is not as specified.
signal is invalid.  ABS control module assembly is
damaged.
CAUTION
Diagnosis Procedure
1 Check front left wheel speed sensor wire harness and connector

c. Disconnect the front left wheel speed sensor connector E-060.
d. Check if the wire harnesses are worn, pierced, pinched or partially broken.
e. Look for broken, bent, protruded or corroded terminals.
25 f. Check if related connector pins are in good condition.
NG Repair or replace front left wheel speed

sensor wire harness and connector

OK
2 Check installation of front left wheel speed sensor

c. Check front left wheel speed sensor mounting bolt for looseness.
d. Check if excessive clearance exists between the installation position of front left wheel speed sensor and
front steering knuckle.
e. Check the installation position of front left wheel speed sensor for dirt.
NG Tighten mounting bolt properly, clean or

replace front left wheel speed sensor
OK
3 Check front left wheel speed sensor
a. Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC).
b. Drive the vehicle straight ahead, and read the data stream of front left wheel speed sensor with X-431 3G
diagnostic tester.
c. Check if the data change of front left wheel speed sensor matches the change of other wheel speed
sensors.
NG Replace front left wheel speed sensor
OK
4 Check front left hub ring gear
a. Remove the front left hub assembly.

b. Check for foreign matter, missing teeth or damage on the front left hub ring gear.
c. Check if the front left hub assembly is securely installed.
NG Replace front left hub ring gear
OK
25

Check wire harness and connector (front left wheel speed sensor - ABS control module
5 assembly)

E-085.
+ -
d. Disconnect the front left wheel speed sensor connector
E-060.
13 12 11 10 9 8 7 6 5 4 3 2 1
e. Using a digital multimeter, check for continuity between 24 23 22 21 20 19 18 17 16 15 14
the terminals of connector E-085 and connector E-060 to 38 25
check if there is an open in the wire harness and 37 36 35 34 33 32 31 30 29 28 27 26
connector according to the table below..

E-085
Standard Condition
Condition 1 2
E-085 (8) -
Always Continuity
E-060 (2) E-060 RT21250230
E-085 (19) -
Always Continuity
E-060 (1)
E-085 (8) -
E-060 (1)
E-085 (19) -
E-060 (2)
E-060 (1) -
E-060 (2)
E-085 (8) -
E-085 (19)
f. Using a digital multimeter, check for continuity between

connector E-085 and body ground to check if the front left
wheel speed sensor is short to ground according to the
table below.
Standard Condition + -
Condition
Connection Condition 13 12 11 10 9 8 7 6 5 4 3 2 1
E-085 (8) - Body 24 23 22 21 20 19 18 17 16 15 14

ground 38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-085 (19) - Body

Always No continuity E-085
ground
25 RT21250240

g. Connect the negative battery cable.

h. Turn ignition switch ON.
i. Using a digital multimeter, measure the voltage between
connector E-085 and body ground to check if the front left V
+ -
wheel speed sensor is short to power supply according to
the table below.
Standard Condition
13 12 11 10 9 8 7 6 5 4 3 2 1
Multimeter Specified 24 23 22 21 20 19 18 17 16 15 14
Condition
Connection Condition 38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-085 (8) - Body

Ignition switch ON Approximately 0 V E-085
ground
E-085 (19) - Body
Ignition switch ON Approximately 0 V
ground
NG Repair or replace wire harness and RT21250250
connector between front left wheel speed

sensor and ABS control module assembly
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

Code C0034-00 Right Front Wheel Speed Sensor
25

IGNITION SWITCH
BATTERY
ON OR START
ENGINE
COMPARTMENT
E-074
I1 A10 E-076
RL
R
1 25 28
ABS
CONTROL
MODULE
E-085
4 16
Br
B
WY
GY
13 38
2 1 E-042
FRONT RIGHT
WHEEL SPEED
SENSOR
E-036
13 12 11 10 9 8 7 6 5 4 3 2 1 A1 A2 A3 A4 A5 I2 I1 1 2
24 23 22 21 20 19 18 17 16 15 14
A6 A7 A8 A9 A10
38 25 E-074
37 36 35 34 33 32 31 30 29 28 27 26
Gr
E-076
Gr E-036
E-085
B
B
25
ET21250070

DTC Detection
Conditions
Right Front Wheel These DTCs occur connecting with the power supply wire
Speed Sensor
Right Front Wheel assembly detects
Right Front Wheel
C0034-11 2. Wheel speed sensor wire is short to ground.
Speed Sensor
line is open.  Sensor head or plug pin is damaged.
Right Front Wheel that the wheel not demagnetized).
C0034-12
Speed Sensor speed sensor signal  Wheel speed sensor body is
Right Front Wheel 4. ABS control module missing, dirty, demagnetized or off
C0034-13 assembly detects
Speed Sensor center.
that the wheel  Clearance between sensor and ring
Right Front Wheel
C0034-29
Speed Sensor 5. Wheel speed sensor  Tire size is not as specified.
signal is invalid.  ABS control module assembly is
damaged.
CAUTION
Diagnosis Procedure
1 Check front right wheel speed sensor wire harness and connector

c. Disconnect the front right wheel speed sensor connector E-036.
25 f. Check if related connector pins are in good condition.
NG Repair or replace front right wheel speed


OK
2 Check installation of front right wheel speed sensor

c. Check front right wheel speed sensor mounting bolt for looseness.
d. Check if excessive clearance exists between the installation position of front right wheel speed sensor and
front steering knuckle.
e. Check the installation position of front right wheel speed sensor for dirt.

replace front right wheel speed sensor
OK
3 Check front right wheel speed sensor
b. Drive the vehicle straight ahead, and read the data stream of front right wheel speed sensor with X-431 3G
diagnostic tester.
c. Check if the data change of front right wheel speed sensor matches the change of other wheel speed
sensors.
NG Replace front right wheel speed sensor
OK
4 Check front right hub ring gear
a. Remove the front right hub assembly.

b. Check for foreign matter, missing teeth or damage on the front right hub ring gear.
c. Check if the front right hub assembly is securely installed.
NG Replace front right hub ring gear
OK
25

Check wire harness and connector (front right wheel speed sensor - ABS control module
5 assembly)

E-085.
+ -
d. Disconnect the front right wheel speed sensor connector
E-036.
13 12 11 10 9 8 7 6 5 4 3 2 1
the terminals of connector E-085 and connector E-036 to 38 25
check if there is an open in the wire harness and 37 36 35 34 33 32 31 30 29 28 27 26
connector according to the table below.

E-085
Standard Condition
Condition 1 2
E-085 (16) -
Always Continuity
E-036 (1) E-036 RT21250260
E-085 (4) -
Always Continuity
E-036 (2)
E-085 (16) -
E-036 (2)
E-085 (4) -
E-036 (1)
E-036 (1) -
E-036 (2)
E-085 (4) -
E-085 (16)

connector E-085 and body ground to check if the front
right wheel speed sensor is short to ground according to
the table below.
Multimeter Specified 12 11 10 9 8 7 6 5 4 3 2
Condition 13 1
Connection Condition 24 23 22 21 20 19 18 17 16 15 14
E-085 (4) - Body 38 37 36 35 34 33 32 31 30 29 28 27 26 25

ground
E-085
E-085 (16) - Body
ground
25 RT21250270

g. Connect the negative battery cable.

h. Turn ignition switch ON.
i. Using a digital multimeter, measure the voltage between
connector E-085 and body ground to check if the front V
+ -
right wheel speed sensor is short to power supply
12 11 10 9 8 7 6 5 4 3 2
Standard Voltage 13 1
24 23 22 21 20 19 18 17 16 15 14
Multimeter Specified 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Condition
E-085
E-085 (4) - Body
ground
E-085 (16) - Body
ground
NG Repair or replace wire harness and RT21250280
connector between front right wheel

speed sensor and ABS control module
assembly
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

DTC C0037-00 Left Rear Wheel Speed Sensor
25

IGNITION SWITCH
BATTERY
ON OR START
ENGINE
COMPARTMENT
E-074
I1 A10 E-076
RL
R
1 25 28
ABS
CONTROL
MODULE
E-085
18 31
Br
GW
B
GR
13 38
E-029
9 20 B-054
GW
GR
1 2 E-042
REAR LEFT
WHEEL SPEED
SENSOR
B-029
13 12 11 10 9 8 7 6 5 4 3 2 1 A1 A2 A3 A4 A5
24 23 22 21 20 19 18 17 16 15 14
A6 A7 A8 A9 A10
38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-076
Gr
E-085
B
11 10 9 8 7 6 5 4 3 2 1 I2 I1 2 1
22 21 20 19 18 17 16 15 14 13 12
E-074 B-029
E-029
Gr
25
W B
ET21250080

DTC Detection
Conditions
Left Rear Wheel Speed These DTCs occur connecting with the power supply wire
Sensor
Left Rear Wheel Speed assembly detects
Sensor that the wheel
Left Rear Wheel Speed 2. Wheel speed sensor wire is short to ground.
C0037-11
Sensor line is open.  Sensor head or plug pin is damaged.
that the wheel not demagnetized).
Left Rear Wheel Speed
C0037-12 speed sensor signal  Wheel speed sensor body is
Sensor
4. ABS control module missing, dirty, demagnetized or off
Left Rear Wheel Speed assembly detects center.
C0037-13
Sensor that the wheel  Clearance between sensor and ring
Left Rear Wheel Speed 5. Wheel speed sensor  Tire size is not as specified.
C0037-29
Sensor signal is invalid.  ABS control module assembly is
damaged.
CAUTION
Diagnosis Procedure
1 Check rear left wheel speed sensor wire harness and connector

c. Disconnect the rear left wheel speed sensor connector B-029.
25
f. Check if related connector pins are in good condition.
NG Repair or replace rear left wheel speed


OK
2 Check installation of rear left wheel speed sensor

c. Check rear left wheel speed sensor mounting bolt for looseness.
d. Check if excessive clearance exists between the installation position of rear left wheel speed sensor and
rear hub ring gear.
e. Check the installation position of rear left wheel speed sensor for dirt.

replace rear left wheel speed sensor
OK
3 Check rear left wheel speed sensor
b. Drive the vehicle straight ahead, and read the data stream of rear left wheel speed sensor with X-431 3G
diagnostic tester.
c. Check if the data change of rear left wheel speed sensor matches the change of other wheel speed
sensors.
NG Replace rear left wheel speed sensor
OK
4 Check rear left hub ring gear
a. Remove the rear left hub assembly.

b. Check for foreign matter, missing teeth or damage on the rear left hub ring gear.
c. Check if the rear left hub assembly is securely installed.
NG Replace rear left hub ring gear
OK
25

Check wire harness and connector (rear left wheel speed sensor - ABS control module
5 assembly)

E-085.
+ -
d. Disconnect the rear left wheel speed sensor connector 
B-029.
13 12 11 10 9 8 7 6 5 4 3 2 1
the terminals of connector E-085 and connector B-029 to 38 25
37 36 35 34 33 32 31 30 29 28 27 26
check if there is an open in the wire harness and
E-085
Standard Condition
Multimeter
Specified 2 1
Condition
Terminal
B-029
E-085 (18) -
Always Continuity RT21250290
B-029 (1)
E-085 (31) -
Always Continuity
B-029 (2)
E-085 (31) -
B-029 (1)
E-085 (18) -
B-029 (2)
B-029 (1) - B-
029 (2)
E-085 (18) -
E-085 (31)
f. Disconnect the engine compartment wire harness

connector E-029 and body wire harness connector B-054.
g. Using a digital multimeter, check for continuity between
the terminals of connector E-085 and connector E-029 to
check if there is an open in the wire harness and + -

Standard Condition 13 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14
Multimeter 38 25
Specified 37 36 35 34 33 32 31 30 29 28 27 26
Condition
Terminal E-085
E-085 (18) -
Always Continuity
E-029 (9) 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
E-085 (31) -
Always Continuity
E-029 (20) E-029
25
RT21250300

h. Using a digital multimeter, check for continuity between

the terminals of connector B-054 and connector B-029 to
Multimeter
Specified 2 1
Condition
Terminal
B-029
B-029 (1) - B-054
Always Continuity
(9)
1 2 3 4 5 6 7 8 9 10 11
B-029 (2) - B-054 12 13 14 15 16 17 18 19 20 21 22
Always Continuity
(20)
B-054
RT21250310
i. Using a digital multimeter, check for continuity between

connector E-085 and body ground to check if the rear left
wheel speed sensor is short to ground according to the
table below.
Multimeter
Specified 13 12 11 10 9 8 7 6 5 4 3 2 1
Condition 24 23 22 21 20 19 18 17 16 15 14
Terminal 38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-085 (18) - Body

ground E-085
E-085 (31) - Body

ground
RT21250320
j. Connect the negative battery cable.

k. Turn ignition switch ON.
l. Using a digital multimeter, measure the voltage between
connector E-085 and body ground to check if the rear left V
+ -
wheel speed sensor is short to power supply according to
the table below.
12 11 10 9 8 7 6 5 4 3 2
Standard Condition 13 1
24 23 22 21 20 19 18 17 16 15 14
Multimeter 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Specified
Condition
Terminal E-085
E-085 (18) - Body

ground 25
E-085 (31) - Body
ground
RT21250330

NG Repair or replace wire harness and

connector between rear left wheel speed
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

DTC C003A-00 Right Rear Wheel Speed Sensor
25

IGNITION SWITCH
BATTERY
ON OR START
ENGINE
COMPARTMENT
E-074
I1 A10 E-076
RL
R
1 25 28
ABS
CONTROL
MODULE
E-085
29 17
VB
Br
B
13 38
E-029
2 1 B-054
VB
1 2 E-042
REAR RIGHT
WHEEL SPEED
SENSOR
B-009
13 12 11 10 9 8 7 6 5 4 3 2 1 A1 A2 A3 A4 A5
24 23 22 21 20 19 18 17 16 15 14
A6 A7 A8 A9 A10
38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-076
Gr
E-085
B
11 10 9 8 7 6 5 4 3 2 1 I2 I1 2 1
22 21 20 19 18 17 16 15 14 13 12
E-074 B-009
E-029
Gr B
25 W
ET21250090

DTC Detection
Conditions
Right Rear Wheel These DTCs occur connecting with the power supply wire
C003A-00 when any of the in reverse.
Speed Sensor
Right Rear Wheel assembly detects
C003A-09 connector is loose or broken.
Right Rear Wheel 2. Wheel speed sensor wire is short to ground.
C003A-11
Speed Sensor line is open.  Sensor head or plug pin is damaged.
that the wheel not demagnetized).
Right Rear Wheel
C003A-12 speed sensor signal  Wheel speed sensor body is
Speed Sensor
4. ABS control module missing, dirty, demagnetized or off
Right Rear Wheel assembly detects center.
C003A-13
Speed Sensor that the wheel  Clearance between sensor and ring
C003A-29
Right Rear Wheel 5. Wheel speed sensor  Tire size is not as specified.
Speed Sensor signal is invalid.  ABS control module assembly is
damaged.
CAUTION
Diagnosis Procedure
1 Check rear right wheel speed sensor wire harness and connector

c. Disconnect the rear right wheel speed sensor connector B-009.
25
NG Repair or replace rear right wheel speed


OK
2 Check installation of rear right wheel speed sensor

c. Check rear right wheel speed sensor mounting bolt for looseness.
d. Check if excessive clearance exists between the installation position of rear right wheel speed sensor and
rear hub ring gear.
e. Check the installation position of rear right wheel speed sensor for dirt.

replace rear right wheel speed sensor
OK
3 Check rear right wheel speed sensor
b. Drive the vehicle straight ahead, and read the data stream of rear right wheel speed sensor with X-431 3G
diagnostic tester.
c. Check if the data change of rear right wheel speed sensor matches the change of other wheel speed
sensors.
NG Replace rear right wheel speed sensor
OK
4 Check rear right hub ring gear
a. Remove the rear right hub assembly.

b. Check for foreign matter, missing teeth or damage on the rear right hub ring gear.
c. Check if the rear right hub assembly is securely installed.
NG Replace rear right hub ring gear
OK
25

Check wire harness and connector (rear right wheel speed sensor - ABS control module
5 assembly)

E-085.
+ -
d. Disconnect the rear right wheel speed sensor connector
B-009.
13 12 11 10 9 8 7 6 5 4 3 2 1
the terminals of connector E-085 and connector B-009 to 38 25
37 36 35 34 33 32 31 30 29 28 27 26
E-085
Standard Condition
Multimeter
Specified 2 1
Condition
Terminal
B-009
E-085 (29) -
B-009 (1)
E-085 (17) -
Always Continuity
B-009 (2)
E-085 (17) -
B-009 (1)
E-085 (29) -
B-009 (2)
B-009 (1) -
B-009 (2)
E-085 (17) -
E-085 (29)

the terminals of connector E-085 and connector E-029 to
check if there is an open in the wire harness and + -

Standard Condition 13 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14
Multimeter 38 25
Specified 37 36 35 34 33 32 31 30 29 28 27 26
Condition
Terminal E-085
E-085 (17) -
Always Continuity
E-029 (1) 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
E-085 (29) -
Always Continuity
E-029 (2) E-029
25
RT21250350


the terminals of connector B-054 and connector B-009 to
Multimeter
Specified 2 1
Condition
Terminal
B-009
B-009 (1) - B-054
Always Continuity
(2)
1 2 3 4 5 6 7 8 9 10 11
B-009 (2) - B-054 12 13 14 15 16 17 18 19 20 21 22
Always Continuity
(1)
B-054
RT21250360

connector E-085 and body ground to check if the rear
right wheel speed sensor is short to ground according to
the table below.
Multimeter
Specified 13 12 11 10 9 8 7 6 5 4 3 2 1
Condition 24 23 22 21 20 19 18 17 16 15 14
Terminal 38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-085 (17) - Body

ground E-085
E-085 (29) - Body

ground
RT21250370
j. Connect the negative battery cable.

k. Turn ignition switch ON.
l. Using a digital multimeter, measure the voltage between
connector E-085 and body ground to check if the rear V
+ -
right wheel speed sensor is short to power supply
12 11 10 9 8 7 6 5 4 3 2
24 23 22 21 20 19 18 17 16 15 14
Multimeter 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Specified
Condition
Terminal E-085
E-085 (17) - Body

25 ground
E-085 (29) - Body
ground
RT21250380

NG Repair or replace wire harness and

connector between rear right wheel speed
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

DTC C006B-00 Stability System Active Too Long
ABS
CONTROL
MODULE
E-085
8 19 4 16 18 31 29 17
GW
WY
GR
GY
VB
Br
R
V
E-029
9 20 2 1 B-054
GW
GR
VB
V
2 1 2 1 1 2 1 2
FRONT LEFT FRONT RIGHT REAR LEFT REAR RIGHT

WHEEL SPEED WHEEL SPEED WHEEL SPEED WHEEL SPEED
E-060 E-036 B-029 B-009
13 12 11 10 9 8 7 6 5 4 3 2 1
1 2 1 2
24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
E-060 E-036
E-085
B B
B
25 2 1 2 1 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
B-009 B-029
B B E-029
W
ET21250100

DTC Detection
Conditions
The DTC occurs when
the following condition  Wheel speed difference is excessive.
is met:
 Wheel speed sensor signal is
Stability System Active 1. ABS receives
C006B-00 incorrect.
Too Long command to
continue operating  ABS control module assembly is
(more than 1 damaged.
minute).
CAUTION
Diagnosis Procedure
1 Check wheel speed sensor wire harness and connector

c. Disconnect all wheel speed sensor connectors.
NG Repair or replace corresponding wheel

speed sensor wire harness and connector
OK
2 Check installation of wheel speed sensor

c. Check the wheel speed sensor mounting bolt for looseness.
d. Check if excessive clearance exists between the installation position of wheel speed sensor and hub ring
gear.
e. Check the installation position of wheel speed sensor for dirt.

replace wheel speed sensor 25
OK

3 Check wheel speed sensor
b. Drive the vehicle straight ahead, and read the data stream of each wheel speed sensor with X-431 3G
diagnostic tester.
c. Check if the data change of each wheel speed sensor matches the change of other wheel speed sensors.
NG Replace corresponding wheel speed

sensor
OK
4 Check hub ring gear
a. Remove the hub assembly.

b. Check for foreign matter, missing teeth or damage on the hub ring gear.
c. Check if the hub assembly is securely installed.
NG Replace corresponding hub ring gear
OK
5 Check wire harness and connector (wheel speed sensor - ABS control module assembly)

E-085.
+ -
d. Disconnect the front left wheel speed sensor connector
E-060 and front right wheel speed sensor connector 
12 11 10 9 8 7 6 5 4 3 2
E-036. 13 1
24 23 22 21 20 19 18 17 16 15 14
e. Disconnect the rear left wheel speed sensor connector 38 25
B-029 and rear right wheel speed sensor connector 
37 36 35 34 33 32 31 30 29 28 27 26
B-009.
E-085
the terminal 8 of connector E-085 and the terminal 2 of
connector E-060 to check if there is an open in the front 1 2
left wheel speed sensor signal wire according to the table
below.
Standard Condition E-060 RT21250390
Multimeter
Specified
Condition
Terminal
25 E-085 (8) - E-060
Always Continuity
(2)


connector E-036 to check if there is an open in the front
right wheel speed sensor signal wire according to the
table below. + -
Standard Condition
13 12 11 10 9 8 7 6 5 4 3 2 1
Multimeter
Specified 24 23 22 21 20 19 18 17 16 15 14
Condition 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Terminal
E-085 (4) - E-036 E-085
Always Continuity
(2)
1 2
E-036 RT21250400

connector B-029 to check if there is an open in the rear
below. + -
Standard Condition
13 12 11 10 9 8 7 6 5 4 3 2 1
Multimeter
Specified 24 23 22 21 20 19 18 17 16 15 14
Condition 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Terminal
E-085 (18) - E-085
Always Continuity
B-029 (1)
2 1
B-029
RT21250410

table below. + -
Standard Condition
13 12 11 10 9 8 7 6 5 4 3 2 1
Multimeter
Specified 24 23 22 21 20 19 18 17 16 15 14
Condition 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Terminal
E-085 (29) - E-085
Always Continuity
B-009 (1)
2 1 25
B-009
RT21250420

j. Disconnect the engine compartment wire harness

k. Using a digital multimeter, check for continuity between
connector E-029 to check if there is an open in the rear + -

below. 13 12 11 10 9 8 7 6 5 4 3 2 1
Standard Condition 24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
Multimeter
Specified
Condition
Terminal
E-085 (18) -
Always Continuity 11 10 9 8 7 6 5 4 3 2 1
E-029 (9) 22 21 20 19 18 17 16 15 14 13 12
E-029
RT21250430
l. Using a digital multimeter, check for continuity between

the terminal 1 of connector B-029 and the terminal 9 of
below. + -
Standard Condition
2 1
Multimeter
Specified
Condition
Terminal B-029
B-029 (1) - B-054

Always Continuity
(9) 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
B-054
RT21250440
m. Using a digital multimeter, check for continuity between

connector E-029 to check if there is an open in the rear
table below. + -
Standard Condition
13 12 11 10 9 8 7 6 5 4 3 2 1
Multimeter
Specified 24 23 22 21 20 19 18 17 16 15 14
Condition 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Terminal
E-085 (29) - E-085
Always Continuity
E-029 (2)
25 11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
E-029
RT21250450

n. Using a digital multimeter, check for continuity between

the terminal 1 of connector B-009 and the terminal 2 of
table below. + -
Standard Condition
2 1
Multimeter
Specified
Condition
Terminal B-009
B-009 (1) - B-054

Always Continuity
(2) 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
NG Repair or replace wire harness and B-054
connector between wheel speed sensor

and ABS control module assembly
RT21250460
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

DTC C1000-16 ECU Voltage Supply
DTC C1000-17 ECU Voltage Supply
IGNITION SWITCH
ON OR START
ENGINE
COMPARTMENT
EF36 EF34 FUSE AND
10A 20A RELAY BOX
E-076
A10
RL
28
ABS
CONTROL
MODULE
E-085
Br
B
13 38
E-042
13 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 A1 A2 A3 A4 A5
38 37 36 35 34 33 32 31 30 29 28 27 26 25 A6 A7 A8 A9 A10
25 E-085
E-076
Gr
B
ET21250110

DTC Detection
Conditions
These DTCs occur
when any of the  Fuse malfunction
C1000-16 ECU Voltage Supply following conditions is
met:  High or low battery voltage
1. Battery voltage is  Charging system malfunction
too high.  Wire harness or connector damaged
2. Battery voltage is  ABS control module assembly
C1000-17 ECU Voltage Supply malfunction
too low.
3. Body ground is poor.
CAUTION
Diagnosis Procedure
1 Check ABS fuse

NG Replace ABS fuse
OK
2 Check battery
a. Using a digital multimeter, measure the voltage between positive battery terminal and negative battery
terminal.
b. The battery voltage should be between 9 V and 16 V.
NG Check charging system (See page 16-6)
OK
3 Check ABS control module assembly wire harness and connector

25
c. Disconnect the ABS control module assembly connector E-085.


NG Repair or replace ABS control module

assembly wire harness and connector
OK

E-085. V
+ -
d. Connect the negative battery cable.
e. Turn ignition switch ON. 13 12 11 10 9 8 7 6 5 4 3 2 1
f. Using a digital multimeter, measure the supply voltage 24 23 22 21 20 19 18 17 16 15 14
between ABS control module assembly connector E-085 38 37 36 35 34 33 32 31 30 29 28 27 26 25
and body ground to check if the power supply circuit is
normal according to the table below. E-085
Standard Voltage
Multimeter
Specified
Condition
Terminal
E-085 (28) - Body RT21250470
ground

OK
25


E-085.
+ -
ABS control module assembly connector E-085 and body
13 1
Multimeter
Specified
Condition
Terminal
E-085 (13) - Body
Always Continuity
ground
E-085 (38) - Body RT21250210
Always Continuity
ground

assembly wire harness and connector
OK
6 Reconfirm DTCs

diagnostic tester.
YES
25

DTC C1001-04 ECU
DTC C1009-00 ECU Hardware Related
IGNITION SWITCH
ON OR START
ENGINE
COMPARTMENT
EF36 EF34 FUSE AND
10A 20A RELAY BOX
E-076
A10
RL
28
ABS
CONTROL
MODULE
E-085
Br
B
13 38
E-042
13 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 A1 A2 A3 A4 A5
38 37 36 35 34 33 32 31 30 29 28 27 26 25 A6 A7 A8 A9 A10
25 E-085
E-076
Gr
B
ET21250110

DTC Detection
Conditions
These DTCs occur
when any of the
C1001-04 ECU following conditions is
met:
 Fuse malfunction
1. ABS control module
assembly power
supply is  ABS control module assembly
malfunctioning. malfunction
ECU Hardware
C1009-00 2. ABS control module
Related
assembly is
damaged.
CAUTION
Diagnosis Procedure
1 Check ABS fuse

NG Replace ABS fuse
OK
2 Check ABS control module assembly wire harness and connector

c. Disconnect the ABS control module assembly connector E-085.

assembly wire harness and connector 25
OK


E-085. V
+ -
e. Turn ignition switch ON. 13 12 11 10 9 8 7 6 5 4 3 2 1
f. Using a digital multimeter, measure the supply voltage 24 23 22 21 20 19 18 17 16 15 14
between ABS control module assembly connector E-085 38 37 36 35 34 33 32 31 30 29 28 27 26 25
and body ground to check if the power supply circuit is
normal according to the table below. E-085
Standard Voltage
Condition
E-085 (28) - Body
ground RT21250470

OK

E-085.
+ -
ABS control module assembly connector E-085 and body
13 1
Condition
E-085 (13) - Body

Always Continuity
ground
E-085 (38) - Body
Always Continuity
ground RT21250210

25 assembly wire harness and connector
OK

5 Reconfirm DTCs

diagnostic tester.
YES
25

ON-VEHICLE SERVICE
ABS Bleeding
WARNING
 When bleeding the brake system, wear safety glasses. If brake fluid gets on your eyes or skin, wash off
with water completely.
 DO NOT drop brake fluid onto the body paint, as brake fluid can corrode the body paint.
CAUTION
 Brake fluid should meet the Chery specified type (DOT 4). DO NOT mix the brake fluid with other types
of brake fluid.
 Brake fluid has strong water absorbability, be sure to place it in the original sealed container.
 To prevent dust and other foreign matter from entering the reservoir, wipe it off before removing the
reservoir cap.
The bleeding procedures for brake system with X-431 3G diagnostic tester are as follows:
1. Make sure all brake lines are installed and tightened properly.
2. Check that battery voltage is normal.
3. Turn ignition switch to LOCK.
4. Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC).
5. Turn ignition switch ON.
6. Using X-431 diagnostic tester, record and clear the DTCs stored in ABS control module assembly.
7. Using X-431 3G diagnostic tester, enter Brake Control System, select Repair Bleed Function, and then
perform operation according to the information and procedures displayed on the diagnostic tester.
HINT:
 If the bleeder plug is open, never depress the brake pedal repeatedly. Doing so will increase the
amount of air in the system.
 Do not drain brake fluid from the brake fluid reservoir while bleeding the system. Otherwise, low fluid
level in the brake reservoir will cause additional air to enter the brake system.
 Always check the brake fluid level at all times to ensure that brake fluid level in the brake reservoir is
always close to the "MAX" level.
8. For X type brake circuit, the bleeding order is: rear left wheel, front left wheel, front right wheel, rear right
wheel.
9. After bleeding is completed, fill the brake reservoir with brake fluid to the "MAX" level .
10.Drive the vehicle to perform a road test, and confirm that the ABS system operates normally and brake
pedal feel is good.
25

ABS Control Module Assembly

Removal
WARNING
 When repairing ABS system, first release the pressure of high pressure brake fluid in the accumulator, to
prevent the high pressure brake fluid from spraying out and causing injury.
 Operation procedures: turn ignition switch off first, and then depress and release brake pedal repeatedly
until brake pedal becomes hard.
 In addition, never turn the ignition switch on before the ABS system is installed completely to prevent the
hydraulic pump from energizing and running.

CAUTION
 Wash off brake fluid immediately if it comes in contact with any paint surface.
 Drained brake fluid should be well kept in a container. Never discard it at will.
4. Remove the engine trim cover assembly.

5. Remove the ABS control module assembly.
a. Press the lock area of ABS control module assembly
connector, move the connector lock bracket upward
and disconnect the ABS control module assembly
connector (arrow).
RT21250070
b. Using a fixing wrench, carefully disconnect 6 brake

pipe coupling plugs (arrow).
25
RT21250080

CAUTION
 When removing brake line, prevent foreign matter form entering the ABS control module assembly
thread holes.
 After disconnecting brake line, sealing measure should be taken to prevent foreign matter form entering.
c. Remove the coupling nut (arrow) between ABS

control module assembly mounting bracket and body.
RT21250081
d. Remove 3 coupling bolts (arrow) between ABS control

module assembly mounting bracket and body.
RT21250090
e. Remove the ABS control module with mounting bracket assembly.
Disassembly
1. Remove the ABS control module assembly.
a. Remove the coupling nuts (arrow) between the lower
part of ABS control module assembly and mounting
bracket. 3
b. Detach the rubber shock pad (1) from the bottom of
1
ABS control module assembly.
c. Detach the ABS control module assembly (3) from the 2
mounting bracket (2).
RT21250100
25

Assembly
CAUTION
 Check if shock pad is deteriorated or damaged. Replace if necessary.
Installation
CAUTION
 ABS control module assembly consists of hydraulic control module and electronic control module. As a
unit, they cannot be repaired or replaced individually.
 When installing fixing bolts and screws, be sure to tighten them to specified torque.
 Perform ABS bleeding procedures for brake system after completing installation (See page 25-70).
 Using X-431 3G diagnostic tester, enter brake control system, record and clear the trouble code, then
drive vehicle to perform a road test, confirming that the ABS system operates normally and brake pedal
feel is good.
25

Front Wheel Speed Sensor

Removal
CAUTION
 Keep the wheel speed sensor away from oil or other dirt. Otherwise, the speed signal generated by
wheel speed sensor may be inaccurate, and the system may fail to operate normally.
HINT:
4. Remove the front left wheel speed sensor.
a. Remove the coupling bolt (arrow) between front left
RT21250106
CAUTION
 Keep the head and installation hole of sensor free of foreign matter.
b. Detach the attachment part (arrow) of front left wheel

speed sensor wire harness from the front left shock
absorber assembly.
HINT:
Observe the winding direction of sensor wire harness
to prevent incorrect installation.
RT21250110
25

c. Detach the attachment part (arrow) and fixing clamp

(1) of front left wheel speed sensor wire harness from 1
the fixing bracket and body.
HINT:
Observe the winding direction of sensor wire harness
to prevent incorrect installation.
RT21250120
d. Disconnect the front left wheel speed sensor wire

RT21250130
e. Detach the front left wheel speed sensor wire harness

cover (arrow) from body.
RT21250140
f. Remove the front left wheel speed sensor.
Inspection
1. Check the front wheel speed sensor.
a. Check front wheel speed sensor surface for breakage, dents or notch.
b. Check front wheel speed sensor connector or wire harness for scratches, breakage or damage.
c. If any of the above conditions occurs, replace the front wheel speed sensor with a new one.
Installation
CAUTION
 When installing coupling bolts, be sure to tighten them to specified torque.

25

Rear Wheel Speed Sensor

Removal
CAUTION
 Keep the wheel speed sensor away from oil or other dirt. Otherwise, the speed signal generated by
wheel speed sensor may be inaccurate, and the system may fail to operate normally.
HINT:
4. Remove the left C-pillar lower protector assembly (See page 49-23).
5. Remove the rear left wheel speed sensor.
a. Remove the coupling bolt (arrow) between rear left
wheel speed sensor and rear left hub bearing unit,
and disengage the rear left wheel speed sensor.
RT21250143
CAUTION
 Keep the head and installation hole of sensor free of foreign matter.
b. Loosen the fixing bands (arrow) from the rear left

wheel speed sensor wire harness.
RT21250150
25

c. Remove 4 fixing screws (arrow) and the front wheel

house protector assembly (1) of rear left wheel.
RT21250160
d. Detach the attachment parts (arrow) between rear left

wheel speed sensor wire harness and fixing bracket, 1
and detach the wire harness cover (1).
RT21250170
e. Disconnect the rear left wheel speed sensor wire

RT21250180
f. Remove the rear left wheel speed sensor.
Inspection
1. Check the rear wheel speed sensor.
a. Check rear wheel speed sensor surface for breakage, dents or notch.
b. Check rear wheel speed sensor connector or wire harness for scratches, breakage or damage.
c. If any of the above conditions occurs, replace the rear wheel speed sensor with a new one.
Installation
CAUTION
 When installing coupling bolts, be sure to tighten them to specified torque.

25

- MEMO -

BRAKE
GENERAL INFORMATION 26-3 Brake Pedal Assembly 26-23
Description 26-3 On-vehicle Inspection 26-23
Tools 26-7 Inspection 26-26
Front Disc Brake Assembly 26-27
Removal 26-28
Inspection 26-11
Disassembly 26-30
Brake Bleeding 26-12 Assembly 26-34
Brake Fluid Replacement 26-13 Installation 26-37
Brake Fluid Reservoir Assembly 26-14 Front Brake Hose Assembly 26-38
On-vehicle Inspection 26-14 Removal 26-38
Installation 26-15 Rear Disc Brake Assembly 26-40
Brake Master Cylinder Assembly 26-16 On-vehicle Inspection 26-41
Vacuum Booster with Brake  Inspection 26-45
Master Cylinder Assembly 26-19 Assembly 26-46
On-vehicle Inspection 26-19 Installation 26-50
Removal 26-20 Rear Brake Hose Assembly 26-51
26

26

26 - BRAKE
GENERAL INFORMATION
BRAKE
Description
Front Disc Brake Assembly
3
4
×4
RT21260010
1 - Front Steering Knuckle 2 - Front Wheel Mudguard

3 - Front Hub Bearing 4 - Front Hub Assembly
5 - Front Brake Disc 6 - Front Brake Caliper Assembly
26

26 - BRAKE
1
2
3 5
RT21260020
1 - Connecting Plate Assembly 2 - Rear Brake Bottom Board

3 - Rear Brake Assembly 4 - Rear Hub Bearing Unit
5 - Rear Brake Caliper Assembly 6 - Rear Brake Disc
Brake system uses following configuration: disc brake is used for front wheels, and DIH (Drum-in-hat) is used
for rear wheels (disc brake is used for driving brake, and drum brake is used for parking brake).
Using lever principle, brake pedal pushes pushrod into vacuum booster, which boosts the force of pushrod by
using vacuum and then transmits the force to brake master cylinder assembly. Hydraulic pressure, produced
in the brake master cylinder assembly, is transmitted to ABS Hydraulic Control Unit (HCU) through brake
tube, and then distributed to individual brake calipers. The brake calipers apply force to brake linings using
hydraulic pressure. The brake linings will cause wheel speed to decrease or stop depending on amount of
brake pressure applied.
26

26 - BRAKE
Specifications

Coupling Nut Between Brake Fluid Reservoir
9±1
Assembly and Body
Coupling Plug Between Brake Master Cylinder
16 ± 2
Assembly and Brake Pipe
Coupling Nut Between Brake Master Cylinder
21 - 25
Assembly and Vacuum Booster Assembly
Coupling Bolt Between Brake Fluid Reservoir
3-5
Assembly and Brake Master Cylinder Assembly
Coupling Nut Between Vacuum Booster Assembly
25 ± 3
and Brake Pedal Assembly
Coupling Nut Between Brake Pedal Assembly and
25 ± 3
Body
27 ± 2
Assembly and Front Brake Hose Assembly
100 ± 10
Front Brake Disc Positioning Screw 10 ± 1
Front Brake Caliper Bleeder Plug 9 - 11
Locating Bolt Between Front Brake Caliper Fixing
25 ± 3
Bracket and Front Brake Cylinder Assembly
Coupling Plug Between Front Brake Hose Assembly
16 ± 2
and Front Brake Pipe
20 ± 2
Assembly and Rear Brake Hose Assembly
100 ± 10
Assembly and Rear Brake Bottom Board Assembly
Rear Brake Disc Positioning Screw 10 ± 1
Rear Brake Caliper Bleeder Plug 9 - 11
Locating Bolt Between Rear Brake Caliper Fixing
25 ± 3
Bracket and Rear Brake Cylinder Assembly
Coupling Plug Between Rear Brake Hose Assembly
16 ± 2
and Brake Pipe
26

26 - BRAKE
Front Disc Brake

(mm) (mm)
Front Brake Disc 25 23 0.06
Front Brake Lining 9.2 2 -

(mm) (mm)
Rear Brake Disc 10 8 0.06
Rear Brake Lining 8.2 2 -
26

26 - BRAKE
Tools
Special Tool
Brake Caliper Piston Pressing Tool
RCH0000053
General Tools
20
10
30
0
40
90
50
80
60
70
RCH0000023
Vernier Caliper
RCH0000019
Digital Multimeter
RCH0000002
26

26 - BRAKE
Circuit Diagram
Brake System
BATTERY IGNITION SWITCH

ON OR START
INSTRUMENT
RF23 RF06 PANEL
FUSE AND
10A 10A RELAY BOX
I-007
23 6
R
P
11 13
INSTRUMENT
CLUSTER
I-015
26 3 5
Br
B
Y
2 I-004
E-071
Y
I-003
1
BREAK
FLUID LEVEL
CLOSE SENSOR
E-082
OPEN
2
B
E-078
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
I-015 13 14 15 16 17 18 19 20 21 22 23 24
L
27 25 26
87
85 86 86 86
6 5 4 3 2 1 87 30 87 30
30 85 85
14 13 12 11 10 9 8 7 1 2
E-082 I-007
I-004 B B
W
26
ET21260010

26 - BRAKE
DIAGNOSIS & TESTING

HINT:

Front brake lining (cracked, deformed, dirty
26-32
or burnished)
Rear brake lining (cracked, deformed, dirty
26-45
or burnished)
Front disc brake locating bolt guide pin
26-30
(worn)
Rear disc brake locating bolt guide pin
26-42
(worn)
Front brake caliper assembly fixing bolt
26-28
(loose)
Noise in brake Rear brake caliper assembly fixing bolt
26-41
(loose)
Front brake disc (scored) 26-32
Rear brake disc (scored) 26-45
Excessive brake disc runout 26-41
Brake shoe stopper spring (damaged) 27-17
Brake shoe return tension spring
27-17
(damaged or elasticity insufficient)
Foreign matter on front brake disc -
Foreign matter on rear brake disc -
Front brake lining (worn, cracked,
26-32
deformed, oily or burnished)
Rear brake lining (worn, cracked,
26-45
deformed, oily or burnished)
Hard pedal but brake inefficient Front brake disc (unevenly worn) 26-32
Rear brake disc (unevenly worn) 26-45
Vacuum booster pushrod position
26-23
(incorrect)
Vacuum leaks in booster system 26-19
Hard pedal (firm-depress unable to lock-up
Vacuum booster (bounce) 26-19
wheels)
Pedal overtravel (vehicle stops normally) Air in brake system 26-12
26-32
Pedal pulsates/bounces during braking Brake disc (unevenly worn) 26
26-45

26 - BRAKE

Air in brake system 26-12
Brake system (leaked) -
Front brake piston seal (worn or damaged) 26-30
Low or spongy pedal Rear brake piston seal (worn or damaged) 26-42
Brake master cylinder assembly
26-16
(malfunctioning)
26-23
(incorrect)
Front brake piston (stuck or frozen) 26-30
Rear brake piston (stuck or frozen) 26-42
Front brake lining (dirty, cracked or
26-32
deformed)
Vehicle pulls during braking
Rear brake lining (dirty, cracked or
26-45
deformed)
Front brake disc (unevenly worn) 26-32
Rear brake disc (unevenly worn) 26-45
Brake pedal free play (minimum) 26-23
Parking brake lever travel (in need of
27-8
adjustment)
Parking brake cable (stuck) 27-13
Parking brake shoe clearance (in need of
27-8
adjustment)
Front brake lining (cracked or deformed) 26-32
Rear brake lining (cracked or deformed) 26-45
Brake stuck Front brake piston (stuck or frozen) 26-30
Rear brake piston (stuck or frozen) 26-42
Brake shoe return tension spring (loose or
27-17
damaged)
26-23
(incorrect)
Vacuum leaks in booster system 26-19
Brake master cylinder assembly
26-16
(malfunctioning)
26

26 - BRAKE
Inspection
CAUTION
 Use well-sealed brake fluid DOT4 or equivalent. DO NOT use oily solution, otherwise brake system seal
may be damaged.
 Brake fluid may damage paint surface. If brake fluid spills on paint surface, wash it off immediately with
water.
 DO NOT use gasoline, kerosene, alcohol, engine oil, transmission oil or any other fluid that contains
mineral oil to clean the system components. These kinds of fluid will damage rubber cover and seal.
 During servicing, make sure to clean grease or other foreign matter on the outer surface of brake caliper
assembly, brake lining, brake disc and wheel hub.
 When operating brake disc and brake caliper, be careful to prevent damaging brake disc and brake
caliper or scratching or cutting brake shoe linings.
1. Check conditions of tires and wheels. Damaged or worn wheels and tires can cause a pull, shudder,
vibration and a condition similar to sudden braking.
2. If noise occurs while braking, check suspension components. Bounce vehicle up and down several times
and check suspension or steering components for any looseness, wear or damage.
3. Check brake fluid level and condition.
a. If brake fluid level is low, check ABS control unit assembly, brake wheel cylinder, brake caliper, brake
line, brake master cylinder assembly and brake fluid reservoir, etc. for leakage.
b. If brake fluid is contaminated, drain an amount of fluid to check. Replace with new fluid as necessary.
HINT:
It is normal that brake fluid will become dark after being used for a period of time. Do not mistake this for
contamination.
26

26 - BRAKE
ON-VEHICLE SERVICE
Brake Bleeding
WARNING
 When bleeding brake system, wear safety glasses.

 Be careful when bleeding air, as brake fluid at high pressure may spray out of bleeder plug.
CAUTION
 Before removing brake fluid reservoir, wipe it off to prevent dust and other foreign matter from dropping
into the brake fluid reservoir.
 Use fresh, clear and well-sealed brake fluid of specified type or equivalent.
 DO NOT allow brake fluid to adhere to any paint surface, such as vehicle body. If brake fluid leaks onto
any paint surface, immediately wash it off.
 During bleeding, do not depress brake pedal repeatedly at any time with bleeder plug opened.
Otherwise, the amount of air in system will increase, and further bleeding is needed.
 DO NOT drain brake fluid in brake fluid reservoir while bleeding brake system.
HINT:
An assistant will be required to assist when bleeding brake system.
1. Fill the brake fluid reservoir with brake fluid to proper level.
2. Loosen the bleeder plug cap and connect a clear plastic hose to the bleeder plug. Submerge the end of
hose into the clear container filled with new brake fluid.
3. Have an assistant depress the brake pedal 3 to 4 times
repeatedly; depress and hold the brake pedal to a lower
position. Then loosen the bleeder plug, and rotate it at
least one turn.
RT21260030
4. Tighten the bleeder plug every time the brake pedal

moves down quickly. Then release the brake pedal.
26
RT21260040

26 - BRAKE
5. Repeat above steps, and bleed the brake lines of each wheel in the same manner in the order of rear left
wheel, front right wheel, rear right wheel and front left wheel, until all air are bled from the brake lines.
Empty sign: a stream of fresh brake fluid flows into the clear container without bubbles.
HINT:
During bleeding the brake system, make sure the brake
fluid level is always near the "MAX" mark. Check the
brake fluid level at all times during bleeding. Add brake
fluid as necessary.
RT21260050
6. Check and adjust the brake fluid level to the "MAX" mark.
7. Check brake pedal effect. If braking effect is improper or the pedal is spongy, air may still exist in the
system. Perform bleeding procedures again for brake system as necessary.
8. Have the vehicle tested to confirm that brake operates properly and pedal feel is correct.
Brake Fluid Replacement

1. Drain the brake fluid.
a. Start the engine and run it at idle.
b. Remove the filler cap of brake fluid reservoir assembly. Remove the bleeder plug cap and connect a
clear plastic hose to the bleeder plug, and submerge the end of hose into the clear container filled with
new brake fluid.
c. Loosen the bleeder plug, and depress the brake pedal
continuously until the brake fluid stops coming out.
RT21260030
2. Add brake fluid.

a. Tighten the bleeder plug after confirming that brake fluid is drained. Fill the brake fluid reservoir with
new brake fluid to the proper level.
3. Perform bleeding procedures.
a. After replacing with new brake fluid, make sure to bleed the brake system for normal operation. See
page 26-12 for detail information about brake bleeding.
26

26 - BRAKE
Brake Fluid Reservoir Assembly

1. Check the brake fluid level warning switch.
a. Remove the brake fluid reservoir filler cap.
b. Disconnect the brake fluid level warning switch wire + -
harness connector.
c. Using ohm band of digital multimeter, check for
continuity between brake fluid level warning switch 1 2
terminals according to conditions shown in the table
below.
Standard Condition

Condition
Terminal 1 - Float upward
No continuity
Terminal 2 (switch ON)
Terminal 1 - Float downward
Continuity
Terminal 2 (switch OFF)
HINT:
 There is a float in the fluid reservoir. The position of float changes according to increasing or decreasing
brake fluid level.
 If result is not as specified, replace brake fluid reservoir assembly.
d. Add brake fluid to the "MAX" mark.
Removal
CAUTION
2. Remove the brake fluid reservoir assembly.

a. Disconnect the brake fluid level warning switch
connector (arrow).
26
RT21260070

26 - BRAKE
b. Remove the coupling nuts (arrow) between brake fluid

reservoir assembly and body. 
RT21260080
c. Loosen the brake fluid tube fixing clamp (arrow) and

disengage the brake fluid tube from brake fluid
reservoir assembly.
RT21260090
d. Remove the brake fluid reservoir assembly.
Installation
HINT:
Perform bleeding procedures for brake system and add brake fluid to the proper level after completing
installation.
26

26 - BRAKE
Brake Master Cylinder Assembly

Removal
CAUTION
 Remove the vacuum remained in vacuum booster before removing brake master cylinder assembly to
avoid damaging brake master cylinder assembly and prevent booster from sucking in any pollutant.
 When engine is not running, remove vacuum by depressing brake pedal repeatedly until the brake pedal
can be depressed firmly.
 When removing brake line, sealing measures should be taken to prevent foreign matter from entering.
CAUTION

3. Remove the brake master cylinder assembly.
a. Loosen the brake fluid tube fixing clamp (arrow) and
reservoir assembly.
RT21260100
b. Loosen the clutch hose fixing clamp (arrow) and

disengage the clutch hose from brake fluid reservoir
assembly (for only MT model).
26 RT21260110

26 - BRAKE
c. Loosen 2 coupling plugs (arrow) between brake

master cylinder assembly and brake pipes.
RT21260120
d. Loosen 2 coupling nuts (arrow) between brake master

cylinder assembly and vacuum booster. 
RT21260130
e. Carefully and vertically slide the brake master cylinder assembly out of vacuum booster.
f. Remove the coupling bolt (arrow) between brake fluid
reservoir assembly and brake master cylinder
assembly.
RT21260140
g. Disengage the connection between brake fluid

reservoir assembly and brake master cylinder
assembly, and remove the brake fluid reservoir
assembly.
RT21260150
26

26 - BRAKE
CAUTION
 Brake master cylinder assembly and piston are designed to make piston fall out easily. To prevent this,
make sure brake master cylinder is horizontal or end surface downward (piston surface facing upward)
when handling the brake master cylinder assembly.
 Make sure that no foreign matter adheres to brake master cylinder assembly piston. If foreign matter
adheres, clean it off with a piece of clean cloth. Then, apply grease to entire outer edge contact surface
of master cylinder piston.
 Master cylinder should be handled carefully. Avoid any impact to the master cylinder, such as falling. The
fallen master cylinder cannot be reused.
 DO NOT tap or pinch master cylinder piston, and avoid damaging master cylinder piston in any other
ways.
Installation
CAUTION
 Make sure to tighten coupling plugs and nuts to the specified torque during installation.
 Perform bleeding procedures for brake system and add brake fluid to the proper level after completing
installation.
26

26 - BRAKE
Vacuum Booster with Brake Master Cylinder Assembly

1. Check vacuum booster assembly.
a. Air tightness check.
 Start engine and stop it after 1 or 2 minutes. Slowly depress brake pedal several times.
 Make sure that booster is airtight. Check that distance every time the pedal depressed is gradually
decreased compare to the previous operation.
If pedal operation is not as specified, check the check valve. If check valve is normal, replace the
vacuum booster assembly.
 Start engine. Depress and hold pedal, then stop engine.
 Make sure that booster is airtight. Depress and hold pedal for 30 seconds, and check that pedal
reserve distance does not change.
If pedal operation is not as specified, check the check valve. If check valve is normal, replace the
b. Operation check.
 Stop engine.
 Depress pedal several times and check that pedal
reserve distance does not change.
RT21260160
 Depress and hold pedal, and then start engine.

Check that pedal can only be depressed lightly.
If pedal operation is not as specified, check the
check valve. If check valve is normal, replace the
RT21260170
26

26 - BRAKE
Removal
CAUTION

3. Remove the vacuum booster with brake master cylinder assembly.
a. Loosen the brake fluid tube fixing clamp (arrow) and
reservoir assembly.
RT21260100
b. Loosen the clutch hose fixing clamp (arrow) and

disengage the clutch hose from brake fluid reservoir
assembly (for only MT model).
RT21260110
c. Loosen 2 coupling plugs (arrow) between brake

master cylinder assembly and brake pipes.
RT21260120
26

26 - BRAKE
d. Disengage the vacuum hose assembly with check

valve (arrow) from vacuum booster assembly.
RT21260180
e. Using needle-nose pliers, remove the locking pin

(arrow) and pushrod pin (1) from vacuum booster
pushrod, and detach the brake pedal assembly.
RT21260190
f. Remove 4 coupling nuts (arrow) between vacuum

booster assembly and brake pedal assembly.
RT21260200
g. Remove the vacuum booster with brake master

cylinder assembly from engine compartment.
RT21260210
26

26 - BRAKE
Inspection
1. Check the check valve.
a. Remove the check valve from vacuum hose assembly.
b. Check that there is airflow (A) from vacuum booster to
engine, and no airflow (B) from engine to vacuum A B
booster.
If result is not as specified, replace vacuum hose
assembly.
RT21260220
Installation
CAUTION
 Make sure to tighten fixing plugs and nuts to the specified torque during installation.
 Perform bleeding procedures for brake system and add brake fluid to proper level after completing
installation.
26

26 - BRAKE
Brake Pedal Assembly

1. Check brake pedal free play.
a. Stop engine. Depress brake pedal several times until no vacuum is left in vacuum booster, and then
release brake pedal.
b. Depress brake pedal until resistance is felt.
c. As shown in the illustration, check the brake pedal
free play by measuring distance between pedal
position in above step and pedal position when it is
released.
Standard brake pedal free play: 1 - 9 mm
Pedal Free Play
RT21260230
2. Adjust brake pedal free play.

a. As shown in the illustration, loosen the vacuum booster
pushrod locking nut (arrow) and rotate the vacuum
booster pushrod clockwise or counterclockwise to
adjust the brake pedal free play to the specified value.
RT21260240
3. Check brake pedal height.

a. As shown in the illustration, turn over the carpet and
measure distance between brake pedal center and
dash panel, which is the brake pedal height.
Standard brake pedal height: 176 - 186 mm
Pedal Height
RT21260250
26

26 - BRAKE
4. Adjust brake pedal height.

a. As shown in the illustration, loosen the vacuum booster
pushrod locking nut (arrow) and rotate the vacuum
booster pushrod clockwise or counterclockwise to
adjust brake height to the specified value.
RT21260240
Removal
1. Remove the brake light switch assembly.
a. Disconnect the brake light switch assembly wire
RT21260260
b. Remove the brake light switch assembly by rotating it

90° clockwise or counterclockwise.
RT21260270
2. Remove the brake pedal assembly.

a. Using needle-nose pliers, remove the locking pin
(arrow) and pushrod pin (1) from vacuum booster
pushrod, and detach the brake pedal assembly.
RT21260190
26

26 - BRAKE
b. Remove 4 coupling nuts (arrow) between vacuum

booster assembly and brake pedal assembly.
RT21260200
c. Remove 2 coupling nuts (arrow) between brake pedal

assembly and body.
RT21260280
d. Remove the brake pedal assembly from the inside of

vehicle.
RT21260290
26

26 - BRAKE
Inspection
1. Check brake light switch assembly.
a. Using ohm band of digital multimeter, check for
continuity between brake light switch assembly
+ -
terminals according to the table below. 1 2

Brake pedal
Terminal 1 -
depressed (switch Continuity
Terminal 3
pin released) RT21260300
Brake pedal
Terminal 2 -
depressed (switch No continuity
Terminal 4
pin released)
Brake pedal
Terminal 1 -
Terminal 3
pin pushed)
Brake pedal
Terminal 2 -
released (switch Continuity
Terminal 4
pin pushed)
If result is not as specified, replace brake light switch

assembly.
Installation
CAUTION
 Make sure to tighten fixing nuts to the specified torque during installation.
 Check that brake light operates properly after completing installation.
26

26 - BRAKE
Front Disc Brake Assembly
1
2
3
4
5 8
14 6
7 9
13
10
11
12
RT21260310
1 - Brake Caliper Locating Bolt 2 - Brake Caliper Locating Bolt Guide Pin
3 - Brake Caliper Guide Pin Rubber Dust Boot 4 - Front Disc Brake Cylinder
5 - Front Disc Brake Piston Seal Ring 6 - Front Disc Brake Piston
7 - Front Disc Brake Piston Dust Boot 8 - Front Disc Brake Caliper Fixing Bracket
9 - Upper Support Gasket 10 - Inner Brake Lining
11 - Outer Brake Lining 12 - Lower Support Gasket
13 - Bleeder Plug 14 - Bleeder Plug Cap
26

26 - BRAKE
1. Check brake disc runout.
a. Remove the front wheel (See page 24-9).
b. Secure the dial indicator (1) to the proper position.
Position the dial indicator pointer approximately 10 2
mm from the outer edge of brake disc.
c. Slowly rotate the brake disc (2) and check the runout.
Mark the lowest and highest points and record these
measurements.
RT21260320
d. Check the runout on the opposite side of brake disc in the same way. Mark the lowest and highest
points and record these measurements.
e. Compare the recorded runout value and limit value.
Maximum runout for front brake disc: 0.06 mm
f. If runout exceeds the maximum value, replace the brake disc.
Removal
HINT:
CAUTION

3. Remove the front left brake caliper assembly.
between front left brake caliper assembly and front left
brake hose assembly.
26 RT21260330

26 - BRAKE
CAUTION
 DO NOT allow brake fluid to be sprayed on your clothes or skin when removing brake hose, as brake
fluid is corrosive.
b. Remove the coupling bolts (arrow) between front left

brake caliper assembly and front left steering knuckle.
RT21260340
c. Remove the front left brake caliper assembly.

4. Remove the front left brake disc.
a. Remove 2 positioning screws (arrow) from front left
brake disc, and remove the front left brake disc.
RT21260350
26

26 - BRAKE
Disassembly
HINT:
WARNING
 Never use high pressure when removing piston from the bore of brake caliper. Otherwise this may cause
personal injuries.
 If it is needed to remove piston with compressed air. DO NOT face the piston to yourself or place your
hands around the brake caliper and piston.
1. Remove the bleeder plug (w/ bleeder plug cap).

a. Remove the bleeder plug (w/ bleeder plug cap)
(arrow) from brake caliper assembly.
RT21260360
2. Remove the brake cylinder assembly.

a. Remove 2 locating bolts (arrow) between brake
caliper fixing bracket and brake cylinder assembly.
RT21260370
b. Detach the brake cylinder assembly and brake caliper fixing bracket.
3. Remove the front brake caliper locating bolt guide pin (w/ dust boot).
a. Remove 2 brake caliper locating bolt guide pins (w/
dust boot) (arrow) from brake caliper fixing bracket.
26 RT21260380

26 - BRAKE
4. Remove the front brake lining.

a. Remove the inner brake lining and outer brake lining
(arrow) from brake caliper fixing bracket.
RT21260390
5. Remove the brake lining support gasket.

a. Remove 2 brake lining support gaskets (arrow) from
brake caliper fixing bracket.
RT21260400
6. Remove the brake cylinder dust boot.

a. Using a flat tip screwdriver wrapped with protective
tape, pry out the dust boots (arrow) on both sides
carefully.
RT21260410
CAUTION
 Be careful not to damage brake piston and brake cylinder.
26

26 - BRAKE
7. Remove the front disc brake piston.

a. Place a wooden board (1) between front disc brake
piston and front disc brake cylinder.
1
b. Use compressed air (2) to carefully press out the
piston from front disc brake cylinder through the
attachment hole.
2
RT21260420
CAUTION
 Be careful not to splash brake fluid.

 DO NOT hold piston by hands to prevent injury.
 DO NOT remove or install brake piston casually, and always perform these operations by professional.
c. Clean the piston bore with alcohol or proper solution. Then wipe it with a piece of lint.
8. Remove the front disc brake piston seal ring.
a. Using a screwdriver wrapped with protective tape,
carefully pry out the seal rings (arrow) on both sides of
front disc brake piston from brake cylinder rear ring
groove.
RT21260430
Inspection
1. Check brake cylinder and piston.
a. Check piston and bore for scratches or corrosion. If there are scratches or corrosion, remove them with
fine sand cloth.
b. Remove dirt on piston with a soft brass wire brush and coarse cloth. Do not clean the piston with
polishing cloth or sand cloth, as this may damage its surface. If surface of piston is damaged, replace it.
If piston is stuck or bore is worn or corroded, replace entire brake caliper assembly. Use polishing cloth
to remove small corrosion points inside the bore.
2. Check brake caliper fixing bracket and brake caliper guide pin set.
a. Clean the contact surface of brake caliper fixing bracket and brake lining support gasket with brake
cleaner. Check for deformation, cracks, rust and foreign matter which is difficult to remove.
b. Check brake caliper guide pin rubber dust boot for deformation, cracks, worn and foreign matter which
is difficult to remove.
c. Install brake caliper guide pin and brake caliper guide pin rubber dust boot to brake caliper fixing
bracket. The brake caliper guide pin set should move smoothly without being stuck when pushing it with
26 hand; otherwise replace it.
d. After installing the brake lining, check if it is easy to fall out (due to insufficient elasticity of support
gasket). Replace as necessary.

26 - BRAKE
3. Check brake lining.

a. Visually check brake lining for flatness, and also check for excessive wear. If condition of lining cannot
be confirmed accurately only by visual inspection, a physical check will be used as necessary.
b. Measure the minimum brake lining thickness. When
the minimum thickness of brake lining is 2 mm or less,
replace the brake lining.
RT21260440
c. When replacing excessively worn brake linings (inner and outer), it is also necessary to replace linings
on the opposite side of vehicle as well as unchecked linings to maintain proper braking performance. If
it is unnecessary to replace brake linings, be sure to reinstall brake linings to the original positions.
4. Check brake disc.
a. Minor scratch or wear on brake disc surface is acceptable. If severe scratch or deformation exists, the
brake disc must be replaced.
b. Excessive wear of brake disc may cause poor contact between brake lining and surface of brake disc. If
protrusion on the disc is not removed before installing new brake lining, abnormal wear of brake disc
will be caused.
c. It is normal that the surface of brake disc is worn when replacing brake lining. If cracks or burned spots
exist, the brake disc must be replaced.
5. Check brake disc thickness.
a. Using a vernier caliper, measure the brake disc
thickness at the center of brake lining contact surface
as shown in the illustration.
Standard thickness: 25 mm
Minimum thickness: 23 mm
RT21260450
b. If it is less than the minimum thickness due to wear of brake disc, replace brake disc.
CAUTION
 DO NOT machine brake disc, because it may make the brake disc thickness less than the minimum
thickness.
26

26 - BRAKE
Assembly
HINT:
CAUTION
 When assembling brake caliper assembly, always keep your hands clean.
 When assembling brake caliper assembly, always use clean new brake fluid.
 Never use old seal ring for front disc brake piston.
1. Install the front disc brake piston seal ring.

a. Apply a light coat of grease to entire inner and outer
circumferences of new front disc brake piston seal
ring.
b. Install the front disc brake piston seal ring onto the
brake cylinder.
Grease RT21260460
CAUTION
 Securely install front disc brake piston seal ring into the rear ring groove of brake cylinder.
2. Install the front disc brake piston.

a. Apply a light coat of grease to the inner and outer
circumferences, and entire periphery of outer flange
top/bottom surfaces of new brake cylinder dust boot
b. Apply a light coat of grease to the entire outer
circumference (part contacting with the brake cylinder
dust boot and front disc brake cylinder) of front disc
brake piston.
Grease
RT21260470
c. Install the brake cylinder dust boot onto the front disc brake piston.
3. Install the brake cylinder dust boot.
a. Install the front disc brake piston to the front disc brake cylinder.
CAUTION
26  DO NOT install piston forcibly to brake cylinder.

26 - BRAKE
b. Install the brake cylinder dust boot to the brake

cylinder.
RT21260480
CAUTION
 Securely install brake cylinder dust boots into front ring grooves (both sides) of disc brake cylinder.
 DO NOT damage brake cylinder dust boot.
4. Install the brake lining support gasket.

a. Securely install the upper and lower support gaskets
(arrow) onto the brake caliper fixing bracket.
RT21260400
5. Install the front brake lining.

a. Securely install the inner brake lining and outer brake
lining (arrow) onto the brake caliper fixing bracket.
Make sure they are clamped in place.
RT21260390
CAUTION
 Make sure the contact surface of lining and brake disc is free of oil and grease.
26

26 - BRAKE
6. Install the front brake caliper locating bolt guide pin (w/ dust boot).
a. Apply a small amount of grease to the contact surface
between locating bolt guide pins and guide pin rubber
dust boots, and securely install the dust boots (arrow)
to the brake caliper fixing bracket.
RT21260380
7. Install the brake cylinder assembly.

a. Using brake cylinder piston pressing tool, slightly
retract the brake cylinder piston (both sides).
RT21260490
b. Align the brake caliper locating bolts (arrow) with the

guide pin hole and securely install the brake cylinder
assembly.
RT21260370
8. Install the bleeder plug (w/ bleeder plug cap).

a. Securely install the bleeder plug (w/ bleeder plug cap)
(arrow) to the front brake caliper assembly.
RT21260360
26

26 - BRAKE
Installation
CAUTION
 Make sure to tighten fixing bolts and nuts to the specified torque during installation.
 Before installing brake linings, completely retract brake caliper piston back into the bore of brake caliper.
 Depress brake pedal several times to secure the brake linings to brake disc in order to ensure safety
after installing the brake linings and before moving vehicle.
 Replace brake linings in pairs. DO NOT replace it alone.
 DO NOT install inner brake lining and outer brake lining reversely.
 Be sure to check brake system for leakage after installation. Repair or replace malfunctioning parts as
necessary.
 Be sure to perform bleeding procedures for brake system after installation.
 Be sure to add brake fluid to the proper level after installation.
26

26 - BRAKE
Front Brake Hose Assembly

Removal
CAUTION

HINT:
CAUTION
3. Remove the front left brake hose assembly.

a. Disengage the fixing clamp (arrow) and loosen the
coupling plug (1) between front left brake hose
assembly and front left brake pipe.
1
RT21260500
CAUTION

 DO NOT allow any foreign matter such as dirt and dust to enter brake tube from joint parts.
 After removing brake line, perform sealing treatment to prevent foreign matter from entering.
26

26 - BRAKE
b. Remove the front left brake hose assembly (arrow)

RT21260510
c. Remove the coupling bolt and washer (arrow)

between front left brake caliper assembly and front left
RT21260330
CAUTION
 DO NOT allow brake fluid to be sprayed on your clothes or skin when removing brake hose, as the brake
fluid is corrosive.
d. Remove the front left brake hose assembly.
Installation
CAUTION
 Make sure to tighten coupling bolts and plug to the specified torque during installation.
necessary.
26

26 - BRAKE
Rear Disc Brake Assembly
5
6
2 3
7
9
10
12
11
RT21260520
1 - Support Gasket 2 - Outer Brake Lining

3 - Inner Brake Lining 4 - Rear Disc Brake Caliper Fixing Bracket
5 - Rear Disc Brake Piston Dust Boot 6 - Rear Disc Brake Piston
7 - Rear Disc Brake Piston Seal Ring 8 - Rear Brake Cylinder
9 - Brake Caliper Locating Bolt Guide Pin (w/ Dust 10 - Brake Caliper Locating Bolt
Boot)
11 - Bleeder Plug 12 - Bleeder Plug Cap
26

26 - BRAKE
1. Check brake disc runout.
a. Remove the rear wheel (See page 24-9).
b. Secure the dial indicator (1) to the proper position.
Position the dial indicator pointer approximately 10
mm from the outer edge of rear brake disc. 2
c. Slowly rotate the brake disc (2) and check the runout.
Mark the lowest and highest points and record these 1
measurements.
RT21260530
d. Check the runout on the opposite side of brake disc in the same way. Mark the lowest and highest
points and record these measurements.
e. Compare the recorded runout value and limit value.
Maximum runout for front brake disc: 0.06 mm
f. If the runout exceeds the maximum value, replace the brake disc.
Removal
HINT:
CAUTION

3. Remove the rear left brake caliper assembly.
between rear left brake caliper assembly and rear left
RT21260540 26

26 - BRAKE
CAUTION
fluid is corrosive.
b. Remove the coupling bolts (arrow) between rear left

brake caliper assembly and rear left brake bottom
board assembly.
RT21260550
c. Remove the rear left brake caliper assembly.

4. Remove the rear left brake disc.
a. Remove the positioning screw (arrow) from rear left
brake disc, and remove the rear left brake disc. 
RT21260560
Disassembly
HINT:
WARNING
 Never use high pressure when removing piston from the bore of brake caliper. Otherwise this may cause
personal injuries.
 If it is needed to remove piston with compressed air. DO NOT allow the piston to face yourself or place
your hands around the brake caliper and piston.
26

26 - BRAKE
1. Remove the bleeder plug (w/ bleeder plug cap).

a. Remove the bleeder plug (w/ bleeder plug cap)
(arrow) from brake caliper assembly.
RT21260570
2. Remove the brake cylinder assembly.

a. Remove 2 locating bolts (arrow) between brake
caliper fixing bracket and brake cylinder assembly.
RT21260580
b. Detach the brake cylinder assembly and brake caliper fixing bracket.
3. Remove the rear brake caliper locating bolt guide pin (w/ dust boot).
a. Remove 2 brake caliper locating bolt guide pins (w/
dust boot) (arrow) from brake caliper fixing bracket.
RT21260590
4. Remove the rear brake lining.

a. Remove the inner brake lining and outer brake lining
(arrow) from brake caliper fixing bracket.
RT21260600
26

26 - BRAKE
5. Remove the brake lining support gasket.

a. Remove 2 brake lining support gaskets (arrow) from
RT21260610
6. Remove the brake cylinder dust boot.

tape, pry out the dust boot carefully.
RT21260620
CAUTION
 Be careful not to damage brake piston and brake cylinder.
7. Remove the rear disc brake piston.

a. Place a wooden board (1) between rear disc brake
piston and rear disc brake cylinder.
b. Use compressed air (2) to carefully press out the 1
piston from rear disc brake cylinder through the
attachment hole.
RT21260630
CAUTION
 Be careful not to splash brake fluid.

 DO NOT hold piston by hands to prevent injury.
 DO NOT remove or install brake piston casually, and always perform these operations by professional.
26
c. Clean the piston bore with alcohol or proper solution. Then wipe it with a piece of lint.

26 - BRAKE
8. Remove the rear disc brake piston seal ring.

carefully pry out the rear disc brake piston seal ring
(arrow) from brake cylinder rear ring groove.
RT21260640
Inspection
1. Check brake cylinder and the piston.
a. Check piston and bore for scratches or corrosion. If there are scratches or corrosion, remove them with
fine sand cloth.
b. Remove dirt on piston with a soft brass wire brush and coarse cloth. Do not clean the piston with
polishing cloth or sand cloth, as this may damage its surface. If surface of piston is damaged, replace it.
If piston is stuck or bore is worn or corroded, replace entire brake caliper assembly. Using polishing
cloth to remove small corrosion points inside the bore.
2. Check brake caliper fixing bracket and brake caliper guide pin set.
a. Clean the contact surface of brake caliper fixing bracket and brake lining support gasket with brake
cleaner. Check for deformation, cracks, rust and foreign matter which is difficult to remove.
b. Check brake caliper guide pin rubber dust boot for deformation, cracks, worn and foreign matter which
is difficult to remove.
c. Install brake caliper guide pin and brake caliper guide pin rubber dust boot to brake caliper fixing
bracket. The brake caliper guide pin set should move smoothly without being stuck when pushing it with
hand; otherwise replace it.
d. After installing the brake lining, check if it is easy to fall out (due to insufficient elasticity of support
gasket). Replace as necessary.
3. Check brake lining.
a. Visually check brake lining for flatness, and also check for excessive wear. If condition of lining cannot
be confirmed accurately only by visual inspection, a physical check will be used as necessary.
b. Measure the minimum brake lining thickness. When
the minimum thickness of brake lining is 2 mm or less,
replace the brake lining.
RT21260650
c. When replacing excessively worn brake linings (inner and outer), it is also necessary to replace linings
on the opposite side of vehicle as well as unchecked linings to maintain proper braking performance. If
it is unnecessary to replace brake linings, be sure to reinstall brake linings to the original positions.
4. Check brake disc.
a. Minor scratch or wear on brake disc surface is acceptable. If severe scratch or deformation exists, the 26
brake disc must be replaced.

26 - BRAKE
b. Excessive wear of brake disc may cause poor contact between brake lining and surface of brake disc. If
protrusion on the disc is not removed before installing new brake lining, abnormal wear of brake disc
will be caused.
c. It is normal that the surface of brake disc is worn when replacing brake lining. If cracks or burned spots
exist, the brake disc must be replaced.
5. Check brake disc thickness.
a. Using a vernier caliper, measure the brake disc
thickness at the center of brake lining contact surface
Standard thickness: 10 mm
RT21260660
b. If it is less than the minimum thickness due to wear of brake disc, replace brake disc.
CAUTION
 DO NOT machine brake disc, because it may make the brake disc thickness less than the minimum
thickness.
Assembly
HINT:
CAUTION
 When assembling brake caliper assembly, always keep your hands clean.
 When assembling brake caliper assembly, always use clean new brake fluid.
 Never use old seal ring for front disc brake piston.
1. Install the rear disc brake piston seal ring.

a. Apply a light coat of grease to entire inner and outer
circumferences of new rear disc brake piston seal
ring.
b. Install the rear disc brake piston seal ring onto the
brake cylinder.
Grease RT21260670
26

26 - BRAKE
CAUTION
 Securely install rear disc brake piston seal ring into the rear ring groove of brake cylinder.
2. Install the rear disc brake piston.

a. Apply a light coat of grease to the inner and outer
circumferences, and entire periphery of outer flange
top/bottom surfaces of new brake cylinder dust boot
b. Apply a light coat of grease to the entire outer
circumference (part contacting with the brake cylinder
dust boot and rear disc brake cylinder) of the rear disc
brake piston.
Grease
RT21260470
c. Install the brake cylinder dust boot onto the rear disc brake piston.
3. Install the brake cylinder dust boot.
a. Install the rear disc brake piston to the rear disc brake cylinder.
CAUTION
 DO NOT install piston forcibly to brake cylinder.
b. Install the brake cylinder dust boot to the brake

cylinder.
RT21260680
CAUTION
 Securely install brake cylinder dust boot into front ring groove of disc brake cylinder.
 DO NOT damage brake cylinder dust boot.
26

26 - BRAKE
4. Install the brake lining support gasket.

a. Securely install the upper and lower support gaskets
onto the brake caliper fixing bracket.
RT21260610
5. Install the rear brake lining.

a. Securely install the inner brake lining and outer brake
lining (arrow) onto the brake caliper fixing bracket.
Make sure they are clamped in place.
RT21260600
CAUTION
 Make sure the contact surface of lining and brake disc is free of oil and grease.
26

26 - BRAKE
6. Install the rear brake caliper locating bolt guide pin (w/ dust boot).
a. Apply a small amount of grease to the contact surface
between locating bolt guide pins and guide pin rubber
dust boots, and securely install the dust boots to the
RT21260590
7. Install the brake cylinder assembly.

a. Using brake cylinder piston pressing tool, slightly
retract the brake cylinder piston (both sides).
RT21260690
b. Align the brake caliper locating bolts (arrow) with the

guide pin hole and securely install the brake cylinder
assembly.
RT21260580
8. Install the bleeder plug (w/ bleeder plug cap).

a. Securely install the bleeder plug (w/ bleeder plug cap)
(arrow) to the rear brake caliper assembly.
RT21260570
26

26 - BRAKE
Installation
CAUTION
 Before installing brake linings, completely retract brake caliper piston back into the bore of brake caliper.
 Depress brake pedal several times to secure the brake linings to brake disc in order to ensure safety
after installing the brake linings and before moving vehicle.
 Replace brake linings in pairs. DO NOT replace it alone.
 DO NOT install inner brake lining and outer brake lining reversely.
necessary.
26

26 - BRAKE
Rear Brake Hose Assembly

Removal
CAUTION

HINT:
CAUTION
2. Remove the rear left brake hose assembly.

between rear left brake caliper assembly and rear left
RT21260540
CAUTION
fluid is corrosive.
26

26 - BRAKE
b. Disengage the fixing clamp (arrow) and loosen the

coupling plug (1) between rear brake hose assembly
and brake pipe.
1
RT21260700
CAUTION

 DO NOT allow any foreign matter such as dirt and dust to enter brake tube from joint parts.
 After removing brake line, perform sealing treatment to prevent foreign matter from entering.
c. Remove the rear brake hose assembly.
Installation
CAUTION
 Make sure to tighten bolt and plug in place.

necessary.
26

PARKING BRAKE
GENERAL INFORMATION 27-3 Parking Brake Control Mechanism 
Circuit Diagram 27-6 Parking Brake Rear Cable Assembly 27-13
Removal 27-13
DIAGNOSIS & TESTING 27-7 Installation 27-14
Problem Symptoms Table 27-7 Rear Brake Assembly 27-15
Adjustment 27-8 Disassembly 27-17
Parking Brake Switch Assembly 27-9 Inspection 27-20
On-vehicle Inspection 27-9 Assembly 27-21
Inspection 27-10
Installation 27-10
27

27

27 - PARKING BRAKE
GENERAL INFORMATION
PARKING BRAKE
Parking Brake Assembly
2
4 5
RT21270010
1 - Parking Brake Control Mechanism Assembly 2 - Rear Right Parking Brake Cable Assembly
3 - Rear Right Brake Assembly 4 - Parking Brake Cable Fixing Clamp
5 - Rear Left Parking Brake Cable Assembly 6 - Rear Left Brake Assembly
7 - Parking Brake Switch Assembly
27

27 - PARKING BRAKE
Description
All vehicles are equipped with a manual-operated parking brake control mechanism assembly, which is
mounted on the center position of front seats. The tension balance block is built into parking brake control
mechanism assembly. Each rear wheel has an individual parking brake rear cable assembly, which is
respectively connected with the parking brake control mechanism assembly and rear brake shoe assembly.
The parking brake cable is made of flexible wire.
Specifications

Coupling Bolt Between Parking Brake Control
23 ± 2
Mechanism Assembly and Body
23 ± 2
Assembly Fixing Bracket and Body
Assembly
Assembly Fixing Bracket and Rear Brake Bottom 23 ± 2
Board Assembly
23 ± 2
Bracket and Rear Brake Bottom Board Assembly
Description Standard Thickness (mm) Minimum Thickness (mm)

Rear Brake Shoe Lining 3 1
Description Standard Inner Diameter (mm) Maximum Inner Diameter (mm)

Rear Brake Disc 186 188
27

27 - PARKING BRAKE
Tools
General Tools
Digital Multimeter
RCH0000002
Vernier Caliper
RCH0000019
27

27 - PARKING BRAKE
Circuit Diagram
Parking Brake System

ON OR START
INSTRUMENT
RF23 RF06 PANEL
FUSE AND
10A 10A RELAY BOX
I-007
23 6
R
P
11 13
INSTRUMENT
CLUSTER
I-015
18 3 5
BG
Br
B
14 I-006
B-003
BG
I-003
PARKING
APPLIED BRAKE
SWITCH
RELEASED B-019
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
13 14 15 16 17 18 19 20 21 22 23 24
I-015
L 27 25 26
87
85 86 86 86
87 30 87 30
30 85 85
10 9 8 7 6 5 4 3 2 1
1
22 21 20 19 18 17 16 15 14 13 12 11 I-007
B-019 B
I-006 B
W
27
ET21270010

27 - PARKING BRAKE
DIAGNOSIS & TESTING

HINT:

Parking brake control mechanism stroke
27-8
(incorrect)
Parking brake stuck Parking brake shoe clearance (incorrect) 27-8
Parking brake shoe return tension spring
27-15
(damaged)
Parking brake shoe (worn) 27-15
Rear brake disc (excessively worn) 26-40
Parking brake rear cable assembly
27-13
(improperly fixed)
Abnormal parking brake operation
Parking brake control mechanism
27-11
assembly (improperly fixed)
Parking brake control mechanism
27-11
assembly (stuck)
Brake warning light does not come on
Warning light circuit (faulty) 27-9
when parking brake is applied
27

27 - PARKING BRAKE
ON-VEHICLE SERVICE
Adjustment
Abnormal parking brake operation may be caused by the worn brake shoe lining, incorrect brake shoe
clearance adjustment, incorrect parking brake control mechanism stroke or incorrect parking brake
component installation. Perform the following procedures to adjust the parking brake control mechanism
stroke:
1. Support and raise the vehicle to a proper height.
3. Remove the rear brake disc (See page 26-41).
5. Adjust the parking brake shoe clearance:
a. Fully release the parking brake control mechanism.
b. Using a flat tip screwdriver, pry off the brake shoe
adjusting hole plug, rotate the brake shoe clearance
adjustment mechanism assembly to adjust parking Shrink
brake shoe clearance, and attempt to rotate the rear
brake disc by hand to confirm that brake disc rotates
freely.
c. Check that there is no brake stuck for the brake shoe. Expansion
RT21270020
6. Adjust the parking brake control mechanism stroke:

b. Rotate the parking brake control mechanism
adjustment nut, until the parking brake control
mechanism stroke is correct.
RT21270030
c. Correct judging method: after adjustment, fully release parking brake control mechanism and rotate
rear wheel by hand.
OK: Rear wheel can be rotated freely without dragging.
Pull up parking brake control mechanism until 1 clicking sound is heard. There is resistance when
rotating rear wheel by hand. Pull up parking brake control mechanism until 5 to 6 clicking sounds are
heard and the rear wheel cannot rotate.
d. When operating the parking brake control mechanism, check that brake warning light illuminates at the
first click.
OK: Parking brake warning light always illuminates at the first click.
e. If result is not as specified, repeat above procedures until the parking brake control mechanism stroke
is proper.
7. Install the auxiliary fascia console assembly (See page 45-9).
8. Install the rear brake disc (See page 26-41).
27 9. Install the rear wheel (See page 24-9).

27 - PARKING BRAKE
Parking Brake Switch Assembly

1. Disconnect parking brake switch assembly connector,
and check the continuity of parking brake switch
+ -
assembly with ohm band of digital multimeter as shown
in the table below.
Standard Condition
1
Condition
Parking brake
applied (switch Continuity RT21270040
Terminal 1 - Body pin released)

ground Parking brake
pin pushed)
If result is not as specified, replace parking brake switch

assembly.
Removal
CAUTION

1. Fix the tire and wheel assembly.

3. Remove the parking brake switch assembly.
a. Disconnect the parking brake switch assembly wire
harness connector (arrow) as shown in the illustration.
RT21270050
27

27 - PARKING BRAKE
b. Using a cross screwdriver, loosen the fixing screw

(arrow) of parking brake switch assembly.
RT21270060
c. Remove the parking brake switch assembly.
Inspection
1. Check parking brake switch assembly.
a. Check parking brake switch assembly for wear or break. Replace parking brake switch assembly as
necessary.
b. Check if parking brake switch assembly compressed spring is damaged or weak elasticity. Replace
parking brake switch assembly as necessary.
Installation
27

27 - PARKING BRAKE
Parking Brake Control Mechanism Assembly

Removal
CAUTION

1. Fix the tire and wheel assembly.

3. Remove the parking brake switch assembly (See page 27-9).
4. Remove the parking brake control mechanism assembly.
b. Loosen the locking nut (arrow) of parking brake
control mechanism assembly to release the tension of
parking brake cable assembly as shown in the
illustration.
RT21270030
c. Remove 4 coupling bolts (arrow) between parking

brake control mechanism assembly and body.
RT21270070
d. Disengage the parking brake rear cable assembly

from two grooves (arrow) on the rear of parking brake
control mechanism assembly.
RT21270080
e. Remove the parking brake control mechanism assembly.

27

27 - PARKING BRAKE
Installation
CAUTION
HINT:
Be sure to check parking brake control mechanism stroke after installing parking brake control mechanism
assembly. Adjust parking brake control mechanism stroke to the proper position by adjusting parking brake
control mechanism locking nut if necessary.
27

27 - PARKING BRAKE
Parking Brake Rear Cable Assembly

Removal
CAUTION

HINT:
3. Remove the parking brake rear cable assembly.
b. Loosen the locking nut (arrow) of parking brake
control mechanism assembly to release the tension of
parking brake cable assembly as shown in the
illustration.
RT21270030
c. Disengage the parking brake rear cable assembly

from two grooves (arrow) on the rear of parking brake
front cable assembly.
RT21270080
d. Loosen the coupling bolts (arrow) between parking

brake rear cable assembly fixing bracket and body,
and disengage the cable fixing bracket.
RT21270090
27

27 - PARKING BRAKE
e. Loosen the coupling bolt (arrow) between parking

brake rear cable assembly fixing bracket and rear
trailing arm assembly, and disengage the cable fixing
bracket.
RT21230450
f. Remove the fixing clamp (arrow) and disengage the

parking brake rear cable assembly from the fixing
bracket.
RT21270100
g. Disengage the parking brake rear cable assembly end

(arrow) from the parking brake pulling arm.
RT21270110
h. Remove the parking brake rear cable assembly.
Installation
CAUTION

 During installation, make sure to align the positioning part of parking brake rear cable assembly fixing
bracket and the positioning hole on body.
HINT:
Parking brake should be adjusted after replacing brake shoe or parking brake cable assembly. Check if
parking brake functions properly after adjustment is completed.
 Fully pull up parking brake control mechanism.
 Release parking brake control mechanism and check if rear wheels rotate freely.
 If wheels are difficult to rotate freely, repeat adjustment procedures.
27  After driving for a period of time, parking brake control mechanism stroke should be readjusted because of
wear of rear brake shoe linings.

27 - PARKING BRAKE
Rear Brake Assembly
5
14
6
13
7
12
8 11
9
10
RT21270111
1 - Rear Brake Disc 2 - Rear Brake Assembly

3 - Brake Shoe Return Tension Spring (Upper) 4 - Parking Pulling Arm Dust Boot
5 - Parking Pulling Arm 6 - Parking Push Rod
7 - Left Parking Brake Shoe Lining 8 - Compressed Spring Tie Rod
9 - Brake Shoe Compressed Spring 10 - Compressed Spring Seat
11 - Brake Shoe Return Tension Spring (Lower) 12 - Brake Shoe Clearance Adjustment Mechanism
Assembly
13 - Right Parking Brake Shoe Lining 14 - Rear Brake Disc Positioning Screw
27

27 - PARKING BRAKE
Removal
CAUTION

HINT:
4. Remove the rear left hub bearing unit (See page 22-19).
5. Remove the rear left brake assembly.
b. Remove the fixing clamp (arrow) and disengage the
parking brake rear cable assembly from the fixing
bracket.
RT21270100
c. Disengage the parking brake rear cable assembly end

(arrow) from the parking brake pulling arm.
RT21270110
d. Remove the coupling bolt (arrow) between parking

brake rear cable assembly fixing bracket and rear
brake bottom board assembly.
RT21270120
27

27 - PARKING BRAKE
e. Remove the coupling bolt (arrow) between rear brake

line fixing bracket and rear brake bottom board
assembly.
RT21270130
f. Remove the rear left brake assembly.
CAUTION
 DO NOT touch interior ornament when removing steering column with intermediate shaft assembly to
avoid scratching the interior ornament.
Disassembly
1. Remove the brake shoe stopper spring set.
a. Using needle-nose pliers, press brake shoe
compressed spring and rotate compressed spring tie
rod to remove the stopper spring sets (arrow) on both
sides as shown in the illustration.
RT21270140
2. Remove the brake shoe return tension spring (upper).

a. Using needle-nose pliers, remove the brake shoe
return tension spring (upper) carefully as shown in the
illustration.
RT21270150
27

27 - PARKING BRAKE
3. Remove the brake shoe return tension spring (lower).

a. Using needle-nose pliers, remove the brake shoe
return tension spring (lower) carefully as shown in the
illustration.
RT21270160
4. Remove the brake shoe clearance adjustment mechanism assembly.

a. Disengage the brake shoe linings on both sides and
remove the clearance adjustment mechanism
assembly as shown in the illustration.
RT21270170
5. Remove the right brake shoe lining.

a. Disengage the right brake shoe lining from the parking
push rod as shown in the illustration.
RT21270180
6. Remove the left brake shoe lining.

a. Disengage the left brake shoe lining from the parking
push rod as shown in the illustration.
RT21270190
27

27 - PARKING BRAKE
7. Remove the parking push rod.

a. Disengage the parking push rod from the parking
pulling arm as shown in the illustration.
RT21270200
8. Remove the parking pulling arm.

a. Remove the parking pulling arm from the parking
pulling arm dust boot as shown in the illustration.
RT21270210
9. Remove the parking pulling arm dust boot.

a. Disengage the parking pulling arm dust boot from the
rear brake bottom board assembly as shown in the
illustration.
RT21270220
10.Remove the rear brake bottom board assembly.
RT21270230
27

27 - PARKING BRAKE
Inspection
1. Check the thickness of brake shoe lining.
a. Using a ruler, measure the thickness of brake shoe
lining as shown in the illustration.
Standard thickness: 3 mm
RT21270240
b. If thickness of brake shoe lining is equal to or less than the minimum value, replace brake shoe lining.
CAUTION
 Replace brake shoe linings in pairs. DO NOT replace it alone.
2. Check the rear brake disc inner diameter.

a. Using a vernier caliper or equivalent, measure rear
brake disc inner diameter.
Standard inner diameter: 186 mm
Maximum inner diameter: 188 mm
RT21270250
b. If rear brake disc inner diameter is more than the maximum value, replace rear brake disc.
3. Check other components.
a. Check if brake shoe return tension spring (upper) is broken, bent, damaged or elasticity is weak.
b. Check if brake shoe return tension spring (lower) is broken, bent, damaged or elasticity is weak.
c. Check if parking push rod and pulling arm is broken, bent or damaged. Replace as necessary.
d. Check if parking pulling arm dust boot is worn, cracked or dirty. Replace as necessary.
e. Check if brake shoe stopper spring set is broken, bent, damaged or elasticity is weak. Replace as
necessary.
f. Check if brake shoe clearance adjustment mechanism assembly is struck, damaged or slides off.
27

27 - PARKING BRAKE
Assembly
CAUTION
 Adjust brake shoe clearance to the proper position by brake shoe clearance adjustment mechanism
assembly after installation is completed.
Installation
CAUTION
 Make sure to install fixing clamp in place.
HINT:
Parking brake should be adjusted after replacing parking brake shoe. Check if parking brake functions
properly after adjustment is completed.
 Fully pull up parking brake control mechanism.
 Release parking brake control mechanism and check if rear wheels rotate freely.
 If wheels are difficult to rotate freely, repeat adjustment procedures.
 After driving for a period of time, parking brake control mechanism stroke should be readjusted because of
wear of rear brake shoe linings.
27

- MEMO -

STEERING COLUMN
GENERAL INFORMATION 28-3 Inspection 28-14
Specifications 28-5 Steering Column with Intermediate 
Tools 28-6 Shaft Assembly (without EPS) 28-16 28
Removal 28-16
DIAGNOSIS & TESTING 28-7 Disassembly 28-18
Problem Symptoms Table 28-7 Inspection 28-19
Steering Wheel Free Play  Assembly 28-19
Inspection 28-9
Installation 28-20
Steering Wheel Centering/
Electronic Power Steering Column 
Returnability Inspection 28-9
with Intermediate Shaft Assembly 28-21
Steering Wheel Assembly 28-10 Disassembly 28-23
Inspection 28-11 Assembly 28-23
Combination Switch Cover 28-13
Removal 28-13

28

28 - STEERING COLUMN
GENERAL INFORMATION
STEERING COLUMN
Description
1
28
3 2
6
7
×2
8 ×2
10
11
RT21280010
1 - Driver Airbag 2 - Steering Wheel Assembly Fixing Nut

3 - Steering Wheel Assembly 4 - Spiral Cable
5 - Combination Switch Upper Cover 6 - Wiper and Washer Combination Switch
7 - Light Combination Switch 8 - Steering Column with Intermediate Shaft
Assembly
9 - Combination Switch Lower Cover 10 - Worm Clamp
11 - Steering Boot

Electronic Power Steering Column
28
3 2
6 7
×2
8 9
×2
10
11
12
13
RT21280011
1 - Driver Airbag 2 - Steering Wheel Assembly Fixing Nut

3 - Steering Wheel Assembly 4 - Spiral Cable
5 - Combination Switch Upper Cover 6 - Wiper and Washer Combination Switch
7 - Light Combination Switch 8 - Steering Column
9 - Combination Switch Lower Cover 10 - EPS Controller Assembly
11 - Intermediate Shaft with Universal Joint 12 - Worm Clamp
Assembly
13 - Steering Boot

Specifications

Steering Wheel Assembly Fixing Nut 35 ± 3
28
Combination Switch Cover Fixing Screw 2 ± 0.5
Steering Column Assembly Upper Bracket Fixing Nut 25 ± 3
Steering Column Assembly Lower Bracket Fixing
25 ± 3
Bolt
Coupling Bolt Between Steering Column with
Intermediate Shaft Assembly and Steering Gear 30 ± 3
Input Shaft
Column with Intermediate Shaft Assembly and 60 ± 5
Steering Gear Input Shaft
Steering Boot Fixing Nut 10 ± 1
50
Column and Intermediate Shaft
Data Specifications
Description Standard Value

Steering Wheel Free Play (Rotation Angle) ≤ 15°
Steering Wheel Centering/Returnability (Rotation
> 70°
Angle)

Tools
Special Tool
28
RCH0000014
General Tool
Electric Drill
RCH0000013

DIAGNOSIS & TESTING

HINT:
sequence. Repair or replace the faulty components, or adjust as necessary. 28
Steering wheel assembly cannot lock or Ignition key cylinder 28-18

unlock Ignition switch lock body 28-18
Front axle hub bearing (seriously worn) 22-10
Intermediate shaft with universal joint
28-23
assembly (seriously worn)
Steering wheel assembly has no free play Ball pin assembly (worn or loose) 29-19
or free play is too large
Steering tie rod assembly 29-21
Steering gear assembly (engagement gap 29-23
of rack and pinion improper) 30-25
Front tire (improperly inflated or unevenly
24-7
worn)
Front sub frame welding assembly 22-17
28-23
assembly (insufficiently lubricated)
Hard steering Ball pin assembly (insufficiently lubricated) 29-19

28-16
Steering column assembly
28-21
29-23
Steering gear assembly
30-25
Steering column motor 28-23


Front tire (improperly inflated or unevenly
24-7
worn)
Front suspension 23-12
28
Ball pin assembly (loose, insufficiently
29-19
lubricated)
Poor returnability
28-23
assembly (loose, insufficiently lubricated)
28-16
Steering column assembly (stuck)
28-21
29-23
Steering gear assembly (stuck)
30-25
Steering column motor 28-23
28-23
assembly
Knocking (or clunking) sound occurs when Control arm ball pin 23-22
turning steering wheel while steering
system is in operation Control arm 23-20
29-23
30-25
28-16
Steering column assembly
Friction sound occurs when steering wheel 28-21
is turned during low speed driving 29-23
30-25
High-pitched sound (squealing sound)
occurs when steering wheel is turned Steering column motor 28-23
slowly with vehicle stopped
Steering wheel vibrates and noise occurs Steering column motor 28-23
when steering wheel is turned with vehicle 28-16
stopped Steering column assembly
28-21

Steering Wheel Free Play Inspection

1. Stop vehicle and position front wheels straight ahead.
2. Slightly turn the steering wheel left and right, and check
rotation angle of steering wheel when the wheels start to
rotate.
Standard value of free play (rotation angle): a ≤ 15°. 28
a
RT21280020
3. If measured value exceeds standard value, check the steering system.
Steering Wheel Centering/Returnability Inspection

Steering wheel centering/returnability inspection should be performed during road test.
1. Perform the slow turn and sharp turn test.
Check for deviation of steering wheel steering force required during left/right turn and centering/
returnability.
2. When vehicle speed is between 20 and 30 km/h, turn the
steering wheel either to left or right by 90° and keep it for
1 to 2 seconds, and then release the steering wheel. If
steering wheel turns back more than 70°, it is determined
that steering wheel centering/returnability is in good 70° 70°
condition.
RT21280030
3. If steering wheel returning angle is not as specified, check the tire pressure, steering system and
suspension system.

ON-VEHICLE SERVICE
Steering Wheel Assembly
Removal
28
WARNING
 Be sure to read the precautions for SRS airbag before removing the steering wheel (See page 32-65).
1. Set steering wheel to straight-ahead position.

CAUTION
 Wait at least 90 seconds after disconnecting the negative battery cable to prevent airbag and belt
pretensioner from being activated.
4. Remove the driver airbag assembly (See page 32-65).

5. Remove the steering wheel assembly.
a. Secure the steering wheel assembly, and put
matchmarks on the steering wheel assembly and
steering column assembly, then remove the steering
wheel assembly fixing nut. 2
3
4
5
6 60
40
80
100 120
140
160
180

1 7
x1000
20 200
8 220
H
RES/+
VOL+ NAV1 SET

ON MENU BAND
OFF
SET/-
MODE
VOL-
L R
A/C
1 3 5
2 4 R
RT21280040
b. As shown in the illustration, install the steering wheel

remover, and then tighten it with a wrench to loosen
the steering wheel assembly from the steering column 5
assembly.
6
OFF L+
VO
L-
DE VO
MO
RT21280050

c. Cut the wire harness band (arrow).
4 100 120
3 5 80 140
6 60 160
2
40 180
1 7
x1000
20 200
8 220
H
RES/+
VOL+ NAV1 SET

ON MENU BAND
OFF
SET/-
MODE
VOL-
L R
A/C
28
1 3 5
2 4 R
RT21280041
d. Disconnect the steering wheel quick button connector

(arrow).
RT21280060
e. Remove the steering wheel assembly.
CAUTION
 Be careful when removing the steering wheel assembly to prevent damage to the airbag connector, horn
connector and quick button connector on the spiral cable.
Inspection
1. Check the steering wheel assembly body for damage or deformation. Replace the steering wheel
assembly if necessary.
2. Check the spline in the steering wheel assembly for damage. Replace the steering wheel assembly if
necessary.

Installation
CAUTION
 Check that front wheels are in the straight-ahead position before installing steering wheel assembly.
28
1. Adjust the spiral cable to correct position.
HINT:
Fully turn the spiral cable inner circle clockwise when
realigning the center, and then turn it counterclockwise to
align with ►◄ while yellow ball (arrow) occurs in the
clear vertical window. Failure to follow these instructions OFF
PULL
MIST
OFF
INT INT
ON
may affect normal function of airbag system and cause

LO
HI
OFF REAR
PBT
injury to driver.
RT21280070
2. Pass the airbag connector, horn connector through the hole of steering wheel assembly, and connect the
steering wheel quick button connector. Then align the matchmarks on steering wheel assembly and
steering column assembly to install the steering wheel assembly.
CAUTION
 Tighten steering wheel assembly fixing nut to the specified torque.

 Install each connector in place.
 After repairing, check that airbag system operates normally.

Combination Switch Cover

Removal
3. Remove the combination switch cover. 28
HINT:
Remove the steering wheel assembly first, and then remove combination switch cover if necessary.
a. Turn the steering wheel to left, and remove the left
side fixing screw (arrow) from the combination switch
cover.
RT21280080
b. Turn the steering wheel to right, and remove the right

side fixing screw (arrow) from the combination switch
cover.
MODE
VOL+
VOL-
<
<

60
40
20
0 220
< <
T
MIS
OFF
INT
INT
PULL
LO
HI
SET
BAND
NAVI MENU
OFF ON A/C
RESI+
SETI-
ON
OFF
RT21280090
c. Remove the lower fixing screw (arrow) from the

combination switch cover.
OFF
OFF
LR
3
2
1
RT21280100

d. Disengage the connecting clip between upper cover

and lower cover, and then disengage upper cover and
lower cover to remove the lower cover.
28
OFF
RT21280110
e. Disengage 6 clips between upper cover and steering

column dust gasket, and then remove the upper
cover.
80
x1000
rpm
ENGINE
START
STOP
2
OFF
OFF
RT21280111
CAUTION
 Operate carefully to prevent damage to components during removal.
Inspection
1. Check the combination switch upper and lower covers for damage or deformation. Replace the upper and
lower covers if necessary.
2. Check if upper and lower cover clips are normal. Replace the upper and lower covers if necessary.

Installation
1. Loosen steering wheel adjusting handle, and adjust steering column assembly to the uppermost position,
then tighten the adjusting handle to the uppermost position.
2. Insert steering column lower cover from right side of ignition switch at an angle, and then install the
adjusting handle into the cover hole.
3. After adjusting lower cover, install upper cover and fix upper and lower cover clips in place, then install the
self-tapping screws.
28
CAUTION
 Tighten the self-tapping screws in place.

 Operate carefully to prevent damage to components during installation.

Steering Column with Intermediate Shaft Assembly (without EPS)

Removal
28 3. Disconnect the negative battery cable.
4. Remove the driver airbag (See page 32-65).
5. Remove the steering wheel assembly (See page 28-10).
7. Remove the spiral cable (See page 32-67).
8. Remove the combination switch assembly.
a. Disconnect the light combination switch connector (1)
and wiper and washer combination switch connector
(2).
4 100 120
3 5 80 140
60 160
2 6
40 180
1 7
20 200
X1000
rpm km/h
0 8 0 220
C H E F
ON
REAR
MIST
OFF OFF
OFF
INT
OFF PULLLO INT
HI
NAVI
L R
3
2
1 2 OFF
RT21280120
b. Loosen the combination switch clamp and pull the

combination switch outward, then disconnect the
combination switch from the steering column to
remove the combination switch.
4 100 120
3 5 80 140
60 160
2 6
40 180
1 7
20 200
X1000
rpm km/h
0 8 0 220
C H E F
ON
REAR
MIST
OFF OFF
OFF
INT
OFF PULLLO INT
HI
NAVI
L R
3
2
OFF
RT21280130
9. Remove the steering column with intermediate shaft assembly.

a. Disconnect the ignition starting switch connector (1),
key switch connector (2) and connector (3) of ignition
switch illumination light and anti-theft coil. 2
RT21280140

b. Remove 3 steering boot nuts (arrow) from the front

baffle plate, and then loosen the worm clamp (1) to
separate the steering boot from the front baffle plate.
(Tightening torque for nut: 10 ± 1 N·m)
(Tightening torque for worm clamp: 2 ± 0.5 N·m)
1 28
RT21280170
c. Remove the coupling bolt (arrow) between steering

column with intermediate shaft assembly and steering
gear input shaft.
RT21280180
d. Remove 2 fixing nuts (arrow) from the upper bracket

of steering column assembly.
RT21280150
e. Remove 2 fixing bolts (arrow) from the lower bracket

RT21280160
f. Carefully remove the steering column with intermediate shaft assembly.
CAUTION
 DO NOT touch the interior ornament when removing the steering column with intermediate shaft
assembly to avoid scratching the interior ornament.

Disassembly
1. Remove the ignition starting switch.
a. Remove the fixing screws (arrow) from the ignition
starting switch, and then remove the ignition starting
switch.
28
RT21280190
2. Remove the ignition switch illumination light.

a. Remove the ignition switch illumination light in the
direction of arrow from the ignition switch lock body.
RT21280191
3. Remove the ignition key cylinder.

a. Turn the ignition switch key cylinder to ACC with key,
and insert a small screwdriver or similar tool into the
ignition switch lock body hole, then pull out the ignition
key cylinder.
RT21280210
4. Remove the ignition switch lock body.

a. Set the steering column assembly onto a vise.
CAUTION
 DO NOT tighten the vise excessively.

b. Using an electric drill (1), drill a hole on the ignition

switch lock body anti-theft bolt (arrow).
1
28
RT21280220
c. Using a screw remover, remove the ignition switch

lock body anti-theft bolt.
RT21280221
d. Remove the ignition switch lock body and ignition switch fixing clamp.
Inspection
1. Check if ignition switch lock body and key cylinder are normal. Replace the ignition switch lock body and
key cylinder if necessary.
2. Check steering column assembly for wear, cracks or deformation, and welding or correction is not allowed.
Replace the steering column assembly if necessary.
3. Check steering column bearing for looseness, wear or sticking. Replace the steering column assembly if
necessary.
Assembly
1. Install the ignition switch assembly.
a. Set the steering column assembly onto a vise.
CAUTION
 DO NOT tighten the vise excessively.
b. Install the ignition switch assembly to the steering

column assembly with a new ignition switch lock body
anti-theft bolt, and then tighten the anti-theft bolt until
its head is disengaged.
RT21280222

2. Install the ignition key cylinder.

a. Push the ignition key cylinder into the ignition switch
lock body until the ignition key cylinder fixing block
locks in place.
28
RT21280211
b. Check the ignition key cylinder for proper operation. When the key is removed, steering lock is locked;
when the key is inserted and ignition switch is turned to ACC or ON, steering lock is unlocked.
Installation
CAUTION
 Before installing steering column assembly, slide the spline at lower part of steering column assembly
onto intermediate shaft upper universal joint first.
 Tighten the fixing nuts, bolts and screws in place.

Electronic Power Steering Column with Intermediate Shaft

Assembly
Removal
2. Turn off all the electrical equipment and ignition switch. 28
8. Remove the combination switch assembly.
a. Disconnect the light combination switch connector (1)
and wiper and washer combination switch connector
(2).
1 2
RT21280230
b. Loosen the combination switch clamp and pull the

combination switch outward, then disconnect the
combination switch from the steering column to
remove the combination switch.
4 100 120
3 5 80 140
60 160
2 6
40 180
1 7
20 200
X1000
rpm km/h
0 8 0 220
C H E F
ON
REAR
MIST
OFF OFF
OFF
INT
OFF PULLLO INT
HI
NAVI
L R
3
2
OFF
RT21280131
9. Remove the lower left protector assembly (See page 45-19).

10.Remove the brake pedal assembly (See page 26-24).
11. Remove 3 steering boot nuts (arrow) from the front baffle
plate, and then loosen the worm clamp (1) to separate
the steering boot from the front baffle plate.
(Tightening torque for worm clamp: 2 ± 0.5 N·m)
RT21280170

12.Remove the coupling bolt (arrow) between steering

28
RT21280240
13.Remove the steering column with intermediate shaft assembly.

a. Disconnect 2 connectors (arrow) from the electronic
controller.
RT21280250
b. Remove 2 fixing nuts (arrow) from the upper bracket

of steering column assembly, and then remove the
upper part of steering column.
RT21280260
c. Remove 2 fixing bolts (arrow) from the lower bracket

25
15
25
10
RT21280270
d. Carefully remove the steering column with intermediate shaft assembly from underneath.
CAUTION
 DO NOT touch the interior ornament when removing the steering column with intermediate shaft
assembly to avoid scratching the interior ornament.

Disassembly
1. Remove the coupling bolt (arrow) between electronic
power steering column and intermediate shaft.
(Tightening Torque: 50 N·m)
28
RT21280280
Inspection
1. Check if electronic controller is normal. Replace the electronic controller if necessary.
2. Check steering column assembly for wear, cracks or deformation, and welding or correction is not allowed.
Replace the steering column assembly if necessary.
3. Check steering column bearing for looseness, wear or sticking. Replace the steering column assembly if
necessary.
Assembly
Installation
CAUTION
 Before installing steering column assembly, slide the spline at lower part of steering column assembly
onto intermediate shaft upper universal joint first.
 Tighten the fixing nuts, bolts and screws in place.

- MEMO -

GENERAL INFORMATION 29-3 Power Steering Pump Assembly 29-17
Operation 29-4 Disassembly 29-18
Tool 29-5 Assembly 29-18 29
Installation 29-18
Ball Pin Assembly 29-19
Removal 29-19
Steering Fluid Draining 29-7
Inspection 29-19
Steering Fluid Adding 29-8
Installation 29-20
Bleeding Procedures 29-9
Steering Tie Rod Assembly 29-21
Steering Fluid Reservoir Assembly 29-10 Inspection 29-21
Inspection 29-10 Steering Gear Assembly 29-23
Installation 29-11 Removal 29-23
Steering Fluid Pipe 29-12 Inspection 29-25
Inspection 29-16 Steering Gear Clearance Adjustment 29-26
Installation 29-16

29

29 - HYDRAULIC ASSIST STEERING
GENERAL INFORMATION
Description
29
2
1 3
4
5
6
8
11
7 12
9
14 ×2 ×2
10
15
13
×2
16
17
19
18
21
20 22
×2
23
24
×2
RT21290010

1 - Ball Pin Locking Nut 2 - Right Steering Tie Rod Ball Pin
3 - Elastic Clamp 4 - Right Steering Tie Rod Boot
5 - Clamping Ring 6 - Right Steering Tie Rod Assembly
7 - Steering Gear Heat Insulation Cover 8 - Steering Gear Assembly
9 - Left Steering Tie Rod Assembly 10 - Left Steering Tie Rod Boot
29 11 - Steering Tie Rod Adjustment Nut 12 - Left Steering Tie Rod Ball Pin
13 - Fluid Return Pipe 1 14 - Fluid Return Pipe 2
15 - Steering Fluid Reservoir Cap 16 - Steering Fluid Reservoir
17 - Steering Fluid Reservoir Bracket 18 - Fluid Suction Pipe
19 - Hollow Bolt 20 - Power Steering Pump Assembly
21 - Idler Pulley 22 - Power Steering Pump Bracket
23 - High Pressure Fluid Pipe 24 - Cooling Pipe
Hydraulic assist steering system consists of power steering pump assembly, steering gear assembly, steering
fluid pipe and steering fluid reservoir assembly, etc. This system can reduce the steering effort when driver
operates steering wheel, thus improving operation convenience and driving safety.

Steering gear assembly is rack & pinion type, which is characterized by simple and compact construction and
high steering sensitivity. The piston-rod is integrated with rack, and there is a boot at the connection between
steering tie rod assembly and rack. The length of steering tie rod can be adjusted properly to match with the
toe-in. Tie rod ball pin assembly and steering knuckle are connected and tightened by locking nut.
Power Steering Pump Assembly

Power steering pump assembly is connected with steering gear assembly through high pressure fluid pipe,
and connected with steering fluid reservoir assembly through fluid suction pipe. Never operate the power
steering pump assembly without fluid. Try to avoid turning the steering wheel to limit position for more than 5
seconds during use.
Steering Fluid Pipe

Steering fluid pipe is used to deliver power steering fluid. Steering fluid pipes are divided into steel pipe, hose
and hybrid type according to the length and operating features of each component. Ferrule connection is
adopted between steel pipe and hose of high pressure fluid pipe assembly. The Joint bolt and O-ring are used
between steel pipe and component, and the hose and clamp are used between hose and component. And all
these provide reliable sealing.
Steering Fluid Reservoir Assembly

Main functions of steering fluid reservoir assembly are to store and supply fluid to the steering fluid pump and
system.
Operation
Steering gear assembly converts the circular motion of steering wheel into the linear motion of rack by
engaging pinion and rack inside the steering gear assembly. Power steering pump assembly delivers fluid into
steering gear assembly to drive pistons to move toward the direction made by driver. Piston transmits force to
steering knuckle by steering tie rod assembly, thus reducing the steering effort needed when driver turns
steering wheel. If steering assist is ineffective, more steering effort is needed.

Specifications

Steering Gear Heat Insulation Cover Fixing Bolt 9±1
29
Clamping Bolt Between High Pressure Fluid Pipe
30 ± 3
and Steering Gear Assembly
Clamping Bolt Between Fluid Return Pipe and
30 ± 3
High Pressure Fluid Pipe Joint Hollow Bolt 40 ± 3
Mounting Bolt Between Steering Gear and Sub
120 ± 10
Frame
Power Steering Pump Bracket Fixing Bolt 25 ± 3
Coupling Bolt Between Power Steering Pump
25 ± 3
Assembly and Steering Pump Bracket
Locking Nut Between Ball Pin Assembly and
45 ± 5
Steering Knuckle Assembly
Mounting Bolt Between Steering Gear Assembly and
120 ± 10
Steering Tie Rod Adjustment Nut 55 ± 5
Tool
Special Tool
Ball Pin Separator
RCH0000024

DIAGNOSIS & TESTING

HINT:
29
Steering fluid (insufficient or dirty) 29-7
Steering tie rod boot (damaged or worn) 29-21
Stuck or sticking occurs when steering in Steering tie rod assembly (rust) 29-21
some position 29-23
30-25
Accessory drive belt (loose) 07-24
Tire (unevenly worn, deformed) or wheel
24-7
(out of balance)
Ball pin assembly (worn or loose) 29-19
Steering tie rod assembly (worn or loose) 29-21
Steering wheel is not centered or centered Intermediate shaft (twisted and deformed)
improperly or universal joint (worn, loose or 28-23
insufficiently lubricated)
Steering knuckle 22-12
Steering gear assembly (incorrect 29-23
clearance) 30-25
Tire (unevenly worn, deformed) or wheel
24-7
(out of balance)
Brake disc and lining (deformed) 26-27
Steering shudders Intermediate shaft (twisted and deformed)

or universal joint (worn, loose or 28-23
insufficiently lubricated)
Steering knuckle assembly 22-12
clearance) 30-25


Tire (improperly inflated) 24-7
Steering fluid (insufficient) 29-7
Fluid pipe (leakage or blocking) 29-12
Steering wheel turns heavily or steering 29
effort is uneven Steering tie rod assembly (worn or loose) 29-21
Front suspension 23-12
Accessory drive belt (loose or damaged) 07-24
Power steering pump assembly 29-17
clearance) 30-25
Steering fluid (insufficient, air or dirty) 29-7
Steering system fluid pressure fluctuates
-
abnormally
Abnormal noises from steering system
Steering tie rod assembly (worn or loose) 29-21
clearance) 30-25
Power steering pump assembly 29-17
Steering Fluid Draining

4. Turn ignition switch to ACC.
5. Open the steering fluid reservoir cap.
7. Remove the fluid suction pipe clamp (arrow) on the
power steering pump assembly side.
RT21290020
8. Place a fluid container under the fluid suction pipe, and disconnect the fluid suction pipe joint to collect
steering fluid flowing from the fluid suction pipe.
9. Turn the steering wheel left and right to the limit positions, and repeat the operation several times to drain
steering fluid in steering system.

WARNING
 If steering fluid sprays on your skin, immediately wash it off with water.
 It is harmful to your skin, if contacting with power steering fluid for a long time.
 Steering wheel should not be in the limit position for more than 5 seconds.
29
 Wasted power steering fluid should be handled according to local environmental regulations.
Steering Fluid Adding

The proper steering fluid level is between "MAX" and "MIN"
marks. It affects power steering system performance directly
whether fluid level of the fluid reservoir is proper. If fluid level
drops below "MIN" mark, it is necessary to add steering fluid.
RT21290030
CAUTION
 DO NOT apply foaming or expired steering fluid to vehicle. Otherwise it may damage the power steering
pump assembly.
1. Open the steering fluid reservoir cap, and add steering fluid to reservoir until the level reaches "MAX"
mark.
2. Start engine and run it at idle to drive the power steering pump assembly, thus filling whole steering system
with steering fluid.
3. Observe fluid level of fluid reservoir while engine is running. If fluid level drops below "MIN" mark, add
steering fluid to a proper level in time to prevent fluid level from dropping excessively and avoid air entering
power steering pump assembly.
4. If bubbles occur in steering fluid reservoir, perform bleeding procedures. Check that level is between
"MAX" and "MIN" marks when there are no bubbles in fluid reservoir and fluid level does not change any
longer.
WARNING
 If steering fluid sprays on your skin, immediately wash it off with water.
 It is harmful to your skin, if contacting with power steering fluid for a long time.

Bleeding Procedures
It is necessary to perform the bleeding procedures when bubbles occur in steering fluid reservoir assembly
and fluid has emulsified or there is excessive noise in power steering pump assembly.
Bleeding procedures are as follows:

1. Open the steering fluid reservoir cap.
2. Raise vehicle with a lifter (with front wheels off ground).
3. Start engine (idling) and turn steering wheel left and right to the limit positions (do not stay at the limit 29
positions more than 2 seconds). Repeat several times to fully bleed air in system from the reservoir.
Observe the fluid level of fluid reservoir during bleeding. If fluid level drops below "MIN" mark, add steering
fluid to proper level in time.
4. After repeatedly turning the steering wheel to the limit positions several times, center the steering wheel,
run engine at idle for 3 or 5 minutes and observe whether there are still bubbles in fluid reservoir. If there
are still bubbles, perform above procedures again until no bubbles are bled. If there are still problems,
perform steering system inspection.

ON-VEHICLE SERVICE
WARNING
 Be sure to wear necessary safety equipment to prevent accidents when servicing.

 When removing and installing high temperature components and surrounding components, wait and
29 operate until they drops to normal temperature to avoid being burned.
 Prevent skin and eyes from contacting with steering fluid.
CAUTION
 After disconnecting steering line, seal it immediately to prevent foreign matter from entering.
 Never run power steering pump assembly when the steering fluid is insufficient.
 Steering wheel should not be in limit positions for more than 5 seconds.
 Never start engine with hose loosened or disconnected.
 Never allow hose to contact with high temperature exhaust pipe.
Steering Fluid Reservoir Assembly

Removal
1. Drain the steering fluid (See page 29-7).
2. Remove the steering fluid reservoir assembly.
a. Remove the fluid suction pipe clamp (1) on steering
fluid reservoir, and disconnect the connection
between fluid suction pipe assembly and steering fluid
reservoir assembly.
b. Remove the fluid return pipe clamp (2) on steering
fluid reservoir, and disconnect the connection
between fluid return pipe assembly and steering fluid
reservoir assembly. 2 1
RT21290040
CAUTION
 Using a plug, clog the disconnected pipe to prevent foreign matter from entering.
c. Pull the steering fluid reservoir assembly upward to remove it from the steering pump bracket.
Inspection
1. Check steering fluid reservoir assembly for breakage or deformation. Replace fluid reservoir if necessary.
2. Check if there is contamination in steering fluid reservoir assembly. Clean or replace if necessary.

Installation
CAUTION
 Install fluid suction pipe clamp and fluid return pipe clamp in place.
 Never tap or hit the fluid reservoir.
29

Steering Fluid Pipe

Removal
 Collect residual steering fluid in the line with a container when disconnecting the line.
29
2. Remove the front bumper (See page 48-11).
3. Remove the fluid suction pipe.
a. Remove the fluid suction pipe clamp (arrow) on
steering fluid reservoir, and disconnect the connection
between fluid suction pipe and steering fluid reservoir
assembly.
RT21290041
b. Remove the fluid suction pipe clamp (arrow) on the

power steering pump assembly side.
RT21290020
c. Loosen the plastic pipe clamp from the front vertical

board of body.
RT21290050
d. Remove the fluid suction pipe.

4. Remove the high pressure fluid pipe.

a. Remove the high pressure fluid pipe joint hollow bolt
(arrow) from the power steering pump assembly.
29
RT21290021
b. Remove the high pressure fluid pipe clamping bolt

from the steering gear assembly. 
RT21290060
c. Remove the high pressure fluid pipe bracket bolt 1

(arrow).
RT21290061
d. Remove the high pressure fluid pipe bracket bolt 2

(arrow).
RT21290070
e. Remove the high pressure fluid pipe.

5. Remove the fluid return pipe.

a. Remove the fluid return pipe clamping bolt from the
steering gear assembly.
29
RT21290062
b. Remove the fluid return pipe bracket bolt 1 (arrow).

RT21290063
c. Loosen the fluid return pipe 1 clamp and disconnect

the fluid return pipe joint.
RT21290080
d. Remove the fluid return pipe bracket nut 2 (arrow).

RT21290081

e. Remove the fluid return pipe bracket bolt 3 (arrow).

29
RT21290090
f. Remove the fluid return pipe bracket nut 4 (arrow).

RT21290100
g. Remove the fixing bolt (arrow) and remove the guide

pipe.
RT21290101
h. Remove the fluid return pipe 2 carefully.

6. Remove the cooling pipe.
a. Remove 3 plastic clamps (arrow) from the right
radiator deflector, and remove the right radiator
deflector.
RT21290102

b. Remove the cooling pipe bracket nut 1.

c. Move away the clamp (arrow) between cooling pipe
and fluid return pipe, and disconnect the connection
between cooling pipe and fluid return pipe.
29
RT21290110
d. Remove the cooling pipe bracket nut 2 (arrow).

RT21290120
e. Remove the cooling pipe carefully.
Inspection
1. Check steering fluid pipe for cracks, wear or blockage. Replace steering fluid pipe assembly if necessary.
2. Check steering fluid pipe joint and O-ring for deformation or damage. Replace steering fluid pipe assembly
if necessary.
3. Check if steering fluid pipe bracket is normal. Replace if necessary.
Installation
CAUTION
 Never tap or squeeze steering fluid pipe.

 Tighten fixing nut to the specified torque.

Power Steering Pump Assembly

Removal
 Collect steering fluid flowing from the line with a container when disconnecting the line.
29
1. Drain steering fluid (See page 29-7).
3. Remove the power steering pump with bracket assembly.
a. Remove the high pressure fluid pipe joint hollow bolt
(1).
1
b. Loosen the elastic clamp (2), and disconnect the
connection between fluid suction pipe and power
steering pump assembly. 2
RT21290022
CAUTION
 Using a plug, clog the disconnected steering system line to prevent foreign matter from entering.
c. Remove 3 fixing bolts (1), (2) and (3) from the steering
pump bracket and the fixing bolt (arrow) from the idler
pulley.
(Tightening torque for steering pump bracket fixing
bolt: 25 ± 3 N·m) 3
(Tightening torque for idler pulley fixing bolt: 50 ± 5
N·m) 2
RT21290130

Disassembly
1. Separate the power steering pump assembly and steering pump bracket.
a. Remove the coupling bolt (arrow) between power
steering pump assembly and pulley side of steering
pump bracket.
29
RT21290140
b. Remove 2 coupling bolts (arrow) between power

steering pump assembly and the other side of
steering pump bracket.
RT21290150
Inspection
1. Check power steering pump assembly for blockage or damage, and power steering pump bearing for
looseness and abnormal noise. Replace the power steering pump assembly if necessary.
2. Check if power steering pump pulley is normal. Replace the power steering pump assembly if necessary.
3. Check if steering pump bracket is normal. Replace the steering pump bracket if necessary.
Assembly
CAUTION
 Tighten the bolts to the specified torque.

 DO NOT tap or hit power steering pump assembly.
Installation
CAUTION
 Tighten the fixing bolts to the specified torque.

 DO NOT tap or hit power steering pump assembly.

Ball Pin Assembly

Removal
HINT:
2. Remove the ball pin assembly.
29
a. Remove the locking nut (arrow) between left steering
tie rod assembly ball pin and front left steering knuckle
assembly.
RT21220120
b. Install the ball pin separator (1), and tighten the ball
steering tie rod ball pin and steering knuckle assembly
1 RT21220130
c. Loosen the steering tie rod adjustment nut (1), and

turn the ball pin assembly (2) counterclockwise to
remove it.
1
RT21290160
HINT:
When removing the ball pin assembly, record the revolutions during removal to make the front wheel toe-in
closer to the setting value after installation.
Inspection
Check ball pin assembly for looseness and insufficient lubrication and bush rubber for damage. Replace the
ball pin assembly if necessary.

Installation
CAUTION
 After installation, it is necessary to perform wheel alignment procedure (See page 23-50).
29

Steering Tie Rod Assembly

Removal
HINT:
2. Remove the battery tray (See page 16-7).
29
4. Remove the ball pin assembly (See page 29-19).
5. Remove the steering tie rod assembly.
a. Remove the steering tie rod boot clamp (2).
b. Remove the steering tie rod boot clamping ring (1)
and remove the steering tie rod boot. 1
RT21290170
CAUTION
 Operate carefully to prevent damaging the boot.

 It is necessary to replace with new clamping ring when reinstalling steering tie rod boot.
c. Using a wrench, remove the steering tie rod ball pin

(arrow).
RT21290171
Inspection
1. Check steering tie rod boot for damage, and clamp for normality. Replace the steering tie rod boot and
clamp if necessary to prevent water and micro dust from entering and causing parts failure prematurely.
2. Check steering tie rod assembly for deformation or wear, and ball for insufficient lubrication. Replace
steering tie rod assembly or add grease if necessary.

Installation
CAUTION
 It is necessary to apply thread seal gum to the ball pin.

 It is necessary to fit the steering tie rod ball pin face and rack face closely.
29


WARNING
 Be sure to wear necessary safety equipment to prevent accidents when servicing.

 When removing and installing high temperature components and surrounding components, wait and
operate them until they drops to the normal temperature to avoid being burned.
 Prevent skin and eyes from contacting with steering fluid when removing the steering system. 29
CAUTION
 After disconnecting steering system line, seal it immediately to prevent foreign matter from entering.
 Never run power steering pump assembly when steering fluid is insufficient.
 Steering wheel should not be in limit positions for more than 5 seconds.
 Never start engine with hose loosened or disconnected.
 Never allow hose to contact with high temperature exhaust manifold or catalyst.
Removal
6. Remove the coupling bolt between steering column with
intermediate shaft assembly and input shaft of steering
gear.
RT21280180
7. Separate the ball pin assembly and steering knuckle.

HINT:

a. Remove the locking nut (arrow) between left steering

tie rod assembly ball pin and front left steering knuckle
assembly.
29
RT21220120
b. Install the ball pin separator (1), and tighten the ball
steering tie rod ball pin and steering knuckle
assembly.
1 RT21220130
8. Remove the steering gear with tie rod assembly.

a. Remove the high pressure fluid pipe clamping bolt (1)
and fluid return pipe clamping bolt (2) from the
steering gear assembly, and disconnect the 2
connectionsbetween fluid return pipe, high pressure
fluid pipe and steering gear assembly.
(Tightening torque for fluid return pipe clamping bolt:
30 ± 3 N·m)
(Tightening torque for high pressure fluid pipe 1
clamping bolt: 30 ± 3 N·m)
RT21290064
b. Remove the high pressure fluid pipe bracket bolt 1

and fluid return pipe bracket bolt 2 from the steering
gear assembly.
2
1
RT21290065

c. Remove 2 mounting bolts between steering gear and

sub frame.
29
RT21290180
d. Slowly remove the steering gear with tie rod assembly.
Inspection
1. Check steering gear assembly housing for damage or deformation, and rack and pinion for sticking.
Replace the steering gear assembly if necessary.
2. Check if steering tie rod boot, clamp and clamping ring are normal. Replace if necessary to prevent water
and micro dust from entering and causing parts failure prematurely.
3. Check steering tie rod assembly and ball pin assembly for serious wear. Replace the steering tie rod
assembly or ball pin assembly if necessary.
Installation
CAUTION
 After installing the steering gear assembly, perform front wheel alignment procedure (See page 23-50).

Steering Gear Clearance Adjustment

1. Set wheels to straight-ahead position.
2. Loosen the adjustment bolt locking nut (arrow).
29
RT21290190
3. Turn steering wheel left and right. If sound is heard from steering gear assembly, adjust the adjustment bolt
until no clattering noise is heard when turning the steering wheel.
4. Tighten the adjustment bolt for more 1/8 turn (approximately 45°).
5. Perform road test.
6. If steering mechanism cannot return to central position, unscrew the bolt by 15°.
7. Perform road test.

GENERAL INFORMATION 30-3 C1352 30-10
Description 30-3 C1901 30-12
Operation 30-4 C1902 30-12
Specifications 30-4 C1910 30-17
Tools 30-4
Circuit Diagram 30-6
EPS Controller Pin Definition 30-7
Ball Pin Assembly 30-22 30
Removal 30-22
DIAGNOSIS & TESTING 30-8 Inspection 30-22
Diagnosis Help 30-8 Installation 30-22
Intermittent DTC Troubleshooting 30-8 Steering Tie Rod Assembly 30-23
Diagnostic Trouble Code (DTC)  Inspection 30-23
Chart 30-9 Installation 30-24
C1301 30-10 Steering Gear Assembly 30-25
C1302 30-10 Removal 30-25
C1307 30-10 Inspection 30-26
C1323 30-10 Installation 30-26
C1332 30-10 Steering Gear Clearance 
C1351 30-10 Adjustment 30-27

30

30 - ELECTRONIC POWER STEERING
GENERAL INFORMATION
Description
1
3
4
5
30
6
2
8
11
10
RT21300010
1 - Right Steering Tie Rod Ball Pin 2 - Tie Rod Ball Pin Locking Nut
3 - Tie Rod Dust Boot Clamp 4 - Right Steering Tie Rod Dust Boot
5 - Clamp 6 - Right Steering Tie Rod Assembly
7 - Steering Gear Assembly 8 - Left Steering Tie Rod Assembly
9 - Left Steering Tie Rod Dust Boot 10 - Left Steering Tie Rod Ball Pin
11 - Steering Gear Heat Shield
The vehicle uses the electronic power steering system, which can reduce the workload when the driver
operates the steering wheel, thus improving the operation convenience and driving safety.

Operation
The circular motion of the steering wheel is converted into linear motion of the rack by engaging the rack and
pinion inside the steering gear. The rack can push and pull the tie rod by lateral motion, thus changing the
direction of the front wheel.
The EPS controller controls the rotating direction of steering motor and the assisting current level based on
the torque sensor signals to finish the steering assist. When the vehicle is not turning, the EPS controller does
not send command to the steering motor controller, and the steering motor does not operate.
Specifications
30

Ball Pin Locking Nut 35 ± 3
Coupling Bolt between Steering Gear Input Shaft
and Steering Column with Intermediate Shaft 60 ± 5
Assembly
Steering Gear Fixing Bolt 120 ± 10
Tools
Special Tools
Ball Pin Separator
RCH0000024
ཽ⪔⊳䖜
RCH0000001

General Tool
Digital Multimeter
RCH0000002
30

Circuit Diagram
30
ON OR START
INSTRUMENT
MF09 EPS RF07 PANEL
POWER FUSE AND
80A 7.5A RELAY BOX
E-064
I-007
7
R
TO CAN
SYSTEM
GB
YB
E-081
A1 B1 B2 B3 A2
CAN H1 CAN L1
EPS
E-077
I-057
1 2 3 4 5 6 7 8 9 10 11 12
A1 A2 B5 B4 B3 B2 B1 13 14 15 16 17 18 19 20 21 22 23 24
B10 B9 B8 B7 B6 27 25 26
E-077 87
E-064 L I-057 85 86 86 86
B 87 30 87 30
30 85 85
I-007
B
ET21300010

EPS Controller Pin Definition

Vehicle supply: controller supply connector (connector A)
Pin Definition
A supply positive
B supply negative 1 2 3 4 5
6 7 8 9 10 B A
Vehicle signal: controller signal connector (connector B)
Pin Definition 30
RT21300030
1 IGN signal
2 CAN High
3 CAN Low
4 -
5 -
6 Signal ground
7 -
8 -
9 -
10 -

DIAGNOSIS & TESTING

Diagnosis Help
2. Confirm that the malfunction exists, and perform the diagnosis tests and service procedures.
3. If the Diagnostic Trouble Codes (DTC) cannot be cleared, it indicates that there is a current malfunction.
4. Only the digital multimeter can be used when measuring the voltage of the electronic system.
30 5. Refer to any Technical Bulletin applied to the malfunction.
6. Visually check the related wire harness.
7. Check and clean the Electronic Power Steering controller (EPS controller) ground related to the latest
DTC.
8. If numerous trouble codes are set, refer to the circuit diagram and look for any common ground circuit or

If it is an intermittent problem, perform the following procedures:
1. Check the connector for looseness.
2. Check the wire harness for wear, piercing, pinch or partial break.
3. Observe the diagnostic tester data related to this circuit.
4. Wiggle the related wire harness and connector and observe if the signal is interrupt in the related circuit.
5. Try to duplicate the conditions under which the DTC is set.
6. Check for the data that has changed or the DTC that has been reset during the wiggle test.
7. Check if the terminals are broken, bent, protruded out or corroded.
8. Check the sensor and mounting area for any condition that would result in an incorrect signal, such as
damage, foreign matter.
9. A data recorder and/or oscilloscope can be helpful in diagnosing the intermittent malfunction.
Ground Inspection
Groundings are often exposed to moisture, dirt or other corrosive areas. Corrosion (rust) may form additional
resistance. This additional resistance will change the way in which a circuit works. A loose or corroded ground
can drastically affect the electronically controlled circuit. Perform the following operations:
2. Check all the contact surfaces for tarnish, dirt, rust, etc.
3. Clean as necessary to ensure that the contacting is in a good condition.
4. Reinstall the bolt or nut securely.
5. Check for the accessories which may interfere with the ground circuit.
6. If several wires are crimped into one ground terminal, check for proper crimps. Make sure that all the wire
harnesses are clean, securely fastened and good contacted without crimping any excessive insulation
coat.


Code Name Code Name
C1301 Steering Angle Sensor Electrical Error
C1302 Steering Angle Sensor Not Trimmed
C1307 Sensor Supply Voltage Error
C1308 Fail safety Relay Error
C1315 W/LAMP Fault 30
C1323 ECU Hardware Fault
C1332 Torque Sensor Error
C1351 Motor Position Sensor Error
C1352 Motor Error
C1901 Battery Under Voltage Error
C1902 Battery Over Voltage Error
C1910 IGN Voltage Error
U0155 ICM Update Error
U0418 Vehicle Speed Error
U1000 EMS Signal Error
U1027 CAN Update Error

DTC C1301 Steering Angle Sensor Electrical Error
DTC C1302 Steering Angle Sensor Not Trimmed
DTC C1307 Sensor Supply Voltage Error
DTC C1323 ECU Hardware Fault

30
DTC C1332 Torque Sensor Error
DTC C1351 Motor Position Sensor Error
DTC C1352 Motor Error
DTC DTC Definition Possible causes

C1301 Steering Angle Sensor Electrical Error
C1302 Steering Angle Sensor Not Trimmed
C1307 Sensor Supply Voltage Error
 EPS booster assembly circuit
C1323 ECU Hardware Fault
 EPS booster assembly fault
C1332 Torque Sensor Error
C1351 Motor Position Sensor Error
C1352 Motor Error
CAUTION
 When performing the circuit diagnosis and test, always refer to the circuit diagram for the specific circuit
and the component information.
Diagnosis Procedure
1 Check EPS booster assembly power supply and ground circuit
a. Check EPS booster assembly power supply and ground circuit.

connector
OK

2 Check for DTCs
a. Using X-431 3G diagnostic tester, read the EPS DTC.

b. Check if DTC C1301, C1302, C1307, C1323, C1332, C1351 or C1352 still exists.
NG Replace EPS booster assembly
OK
30
The system is operating normally.
Reassemble the vehicle and perform a road test to confirm that the malfunction reported by the
customer has been repaired.

DTC C1901 Battery Under Voltage Error
DTC C1902 Battery Over Voltage Error
30
BATTERY
MF09 EPS
POWER
80A
E-064
R
E-081
A1 A2
EPS
E-077
A1 A2
E-077
E-064 L
ET21300020


 Fuse
C1901 Battery Under Voltage Error  Wire harness or connector
 Battery
C1902 Battery Over Voltage Error  Battery terminal
 EPS booster assembly
CAUTION
30
Diagnosis Procedure
1 Check battery
a. Check if battery voltage is normal.
OK
2 Check battery terminals
a. Check if battery terminals are loose or corroded.
NG Tighten or replace battery terminals
OK
3 Check EPS ground point

b. Check EPS ground point E-081.

ground point
OK

4 Check EPS power supply connector
a. Disconnect EPS power supply connector E-077.

b. Check connector.
NG Repair or replace EPS power supply

connector
30 OK
5 Check EPS power supply voltage
a. Measure voltage between EPS power supply connector

E-077 terminal A1 and body ground.
Condition V
E-077 (A1) - Body

Always 11 to 14 V
ground
A1 A2
OK Go to step 8 E-077
RT21305001
NG
6 Check EPS power supply fuse
a. Check EPS power supply fuse MF09 (80A) outside the engine compartment fuse and relay box.
NG Replace EPS power supply fuse
OK

7 Check wire harness and connector (EPS - EPS power supply)
a. Disconnect EPS power supply connector E-064.

b. Check wire harness between the connector terminals.
Check for Open
Specified + -
Condition
E-064 - E-077 (A1) Continuity 30
A1 A2
Specified
Condition
E-077 (A1) - Body ground No continuity
E-064
connector RT21305002
OK
8 Check EPS ground circuit
a. Disconnect EPS connector E-077.

b. Check wire harness between terminal A2 of E-077 and
ground point E-081.
Condition
E-077 (A2) -
Always Continuity
E-081 A1 A2
E-077

connector
E-081
RT21305003
OK

9 Check for DTCs

b. Check if DTC C1901or C1902 still exists.
OK
30

DTC C1910 IGN Voltage Error
30
ON OR START
INSTRUMENT
MF09 EPS RF07 PANEL
POWER FUSE AND
80A 7.5A RELAY BOX
E-064
I-007
7
R
E-081
A1 B1 A2
EPS
E-077
I-057
1 2 3 4 5 6 7 8 9 10 11 12
A1 A2 B5 B4 B3 B2 B1 13 14 15 16 17 18 19 20 21 22 23 24
B10 B9 B8 B7 B6 27 25 26
E-077 87
E-064 L I-057 85 86 86 86
B 87 30 87 30
30 85 85
I-007
B
ET21300030


 Fuse
C1910 IGN Voltage Error  Wire harness or connector
 EPS booster assembly
CAUTION
30 and the component information.
Diagnosis Procedure
1 Check EPS ground point

b. Check EPS ground point E-081.

ground point
OK
2 Check EPS connector
a. Disconnect two EPS connectors.

b. Check connectors.
NG Repair or replace EPS connector
OK

3 Check EPS ignition switch voltage
a. Measure voltage between terminal B1 of EPS connector

B I-057 and body ground.
Condition V
I-057 (B1) - Body

ground B5 B4 B3 B2 B1
B10 B9 B8 B7 B6
30
OK Go to step 8 I-057
E-081
RT21305004
NG
4 Check EPS fuse
a. Unplug EPS fuse RF07 (7.5 A) from instrument panel fuse and relay box.
NG Replace fuse
OK

5 Check wire harness and connector (EPS - instrument panel fuse and relay box)
a. Disconnect instrument panel fuse and relay box

connector I-007.
b. Check wire harness between connector terminals.
Check for Open
+ -
Specified B5 B4 B3 B2 B1
Condition B10 B9 B8 B7 B6
30
I-007 (7) - I-057 (B1) Continuity I-057
Check for Short 1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
Specified
Multimeter Connection 27 25 26
Condition 87
85 86 86 86
I-007 (7) - Body ground No continuity 30 85
87 30
85
87 30
I-007
NG Repair or replace wire harness or RT21305005
connector
OK
Repair or replace instrument panel fuse and relay box or wire harness (instrument panel fuse and
relay box - ignition switch)
6 Check EPS ground circuit
a. Disconnect EPS connector E-077.

b. Check wire harness between terminal A2 of E-077 and
ground point E-081.
Condition
E-077 (A2) -
Always Continuity
E-081 A1 A2
E-077

connector
E-081
RT21305003
OK

7 Check for DTCs

b. Check if DTC C1910 still exists.
OK
30

ON-VEHICLE SERVICE
Ball Pin Assembly
Removal
HINT:
30 1. Turn the steering wheel to the straight ahead position.
5. Remove the tie rod ball pin.
a. Remove the left side steering tie rod assembly ball pin
and locking nut (arrow) of front left steering knuckle
assembly.
RT21220120
b. Install ball pin separator (1), and tighten ball pin

separator bolt with wrench (2), then separate the tie
rod ball pin from the steering knuckle assembly.
1 RT21220130
c. Remove the ball pin from the steering gear tie rod.
Inspection
1. Check the tie rod ball pin for looseness and the rubber boot for damage. Replace the ball pin assembly if
necessary.
2. Check the tie rod ball pin dust boot for damage. If damaged, replace the dust boot.
Installation
CAUTION
 After installing the tie rod ball pin assembly, it is necessary to perform the wheel alignment procedure
(See page 23-50).

Steering Tie Rod Assembly

Removal
HINT:
1. Remove engine trim cover assembly (See page 10-10).
2. Remove air filter assembly (See page 10-17).
3. Remove front wheel (See page 24-9). 30
4. Remove ball pin assembly (See page 30-22).
5. Remove steering tie rod assembly.
a. Remove steering tie rod boot clamp (2).
b. Remove steering tie rod boot clamping ring (1) and
remove steering tie rod boot. 1
RT21300170
CAUTION
 Operate carefully to prevent damage to the boot.

 It is necessary to replace with new clamping ring when reinstall the tie rod boot.
c. Using a wrench, remove steering tie rod assembly

(arrow).
RT21300171
Inspection
1. Check tie rod dust boot for damage and clamp for normal conditions. Replace the tie rod boot and clamp if
necessary to prevent water and micro dust from entering and causing parts failure prematurely.
2. Check tie rod for deformation or wear and ball for insufficient lubrication. Replace tie rod assembly or add
grease if necessary.

Installation
CAUTION
 It is necessary to apply thread seal gum to the tie rod ball pin.
 It is necessary to fit the tie rod ball pin face and the rack face closely.
30


Removal
1. Turn the steering wheel to the straight ahead position.
4. Remove the front wheels (See page 24-9).
5. Remove steering tie rod ball pin.
a. Remove the left side steering tie rod assembly ball pin 30
and locking nut (arrow) of front left steering knuckle
assembly.
RT21220120
b. Install ball pin separator (1), and tighten ball pin

separator bolt with wrench (2), then separate the tie
rod ball pin from the steering knuckle assembly.
1 RT21220130
6. Remove the coupling bolt (arrow) between steering

RT21280240
7. Remove two fixing bolts on both sides of steering gear

brackets.
RT21300150

8. Remove steering gear assembly.
Inspection
1. Check the steering gear dust boot for damage and the clamp for looseness. Replace them if necessary.
Otherwise, it is easy for water and dust to enter, and cause parts failure prematurely.
2. Check the steering gear for damage. Replace the power steering gear if necessary.
Installation
30 HINT:
When installing the coupling bolt between the steering column lower universal joint and the steering gear input
shaft, it is necessary to assemble it reliably.
CAUTION
 Perform the front wheel alignment procedure after installing the steering gear (See page 23-50).

Steering Gear Clearance Adjustment

1. Position the wheels straight ahead.
2. Turn the steering wheel to the right and left.
3. If there is noise in the steering gear, adjust the bolt
(arrow) until the collision noise cannot be heard when
turning the steering wheel.
30
RT21300160
4. Retighten the bolt in 1/8 turn (approximately 45°).

5. Perform a road test.
6. Loosen the bolt by 15° if the steering gear cannot return to the center position by itself.
7. Perform a road test.

- MEMO -

AIR CONDITIONING
GENERAL INFORMATION 31-3 Blower Assembly 31-73
Circuit Diagram 31-8 Blower Speed Resistor 31-74
Removal 31-74
Installation 31-74
Inner/Outer Circulation Damper 
Diagnosis Procedure 31-17 Motor 31-75
31
A/C System Function 31-19 Removal 31-75
DTC Confirmation Procedure 31-21 Installation 31-75
Intermittent DTC Troubleshooting 31-21 Mode Damper Servo Motor 31-76
Diagnostic Trouble Code (DTC)  Installation 31-76
Chart 31-22
Mix Damper Servo Motor 31-77
B2133 31-23
Removal 31-77
B2134 31-23
Installation 31-77
B2120 31-28
HVAC Assembly 31-78
B2121 31-28
Removal 31-78
B2126 31-32
Disassembly 31-80
B2127 31-37
Inspection 31-90
B2135 31-41
Assembly 31-93
B2160 31-45
Installation 31-93
B2163 31-45
A/C Low Pressure Line 31-94
B2166 31-50
Removal 31-94
B2169 31-54
Installation 31-95
B2172 31-59
A/C High Pressure Line 31-96
Compressor Assembly Noise  Compressor Assembly 31-99
Refrigerant Leakage Inspection 31-64 Installation 31-101
Refrigerant Recovering/Draining 31-66 Condenser Assembly 
Vacuum Pumping 31-67 (w/Receiver Drier) 31-102
Refrigerant Recharging 31-67 Removal 31-102
Refrigerant Oil Recovering 31-68 Inspection 31-103
Refrigerant Oil Charging 31-69 Installation 31-104
A/C Control Panel Assembly 31-70 Mix Damper Servo Motor 
Removal 31-70 (Left - Automatic A/C) 31-105
A/C Element 31-72 Room Temperature Sensor 
Removal 31-72 (for Automatic A/C) 31-106
Removal 31-106
Installation 31-72
Inspection 31-107
Installation 31-108

Outside Temperature Sensor  Heater Core Sensor 
(for Automatic A/C) 31-109 (for Automatic A/C) 31-112
31

31 - AIR CONDITIONING
GENERAL INFORMATION
AIR CONDITIONING
Description
1
3
31
6 4
7 5
RT21310010
1 - Condenser Assembly (w/Receiver Drier) 2 - O-ring

3 - Condenser to Evaporator Line Assembly 4 - HVAC Assembly
5 - A/C Control Panel Assembly 6 - Evaporator to Compressor Line Assembly
7 - Compressor Assembly 8 - Compressor to Condenser Line Assembly

1. System composition
This model is equipped with two types of A/C: electrical A/C and automatic A/C. The A/C system consists
of the following four parts:
Air conditioning and distribution system: air mixing and distributor part of HVAC, inner/outer circulation
inlet, outlet and air filter.
Control system: A/C control panel assembly, inner/outer circulation damper motor, mode damper servo
motor, mix damper servo motor, blower, blower speed resistor, A/C pressure sensor, evaporator
temperature sensor, heater core sensor (for automatic A/C), room temperature sensor (for automatic A/C),
outside temperature sensor (for automatic A/C) and sun sensor.
Heating system: heater core assembly, heating inlet hose, heating outlet hose and engine cooling
circulation system.
31 Cooling system: compressor assembly, condenser assembly (w/receiver drier), expansion valve,
evaporator core assembly and A/C high/low pressure line.
2. Operation
High-pressure Low-pressure
Gas Liquid
High-pressure Low-pressure
Liquid Gas
Compressor
Outside Air
Condenser
Evaporator
Blower Motor
A/C Pressure Sensor Expansion Valve
RT21310020
Outside fresh air enters the air inlet filter assembly through the cowl top opening at the right side of
windshield base. Fresh air flows through the evaporator core and heater core, and then enters the vehicle
through the outlets on the instrument panel and the floor. The intake air volume can be adjusted by the
blower speed switch on the A/C control panel assembly. Turn on the compressor assembly by pressing the
A/C switch on the A/C control panel. The refrigerant is compressed by the compressor assembly and
converted into high temperature - high pressure gas, which is then condensed into high pressure liquid in
the condenser. Then the liquid is filtered and dried by the receiver drier and delivered to the expansion
valve and becomes low-pressure liquid through throttling and depressurization. Finally the liquid enters the
evaporator in vehicle, absorbs the heat and evaporates, thus refrigeration is achieved. A/C heating is
realized by the engine coolant circulation system. Heater core is the main component of the heating

system. With the engine running, engine coolant flows from the engine water pump to the heater core, the
heater core transmits the heat from engine coolant to the air that flows through the heater core. At this
time, the A/C switch is off. The air flowing through the heater core becomes hot wind through the heat
exchanger, thus providing heating. The temperature adjustment control mechanism can be controlled by
rotating the temperature adjustment knob, and the mix damper closes when temperature adjustment knob
is rotated counterclockwise to MAX COOL position. If the airflow does not flow through the heater core, the
heat transmission will not occur. When rotating the temperature adjustment knob clockwise from MAX
COOL position, the mix damper will open slowly, allowing air flows through the heater core. Most of the
airflow is heated in this way and the discharged air becomes warm. When the temperature adjustment
knob is rotated counterclockwise to MAX HOT position, the mix damper is opened fully and all the air flows
through the heat core, thus the air is heated. Mode buttons on the A/C control panel are used to direct
temperature adjusted air through selected outlets.
31
Specifications

A/C Control Panel Assembly Fixing Screw 2.5 ± 0.5
Coupling Bolt Between A/C High/Low Pressure Line
7±1
and Expansion Valve
Fixing Nut Between HVAC Assembly and Instrument
7±1
Fixing Bolt Between HVAC Assembly and Instrument
4±1
Fixing Bolt Between HVAC Assembly and Body 7±1
Air Inlet Assembly Right Fixing Screw 2.5 ± 0.5
Air Inlet Assembly Left Fixing Screw 2.5 ± 0.5
Air Inlet Assembly Rear Fixing Screw 2.5 ± 0.5
Left Foot Fan Shield Fixing Screw 2.5 ± 0.5
Right Foot Fan Shield Fixing Screw 2.5 ± 0.5
Coupling Bolt Between Expansion Valve and
7±1
Expansion Valve Mounting Pressure Plate
Blower Case Assembly Upper Fixing Screw 2.5 ± 0.5
Blower Case Assembly Lower Fixing Screw 2.5 ± 0.5
Evaporator Case Assembly Fixing Screw 2.5 ± 0.5
Heater Core Line Pressure Plate Fixing Screw 2.5 ± 0.5
Heater Core Line Cover Plate Fixing Screw 2.5 ± 0.5
Mode Damper Adjustment Mechanism Set Fixing
2.5 ± 0.5
Screw
Coupling Nut Between A/C High/Low Pressure Line
7±1
Fixing Bracket and Body
Fixing Bolt Between A/C Low Pressure Line and
25 ± 2.5
Compressor Assembly
Fixing Bolt Between A/C High Pressure Line and
25 ± 2.5
Compressor Assembly


Fixing Nut Between A/C High Pressure Line I and
7±1
Condenser Assembly
Fixing Nut Between A/C High Pressure Line II and
7±1
Condenser Assembly
70 ± 5
70 ± 5
31 Coupling Bolt Between Front Mounting Cushion

70 ± 5
70 ± 5
80 ± 6
Coupling Nut Between Right Mounting Cushion
80 ± 6
70 ± 5
Assembly and Body
Fixing Bolt Between Compressor Assembly and
40 ± 5
Mounting Bracket
Fixing Bolt Between Condenser Assembly and Tank
7±1
Upper Crossmember Fixing Bracket
Refrigerant Charging Specification
Description Charging Capacity (g)

R134a Refrigerant 600 ± 10
Refrigerant Oil Charging Specifications
Description Charging Capacity (ml)

It is necessary to pour out 50 ml of refrigerant oil
Compressor Assembly Replacement
from the new compressor assembly
Condenser Replacement 50
Evaporator Replacement 50
A/C Line Replacement 10

Tools
General Tools
Refrigerant Recycling Machine
RCH0000046 31
Digital Multimeter
RCH0000002

Circuit Diagram
Electrical A/C System (Page 1 of 3)
IGNITION SWITCH IGNITION SWITCH MT

BATTERY
ON OR START ON OR ACC
RF10 RF13 RF33

7.5A 7.5A 25A INSTRUMENT
PANEL FUSE
AND RELAY
31 85 30
DEFOGER
BOX
I-007
RELAY RF42
I-031
RRLY02 10A B-060
86 87
10 13 E3 E4 F13 F9 F10
R
WB
BG
YR
R
13 B-012
T-004
I-034 15 B-059
E-027 7
R
A12 I-035
1
DEFROSTER
YR
BCM
T-002
I-005
T-010
A21 1
B
T-004
11
WV
B-012 R
B
1
B-017
A
I-039
4 10 11
K-007
RW
BR
LG
2 24 27
HVAC
CONTROL
PANEL
K-002
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
27 25 26 E1 E2 E3 E4 E5 E6 E7 E8 F1 F2 F3 F4 F5 F6 F7
E13 E14 E15 E16 F11 F12 F13 F14
87 E9 E10 E11 E12 E17 E18 E19 E20 F8 F9 F10 F15 F16 F17 F18
85 86 86 86
87 30 87 30
30 85 85
I-031 B-060
I-007 W W
B
4 3 2 1 1 2 3 4 5 6 7 8
8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 9 8 7 6 5 9 10 11 12 13 14 15
15 14 13 12 11 10 9 10 11 12 13 14 15 16 17 18 14 13 12 11 10
19 18 17 16 15
I-034 B-059 22 21 20
W W
I-039 B-012
B W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32
1 1
K-002 T-002 T-010
B B I-005
W
L ET21310010

MT
BATTERY
MF05
ENGINE
30A COMPARTMENT
FUSE AND
85 30 RELAY BOX
BLOWER E-063
RELAY
ERLY15
E-069
31
86 87
F8 F9 5
GR
YR
A ECM-2
E-027 8 13 E-033
I-034
28
GR
Y
I-039
2 7 17 4 E-027
K-007 I-038
Br I-034
RB
2
3 6 1 ILLUMINATION
SPEED RESISTOR
Lg
B
Y
M BLOWER
K-004
K-008
4 5 2 I-037
1 I-039
RW 15 8 1 K-007
WBL
BrW
YG
YB
25 28 26 23 4 3
HVAC
CONTROL
PANEL
K-002
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
E-069
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 E-033
W
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
5
1 1 2 3 4 5 6 7 8
2 9 10 11 12 13 14 15
E-063 K-008
W E-027
W
1 2 3 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
5 6 7 8 9 1 2 3 4 5 6
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 K-007
10 11 12 13 14
W
K-002 15 16 17 18 19 K-004
W 20 21 22 B ET21310020

MT
HVAC
CONTROL
PANEL
K-002
10 12 9 1 11 19 17 20 18 8 6 7 5 29 22
31
BBL
YW
WL
GR
LW
GY
RY
BY
Br
Br
Br
W
O
R
B
Y
L
6 4 3 2 1 6 4 3 2 1 6 4 3 2 1 1 2
EVAPORATOR
TEMPERATURE
M M M
SENSOR
B A B A B A
K-005
MIXED DAMPER MOTOR MODE DAMPER MOTOR INNER AND OUTER
K-003 K-001 CIRCULATION MOTOR
K-006
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 4 1 1 2
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 5 2 K-001 K-003 K-006
6 3 B B B K-005
K-002 W
W
ET21310030

Automatic A/C System (Page 1 of 4)
IGNITION SWITCH IGNITION SWITCH CVT

BATTERY
RF10 RF13 RF33 RF21

INSTRUMENT
7.5A 7.5A 25A 10A
PANEL FUSE
AND RELAY
85 30 BOX
DEFOGER I-007
RELAY RF42 I-031
86 87
RRLY02 10A B-060 31
10 13 E3 E4 F13 F9 F10 21
R
WB
BG
YR
Y
13 B-012
T-004
I-034 15 B-059
E-027 7
R
A12 I-035
1
DEFROSTER
YR
BCM T-002
I-005
T-010
A21 1
B
T-004
11 B-012
WV
R
B
1
B-017
A
I-039
4 10 11 19
K-007
RW
WV
BR
LG
2 24 27 21
HVAC
CONTROL
PANEL
K-012
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
27 25 26 E1 E2 E3 E4 E5 E6 E7 E8 F1 F2 F3 F4 F5 F6 F7
E13 E14 E15 E16 F11 F12 F13 F14
87 E9 E10 E11 E12 E17 E18 E19 E20 F8 F9 F10 F15 F16 F17 F18
85 86 86 86
87 30 87 30
30 85 85
I-031 B-060
I-007 W W
B
4 3 2 1 1 2 3 4 5 6 7 8
8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 9 8 7 6 5 9 10 11 12 13 14 15
15 14 13 12 11 10 9 10 11 12 13 14 15 16 17 18 14 13 12 11 10
19 18 17 16 15
I-034 B-059 22 21 20
W W
I-039 B-012
B W
1 1
K-012 T-002 T-010
B B I-005
W
L ET21310040

CVT
BATTERY
MF05
ENGINE
30A COMPARTMENT
FUSE AND
85 30 RELAY BOX
BLOWER E-063
31 RELAY
ERLY15
E-069
86 87
F8 F9 5
GR
YR
A
E-027 8 13
I-034
GR
I-039
2 7 17
K-007 I-038
Br
RB
2
3 6 1 ILLUMINATION
SPEED RESISTOR
Lg
B
M BLOWER
K-004
K-008
4 5 2 I-037
1 I-039
RW 8 1 K-007
WBL
BrW
YB
25 28 26 4 3
HVAC
CONTROL
PANEL
K-012
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
K-012
E-069 W
W
5
1 2 3 4 1
1 2 3 4 5 6 7 8
5 6 7 8 9 1 2 3 4 5 6 2
9 10 11 12 13 14 15 K-007
10 11 12 13 14
W K-004 E-063 K-008
15 16 17 18 19
B W
E-027 20 21 22
W
ET21310050

CVT
SUN SENSOR
I-021
3 4
OUTSIDE
TEMPERATURE
31
1
SENSOR
TO CAN E-047
SYSTEM 1 2
YW
Y
15 14 E-027
GW
OB
V
I-034
O
YW
Y
I-039
13 14 5 6 16 3 9 K-007
BlW
BlW
PW
VW
GB
YR
LG
LW
13 14 36 37 30 38 22
CAN H2 CAN L2 HVAC
CONTROL
PANEL
K-012
1 2 3 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8 9
1 2 3 4 5 6 7 8
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 10 11 12 13 14
9 10 11 12 13 14 15 1 2
15 16 17 18 19
K-012
20 21 22
W
E-027 E-047
K-007
W B
W
4 3 2 1
I-021
B
ET21310060

CVT
EVAPORATOR LEFT ROOM RIGHT ROOM

TEMPERATURE HEATER CORE TEMPERATURE TEMPERATURE
K-005 K-002 K-011 K-001
2 1 2 1 2 1 2 1
31
BlW
BlW
BrY
WY
LW
O
B
B
29 33 34 35
HVAC CONTROL PANEL

K-012
39 16 40 1 15 10 12 9 11 19 17 20 18 8 6 7 5
BBL
GBr
WG
YW
BlB
WL
GR
GY
RY
VB
BY
Br
Br
Br
Br
W
R
B
Y
L
6 4 3 2 1 6 4 3 2 1 6 4 3 2 1 6 4 3 2 1
M M M M
B A B A B A B A
LEFT MIXED DAMPER MOTOR RIGHT MIXED DAMPER MOTOR MODE DAMPER MOTOR INNER AND OUTER
K-010 K-003 K-009 CIRCULATION MOTOR
K-006
4 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
K-001 K-002 K-005 K-011 5 2 K-003 K-006 K-009 K-010
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1 2
W W W W B B B B
6 3
K-012
W
ET21310070

DIAGNOSIS & TESTING

HINT:

Blower fuse (damaged) 51-34
Blower relay (damaged) 51-34 31
Blower speed switch (damaged) 31-70
Blower motor (damaged) 31-73
Mix damper control mechanism (stuck or
31-80
damaged)
A/C no heating
Mix damper control knob (stuck or
31-70
damaged)
Warm air water pipe (blocked or damaged) 31-78
Heater core assembly (blocked or
31-80
damaged)
Wire harness or connector (open or short) -
Leak in system 31-64
Refrigerant (overcharged) 31-66
A/C pressure sensor (damaged) -
Evaporator temperature sensor (damaged) 31-80
A/C switch (damaged) 31-70
Compressor assembly fuse (damaged) 51-34
Compressor assembly relay (damaged) 51-34
A/C no cooling
Compressor assembly belt (loose) 31-99
Compressor assembly (damaged) 31-99
Condenser assembly (blocked or
31-102
damaged)
Expansion valve (blocked or frosted) 31-80
Evaporator core assembly (blocked or
31-80
damaged)
Wire harness or connector (open or short) -
A/C intermittent cooling Moisture in system -


Leak in system 31-64
Refrigerant (insufficient) 31-66
Refrigerant (overcharged) 31-66
Air in refrigerant 31-67
Moisture in refrigerant -
Condenser (dirty or blocked) 31-102
A/C insufficient cooling Expansion valve (dirty or blocked) 31-80
31 Evaporator core (dirty or blocked) 31-80
A/C high/low pressure line (dirty or
31-94
blocked)
Blower speed switch (damaged) 31-70
Blower motor (damaged) 31-73
Compressor assembly belt (loose) 31-99
Compressor assembly belt (slip) 31-99
Compressor assembly clutch bearing
-
(worn and excess clearance)
Compressor assembly solenoid coil (faulty
-
or loose joint)
Too much noise in system
Compressor assembly belt (over tightened) 31-99
Compressor assembly mounting bolt
31-99
(loose)
Cooling fan blade (distorted) -
Refrigerant oil (too low) 31-68
Pressure on low pressure side switches
between normal and vacuum during Moisture in refrigerant (excessive) -
operation
Pressure is low on both low and high A/C system (leaked) 31-64
pressure sides, cooling performance is
insufficient Refrigerant (insufficient) 31-66
Pressure is low on both low and high

pressure sides, frost exists on line from Condenser (dirty or blocked) 31-102
condenser to A/C unit
Moisture in refrigerant (excessive) -
Vacuum occurs on low pressure side, and
pressure on high pressure side is too low, Expansion valve (dirty or blocked) 31-80
frost exists on lines on both sides of A/C line (leaked) 31-94
condenser or expansion valve
Condenser (dirty or blocked) 31-102
Pressure is too high on both low and high Expansion valve (faulty) -
pressure sides Refrigerant oil (excessive) 31-68


Surface of condenser (dirty) 31-102
Cooling fan (not operating) -
Pressure on low pressure side is normal or
slightly low, and pressure on high pressure Refrigerant (overcharged) 31-66
side is too high
Air in refrigerant 31-67
Engine (overheating) -
Pressure on low pressure side is too high, Compressor assembly belt (slip) 31-99
and pressure on high pressure side is too
low Compressor assembly (faulty) 31-99
31
Pressure on low pressure side is too low, A/C high pressure line (blocked) 31-96
and pressure on high pressure side is too
high Expansion valve (faulty) -
Diagnosis Procedure
HINT:
Use the following procedures to troubleshoot the A/C system.
NEXT
NEXT
NEXT
4 Check panel diagnosis
a. Check each actuator and sensor code (See page 31-19).

 Indicator inspection
 Sensor inspection
NEXT

5 Check and clear DTCs, then read DTCs again
DTC
occurs
No 
DTC
6 Overall analysis and troubleshooting

31
a. On-vehicle inspection
b. Inspection
NEXT
NEXT
NEXT
9 Confirm troubleshooting and perform test
NEXT
10 End

A/C System Function

1. Self-checking Operation
a. Turn ignition switch ON.
b. Press the A/C + rear defogger button on A/C control panel for 10 seconds and A/C begins 
self-checking. The self-checking takes about 15 seconds, during which the A/C cannot work.
HINT:
If it is unable to determine whether A/C has begun self-checking, turn on the blower before performing 
self-checking and push the A/C + rear defogger button. If no air comes out, it indicates A/C is performing
self-checking.
2. Self-diagnosis Function
a. Electrical A/C 31
Self-diagnosis operation: Press the A/C + outer circulation button for more than 5 seconds.
Malfunction display: Malfunction is indicated by flashing indicator. A/C indicator flash indicates the ten
digit and rear defogger indicator flash indicates the single digit. The interval of flashes for ten digit and
single digit is 0.5 seconds, and the interval of flashes between ten digit and single digit is 2 seconds. If
there are more than one malfunctions, the ten digit and single digit indicators will display (as the first
DTC) again 5 seconds after the single digit indicator turns off. The ten digit and single digit indicators
remain on for 3 seconds at the same time after the single digit indicator goes off for 2 seconds, which
indicates self-diagnosis is completed and it has exited the system (power on or turn on/off A/C
controller can both force the diagnosis function to end). System enters the state before diagnosis after
exiting self-diagnosis mode.
Detail correspondence of codes and malfunction is as follows:
Code Content Code Content

No malfunction, system operates Circulation damper motor
00 12
properly malfunction (invalid adjustment)
Mode damper motor malfunction
01 Reserve 13
(invalid adjustment)
02 Reserve 14 Reserve
Mix damper motor malfunction
04 Reserve 16
(invalid adjustment)
Evaporator temperature sensor
08 20 Reserve
malfunction (short or open)
Communication with BCM
10 Reserve 22
malfunction
Blower malfunction (invalid
11
adjustment)

b. Automatic A/C
Self-diagnosis operation: press the A/C + inner/outer circulation button for more than 5 seconds.
Malfunction display: Switch DVD to FM mode, set the driver A/C temperature to 29.5°C and long press
the A/C + inner/outer circulation button for more than 5 seconds to enter self-diagnosis mode.
Automatic controller background automatically performs self-checking, runs the A/C system actuators
and sensors, and then shows the malfunction code by DVD screen (other information is not
shown).The system automatically exits self-checking after displaying the code for 5 seconds (power on
can force the diagnosis function to end). If there is no malfunction, it will display 00, and 5 seconds
later, it will exit self-diagnosis mode. System enters the state before diagnosis after exiting 
self-diagnosis mode.
Detail correspondence of codes and malfunction is as follows:
31 Code Content Code Content
No malfunction, system operates Circulation damper motor
00 12
properly malfunction (invalid adjustment)
Outside temperature sensor Left mode damper motor malfunction
01 13
malfunction (open or short) (invalid adjustment)
Left room temperature sensor
02 14 Reserve
malfunction (open or short)
Right room temperature sensor Left mix damper motor malfunction
03 15
malfunction (open or short) (invalid adjustment)
Left sun sensor malfunction (open or Right mix damper motor malfunction
04 16
short) (invalid adjustment)
Right sun sensor malfunction (open
05 17 Reserve
or short)
Evaporator temperature sensor
08 20 Reserve
malfunction (short or open)
Control panel CAN communication
Heater core sensor malfunction
09 21 malfunction (CAN communication
(short or open)
interrupted)
Communication with BCM
10 Reserve 22
malfunction
Blower malfunction (invalid
11
adjustment)
3. Malfunction Compensation Function

To guarantee the proper work of A/C system, when the controller detects an invalid or defect sensor in A/C
system, the system will work based on the sensor failure alternative value.
Definition of sensor failure alternative value is as follows:
Failure Alternative Failure Alternative

Description Description
Value Value
Outside Temperature Sensor 25°C Heater Sensor 85°C
Room Temperature Sensor 25°C Evaporator Sensor 0°C
Sun Sensor 0 W/m2 Vehicle Seed Sensor 10 km/h


Confirm that the battery voltage is normal before performing the following procedures.
 Using X-431 3G diagnostic tester to record and clear the DTCs stored in the A/C control module assembly.
 Using X-431 3G diagnostic tester to select "Read Code".
31

If the malfunction is intermittent, perform the followings:
 Inspect the A/C system sensors and mounting areas for damage, foreign matter, etc. that will cause
incorrect signals.
 Remove the A/C control panel assembly from the malfunctioning vehicle and install it to a new vehicle and
perform a test. If DTC cannot be cleared, the A/C control panel assembly is malfunctioning. If DTC can be
cleared, reinstall the A/C control panel assembly to original vehicle.
Ground Inspection
Groundings are very important to the proper operation of circuits. Ground points are often exposed to
moisture, dirt and other corrosive environments. Corrosion (rust) can increase load resistance. This situation
may change the way in which a circuit works.
Circuits are very sensitive to proper grounding. A loose or corroded ground may seriously affect the control
circuit. The operations to check the ground points are as follows:


B2133 AC Solar Sensor Short to Ground or Open Circuit (Left Side)
B2134 AC Solar Sensor Short to Ground or Open Circuit (Right Side)
B2120 AC in Car Temperature Sensor Short to Ground or Open Circuit (Left Side)
B2121 AC in Car Temperature Sensor Short to Ground or Open Circuit (Right Side)
B2126 AC Ambient Temperature Sensor Short to Ground or Open Circuit
B2127 AC Evaporator Temperature Sensor Short to Ground or Open
31
B2135 AC Heater Core Sensor Short to Ground Or Open Circuit
B2160 Error of AC Mix Actuator (Left Side)
B2163 Error of AC Mix Actuator (Right Side)
B2166 Error of AC Mode Actuator
B2169 Error of AC Blower Actuator
B2172 AC Recirculation Actuator

AC Solar Sensor Short to Ground or Open Circuit (Left

DTC B2133
Side)
AC Solar Sensor Short to Ground or Open Circuit (Right

DTC B2134
Side)
IGNITION SWITCH
BATTERY
ON OR START
31
INSTRUMENT
PANEL FUSE
RF10 RF21 AND RELAY
7.5A 10A BOX
I-007
10 21
WB
I-039
4 19
K-007
WV
BR
2 21
HVAC
CONTROL
PANEL
K-012
30 37 36 4
BlW
YR
LG
BrW
K-007
16 6 5 8
I-039
B
V
GW
I-037
1
SUN SENSOR
4 3
I-021
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4
4 3 2 1
5 6 7 8 9
13 14 15 16 17 18 19 20 21 22 23 24 9 8 7 6 5
10 11 12 13 14
27 25 26 14 13 12 11 10
15 16 17 18 19
87 19 18 17 16 15
20 21 22
85 86 86 86 22 21 20
87 30 87 30
30 85 85
K-007
I-039 W
I-007 B
B
4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
I-021
K-012 B
W
ET21310080

DTC Detection
Condition
AC Solar Sensor Short
B2133 to Ground or Open
 Sun sensor
Circuit (Left Side)
Ignition switch ON  Wire harness and connector
AC Solar Sensor Short
 HVAC control panel
B2134 to Ground or Open
Circuit (Right Side)
31 CAUTION
Diagnosis Procedure

c. Disconnect the HVAC control panel assembly connector K-012 and sun sensor connector I-021.
d. Disconnect the A/C wire harness connector K-007 and instrument panel wire harness connector I-039.
g. Check if related connector pins are in good condition.

connector
OK
2 Check sun sensor
a. Remove the sun sensor.

b. Install the new sun sensor to vehicle.
c. Use X-431 3G diagnostic tester to check if DTCs are still output.
NO Replace sun sensor
YES

3 Check wire harness and connector (HVAC control panel assembly - sun sensor)

c. Disconnect the HVAC control panel assembly connector
K-012 and sun sensor connector I-021.
+ -
terminals of connector K-012 and connector I-021 to
check if there is an open in system according to the table 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
below. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Standard Condition
K-012
31
Condition
Connection Condition 4 3 2 1
K-012 (36) -
I-021 (3)
K-012 (37) -
Always Continuity
I-021 (1) RT21311000
K-012 (30) -
Always Continuity
I-021 (4)
e. Disconnect the A/C wire harness connector K-007 and

instrument panel wire harness connector I-039.
terminals of connector K-012 and connector K-007 to
check if there is an open in system according to the table + -
below.
Standard Condition
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Condition
Connection Condition K-012
K-012 (36) -
K-007 (5) 5 6 7 8 9
10 11 12 13 14
K-012 (37) -
Always Continuity 15 16 17 18 19
K-007 (6) 20 21 22
K-012 (30) - K-007

Always Continuity
K-007 (16) RT21311010


terminals of connector I-039 and connector I-021 to
check if there is an open in system according to the table
below.
4 3 2 1
Multimeter Specified 9 8 7 6 5
Condition
Connection Condition 14 13 12 11 10
19 18 17 16 15
I-039 (5) - 22 21 20
Always Continuity
I-021 (3)
I-039
I-039 (6) -
Always Continuity
31 I-021 (1)
4 3 2 1
I-039 (16) -
Always Continuity
I-021 (4) I-021
NG Repair or replace related wire harness and RT21311020
connector
OK
4 Check wire harness and connector (HVAC control panel assembly - body ground)

K-012.
+ -
connector K-012 and body ground to check if system is
short to ground according to the table below. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Standard Condition 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
K-012
Condition
K-012 (36) - Body
ground
K-012 (37) - Body
ground
RT21311030
K-012 (30) - Body
ground
NG Repair or replace A/C wire harness and

connector
OK

5 Reconfirm DTCs
a. Reconnect all disconnected connectors securely.

d. Use X-431 3G diagnostic tester (the latest software) to record and clear DTCs stored in the HVAC control
panel assembly.
e. Turn ignition switch to LOCK and wait for a few seconds.
f. Turn ignition switch ON.
g. Use X-431 3G diagnostic tester to read DTCs stored in the HVAC control panel assembly again. 31
NG Replace HVAC control panel assembly
OK

AC in Car Temperature Sensor Short to Ground or Open

DTC B2120
Circuit (Left Side)
AC in Car Temperature Sensor Short to Ground or Open

DTC B2121
Circuit (Right Side)
IGNITION SWITCH
31
BATTERY
ON OR START
INSTRUMENT
PANEL FUSE
RF10 RF21 AND RELAY LEFT ROOM RIGHT ROOM
7.5A 10A BOX TEMPERATURE TEMPERATURE
I-007 SENSOR SENSOR
K-011 K-001
10 21
WB
2 1 2 1
Y
BlW
BlW
BrY
WY
I-039
4 19
K-007
WV
BR
2 21 22 34 35
HVAC
CONTROL
PANEL
K-012
4
BrW
K-007
8
I-039
B
I-037
1 2 3 4 5 6 7 8 9 10 11 12
4 3 2 1 1 2 3 4
13 14 15 16 17 18 19 20 21 22 23 24 9 8 7 6 5 5 6 7 8 9
14 13 12 11 10 10 11 12 13 14
27 25 26
87 19 18 17 16 15 15 16 17 18 19
85 86 86 86 20 21 22
87 30 87 30 22 21 20
30 85 85
I-039 K-007
I-007 B W
B
1 2 1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
K-001 K-011
K-012 W W
W
ET21310090

DTC Detection
Condition
AC in Car Temperature
Sensor Short to
B2120
Ground or Open Circuit
 Room temperature sensor
(Left Side)
AC in Car Temperature
Sensor Short to
B2121
Ground or Open Circuit
(Right Side)
31
CAUTION
Diagnosis Procedure

c. Disconnect the HVAC control panel assembly connector K-012.
d. Disconnect the left room temperature sensor connector K-011 and right room temperature sensor
connector K-001.

connector
OK
2 Check room temperature sensor
a. Remove the room temperature sensor.

b. Install the new room temperature sensor to vehicle.
NO Replace room temperature sensor
YES

Check wire harness and connector (HVAC control panel assembly - room temperature
3 sensor)

K-012.
+ -
d. Disconnect the left room temperature sensor connector
K-011 and right room temperature sensor connector 
K-001.
31 e. Using a digital multimeter, check for continuity between 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
terminals of connector K-012 and connector K-011 to 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
check if there is an open in left room temperature sensor
according to the table below. K-012
Standard Condition
1 2
Multimeter Specified K-011

Condition
K-012 (22) -
K-011 (2)
K-012 (34) -
Always Continuity
K-011 (1)

check if there is an open in right room temperature
sensor according to the table below.
Condition
K-012 (22) - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Always Continuity 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
K-001 (2)
K-012
K-012 (35) -
Always Continuity
K-001 (1)
1 2
K-001
connector
RT21311050
OK


K-012.
+ -
short to ground according to the table below.
Standard Condition
31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Condition
K-012 (22) - Body

ground
K-012 (34) - Body
ground
RT21311060
K-012 (35) - Body
ground

connector
OK
5 Reconfirm DTCs

panel assembly.
g. Use X-431 3G diagnostic tester to read DTCs stored in the HVAC control panel assembly again.
OK

AC Ambient Temperature Sensor Short to Ground or

DTC B2126
Open Circuit
IGNITION SWITCH
BATTERY
ON OR START
OUTSIDE
TEMPERATURE
31 INSTRUMENT
SENSOR
E-047
PANEL FUSE 1 2
RF10 RF21 AND RELAY
YW
Y
7.5A 10A BOX
I-007
15 14 E-027
10 21
I-034
YW
V
WB
I-039
3 9 K-007
I-039
4 19
BlW
K-007
VW
WV
BR
LW
2 21 38 22
HVAC
CONTROL
PANEL
K-012
4
BrW
K-007
8
I-039
B
I-037
1 2 3 4 5 6 7 8 9 10 11 12
4 3 2 1 1 2 3 4
13 14 15 16 17 18 19 20 21 22 23 24 9 8 7 6 5 5 6 7 8 9
14 13 12 11 10 10 11 12 13 14
27 25 26
87 19 18 17 16 15 15 16 17 18 19
85 86 86 86 20 21 22
87 30 87 30 22 21 20
30 85 85
I-039 K-007
I-007 B W
B
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 9 10 11 12 13 14 15 1 2
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
K-012 E-047
E-027
W
W B
ET21310100

DTC Detection
Condition
AC Ambient  Outside temperature sensor
Temperature Sensor
B2126 Ignition switch ON  Wire harness and connector
Short to Ground or
Open Circuit  HVAC control panel
CAUTION
31
Diagnosis Procedure

c. Disconnect the HVAC control panel assembly connector K-012 and A/C wire harness connector K-007.
d. Disconnect the instrument panel wire harness connectors I-039 and I-034.
e. Disconnect the engine compartment wire harness connector E-027 and outside temperature sensor
connector E-047.
f. Check if wire harnesses are worn, pierced, pinched or partially broken.
g. Look for broken, bent, protruded or corroded terminals.
h. Check if related connector pins are in good condition.

connector
OK
2 Check outside temperature sensor
a. Remove the outside temperature sensor.

b. Install the new outside temperature sensor to vehicle.
NO Replace outside temperature sensor
YES

Check wire harness and connector (HVAC control panel assembly - outside temperature
3 sensor)

K-012 and outside temperature sensor connector E-047.
+ -
terminals of connector K-012 and connector E-047 to
below. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
31 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Standard Condition
K-012
Condition
K-012 (38) -
Always Continuity 1 2
E-047 (1)
K-012 (22) - E-047
Always Continuity
E-047 (2) RT21311070
e. Disconnect the instrument panel wire harness connectors

I-039 and I-034.
connector E-027 and A/C wire harness connector K-007.
+ -
check if there is an open in system according to the table 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
below. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Standard Condition K-012
Condition 1 2 3 4
10 11 12 13 14
K-012 (38) -
K-007 (3) 20 21 22
K-012 (22) - K-007

Always Continuity
K-007 (9) RT21311080


terminals of connector I-039 and connector I-034 to
below.
4 3 2 1
Multimeter Specified 9 8 7 6 5
Condition
19 18 17 16 15
I-039 (3) - I-034 22 21 20
Always Continuity
(15)
I-039
I-039 (9) - I-034
Always Continuity
(14) 8 7 6 5 4 3 2 1 31
15 14 13 12 11 10 9
I-034
RT21311090

terminals of connector E-027 and connector E-047 to
below.
Condition 1 2 3 4 5 6 7 8
Connection Condition 9 10 11 12 13 14 15
E-027 (15) -
Always Continuity
E-047 (1) E-027
E-027 (14) -
Always Continuity
E-047 (2)
1 2
connector E-047
RT21311100
OK


K-012.
+ -
Standard Condition
31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Condition
K-012 (38) - Body

ground
K-012 (22) - Body
ground
RT21311110

connector
OK
5 Reconfirm DTCs

panel assembly.
OK

AIR CONDITIONING
AC Evaporator Temperature Sensor Short to Ground or

DTC B2127
Open
IGNITION SWITCH
BATTERY
ON OR START
INSTRUMENT 31
PANEL FUSE
RF10 RF21 AND RELAY EVAPORATOR
7.5A 10A BOX TEMPERATURE
I-007 SENSOR
K-005
10 21
WB
2 1
Y
LW
O
I-039
4 19
K-007
WV
BR
2 21 22 29
HVAC
CONTROL
PANEL
K-012
4
BrW
K-007
8
I-039
B
I-037
1 2 3 4 5 6 7 8 9 10 11 12
4 3 2 1 1 2 3 4
13 14 15 16 17 18 19 20 21 22 23 24 9 8 7 6 5 5 6 7 8 9
14 13 12 11 10 10 11 12 13 14
27 25 26
87 19 18 17 16 15 15 16 17 18 19
85 86 86 86 20 21 22
87 30 87 30 22 21 20
30 85 85
I-039 K-007
I-007 B W
B
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 K-005
K-012 W
W
ET21310110

DTC Detection
Condition
AC Evaporator  Evaporator temperature sensor
Temperature Sensor
Short to Ground or
Open  HVAC control panel
CAUTION
31  When performing electrical equipment diagnosis and test, always refer to the circuit diagram for related
Diagnosis Procedure

c. Disconnect the HVAC control panel assembly connector K-012 and evaporator temperature sensor
connector K-005.
d. Check if wire harnesses are worn, pierced, pinched or partially broken.

connector
OK
2 Check evaporator temperature sensor
a. Remove the evaporator temperature sensor.

b. Install the new evaporator temperature sensor to vehicle.
NO Replace evaporator temperature sensor
YES

Check wire harness and connector (HVAC control panel assembly - evaporator temperature
3 sensor)

K-012 and evaporator temperature sensor connector 
+ -
K-005.
below.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 31
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Standard Condition
K-012
Condition
1 2
K-012 (22) -
Always Continuity K-005
K-005 (2)
K-012 (29) - RT21311120
Always Continuity
K-005 (1)

connector
OK

K-012.
+ -
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Condition K-012
K-012 (22) - Body
ground
K-012 (29) - Body
ground
RT21311130

connector
OK

5 Reconfirm DTCs

panel assembly.
31 g. Use X-431 3G diagnostic tester to read DTCs stored in the HVAC control panel assembly again.
OK

DTC B2135 AC Heater Core Sensor Short to Ground Or Open Circuit
IGNITION SWITCH
BATTERY
ON OR START
INSTRUMENT
RF10 RF21
PANEL FUSE
AND RELAY
HEATER CORE
31
7.5A 10A BOX
I-007 SENSOR
K-002
10 21
WB
2 1
I-039
4 19
K-007
B
WV
BR
2 21 22 33
HVAC
CONTROL
PANEL
K-012
4
BrW
K-007
8
I-039
B
I-037
1 2 3 4 5 6 7 8 9 10 11 12
4 3 2 1 1 2 3 4
13 14 15 16 17 18 19 20 21 22 23 24 9 8 7 6 5 5 6 7 8 9
14 13 12 11 10 10 11 12 13 14
27 25 26
87 19 18 17 16 15 15 16 17 18 19
85 86 86 86 22 21 20 20 21 22
87 30 87 30
30 85 85
I-039 K-007
I-007 B W
B
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 K-002
K-012 W
W
ET21310120

DTC Detection
Condition
AC Heater Core  Heater core sensor
Sensor Short to
Ground Or Open
Circuit  HVAC control panel
CAUTION
Diagnosis Procedure

c. Disconnect the HVAC control panel assembly connector K-012 and heater core sensor connector K-002.

connector
OK
2 Check heater core sensor
a. Remove the heater core sensor.

b. Install the new heater core sensor to vehicle.
NO Replace heater core sensor
YES

3 Check wire harness and connector (HVAC control panel assembly - heater core sensor)

K-012 and heater core sensor connector K-002.
+ -
below.
31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
K-012
Condition
1 2
K-012 (22) -
Always Continuity
K-002 (2)
K-002
K-012 (33) -
Always Continuity
K-002 (1) RT21311140

connector
OK

K-012.
+ -
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Condition K-012
K-012 (22) - Body
ground
K-012 (33) - Body
ground
RT21311150

connector
OK

5 Reconfirm DTCs

panel assembly.
31 g. Use X-431 3G diagnostic tester to read DTCs stored in the HVAC control panel assembly again.
OK

DTC B2160 Error of AC Mix Actuator (Left Side)
DTC B2163 Error of AC Mix Actuator (Right Side)
IGNITION SWITCH
BATTERY
ON OR START
INSTRUMENT
PANEL FUSE
RF10
7.5A 10A
RF21 AND RELAY
BOX
31
I-007
10 21
WB
Y
I-039
4 19
K-007
WV
BR
2 21
HVAC
CONTROL
PANEL
K-012
39 16 40 1 15 10 12 9 11 4
BrW
GBr
WG
BlB
VB
Br
Br
R
B
Y
L
K-007
8
I-039
B
6 4 3 2 1 6 4 3 2 1
I-037
M M
B A B A
LEFT MIXED DAMPER MOTOR RIGHT MIXED DAMPER MOTOR

K-010 K-003
1 2 3 4 5 6 7 8 9 10 11 12
4 3 2 1 1 2 3 4
13 14 15 16 17 18 19 20 21 22 23 24 9 8 7 6 5 5 6 7 8 9
14 13 12 11 10 10 11 12 13 14
27 25 26
87 19 18 17 16 15 15 16 17 18 19
85 86 86 86 22 21 20 20 21 22
87 30 87 30
30 85 85
I-039 K-007
I-007 B W
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 4 1 4 1
5 2 K-003 5 2 K-010
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
B B
6 3 6 3
K-012
W
ET21310130

DTC Detection
Condition
Error of AC Mix
B2160  Mix damper motor
Actuator (Left Side)
Error of AC Mix
B2163  HVAC control panel
Actuator (Right Side)
CAUTION
Diagnosis Procedure

d. Disconnect the left mix damper motor connector K-010 and right mix damper motor connector K-003.

connector
OK
2 Check mix damper motor
a. Remove the mix damper motor.

b. Install the new mix damper motor to vehicle.
NO Replace mix damper motor
YES

3 Check wire harness and connector (HVAC control panel assembly - mix damper motor)

K-012.
+ -
d. Disconnect the left mix damper motor connector K-010
and right mix damper motor connector K-003.
e. Using a digital multimeter, check for continuity between
31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
check if there is an open in left mix damper motor 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
K-012
Standard Condition
4 1
Multimeter Specified 5 2
Condition
K-012 (15) - K-010

Always Continuity
K-010 (1) RT21311160
K-012 (1) -
Always Continuity
K-010 (2)
K-012 (40) -
Always Continuity
K-010 (3)
K-012 (16) -
Always Continuity
K-010 (4)
K-012 (39) -
Always Continuity
K-010 (6)

check if there is an open in right mix damper motor
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
K-012 (11) -
Always Continuity 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
K-003 (1)
K-012
K-012 (1) -
Always Continuity
K-003 (2)
4 1
K-012 (9) - 5 2
K-003 (3)
K-003
K-012 (12) -
Always Continuity
K-003 (4) RT21311170
K-012 (10) -
Always Continuity
K-003 (6)

connector

OK

K-012.
+ -
connector K-012 and body ground to check if left mix
31 damper motor circuit is short to ground according to the
table below.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
K-012
Condition
K-012 (1) - Body
ground
K-012 (15) - Body
ground RT21311180
K-012 (16) - Body

ground
K-012 (39) - Body
ground
K-012 (40) - Body
ground

connector K-012 and body ground to check if right mix
damper motor circuit is short to ground according to the
table below.
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
K-012 (1) - Body
Always No continuity 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
ground
K-012
K-012 (9) - Body
ground
K-012 (10) - Body
ground
K-012 (11) - Body
ground RT21311190
K-012 (12) - Body

ground

connector

OK
5 Reconfirm DTCs

panel assembly.
e. Turn ignition switch to LOCK and wait for a few seconds. 31
OK

DTC B2166 Error of AC Mode Actuator
IGNITION SWITCH
BATTERY
ON OR START
INSTRUMENT
PANEL FUSE
RF10 RF21 AND RELAY
7.5A 10A BOX
I-007
31 10 21
WB
Y
I-039
4 19
K-007
WV
BR
2 21
HVAC
CONTROL
PANEL
K-012
19 17 20 1 18 4
BrW
YW
WL
GR
Br
K-007
8
I-039
6 4 3 2 1
B
I-037
M
B A
MODE DAMPER MOTOR

K-009
1 2 3 4 5 6 7 8 9 10 11 12
4 3 2 1 1 2 3 4
13 14 15 16 17 18 19 20 21 22 23 24 9 8 7 6 5 5 6 7 8 9
14 13 12 11 10 10 11 12 13 14
27 25 26
87 19 18 17 16 15 15 16 17 18 19
85 86 86 86 20 21 22
87 30 87 30 22 21 20
30 85 85
I-039 K-007
I-007 B W
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 4 1
5 2 K-009
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
B
6 3
K-012
W
ET21310140

DTC Detection
Condition
 Mode damper motor
Error of AC Mode
Actuator
CAUTION
circuit and component information. 31
Diagnosis Procedure

d. Disconnect the mode damper motor connector K-009.

connector
OK
2 Check mode damper motor
a. Remove the mode damper motor.

b. Install the new mode damper motor to vehicle.
NO Replace mode damper motor
YES

3 Check wire harness and connector (HVAC control panel assembly - mode damper motor)

K-012.
+ -
d. Disconnect the mode damper motor connector K-009
check if there is an open in mode damper motor
31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
according to the table below. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Condition 4 1
6 3
K-012 (18) -
Always Continuity
K-009 (1) K-009
K-012 (1) - K-009 RT21311200

Always Continuity
(2)
K-012 (20) -
Always Continuity
K-009 (3)
K-012 (17) -
Always Continuity
K-009 (4)
K-012 (19) -
Always Continuity
K-009 (6)

connector
OK

K-012.
+ -
connector K-012 and body ground to check if mode
damper motor circuit is short to ground according to the
table below.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
K-012
Condition
K-012 (1) - Body
ground
K-012 (17) - Body
ground RT21311210

Condition
K-012 (18) - Body
ground
K-012 (19) - Body
ground
K-012 (20) - Body
ground

connector 31
OK
5 Reconfirm DTCs

panel assembly.
OK

DTC B2169 Error of AC Blower Actuator

ON OR ACC
INSTRUMENT MF05
RF13
PANEL FUSE ENGINE
30A
31 7.5A AND RELAY
BOX
COMPARTMENT
FUSE AND
I-007 85 30 RELAY BOX
BLOWER E-063
13 E-069
RELAY
ERLY15
86 87
YR
F8 F9 5
GR
R
I-034
E-027 7
YR
E-027 8 13
I-034
GR
B
I-039
2 7 17
K-007 I-038
Br
RB
2
3 6 1
SPEED RESISTOR
M BLOWER
K-004
K-008
4 5 2
RW 1
WBL
25 28 26
HVAC
CONTROL
PANEL
K-012
1 2 3 4 5 6 7 8 9 10 11 12
5
13 14 15 16 17 18 19 20 21 22 23 24 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 1
2
27 25 26 F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
87 E-063 K-008
85 86 86 86 W
87 30 87 30 E-069
30 85 85
W
I-007
1 2 3 4
B
5 6 7 8 9 1 2 3 4 5 6 7 8
10 11 12 13 14 K-007 9 10 11 12 13 14 15
W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 15 16 17 18 19
K-012
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 20 21 22
W E-027
W
8 7 6 5 4 3 2 1
I-034 1 2 3 4 5 6 K-004
15 14 13 12 11 10 9
W B
ET21310150

DTC Detection
Condition
 Fuse
 Relay
Error of AC Blower  Blower motor
B2169 Ignition switch ON
Actuator  Blower speed resistor
 Wire harness and connector
31
CAUTION
Diagnosis Procedure

d. Disconnect the blower connector K-008 and blower speed resistor connector K-004.

connector
OK
2 Check blower
a. Remove the blower.

b. Install the new blower to vehicle.
NO Replace blower
YES

3 Check wire harness and connector (HVAC control panel assembly - blower speed resistor)

K-012.
+ -
d. Disconnect the blower speed resistor connector K-004.
31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
below. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Condition
Connection Condition 1 2 3 4 5 6
K-012 (28) -
Always Continuity K-004
K-004 (4)
K-012 (26) - RT21311240
Always Continuity
K-004 (5)

connector
OK
4 Check wire harness and connector (blower - blower speed resistor)

c. Disconnect the blower connector K-008.
d. Disconnect the blower speed resistor connector K-004. + -
terminals of connector K-008 and connector K-004 to 1
check if there is an open in system according to the table 2
below.
Condition
K-008 (1) - K-004 K-004

Always Continuity
(2)
K-008 (2) - K-004
Always Continuity
(1) RT21311250

connector
OK

5 Check wire harness and connector (blower speed resistor - body ground)

c. Disconnect the blower speed resistor connector K-004.
d. Using a digital multimeter, check for continuity between + -
terminal 6 of connector K-004 and body ground to check
if ground circuit is in good condition according to the table
below.
Standard Condition 1 2 3 4 5 6
31
Multimeter Specified K-004
Condition
K-004 (6) - Body
Always Continuity
ground

connector RT21311260
OK
6 Check wire harness and connector (blower speed resistor - battery)

c. Disconnect the blower speed resistor connector K-004.
d. Connect the negative battery cable. V
+ -
e. Turn ignition switch ON.
f. Using a digital multimeter, check the voltage between
terminal 3 of connector K-004 and body ground to check
if power supply circuit is in good condition according to 1 2 3 4 5 6
the table below.

K-004
Standard Condition
Condition
K-004 (3) - Body
ground
RT21311270
NG Check wire harness and connector among

blower relay, fuse MF05, engine
compartment fuse and relay box and
blower speed resistor
OK

7 Check blower speed resistor
a. Remove the blower speed resistor.

b. Install the new blower speed resistor to vehicle.
NO Replace blower speed resistor
YES
31 8 Reconfirm DTCs

panel assembly.
OK

DTC B2172 AC Recirculation Actuator
IGNITION SWITCH
BATTERY
ON OR START
INSTRUMENT
PANEL FUSE
RF10 RF21 AND RELAY
7.5A 10A BOX
I-007
31
10 21
WB
Y
I-039
4 19
K-007
WV
BR
2 21
HVAC
CONTROL
PANEL
K-012
8 6 7 1 5 4
BBL
GY
RY
BY
Br
BrW
K-007
8
6 4 3 2 1 I-039
I-037
M
B A
INNER AND OUTER

CIRCULATION MOTOR
K-006
1 2 3 4 5 6 7 8 9 10 11 12
4 3 2 1 1 2 3 4
13 14 15 16 17 18 19 20 21 22 23 24 9 8 7 6 5 5 6 7 8 9
14 13 12 11 10 10 11 12 13 14
27 25 26
87 19 18 17 16 15 15 16 17 18 19
85 86 86 86 22 21 20 20 21 22
87 30 87 30
30 85 85
I-039 K-007
I-007 B W
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 4 1
5 2 K-006
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
B
6 3
K-012
W
ET21310160

DTC Detection
Condition
 Inner/Outer circulation damper motor
AC Recirculation
Actuator
CAUTION
31 circuit and component information.
Diagnosis Procedure

d. Disconnect the inner/outer circulation damper motor connector K-006.

connector
OK
2 Check inner/outer circulation damper motor
a. Remove the inner/outer circulation damper motor.

b. Install the new inner/outer circulation damper motor to vehicle.
NO Replace inner/outer circulation damper

motor
YES

Check wire harness and connector (HVAC control panel assembly - inner/outer circulation
3 damper motor)

K-012.
+ -
d. Disconnect the inner/outer circulation damper motor
connector K-006.
terminals of connector K-012 and connector K-006 to 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 31
check if there is an open in inner/outer circulation damper 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
motor according to the table below.
K-012
Standard Condition
4 1
Condition
K-012 (5) - K-006 K-006

Always Continuity
(1) RT21311220
K-012 (1) - K-006

Always Continuity
(2)
K-012 (7) - K-006
Always Continuity
(3)
K-012 (6) - K-006
Always Continuity
(4)
K-012 (8) - K-006
Always Continuity
(6)

connector
OK


K-012.
+ -
connector K-012 and body ground to check if inner/outer
circulation damper motor circuit is short to ground
31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
K-012
Condition
K-012 (1) - Body
ground
K-012 (5) - Body
ground RT21311230
K-012 (6) - Body

ground
K-012 (7) - Body
ground
K-012 (8) - Body
ground

connector
OK
5 Reconfirm DTCs

panel assembly.
OK

ON-VEHICLE SERVICE
HINT:
The A/C refrigerant lines and hoses are used to transfer refrigerant among the A/C system components. Any
twist or bent in the refrigerant lines and hoses will reduce the performance of A/C system and refrigerant flow
in system.
There remains high pressure in refrigerant when the A/C compressor assembly is operating. It is necessary to
ensure that each connecting part in A/C system is sealed well. Check all the system lines at least once a year
to ensure that they are in good condition and properly routed. The refrigerant lines and hoses cannot be
repaired and must be replaced if leakage or damage exists. 31
1. General inspection
a. Check if there exists any oil or dust in each joint of the A/C line. If this occurs, there may exist leak.
b. Check if the surface of condenser is dirty and the fins are deformed.
c. Check for harsh noises while the compressor assembly is operating normally.
d. Temperature difference should be noticeable by feeling the intake line and exhaust line of compressor
assembly with hand. Normally, the intake line is cool while the exhaust line is hot. Feel the temperature
of intake duct and exhaust duct of condenser with hand. Normally, the temperature of intake duct is
higher than that of exhaust duct. Feel the temperature difference between expansion valve inlet and
outlet line with hand. Normally, the expansion valve inlet line is hot while the outlet line is cool, and
temperature difference is noticeable between both.
2. Using the pressure gauge set, check the refrigerant pressure.
a. Connect the manifold pressure gauge set. After the following conditions are met, read the pressure on
pressure gauge. Measurement conditions are as follows:
 Inner/outer circulation switch is in outer circulation position.
 Engine runs at approximately 2000 rpm.
 Adjust the temperature knob to MAX. COOL.
 Blower speed control switch is in highest band.
 Turn on the A/C switch.
Observe the pressure value on the pressure gauge. In normal condition, the pressure of low pressure side
is 0.15 - 0.20 MPa and the pressure of high pressure side is 1.3 -1.7 MPa.
Compressor Assembly Noise Inspection

When checking noise related to A/C system, you must first know the conditions under which the noise occurs.
These conditions include: weather, vehicle speed, engine speed, engine temperature and any other special
conditions. Louder noises during A/C operation can often mislead someone. For example, what sounds like a
failed bearing, may be caused by loose bolts, mounting brackets or a loose compressor assembly.
CAUTION
 A/C compressor assembly must be replaced if any abnormal compressor assembly noise is heard.
 Noise may occur from the drive belt at different engine speeds, and you may mistake it for a noise from
A/C compressor assembly. The noise occurs when the compressor assembly operates at the maximum
displacement, and it will not occur at the minimum displacement.
1. Select a quiet place for testing.

2. Duplicate the customer's feedback information as much as possible.
3. Turn the A/C system on and off several times to clearly identify the compressor assembly noise.

4. Listen to the operation sound of A/C compressor assembly while it is operating at maximum and minimum
displacement positions.
5. Using an engine sound scope or a long screwdriver with handle, hold the A/C compressor assembly near
your ear for detecting, in order to locate the noise source easier.
6. To duplicate a high temperature condition (high pressure), air is limited to flow through the A/C condenser.
Install a manifold pressure gauge set to ensure that the discharge pressure is lower than 2550 kPa.
7. Check the condition of compressor assembly belt.
8. Check the compressor assembly hub, pulley and bearing assembly. Make sure that the hub and pulley are
aligned correctly, and the pulley bearing is securely installed to the A/C compressor assembly.
9. Check if the refrigerant line routes incorrectly, is damaged or has an interference that could result in an
abnormal noise. Also, check the refrigerant line for twist or bend, otherwise the refrigerant will be limited to
31 flow, which will cause a noise.
10.Loosen all the compressor assembly tightening bolts and retighten them.
11. If noise occurs when the liquid refrigerant in A/C suction pipe is under a slugging condition, replace the
condenser and check the refrigerant oil level and the charging condition for refrigerant.
12.If the slugging condition still exists after replacing the condenser, replace the A/C compressor assembly.
WARNING
 DO NOT race engine when vacuum pump operates or vacuum exists in the A/C system. Failure to do so
may result in a serious damage to the A/C compressor assembly.
Refrigerant Leakage Inspection

WARNING
 DO NOT perform pressure test or leakage test to R134a service device or vehicle A/C system with
compressed air. Air mixture and R134a is inflammable at high pressure. These mixtures have potential
danger, and it may cause a fire or explosion, resulting in vehicle damage, personal injury or death.
 Avoid inhaling vapor or moisture from the A/C refrigerant and refrigerant oil.
 Only use technical service device to discharge the R134a system. If system is discharged unexpectedly,
ventilate the work place before servicing.
CAUTION
 If the A/C refrigerant filling amount is empty or low, the A/C system may have leak. Check all A/C lines,
joints and parts for remaining oil. The remaining oil is the indication mark of A/C system leaking position.
Check refrigerant for leakage

1. After recharging refrigerant, use the gas leak detector to check the refrigerant gas for leakage.
2. Perform operations under the following conditions:
 Stop the engine.
 Ensure the ventilation is well (the gas leak detector may react to volatile gases which are not from
refrigerant, such as gasoline vapor or exhaust gas).
 Repeat the test for 2 or 3 times.
 Make sure that there is some refrigerant remaining in the refrigerant system.

3. Place air leakage tester near the joint of A/C line, and
check A/C line for leakage. If the air leakage tester
makes a sound, it indicates that a leakage exists. Repair
or replace the leaking A/C line as necessary.
RT21310030
4. Disconnect the A/C pressure sensor connector, and use the same procedures to check the A/C pressure 31
sensor for leakage. Replace the A/C pressure sensor as necessary.
5. Insert the air leakage tester into the evaporator tank assembly, and use the same procedures to check the
evaporator for leakage. Clean or replace the evaporator core assembly as necessary.
6. Use the same procedures to check the condenser for leakage. Clean or replace the condenser assembly
as necessary.
MAX
MIN
RT21310040

Refrigerant Recovering/Draining
WARNING
 Take extra care when servicing the A/C system under high pressure.
 Because there is refrigerant under high pressure in the A/C system, it must be serviced by professional
technician. Otherwise, a wrong service procedure may cause a serious danger or fatal injury.
 If A/C system is discharged unexpectedly, ventilate the work place before servicing. In a closed work
place, a large amount of refrigerant is discharged, which may cause oxygen reduction and result in
smothering, causing a serious or fatal injury.
31
 Never drain the refrigerant in A/C system into the atmosphere directly, and avoid environmental
contamination.
CAUTION
 It is necessary to recover refrigerant with R134a refrigerant special recycling machine.

 DO NOT work near the open flame.
 Always dispose of recovered refrigerant as specified.
 Never charge R-12 to the refrigerant system which is designed to use R134a. These refrigerants are
incompatible, which could damage the A/C system.
 DO NOT race engine when vacuum pump operates or vacuum exists in the A/C system. Failure to do so
may result in serious damage to the A/C compressor assembly.
1. Open the hood, and loosen the joint cover of A/C high/low pressure line.
2. Connect the refrigerant recycling machine to A/C high/low pressure line joint.
a. Connect the red connector to A/C high pressure line
joint (1).
b. Connect the blue connector to A/C low pressure line
joint (2).
2
1
RT21310050
3. Open the high pressure valve and low pressure valve of refrigerant recycling machine.
4. Choose the "recovering" item on machine and make it start to operate.
5. Check the low pressure value on pressure gauge to ensure that the recycling is completed, and then turn
the machine off.
6. Disconnect the connections between refrigerant recycling machine and A/C line joint.
7. Reinstall the cover onto the refrigerant line joint.

Vacuum Pumping
1. Open the hood, and loosen the joint cover of A/C high/low pressure line.
joint (1).
joint (2).
2
1
31
RT21310050
4. Choose the "vacuum pumping" item on machine and the time setting is 15 minutes, then choose OK and
make it start to operate.
5. Wait for 10 minutes after completing the operation, check if there is any change in the A/C system vacuum.
If there is any change, the A/C system leakage may exist, you should check and repair the A/C system. If
there is no change, proceed to perform the refrigerant charging procedures.
Refrigerant Recharging
CAUTION
 A small amount of refrigerant oil in the A/C system will be discharged when recovering and draining the
refrigerant. Be sure to supplement the lost refrigerant oil during recovering when filling the A/C system.
 DO NOT fill excessive refrigerant. Otherwise, it will cause excessive pressure to the compressor
assembly, resulting in compressor assembly noise and A/C system failure.
 Always perform vacuum pumping before recharging refrigerant.
1. Perform vacuum pumping with vacuum pump.

2. Charge refrigerant oil after checking that there is no leakage in A/C system.
3. Perform vacuum pumping for 3 minutes again after charging refrigerant oil, then charge refrigerant.
4. Choose the "charging" item on machine and set the amount of charging to the specified value, then
choose OK and make it start to operate.
5. Open the suction valve and close the exhaust valve, and then open the charge valve to allow refrigerant to
flow into the system.
6. When the delivery of refrigerant has stopped, close the charge valve.
7. If the charged refrigerant is not delivered to the specified position, start the engine to operate the A/C
compressor assembly.
8. Open the charge valve to deliver the remaining refrigerant to A/C system.
WARNING
 At this time, do not open the exhaust (high pressure) valve. Failure to do so may result in serious
personal injury or even death.
9. Perform A/C system pressure test after charging is completed.

10.Remove the connecting pipe for refrigerant charging after the test is completed.
11. Reinstall the cover onto the A/C line joint.
Refrigerant Oil Recovering

CAUTION
 Special service equipment for R134a refrigerant must be used.

 Always keep the work area in good ventilation, because the A/C system is easy to leak.
 Always dispose of the recovered refrigerant as specified.
 Refrigerant oil must be charged after replacing the A/C system components or recovering the refrigerant.
31
1. Open the engine hood and loosen the joint cover of A/C high/low pressure line.
joint (1).
joint (2).
2
1
RT21310050
4. Recover the refrigerant oil according to the instructions on machine.
5. Record the amount of recovered refrigerant oil.
6. Disconnect the connections between refrigerant recycling machine and A/C line joint.
7. Reinstall the joint cover onto the refrigerant line joint.

Refrigerant Oil Charging

Refrigerant Oil Charging Amount Specifications
A/C Compressor
Condenser Evaporator
Item Assembly Line Replacement
Replacement Replacement
Replacement
It is necessary to pour
Charging out 50 ml of refrigerant
50 ml 50 ml 10 ml
Capacity (ml) oil from the new
compressor assembly
1. Perform vacuum pumping with vacuum pump. Wait for approximately 10 minutes after completing the 31
operation, check if there is any change in A/C system pressure. If there is any change, A/C system
leakage may exist, you should check and repair the A/C system. If there is no change, proceed to perform
the refrigerant oil charging procedures.
2. Open the suction valve and close the exhaust valve, and then open the charge valve to allow the
refrigerant oil to flow into the system.
3. Close the charging valve after the refrigerant oil charging is completed.
4. Perform the vacuum pumping again for 3 minutes.
5. Continue to perform refrigerant charging procedures after the operation is completed.

A/C Control Panel Assembly

Removal
3. Remove the A/C control panel assembly.
tape, pry out the console panel assembly carefully.
31
RT21310060
b. Disconnect the audio system connectors (arrow).
12V 120W
RT21310070
c. Remove 2 fixing screws (arrow) from the A/C control

panel assembly, and detach the fixing clip on the
lower part.
RT21310080
d. Disconnect the A/C control panel assembly connector

(arrow).
1 3 5
2 4 R
RT21310090
e. Remove the A/C control panel assembly.

Inspection
1. Check the A/C control panel assembly.
a. Remove the A/C control panel assembly.
b. Connect the positive (+) battery lead to terminal 3 and
-
negative (-) battery lead to terminal 4, then check if +
the A/C control panel assembly switch backlight

comes on.
20 1
OK: Light comes on. 40 21
31
RT21310100
If result is not as specified, replace the A/C control panel assembly.
Installation
CAUTION
 Be sure to install clip on the lower part of A/C control panel assembly in place during installation.
 Be sure to align the positioning hole on upper part of A/C control panel assembly with the dowel pin of
instrument panel during installation.

A/C Element
Removal
2. Remove the A/C element.
a. Detach the claws on both sides of A/C element cover,
and remove the A/C element cover (arrow) from the
air inlet assembly.
31
RT21310110
b. Pull out the A/C element (arrow) slowly from the air
inlet assembly.
RT21310120
Installation
CAUTION
 Be sure to check the A/C element for dirt during installation. Clean as necessary.
 If A/C element is too dirty or damaged, replace with a new one.

Blower Assembly
Removal
3. Remove the blower assembly.
a. Disconnect the blower assembly connector (arrow).
31
RT21310130
b. Detach the fixing claw (arrow) from the blower

assembly.
RT21310140
c. Rotate the blower assembly lightly to remove it.
Inspection
1. Check the blower motor.
a. Remove the blower assembly.
-
negative (-) battery lead to terminal 2. Check that the +
blower motor operates smoothly.

1
2
RT21310150
If operation is not as specified, replace the blower assembly.
Installation

Blower Speed Resistor

Removal
WARNING
 During normal operation, the blower speed resistor may be very hot. Turn off the blower and wait for a
few minutes to cool the blower speed resistor before diagnosing or servicing, in order to avoid burns.
31 CAUTION
 DO NOT operate the blower assembly when removing blower speed resistor from vehicle. Failure to do
so may result in damage to the blower assembly.

3. Remove the blower speed resistor.
a. Disconnect the blower speed resistor connector
(arrow).
RT21310160
b. Detach the fixing claw (arrow) from the blower speed

resistor.
RT21310170
c. Remove the blower speed resistor.
Installation

Inner/Outer Circulation Damper Motor

AIR CONDITIONING
Removal
4. Remove the inner/outer circulation damper motor.
a. Disconnect the inner/outer circulation damper motor
connector (arrow).
31
RT21310190
b. Detach the fixing claw, and remove the inner/outer

circulation damper motor (arrow) from the air inlet
assembly carefully.
RT21310200
Installation
CAUTION
 When installing, apply a small amount of grease to the contact surface between inner/outer circulation
damper motor lever and inner/outer circulation damper set to ensure the motor operates smoothly.

Mode Damper Servo Motor

Removal
3. Remove the mode damper servo motor.
a. Disconnect the mode damper servo motor connector
(arrow).
31
RT21310220
b. Detach the fixing claw, and remove the mode damper

servo motor (arrow) from the evaporator tank
assembly carefully.
RT21310230
Installation
CAUTION
 When installing, apply a small amount of grease to the contact surface between mode damper servo
motor lever and mode damper adjustment mechanism set to ensure the motor operates smoothly.

Mix Damper Servo Motor

Removal
3. Remove the mix damper servo motor.
a. Disconnect the mix damper servo motor connector
(arrow).
31
RT21310240
b. Detach the fixing claw, and remove the mix damper

assembly carefully.
RT21310250
Installation
CAUTION
 When installing, apply a small amount of grease to the contact surface between mix damper servo motor
lever and mix damper adjustment mechanism set to ensure the motor operates smoothly.

HVAC Assembly
Removal
CAUTION
 Special service equipment for R134a refrigerant must be used to recover/charge refrigerant.
 Be careful not to damage hoses during removal and installation.
 Always keep the work area in good ventilation.
 The disconnected A/C line and connecting part should be sealed to prevent foreign matter from entering.
31
1. Recover the refrigerant from the A/C system (See page 31-66).
5. Remove the steering column (See page 28-16).
6. Remove the instrument panel body assembly (See page 45-17).
7. Remove the instrument panel crossmember assembly (See page 45-24).
8. Remove the HVAC assembly.
a. Remove the fixing bolt (arrow) between A/C high/low
pressure line and expansion valve, and detach the A/C
high/low pressure line.
RT21310260
b. Using snap spring calipers, disengage the fixing

clamps (arrow) from the heating inlet hose and
heating outlet hose, and disengage the heating inlet
and outlet hoses.
RT21310270

c. Remove 4 fixing nuts and 2 fixing bolts (arrow)

between HVAC assembly and instrument panel
(Tightening torque for bolt: 4 ± 1 N·m)
RT21310280
d. Remove 2 fixing bolts (arrow) between HVAC 31

RT21310290
e. Remove the instrument panel wire harness assembly

fixing clips (arrow) from the HVAC assembly.
RT21310300
f. Disengage the A/C drain pipe (arrow) from the body

positioning hole.
RT21310310

g. Disconnect the connector (arrow) connecting A/C wire

harness assembly and instrument panel wire harness
assembly.
RT21310320
31 h. Carefully take off the HVAC assembly from the cabin.
Disassembly
1. Remove the A/C element (See page 31-72).
2. Remove the blower assembly (See page 31-73).
3. Remove the blower speed resistor (See page 31-74).
4. Remove the inner/outer circulation damper motor (See page 31-75).
5. Remove the mode damper servo motor (See page 31-76).
6. Remove the mix damper servo motor (See page 31-77).
7. Remove the HVAC assembly transition duct.
a. Detach the claws (arrow) on both sides and remove
the transition duct (1) from the HVAC assembly.
1
RT21310330
8. Remove the air inlet assembly.

a. Remove the air inlet assembly right fixing screw
(arrow) and detach the fixing claws (1).
RT21310340

b. Remove 2 fixing screws (arrow) from the left side of

air inlet assembly.
RT21310350
c. Remove the air inlet assembly. 31

9. Remove the inner/outer circulation damper set.
a. Remove the air inlet assembly grommet (arrow) and
detach the fixing claw (1) on front part.
1
RT21310360
b. Remove the air inlet assembly rear fixing screw

(arrow) and detach the fixing claws (1).
RT21310370
c. Detach the air inlet housing assembly and remove the

inner/outer circulation damper set.
RT21310380

10.Remove the left foot fan shield.

a. Remove the fixing screw (arrow), detach the fixing
claw and detach the left foot fan shield (1) from the
HVAC assembly.
RT21310390
31
11. Remove the right foot fan shield.
a. Remove the fixing screw (arrow), detach the fixing
claw and detach the right foot fan shield (1) from the
HVAC assembly.
RT21310400
12.Remove the expansion valve.

a. Remove the evaporator core line grommet (arrow).
RT21310410
b. Remove 2 fixing bolts (arrow) between expansion

valve and expansion valve mounting pressure plate. 
RT21310420

c. Detach the A/C high/low pressure line and remove the

expansion valve carefully.
RT21310430
13.Remove the blower case assembly. 31

a. Detach the A/C wire harness and connector (arrow)
from the blower case assembly.
RT21310440
b. Detach the evaporator temperature sensor wire

harness and connector (arrow) from the blower case
assembly.
RT21310450
c. Detach the A/C wire harness (arrow) from the blower

case assembly.
RT21310460

d. Detach the fixing claws (arrow) from the expansion

valve cover plate and remove the expansion valve
cover plate.
RT21310470
31 e. Remove 2 fixing screws (arrow) between blower case

assembly and the upper part of evaporator tank
assembly.
RT21310480
f. Remove 2 fixing screws (arrow) between blower case

assembly and the lower part of evaporator tank
assembly.
RT21310490
g. Detach the blower case assembly from the evaporator tank assembly.
14.Remove the evaporator core assembly.
a. Remove the expansion valve mounting pressure plate
(arrow) from the evaporator core line.
RT21310500

b. Remove 4 fixing screws (arrow) from the bottom of

evaporator tank assembly.
RT21310510
c. Take out the evaporator core (arrow) from the 31

evaporator tank assembly carefully.
RT21310520
15.Remove the evaporator temperature sensor.

a. Disconnect the evaporator temperature sensor
connector (arrow).
RT21310530
b. Remove the evaporator temperature sensor (arrow)

from the evaporator core.
RT21310540

16.Remove the heater core assembly.

a. Remove the heater core line grommet (arrow).
RT21310550
31
b. Remove the heater core line pressure plate fixing
screw (arrow).
RT21310560
c. Remove 2 fixing screws (arrow) from the evaporator

case.
RT21310570
d. Remove 2 fixing screws (arrow) from the heater core

line cover plate.
RT21310580

e. Remove the heater core outlet pipe fixing clamp

(arrow).
RT21310590
f. Take out the heater core assembly carefully. 31
RT21310600
17.Remove the A/C drain pipe.

a. Remove the A/C drain pipe (arrow) from the bottom of
evaporator tank assembly.
RT21310610
18.Remove the mode damper adjustment mechanism set.

a. Remove 4 fixing screws (arrow) from the mode
damper adjustment mechanism set.
RT21310620

b. Remove 2 fixing screws (arrow) from the mode

damper adjustment mechanism set.
RT21310630
31 c. Detach the mode damper adjustment mechanism set from the evaporator tank assembly carefully.
19.Remove the temperature/face/defroster/foot damper set.
a. Detach the A/C wire harness assembly (arrow) from
the evaporator tank assembly.
RT21310640
b. Remove 2 fixing screws (arrow) from the front part of

RT21310650
c. Remove the fixing screw (arrow) from the upper part

of evaporator tank assembly.
RT21310660

d. Remove the fixing screw (arrow) from the lower part of

RT21310670
e. Detach the fixing clips, separate the evaporator case, 31

and remove the temperature damper set.
RT21310680
f. Remove the face damper set.
RT21310690
g. Remove the defroster damper set.
RT21310700

h. Remove the foot damper set.
RT21310710
31 Inspection
1. Check the evaporator temperature sensor.
a. Using the ohm band of digital multimeter, measure the
resistance of evaporator temperature sensor
+ -
1 2
RT21310720
Standard Resistance
Specified Specified Specified

Multimeter Temperature Temperature Temperature
Condition Condition Condition
Connection (°C) (°C) (°C)
(Ω) (Ω) (Ω)
Terminal 1 -
-40 45636 -8 8916 24 2294
Terminal 2
Terminal 1 -
-39 43408 -7 8516 25 2200
Terminal 2
Terminal 1 -
-38 41180 -6 8116 26 2125
Terminal 2
Terminal 1 -
-37 38953 -5 7716 27 2050
Terminal 2
Terminal 1 -
-36 36725 -4 7412 28 1975
Terminal 2
Terminal 1 -
-35 34498 -3 7107 29 1900
Terminal 2
Terminal 1 -
-34 32864 -2 6803 30 1825
Terminal 2
Terminal 1 -
-33 31230 -1 6498 31 1764
Terminal 2
Terminal 1 -
-32 29596 0 6194 32 1704
Terminal 2
Terminal 1 -
-31 27962 1 5922 33 1643
Terminal 2


(Ω) (Ω) (Ω)
Terminal 1 -
-30 26328 2 5663 34 1583
Terminal 2
Terminal 1 -
-29 25117 3 5418 35 1522
Terminal 2
Terminal 1 -
-28 23906 4 5185 36 1473
Terminal 2
Terminal 1 -
Terminal 2
-27 22695 5 4963 37 1424 31
Terminal 1 -
-26 21484 6 4752 38 1375
Terminal 2
Terminal 1 -
-25 20273 7 4552 39 1326
Terminal 2
Terminal 1 -
-24 19367 8 4361 40 1277
Terminal 2
Terminal 1 -
-23 18461 9 4180 41 1237
Terminal 2
Terminal 1 -
-22 17554 10 4007 42 1197
Terminal 2
Terminal 1 -
-21 16648 11 3857 43 1156
Terminal 2
Terminal 1 -
-20 15742 12 3708 44 1116
Terminal 2
Terminal 1 -
-19 15058 13 3558 45 1076
Terminal 2
Terminal 1 -
-18 14374 14 3408 46 1043
Terminal 2
Terminal 1 -
-17 13689 15 3259 47 1010
Terminal 2
Terminal 1 -
-16 13005 16 3141 48 978
Terminal 2
Terminal 1 -
-15 12321 17 3023 49 945
Terminal 2
Terminal 1 -
-14 11800 18 2905 50 912
Terminal 2
Terminal 1 -
-13 11279 19 2787 51 885
Terminal 2
Terminal 1 -
-12 10758 20 2669 52 858
Terminal 2
Terminal 1 -
-11 10237 21 2575 53 830
Terminal 2
Terminal 1 -
-10 9716 22 2481 54 803
Terminal 2


(Ω) (Ω) (Ω)
Terminal 1 -
-9 9316 23 2388 55 776
Terminal 2
HINT:
Resistance decreases as the temperature increases.
CAUTION
31
 Resistance value may change even if the sensor is touched slightly. Make sure that the connector of
sensor is held firmly.
 During measurement, the sensor temperature must be almost the same as the ambient temperature.
If result is not as specified, replace the evaporator temperature sensor.

2. Check the evaporator core assembly.
a. Check if the evaporator core assembly is cracked, damaged and leaked.
If any problem is found, replace the evaporator core assembly.
b. Check the fin for bends.
If any fin is bent, carefully straighten it with a
screwdriver or pliers.
RT21310730
3. Check the heater core assembly.

a. Check if the heater core assembly is cracked, damaged or leaked.
If any problem is found, replace the heater core assembly.
b. Check the fin for bends.
If any fin is bent, carefully straighten it with a
RT21310740

4. Check the damper control mechanism assembly.

a. Check if the mode damper adjustment mechanism set is stuck, fell out, deformed or damaged. Replace
as necessary.
b. Check if the inner/outer circulation/temperature/face/defrost/foot damper set is stuck, fell out, deformed
or damaged. Replace as necessary.
Assembly
CAUTION
 If evaporator core is to be reused, do not insert the evaporator temperature sensor into a location where 31
the sensor was previously inserted. Insert it to a location that is 1 fin to the right or left of its previous
location.
 During installation, apply a small amount of grease to the contact surface of mode damper adjustment
mechanism set to ensure that it can operate smoothly.
 Always check that inner/outer circulation damper mechanism assembly operates normally after
installation is completed.
 Always check that mode damper mechanism assembly operates normally after installation is completed.
 Always check that temperature damper mechanism assembly operates normally after installation is
completed.
Installation
CAUTION
 Tighten fixing bolts and fixing nuts to specified torque.

 It is necessary to replace the refrigerant line O-ring when installing the refrigerant line. Failure to do so
may result in refrigerant leaks.
 Lubricate the new rubber O-ring with clean refrigerant oil and install it to the refrigerant line joint.
 Only use the specified O-ring, as it is made of special materials for R134a system.
 Only use recommended refrigerant oil which is applicable to the A/C compressor assembly on vehicle.
 Be sure to recharge the refrigerant and check refrigerant fo leakage after installation.

A/C Low Pressure Line

Removal
CAUTION
31 1. Recover the refrigerant from the A/C system (See page 31-66).
4. Remove the A/C low pressure line (compressor to evaporator).
pressure line and expansion valve, and detach the A/C
low pressure line.
RT21310260
b. Remove the coupling nut (arrow) between A/C high/low

pressure line fixing bracket and body, and disengage
the A/C low pressure line.
RT21310750
c. Remove the coupling nut (arrow) between A/C high/

low pressure line fixing bracket and body, and
disengage the A/C low pressure line.
RT21310760

d. Disengage the fixing clamp (arrow) between A/C low

pressure line and coolant circulation line.
RT21310770
e. Remove the fixing bolt (arrow) between A/C low 31

disengage the A/C low pressure line from the
compressor assembly.
RT21310780
f. Remove the A/C low pressure line (compressor to evaporator).
Installation
CAUTION

 Perform recharging for the A/C system and check refrigerant for leakage.

A/C High Pressure Line

Removal
CAUTION
4. Remove the front bumper assembly (See page 48-11).
5. Remove the A/C high pressure line I (compressor to evaporator).
pressure line and expansion valve, and disengage the
A/C high pressure line I.
RT21310260
b. Remove the coupling nut (arrow) between A/C high/

disengage the A/C high pressure line I.
RT21310750
c. Disconnect the A/C pressure sensor wire harness

connector (arrow).
RT21310790

d. Remove the coupling nut (arrow) between A/C high/

disengage the A/C high pressure line I.
RT21310760
e. Remove the fixing nut (arrow) between A/C high 31

pressure line I and condenser assembly, and
disengage the A/C high pressure line I from the
condenser assembly.
RT21310800
f. Remove the A/C high pressure line I (condenser to evaporator).

6. Remove the A/C high pressure line II (compressor to condenser).
a. Remove the fixing nut (arrow) between A/C high
pressure line II and condenser assembly, and
disengage the A/C high pressure line II from the
RT21310810
b. Remove the fixing bolt (arrow) between A/C high

pressure line II and body and disengage the fixing
clamp (1) from the coolant circulation line. 
1
RT21310820

c. Disengage the fixing clamp (arrow) between A/C high

pressure line II and coolant circulation line.
RT21310830
31 d. Remove the fixing bolt (arrow) between A/C high

pressure line II and compressor assembly, and
RT21310840
e. Remove the A/C high pressure line II (compressor to condenser).
Installation
CAUTION


Compressor Assembly
WARNING
 Be sure to follow the safety precautions before performing the procedure. Failure to do so may result in
serious personal injury or even death.
CAUTION
 Special service equipment for R134a refrigerant must be used to recover/charge refrigerant. 31
 If the A/C compressor assembly has an internal malfunction, it is necessary to replace the A/C fluid line.
Failure to do so may result in a serious damage to A/C compressor assembly after replacing.
 When replacing compressor assembly, it is necessary to measure the refrigerant oil amount removed
from the new A/C compressor assembly.
Removal
1. Recover the refrigerant from the A/C system (See page 31-66).
4. Remove the engine lower right protector assembly.
5. Remove the power steering pump assembly (See page 29-17).
6. Remove the compressor assembly.
a. Turn the tensioner with a wrench in the direction of
arrow as shown in the illustration, and then remove
the accessory drive belt (1).
RT21160060
b. Remove the idler pulley fixing bolt (arrow) and then

remove the idler pulley (1).
RT21310841

c. Disconnect the compressor assembly wire harness

connector (arrow).
RT21310850
31 d. Remove 2 fixing bolts (arrow) between A/C high/low

disengage the A/C high/low pressure line from the
RT21310860

rear mounting cushion assembly and rear mounting
bracket.
RT21220180
f. Remove the coupling bolt and nut (arrow) between

front mounting cushion assembly and front mounting
bracket.
RT21220190

g. Remove the coupling bolt (1) and coupling nuts (2)

between right mounting cushion assembly and right
1
h. Remove 3 coupling bolts (arrow) between right
2
RT21070690
i. Lower the engine assembly and remove 2 fixing bolts 31

(arrow) between compressor assembly and mounting
bracket.
RT21310870
j. Carefully remove the compressor assembly from below.
Installation
CAUTION
 Tighten the fixing bolts to specified torque.

 When installing a new compressor assembly, always remove a certain amount of refrigerant oil from the
new A/C compressor assembly as specified.

Condenser Assembly (w/Receiver Drier)

Removal
CAUTION
5. Remove the condenser assembly (w/ receiver drier).
a. Remove the fixing nut (arrow) between A/C high
pressure line I and condenser assembly, and
disengage the A/C high pressure line I from the
RT21310800
b. Remove the fixing nut (arrow) between A/C high

pressure line II and condenser assembly, and
RT21310810
c. Remove 4 fixing bolts (arrow) from the tank upper

crossmember fixing bracket and disengage the upper
part of condenser assembly. 
RT21310880

d. Remove the condenser deflector fixing clips (arrow)

and remove the deflectors on both sides.
RT21310890
e. Disengage the lower part of condenser assembly from 31

the positioning holes (arrow) of tank lower
crossmember assembly.
RT21310900
f. Carefully remove the condenser assembly (w/receiver drier) from above.
Inspection
1. Check the condenser fins.
a. If the condenser fins are dirty, wash them with water. And then dry the fins with compressed air.
CAUTION
 DO NOT damage the condenser fins.
b. If the condenser fins are bent, straighten them with a

RT21310910

Installation
CAUTION
 When installing condenser assembly (w/receiver drier), be sure to align the upper part of it with the
positioning hole of tank upper crossmember fixing bracket.
 When installing the condenser assembly (w/receiver drier), be sure to align the lower part of it with the
positioning hole of tank lower crossmember.
31  Lubricate the new rubber O-ring with clean refrigerant oil and install it to the refrigerant line joint.

Mix Damper Servo Motor (Left - Automatic A/C)

Removal
3. Remove the mix damper servo motor (left - automatic A/C).
a. Disconnect the mix damper servo motor connector
(arrow).
31
RT21310920
b. Detach the fixing claw, and remove the mix damper

assembly carefully.
RT21310930
Installation
CAUTION
 When installing, apply a small amount of grease to the contact surface between mix damper servo motor
lever and mix damper adjustment mechanism set to ensure the motor operates smoothly.

Room Temperature Sensor (for Automatic A/C)

Removal
3. Remove the room temperature sensor (for automatic A/C).
a. Disconnect the room temperature sensor wire
harness bands (arrow).
31
RT21310940
b. Disconnect the room temperature sensor wire

harness connectors (arrow).
RT21310950
c. Rotate and detach the connecting part (arrow)

between room temperature sensor and HVAC
assembly.
RT21310960
d. Remove the room temperature sensor.

Inspection
1. Check the room temperature sensor.
resistance of room temperature sensor according to
+ -
the table below.
2 1
RT21310970 31
Standard Resistance
Specified
Multimeter Connection Temperature (°C) Upper Limit (KΩ) Lower Limit (KΩ)
Condition (KΩ)
Terminal 1 - Terminal 2 -40 332.1 317.4 347.8
Terminal 1 - Terminal 2 -35 239.9 230 250.1
Terminal 1 - Terminal 2 -30 175.2 168.5 182
Terminal 1 - Terminal 2 -25 130 126.4 134.7
Terminal 1 - Terminal 2 0 32.97 32.24 33.7
Terminal 1 - Terminal 2 15 15.77 15.55 16
Terminal 1 - Terminal 2 25 10 9.9 10.1

HINT:
CAUTION
If result is not as specified, replace the room temperature sensor.
Installation
31 Installation is in the reverse order of removal.

Outside Temperature Sensor (for Automatic A/C)

Inspection
1. Check the outside temperature sensor.
resistance of outside temperature sensor according to
+ -
the table below.
2 1
31
RT21310980
Standard Resistance

(Ω) (Ω) (Ω)
Terminal 1 -
-40 332.1 2 29.76 44 4.527
Terminal 2
Terminal 1 -
-39 310.9 3 28.29 45 4.353
Terminal 2
Terminal 1 -
-38 291.2 4 26.9 46 4.186
Terminal 2
Terminal 1 -
-37 272.8 5 25.59 47 4.027
Terminal 2
Terminal 1 -
-36 255.7 6 24.35 48 3.874
Terminal 2
Terminal 1 -
-35 239.9 7 23.17 49 3.728
Terminal 2
Terminal 1 -
-34 225 8 22.06 50 3.588
Terminal 2
Terminal 1 -
-33 211.2 9 21.01 51 3.454
Terminal 2
Terminal 1 -
-32 198.4 10 20.02 52 3.326
Terminal 2
Terminal 1 -
-31 186.4 11 19.07 53 3.204
Terminal 2
Terminal 1 -
-30 175.2 12 18.18 54 3.086
Terminal 2
Terminal 1 -
-29 164.7 13 17.33 55 2.974
Terminal 2
Terminal 1 -
-28 154.9 14 16.53 56 2.866
Terminal 2
Terminal 1 -
-27 145.8 15 15.77 57 2.762
Terminal 2


(Ω) (Ω) (Ω)
Terminal 1 -
-26 137.2 16 15.05 58 2.663
Terminal 2
Terminal 1 -
-25 130 17 14.37 59 2.568
Terminal 2
Terminal 1 -
-24 122.5 18 13.72 60 2.477
Terminal 2
Terminal 1 -
31 Terminal 2
-23 115.6 19 13.1 61 2.39
Terminal 1 -
-22 109.1 20 12.52 62 2.306
Terminal 2
Terminal 1 -
-21 102.9 21 11.96 63 2.225
Terminal 2
Terminal 1 -
-20 99.03 22 11.31 64 2.148
Terminal 2
Terminal 1 -
-19 93.39 23 10.93 65 2.074
Terminal 2
Terminal 1 -
-18 88.11 24 10.45 66 2.002
Terminal 2
Terminal 1 -
-17 83.17 25 10 67 1.934
Terminal 2
Terminal 1 -
-16 78.53 26 9.57 68 1.868
Terminal 2
Terminal 1 -
-15 74.18 27 9.16 69 1.805
Terminal 2
Terminal 1 -
-14 70.1 28 8.77 70 1.744
Terminal 2
Terminal 1 -
-13 66.26 29 8.4 71 1.686
Terminal 2
Terminal 1 -
-12 62.67 30 8.047 72 1.63
Terminal 2
Terminal 1 -
-11 59.28 31 7.71 73 1.576
Terminal 2
Terminal 1 -
-10 56.1 32 7.39 74 1.524
Terminal 2
Terminal 1 -
-9 53.12 33 7.085 75 1.474
Terminal 2
Terminal 1 -
-8 50.3 34 6.794 76 1.426
Terminal 2
Terminal 1 -
-7 47.66 35 6.517 77 1.379
Terminal 2
Terminal 1 -
-6 45.17 36 6.252 78 1.335
Terminal 2


(Ω) (Ω) (Ω)
Terminal 1 -
-5 42.82 37 6 79 1.292
Terminal 2
Terminal 1 -
-4 40.61 38 5.759 80 1.25
Terminal 2
Terminal 1 -
-3 38.53 39 5.53 81 1.211
Terminal 2
Terminal 1 -
Terminal 2
-2 36.56 40 5.31 82 1.172 31
Terminal 1 -
-1 34.71 41 5.101 83 1.135
Terminal 2
Terminal 1 -
0 32.97 42 4.901 84 1.1
Terminal 2
Terminal 1 -
1 31.32 43 4.71 85 1.065
Terminal 2
HINT:
CAUTION
If result is not as specified, replace the outside temperature sensor.

Heater Core Sensor (for Automatic A/C)

Inspection
1. Check the heater core sensor.
resistance of heater core sensor according to the
+ -
table below. 2 1
31
RT21310990
Standard Resistance
Lower Standard Upper Lower Standard Upper

Multimeter Temperature Temperature
Limit Value Limit Limit Value Limit
Connection (°C) (°C)
(KΩ) (mm) (KΩ) (KΩ) (mm) (KΩ)
Terminal 1 -
36°C 1.388 1.453 1.520 69°C 0.451 0.483 0.516
Terminal 2
Terminal 1 -
37°C 1.337 1.400 1.467 70°C 0.437 0.468 0.501
Terminal 2
Terminal 1 -
38°C 1.289 1.351 1.415 71°C 0.424 0.454 0.486
Terminal 2
Terminal 1 -
39°C 1.242 1.303 1.366 72°C 0.411 0.441 0.472
Terminal 2
Terminal 1 -
40°C 1.198 1.258 1.319 73°C 0.398 0.428 0.458
Terminal 2
Terminal 1 -
41°C 1.156 1.213 1.274 74°C 0.386 0.415 0.445
Terminal 2
Terminal 1 -
42°C 1.114 1.172 1.230 75°C 0.378 0.398 0.418
Terminal 2
Terminal 1 -
43°C 1.075 1.131 1.189 76°C 0.364 0.390 0.420
Terminal 2
Terminal 1 -
44°C 1.037 1.091 1.148 77°C 0.353 0.379 0.408
Terminal 2
Terminal 1 -
45°C 1.001 1.056 1.110 78°C 0.343 0.368 0.397
Terminal 2
Terminal 1 -
46°C 0.966 1.018 1.073 79°C 0.333 0.358 0.385
Terminal 2
Terminal 1 -
47°C 0.933 0.984 1.038 80°C 0.323 0.348 0.375
Terminal 2
Terminal 1 -
48°C 0.900 0.950 1.004 81°C 0.314 0.337 0.364
Terminal 2
Terminal 1 -
49°C 0.870 0.919 0.970 82°C 0.305 0.328 0.354
Terminal 2

Lower Standard Upper Lower Standard Upper

Multimeter Temperature Temperature
Limit Value Limit Limit Value Limit
Connection (°C) (°C)
(KΩ) (mm) (KΩ) (KΩ) (mm) (KΩ)
Terminal 1 -
50°C 0.840 0.890 0.937 83°C 0.296 0.319 0.344
Terminal 2
Terminal 1 -
51°C 0.812 0.858 0.908 84°C 0.287 0.310 0.335
Terminal 2
Terminal 1 -
52°C 0.784 0.830 0.879 85°C 0.279 0.300 0.326
Terminal 2
Terminal 1 -
Terminal 2
53°C 0.758 0.803 0.850 86°C 0.271 0.293 0.317 31
Terminal 1 -
54°C 0.733 0.777 0.823 87°C 0.264 0.285 0.308
Terminal 2
Terminal 1 -
55°C 0.708 0.751 0.797 88°C 0.256 0.276 0.300
Terminal 2
Terminal 1 -
56°C 0.685 0.727 0.772 89°C 0.249 0.269 0.292
Terminal 2
Terminal 1 -
57°C 0.663 0.704 0.748 90°C 0.242 0.262 0.284
Terminal 2
Terminal 1 -
58°C 0.641 0.681 0.724 91°C 0.236 0.254 0.277
Terminal 2
Terminal 1 -
59°C 0.621 0.660 0.702 92°C 0.229 0.247 0.269
Terminal 2
Terminal 1 -
60°C 0.601 0.643 0.680 93°C 0.223 0.241 0.262
Terminal 2
Terminal 1 -
61°C 0.581 0.621 0.659 94°C 0.217 0.234 0.255
Terminal 2
Terminal 1 -
62°C 0.562 0.600 0.639 95°C 0.211 0.228 0.249
Terminal 2
Terminal 1 -
63°C 0.545 0.582 0.620 96°C 0.205 0.222 0.242
Terminal 2
Terminal 1 -
64°C 0.496 0.564 0.601 97°C 0.200 0.216 0.236
Terminal 2
Terminal 1 -
65°C 0.511 0.546 0.582 98°C 0.194 0.210 0.230
Terminal 2
Terminal 1 -
66°C 0.495 0.530 0.565 99°C 0.189 0.205 0.224
Terminal 2
Terminal 1 -
67°C 0.480 0.513 0.548 100°C 0.184 0.200 0.219
Terminal 2
Terminal 1 -
68°C 0.465 0.498 0.532
Terminal 2
HINT:
If result is not as specified, replace the automatic A/C wire harness assembly.

- MEMO -

GENERAL INFORMATION 32-3 B0072-1B 32-39
Description 32-3 B0072-1C 32-39
Operation 32-4 B1231-12 32-46
Specifications 32-5 B1231-1C 32-46
Tools 32-6 B1232-12 32-51
Circuit Diagram 32-7 B1232-1C 32-51
B1210-00 32-56
B1211-00 32-56
SRS Control Module Assembly 
B125A-00 32-56
Terminal List 32-10
B1240-96 32-56 32
B1251-49 32-56
B1250-16 32-57
B1250-17 32-57
U1300-55 32-62
B0001-11 32-15 ON-VEHICLE SERVICE 32-64
B0001-12 32-15 Driver Airbag 32-64
B0001-1A 32-15 On-vehicle Inspection 32-64
B0001-1B 32-15 Removal 32-65
B0001-1C 32-15 Installation 32-66
B0010-11 32-23 Disposal 32-66
B0010-12 32-23 Spiral Cable 32-67
B0010-1A 32-23 Removal 32-67
B0010-1B 32-23 Inspection 32-67
B0010-1C 32-23 Installation 32-68
B0070-11 32-31 Front Passenger Airbag 32-69
B0070-12 32-31 On-vehicle Inspection 32-69
B0070-1A 32-31 Removal 32-69
B0070-1B 32-31 Installation 32-71
B0070-1C 32-31 Disposal 32-71
B0072-11 32-39 SRS Control Module Assembly 32-72
B0072-12 32-39 Removal 32-72
B0072-1A 32-39 Installation 32-72

32

32 - SUPPLEMENTAL RESTRAINT SYSTEM
GENERAL INFORMATION
Description
This vehicle adopts the occupant restraint system, which includes active and supplemental types. Active
restraint system requires occupants to take some actions, such as fastening seat belt; while supplemental
restraint system requires no actions from occupants.
Active Restraint system:
 Driver seat belt and front passenger seat belt
 Rear seat belt
Supplemental Restraint System:
 Airbag system
 Driver seat belt pretensioner and front passenger seat belt pretensioner 32
Airbag system consists of the following components:
 Driver airbag
Driver airbag is installed in the steering wheel, which will inflate to protect the driver in the event of a
severe collision.
 Front passenger airbag
Front passenger airbag is installed in the upper right side of instrument panel, which will inflate to protect
the front passenger in the event of a severe collision.
 SRS control module assembly
SRS control module assembly has a built-in collision sensor which is installed on the body floor of auxiliary
fascia console body assembly. It controls the inflation of airbag so as to protect driver and front passenger
in the event of a severe collision.
 Spiral cable
It is used to connect the driver airbag while ensuring that steering wheel has enough steering angle.
 Airbag malfunction indicator
After ignition switch is turned to ON, if the malfunction indicator goes off after coming on for approximately
3 seconds, it means the supplemental restraint system operates normally. If the malfunction indicator does
not come on, remains on or flashes, it means the supplemental restraint system has a problem and it is
necessary to perform tests and repairs.
 Wire harness
Generally, it is yellow and used to connect the elements of supplemental restraint system. The connector
has a safety mechanism.
Airbag system function:
 Airbag must work together with the seat belt, and it is not a substitute for the seat belt. Driver and
passengers should always fasten their seat belts when driving, and adjust the belts to the proper position
according to their size.
 Minor collision will not activate the airbag system. The airbags will quickly inflate to protect the driver and
front passenger only when severe frontal collision occurs.
Seat belt pretensioner consists of the following components:
 Driver seat belt pretensioner
Driver seat belt pretensioner is located on the driver seat belt retractor, which will retract the driver seat belt
to protect the driver in the event of a severe collision.
 Front passenger seat belt pretensioner
Front passenger seat belt pretensioner is located on the front passenger seat belt retractor, which will
retract the front passenger seat belt to protect the front passenger in the event of a severe collision.

Seat belt pretensioner function:

 At the moment of collision, the pretensioner retracts the seat belt before occupant moves forward, and
restraints occupant onto the seat, then locks the seat belt to prevent occupant from leaning forward, thus
protecting occupant safety.
 Seat belt pretensioner works with airbag. Once frontal collision impact is detected higher than specified
valve, the seat belt with pretensioner will work together with the airbag system to protect occupant safety.
Operation
Supplemental restraint system can improve the safety of occupants only when used in combination with the
seat belts. Occupants must fasten their seat belts in order to gain full protection from the supplemental
restraint system.
Supplemental restraint system circuit is continuously monitored and controlled by the SRS control module
assembly. The airbag indicator on instrument cluster illuminates for approximately 3 seconds for a test each
32 time ignition switch is turned ON. The airbag indicator goes off after the test is completed. If the indicator
comes on at any time other than the test time, it indicates that there is a problem in the supplemental restraint
system circuit.
Whether the airbag deploys or not depends on the angle and severity of the impact. When vehicle is
subjected to severe collision, the microprocessor in supplemental restraint system sends signals to the
corresponding inflator units of airbag to deploy the airbags quickly , thus protecting occupants.
CAUTION
 Before removing airbag system components, disconnect the negative battery cable at least 90 seconds.
Before servicing steering system, remove the driver airbag and spiral cable for safekeeping.
 If vehicle has been involved in a minor collision but the airbags do not deploy, always inspect the airbag
components.
 If airbag may be touched during servicing, remove the airbag as necessary for safekeeping before
servicing.
 Never use airbag components from another vehicle. When replacing the airbag components, replace
with new ones.
 If an airbag component is dropped or if there are any cracks, dents or other defects in the case, bracket
or connector, replace the airbag component with a new one.
 Information labels are attached to the periphery of airbag components. Always follow the cautions and
instructions on labels.
WARNING
 Never expose airbag components directly to hot air or open flames.

 Never attempt to disassemble or repair airbag components.
 The removed airbag should be kept properly. Never put other objects on it. If triggered accidentally, the
airbag may cause personal injury.
 As a disposable component, the airbag must be replaced after deployment and avoid reusing it.
 Always dispose of vehicle together with airbag, or the airbag may be triggered accidentally to cause
personal injury.

Specifications

Coupling Bolt Between Front Passenger Airbag and
10 ± 1
Coupling Nut Between SRS Control Module
10 ± 1
Assembly and Body
32

Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
32
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Supplemental Restraint System (Page 1 of 3)
*1: SRS control module connector is I-046

*2: SRS control module connector is B-072
IGNITION SWITCH
BATTERY
ON OR START
32
INSTRUMENT
RF23 RF06 RF08 PANEL FUSE
AND RELAY BOX
10A 10A 10A
I-007
23 6 8
P
R
11 13
AIRBAG
INSTRUMENT
MICROPROCESSOR CLUSTER
R
GND CAN-H2 CAN-L2 I-015
3 5 30 29
B
TO CAN
SYSTEM
OB
OB
TO CAN I-036 *2
I-003
SYSTEM 4 9 10 B-055
OB
O
R
1 2 17
CAN-L1 CAN-H1 SRS
CONTROL
MODULE
B-072
I-046
1 2 3 4 5 6 7 8 9 10 11 12
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 B-072 I-046
13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B Gr
I-007
27 25 26
87
B
85 86 86 86
87 30 87 30
30 85 85
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-015
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 8 7 6 5 4 3 2 1 I-036
L
16 15 14 13 12 11 10 9 W
ET21320010


SRS
CONTROL
MODULE
32 I-046
B-072
5 6 GY 3 4 9 10
R
GW
LW
LB
*2 *1
B-055 I-035
7 8 5 6 1 2
I-036 B-059
GY
GW
LW
LB
I-012
9 1
I-054
R
1 2
SPIRAL
CABLE - +
R
1 2 2 1
- + + -
DRIVER SEAT BELT
PRE-TENSIONER
B-034
FRONT DRIVER
PASSENGER AIRBAG
AIRBAG I-055
I-028
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 9 10 11 12 13 14 15 16 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 18 17 16 15 14 13 12 11 10
I-046 B-072 I-012 I-035

Gr B W W
1 2 1 2
2 1
I-028 - + B-034 I-055 8 7 6 5 4 3 2 1 I-036
Gr B B 16 15 14 13 12 11 10 9 W
ET21320020


SRS
CONTROL
MODULE
32
I-046
B-072
7 8 20 25 16
BR
BL
VW
B
*1
I-006
1 2 15 16
B-003
I-045
BR
BL
VW
1 1
FRONT SEAT
PASSENGER BELT
SEAT BELT REMINDER
2 1 SWITCH B-049
+ - B-050
2 2
B
B
B
FRONT
PASSENGER B-003
11
SEAT BELT I-006
PRE-TENSIONER
B
B-002
I-045
1 2
B-002 1 2 B-050 1 2 B-049
- +
B B W
10 9 8 7 6 5 4 3 2 1 I-006 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-046 B-072

22 21 20 19 18 17 16 15 14 13 12 11 W 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Gr B
ET21320030

DIAGNOSIS & TESTING

SRS Control Module Assembly Terminal List
1 Power Supply 17 CAN-H1
2 CAN-L1 18 -
3 Driver Airbag Positive 19 -
4 Driver Airbag Negative 20 Front Passenger Seat Belt Switch
5 Front Passenger Airbag Negative 21 -
32 6 Front Passenger Airbag Positive 22 -
Front Passenger Seat Belt
7 23 -
Pretensioner Positive
Front Passenger Seat Belt
8 24 -
Pretensioner Negative
Driver Seat Belt Pretensioner
9 25 Seat Belt Reminder
Negative
Driver Seat Belt Pretensioner
10 26 -
Positive
11 - 27 -
12 - 28 -
13 - 29 -
14 - 30 -
15 - 31 -
16 Ground 32 -

 Use X-431 3G diagnostic tester to record and clear the DTCs stored in the supplemental restraint system.
 Turn ignition switch ON, and then select "Read Code".


 Wiggle related wire harnesses and connectors and observe if signal is interrupt in the related circuit.
 Inspect the airbag components and mounting areas for damage, foreign matter, etc. that will cause
incorrect signals.
 Remove the SRS control module assembly from the malfunctioning vehicle and install it to a new vehicle
and perform a test. If DTC cannot be cleared, the SRS control module assembly is malfunctioning. If DTC
can be cleared, reinstall the SRS control module assembly to original vehicle.
 Refer to Technical Bulletin that is applied to the malfunction. 32
Ground Inspection
Groundings are very important to the entire circuit system, which are normal or not can seriously affect the
entire circuit system. Groundings are often exposed to moisture, dirt and corrosive elements. Corrosion (rust)
can increase resistance which will change the way in which a circuit works.
Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can affect
the electronically controlled circuit. Perform the following operations when checking the ground points:
1. Remove the ground nut.
4. Reinstall the ground nut securely.
6. If several wire harnesses are crimped into one ground eyelet terminal, check if the wire harnesses are
installed correctly. Make sure all wire harnesses are clean, securely fastened and providing a good ground
path.
Diagnosis Procedure
HINT:
Use following procedures to troubleshoot the Supplemental Restraint System (SRS).
NEXT
NEXT

3 Check SRS warning light
NEXT
4 Check for DTCs (current DTC and history DTC)
DTC
occurs
32 No 
DTC
5 Diagnostic Trouble Code (DTC) chart
NEXT
6 Circuit inspection
HINT:
An activation prevention mechanism is built in the airbag system connector. When the connector is
disconnected, this mechanism cuts off the circuit by bringing the short spring plate into contact with the
terminals, thus insulating the circuit from external power sources to prevent accidental airbag activation.
To release the activation prevention mechanism, insert a piece of paper with the same thickness as the male
terminal between terminals and short spring plate to disconnect the connection.
WARNING
 DO NOT release the activation prevention mechanism unless specially directed by the troubleshooting
procedure.
During circuit troubleshooting for the airbag system, make sure to cut off the battery power source, and wait
for at least 90 seconds to discharge the system condenser.
When performing electrical diagnosis and test, always refer to the relevant circuit diagram for the special
NEXT
7 Repair
NEXT

8 Clear DTCs (current DTC and history DTC)
NEXT
DTC
Go to step 5
output
No DTC
output
Go to next step 32
NEXT
10 Confirmation test
NEXT
11 End


B0001-11 Front Airbag Driver Loop Circuit Short to Ground
B0001-12 Front Airbag Driver Loop Circuit Short to Battery
B0001-1A Front Airbag Driver Loop Circuit Resistance Below Threshold
B0001-1B Front Airbag Driver Loop Circuit Resistance Above Threshold
B0001-1C Front Airbag Driver Loop Circuit Voltage Out of Range
B0010-11 Front Airbag Passenger Loop Circuit Short to Ground
B0010-12 Front Airbag Passenger Loop Circuit Short to Battery
32 B0010-1A Front Airbag Passenger Loop Circuit Resistance Below Threshold
B0010-1B Front Airbag Passenger Loop Circuit Resistance Above Threshold
B0010-1C Front Airbag Passenger Loop Circuit Voltage Out of Range
B0070-11 Belt Pretensioner Front Driver Loop Circuit Short to Ground
B0070-12 Belt Pretensioner Front Driver Loop Circuit Short to Battery
B0070-1A Belt Pretensioner Front Driver Loop Circuit Resistance Below Threshold
B0070-1B Belt Pretensioner Front Driver Loop Circuit Resistance Above Threshold
B0070-1C Belt Pretensioner Front Driver Loop Circuit Voltage Out of Range
B0072-11 Belt Pretensioner Front Passenger Loop Circuit Short to Ground
B0072-12 Belt Pretensioner Front Passenger Loop Circuit Short to Battery
B0072-1A Belt Pretensioner Front Passenger Loop Circuit Resistance Below Threshold
B0072-1B Belt Pretensioner Front Passenger Loop Circuit Resistance Above Threshold
B0072-1C Belt Pretensioner Front Passenger Loop Circuit Voltage Out of Range
B1231-12 Buckle Switch Front Passenger (BLFP) Circuit Short to Battery
B1231-1C Buckle Switch Front Passenger (BLFP) Circuit Voltage Out of Range
B1232-12 PDM (Passenger Detection Mat) Switch Circuit Short to Battery
B1232-1C PDM (Passenger Detection Mat) Switch Circuit Voltage Out of Range
B1210-00 Front Deployment
B1211-00 BT Deployment
B125A-00 Crash Counter Reached Max
B1240-96 ICM Airbag Lamp Failed
B1251-49 Electronic Control Unit (ECU), Internal Electronic Failure
B1250-16 Battery Voltage Circuit Voltage Below Threshold
B1250-17 Battery Voltage Circuit Voltage Above Threshold
U1300-55 Software Configuration Error

DTC B0001-11 Front Airbag Driver Loop Circuit Short to Ground
DTC B0001-12 Front Airbag Driver Loop Circuit Short to Battery
Front Airbag Driver Loop Circuit Resistance Below

DTC B0001-1A
Threshold
Front Airbag Driver Loop Circuit Resistance Above

DTC B0001-1B
Threshold
32
DTC B0001-1C Front Airbag Driver Loop Circuit Voltage Out of Range


IGNITION SWITCH
ON OR START
INSTRUMENT
RF08 PANEL FUSE
AND RELAY BOX
10A
I-007
8
R
I-036 *2
32 4 B-055
R 1
SRS
CONTROL
MODULE
I-046
B-072
3 4 16
GY
GW
*2
B-055
5 6
I-036
I-045
GY
GW
I-012
9 1
I-054
SPIRAL
CABLE
R
2 1
+ -
DRIVER
AIRBAG
I-055
1 2 3 4 5 6 7 8 9 10 11 12
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-046 B-072
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Gr B 13 14 15 16 17 18 19 20 21 22 23 24
27 25 26
9 10 11 12 13 14 15 16 I-012 87
1 2 3 4 5 6 7 8 W 2 1 85 86 86 86
I-055 87 30 87 30
30 85 85
B
8 7 6 5 4 3 2 1 I-036 I-007
16 15 14 13 12 11 10 9 W B
ET21320040


Condition Condition
Front Airbag Driver
B0001-11 Loop Circuit Short to
Ground
Front Airbag Driver
B0001-12 Loop Circuit Short to
Battery
 Driver airbag
Front Airbag Driver  Spiral cable
Loop Circuit
B0001-1A  Wire harness and
Resistance Below
Threshold
Ignition switch ON ON
connector 32
 SRS control
Front Airbag Driver module assembly
Loop Circuit
B0001-1B
Resistance Above
Threshold
Front Airbag Driver
B0001-1C Loop Circuit Voltage
Out of Range
HINT:
Diagnosis Procedure
1 Check driver airbag
a. Turn ignition switch to LOCK, disconnect the negative battery cable and wait for at least 90 seconds.
b. Disconnect driver airbag connector, and connect the new driver airbag to connector I-055.
WARNING
 Never measure the driver airbag directly, otherwise, it may cause serious personal injury due to
accidental deployment of the airbag.
c. Reconnect the negative battery cable and wait for a few seconds.
d. Turn ignition switch ON and wait for at least 90 seconds.
e. Use X-431 3G diagnostic tester to clear the DTCs.
f. Turn ignition switch to LOCK.
g. Turn ignition switch ON and wait for at least 90 seconds.
h. Use X-431 3G diagnostic tester to check if the DTCs are still output.
NO Replace driver airbag
YES

Use circuit diagram as a guide to perform the following procedures:

b. Disconnect the driver airbag connector I-055 and SRS control module assembly connector I-046/B-072.
c. Disconnect the spiral cable connector I-054 and instrument panel wire harness connector I-012.
d. Disconnect the instrument panel wire harness connector I-036 and body wire harness connector B-055
(*2) .
f. Check for broken, bent, protruded or corroded terminals.
g. Check if related connector terminal contact pins are in good condition.
32
NG Repair or replace instrument panel/body/
spiral cable wire harness and connector
OK
3 Check driver airbag control circuit
a. Turn ignition switch to LOCK, disconnect the negative

battery cable and wait for at least 90 seconds.
b. Disconnect the SRS control module assembly connector
I-046/B-072. V
+ -
c. Disconnect the driver airbag connector I-055.
d. Connect the negative battery cable and wait for a few
seconds. 2 1

f. Using a digital multimeter, measure the voltage between
driver airbag connector I-055 and body ground to check I-055
for a short circuit to power supply according to the table
below.
Standard Voltage
Condition
RT21320160
I-055 (1) - Body
Ignition switch ON Below 1 V
ground
I-055 (2) - Body
ground

g. Turn ignition switch to LOCK, disconnect the negative

driver airbag connector I-055 and body ground to check
for a short circuit to ground according to the table below. + -
Standard Condition
Condition
I-055 (1) - Body
Always No continuity I-055
ground
I-055 (2) - Body
ground
32
RT21320170
i. Release the activation prevention mechanism built into the

SRS control module assembly connector I-046/B-072.
j. Using a digital multimeter, check for continuity between
the terminals of driver airbag connector I-055 according
to the table below. + -
2 1
Standard Condition

Condition
RT21320180
I-055 (1) -
I-055 (2)
OK Replace SRS control module assembly
NG

Check airbag wire harness and connector (SRS control module assembly - body wire
4 harness connector)

b. Disconnect body wire harness connector B-055 and SRS
control module assembly connector B-072 (*2).
+ -
c. Using a digital multimeter, check for continuity between
the terminals of connector B-055 and connector B-072
1 2 3 4 5 6 7 8
according to the table below. 9 10 11 12 13 14 15 16
Standard Condition
B-055
32 Connection
Condition
Condition
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
B-055 (5) - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Always Continuity
B-072 (3) B-072
B-055 (6) -
Always Continuity
B-072 (4)
RT21320181
NG Replace instrument panel wire harness

and connector
OK

Check airbag wire harness and connector (SRS control module assembly - spiral cable
5 connector)

b. Disconnect the instrument panel wire harness connector
I-012 and SRS control module assembly connector 
I-046/B-072. + -

the terminals of connector I-012 and connector  9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
I-046/B-072 according to the table below.
Standard Condition I-012
32
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-012 (9) -
Always Continuity
I-046/B-072 (3) I-046 B-072
I-012 (1) -
Always Continuity
I-046/B-072 (4) RT21320190
I-012 (1) -
Always Continuity
I-046/B-072 (3)
I-012 (9) -
Always Continuity
I-046/B-072 (4)
I-012 (1) -
Always Continuity
I-012 (9)
I-046/B-072 (3) -
Always Continuity
I-046/B-072 (4)

d. Release the activation prevention mechanism built into the

the terminals of connector I-012 and connector 
I-046/B-072 according to the table below. + -
Standard Condition
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
Condition
Connection Condition I-012
I-012 (9) -
Always Continuity
I-046/B-072 (3)
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
I-012 (1) - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Always Continuity
I-046/B-072 (4)
32 I-046 B-072
I-012 (1) -
I-046/B-072 (3)
RT21320190
I-012 (9) -
I-046/B-072 (4)
I-012 (1) -
I-012 (9)
I-046/B-072 (3) -
I-046/B-072 (4)

and connector
.
OK
Replace spiral cable

DTC B0010-11 Front Airbag Passenger Loop Circuit Short to Ground
DTC B0010-12 Front Airbag Passenger Loop Circuit Short to Battery
Front Airbag Passenger Loop Circuit Resistance Below

DTC B0010-1A
Threshold
Front Airbag Passenger Loop Circuit Resistance Above

DTC B0010-1B
Threshold
32
Front Airbag Passenger Loop Circuit Voltage Out of
DTC B0010-1C
Range


IGNITION SWITCH
ON OR START
INSTRUMENT
RF08 PANEL FUSE
AND RELAY BOX
10A
I-007
8
R
I-036 *2
32 4 B-055
R 1
SRS
CONTROL
MODULE
I-046
B-072
5 6 16
R
*2
B-055
7 8
I-036
I-045
R
1 2
- + FRONT
PASSENGER
AIRBAG
I-028
1 2 3 4 5 6 7 8 9 10 11 12
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-046 B-072
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Gr B 13 14 15 16 17 18 19 20 21 22 23 24
27 25 26
87
85 86 86 86
1 2 87 30 87 30
30 85 85
8 7 6 5 4 3 2 1 I-036 I-028
16 15 14 13 12 11 10 9 W Gr
I-007
B
ET21320050


Condition Condition
Front Airbag
B0010-11 Passenger Loop
Circuit Short to Ground
Front Airbag
Circuit Short to Battery
Front Airbag  Front passenger
Passenger Loop airbag
B0010-1A
Circuit Resistance  Wire harness and 32
Below Threshold connector
Front Airbag  SRS control
Passenger Loop module assembly
B0010-1B
Circuit Resistance
Above Threshold
Front Airbag
Passenger Loop
B0010-1C
Circuit Voltage Out of
Range
HINT:
Diagnosis Procedure
1 Check front passenger airbag
b. Disconnect front passenger airbag connector, and connect the new front passenger airbag to connector 
I-028.
WARNING
 Never measure the front passenger airbag directly, otherwise, it may cause serious personal injury due
to accidental deployment of the airbag.
NO Replace front passenger airbag
YES


b. Disconnect the front passenger airbag connector I-028 and SRS control module assembly connector 
I-046/B-072.
c. Disconnect the body wire harness connector B-055 and instrument panel wire harness connector I-036
(*2).
e. Check for broken, bent, protruded or corroded terminals.
f. Check if related connector terminal contact pins are in good condition.
32
NG Repair or replace instrument panel/body
OK
3 Check front passenger airbag control circuit

I-046/B-072. V
+ -
c. Disconnect the front passenger airbag connector I-028.
d. Connect the negative battery cable and wait for a few
seconds.
1 2
f. Using a digital multimeter, measure the voltage between
front passenger airbag connector I-028 and body ground
I-028
to check for a short circuit to power supply according to
the table below.
Standard Voltage
Condition
RT21320200
I-028 (1) - Body
ground
I-028 (2) - Body
ground


front passenger airbag connector I-028 and body ground
to check for a short circuit to ground according to the + -
table below.
Standard Condition
1 2
Condition
I-028
I-028 (2) - Body
ground
32
RT21320210

the terminals of front passenger airbag connector I-028
according to the table below. + -
Standard Condition
Condition
I-028 (1) -
Always No continuity I-028
I-028 (2)
1 2
I-028
RT21320220
NG

Check airbag wire harness and connector (SRS control module assembly - body wire
4 harness connector)

b. Disconnect body wire harness connector B-055 and SRS
control module assembly connector B-072 (*2).
+ -
the terminals of connector B-055 and connector B-072
1 2 3 4 5 6 7 8
according to the table below. 9 10 11 12 13 14 15 16
Standard Condition
B-055
32 Connection
Condition
Condition
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
B-055 (7) - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Always Continuity
B-072 (5) B-072
B-055 (8) -
Always Continuity
B-072 (6)
RT21320221
NG Replace body wire harness and connector
OK

Check airbag wire harness and connector (SRS control module assembly - front passenger
5 airbag)

I-046/B-072 and front passenger airbag connector I-028.
+ -
the terminals of connector I-046/B-072 and connector 
I-028 according to the table below.
Standard Condition 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Connection
Condition
Condition
I-046 B-072 32
I-046/B-072 (5) -
Always Continuity
I-028 (1) 1 2
I-046/B-072 (6) -
Always Continuity
I-028 (2)
I-028
I-046/B-072 (6) - RT21320230
Always Continuity
I-028 (1)
I-046/B-072 (5) -
Always Continuity
I-028 (2)
I-046/B-072 (5) -
Always Continuity
I-046/B-072 (6)
I-028 (1) -
Always Continuity
I-028 (2)


the terminals of connector I-046/B-072 and connector 
I-028 according to the table below. + -
Standard Condition
Condition 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
I-046/B-072 (5) - I-046 B-072

Always Continuity
I-028 (1)
I-046/B-072 (6) -
I-028 (2)
32
I-046/B-072 (6) -
I-028 (1)
I-028
RT21320230
I-046/B-072 (5) -
I-028 (2)
I-046/B-072 (5) -
I-046/B-072 (6)
I-028 (1) -
I-028 (2)

and connector

Belt Pretensioner Front Driver Loop Circuit Short to

DTC B0070-11
Ground
Belt Pretensioner Front Driver Loop Circuit Short to

DTC B0070-12
Battery
Belt Pretensioner Front Driver Loop Circuit Resistance

DTC B0070-1A
Below Threshold
Belt Pretensioner Front Driver Loop Circuit Resistance 32

DTC B0070-1B
Above Threshold
Belt Pretensioner Front Driver Loop Circuit Voltage Out

DTC B0070-1C
of Range


IGNITION SWITCH
ON OR START
INSTRUMENT
RF08 PANEL FUSE
AND RELAY BOX
10A
I-007
8
R
I-036 *2
32 4 B-055
R 1
SRS
CONTROL
MODULE
I-046
B-072
9 10 16
LW
LB
*1
I-035
1 2
B-059
I-045
LW
LB
1 2
- +
DRIVER SEAT BELT

PRE-TENSIONER
B-034
1 2 3 4 5 6 7 8 9 10 11 12
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-046 B-072
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Gr B 13 14 15 16 17 18 19 20 21 22 23 24
27 25 26
87
85 86 86 86
1 2 87 30 87 30
9 8 7 6 5 4 3 2 1 I-035 30 85 85
- + B-034
18 17 16 15 14 13 12 11 10 W B
I-007
8 7 6 5 4 3 2 1 I-036 B
16 15 14 13 12 11 10 9 W
ET21320060


Condition Condition
Belt Pretensioner Front
B0070-11 Driver Loop Circuit
Short to Ground
B0070-12 Driver Loop Circuit
Short to Battery
 Driver seat belt
Belt Pretensioner Front pretensioner
Driver Loop Circuit
B0070-1A  Wire harness and
Resistance Below Ignition switch ON ON
connector 32
Threshold
 SRS control
Belt Pretensioner Front module assembly
Driver Loop Circuit
B0070-1B
Resistance Above
Threshold
B0070-1C Driver Loop Circuit
Voltage Out of Range
HINT:
Diagnosis Procedure
1 Check driver seat belt pretensioner
b. Disconnect driver seat belt pretensioner connector, and connect the new driver seat belt pretensioner
connector to connector B-034.
WARNING
 Never measure the driver seat belt pretensioner directly, otherwise, it may cause serious personal injury
due to accidental deployment of the airbag.
NG Replace driver seat belt pretensioner
OK


b. Disconnect the driver seat belt pretensioner connector B-034 and SRS control module assembly
connector I-046/B-072.
(*1).
32
OK
3 Check driver seat belt pretensioner control circuit

I-046/B-072. V
c. Disconnect the driver seat belt pretensioner connector  + -
B-034.
d. Connect the negative battery cable and wait for a few 1 2
seconds. - +

f. Using a digital multimeter, measure the voltage between B-034
driver seat belt pretensioner connector B-034 and body
ground to check for a short circuit to power supply
Standard Voltage
B-034 (1) - Body
ground
B-034 (2) - Body
ground


driver seat belt pretensioner connector B-034 and body
ground to check for a short circuit to ground according to + -
the table below.

- +
Condition
B-034
B-034 (2) - Body
ground
32
RT21320250

the terminals of driver seat belt pretensioner connector 
B-034 according to the table below. + -
1 2
Standard Condition - +
Condition
RT21320260
B-034 (1) -
B-034 (2)
NG

Check driver seat belt pretensioner wire harness and connector (SRS control module
4 assembly - instrument panel wire harness connector)

I-035 and SRS control module assembly connector I-046
(*1). + -

the terminals of connector I-035 and connector I-046 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
Standard Condition I-035
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-035 (1) -
Always Continuity
I-046 (9) I-046
I-035 (2) -
Always Continuity
I-046 (10) RT21320270

and connector
OK

Check wire harness and connector (SRS control module assembly - driver seat belt
5 pretensioner)

b. Disconnect driver seat belt pretensioner connector B-034
and SRS control module assembly connector 
I-046/B-072. + -
c. Using a digital multimeter, check for continuity between 1 2
the terminals of connector B-034 and connector  - +
I-046/B-072 according to the table below.

Standard Condition
B-034 32
Condition 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
B-034 (1) - I-046/

Always Continuity B-072 I-046
B-072 (9)
B-034 (2) - I-046/
Always Continuity
B-072 (10) RT21320271
B-034 (2) - I-046/

Always Continuity
B-072 (9)
B-034 (1) - I-046/
Always Continuity
B-072 (10)
B-034 (1) -
Always Continuity
B-034 (2)
I-046/B-072 (9) -
Always Continuity
I-046/B-072 (10)

d. Release the activation prevention mechanism built into

the SRS control module assembly connector 
I-046/B-072.
the terminals of connector B-034 and connector  + -
I-046/B-072 according to the table below. 1 2
Standard Condition - +
Condition
B-034 (1) - I-046/

B-072 (9) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B-034 (2) - I-046/

32
B-072 I-046
Always Continuity
B-072 (10)
B-034 (2) - I-046/
B-072 (9) RT21320271
B-034 (1) - I-046/

B-072 (10)
B-034 (1) -
B-034 (2)
I-046/B-072 (9) -
I-046/B-072 (10)

Belt Pretensioner Front Passenger Loop Circuit Short to

DTC B0072-11
Ground
Belt Pretensioner Front Passenger Loop Circuit Short to

DTC B0072-12
Battery
Belt Pretensioner Front Passenger Loop Circuit

DTC B0072-1A
Resistance Below Threshold
Belt Pretensioner Front Passenger Loop Circuit

DTC B0072-1B
Resistance Above Threshold
32
Belt Pretensioner Front Passenger Loop Circuit Voltage

DTC B0072-1C
Out of Range


IGNITION SWITCH
ON OR START
INSTRUMENT
RF08 PANEL FUSE
AND RELAY BOX
10A
I-007
8
R
I-036 *2
32 4 B-055
R 1
SRS
CONTROL
MODULE
I-046
B-072
7 8 16
VW
*1
I-006
1 2
B-003
I-045
VW
2 1
+ - FRONT
PASSENGER
SEAT BELT
PRE-TENSIONER
B-002
1 2 3 4 5 6 7 8 9 10 11 12
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-046 B-072
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Gr B 13 14 15 16 17 18 19 20 21 22 23 24
27 25 26
87
10 9 8 7 6 5 4 3 2 1 I-006 85 86 86 86
22 21 20 19 18 17 16 15 14 13 12 11 W 1 2 87 30 87 30
30 85 85
B-002
- +
B
8 7 6 5 4 3 2 1 I-036 I-007
16 15 14 13 12 11 10 9 W B
ET21320070


Condition Condition
 Front passenger
Belt Pretensioner Front seat belt
Passenger Loop pretensioner
B0072-1A
Circuit Resistance
Below Threshold
Ignition switch ON ON  Wire harness and 32
connector
Belt Pretensioner Front  SRS control
Passenger Loop module assembly
B0072-1B
Circuit Resistance
Above Threshold
Passenger Loop
B0072-1C
Range
HINT:
Diagnosis Procedure
1 Check front passenger seat belt pretensioner
b. Disconnect front passenger seat belt pretensioner connector, and connect the new front passenger seat
belt pretensioner connector to connector B-002.
WARNING
 Never measure the front passenger seat belt pretensioner directly, otherwise, it may cause serious
personal injury due to accidental deployment of the airbag.
NG Replace front passenger seat belt

pretensioner

OK

b. Disconnect the front passenger seat belt pretensioner connector B-002 and SRS control module assembly
(*1).
32 e. Check for broken, bent, protruded or corroded terminals.

OK
3 Check front passenger seat belt pretensioner control circuit

I-046/B-072. V
+ -
c. Disconnect the front passenger seat belt pretensioner
connector B-002.
d. Connect the negative battery cable and wait for a few 1 2
seconds. - +

f. Using a digital multimeter, measure the voltage between B-002
front passenger seat belt pretensioner connector B-002
and body ground to check for a short circuit to power
supply according to the table below.
Standard Voltage
B-002 (1) - Body
ground
B-002 (2) - Body
ground


front passenger seat belt pretensioner connector B-002
and body ground to check for a short circuit to ground + -

- +
Condition
B-002 (1) - Body B-002
ground
B-002 (2) - Body
ground
Always No continuity 32
RT21320290
i. Release the activation prevention mechanism built into

the SRS control module assembly connector I-046/B-
072.
the terminals of front passenger seat belt pretensioner
connector B-002 according to the table below.
Standard Condition
Condition
B-002 (1) - B-002
Always No continuity + -
(2) 1 2
- +

B-002
RT21320300
NG

Check front passenger seat belt pretensioner wire harness and connector (SRS control
4 module assembly - instrument panel wire harness connector)

(*1). + -
c. Using a digital multimeter, check for continuity between the

terminals of connector I-006 and connector I-046
10 9 8 7 6 5 4 3 2 1
according to the table below. 22 21 20 19 18 17 16 15 14 13 12 11
Standard Condition
I-006
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-006 (1) - I-046
Always Continuity
(7) I-046
I-006 (2) - I-046

Always Continuity
(8) RT21320310

and connector
OK
Check wire harness and connector (SRS control module assembly - front passenger seat
5 belt pretensioner)

b. Disconnect front passenger seat belt pretensioner
connector B-002 and SRS control module assembly
connector I-046/B-072. + -
c. Using a digital multimeter, check for continuity between the 1 2
terminals of connector B-002 and connector I-046/B-072 - +

Standard Condition
B-002
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B-002 (1) - I-046/

B-072 (8)
B-002 (2) - I-046/
Always Continuity
B-072 (7) RT21320311
B-002 (2) - I-046/

Always Continuity
B-072 (8)
B-002 (1) - I-046/
Always Continuity
B-072 (7)
B-002 (1) - B-002
Always Continuity
(2)

Condition
I-046/B-072 (7) -
Always Continuity
I-046/B-072 (8)

e. Using a digital multimeter, check for continuity between the
terminals of connector B-002 and connector I-046/B-072
1 2
Condition - +
32
B-002 (1) - I-046/
B-072 (8)
B-002 (2) - I-046/
B-072 (7) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B-002 (2) - I-046/ B-072 I-046

B-072 (8)
B-002 (1) - I-046/
B-072 (7) RT21320311
B-002 (1) - B-002

(2)
I-046/B-072 (7) -
I-046/B-072 (8)

Buckle Switch Front Passenger (BLFP) Circuit Short to

DTC B1231-12
Battery
Buckle Switch Front Passenger (BLFP) Circuit Voltage

DTC B1231-1C
Out of Range
32


IGNITION SWITCH
ON OR START
INSTRUMENT
RF08 PANEL FUSE
AND RELAY BOX
10A
I-007
8
R
I-036 *2
4 B-055
32
R
1
SRS
CONTROL
MODULE
I-046
B-072
20 16
BR
*1 B
I-006
15
B-003
I-045
BR
1
FRONT
PASSENGER
SEAT BELT
SWITCH
B-050
2
B
B
B-003
11
I-006
B
I-045
1 2 3 4 5 6 7 8 9 10 11 12
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-046 B-072
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Gr B 13 14 15 16 17 18 19 20 21 22 23 24
27 25 26
87
10 9 8 7 6 5 4 3 2 1 I-006
1 2 85 86 86 86
22 21 20 19 18 17 16 15 14 13 12 11 W 87 30 87 30
30 85 85
B-050
B
8 7 6 5 4 3 2 1 I-036 I-007
16 15 14 13 12 11 10 9 W B
ET21320080


Condition Condition
Buckle Switch Front
 Front passenger
B1231-12 Passenger (BLFP)
seat belt switch
 Wire harness and
Buckle Switch Front Ignition switch ON ON
connector
Passenger (BLFP)
B1231-1C  SRS control
module assembly
Range
32 HINT:
Diagnosis Procedure
1 Check front passenger seat belt switch
b. Disconnect front passenger seat belt switch connector, and connect the new front passenger seat belt
switch connector to connector B-050.
NO Replace front passenger seat belt switch
YES

b. Disconnect the front passenger seat belt switch connector B-050 and SRS control module assembly
(*1).


OK
3 Check front passenger seat belt switch control circuit

b. Disconnect the front passenger seat belt switch
connector B-050 and SRS control module assembly V
c. Connect the negative battery cable and wait for a few

seconds.
d. Turn ignition switch ON. 1 2 32
e. Using a digital multimeter, measure the voltage between
front passenger seat belt switch connector B-050 and B-050
body ground to check for a short circuit to power supply
Standard Voltage
Condition
RT21320320
B-050 (1) - Body
ground
f. Turn ignition switch to LOCK, disconnect the negative

front passenger seat belt switch connector B-050 and
body ground to check for a short circuit to ground + -

Standard Condition
1 2
Condition
B-050 (1) - Body

ground
RT21320330
NG

Check front passenger seat belt switch wire harness and connector (SRS control module
4 assembly - instrument panel wire harness connector)

I-006 and SRS control module assembly connector I-046/
(*1). + -

the terminals of connector I-006 and connector I-046
10 9 8 7 6 5 4 3 2 1
Standard Condition
I-006
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-006 (15) - I-046
Always Continuity
(20) I-046
NG Replace instrument panel wire harness RT21320340

and connector
OK
5 belt switch)

b. Disconnect front passenger seat belt switch connector B-
050 and SRS control module assembly connector I-046/
B-072. + -

the terminals of connector B-050 and connector I-046/B- 1 2
072 according to the table below.

B-050
Standard Condition
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B-050 (1) - I-046/

B-072 (20)
NG Replace body wire harness and connector RT21320341

PDM (Passenger Detection Mat) Switch Circuit Short to

DTC B1232-12
Battery
PDM (Passenger Detection Mat) Switch Circuit Voltage

DTC B1232-1C
Out of Range
32


IGNITION SWITCH
ON OR START
INSTRUMENT
RF08 PANEL FUSE
AND RELAY BOX
10A
I-007
8
R
I-036 *2
4 B-055
32
R
1
SRS
CONTROL
MODULE
I-046
B-072
25 16
BL
*1 B
I-006
16
B-003
I-045
BL
1
SEAT
BELT
REMINDER
B-049
2
B
B-003
11
I-006
B
I-045
1 2 3 4 5 6 7 8 9 10 11 12
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-046 B-072
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Gr B 13 14 15 16 17 18 19 20 21 22 23 24
27 25 26
87
10 9 8 7 6 5 4 3 2 1 I-006 1 2
85 86 86 86
22 21 20 19 18 17 16 15 14 13 12 11 W 87 30 87 30
30 85 85
B-049
W
8 7 6 5 4 3 2 1 I-036 I-007
16 15 14 13 12 11 10 9 W B
ET21320090


Condition Condition
PDM (Passenger  Front passenger
B1232-12 Detection Mat) Switch seat belt reminder
Circuit Short to Battery switch
PDM (Passenger Ignition switch ON ON  Wire harness and
Detection Mat) Switch connector
B1232-1C
Circuit Voltage Out of  SRS control
Range module assembly
HINT:
32
Diagnosis Procedure
1 Check front passenger seat belt reminder switch
b. Disconnect front passenger seat belt reminder switch connector, and connect the new front passenger
seat belt reminder switch connector to connector B-049.
NO Replace front passenger seat belt

reminder switch
YES

b. Disconnect the front passenger seat belt reminder switch connector B-049 and SRS control module
assembly connector I-046/B-072.
(*1).


OK
3 Check front passenger seat belt reminder switch control circuit

b. Disconnect the front passenger seat belt reminder switch
connector B-049 and SRS control module assembly V

seconds.
32 d. Turn ignition switch ON. 1 2
e. Using a digital multimeter, measure the voltage between

B-049
front passenger seat belt reminder switch connector B-049
and body ground to check for a short circuit to power
supply according to the table below.
Standard Voltage
Condition
RT21320350
B-049 (1) - Body
ground
f. Turn ignition switch to LOCK, disconnect the negative

front passenger seat belt reminder switch connector B-049
and body ground to check for a short circuit to ground + -

Standard Condition
1 2
Condition
B-049 (1) - Body

ground
RT21320360
NG

Check front passenger seat belt reminder switch wire harness and connector (SRS control
4 module assembly - instrument panel wire harness connector)

(*1). + -

the terminals of connector I-006 and connector I-046
10 9 8 7 6 5 4 3 2 1
Standard Condition
I-006
32
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-006 (16) - I-046
Always Continuity
(25) I-046
NG Replace instrument panel wire harness RT21320370

and connector
OK
5 belt reminder switch)

b. Disconnect front passenger seat belt reminder switch
connector B-049 and SRS control module assembly

the terminals of connector B-049 and connector I-046/B- 1 2

B-049
Standard Condition
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B-049 (1) - I-046/

B-072 (25)
NG Replace body wire harness and connector RT21320371

DTC B1210-00 Front Deployment
DTC B1211-00 BT Deployment
DTC B125A-00 Crash Counter Reached Max
DTC B1240-96 ICM Airbag Lamp Failed
DTC B1251-49 Electronic Control Unit (ECU), Internal Electronic Failure

32 Self-diagnosis Detection Logic

Condition Condition
B1210-00 Front Deployment
B1211-00 BT Deployment
Crash Counter
B125A-00
Reached Max
 SRS control
ICM Airbag Lamp module assembly
B1240-96
Failed
Electronic Control Unit
B1251-49 (ECU), Internal
Electronic Failure
HINT:
Diagnosis Procedure
1 Check SRS control module assembly

b. Disconnect the negative battery cable and wait for at least 90 seconds.
c. Connect the negative battery cable.
d. Turn ignition switch ON.
e. Use X-431 3G diagnostic tester (the latest software) to record and clear the DTCs stored in the
supplemental restraint system.
f. Turn ignition switch to LOCK and wait for a few seconds.
g. Turn ignition switch ON, and then select "Read Code".
NG Replace SRS control module assembly
OK
Malfunction has been solved and system operates normally

DTC B1250-16 Battery Voltage Circuit Voltage Below Threshold
DTC B1250-17 Battery Voltage Circuit Voltage Above Threshold
32


IGNITION SWITCH
BATTERY
ON OR START
INSTRUMENT
RF23 RF06 RF08 PANEL FUSE
AND RELAY BOX
10A 10A 10A
32 23 P 6 8
I-007
R
11 13
AIRBAG
INSTRUMENT
R
GND CAN-H2 CAN-L2 I-015
3 5 30 29
B
TO CAN
SYSTEM
OB
OB
O
TO CAN I-036 *2
I-003
SYSTEM 4 OB 9 10 B-055
O
R
1 2 17
CAN-L1 CAN-H1 SRS
CONTROL
MODULE
I-046
B-072
16
B
I-045
1 2 3 4 5 6 7 8 9 10 11 12
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-015
13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 L
I-007
27 25 26
87
B
85 86 86 86
87 30 87 30 8 7 6 5 4 3 2 1 I-036
30 85 85
16 15 14 13 12 11 10 9 W
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-046 B-072
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Gr B
ET21320100


Condition Condition
Battery Voltage Circuit  Battery
B1250-16 Voltage Below  Charging system
Threshold
Ignition switch ON ON  Wire harness and
Battery Voltage Circuit connector
B1250-17 Voltage Above  SRS control
Threshold module assembly
HINT:
When performing electrical diagnosis and test, always refer to the relevant circuit diagram for the special 32
Diagnosis Procedure
1 Check battery
a. Using a digital multimeter, check the battery voltage.

NG Check charging system (See page 16-6)
OK
Check wire harness and connector (SRS control module assembly - instrument panel fuse
2 and relay box)

b. Disconnect the SRS control module assembly connector I-046/B-072 and instrument panel fuse and relay
box wire harness connector I-007.
(*2).

OK

3 Check wire harness and connector (SRS control module assembly - battery)

I-046/B-072. V
+ -
seconds.
e. Using a digital multimeter, measure the power supply 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
voltage of SRS control module assembly connector I-
046/B-072 to check if the system power supply is normal
B-072 I-046
Standard Voltage
Condition
I-046/B-072 (1) -
Ignition switch ON 11 V to 14 V RT21320380
Body ground

OK
4 Check wire harness and connector (SRS control module assembly - body ground)

I-046/B-072.
+ -
c. Using a digital multimeter, measure the ground circuit of
SRS control module assembly connector I-046/B-072 to
check if the system ground is normal according to the
table below. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Standard Condition 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B-072 I-046
Condition
I-046/B-072 (16) -
Always Continuity
Body ground
OK Repair or replace instrument panel wire RT21320390

NG

5 Reconfirm DTCs
a. Reconnect the SRS control module assembly connector I-046/B-072 securely.

b. Reconnect the instrument panel fuse and relay box wire harness connector I-007 securely.
g. Turn ignition switch ON.
h. Use X-431 3G diagnostic tester to read the DTCs stored in the supplemental restraint system again.
i. Check if the same DTCs are still output. 32
YES
Replace SRS control module assembly

DTC U1300-55 Software Configuration Error


Condition Condition
 Peripherals
Software Configuration configuration error
U1300-55 Ignition switch ON ON
Error  SRS control
module assembly
HINT:
32 When performing electrical diagnosis and test, always refer to the relevant circuit diagram for the special
Diagnosis Procedure
1 Check DTCs
a. Use X-431 3G diagnostic tester (the latest software) to record and clear the DTCs stored in the
c. Check if the same DTC is output.
NO Malfunction indicated by DTC is

intermittent
YES
2 Check SRS control module assembly configuration
a. Turn ignition switch ON.

b. Use X-431 3G diagnostic tester (the latest software) to check if SRS control module assembly setting
matches actual vehicle configuration.
NO Reset SRS control module assembly
YES
3 Reconfirm DTCs

b. Disconnect the negative battery cable and wait for at least 90 seconds.

g. Turn ignition switch ON, and then select "Read Code".
NG Replace SRS control module assembly
OK
Malfunction has been solved and system operates normally
32

ON-VEHICLE SERVICE
Driver Airbag
1. Check the driver airbag (vehicle is not involved in a collision and airbag is not deployed).
a. Perform a diagnosis system inspection.
b. Perform visual inspection with the driver airbag on
vehicle:
 Check for cuts, cracks or discoloration on the outer
surface of driver airbag and in the grooved portion.
 If any defect above is found, replace the driver
32 airbag with a new one.
RT21320010
2. Check the driver airbag (vehicle is involved in a collision but airbag is not deployed).
b. Perform visual inspection with the driver airbag
removed from vehicle:
 Check for cuts, cracks or discoloration on the outer
surface of driver airbag and in the grooved portion.
 Check wire harnesses for cuts and cracks, and if
connectors are chipped.
 Check steering wheel for deformation.
RT21320020
WARNING
 Be sure to follow the correct procedures to remove and install driver airbag.
HINT:
 If the driver airbag contact plate is deformed, never
repair it. Always replace with a new one.
 There should not be any contact between driver
airbag and steering wheel, and keep an even
clearance all around when installing the new driver
airbag onto the steering wheel.
RT21320030

Removal
CAUTION
 Handle the airbag and airbag control module assembly carefully, and never tap or strike them fiercely.
 Removal, inspection and installation of airbag system must meet the relevant requirements and
specifications, and never perform operation casually.
 The removed airbag should be kept properly with the face up. Store the airbag in a place with enough
spare space to prevent accidental airbag deployment.

2. Disconnect the negative battery cable. 32
WARNING
 Wait at least 90 seconds after disconnecting negative battery cable to disable supplemental restraint
system.
3. Remove the driver airbag.

a. Position the front wheels straight ahead.
b. Using a flat tip screwdriver wrapped with protective
tape, push the driver airbag snap springs (arrow) from
the service hole.
RT21320040
c. Disengage the driver airbag from the steering wheel, and support the driver airbag smoothly by hand.
d. Disconnect the driver airbag wire harness connector
(1) and horn wire harness connector (2).
RT21320050
CAUTION
 DO NOT pull the airbag wire harness when removing driver airbag.

WARNING
 DO NOT damage the airbag wire harness when handling airbag wire harness connector.
e. Remove the driver airbag.
Installation
CAUTION
32  Be sure to install the snap springs in place during installation.

 Check that horn operates normally after installation.
 Check the SRS warning light after installation, and make sure that supplemental restraint system
operates normally.
Disposal
Always dispose of the airbag together with the vehicle which is equipped with supplemental restraint system.
Otherwise, the airbag will be in chemical and physical dangerous state. Failure to handle it properly will cause
personal injury. Do not dispose of airbag by oneself, and always contact the professional service department
to perform the disposal.

Spiral Cable
Removal
WARNING
system.
3. Position the front wheels straight ahead.

32
6. Remove the spiral cable.
a. Disconnect the spiral cable wire harness connector
(arrow).
RT21320060
b. Detach the fixing claws (arrow) between spiral cable ×1000

rpm
and steering column.
MIST
OF
PUL
IN F
LOT
L
H
I INT
ON
OF A/C
F
RE
AR
RT21320080
c. Remove the spiral cable.
Inspection
1. Check the spiral cable.
a. Check that there are no scratches or cracks on the connectors, and/or no cracks, dents or chipping on
the cable.

b. If there are scratches, cracks, dents or cuts on the

connectors or the spiral cable, replace the spiral cable
with a new one.
RT21320090
Installation
32
HINT:
Always install the spiral cable correctly according to the
matchmarks on spiral cable and steering column (fully turn
the spiral cable clockwise slowly, then turn it
counterclockwise until yellow ball appears in the transparent
neutral window and align with the arrow marks), otherwise,
the spiral cable may be damaged.
RT21320100
CAUTION
 Always install the spiral cable correctly according to the specified operating instructions.
 DO NOT rotate the spiral cable over specified turns to prevent it from breaking.
 Be sure to install the fixing claws in place when installing spiral cable.
 Check that horn operates normally after installation.
operates normally.

Front Passenger Airbag

1. Check the front passenger airbag (vehicle is involved in a collision but airbag is not deployed).
b. Perform visual inspection with the front passenger
airbag removed from vehicle.
 Check for cuts, cracks or discoloration on the front
passenger airbag.
 Check for cracks or other damage on the connector.
 Check instrument panel or instrument panel
crossmember assembly for deformation or break. If
any defect above is found, replace the front 32
passenger airbag with a new one.
RT21320110
WARNING
 Be sure to follow the correct procedures to remove and install front passenger airbag.
Removal
CAUTION
 Handle the airbag and airbag control module assembly carefully, and never tap or strike them fiercely.
 Removal, inspection and installation of airbag system must meet the relevant requirements and
specifications, and never perform operation casually.
 The removed airbag should be kept properly. Store the airbag in a place with enough spare space to
prevent accidental airbag deployment.

WARNING
system.

4. Remove the front passenger airbag.


passenger airbag and instrument panel crossmember
assembly.
RT21320120
b. Disconnect the front passenger airbag wire harness

connector (arrow).
32
RT21320130
WARNING
c. Remove the instrument panel body assembly (See page 45-17).

d. Using a flat tip screwdriver wrapped with protective
tape, slightly pry the fixing claws (arrow) around the
front passenger airbag mounting bracket to separate it
from the instrument panel body assembly.
RT21320140
e. Remove the front passenger airbag.

Installation
CAUTION
 Before installing the tightening bolts, always make sure that the airbag wire harness is not hold down or
stuck. Adjust if necessary and install it in place.
 Be sure to tighten fixing bolts to the specified torque during installation.
 When installing front passenger airbag, first slide the hook on one side into the locating hole in airbag
box, and then press in the hook on the other side firmly, making sure that hooks on both sides enter the
corresponding locating holes correctly.
 Always keep the vehicle power off during installation, and never install the front passenger airbag when
vehicle is powered on.
 During the installation of instrument panel body assembly, if installation cannot proceed due to contact of
32
front passenger airbag bracket and instrument panel crossmember assembly, hold the airbag slightly at
the opening of glove box assembly to install it in place.
operates normally.
Disposal
Always dispose of the airbag together with the vehicle which is equipped with supplemental restraint system.
Otherwise, the airbag will be in chemical and physical dangerous state. Failure to handle it properly will cause
personal injury. Do not dispose of airbag by oneself, and always contact the professional service department
to perform the disposal.

SRS Control Module Assembly

Removal
WARNING
system.
3. Remove the auxiliary fascia console body assembly (See page 45-9).
32
4. Remove the SRS control module assembly.
a. Disconnect the SRS control module assembly wire harness connector (1).
WARNING
b. Remove 2 fixing nuts (arrow) between SRS control

module assembly and body.
1
RT21320150
c. Remove the SRS control module assembly.
Installation
CAUTION
 Be sure to tighten fixing nuts to the specified torque during installation.

 Always install the SRS control module assembly correctly in the direction of arrow on the SRS control
module assembly.
 DO NOT put any object between SRS control module assembly and installation surface.
 Always keep the vehicle power off during installation.
operates normally.

SEAT BELT
Operation 33-5 Height Adjuster Assembly 33-13
Circuit Diagram 33-6 Rear Seat Belt Assembly 33-14
Removal 33-14
Inspection 33-15
Seat Belt Inspection 33-7
Installation 33-15
ON-VEHICLE SERVICE 33-8 Center Seat Belt Assembly 33-16
Front Seat Belt Assembly 33-8 Removal 33-16
Removal 33-8 Inspection 33-17 33
Installation 33-10 Rear Seat Belt Buckle Assembly 33-19
Front Seat Belt Buckle Assembly 33-11 Removal 33-19

33

33 - SEAT BELT
GENERAL INFORMATION
SEAT BELT
Description
Front Seat Belt Assembly
2 33
RT21330010
1 - Height Adjuster Assembly 2 - B-pillar Upper Protector Assembly

3 - Front Seat Belt Assembly 4 - B-pillar Lower Protector Assembly
5 - Seat Belt Lower Bolt Protective Cap 6 - Front Seat Belt Buckle Assembly

33 - SEAT BELT
Rear Seat Belt Assembly
4
2
33
3
6
RT21330020
1 - C-pillar Upper Protector Assembly 2 - Rear Seat Belt Assembly

3 - C-pillar Lower Protector Assembly 4 - Center Seat Belt Assembly
5 - Rear Seat Belt Buckle Assembly 6 - Rear Center Seat Belt Buckle Assembly
7 - Rear Right Seat Belt Buckle Assembly
The front seat belt assembly is a 3 point type belt with limiter and pretensioner, and front seat belt buckle
assembly is a device with alarm function. Front seat belt is equipped with seat belt reminder. The reminder will
not work until ignition switch is turned to ON. If driver or front passenger seat belt unfastened, the reminder
will continue flashing. When vehicle speed exceeds 25 km/h, the buzzer will sound to inform driver and front
passenger to fasten their seat belts. Seat belt reminder will go off immediately after seat belt is fastened.
The rear seat belt assembly is 3 point emergency locking type belt.

33 - SEAT BELT
Operation
In the event of a collision, the seat belt lock starts to work. Seat belt is locked securely and cannot be pulled
out from the retractor freely, so that the passenger will be restricted to seat to prevent head and chest from
hitting the steering wheel, instrument panel, windshield or front seat, which can reduce the risk of second
collision.
Specifications

Height Adjuster Fixing Bolt 23 ± 2
Front Seat Belt Assembly Fixing Bolt 50 ± 5
Front Seat Belt Retractor Fixing Screw 3 ± 0.5 33
Front Seat Belt Assembly Center Fixing Screw 1.5 ± 0.5
Rear Seat Belt Assembly Fixing Bolt 50 ± 5
Rear Seat Belt Assembly Fixing Screw 1.5 ± 0.5
Center Seat Belt Assembly Fixing Bolt 50 ± 5
Center Seat Belt Inner Trim Cover Fixing Screw 3 ± 0.5
Rear Seat Belt Buckle Assembly Fixing Bolt 50 ± 5
Rear Center Seat Belt Buckle Assembly Fixing Bolt 50 ± 5
Rear Right Seat Belt Buckle Assembly Fixing Bolt 50 ± 5
Front Seat Belt Buckle Fixing Nut 50 ± 5
Tool
General Tool
Digital Multimeter
RCH0000002

33 - SEAT BELT
Circuit Diagram
Seat Belt System

ON OR START
INSTRUMENT
RF23 RF06 PANEL
FUSE AND
10A 10A RELAY BOX A
33 23 6
I-007
R
P
11 13
INSTRUMENT
CLUSTER
I-015
19 3 5
BG
Br
I-035
17 B-059
BG
1 I-003
DRIVER SEAT
BELT SWITCH
B-039
2
B
B-042
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-015 1 2 B-039 9 8 7 6 5 4 3 2 1
I-035
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 L B 18 17 16 15 14 13 12 11 10 W
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
27 25 26 I-007
87 B
85 86 86 86
87 30 87 30
30 85 85
ET21330010

33 - SEAT BELT
DIAGNOSIS & TESTING

Seat Belt Inspection
1. When pulling seat belt downward slowly by hand, the seat belt should be pulled out smoothly from the
retractor and can return back after releasing. If it is not as specified, replace the seat belt.
The seat belt should be locked automatically as it is pulled out quickly. If not, replace the seat belt.
2. Check seat belt for cuts, wear and looseness. If damaged, replace the seat belt assembly.
3. Check seat belt for overstretch (for example after accident). If damaged, replace the seat belt assembly or
related components.
4. Tighten and release seat belt and seat belt buckle repeatedly to check engagement between them. If those
conditions (difficult operation, excessive sliding resistance and sticking, etc.) occur, replace the seat belt
assembly or seat belt buckle assembly.
WARNING
33
 The seat belt system should be checked regularly to reduce the possibility and serious level of injury
caused by accident.
 When checking impacted vehicle, be sure to check the seat belt system to reduce the possibility and
serious level of injury caused by accident.

33 - SEAT BELT
ON-VEHICLE SERVICE
Front Seat Belt Assembly
Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing front seat belt assembly.
 Appropriate force should be applied when removing front seat belt assembly, and avoid operating
roughly.
33
 DO NOT scratch the interior when removing front seat belt assembly.

3. Remove the front left seat belt assembly.
a. Using a screwdriver wrapped with protective tape, pry
the lower bolt protective cap (arrow) of front seat belt
assembly.
RT21490330
b. Remove the fixing bolt (arrow) from the lower part of

front seat belt assembly.
RT21490340
c. Remove the left B-pillar lower protector assembly (See page 49-20).
d. Remove the left B-pillar upper protector assembly (See page 49-21).

33 - SEAT BELT
e. Remove the fixing bolt (arrow) from the upper part of

f. Remove 2 fixing screws (1) from the center part of
1
RT21330030
g. Disconnect the connector (1) from the front seat belt.

h. Remove the fixing screw (2) from the front seat belt
retractor.
i. Remove the fixing bolt (arrow) from the front seat belt 2
1 33
retractor.
RT21330040
j. Remove the front left seat belt assembly.
Inspection
Check the front seat belt retractor.
CAUTION
 DO NOT disassemble the front seat belt retractor.
HINT:
When the inclination of front seat belt retractor is 15° or less,
check that the front seat belt can be pulled out from the front 45 o
seat belt retractor. When the inclination of front seat belt

retractor is over 45°, check that the front seat belt locks.
If result is not as specified, replace the front seat belt
assembly.
Unlock
Retractor
lock
RT21330050

33 - SEAT BELT
Installation
CAUTION
 Keep seat belt assembly clean, avoid attaching oil and check seat belt assembly for damage when
installing the front seat belt assembly.
 Make sure to tighten all fixing bolts and fixing screws according to the specified torque when installing
the front seat belt assembly.
33

33 - SEAT BELT
Front Seat Belt Buckle Assembly

1. Check the front seat belt buckle assembly.
a. Disconnect the front seat belt buckle connector
(arrow).
RT21330060
33
b. Using a digital multimeter, measure the resistance
between terminals 1 and 2 of front seat belt buckle
assembly connector.
Under normal conditions, the measured resistance is
∞ Ω (no continuity) when front seat belt assembly is
fastened; the measured resistance is less than 0 Ω
(continuity) when front seat belt assembly is
unfastened.
If result is not as specified, replace the front seat belt
buckle assembly.
2 1
RT21330070

33 - SEAT BELT
Removal
HINT:
 Use the same procedures for the front passenger seat belt buckle assembly and driver seat belt buckle
assembly.
 The procedures listed below are for the driver seat belt buckle assembly.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing front seat belt buckle
assembly.
 DO NOT scratch the interior when removing front seat belt buckle assembly.
 DO NOT damage the wire harness and connector when removing front seat belt buckle assembly.
33 1. Turn off all the electrical equipment and ignition switch.

3. Remove the front seat belt buckle assembly.
the clip (1) on the wire harness connector.
b. Disconnect the front seat belt buckle connector
(arrow).
RT21330080
c. Remove the fixing nut (arrow) from front seat belt

buckle assembly.
RT21330090
d. Remove the front seat belt buckle assembly.
Installation
CAUTION
 Make sure to tighten all fixing nuts according to the specified torque when installing the front seat belt
buckle assembly.
 Install the connector in place when installing the front seat belt buckle assembly.

33 - SEAT BELT
Height Adjuster Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the height adjuster assembly.
 DO NOT scratch the interior when removing the height adjuster assembly.

2. Disconnect the negative battery cable. 33
3. Remove the left B-pillar lower protector assembly (See page 49-20).
4. Remove the left B-pillar upper protector assembly (See page 49-21).
5. Remove the height adjuster assembly.
a. Remove the fixing bolt (arrow) from upper part of front
seat belt assembly.
RT21330031
b. Remove the fixing bolt (arrow) from the height

adjuster assembly.
c. Remove the height adjuster assembly in the direction
of arrow as shown in the illustration.
RT21330100
Installation
CAUTION
 Make sure to tighten all fixing bolts according to the specified torque when installing the height adjuster
assembly.

33 - SEAT BELT
Rear Seat Belt Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear seat belt assembly.
 Appropriate force should be applied when removing the rear seat belt assembly, and avoid operating
roughly.
 DO NOT scratch the interior when removing the rear seat belt assembly.
33
3. Remove the rear seat assembly (See page 46-25).
4. Remove the rear left seat belt assembly.
a. Remove the fixing bolt (arrow) from the lower part of
rear seat belt assembly.
RT21330110
b. Remove the left C-pillar lower protector assembly (See page 49-23).
c. Remove the left C-pillar upper protector assembly (See page 49-26).
d. Remove the fixing bolt (arrow) from the upper part of
rear seat belt assembly.
RT21330121

33 - SEAT BELT
e. Remove the fixing bolt (arrow) from the rear seat belt
retractor.
f. Remove the fixing screw (1) from the rear seat belt
retractor.
RT21330120
g. Remove the rear left seat belt assembly.
Inspection
Check the rear seat belt retractor.
33
CAUTION
 DO NOT disassemble the rear seat belt retractor.
HINT:
When inclination of rear seat belt retractor is 15° or less,
check that rear seat belt can be pulled out from rear seat belt 45 o
retractor. When the inclination of rear seat belt retractor is

over 45°, check that rear seat belt locks.
If result is not as specified, replace the rear seat belt
assembly.
Unlock
lock
Retractor
RT21330130
Installation
CAUTION
installing the rear seat belt assembly.
 Make sure to tighten all fixing bolts and fixing screws according to the specified torque when installing
rear seat belt assembly.

33 - SEAT BELT
Center Seat Belt Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing center seat belt assembly.
 Appropriate force should be applied when removing center seat belt assembly, and avoid operating
roughly.
 DO NOT scratch the interior when removing center seat belt assembly.

33 3. Remove the center seat belt outer trim cover.
the clip on the center seat belt outer trim cover, and
remove the center seat belt outer trim cover.
RT21490311
4. Remove the roof assembly (See page 49-30).

HINT:
It is unnecessary to completely remove the roof assembly, but it is necessary to lower the rear part of roof
assembly, so that the center seat belt assembly can be removed.
5. Remove the center seat belt inner trim cover.
a. Remove 2 fixing screws (arrow) from the center seat
belt inner trim cover.
RT21330150

33 - SEAT BELT
b. Using a screwdriver wrapped with protective tape, pry

the clip on the center seat belt inner trim cover.
c. Remove the center seat belt inner trim cover.
RT21330140
6. Remove the center seat belt assembly.

a. Remove 2 fixing bolts (arrow) from the center seat belt
assembly.
33
RT21330160
b. Remove the center seat belt assembly.
Inspection
Check the center seat belt retractor.
CAUTION
 DO NOT disassemble the center seat belt retractor.
HINT:
When the inclination of center seat belt retractor is 15° or
Retractor
less, check that the center seat belt can be pulled out from Unlock
center seat belt retractor. When the inclination of center seat
belt retractor is over 45°, check that center seat belt locks.
If result is not as specified, replace the center seat belt 45 o
assembly.
lock
RT21330170

33 - SEAT BELT
Installation
CAUTION
installing the center seat belt assembly.
 Make sure to tighten all fixing bolts according to the specified torque when installing the center seat belt
assembly.
33

33 - SEAT BELT
Rear Seat Belt Buckle Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear seat belt buckle
assembly.
 DO NOT scratch the interior when removing the rear seat belt buckle assembly.

4. Remove the rear left seat belt buckle assembly. 33
a. Remove the fixing bolt (arrow) from the rear left seat
belt buckle assembly.
b. Pull out and remove the rear left seat belt buckle
assembly from the rear left seat assembly.
RT21330190
5. Remove the rear center seat belt buckle assembly.

a. Remove the fixing bolt (arrow) from the rear center
seat belt buckle assembly.
b. Pull out and remove the rear center seat belt buckle
assembly from the rear left seat assembly.
RT21330180
6. Remove the rear right seat belt buckle assembly.

a. Remove the fixing bolt (arrow) from the rear right seat
belt buckle assembly.
b. Pull out and remove the rear right seat belt buckle
assembly from the rear right seat assembly.
RT21330200

33 - SEAT BELT
Installation
CAUTION
 Make sure to tighten all fixing bolts according to the specified torque when installing the rear seat belt
buckle assembly.
33

ENGINE IMMOBILIZER
GENERAL INFORMATION 34-3 Diagnostic Trouble Code (DTC) Chart 34-11
Description 34-3 B1300 34-12
Operation 34-3 B1301 34-13
Tools 34-4 B1302 34-15
Circuit Diagram 34-5 B1303 34-16
Immobilizer Control Module Terminal  B1304 34-19
List 34-6 B1305 34-22
B1306 34-23
U0100 34-24
U0073 34-24
Engine Immobilizer System Match 34-7
Diagnostic Help 34-10 ON-VEHICLE SERVICE 34-26
Intermittent DTC Troubleshooting 34-11 Immobilizer Control Module 34-26
Ground Inspection 34-11 Removal & Installation 34-26 34

34

34 - ENGINE IMMOBILIZER
GENERAL INFORMATION
ENGINE IMMOBILIZER
Description
3
34
4
ON S
CC T
A
AR
1
LOCK
RT21340010
1 - Ignition Key (Built-in Transponder) 2 - Ignition Switch (Built-in Immobilizer Coil)

3 - Engine Control Module (ECM) 4 - Immobilizer Control Module
The vehicle is equipped with engine immobilizer system. The anti-theft features of the vehicle have improved
due to the integration technology of ignition key identification and engine start-up. When the engine is started
with unprogrammed ignition key, the engine immobilizer sends the detected signal to the engine control
module and the engine control module outputs the prohibit starting command, thus effectively reduces the
possibility of being stolen.
Operation
When the ignition key is inserted into the ignition switch, the immobilizer coil can detect the data information of
the ignition key, and sends the data information to the immobilizer control module. The immobilizer control
module communicates with the engine control module (ECM) via CAN - Line, realizing codes verification and
mutual certification. The ignition switch supply power to the immobilizer control module continuously, allowing
the immobilizer to save the trigger memory that has been generated and the malfunctioning content.

Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
34
Digital Multimeter
RCH0000002

Circuit Diagram
Engine Immobilizer System
IGNITION SWITCH
ON OR START
INSTRUMENT
PANEL FUSE
RF06 AND RELAY
10A BOX
I-007
6 IMMOBILIZER
COIL
R
Br
34
B
4 2 3 4
IG-SW ANT A ANT B GND
IMMOBILIZER
CONTROL
MODULE
CAN-L CAN-H GND I-018
6 8 2
O
OB
B
OB
I-034
O
10 9 I-003
E-027
OB
17 1 14 6
DIAGNOSTIC
ECM-2
INTERFACE
E-033
I-050
1 2 3 4 5 6 7 8 9 10 11 12
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
13 14 15 16 17 18 19 20 21 22 23 24
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
27 25 26
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 87
85 86 86 86
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 87 30 87 30
30 85 85
I-007
B
E-033
B
1 3 5 7 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9
1 2 3 4
2 4 6 8 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-034 I-050 IMMOBILIZER COIL

I-018
B W B
ET21340010

Immobilizer Control Module Terminal List

1 - -
2 GND Ground
3 - -
4 IG-SW Ignition Switch Power Supply
5 - -
6 CAN-L CAN Low (Diagnosis)
7 - -
8 CAN-H CAN High (Diagnosis)
B1 ANT A Coil (ANT A)
34 B2 ANT B Coil (ANT B)

B3 GND Coil (GND)

DIAGNOSIS & TESTING

HINT:

Ignition key (transponder) 37-58
Immobilizer coil 34-20
Immobilizer system causes the engine Wire harness or connector -
cannot start or immobilizer system has
failed Immobilizer control module 34-26
Electronic fuel injection system -
ECM 06-256
34
Engine Immobilizer System Match

If the transponder, ECM or immobilizer control module is replaced, match the system again using diagnostic
tester. When matching the engine immobilizer system, please send the VIN of the vehicle to After-Sales
Service Department of Chery International to get the safety code.
The operation procedures are as follows:
1. Connect the X-431 3G diagnostic tester to the Data Link Connector (DLC).
2. Turn ignition switch to ON.
3. Turn the X-431 3G diagnostic tester on, then select
"T21". Menu
M12 System
S16
Help
A13
File
A13A
A21FL-C PgUp
B16
PgDn
S15
M16 Reset
T21
Back
RT21340020
4. Select "IMMO".
Menu
ENG System
SRS
Help
ABS
File
ISU
ICM PgUp
ITM
PgDn
A/T
IMMO Reset
BCM
Back
RT21340030

5. Select "After sale function".

SELECT FUNCTION
Read fault code System
Erase fault code

Help
Read data stream
File
write data
After sale function PgUp
PgDn
Reset
Back
RT21340040
6. Select the required match item.
After sale function
Match all the systems. System
Programming ECM
Help
Programming IMMO(learn SK from EMS)
File
34
Programming IMMO(learn SK from TCU)
Programming ECM PgUp
Programming IMMO
PgDn
key match
Erase keys. Reset
Write PIN
Back
After sale function
Programming TCU System
Reset TCU
Help
Programming ESCL
File
Erase ESCL
PgUp
PgDn
Reset
Back
RT21030050
7. Input the Security Code or PIN Code (from Chery), and

then click "OK". Input
Please enter a PIN with 8 digits. System
Help
File
12345678
1 2 3 4 5 6 7 8 9 0 - = bs
PgUp
Q W E R T Y U I O P [ ] \
A S D F G H J K L ; ‘ Enter PgDn
Z X C V B N M , . / lt rt
` Tab Caps Space Ins Del Reset
OK Cancel
Back
RT21340060
CAUTION
 The code in the illustration is only an example.

8. Input the VIN code, and then click "OK".
Input
Please Input the VIN. System

The length is 17 digits form 0 to 9, A~Z, a~z.
Help
File
12345678123456789
1 2 3 4 5 6 7 8 9 0 - = bs
PgUp
A S D F G H J K L ; ‘ Enter PgDn
` Tab Caps Space Ins Del Reset
OK Cancel
Back
RT21340070
9. Match all the systems. 34

If the transponder, immobilizer control module and ECM have been all replaced, select "Match all the
systems" and finish the procedures according the following steps.
a. Input the VIN code to the diagnostic tester;
b. Input the SC (Security Code) code to the diagnostic tester;
c. Match the immobilizer control module with diagnostic tester;
d. Match the ECM with diagnostic tester;
e. Add the key;
f. Clear the code.
10.Programming ECM.
If the ECM has been replaced, select "Programming ECM" and finish the procedures according the
following steps.
b. Input the SC code to the diagnostic tester;
c. Match the ECM with diagnostic tester;
d. Input the service station code;
e. Input program date.
11. Programming IMMO.
If the immobilizer control module has been replaced, select "Programming IMMO" and finish the
procedures according the following steps.
b. Input the SC code to the diagnostic tester;
c. Match the immobilizer control module with diagnostic tester;

CAUTION
 Add the old key (See page 37-9) after programming immobilizer control module.
 If both ECM and immobilizer control module are replaced at the same time, there are two cases, one, if
the immobilizer control module has no communication problem, replace the ECM first, and then perform
the ECM programming and match with immobilizer control module that need to be replaced, after that,
replace the immobilizer control module and programming the IMMO, and finally, immobilizer control
module matches the old key, there is no need to replace a new key. Two, if the immobilizer control
module has communication problem, replace the ECM, immobilizer control module and key with now
one and perform match all the systems.
12.Programming TCU.
If the TCU has been replaced, select "Programming TCU" and finish the procedures according the
following steps.
34 b. Input the SC code to the diagnostic tester;
c. Match the TCU with diagnostic tester;
13.Key match
a. Add new key.
 Input the SC code to the diagnostic tester;
 Perform add new key procedure.
b. Add old key.
 Input the SC code to the diagnostic tester;
 Perform add old key procedure.
c. Erase key
 Erase all key
- Input the SC code to the diagnostic tester;
- Perform erase all key procedure.
 Erase key X
- Input the SC code to the diagnostic tester;
- Perform erase key X (X = 1, 2, 3, 4, 5) procedure.
Diagnostic Help
1. Connect X-431 3G diagnostic tester (the latest version) to the Data Link Connector (DLC), and make it
communicate with the vehicle electronic module by the data network.
2. Confirm that malfunction is current, and carry out the diagnostic test and repair procedures.
4. Only use a digital multimeter to measure the voltage of the electrical system.
6. Visually check related wire harness.
7. Check and clean all the immobilizer control module ground related to the current DTC.
8. If multiple trouble codes were set, use the circuit diagrams and look for any common ground circuit or


If the malfunction is intermittent, perform the following:
 Monitor the X-431 3G diagnostic tester (the latest version) data that is related to this circuit.
 Wiggle related wire harness and connector and observe if the signal is interrupt in the related circuit.
 Look for data that has changed or the DTC to reset during the wiggle test.
 Inspect sensor and mounting areas for damage, foreign matter, etc. that will cause incorrect signals.
 A data recorder and/or oscilloscope can be helpful in diagnosing the intermittent malfunction.
Ground Inspection
Groundings are very important to the proper operation of the electrical equipment and circuits. Groundings are
often exposed to moisture, dirt and corrosive elements. Corrosion (rust) may form additional resistance. This 34
additional resistance will change the way in which a circuit works.
the electronically controlled circuit. Perform the following operations when checking the groundings:
2. Check all the contact surfaces for tarnish, dirt, rust, etc.
4. Reinstall the bolt or nut securely.
5. Check for the accessories which may interfere with the ground circuit.
6. If several wires are crimped into one ground terminal, check for proper crimps. Make sure that all the wire
harnesses are clean, securely fastened and good contacted without crimping any excessive insulation
coat.

B1300 Internal Control Module EEPROM Error
B1301 Immobilizer and ECM authentication failed
B1302 VIN Not Programmed
B1303 The antenna communication is disturbed
B1304 None transponder was detected
B1305 Immobilizer has none key was storage
B1306 Security code was not programmed
U0100 Lost communication With ECM authentication frame
U0073 Control Module communication Bus Off

DTC B1300 Internal Control Module EEPROM Error
DTC Detection
DTC Code DTC Definition Possible Causes
Conditions
Internal Control
B1300 Module EEPROM Ignition switch ON  Immobilizer Control Module
Error

CAUTION
 If the ECM or immobilizer control module is replaced, match the system with the X-431 3G diagnostic
tester (See page 34-7).
Diagnosis Procedure
1 Replace immobilizer control module
OK
System is operating normally

DTC B1301 Immobilizer and ECM authentication failed
DTC Detection
Conditions
Immobilizer and ECM
B1301 Ignition switch ON  Immobilizer control module
authentication failed
 ECM

34
CAUTION
Diagnosis Procedure
1 Check ground connection

b. Loosen and retighten the ground bolt or nut.
c. Check the installation position of the ground connection.
NG Repair or replace ground connection
OK
2 Check engine control module (ECM) connector

b. Disconnect the ECM connector E-033.
RT21380241
c. Check if connector is damaged.
NG Repair or replace connector if necessary
OK
34
3 Check immobilizer control module connector and immobilizer coil connector

b. Disconnect the immobilizer control module connector 
I-018 and immobilizer coil connector.
RT21340100
c. Check if connectors are damaged.
NG Repair or replace connectors if necessary
OK
4 Replace immobilizer control module
a. Replace the immobilizer control module and match it with X-431 3G diagnostic tester (See page 34-7).
b. Reconnect all the wire harness connectors that are disconnected.
c. Check if DTC still exists.
NG Replace ECM
OK

DTC B1302 VIN Not Programmed
DTC Detection
Conditions
B1302 VIN Not Programmed Ignition switch ON  Immobilizer control module

34
CAUTION
Diagnosis Procedure
1 Write VIN data
a. Using X-431 3G diagnostic tester, write the VIN data (See page 34-7).
NG Replace immobilizer control module
OK

DTC B1303 The antenna communication is disturbed
DTC Detection
Conditions
The antenna  Wire harness or connector

B1303 communication is Ignition switch ON  Immobilizer control module
disturbed  ECM

CAUTION
Diagnosis Procedure
1 Check ground connection

OK

RT21380241
c. Check if connector is damaged.
OK
34

RT21340100
OK
4 Check immobilizer control module and ECM communication circuit
a. Turn the ignition switch to LOCK.

b. Disconnect the immobilizer control module connector I-

018 and ECM connector E-033.
c. Check the wire harness between terminals of immobilizer
control module and ECM. 1 3 5 7
+ - 2 4 6 8
Check for open
I-018
Condition
I-018 (6) - E-033 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Always Continuity
(17) 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
I-018 (8) - E-033 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Always Continuity
(1)
NG Repair or replace harness if necessary E-033

RT21340110
34 OK

DTC B1304 None transponder was detected
DTC Detection
Conditions
 Transponder
None transponder was  Wire harness or connector
detected  Immobilizer coil
 Immobilizer control module

34
CAUTION
Diagnosis Procedure
1 Start the engine with another ignition key
a. Try to restart the engine with another ignition key.

b. Check if the engine can be started.
NG Go to next step 3
OK
2 Replace first ignition key or transponder
a. Replace the first ignition key or transponder in it, and match it (See page 34-7).
OK


RT21340100

34
OK
4 Check immobilizer coil
a. Measure the immobilizer coil resistance.
Condition
1 2 3 4
2-3 Always 15 - 20 Ω
RT21340120

b. Check for the continuity of immobilizer coil connector.
Condition
1 2 3 4
2-4 Always No continuity
3-4 Always No continuity
NG Replace immobilizer coil
RT21340120
OK 34
Replace immobilizer control module

DTC B1305 Immobilizer has none key was storage
DTC Detection
Conditions
Immobilizer has none  Wire harness or connector
key was storage  Immobilizer control module

34  Turn ignition switch to LOCK and wait for a few seconds.
CAUTION
Diagnosis Procedure
1 Match ignition key
a. Using the X-431 3G diagnostic tester, match the ignition key (See page 34-7).
NG Replace immobilizer control module
OK

DTC B1306 Security code was not programmed
DTC Detection
Conditions
Security code was not  Wire harness or connector
programmed  Immobilizer control module

34
CAUTION
Diagnosis Procedure
1 Write security code
a. Using the X-431 3G diagnostic tester, write the security code (See page 34-7).
NG Replace the immobilizer control module
OK

DTC U0100 Lost communication With ECM authentication frame
DTC U0073 Control Module communication Bus Off
DTC Detection
Conditions
Lost communication  Wire harness or connector
U0100 With ECM Ignition switch ON
authentication frame  ECM
Control Module
U0073 communication Bus Ignition switch ON  CAN Line
Off

34 Confirm that battery voltage is between 11 and 14 V before performing the following procedures.
CAUTION
Diagnosis Procedure
1 Check the ground connection

OK

RT21380241
c. Check if the connector is damaged.
OK
34

RT21340100
c. Check if the connectors are damaged.
OK
4 Replace ECM
NG Repair or replace CAN BUS line
OK

ON-VEHICLE SERVICE
Immobilizer Control Module
3. Remove the right lower instrument panel protector (See page 45-17).
4. Disconnect the connectors (arrow) and remove the fixing
bolt (1) of the immobilizer control module with a wrench.
34
1
RT21340101
CAUTION
 Install the connectors in place.

 Tighten the fixing bolt in place.

LIGHTING SYSTEM
GENERAL INFORMATION 35-3 Rear Combination Light Assembly 
Light Position Diagram 35-3 (Fixed Part) 35-74
System Assembly Diagram 35-5 Removal 35-74
Specifications 35-6 Rear Combination Light Assembly 
Tools 35-7 (Movable Part) 35-76
Removal 35-76
Installation 35-77
DIAGNOSIS & TESTING 35-22 Front Fog Light Assembly 35-78
Problem Symptoms Table 35-22 Removal 35-78
DTC Confirmation Procedure 35-25 Installation 35-78
Intermittent DTC Troubleshooting 35-25 Rear Fog Light & Reflector 
Ground Inspection 35-25 Assembly 35-79
System Diagnosis 35-26 Removal 35-79
Diagnosis Procedure 35-28 Installation 35-79 35
Diagnostic Trouble Code (DTC)  Front Dome Light Assembly 35-80
chart 35-30 Removal 35-80
B100111 35-31 Inspection 35-81
B100113 35-31 Installation 35-81
B100119 35-31 Rear Dome Light Assembly 35-82
B100211 35-38 Removal 35-82
B100213 35-38 Inspection 35-83
B100311 35-45 Front Door Courtesy Light 35-84
B100313 35-45 Removal 35-84
B100411 35-52 High Mounted Stop Light 
B100413 35-52 Assembly 35-85
B100419 35-52 Removal 35-85
B100871 35-59 License Plate Light Assembly 35-86
Removal 35-86
Installation 35-86
Headlight Adjustment Switch 
Luggage Compartment Light 
Assembly 35-64
Assembly 35-87
Removal 35-64
Removal 35-87
Inspection 35-65
Installation 35-87
Installation 35-66
Back-up Light Switch Assembly 35-88
Combination Light Adjustment 
Removal 35-88
Switch 35-67
Inspection 35-88
Removal 35-67
Hazard Warning Light Switch 35-90
Installation 35-68
Removal 35-90
Headlight Assembly 35-69
Installation 35-91
Installation 35-70
Adjustment 35-70

35

35 - LIGHTING SYSTEM
GENERAL INFORMATION
LIGHTING SYSTEM
Light Position Diagram
35
7
6
10
9
8
12
11
RT21350010

1 - Headlight Assembly (Low Beam Light, High 2 - Interior Front Dome Light
Beam Light, Position Light, Turn Signal Light)
3 - Side Turn Signal Light 4 - Front Door Courtesy Light
5 - Front Fog Light 6 - High Mounted Stop Light
7 - Interior Rear Dome Light 8 - Luggage Compartment Light
9 - Rear Combination Light (Fixed Part) (Turn Signal 10 - Rear Combination Light (Movable Part) 
Light, Position Light, Brake Light) (Back-up Light)
11 - Rear Fog Light 12 - License Plate Light
35

System Assembly Diagram
4
3
1 7
35
6
8
9
10
RT21350020
1 - Instrument Panel Fuse and Relay Box A 2 - Body Control Module (BCM)
3 - Headlight Adjustment Switch Assembly 4 - Hazard Warning Light Switch
5 - Instrument Panel Fuse and Relay Box B 6 - Headlight Leveling Switch
7 - Backlight Adjustment Switch 8 - Interior Rear Dome Light Switch
9 - Interior Front Dome Light Switch 10 - Engine Compartment Fuse and Relay Box

Description
Lighting system on this model consists of vehicle lighting device and light signal device, which are used for
normal operation of vehicle to ensure safety when driving at night or in fog.
Lighting system consists of headlight assembly (including low beam light, high beam light, position light and
turn signal light), front fog light, side turn signal light, front dome light, front door courtesy light, instrument
panel backlight, rear combination light (including turn signal light, position light, brake light and back-up light),
rear fog light (rear fog light and reflector), license plate light, high mounted stop light, rear dome light and
luggage compartment light. The headlight assembly and rear combination light use semi-closed structure for
easy inspection and repair.
Specifications
Bulb Specifications
Bulb Name Nominal Light Source (Model/Type)

Headlight (High Beam/Low Beam) H1/H7
Front Position Light LED
35 Front Turn Signal Light PY21W
Brake Light LED
Front Fog Light H7
Rear Fog Light P21W
License Plate Light C5W
High Mounted Stop Light LED
Rear Position Light LED
Rear Turn Signal Light PY21W
Back-up Light W16W
Side Turn Signal Light LED
Front Dome Light C10W
Rear Dome Light 10W
Luggage Compartment Light C5W
Front Door Courtesy Light 3W


Headlight Assembly Fixing Bolt 3.5 ± 0.5
Rear Combination Light Assembly Fixing Nut 4.5 ± 1
Rear Combination Light Assembly Fixing Screw 1.5 ± 0.5
Front Dome Light Assembly Fixing Screw 1.5 ± 0.5
Rear Dome Light Assembly Fixing Screw 1.5 ± 0.5
Rear Fog Light & Reflector Assembly Fixing Screw 1.5 ± 0.5
Tools
35
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
High/Low Beam Light (Page 1 of 2)
BATTERY
LOW HIGH ENGING

BEAM BEAM COMPARTMENT
RELAY RELAY FUSE AND
RELAY BOX
E-067
E-068
EF04 EF02 EF03 EF01
20A 20A 20A 20A
D2 D4 H2 D3 D5 H1
35
BBr
GR
RV
RB
RL
BL
BBr
1 A
BL
2 B
E-070 B-048
GR
GR
RL
RL
7 4 2 7 4 2
FRONT LEFT FRONT RIGHT

M HEADLIGHT M HEADLIGHT
E-056 E-034
5 3 6 5 3 6
GY
GY
B
GY
5 C
E-071 I-004
B
E-058 E-031
D1 D2 D3 D4 D5 9 7 5 3 1 9 7 5 3 1 H8 H7 H6 H5 H4 H3 H2 H1
10 8 6 4 2 10 8 6 4 2
D6 D7 D8 D9 D10 H16 H15 H14 H13 H12 H11 H10 H9
E-034 E-056 E-067

E-068
B B W
W
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6
11 12 13 14 15 16 17 18 19 20 21 22 7 8 9 10 11 12 13 14
E-070
W E-071
B
ET21350010

High/Low Beam Light (Page 2 of 2)
IGNITION SWITCH
ON OR START
INSTRUMENT
RF02 PANEL FUSE
AND RELAY
10A
HIGH BEAM
LOW BEAM
COMBINATION BOX
FLASH
PARK
I-007
OFF
LIGHT SWITCH
I-011
150
330
220
150
2
A
B
9 8
BBr
BL
Gr
B
L
B30 B31 A32 A26 A10
RL
35
BCM I-005 B-043 B-047
C8
LG
B-003
22
I-006
LG
7 Lg
6 IC ILLUMINATION
HEADLIGHT
8 ADJUSTMENT
SWITCH
I-009
1 R5 R4 R3 R2 R1
B
2 1
3 0
I-003
R0 2
BrG
C
B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 10 9 8 7 6
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
B-047 I-011
27 25 26 L B
87
85 86 86 86 C1 C2 C3 C4 C5 C6 C7 C8 C9 9 10 11 12 13 14 15 16
87 30 87 30
30 85 85 1 2 3 4 5 6 7 8
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
I-007 B-043 I-009

B W Br
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 10 9 8 7 6 5 4 3 2 1
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 22 21 20 19 18 17 16 15 14 13 12 11
I-005 I-006
L W ET21350020

Position Light
BATTERY
2
ENGINE
COMPARTMENT
MF03
FUSE AND
60A RELAY BOX
E-061 COMBINATION
PARK
OFF
LIGHT SWITCH
3
I-011
220
R
B
8
L
E1 A32 A10
BCM E-072 B-043 I-005
35
C7 C8
WY
LG
16 15 B-048
WY
LG
E-070
WY
LG
6 8 8 6
REAR REAR
LEFT FRONT FRONT RIGHT
POSI- POSI- LEFT POSI- RIGHT POSI-
COMBI- COMBI-
TION TION HEADLIGHT TION HEADLIGHT TION
NATION NATION
LIGHT LIGHT E-056 LIGHT E-034 LIGHT
LIGHT LIGHT
1 B-021 1 1 1 B-016
B
B-022 E-058 E-031 B-018
3
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 C1 C2 C3 C4 C5 C6 C7 C8 C9
E1
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
E-061 E-072 I-005 B-043

W L W
10 9 8 7 6 5 4 3 2 1 5 3 1 B-021 5 3 1 B-016 10 9 8 7 6
6 4 2 B 6 4 2 B 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 11
I-011
B-048 B
W
9 7 5 3 1 9 7 5 3 1
E-034 E-056
10 8 6 4 2 B 10 8 6 4 2 B
ET21350060

Turn Signal Light
BATTERY
B
2 2 5
ENGINE RIGHT LEFT I-003

COMPARTMENT COMBINATION
MF03 FUSE AND HAZARD SWITCH
330
150
LIGHT SWITCH
60A RELAY BOX I-001
I-011
E-061
3 10 1 3 4
GrB
YR
Lg
R
W
ILLUMINATION
E1 A32 A27 A17 A1
BCM E-072 I-005 B-043
C16 C6
WL
GR
35
WL
GR
WL
GR
3 3
REAR REAR
LEFT RIGHT
TURN TURN
B-041 COMBI- B-061
7 SIGNAL SIGNAL COMBI- 15
F-007 NATION H-002
LIGHT LIGHT NATION
LIGHT LIGHT
B-021
WL
1 1 B-016
GR
B
13 13
B-022 B-018 POWER
POWER
11 12 B-048 REAR
TURN REAR VIEW TURN
E-070 VIEW
SIGNAL MIRROR SIGNAL
MIRROR
LIGHT MOTOR LIGHT
WL
GR
MOTOR
F-005
4 4 H-008
10 10
B
B
FRONT FRONT
TURN TURN
LEFT RIGHT
SIGNAL SIGNAL
F-007 HEADLIGHT HEADLIGHT H-002
3 LIGHT LIGHT 3
B-040 E-056 E-034 B-061
9 9
B
B-036 E-058 E-031 B-062
3
E1 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
E-061 E-072 I-005 B-043

W L W
5 3 1 5 3 1 1 4
10 9 8 7 6 5 4 3 2 1 B-021 B-016 10 9 8 7 6 I-011 I-001
2 5
6 4 2 B 6 4 2 B 5 4 3 2 1 B B
22 21 20 19 18 17 16 15 14 13 12 11 3 6
B-048
W 9 7 5 3 1 7 6 5 4 3 2 1
E-056 F-005
10 8 6 4 2 16 15 14 13 12 11 10 9 8
B W
1 4 7 10 13 16 16 13 10 7 4 1 1 4 7 10 13 16
2 5 8 11 14 17 17 14 11 8 5 2 2 5 8 11 14 17
9 7 5 3 1 7 6 5 4 3 2 1
3 6 9 12 15 18 18 15 12 9 6 3 3 6 9 12 15 18 E-034 H-008
10 8 6 4 2 B 16 15 14 13 12 11 10 9 8 W
B-040 B-041 B-061
W Gr W ET21350050

Fog Light (Page 1 of 2)
IGNITION SWITCH IGNITION SWITCH

BATTERY
30 85 ENGINE
FRONT
COMPARTMENT
FOG INSTRUMENT
FUSE AND RF07 RF13
MF03 RELAY PANEL FUSE
RELAY BOX 7.5A 7.5A
ERLY03 AND RELAY BOX
60A 87 86 E-061
I-007
EF05 E-067
15A E-068 7 13
3 D1 H3
BrG
YR
35
RBr
RG
YR
YR
E-070
2 2 3 B-048
R
FRONT FRONT
LEFT RIGHT
FOG FOG
1 LIGHT 1 LIGHT
E-055 E-037
B
BrG
E-058 E-031
E1 B29 A25 A9
BCM E-072 I-005 B-047
1 2 3 4 5 6 7 8 9 10 11 12 H8 H7 H6 H5 H4 H3 H2 H1 E-067
E1 1 2 1 2
13 14 15 16 17 18 19 20 21 22 23 24 W
H16 H15 H14 H13 H12 H11 H10 H9
E-072 27 25 26 I-007 E-037 E-055
W 87 B B B
85 86 86 86 1 2 3 4 5 6 7 8 9 10
87 30 87 30 E-070
30 85 85
11 12 13 14 15 16 17 18 19 20 21 22 W
3
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 I-005
D1 D2 D3 D4 D5 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 L
E-068
E-061 W
D6 D7 D8 D9 D10
B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32
B-047
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 L ET21350030

Fog Light (Page 2 of 2)
BCM B-043 I-005 B-046
A20 A32 A5 C13 F1
35
WB
GL
LY
B
WB
WB
2
COMBINATION 2 2 REAR
REAR B-045
LIGHT RIGHT LEFT
SWITCH FOG FOG
I-011 LIGHT LIGHT
FRONT REAR 1 1
FOG FOG B-037 B-028
B
5 3
B
B-022
C1 C2 C3 C4 C5 C6 C7 C8 C9
F1 B-046 10 9 8 7 6 I-011 B-043
B 5 4 3 2 1 B C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 W
1 2 B-028 1 2 B-037 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 I-005
B B A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 L
ET21350040

Dome Light

BATTERY
ENGINE
INSTRUMENT
COMPARTMENT
MF03 RF07 RF13 PANEL FUSE
FUSE AND AND RELAY BOX
60A RELAY BOX 7.5A 7.5A
I-007
E-061
3 7 13
RBr
RG
R
35 E1 A25 A9
BCM E-072 I-005 B-043 B-044 B-046
C5 D10 F1
R
B
R
2 2
FRONT REAR
ROOM ROOM
LIGHT LIGHT
B-008 B-010
OFF B-045
1 1
B
BW
B-007
1 2 3 4 5 6 7 8 9 10 11 12
E1
13 14 15 16 17 18 19 20 21 22 23 24 D1 D2 D3 D4 D5 B-044
E-072 I-007 D6 D7 D8 D9 D10 D11D12 W
W 27 25 26
87 B
85 86 86 86
F1 87 30 87 30
30 85 85
B-046 I-005
B A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 L
3
C1 C2 C3 C4 C5 C6 C7 C8 C9 B-043 1 2 B-008 B-010
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 W 2 1
3 4 5 6 W W
E-061 ET21350130

License Plate Light

BATTERY
ENGINE
INSTRUMENT
COMPARTMENT
I-007
E-061
3 7 13
RBr
RG
R
E1 A25 A9
35
BCM I-005 E-072 B-046 B-043
C07 F1
WY
B-012
7
T-004
B
WY
WY
WY
1 RIGHT 1 LEFT
LICENSE LICENSE B-045
PLATE PLATE
LIGHT LIGHT
2 T-003 2 T-008
B
T-004
8 B-012
B
B-018
1 2 3 4 5 6 7 8 9 10 11 12
E1 2 1 T-008 T-003
2 1
13 14 15 16 17 18 19 20 21 22 23 24 W W
E-072 27 25 26 I-007
W 87 B
85 86 86 86 1 2 3 4 5 6 7 8 B-012
87 30 87 30
F1 30 85 85 9 10 11 12 13 14 15 W
B-046
B
C1 C2 C3 C4 C5 C6 C7 C8 C9 B-043 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32
3 I-005
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 W L
ET21350080
E-061

Ignition Switch Illumination

BATTERY
ENGINE
INSTRUMENT
COMPARTMENT
MF03 RF24 RF07 RF13 PANEL FUSE
60A RELAY BOX 7.5A 7.5A 7.5A
I-007
E-061
3 24 7 13
RBr
RG
1
R
KEY
REMINDER
SWITCH
35 （FOR MT）
I-002
2
GW
E1 A8 A25 A9
BCM I-005 B-043 B-044 E-072 B-046
D10 C5 F1
BW
B-003
18 10
B
I-006
BW
1
KEY
LAMP
（FOR MT） B-045
R
I-016
2
1 2 3 4 5 6 7 8 9 10 11 12 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 I-005
E1 L
13 14 15 16 17 18 19 20 21 22 23 24
E-072 I-007
27 25 26
W 87 B C1 C2 C3 C4 C5 C6 C7 C8 C9 B-043
85 86 86 86
F1 87 30 87 30 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 W
30 85 85
B-046
B 1 2 3 4 5 6 7 8 9 10
D1 D2 D3 D4 D5 B-003
3 1 2 11 12 13 14 15 16 17 18 19 20 21 22 W
2 1 D6 D7 D8 D9 D10 D11D12
3 4
I-016 B-044
I-002 W
E-061 B B ET21350110

Back-up Light (Page 1 of 2)
MT
IGNITION SWITCH
ON OR START
ENGINE
COMPARTMENT
EF34 EF28 FUSE AND
20A 10A RELAY BOX
E-023
C8
LR
1
BACK-UP
LIGHT
CLOSE SWITCH
OPEN E-025
2
L
E-007
35
E-038
35
L
E-029
3 B-054
L
9 B-012
T-004
L
B17 2 2
BCM REAR LEFT REAR RIGHT

COMBINATION COMBINATION
B-047
LIGHT LIGHT
T-011 T-001
1 1
B
T-004
8
B-012
B
B-018
C1 C2 C3 C4 C5 42 38 34 30 25 20 15 10 5
41 37 33 29 24 19 14 9 4
C6 C7 C8 C9 C10 28 23 18 13 8 3 E-007
40 36 32
27 22 17 12 7 2 B B-047
39 35 31 26 21 16 11 6 L
E-023 1
L
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
1 2
11 10 9 8 7 6 5 4 3 2 1
2 1
22 21 20 19 18 17 16 15 14 13 12
T-011 T-001
E-029 E-025 B-012 B B
W B W ET21350090

Back-up Light (Page 1 of 2)
IGNITION SWITCH CVT

BATTERY
ON OR START
INSTRUMENT EF30 ENGINE

PANEL 10A COMPARTMENT
RF03 FUSE AND 85 30 FUSE AND
7.5A RELAY BOX RELAY BOX
I-007 REVERSE E-023
3 RELAY
E-069
86 87
Y
F3 F2 C6
L
12
I-004 E-071 E-007
Br
35
E-038
L
E-029
3 B-054
35
L
9 B-012
T-004
Br
L
8 B17 2 2
REAR LEFT REAR RIGHT
BCM
COMBINATION COMBINATION
B-047
LIGHT LIGHT
CONNECTOR A T-011 T-001
E-050 1 1
B
T-004
8
B-012
B
B-018
1 2 3 4 5 6 7 8 9 10 11 12 6 5 4 3 2 1
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 14 13 12 11 10 9 8 7
13 14 15 16 17 18 19 20 21 22 23 24
27 25 26 F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
87 I-004
85 86 86 86 E-069 W
87 30 87 30
30 85 85
W
I-007 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32
6 4 2 1 5 3
B B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16
10 9 7 8
B-047 E-050
L B
42 38 34 30 25 20 15 10 5 11 10 9 8 7 6 5 4 3 2 1 E-029
C1 C2 C3 C4 C5
W
41 37 33 29 24 19 14 9 4 22 21 20 19 18 17 16 15 14 13 12 1 2
C6 C7 C8 C9 C10 28 23 18 13 8 3 E-007
40 36 32 B
27 22 17 12 7 2 1 2 3 4 5 6 7 8
39 35 31 26 21 16 11 6 1
B-012 T-011 T-001
E-023 9 10 11 12 13 14 15 W B B
L
ET21350100

Brake Light
BATTERY
INSTRUMENT
PANEL FUSE
RF35
AND RELAY
10A BOX
B-060
F18
GR
1
BRAKE
SWITCH
B-052
35
3
RB
RB
5 B-012
RB
T-004 RB
RB
2 2 2
REAR LEFT HIGH REAR RIGHT
STOP COMBINATION STOP MOUNTED STOP COMBINATION
LIGHT LIGHT LIGHT STOP LIGHT LIGHT LIGHT
B-021 T-005 B-016
1 1 1
B
T-004
8
B
B-012
B
B-022 B-018 B-018
1 2 3 4 5 6 7 8
F1 F2 F3 F4 F5 F6 F7
F11 F12 F13 F14 9 10 11 12 13 14 15
F8 F9 F10 F15 F16 F17 F18
B-060
W B-012
W
5 3 1 5 3 1 2 1
2 1
4 3 6 4 2 6 4 2
B-052 B-016 B-021

Lg B B
T-005
W
ET21350070

Luggage Compartment Light

BATTERY
ENGINE
INSTRUMENT
COMPARTMENT
I-007
E-061
3 7 13
RBr
RG
R
35
E1 A25 A9
BCM I-005 B-043 B-044 E-072 B-046
C5 D9 F1
R
2 B
LUGGAGE
COMPARTMENT
LIGHT
B-011
B-045
1
BW
1 2 3 4 5 6 7 8 9 10 11 12
E1
13 14 15 16 17 18 19 20 21 22 23 24 D1 D2 D3 D4 D5
E-072 1 2
27 25 26 D6 D7 D8 D9 D10 D11D12
W 87
85 86 86 86
85
87 30
85
87 30 B-044 B-011
30
F1 W B
B-046 I-007
B B
3
C1 C2 C3 C4 C5 C6 C7 C8 C9 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16
E-061
B-043 I-005
W L
ET21330140

Front Door Courtesy Light

BATTERY
ENGINE
COMPARTMENT INSTRUMENT
60A FUSE AND
7.5A 7.5A AND RELAY BOX
RELAY BOX
I-007
E-061
3 7 13
RBr
RG
R
E1 A25 A9
35
BCM E-072 B-043 B-046 B-047 I-005
B27 C5 B26 F1
R
L
Gr
B-040 B-061
5 6 6 5
F-007 H-002 B
R
1 FRONT LEFT 1
FRONT RIGHT
DOOR DOOR
YW
YW
COURTESY COURTESY
LIGHT B-045
LIGHT
2 F-001 2 H-006
1 2 3 4 5 6 7 8 9 10 11 12 3
13 14 15 16 17 18 19 20 21 22 23 24 E1 F1 1 2 1 2
27 25 26
B-046 F-001 H-006
87 E-061 E-072
B W W
85 86 86 86 W
87 30 87 30
30 85 85
I-007
B 1 4 7 10 13 16 1 4 7 10 13 16
2 5 8 11 14 17 2 5 8 11 14 17
3 6 9 12 15 18 3 6 9 12 15 18
B-061 B-040
I-005 W W
L
B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 C1 C2 C3 C4 C5 C6 C7 C8 C9
B-047 B-043
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 L C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 W
ET21350120

DIAGNOSIS & TESTING

HINT:
Position Light, Low Beam Light, High Beam Light

Fuse 51-34
Low beam does not come on (one side) Low beam bulb -
Fuse 51-34
Low beam bulb -
35 Headlight adjustment switch assembly 35-64
Low beam does not come on (both sides)
Low beam relay 51-34
Body Control Module (BCM) -
Fuse 51-34
High beam does not come on (one side) High beam bulb -
Fuse 51-34
High beam bulb -
Headlight adjustment switch assembly 35-64
High beam does not come on (both sides)
High beam relay 51-34
Position light bulb (all) -
Position light does not come on (all)
Position light bulb -
Position light does not come on (one side)

Front Fog Light

Fuse 51-34
Relay 51-34
Front fog light bulb -
Front fog light does not come on
Rear Fog Light

Rear fog light bulb -
Rear fog light does not come on 35
Turn Signal Light and Hazard Warning Light

Bulb -
Hazard warning light and turn signal light
Hazard Warning Light Switch 35-90
do not come on
Hazard warning light does not come on Hazard Warning Light Switch 35-90
(turn signal light is normal) Wire harness or connector -
Turn signal light does not come on (hazard Headlight adjustment switch assembly 35-64
warning light is normal) Wire harness or connector -
License Plate Light

License plate light bulb -
License plate light does not come on

Luggage Compartment Light

Luggage compartment light bulb -
Luggage compartment light does not come
on

Front door courtesy light bulb -
Front door courtesy light does not come on Wire harness or connector -
Brake Light
35
Brake light bulb -
Brake light does not come on (all) Brake light switch 26-26
Brake light bulb -
Only one brake light does not come on
Front Dome Light

Front dome light bulb -
Front dome light does not come on
Front dome light assembly 35-80
Rear Dome Light

Rear dome light bulb -
Rear dome light does not come on
Rear dome light assembly 35-82

Back-up Light

Fuse 51-34
Relay (CVT model) 51-34
Back-up light does not come on (all) Back-up light bulb -
Back-up light switch 35-88

 Use X-431 3G diagnostic tester to record and clear the DTCs stored in the lighting system.
35
 Turn ignition switch to ON and then select Read Code.
 If DTC is not detected, the malfunction indicated by the DTC is intermittent. Please refer to the Intermittent

 Inspect the mounting areas of headlight adjustment switch assembly and light assemblies and so on for
power supply circuit applied to the DTC.
Refer to Technical Bulletin that is applied to the malfunction.
Ground Inspection
the circuit.
the electronically controlled circuit. The operations to check the ground points are as follows:


System Diagnosis
1. Description
a. Lighting system data and Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of vehicle. When system seems to be malfunctioning, use X-431 3G diagnostic tester to
check for a malfunction and perform repairs.
2. Check battery voltage
Standard Voltage: 11 to 14 V
DTC Check/Clear
1. Check DTCs
b. Turn ignition switch to ON, and turn X-431 3G diagnostic tester on.
35 c. Enter the following menus to read the current malfunction: T21/BCM/Read fault code/Read present
fault code.
d. Read DTCs.
2. Clear DTCs.
c. Enter the following menus: T21/BCM/Erase fault code.
d. Clear the DTCs by following the indications on the tester screen.
Data List/Active Test

1. Read the Data List.
HINT:
Using the X-431 3G diagnostic tester Data List to perform Active Tests allows the values or states of
switches, sensors, actuators and other items to be read without removing any parts. This non-intrusive
inspection can be very useful because intermittent problems or signals may be discovered before parts or
wiring is disturbed. Reading the Data List information early in troubleshooting is one way to save
diagnostic time.
CAUTION
 In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely
on these reference values when deciding whether a part is faulty or not.

c. Enter the following menus: T21/BCM/Read data strean/Input status (Light).
d. Read the Data List according to the display on the tester.

Tester Display Measurement Item/Range Normal Condition

Left turn signal On: Active
Left Hand Turn Light Left turn signal/On or Off
Left turn signal Off: Inactive
Right turn signal On: Active
Right Hand Turn Light Right turn signal/On or Off
Right turn signal Off: Inactive
Front fog light signal On: Active
Front Fog Light Front fog light signal/On or Off
Front fog light signal Off: Inactive
Rear fog light signal On: Active
Rear Fog Light Rear fog light signal/On or Off
Rear fog light signal Off: Inactive
Position light signal On: Active
Position Light Position light signal/On or Off
Position light signal Off: Inactive
Low beam light signal On: Active
Low Beam Low beam light signal/On or Off
Low beam light signal Off: Inactive
High beam light signal On: Active
High Beam High beam light signal/On or Off High beam light signal Off: 35
Inactive
Hazard light signal On: Active
Hazard Hazard light signal/On or Off
Hazard light signal Off: Inactive
Reversing light signal On: Active
Reversing Light Reversing light signal/On or Off
Reversing light signal Off: Inactive
Passing light signal On: Active
Passing Light Passing light signal/On or Off
Passing light signal Off: Inactive
2. Perform the Active Test.

HINT:
Using theX-431 3G diagnostic tester to perform Active Tests allows items to be tested without removing
any parts. This non-intrusive functional inspection can be very useful because intermittent problems may
be discovered before parts or wiring is disturbed. Perform the Active Test early in troubleshooting is one
way to save diagnostic time.The Data List information can be displayed when performing the Active Test.
c. Enter the following menus: T21/BCM/Action Test.
d. Perform the Active Test according to the tester display.
Tester Part Control Range

Left Hand Turn Light Active/Inactive
Right Hand Turn Light Active/Inactive
Position Light Active/Inactive
Low Beam Active/Inactive
High Beam Active/Inactive
Front Fog Light Active/Inactive
Rear Fog Light Active/Inactive
Dome Lamp Active/Inactive

Tester Part Control Range

Welcome Lamp Active/Inactive
Security Indicator Active/Inactive
Diagnosis Procedure
HINT:
Perform troubleshooting according to the procedures below.
NEXT
35 Standard voltage: 11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding to next step.
NEXT
DTC
occurs
No 
DTC
4 Diagnostic Trouble Code (DTC) chart
NEXT
5 Circuit inspection
NEXT
6 Repair or replace
NEXT
7 Clear DTCs (current DTC and history DTC)

NEXT
DTC
Go to step 4
output
NO DTC
Go to next step
output
9 Confirmation test
NEXT
10 End 35

Diagnostic Trouble Code (DTC) chart

B100111 Left Side Turn Lamp Control Circuit Circuit Short to Ground
B100113 Left Side Turn Lamp Control Circuit Circuit Open
B100119 Left Side Turn Lamp Control Circuit Circuit Current Above Threshold
B100211 Right Side Turn Lamp Control Circuit Circuit Short to Ground
B100213 Right Side Turn Lamp Control Circuit Circuit Open
B100219 Right Side Turn Lamp Control Circuit Circuit Current Above Threshold
B100311 Left Park Light Output Control Circuit Circuit Short to Ground
B100313 Left Park Light output Control Circuit Circuit Open
B100319 Left Park Light Output Control Circuit Circuit Current Above Threshold
B100411 Right Park Light Output Control Circuit Circuit Short to Ground
B100413 Right Park Light output Control Circuit Circuit Open
35
B100419 Right Park Light Output Control Circuit Circuit Current Above Threshold
B100813 Rear Fog Control Circuit Circuit Open
B100871 Rear Fog Control Circuit Actuator Stuck

LIGHTING SYSTEM
Left Side Turn Lamp Control Circuit Circuit Short to

DTC B100111
Ground
DTC B100113 Left Side Turn Lamp Control Circuit Circuit Open
Left Side Turn Lamp Control Circuit Circuit Current

DTC B100119
Above Threshold
35

BATTERY
B
2 2 5

330
150
LIGHT SWITCH
60A RELAY BOX I-001
I-011
E-061
3 10 1 3 4
GrB
YR
Lg
R
W
ILLUMINATION
E1 A32 A27 A17 A1
BCM E-072 I-005 B-043
C16
WL
WL
WL
3
35 TURN
REAR
LEFT
7 B-041 COMBI-
SIGNAL
F-007 NATION
LIGHT
LIGHT
B-021
WL
13 B
B-022
POWER
TURN REAR VIEW 11 B-048
SIGNAL MIRROR E-070
LIGHT MOTOR
WL
F-005
4 10
B
FRONT
TURN
LEFT
SIGNAL
F-007 HEADLIGHT
3 LIGHT
B-040 E-056
9
B
B-036 E-058
E1 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
E-072 I-005 B-043

W L W
5 3 1 1 4
10 9 8 7 6 5 4 3 2 1 B-021 10 9 8 7 6 I-011 I-001
2 5
6 4 2 B 5 4 3 2 1 B B
22 21 20 19 18 17 16 15 14 13 12 11 3 6
B-048
W 9 7 5 3 1 7 6 5 4 3 2 1
E-056 F-005
10 8 6 4 2 16 15 14 13 12 11 10 9 8
B W
3 1 4 7 10 13 16 16 13 10 7 4 1
2 5 8 11 14 17 17 14 11 8 5 2
3 6 9 12 15 18 18 15 12 9 6 3
E-061 B-040 B-041

W Gr ET21350150

DTC Detection
DTC Code DTC Definitions DTC Setting Conditions
Conditions
Left Side Turn Lamp

B100111 Control Circuit Circuit
Short to Ground
Left Side Turn Lamp  Turn signal light bulb

B100113 Control Circuit Circuit Ignition switch ON  Wire harness or connector
Open  Body Control Module (BCM)
Left Side Turn Lamp

Control Circuit Circuit
B100119
Current Above
Threshold
HINT: 35
While performing the electrical diagnosis and testing, always refer to the relevant circuit diagram for the
special circuit and component information.
Diagnosis Procedure
1 Check turn signal light bulb
a. Remove the turn signal light bulb, and check if the turn signal light bulb filament is blown.
NG Replace turn signal light bulb
OK

a. Turn ignition switch to LOCK, and disconnect the negative battery cable.
b. Disconnect the Body Control Module (BCM) connectors B-043 and E-072.
c. Disconnect the left turn signal light wire harness connectors F-005, E-056 and B-021.
d. Disconnect the body wire harness connectors B-048 and B-041, front left door wire harness connector 
F-007 and engine compartment wire harness connector E-070.
g. Check if the related connector terminal contact pins are in good condition.

connector
OK

3 Check left turn signal light control circuit

c. Disconnect the Body Control Module (BCM) connectors
B-043 and E-072.
+ -
terminal C16 of BCM connector B-043 and terminal E1 of
BCM connector E-072 to check if it is short to power C1 C2 C3 C4 C5 C6 C7 C8 C9
supply according to the table below. C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
Standard Condition B-043
Condition
B-043 (C16) - E1
E-072 (E1) E-072
35 RT21350460

terminal C16 of BCM connector B-043 and body ground
to check if it is short to ground according to the table
below.
Condition C1 C2 C3 C4 C5 C6 C7 C8 C9
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-043 (C16) -
Always No continuity B-043
Body ground

connector
RT21350470
OK

4 Check wire harness and connector (left turn signal light - Body Control Module (BCM))

c. Disconnect the Body Control Module (BCM) connector 
B-043.
+ -
d. Disconnect the left turn signal light wire harness
connectors F-005, E-056 and B-021.
e. Disconnect the body wire harness connectors B-048 and C1 C2 C3 C4 C5 C6 C7 C8 C9
B-041, front left door wire harness connector F-007 and C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
engine compartment wire harness connector E-070. B-043

terminal C16 of BCM connector B-043 and terminal 11 of
body wire harness connector B-048 according to the 10 9 8 7 6 5 4 3 2 1
table below. 22 21 20 19 18 17 16 15 14 13 12 11
Standard Condition
B-048
Multimeter
Condition
Specified
RT21350480
35
B-043 (C16) -
Always Continuity
B-048 (11)

terminal 11 of engine compartment wire harness
connector E-070 and terminal 10 of front left headlight
wire harness connector E-056 according to the table
below. + -
Standard Condition
1 2 3 4 5 6 7 8 9 10
Condition 11 12 13 14 15 16 17 18 19 20 21 22
E-070
E-070 (11) -
Always Continuity
E-056 (10)
9 7 5 3 1
10 8 6 4 2
E-056
RT21350490


body wire harness connector B-041 according to the
table below.
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-043 (C16) -
B-041 (7)
16 13 10 7 4 1
17 14 11 8 5 2
18 15 12 9 6 3
B-041
RT21350500
35 i. Using a digital multimeter, check for continuity between

terminal 7 of front left door wire harness connector F-007
and terminal 13 of left outside rear view mirror wire
harness connector F-005 according to the table below.
7 8 9 9 8 7
F-007
F-007 (7) - 10 11 12 12 11 10
F-005 (13) 16 17 18 18 17 16
7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 F-005
RT21350510

rear left combination light wire harness connector B-021
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-043 (C16) -
B-021 (3)
NG Repair or replace related wire harness and 5 3 1

connector 6 4 2
B-021
RT21350520

OK
5 Reconfirm DTCs
a. Firmly reconnect all disconnected connectors.

c. Turn ignition switch to ON.
d. Use X-431 3G diagnostic tester (the latest software) to record and clear the DTCs stored in the Body
Control Module (BCM).
f. Turn ignition switch to ON.
g. Use X-431 3G diagnostic tester to read the DTCs in the Body Control Module (BCM) again.
Result Precede to
DTC B100111, B100113 and B100119 are output NG
No DTC is output OK 35
NG Replace Body Control Module (BCM)
OK
System is normal

Right Side Turn Lamp Control Circuit Circuit Short to

DTC B100211
Ground
DTC B100213 Right Side Turn Lamp Control Circuit Circuit Open
Right Side Turn Lamp Control Circuit Circuit Current

DTC B100219
Above Threshold
35

BATTERY
B
2 2 5

330
150
LIGHT SWITCH
60A RELAY BOX I-001
I-011
E-061
3 10 1 3 4
GrB
YR
Lg
R
W
ILLUMINATION
E1 A32 A27 A17 A1
BCM E-072 I-005 B-043
C6
GR
GR
GR
3
TURN
REAR
RIGHT 35
B-061
SIGNAL COMBI- 15
LIGHT NATION H-002
LIGHT
1 B-016
GR
B
13
B-018 POWER
12 B-048 REAR
TURN
E-070 VIEW
SIGNAL
MIRROR
LIGHT
GR
MOTOR
4 H-008
10
B
FRONT
TURN
RIGHT
SIGNAL
HEADLIGHT H-002
LIGHT 3
E-034 B-061
9
B
E-031 B-062
I-005 B-043
L W
3 10 9 8 7 6
10 9 8 7 6 5 4 3 2 1 5 3 1
E1 6 4 2 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 11
E-072 I-011
B-048 E-061 B-016 B
W B
W
1 4 7 10 13 16
2 5 8 11 14 17
1 4
9 7 5 3 1 7 6 5 4 3 2 1 I-001
3 6 9 12 15 18 E-034 H-008 2 5
10 8 6 4 2 B 16 15 14 13 12 11 10 9 8 W 3 6 B
B-061
W ET21350160

DTC Detection
Conditions
Right Side Turn Lamp

Short to Ground
Right Side Turn Lamp  Turn signal light bulb

Right Side Turn Lamp

B100219
Current Above
Threshold
35 HINT:
Diagnosis Procedure
1 Check turn signal light bulb
a. Remove the turn signal light bulb, and check if the turn signal light bulb filament is blown.
NG Replace turn signal light bulb
OK

c. Disconnect the right turn signal light wire harness connectors H-008, E-034 and B-016.
d. Disconnect the body wire harness connectors B-048 and B-061, front right door wire harness connector 
H-002 and engine compartment wire harness connector E-070.

connector
OK

3 Check right turn signal light control circuit

B-043 and E-072.
+ -
Condition
B-043 (C6) - E1
E-072 (E1) E-072
RT21350530
35

terminal C6 of BCM connector B-043 and body ground to
check if it is short to ground according to the table below.
Standard Condition
+ -
Condition
C1 C2 C3 C4 C5 C6 C7 C8 C9
B-043 (C6) - Body C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
ground
B-043

connector
RT21350540
OK

4 Check wire harness and connector (right turn signal light - Body Control Module (BCM))

B-043.
+ -
d. Disconnect the right turn signal light wire harness
connectors H-008, E-034 and B-016.
e. Disconnect the body wire harness connectors B-048 and C1 C2 C3 C4 C5 C6 C7 C8 C9
B-061, front right door wire harness connector H-002 and C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20

f. Using the digital multimeter, check for continuity between
table below. 22 21 20 19 18 17 16 15 14 13 12 11
Standard Condition
B-048
35 Multimeter
Condition
Specified
RT21350550
B-043 (C6) -
Always Continuity
B-048 (12)

connector E-070 and terminal 10 of front right headlight
below. + -
Standard Condition
Multimeter Specified 1 2 3 4 5 6 7 8 9 10
Condition 11 12 13 14 15 16 17 18 19 20 21 22
E-070
E-070 (12) -
Always Continuity
E-034 (10)
9 7 5 3 1
10 8 6 4 2
E-034
RT21350560


body wire harness connector B-061 according to the
table below.
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-043 (C6) -
B-061 (15)
1 4 7 10 13 16
2 5 8 11 14 17
3 6 9 12 15 18
B-061
RT21350570

terminal 15 of front right door wire harness connector
35
H-002 and terminal 13 of right outside rear view mirror
wire harness connector H-008 according to the table
below. + -
Standard Condition
1 2 3 3 2 1
Multimeter Specified 4 5 6 6 5 4
Condition
H-002
10 11 12 12 11 10
H-002 (15) - 13 14 15 15 14 13
H-008 (13)
7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 H-008
RT21350580

rear right combination light wire harness connector B-016
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-043 (C6) -
B-016 (3)
NG Repair or replace related wire harness and 5 3 1

6 4 2
connector
B-016
RT21350590

OK
5 Reconfirm DTCs

Result Precede to
35 No DTC is output OK
OK
System is normal

Left Park Light Output Control Circuit Circuit Short to

DTC B100311
Ground
DTC B100313 Left Park Light output Control Circuit Circuit Open
Left Park Light Output Control Circuit Circuit Current

DTC B100319
Above Threshold
35

BATTERY
2
ENGINE
COMPARTMENT
MF03
FUSE AND
60A RELAY BOX
E-061 COMBINATION
PARK
OFF
LIGHT SWITCH
3
I-011
220
R
B
8
L
E1 A32 A10
BCM E-072 B-043 I-005
35 C7
WY
16 B-048
WY
E-070
WY
6 8
REAR
LEFT FRONT
POSI- POSI- LEFT
COMBI-
TION TION HEADLIGHT
NATION
LIGHT LIGHT E-056
LIGHT
1 B-021 1
B
B-022 E-058
3
E1
E-061 E-072 I-005 B-043

W L W
10 9 8 7 6 5 4 3 2 1 5 3 1 9 7 5 3 1 10 9 8 7 6
6 4 2 10 8 6 4 2 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 11
I-011
B-021 B
B-048 E-056
B
W B
ET21350170

DTC Detection
Conditions
Left Park Light Output

Short to Ground
Left Park Light output  Position light bulb

Left Park Light Output

B100319
Current Above
Threshold
HINT: 35
Diagnosis Procedure
1 Check position light bulb
a. Remove the position light bulb, and check if the position light bulb filament is blown.
NG Replace position light bulb
OK

c. Disconnect the front left headlight wire harness connector E-056 and rear left combination light wire
harness connector B-021.
d. Disconnect the body wire harness connector B-048 and engine compartment wire harness connector 
E-070.

connector
OK

3 Check left position light control circuit

B-043 and E-072.
+ -
Condition
B-043 (C7) - E1
E-072 (E1) E-072
35 RT21350600

Standard Condition
+ -
Condition
C1 C2 C3 C4 C5 C6 C7 C8 C9
ground
B-043

connector
RT21350610
OK

4 Check wire harness and connector (left position light - Body Control Module (BCM))

B-043.
+ -
d. Disconnect the front left headlight wire harness
connector E-056 and rear left combination light wire
harness connector B-021. C1 C2 C3 C4 C5 C6 C7 C8 C9
e. Disconnect the body wire harness connector B-048 and C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20

table below. 22 21 20 19 18 17 16 15 14 13 12 11
Standard Condition
B-048
Multimeter
Condition
Specified
RT21350620
35
B-043 (C7) -
Always Continuity
B-048(16)

connector E-070 and terminal 8 of front left headlight wire
harness connector E-056 according to the table below.
Condition 1 2 3 4 5 6 7 8 9 10
E-070 (16) -
E-056 (8)
9 7 5 3 1
10 8 6 4 2
E-056
RT21350630


rear left combination light wire harness connector B-021
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-043 (C7) -
B-021 (6)
5 3 1
6 4 2
B-021
RT21350640
35 i. Disconnect the body wire harness connector B-048 and

engine compartment wire harness connector E-070.
rear left combination light wire harness connector E-056 + -

Standard Condition C1 C2 C3 C4 C5 C6 C7 C8 C9
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
Condition
B-043 (C7) -
Always Continuity
E-056 (8) 9 7 5 3 1
10 8 6 4 2
NG Repair or replace related wire harness and E-056

connector
RT21350650
OK

5 Reconfirm DTCs

Result Precede to
No DTC is output OK

35
OK
System is normal

Right Park Light Output Control Circuit Circuit Short to

DTC B100411
Ground
DTC B100413 Right Park Light output Control Circuit Circuit Open
Right Park Light Output Control Circuit Circuit Current

DTC B100419
Above Threshold
35

BATTERY
2
ENGINE
COMPARTMENT
MF03
FUSE AND
60A RELAY BOX
E-061 COMBINATION
PARK
OFF
LIGHT SWITCH
3
I-011
220
R
B
8
L
E1 A32 A10
BCM E-072 B-043 I-005
C8 35
LG
15 B-048
LG
E-070
LG
8 6
REAR
FRONT RIGHT
POSI- RIGHT POSI-
COMBI-
TION HEADLIGHT TION
NATION
LIGHT E-034 LIGHT
LIGHT
1 1 B-016
B
E-031 B-018
3
E1
E-061 E-072 I-005 B-043

W L W
10 9 8 7 6 5 4 3 2 1 9 7 5 3 1 5 3 1 10 9 8 7 6
5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 11 10 8 6 4 2 6 4 2
B-048 E-034 B-016 I-011

W B B B
ET21350180

DTC Detection
Conditions
Right Park Light

B100411 Output Control Circuit
Right Park Light output  Position light bulb

Right Park Light

Output Control Circuit
B100419
Circuit Current Above
Threshold
35 HINT:
Diagnosis Procedure
1 Check position light bulb
a. Remove the position light bulb, and check if the position light bulb filament is blown.
NG Replace position light bulb
OK

c. Disconnect the front right headlight wire harness connector E-034 and rear right combination light wire
harness connector B-016.
d. Disconnect the body wire harness connector B-048 and engine compartment wire harness connector 
E-070.

connector
OK

3 Check right position light control circuit

B-043 and E-072.
+ -
Condition
B-043 (C8) - E1
E-072 (E1) E-072
RT21350660
35

Standard Condition
+ -
Condition
C1 C2 C3 C4 C5 C6 C7 C8 C9
ground
B-043

connector
RT21350670
OK

4 Check wire harness and connector (right position light - Body Control Module (BCM))

B-043.
+ -
d. Disconnect the front right headlight wire harness
connector E-034 and rear right combination light wire
harness connector B-016. C1 C2 C3 C4 C5 C6 C7 C8 C9
e. Disconnect the body wire harness connector B-048 and C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20

table below. 22 21 20 19 18 17 16 15 14 13 12 11
Standard Condition
B-048
35 Multimeter
Condition
Specified
RT21350680
B-043 (C8) -
Always Continuity
B-048 (15)

connector E-070 and terminal 8 of front right headlight
below. + -
Standard Condition
Multimeter Specified 1 2 3 4 5 6 7 8 9 10
Condition 11 12 13 14 15 16 17 18 19 20 21 22
E-070
E-070 (15) -
Always Continuity
E-034 (8)
9 7 5 3 1
10 8 6 4 2
E-034
RT21350690


rear right combination light wire harness connector B-016
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-043 (C8) -
B-016 (6)
5 3 1
6 4 2
B-016
RT21350700
i. Disconnect the body wire harness connector B-048

and engine compartment wire harness connector 
35
E-070.
terminal C8 of BCM connector B-043 and terminal 8 of + -
front right headlight wire harness connector E-034

according to the table below. C1 C2 C3 C4 C5 C6 C7 C8 C9
Standard Condition C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20

Condition
B-043 (C8) - 9 7 5 3 1
Always Continuity
E-034 (8) 10 8 6 4 2
E-034
connector
RT21350710
OK

5 Reconfirm DTCs

Result Precede to
No DTC is output OK

35
OK
System is normal

DTC B100813 Rear Fog Control Circuit Circuit Open
DTC B100871 Rear Fog Control Circuit Actuator Stuck

BATTERY
ENGINE
COMPARTMENT
FUSE AND
MF03 INSTRUMENT
RELAY BOX RF07 RF13
60A PANEL FUSE
E-061 7.5A 7.5A
AND RELAY BOX
I-007
7 13
35
RBr
RG
R
E1 A25 A9
BCM E-072 I-005 B-047 B-043 B-046
A20 A32 A5 C13 F1

WB
GL
LY
B
WB
WB
2 2 2
REAR REAR
RIGHT LEFT
COMBINATION FOG FOG
LIGHT LIGHT B-045
LIGHT 1 1
SWITCH B-037 B-028
B
I-011
FRONT REAR
FOG FOG
5 3
B
B-022
1 2 3 4 5 6 7 8 9 10 11 12 B-047
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 L
13 14 15 16 17 18 19 20 21 22 23 24
27 25 26
87 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 I-005
85 86 86 86 L
87 30 87 30 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16
30 85 85
I-007
3 C1 C2 C3 C4 C5 C6 C7 C8 C9 B-043
B 10 9 8 7 6
E1 F1 1 2 W
5 4 3 2 1 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
E-072 B-046 B-028 B-037 I-011

W E-061 B B B B
ET21350190

DTC Detection
Conditions
Rear Fog Control
B100813  Rear fog light bulb
Circuit Circuit Open
Rear Fog Control
B100871  Body Control Module (BCM)
Circuit Actuator Stuck
HINT:
Diagnosis Procedure
1 Check rear fog light bulb
a. Remove the rear fog light bulb, and check if the rear fog light bulb filament is blown.
35
NG Replace rear fog light bulb
OK

c. Disconnect the rear left fog light wire harness connector B-028 and rear right fog light wire harness
connector B-037.
f. Check if the related connector terminal contact pins are in good condition.

connector
OK

3 Check rear fog light control circuit

B-043 and E-072.
+ -
Condition
B-043 (C13) - E1
E-072 (E1) E-072
RT21350720
35

terminal C13 of BCM connector B-043 and body ground
to check if it is short to ground according to the table
below.
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-043 (C13) -
Always No continuity B-043
Body ground

connector
RT21350730
OK

4 Check wire harness and connector (rear fog light - Body Control Module (BCM))

B-043.
+ -
d. Disconnect the rear left fog light wire harness connector
B-028 and rear right fog light wire harness connector 
B-037. C1 C2 C3 C4 C5 C6 C7 C8 C9
e. Using a digital multimeter, check for continuity between C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
terminal C13 of BCM connector B-043 and terminal 2 of B-043

rear left fog light wire harness connector B-028 according
to the table below.
B-028
Condition
35 B-043 (C13) -
B-028 (2)

rear right fog light wire harness connector B-037
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-043 (C13) -
B-037 (2)
NG Repair or replace related wire harness and 1 2

connector
B-037
RT21350750
OK

5 Reconfirm DTCs

Result Precede to
DTC B100813 and B100871 are output NG
No DTC is output OK
NG Replace Body Control Module (BCM) 35

OK
System is normal

ON-VEHICLE SERVICE
LIGHTING SYSTEM
Headlight Adjustment Switch Assembly

Removal
7. Remove the headlight adjustment switch assembly.
a. Remove the headlight adjustment switch assembly
and wiper switch assembly wire harness connectors
(arrow).
35
RT21350060
b. Remove the combination switch assembly from steering column.

c. Press the claw (arrow) on wiper switch assembly, and
separates it from headlight adjustment switch
assembly.
RT21350070
d. Remove the headlight adjustment switch assembly.

Inspection
1. Check headlight adjustment switch assembly.
continuity between terminals as shown in the table.
+ -
Headlight Adjustment Switch Assembly (Position
Light/Low Beam Light/High Beam Light Switch)
6 7 8 9 10
1 2 3 4 5

Terminal 2 -
Switch OFF No continuity
Terminal 8
Terminal 2 - Switch in position RT21350080
220 Ω
Terminal 8 light
Terminal 2 - Switch in low
150 Ω
Terminal 8 beam
Terminal 2 - Switch in high
150 Ω
Terminal 9 beam
Terminal 2 - Switch in passing 35
330 Ω
Terminal 9 light
If result is not as specified, replace headlight

adjustment switch assembly.
b. Using ohm band of digital multimeter, check for

+ -
Headlight Adjustment Switch Assembly (Front Fog
Light/Rear Fog Light Switch)
6 7 8 9 10
1 2 3 4 5

Terminal 2 - Switch in front fog
Continuity
Terminal 5 light
Terminal 2 - Switch in rear fog RT21350080
Continuity
Terminal 3 light

c. Using ohm band of digital multimeter, check for

+ -
Headlight Adjustment Switch Assembly (Turn Signal
Light Switch)
6 7 8 9 10
1 2 3 4 5

Terminal 2 -
Switch in left turn 150 Ω
Terminal 10
Terminal 2 - Switch in right RT21350080
330 Ω
Terminal 10 turn


Installation
CAUTION
 Always install spiral cable correctly according to the specified operating instructions.
 Check that the horn operates normally after installation.
 Check SRS warning light after installation, and make sure that supplemental restraint system operates
normally.
35

Combination Light Adjustment Switch

Removal
3. Remove the combination light adjustment switch.
both ends of combination light adjustment switch
carefully to remove it.
RT21440120
b. Disconnect the combination light adjustment switch 35

wire harness connectors (arrow).
RT21350090
c. Remove the combination light adjustment switch.

Inspection
1. Check combination light adjustment switch (headlight leveling switch).
a. Turn digital multimeter to ohm band, and connect red
probe of multimeter to terminal 1, and black probe to
+ -
terminal 2.
Observe resistance change on the digital multimeter 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
while turning the headlight leveling switch to each
position.
Switch Position
Connection Condition (KΩ)
Terminal 1 -
0 1.297 RT21350100
Terminal 2
Terminal 1 -
1 1.808
Terminal 2
Terminal 1 -
2 2.735
Terminal 2
35 Terminal 1 -
3 3.945
Terminal 2
If result is not as specified, replace combination light

adjustment switch.
2. Check combination light adjustment switch (backlight switch).
a. Connect positive battery lead to terminal 6 and
+ -
negative battery lead to terminal 8 of combination light
adjustment switch. Check if the backlight comes on.
Observe if the backlight brightness changes gradually 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
while turning the backlight switch.
OK: Comes on and changes gradually.
RT21350110
b. Connect positive battery lead to terminal 7 and

+ -
negative battery lead to terminal 8 of combination light
adjustment switch. Check if the backlight comes on.
1 2 3 4 5 6 7 8
OK: Comes on. 9 10 11 12 13 14 15 16
If result is not as specified, replace combination light

adjustment switch.
RT21350110
Installation

Headlight Assembly
Removal
HINT:
Use the same procedures for the right side and left side.
Procedures listed below are for the left side.
5. Remove the headlight assembly.
a. Remove 3 fixing bolts (arrow) from headlight
assembly.
35
RT21350120
b. Move the headlight assembly along vehicle driving

direction, and detach the fixing clip (arrow) between
headlight assembly and mounting bracket.
RT21350130
c. Disconnect the headlight assembly wire harness

connector (arrow), and remove the headlight
assembly.
RT21350140

Installation
CAUTION
 When installing headlight assembly, make sure the fitting clearance between headlight and hood, front
fender, front bumper is appropriate. Adjust as necessary.
Adjustment
1. Preparations:
a. Tire inflation pressure comes up to standard.
b. Vehicle is unloaded (besides spare tire and tool kit, it is generally specified to include the weight of
driver).
c. Park vehicle on a level ground or a workplace.
d. Keep lens surface of headlight free from dirt.
e. Check if power supply operates normally and bulbs are installed correctly.
35 f. Headlight beam can be adjusted up and down, left and right by using headlight leveling switch or
adjustment area at the rear of headlight. Always perform adjustment according to the international
standard.
No. Item Standard

Reference center height of headlight
1 H = 903 mm
low beam
Up and down offset of left/right low Adjust center: 0.85H = 768 mm
2
beam Adjust range: 0.8H - 0.9H = 722 - 813 mm
Left offset no more than 170 mm, right offset no more
3 Left and right offset of left low beam
than 350 mm
Left and right offset of right low Left offset no more than 170 mm, right offset no more
4
beam than 350 mm
Left offset no more than 170 mm, right offset no more
5 Left and right offset of left high beam
than 350 mm
Left and right offset of right high Left offset no more than 350 mm, right offset no more
6
beam than 350 mm
7 High beam light intensity ≥ 39000 cd

2. Headlight leveling can be adjusted according to the

number of passengers and loading condition. There are 4 3
adjustment bands to select on headlight leveling knob: 0, 2
1, 2 and 3.
1
Turn up: Rise headlight beam.
Turn down: Lower headlight beam. O
Adjust the light according to the table below.
Occupant and Luggage Loading

Condition
Knob Position RT21350150
Luggage
Occupant
Loading
Driver None 0
Driver + Front
None 0
Passenger
Full Occupied None 1
Full Luggage
Full Occupied 2
Loading 35
Full Luggage
Driver 3
Loading
CAUTION
 Whether headlight leveling is correct or not will directly affects driving safety. Be sure to adjust it
according to the related specification.
3. Manual headlight leveling: the headlight leveling can be changed by adjusting the following areas manually
Adjustment method for left headlight
a. Low beam left/right adjustment
When rotating the screwdriver clockwise, the beam
move to left; when rotating the screwdriver
counterclockwise, the beam move to right.
RT21350160
b. Low beam up/down adjustment

move downward; when you rotating the screwdriver
counterclockwise, the beam move upward.
RT21350170

c. High beam left/right adjustment

RT21350180
d. High beam up/down adjustment

move upward; when rotating the screwdriver
counterclockwise, the beam move downward.
35
RT21350190
Adjustment method for right headlight

a. Low beam left/right adjustment
RT21350200
b. Low beam up/down adjustment

move downward; when you rotating the screwdriver
counterclockwise, the beam move upward.
RT21350210

c. High beam left/right adjustment

RT21350220
d. High beam up/down adjustment

move upward; when rotating the screwdriver
counterclockwise, the beam move downward.
35
RT21350230

Rear Combination Light Assembly (Fixed Part)

Removal
HINT:
 Procedures listed below are for rear left combination light.
3. Remove the rear combination light assembly (fixed part).
tape, pry up and remove the rear combination light
service cover.
35
RT21490153
b. Disconnect the rear combination light assembly (fixed

part) wire harness connector (arrow), and detach the
wire harness fixing clip.
RT21350240
c. Remove 2 fixing screws (arrow) from outer part of rear

combination light assembly (fixed part).
RT21350250

d. Remove 2 fixing nuts (arrow) from inner part of rear

combination light assembly (fixed part), and detach
the inner fixing clip.
(Tightening torque: 4.5 ± 1 N·m)
RT21350260
e. Remove the rear combination light assembly (fixed part).
Installation
CAUTION
 When installing rear combination light assembly, make sure the fitting clearance between rear 35
combination light assembly and back door, rear bumper is appropriate. Adjust it as necessary.

Rear Combination Light Assembly (Movable Part)

Removal
HINT:
3. Remove the rear combination light assembly (movable part).
tape, pry up and remove the rear left combination light
service cover on back door.
35
RT21350270
b. Disconnect the rear combination light assembly

(movable part) wire harness connector (arrow), and
detach the wire harness fixing clip.
RT21350280
c. Remove 3 fixing nuts (arrow) from rear combination

light assembly (movable part).
RT21350290
d. Remove the rear combination light assembly (movable part).

Installation
CAUTION
 When installing rear combination light assembly, make sure the fitting clearance between rear
combination light assembly and back door, rear bumper is appropriate. Adjust it as necessary.
35

Front Fog Light Assembly

Removal
HINT:
3. Remove the front wheel house protector assembly (See page 48-24).
4. Remove the front fog light assembly.
a. Disconnect the front fog light assembly wire harness
connector (arrow).
35
RT21350300
b. Remove 3 fixing crews (arrow) from front fog light

assembly.
RT21350310
c. Remove the front fog light assembly.
Installation

Rear Fog Light & Reflector Assembly

Removal
HINT:
3. Remove the rear bumper assembly (See page 48-30).
4. Remove the rear fog light & reflector assembly.
a. Disconnect the rear fog light & reflector assembly wire
35
RT21350320
b. Remove 4 fixing crews (arrow) from rear fog light &

reflector assembly.
RT21350330
c. Remove the rear fog light & reflector assembly.
Installation

Front Dome Light Assembly

Removal
3. Remove the front dome light assembly.
a. Open the glasses box in the direction of arrow as
RT21490250
35 b. Using a flat tip screwdriver wrapped with protective

tape, remove the front dome light assembly cover.
RT21490260
c. Remove 3 fixing crews (arrow) from front dome light

assembly.
RT21490270
d. Disconnect the front dome light assembly wire

RT21490280
e. Remove the front dome light assembly.

Inspection
1. Check front dome light assembly.
continuity between terminals of front dome light
+ -
assembly as shown in the table. 2 1
6 5 4 3
Switch Position
Terminal 1 -
Switch pushed Continuity
Terminal 2
Terminal 1 -
Switch released No continuity
If result is not as specified, replace front dome light

assembly.
Installation
35

Rear Dome Light Assembly

Removal
3. Remove the rear dome light assembly.
tape, remove the rear dome light assembly cover.
RT21490290
35 b. Remove 2 fixing screws (arrow) from rear dome light

assembly.
RT21490300
c. Disconnect the rear dome light assembly wire harness

connector (arrow).
RT21490310
d. Remove the rear dome light assembly.

Inspection
1. Check rear dome light assembly.
a. Connect battery positive (+) to terminal 2 of rear dome
+ -
light assembly, and battery negative (-) to terminal 1.
Check operation of rear dome light when turn rear
1 2
dome light assembly switch to ON, OFF and DOOR
position.
Standard Condition:
Switch ON: Does not come on.
Switch OFF: Does not come on.
Switch DOOR: Comes on.
If result is not as specified, replace rear dome light RT21350350
assembly.
Installation
35


Removal
3. Remove the front door protector assembly. (See page 47-23).
4. Remove the front door courtesy light.
a. Disconnect the front door courtesy light wire harness
connector (arrow).
35
RT21350360
b. Turn the front door courtesy light counterclockwise,

and remove it from front door protector assembly.
RT21470311
Installation

High Mounted Stop Light Assembly

Removal
3. Remove the back door protector assembly (See page 47-47).
4. Remove the high mounted stop light assembly.
a. Disconnect the high mounted stop light assembly wire
RT21350370
35
b. Remove the rear spoiler assembly (See page 48-43).
c. Remove 3 fixing nuts (arrow) from high mounted stop
light assembly.
RT21480542
d. Remove the high mounted stop light assembly from rear spoiler assembly.
Installation

License Plate Light Assembly

Removal
3. Remove the license plate light assembly.
tape, pry out the license plate light assembly.
RT21350380
35 b. Disconnect the license plate light assembly wire

RT21350390
c. Remove the license plate light assembly.
Installation

Luggage Compartment Light Assembly

Removal
3. Remove the luggage compartment light assembly.
tape, pry out the luggage compartment light assembly
cover (right side).
RT21490162
b. Disconnect the luggage compartment light assembly 35

wire harness connector (arrow).
RT21490163
c. Remove the luggage compartment light assembly.
Installation

Back-up Light Switch Assembly

Removal
1. Remove the back-up light switch assembly.
a. Stop the vehicle on a lifter, and support it with the lifter.
b. Turn off all the electrical equipment and ignition switch.
c. Disconnect the negative battery cable.
d. Raise the vehicle with the lifter.
WARNING
 Bear sure to wear necessary safety equipments to avoid accidents.

e. Disconnect the back-up light switch assembly wire harness connector (arrow).
f. Remove the back-up light switch assembly (1).
35
RT21350400
HINT:
Transmission oil may flow out when removing back-up light switch assembly. Use a container to collect the
oil.
 Drained transmission oil should be collected with a recovering tool.
Inspection
1. Check back-up light switch assembly.
continuity between terminals of back-up light switch
+ -
assembly as shown in the table.
Switch Position
Terminal 1 -
Terminal 2
Terminal 1 -

Installation
1. Apply thread locker to the threads of back-up light, and clean the transmission oil on the area between
transmission and back-up light switch assembly before installing the back-up light switch assembly. Then
install and tighten the back-up light switch.
2. Check if the transmission oil level is in the proper position after installation.
a. It is not necessary to do anything, if it is in the proper position.
b. It is necessary to fill transmission oil to the specified position, if it is not in the proper position (fill the oil
until it flows out of retaining plug).
35

Hazard Warning Light Switch

Removal
4. Remove the hazard warning light switch.
a. Disconnect the hazard warning light switch wire
A/C
RT21350420
35
b. Press the claws (arrow) on both ends of the hazard
warning light switch by hand, and push outward
forcefully to remove it.
A/C
RT21350430
Inspection
1. Check hazard warning light switch.
continuity between terminals of hazard warning light
+ -
switch as shown in the table.
4 1
5 2
Multimeter Switch Specified 6 3

Terminal 1 -
Terminal 2
Terminal 1 -
If result is not as specified, replace hazard warning light

switch.

2. Check hazard warning light switch illumination.

a. Connect positive (+) battery lead to terminal 3 and
-
negative (-) battery lead to terminal 5, then check that +
the switch illumination comes on.

OK: LED comes on. 4
5
1
2
6 3
negative (-) battery lead to terminal 5, then check that
the switch illumination comes on.
OK: LED comes on.
If result is not as specified, replace hazard warning light
switch. RT21350450
Installation
35

- MEMO -

WIPER AND WASHER
Specifications 36-5 Front Washer Nozzle Assembly 36-29
Circuit Diagram 36-6 Inspection 36-29
Installation 36-30
Rear Wiper Arm Assembly 36-31
Removal 36-31
Diagnosis Tools 36-9
Installation 36-32
Rear Wiper Motor Assembly 36-33
Removal 36-33
Inspection 36-34
Installation 36-34
Diagnostic Trouble Code (DTC) 
Rear Washer Nozzle Assembly 36-35
Chart 36-12
Removal 36-35
B101471 36-13
Inspection 36-35
B101571 36-13
Installation 36-36
36
B101671 36-13
Washer Pump Assembly 36-37
B101713 36-13
Removal 36-37
B101771 36-13
Installation 36-38
B101813 36-13
Inspection 36-38
B101871 36-13
Washer Fluid Reservoir Assembly 36-39
Wiper Switch Assembly 36-22 Inspection 36-40
Inspection 36-23 Washer Line Assembly 36-41
Front Wiper Arm Assembly 36-24 Installation 36-42
Removal 36-24 Rain Gutter Rail Reinforcement 
Front Wiper Motor Assembly 36-26 Removal 36-43

36

36 - WIPER AND WASHER
GENERAL INFORMATION
WIPER AND WASHER
Description
4
1
2
3
5
6
×3
36
9
10
7
8
11
12
14
×12
13
17 ×2
15 ×3
18
×4
16
19
20
21
RT21360010

1 - Rear Wiper Arm Trim Cap 2 - Rear Wiper Arm Assembly

3 - Rear Wiper Arm Blade 4 - Rear Washer Nozzle Assembly
5 - Rear Wiper Motor Assembly 6 - Grommet
7 - Sub Wiper Arm Blade 8 - Sub Wiper Arm Assembly
9 - Main Wiper Arm Blade 10 - Main Wiper Arm Assembly
11 - Front Wiper Arm Trim Cap 12 - Front Windshield Lower Garnish Assembly
13 - Front Washer Nozzle Assembly 14 - Wiper Link Rod
15 - Front Wiper Motor Assembly 16 - Rain Gutter Rail Reinforcement Assembly
17 - Washer Line Assembly 18 - Guide Pipe Assembly
19 - Washer Fluid Reservoir Assembly 20 - Front Washer Pump
21 - Rear Washer Pump
Wiper and washer are important equipment for cleaning the windshield assembly. Wiper and washer systems
are controlled by wiper switch assembly, which can be operated only when the ignition switch is turned to ON.
Driver controls all operations of wiper and washer by moving switch control lever.
36

Specifications

Front Wiper Arm Assembly Fixing Nut 18 ± 2
Wiper Motor and Link Rod Assembly Fixing Bolt 10 ± 1
Front Wiper Motor Assembly Fixing Screw 10 ± 1
Front Wiper Motor Assembly Fixing Nut 10 ± 1
Rear Wiper Arm Assembly Upper Fixing Nut 10 ± 1
Rear Wiper Motor Assembly Fixing Bolt 10 ± 1
Guide Pipe Assembly Fixing Bolt 7±1
Washer Fluid Reservoir Assembly Fixing Bolt 7±1
Brake Fluid Reservoir Assembly Fixing Nut 9±1
Rain Gutter Rail Reinforcement Assembly Fixing Bolt 10 ± 1
Tool 36
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Wiper and Washer Systems (Page 1 of 2)

BATTERY
BCM POWER INSTRUMENT

MF03 SUPPLY RF07 RF13 PANEL FUSE
60A E-061 7.5A 7.5A AND RELAY BOX A
I-007
3 7 13
RBr
RG
R
E1 A25 A9
BCM E-071 I-005 B-043 B-047
36 B02 C15 C17 C1 C10 B18 C14
RGr
GBr
GW
WR
Br
B-048 5 10 9 7 8 B-012 1 12
E-070 T-004
RGr
GBr
GW
WR
G
G
Br
1 1 2 3
3 2
LOW REAR
REAR FRONT
WASHER WIPER
WASHER
HIGH 1 M MOTOR M M MOTOR
M MOTOR
E-040 T-007
FRONT E-039
WIPER
TS MOTOR
2 2 1
E-077
B
4 T-004
11 B-012
B
E-078 E-032 B-018
1 2 3 4 5 6 7 8 B-012
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 9 10 11 12 13 14 15 W T-007
1 2 3
7 8 9 10 11 12 13 14 13 14 15 16 17 18 19 20 21 22 23 24 W
27 25 26 I-007
E-071 87 B
B 85 86 86 86
87 30 87 30
30 85 85 1 2 3 4
3
E-061 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 I-005
L E-077
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 B
1 2 E-039
C1 C2 C3 C4 C5 C6 C7 C8 C9 B-043 10 9 8 7 6 5 4 3 2 1 B-048
Gr
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 W 22 21 20 19 18 17 16 15 14 13 12 11 W
E-040 B-047
1 2 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16
Gr L
ET21360010

Wiper and Washer Systems (Page 2 of 2)
B
3
WIPER/WASHER FRONT WIPER SW

(AUTO RETURN) (AUTO RETURN)
WIPER
AUTO MIST
ON OFF
RETURN
OFF
INT
WIPER
WIPER/WASHER LO
(AUTO RETURN) WIPER
150
220
330
HI
68
SWITCH
FRONT WASHER SW
WIPER/WASHER
I-014
(AUTO RETURN)
(AUTO RETURN)
MIST
WIPER
ON OFF
INT
INT SW
OFF
LO
WIPER
WIPER/WASHER
(AUTO RETURN)
HI
36
4 10 7 9 1 2
B-045
BG
LW
Gr
B
L
A18 A11 A22 A6 A4 A19 A32 F1
BCM I-005 B-046
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 5 4 3 2 1 B-046
I-005 I-014
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 L 10 9 8 7 6 B F1 B
ET21360020

DIAGNOSIS & TESTING

HINT:

Wiper switch assembly 36-22
Front wiper motor assembly 36-26
Both front wiper and washer systems do
Front washer pump 36-37
not operate
BCM -
Front wiper system does not operate in LO Front wiper motor assembly 36-26
or HI
36 BCM -
Front wiper system does not operate in INT
BCM -
Front wiper system does not operate
BCM -
Front wiper arm and blade do not return to
original position when front wiper switch is BCM -
off
Rear wiper motor assembly 36-33
Both rear wiper and washer systems do not
Rear washer pump assembly 36-37
operate
BCM -
Rear wiper motor assembly 36-33
Rear wiper system does not operate
BCM -


Rear washer nozzle assembly 36-35
Rear washer system does not operate Rear washer pump assembly 36-37
BCM -
Diagnosis Tools
When connecting the X-431 3G diagnostic tester:
 Connect the X-431 3G diagnostic tester (the latest software) to the Data Link Connector (DLC) for
communication with vehicle.
 DLC is located on the driver side instrument panel crossmember.
 DLC uses a trapezoidal design which can hold 16 terminals.
Digital Multimeter
When using the digital multimeter: 36
 Troubleshoot the electrical malfunctions and wire harness system.
 Look for the basic fault.
 Measure the voltage, current and resistance.

Confirm that the battery voltage is normal before performing the following procedures.
 Connect the X-431 3G diagnostic tester (the latest software) to the Data Link Connector (DLC), and make
it communicate with the vehicle electronic module by data network.
 Using the X-431 3G diagnostic tester to record and clear the DTCs stored in Body Control Module (BCM).
 Turn ignition switch ON, and then select "Read Code".
 If no DTC is detected, the malfunction indicated by the DTC is intermittent. Please refer to the Intermittent


If the malfunction is intermittent, perform the followings:
 Wiggle the related wire harnesses and connectors and observe if the signal is interrupted in the related
circuit.
 Inspect the mounting areas of wiper motor assembly, wire harness or wire harness connector and so on for
 Check and clean all the wire harness connectors and grounding parts related to the current DTC.
 Remove the Body Control Module (BCM) from the malfunctioning vehicle and install it to a new vehicle and
perform a test. If the DTC cannot be cleared, the Body Control Module (BCM) is malfunctioning. If the DTC
can be cleared, reinstall the Body Control Module (BCM) to the original vehicle.
 Refer to the Technical Bulletin that is applied to the malfunction.
36
Ground Inspection
Ground points are very important to the entire circuit system, and the grounding condition can seriously affect
the entire circuit system. Ground points are often exposed to moisture, dirt and other corrosive environments.
Corrosion (rust) and oxidation can increase load resistance. This situation will seriously affect the normal
operation of circuit. Operations to check the ground points are as follows:
2. Check all the matching surfaces for tarnish, dirt, rust, etc.
5. Check if the add-on accessories interfere with the ground circuit.
sure all the wire harnesses are clean, securely fastened and providing a good ground path.
Diagnosis Procedure
HINT:
Use the following procedures to troubleshoot the wiper and washer systems.
NEXT
NEXT

NEXT
DTC
occurs
No 
DTC
NEXT
36
NEXT
NEXT
8 Adjust, repair or replace
NEXT
9 Conduct test and confirm malfunction has repaired
NEXT
10 End


B101471 Front Wiper Lo Control Circuit Actuator Stuck
B101571 Front Wiper HI Control Circuit Actuator Stuck
B101671 Rear Wiper Control Circuit Actuator Stuck
B101713 Front Washer Control Circuit Circuit Open
B101771 Front Washer Control Circuit Actuator Stuck
B101813 Rear Washer Control Circuit Circuit Open
B101871 Rear Washer Control Circuit Actuator Stuck
36

DTC B101471 Front Wiper Lo Control Circuit Actuator Stuck
DTC B101571 Front Wiper HI Control Circuit Actuator Stuck
DTC B101671 Rear Wiper Control Circuit Actuator Stuck
DTC B101713 Front Washer Control Circuit Circuit Open
DTC B101771 Front Washer Control Circuit Actuator Stuck
DTC B101813 Rear Washer Control Circuit Circuit Open
DTC B101871 Rear Washer Control Circuit Actuator Stuck

36
Condition Condition
Front Wiper Lo Control
B101471
 Wiper switch
Front Wiper HI Control assembly
B101571
 Front wiper motor
Rear Wiper Control assembly
B101671
Circuit Actuator Stuck  Front washer pump
Front Washer Control  Rear wiper motor
B101713 Ignition switch ON ON
Circuit Circuit Open assembly
Front Washer Control  Rear washer pump
B101771
Circuit Actuator Stuck  Wire harness or
connector
Rear Washer Control
B101813  Body Control
Circuit Circuit Open
Module (BCM)
Rear Washer Control
B101871
CAUTION
 When performing circuit diagnosis and test, always refer to circuit diagram for specific circuit and

Diagnosis Procedure
1 Check wiper switch assembly
a. Remove the wiper switch assembly from malfunctioning vehicle, and install it to a new vehicle to perform a
test.
NG Replace wiper switch assembly
OK
2 Check front wiper motor assembly
a. Remove the front wiper motor assembly from malfunctioning vehicle, and install it to a new vehicle to
perform a test.
NG Replace front wiper motor assembly
OK
36
3 Check rear wiper motor assembly
a. Remove the rear wiper motor assembly from malfunctioning vehicle, and install it to a new vehicle to
perform a test.
NG Replace rear wiper motor assembly
OK
4 Check front washer pump
a. Remove the front washer pump from malfunctioning vehicle, and install it to a new vehicle to perform a
test.
NG Replace front washer pump
OK
5 Check rear washer pump
a. Remove the rear washer pump from malfunctioning vehicle, and install it to a new vehicle to perform a test.
NG Replace rear washer pump
OK


c. Disconnect the instrument panel wire harness connectors
I-005 and I-014.
+ -
instrument panel wire harness connectors I-005 and 
I-014 according to the value(s) in the table below.
Multimeter Specified A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16

Condition
Connection Condition I-005
I-005 (A18) -
Always Continuity
I-014 (4) 5 4 3 2 1
10 9 8 7 6
I-005 (A11) -
Always Continuity
I-014 (10) I-014
I-005 (A22) -
Always Continuity
I-014 (7) RT21360400
I-005 (A6) -
Always Continuity
36
I-014 (9)
I-005 (A4) -
Always Continuity
I-014 (1)
I-005 (A19) -
Always Continuity
I-014 (2)
I-005 (A32) -
Always Continuity
I-014 (3)

OK


c. Disconnect the body wire harness connectors B-043 and
B-048.
+ -
body wire harness connectors B-043 and B-048
according to the value(s) in the table below.
C1 C2 C3 C4 C5 C6 C7 C8 C9
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
Condition
B-043 (C15) -
Always Continuity 10 9 8 7 6 5 4 3 2 1
B-048 (10) 22 21 20 19 18 17 16 15 14 13 12 11
B-043 (C17) -
Always Continuity
B-048 (9) B-048
B-043 (C1) -
Always Continuity
B-048 (7) RT21360410
36 B-043 (C10) -
Always Continuity
B-048 (8)
e. Disconnect the body wire harness connectors B-047 and

B-012.
according to the value(s) in the table below. + -
Multimeter Specified B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32
Condition
Connection Condition B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16
B-047 (B18) - B-047

Always Continuity
B-012 (1)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
B-012
RT21360420

g. Disconnect the body wire harness connectors B-043 and

B-012.
Connection Condition C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-043 (C14) - B-043

Always Continuity
B-012 (12)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
B-012
RT21360430
i. Disconnect the body wire harness connector B-012 and

ground B-018.
j. Using a digital multimeter, check for continuity between 36
body wire harness connector B-012 and ground B-018
Condition
Connection Condition 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
B-012 (11) -
Always Continuity
B-018
B-012
B-018
RT21360440
k. Disconnect the body wire harness connector B-046 and

ground B-045.
Condition F1
B-046
B-046 (F1) -
Always Continuity
B-045

connector
B-045
RT21360450

OK
8 Check engine compartment wire harness and connector

c. Disconnect the engine compartment wire harness
connectors E-069 and E-077.
+ -
engine compartment wire harness connectors E-069 and
E-077 according to the value(s) in the table below. F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
Condition
E-069 (F5) -
Always Continuity
E-077 (3)
E-069 (F10) -
E-077 (2)
36 E-069 (F9) - E-077
Always Continuity
E-077 (1) RT21360460
e. Disconnect the engine compartment wire harness

E-040 according to the value(s) in the table below. + -
Condition
Connection Condition F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
E-069 (F7) - F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
Always Continuity
E-040 (1)
E-069
1 2
E-040
RT21360470

g. Disconnect the engine compartment wire harness

E-039 according to the value(s) in the table below. + -
Condition
Connection Condition F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
E-069 (F8) - F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
Always Continuity
E-039 (1)
E-069
1 2
E-039
RT21360480
i. Disconnect the engine compartment wire harness

connector E-077 and ground E-078.
j. Using a digital multimeter, check for continuity between 36
engine compartment wire harness connector E-077 and
ground E-078 according to the value(s) in the table + -
below.
Condition 1 2 3 4
E-077 (4) - E-078 Always Continuity E-077
E-078
RT21360490
k. Disconnect the engine compartment wire harness

below.
1 2
Condition
E-040
E-040 (2) - E-032 Always Continuity
E-032
RT21360500

m. Disconnect the engine compartment wire harness

below.
1 2
Condition
E-039

E-032
RT21360510
OK
36
9 Check back door wire harness and connector

c. Disconnect the back door wire harness connectors T-004
and T-007.
+ -
back door wire harness connectors T-004 and T-007
according to the value(s) in the table below.
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
Condition T-004
T-004 (1) - T-007
Always Continuity
(2)
1 2 3
T-004 (12) - T-007

Always Continuity T-007
(3)
T-004 (11) - T-007
Always Continuity
(1) RT21360520
NG Repair or replace back door wire harness

and connector
OK

10 Reconfirm DTCs
a. Connect all connectors.

d. Use the X-431 3G diagnostic tester (the latest software) to record and clear the DTCs stored in Body
g. Use the X-431 3G diagnostic tester (the latest software) to read DTCs stored in Body Control Module
(BCM) again.
h. Read DTCs.
Result Precede to
DTCs B101471, B101571, B101671, B101713,
NG
B101771, B101813, B101871 are output
No DTCs are output OK
36
OK

ON-VEHICLE SERVICE
Wiper Switch Assembly
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing wiper switch assembly.
 Appropriate force should be applied when removing wiper switch assembly. Be careful not to operate
roughly.
 Try to prevent interior and body paint surface from being scratched when removing wiper switch
assembly.

3. Remove the instrument cluster (See page 38-42).
36 4. Remove the wiper switch assembly.
a. Disconnect the wiper switch assembly connector
(arrow).
RT21360020
b. Using a screwdriver wrapped with protective tape,

press the claws of wiper switch assembly and remove
the wiper switch assembly by gently sliding outward.
RT21360030

Inspection
1. Check wiper switch assembly.
a. Using a digital multimeter, check for continuity
between terminals of wiper switch assembly
+ -
AR
RE
Terminal 1 - 1 2 3 4 5
MIST Continuity 6 7 8 9 10
Terminal 3
Terminal 2 -
INT Continuity
Terminal 1 -
LO Continuity
Terminal 3
Terminal 1, 2 -
HI Continuity
Terminal 3
Terminal 3 -
FRONT WASHER Continuity
Terminal 4
Terminal 3, 7 -
REAR WASHER Continuity
36
Terminal 9
If result is not as specified, replace wiper switch

assembly.
Installation
CAUTION
 Always operate carefully to prevent components from being damaged when installing wiper switch
assembly.
 Install connector in place when installing wiper switch assembly.
 Check wiper switch for proper operation after installing wiper switch assembly.

Front Wiper Arm Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing front wiper arm assembly.
 Appropriate force should be applied when removing front wiper arm assembly. Be careful not to operate
roughly.
 Try to prevent front windshield assembly from being scratched when removing front wiper arm assembly.

3. Remove the front wiper arm blade.
a. Lift up the front wiper arm assembly in the direction of
36
RT21360050
b. Pull the front wiper arm blade out of front wiper arm
illustration.
RT21360060
4. Remove the front wiper arm assembly.

remove the front wiper arm trim caps (1). 1
b. Remove 2 fixing nuts (arrow) from front wiper arm

assembly and remove the front wiper arm assembly.
RT21360070

Installation
CAUTION
 Always operate carefully to prevent other components from being damaged when installing front wiper
arm assembly.
 Make sure to tighten fixing nuts to the specified torque when installing front wiper arm assembly.
 Check front wiper arm assembly for proper operation after installation.
HINT:
 Always adjust the front wiper arm assembly to the proper
position during installation.
 Pay attention to the locating point on front windshield
assembly during assembly. Wiper arm blade should be
pressed against the locating point as shown in the
illustration.
36
RT21360080

Front Wiper Motor Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing front wiper motor assembly.
 Appropriate force should be applied when removing front wiper motor assembly. Be careful not to
operate roughly.
 Try to prevent body paint surface from being scratched when removing front wiper motor assembly.

3. Remove the front wiper arm assembly (See page 36-24).
4. Remove the front windshield lower garnish assembly (See page 48-39).
5. Remove the wiper motor and link rod assembly.
a. Disconnect the connector (1) from wiper motor and
link rod assembly.
36
b. Remove 3 fixing bolts (arrow) from wiper motor and
link rod assembly.
1
c. Remove the wiper motor and link rod assembly.
RT21360090
6. Remove the front wiper motor assembly.

a. Remove 3 fixing bolts (arrow) from front wiper motor
assembly.
b. Remove the fixing nut (1) from front wiper motor
assembly.
RT21360100
c. Using a screwdriver wrapped with protective tape,

separate the front wiper motor assembly and wiper
link rod.
RT21360101

Inspection
1. Check front wiper motor assembly.
a. Check LO operation.
Measurement Condition Specified Condition

Battery positive (+) → Terminal 2
Motor running at low speed (LO)
Battery negative (-) → Terminal 4
If result is not as specified, replace front wiper motor assembly.

b. Check HI operation.

Motor running at high speed (HI)

c. Check auto reset function.
 Connect positive (+) battery lead to terminal 1 or 2
and negative (-) battery lead to terminal 4. When + -
motor is running at low speed (LO) or high speed

(HI), disconnect battery positive (+) to stop the 1 2 3 4 36
front wiper motor at any position other than the
original position.
 Connect terminals 2 and 3 with a lead, using
another lead extracted from lead between
terminals 2 and 3 to connect battery positive (+),
and connect negative (-) battery lead to terminal 4
to run the motor to the original position at low RT21360110
speed (LO).
 Check if front wiper motor assembly can stop automatically after running to the original position.
OK: Motor stops automatically after running to the original position, which indicates that the
motor can reset automatically.
2. Check wiper link rod.
a. Check the rotation shaft (1) for looseness or falling off,
link rod (2) for deformation or break, and shaft sleeve
(3) for sticking. Replace wiper link rod if necessary. 3
2
RT21360120

Installation
CAUTION
 Always operate carefully to prevent other components from being damaged when installing front wiper
motor assembly.
 Adjust and make sure wiper motor and wiper link rod are at the original position before installing front
wiper motor assembly. Otherwise, wiper system will not operate normally.
 Install connector in place and tighten fixing bolts and nuts to the specified torque when installing front
wiper motor assembly.
 Check wiper system for proper operation after installing front wiper motor assembly.
36

Front Washer Nozzle Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing front washer nozzle assembly.
 Appropriate force should be applied when removing front washer nozzle assembly. Be careful not to
operate roughly.

3. Remove the front washer nozzle assembly.
a. Loosen the front washer nozzle assembly in the
36
RT21360130
b. Disconnect the joint (arrow) between washer line and

front washer nozzle assembly, and remove the front
washer nozzle assembly.
RT21360140
Inspection
1. Check front washer nozzle assembly.
a. Check front washer nozzle for blockage, deformation
or damage. Replace front washer nozzle if necessary.
RT21360150

Installation
CAUTION
 Always operate carefully to prevent components from being damaged when installing front washer
nozzle assembly.
 Install washer line joint in place when installing front washer nozzle assembly.
 Check front washer nozzle for proper operation after installing front washer nozzle assembly.
36

Rear Wiper Arm Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rear wiper arm assembly.
 Appropriate force should be applied when removing rear wiper arm assembly. Be careful not to operate
roughly.
 Try to prevent rear windshield assembly from being scratched when removing rear wiper arm assembly.

3. Remove the rear wiper arm blade.
a. Lift up the rear wiper arm assembly in the direction of
36
RT21360170
b. Pull the rear wiper arm blade out of rear wiper arm
illustration.
RT21360180
4. Remove the rear wiper arm assembly.

remove the rear wiper arm trim cap (1).
b. Remove 2 fixing nuts (2) from rear wiper arm
assembly. 1
RT21360190
c. Remove the rear wiper arm assembly.

Installation
CAUTION
 Always operate carefully to prevent other components from being damaged when installing rear wiper
arm assembly.
 Make sure to tighten fixing nuts to the specified torque when installing rear wiper arm assembly.
 Check rear wiper arm assembly for proper operation after installation.
36

Rear Wiper Motor Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rear wiper motor assembly.
 Appropriate force should be applied when removing rear wiper motor assembly. Be careful not to operate
roughly.
 Try to prevent body paint surface from being scratched when removing rear wiper motor assembly.

3. Remove the rear wiper arm assembly (See page 36-31).
5. Remove the rear wiper motor assembly.
a. Disconnect the rear wiper motor assembly connector
(1).
36
b. Remove 3 fixing bolts (arrow) from rear wiper motor
assembly.
RT21360200
c. Remove the rear wiper motor assembly.

d. Using a screwdriver wrapped with protective tape, pry
up the grommet (arrow).
RT21360210

Inspection
1. Check rear wiper motor assembly.
a. Check operation of rear wiper motor assembly.

Motor runs normally
If result is not as specified, replace rear wiper motor assembly.

b. Check auto reset function.
 Connect positive (+) battery lead to terminal 3 and
-
negative (-) battery lead to terminal 1. When motor +
is running, disconnect battery negative (-) to stop

rear wiper motor at any position other than the
1 2 3
automatic stop position.
 Connect positive (+) battery lead to terminal 3 and
negative (-) battery lead to terminal 2 to make the
motor run again.
36 RT21360221
 Check that motor can reset automatically.

OK: Motor can reset automatically.
If result is not as specified, replace rear wiper motor assembly.
2. Check grommet for deterioration, deformation or damage. Replace grommet if necessary.
Installation
CAUTION
 Always operate carefully to prevent other components from being damaged when installing rear wiper
motor assembly.
 Tighten fixing bolts to the specified torque when installing rear wiper motor assembly.
 Check wiper system for proper operation after installing rear wiper motor assembly.

Rear Washer Nozzle Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rear washer nozzle assembly.
 Appropriate force should be applied when removing rear washer nozzle assembly. Be careful not to
operate roughly.

4. Remove the rear spoiler assembly (See page 48-43).
5. Remove the rear washer nozzle assembly.
a. Disconnect the joint (arrow) between washer line and
rear washer nozzle assembly.
36
RT21360220
b. As shown in the illustration, press the rear washer

nozzle assembly claws (arrow) and remove the rear
washer nozzle assembly.
RT21360230
Inspection
1. Check rear washer nozzle assembly.
a. Check rear washer nozzle assembly for blockage,
deformation or damage. Replace rear washer nozzle
if necessary.
RT21360240

Installation
CAUTION
 Always operate carefully to prevent components from being damaged when installing rear washer nozzle
assembly.
 Install washer line joint in place when installing rear washer nozzle assembly.
 Check rear washer nozzle for proper operation after installing rear washer nozzle assembly.
36

Washer Pump Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing washer pump assembly.
 Appropriate force should be applied when removing washer pump assembly. Be careful not to operate
roughly.
 Try to prevent body paint surface from being scratched when removing washer pump assembly.

4. Remove the front/rear washer pump assembly.
CAUTION
 Put a container under washer pump to collect washer fluid before removing washer pump assembly. 36
a. Disconnect the front washer pump connector (1) and

rear washer pump connector (2).
b. Disconnect the joint (3) between washer line and front
washer pump, and the joint (4) between washer line
2
and rear washer pump.
1
3 4
RT21360260

remove the front washer pump assembly (1) and rear
washer pump assembly (2).
RT21360270

Installation
CAUTION
 Always operate carefully to prevent components from being damaged when installing washer pump
assembly.
 Install washer line joint in place when installing washer pump assembly.
 Check washer system for proper operation after installing washer pump assembly.
Inspection
1. Check front/rear washer pump assembly.
a. Fill washer fluid reservoir assembly with washer fluid.
b. Connect positive (+) battery lead to terminal 1 of
washer pump and negative (-) battery lead to terminal
2.
2 1
36
RT21360280
c. Check that washer fluid flows out of washer pump.

OK: Washer fluid flows out of washer pump.
If result is not as specified, replace washer pump assembly.

Washer Fluid Reservoir Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing washer fluid reservoir assembly.
 Appropriate force should be applied when removing washer fluid reservoir assembly. Be careful not to
operate roughly.
 Try to prevent body paint surface from being scratched when removing washer fluid reservoir assembly.

3. Remove the guide pipe assembly.
a. Remove the fixing bolt (arrow) from guide pipe
assembly.
36
RT21360290
b. Remove the guide pipe assembly from washer fluid reservoir assembly.
5. Remove the washer pump assembly (See page 36-37).
6. Remove the washer fluid reservoir assembly.
a. Detach the washer lines (arrow) from groove on the
washer fluid reservoir assembly.
RT21360300
b. Remove the clips (arrow) from washer fluid reservoir

assembly.
RT21360311

c. Remove 3 fixing bolts (arrow) from washer fluid

reservoir assembly, and remove the washer fluid
reservoir assembly.
RT21360310
Inspection
1. Check washer fluid reservoir assembly.
a. Check washer fluid reservoir assembly for leakage,
deformation or damage. Replace washer fluid
reservoir assembly if necessary.
b. Check internal and external sides of washer fluid
reservoir for dirt. Remove dirt or replace washer fluid
reservoir assembly if necessary.
36 c. Check the grommet for damage. Replace the
grommet if necessary.
RT21360320
Installation
CAUTION
 Always operate carefully to prevent components from being damaged when installing washer fluid
reservoir assembly.
 Tighten fixing bolts to the specified torque when installing washer fluid reservoir assembly.
 Install washer line joint in place when installing washer fluid reservoir assembly.

Washer Line Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing washer line assembly.
 Appropriate force should be applied when removing washer line assembly. Be careful not to operate
roughly.
 Try to prevent body paint surface from being scratched when removing washer line assembly.

4. Remove the front wheel house protector assembly (See page 48-24).
5. Remove the front washer nozzle assembly (See page 36-29).
6. Remove the hood sound-absorbing pad.
a. Remove the clips (arrow) from hood sound-absorbing 36
pad, and remove the hood sound-absorbing pad.
RT21470050
7. Remove the service cover.

up the claws on service cover, and remove the service
cover.
RT21360340

8. Remove the washer line assembly.

a. Disconnect the joint (1) between washer line and front
washer bump.
b. Detach the washer line (arrow) from the groove on 2
washer fluid reservoir assembly.
c. Using a screwdriver wrapped with protective tape, pry
up the rubber cover (2).
RT21360330

e. Detach the washer hose from clips (arrow).
36
RT21470051
f. Remove the washer line assembly from clips.
RT21360350
Installation
CAUTION
 Always operate carefully to prevent components from being damaged when installing washer line
assembly.
 Install washer line joint in place when installing washer line assembly.
 Check washer system for proper operation after installing washer line assembly.

Rain Gutter Rail Reinforcement Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rain gutter rail reinforcement
assembly.
 Try to prevent body paint surface from being scratched when removing rain gutter rail reinforcement
assembly.

5. Remove the wiper motor assembly (See page 36-26).
6. Remove the Engine Control Module (ECM) (See page 06-256).
7. Remove the TCU (See page 18-129).
36
8. Remove the rain gutter rail reinforcement assembly.
loosen the rubber bush (1) and clip (2).
2
1
RT21360370
b. Remove 2 fixing nuts (arrow) from brake fluid

reservoir assembly, and remove the brake fluid
reservoir assembly.
RT21360360

c. Remove 14 fixing bolts from rain gutter rail

reinforcement assembly, and remove the rain gutter
rail reinforcement assembly.
RT21360380
Installation
CAUTION
 Always operate carefully to prevent components from being damaged when installing rain gutter rail
reinforcement assembly.
 Try to prevent body paint surface from being scratched when installing rain gutter rail reinforcement
assembly.
36

DOOR LOCK
GENERAL INFORMATION 37-3 Front Door Key Cylinder 37-44
Tools 37-13 Front Door Lock Striker Assembly 37-46
Installation 37-46
Rear Door Lock Assembly 37-47
Removal 37-47
Inspection 37-48
Installation 37-49
Rear Door Lock Striker Assembly 37-50
Removal 37-50
Installation 37-50
Back Door Lock Assembly 37-51
B101D11 37-22
Removal 37-51
B101D13 37-22
Inspection 37-52
B101D12 37-22
Installation 37-52
B102471 37-27
B102711 37-27
Back Door Lock Striker Assembly 37-53 37
Removal 37-53
Engine Hood Lock Assembly 37-39 Low Frequency Antenna 37-54
Front Door Lock Assembly 37-41 Wireless Key 37-58
Installation 37-43

37

37 - DOOR LOCK
GENERAL INFORMATION
DOOR LOCK
Description
2 4
37
RT21370010
1 - Engine Hood Lock Assembly 2 - Front Right Door Lock Assembly

3 - Rear Right Door Lock Assembly 4 - Back Door Lock Assembly
5 - Rear Left Door Lock Assembly 6 - Front Left Door Lock Assembly
1. Power door lock system function description (w/o passive entry & passive start)
a. Power door lock system can lock/unlock all doors by remote controller, mechanical key and center
controls operation.
 Remote controller sends the lock/unlock request signals to Body Control Module (BCM). Then, Body
Control Module (BCM) sends these request signals to the lock fastener of each door in order to lock/
unlock all doors simultaneously.
 After inserting the mechanical key into the driver side door key cylinder, all doors can be locked/
unlocked by turning the key clockwise or counterclockwise, but anti-theft function cannot be set.

37 - DOOR LOCK
 Function active: effective at any time, even when engine starts.

 Lock success: when all doors are closed fully, lock signal from the center controls is input to execute
the lock command.
 Lock failure: when at least one door is not closed fully, lock signal from the center controls is input to
execute the lock command, and then lock command is executed after 1 second delay.
 Unlock success: unlock signal from the center controls is input to execute the unlock command,
regardless of whether the doors are closed fully.
 Door lock response: when the protection is not activated, Body Control Module (BCM) responses to
each input of lock or unlock.
b. Function (w/o passive entry & passive start)
Component Function
Lock/unlock all doors.
Remote Controller Lock/Unlock Remote controller lock/unlock request is input to
Body Control Module (BCM), which outputs lock/
unlock signal to lock/unlock each door.
Mechanical Key Lock/Unlock Mechanical key lock/unlock request is input to Body
Control Module (BCM), which outputs lock/unlock
signal to lock/unlock each door.
37
Center Controls Lock/Unlock Center controls lock/unlock request is input to Body
Lock/unlock front left door with a fastener.
Front Left Door Lock Assembly Built-in door lock/unlock switch sends lock/unlock
signal to Body Control Module (BCM) to lock/unlock
each door.
Front Right Door Lock Assembly Lock/unlock front right door with a fastener.
Rear Left Door Lock Assembly Lock/unlock rear left door with a fastener.
Rear Right Door Lock Assembly Lock/unlock rear right door with a fastener.
c. Wireless key match (w/o passive entry & passive start)

If the wireless key is lost, damaged, or Body Control Module (BCM) is replaced, the wireless key needs
to rematch. There are two ways and detailed operation procedures are as follows:
 Connect X-431 3G diagnostic tester (the latest
software) to Data Link Connector (DLC), and make Menu
it communicate with vehicle electronic module by ENG
the data network. Then select corresponding ABS
model (T21) on X-431 3G diagnostic tester (the SRS
latest software) to enter system and select "IMMO"

BCM
system.
ICM
PEPS
IMMO
AT
RT21370020

37 - DOOR LOCK
 Please select [After sale function] on SELECT

FUNCTION screen. SELECT FUNCTION
Read fault code
Erase fault code
Read data stream
Write data
After sale function
RT21370030
 Please select [Key match] on After sale function

screen. After sale function
Match all the systems
Programming ECM
Reprogramming ECM
Reprogramming IMMO
Key match
Erase keys
RT21370040
37
 Please select [Add new keys] on Perform routine
program screen. Perform routine program
Add new keys.
Add the old keys.
RT21370041
 When "Please enter a PIN with 8 digits" is

displayed on Input screen, input PIN code and Input
click "OK". Please enter a PIN with 8 digits.
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
A S D F G H J K L ; ‘ ENTER
` Tab Caps Space Ins Del
OK Cancel
RT21370043

37 - DOOR LOCK
 When "Please enter again" is displayed on Input

screen, input PIN code again and click "OK". Input
Please enter again.
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RT21370044
 When "Please Input Repair Shop Code. The length

is 10 digits from 0 to 9, A-Z, a-z" is displayed, click Input
"Cancel". Please Input Repair Shop Code.

The length is 10 digits from 0 to 9. A~z. a~z
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RT21370045
37
 When "Please Input programming. The length is 8
digits from 0 to 9" is displayed, click "Cancel". Input
Please Input programming.

The length is 8 digits from 0 to 9
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RT21370046
 When "Succeeded to add new key!" is displayed,

click "OK". Key match
Succeeded to add new key!
OK
RT21370047
 Key match is completed.

d. The vehicle security has 6 modes (w/o passive entry & passive start):
Lock mode
 Enter lock mode when the following conditions are met:
- Remove the key.
- All doors, engine hood and back door are closed.
- All doors are locked by the lock button on wireless key.

37 - DOOR LOCK
 When vehicle is in lock mode, following features will occur:

- Turn signal lights blink once, anti-theft horn sounds once and anti-theft indicator on the front left
door protector blinks normally to indicate that vehicle is in lock state.
- In lock state, if no door is opened within 30 seconds after unlocking the doors by wireless key, the
doors will lock again automatically.
Lock failure mode
 System will enter lock failure mode under the following conditions and will show the following
features:
- When any door is not closed fully, turn signal lights blink twice and anti-theft horn does not
sound.
- When engine hood is not closed fully, turn signal lights blink twice, doors are locked and horn
does not sound.
- When back door is not closed fully, turn signal lights blink twice, doors are locked and horn does
not sound.
Lock deactivation mode
 In lock mode, the locking mode of entire vehicle will be deactivated if the following condition occurs:
- Press the unlock button on the wireless key.
 The following features occur in lock deactivation mode (by wireless key):
- All doors are unlocked.
- Turn signal lights blink twice, anti-theft horn does not sound and anti-theft indicator stops
blinking. 37
- Within 30 s after the doors are unlocked by wireless key, when no further operation is performed
(opening a door, turning the key or opening engine hood and back door), the vehicle will return to
the locking state.
 If the following conditions occur within 30 s after the doors are unlocked by wireless key, the vehicle
will not return to the locking state and the doors will not lock automatically:
- Turn ignition switch to ON.
- Any door is opened.
- Engine hood is opened.
- Back door is opened.
Alarm mode
 When vehicle is in lock mode, the alarm will be triggered if the following occurs:
- Open any door, engine hood and back door manually.
 When vehicle is in alarm mode, the following occurs:
- After the alarm is triggered, turn signal lights blink and anti-theft horn sounds for 25 seconds. The
condition will occur again after an interval of 5 seconds. This process will repeat for 3 times. At
the same time, the security indicator blinks quickly to indicate system is in a non-secure state. If
all doors/engine hood are fully closed or ignition switch is turned off during the cycle, the turn
signal lights will complete the cycle and all doors will lock again automatically after an interval of
5 seconds. At this time, the vehicle anti-theft system will be reactivated.
Alarm deactivation mode
 The following operation will deactivate the alarm mode:
- Press the unlock button on wireless key.
Back door open mode
 In lock mode, if the back door opener switch on remote controller is pressed for more than 1.5
seconds, turn signal lights will come on for 1 second. After that, if the back door opener switch is
pressed with 30 seconds, BCM will open the back door, but the anti-theft horn will not alarm. After 30
seconds, the back door cannot be opened.

37 - DOOR LOCK
2. Power door lock system function description (w/ passive entry & passive start)
a. Power door lock system can lock/unlock all doors by remote controller, mechanical key, central controls
and contact switch on handle operation.
 Remote controller sends lock/unlock request signals to Passive Entry & Passive Start (PEPS)
controller to control the Body Control Module (BCM) by CAN. Then, Body Control Module (BCM)
sends these request signals to the lock fastener of each door in order to lock/unlock all doors
simultaneously.
 After inserting the mechanical key into the driver side door key cylinder, all doors can be locked/
unlocked by turning the key clockwise or counterclockwise, but anti-theft function cannot be set.
 When the remote controller is outside vehicle, in an operation range of 1.5 m from front door handle,
the door can be locked/unlocked by pressing door handle contact switch.
 When the remote controller is outside back door, in a operation range of 1.5 m from back door
handle, the door can be locked/unlocked by pressing back door handle contact switch.
 Function active: effective at any time, even when engine starts.
 Lock success: when all doors are closed fully, lock signal from the center controls is input to execute
the lock command.
 Lock failure: when at least one door is not closed fully, lock signal from the center controls is input to
execute the lock command, and then lock command is executed after 1 second delay.
 Unlock success: unlock signal from the center controls is input to execute the lock command,
regardless of whether the doors are closed fully.
 Door lock response: when the protection is not activated, Body Control Module (BCM) responses to
37 each input of lock or unlock.
b. Function (w/ passive entry & passive start)
Component Function
Remote controller inputs lock/unlock request to
Remote Controller Lock/Unlock Passive Entry & Passive Start (PEPS), which
controls Body Control Module (BCM) by CAN to
output lock/unlock signals to lock/unlock each door.
Mechanical Key Lock/Unlock Mechanical key lock/unlock request is input Body
Contact switch on handle inputs lock/unlock request
Contact Switch on Handle Lock/Unlock Button to Passive Entry & Passive Start (PEPS), which
controls Body Control Module (BCM) by CAN to
output lock/unlock signals to lock/unlock each door.
Center Controls input lock/unlock request to Passive
Center Controls Lock/unlock Button Entry & Passive Start (PEPS), which controls Body
Control Module (BCM) by CAN to output lock/unlock
signals to lock/unlock each door.
Lock/unlock front left door with a fastener.
Front Left Door Lock Assembly Built-in door lock/unlock switch sends lock/unlock
signal to Body Control Module (BCM) to lock/unlock
each door.

37 - DOOR LOCK
Component Function
Front Right Door Lock Assembly Lock/unlock front right door with a fastener.
Rear Left Door Lock Assembly Lock/unlock rear left door with a fastener.
Rear Right Door Lock Assembly Lock/unlock rear right door with a fastener.
c. Wireless key match (w/ passive entry & passive start)

 Connect X-431 3G diagnostic tester (the latest
software) to Data Link Connector (DLC), and make Menu
it communicate with vehicle electronic module by ENG
the data network. Then select corresponding ABS
model (T21) from X-431 3G diagnostic tester (the SRS
latest software) to enter the system and select

BCM
"IMMO" system.
ICM
PEPS
IMMO
AT
RT21370020
 Please select [After sale function] on SELECT

FUNCTION screen. SELECT FUNCTION
Read fault code
Erase fault code
Read data stream

37
Write data
After sale function
RT21370030
 Please select [Key match] on After sale function

screen. After sale function
Match all the systems
Programming ECM
Reprogramming ECM
Reprogramming IMMO
Key match
Erase keys
RT21370040
 Please select [Add the old keys] on Perform

routine program screen. Perform routine program
Add new keys.
Add the old keys.
RT21370042

37 - DOOR LOCK
 When "Please enter a PIN with 8 digits" is

displayed on Input screen, input PIN code and Input
click "OK". Please enter a PIN with 8 digits.
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RT21370043
 When "Please enter again" is displayed on Input

screen, input PIN code again and click "OK". Input
Please enter again.
XXXXXXXX
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RT21370044
37
 When "Please Input Repair Shop Code. The length
is 10 digits from 0 to 9, A-Z, a-z" is displayed, click Input
"Cancel". Please Input Repair Shop Code.

The length is 10 digits from 0 to 9. A~z. a~z
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RT21370045
 When "Please Input programming. The length is 8

digits from 0 to 9" is displayed, click "Cancel". Input
Please Input programming.

The length is 8 digits from 0 to 9
1 2 3 4 5 6 7 8 9 0 - = bs
OK Cancel
RT21370046

37 - DOOR LOCK
 When "Succeeded to add old key!" is displayed,

click "OK". Key match
Succeeded to add old key!
OK
RT21379947
 Key match is completed.

d. The vehicle security has 6 modes (w/ passive entry & passive start):
Locking mode
 Enter lock mode when the following conditions are met:
- All doors, engine hood and back door are closed.
- All doors are locked by operating the lock button on PEPS controller.
- All doors are locked by operating the front door handle button (REK of PEPS in the detecting
range of this door handle antenna).
 When vehicle is in lock mode, following features will occur:
- Turn signal lights blink once, anti-theft horn sounds once and anti-theft indicator on the front left
door protector blinks normally to indicate that vehicle is in lock state.
37
- In lock state, if no door is opened within 30 seconds after unlocking the doors by wireless key, the
doors will lock again automatically.
Locking failure mode
 System will enter lock failure mode under the following conditions and will show the following
features:
- When any door is not closed fully, turn signal lights blink twice anti-theft and horn does not
sound.
- When engine hood is not closed fully, turn signal lights blink twice, doors are locked and horn
does not sound.
- When back door is not closed fully, turn signal lights blink twice, doors are locked and horn does
not sound.
Lock deactivation mode
 In lock mode, the locking mode of entire vehicle will be deactivated if the following condition occurs:
- Press the unlock button on PEPS controller.
- Press the front door handle button (REK of PEPS in the detecting range of this door handle
antenna).
 When vehicle is in lock deactivation mode (by PEPS controller and front door handle button (REK of
PEPS in the detecting range of this door handle antenna)), following conditions will occur:
- All doors are unlocked.
- Turn signal lights blink twice, anti-theft horn does not sound and anti-theft indicator stops
blinking.
- Within 30 s after the doors are unlocked by wireless key, when no further operation is performed
(opening a door, opening engine hood and back door), the vehicle will return to the lock state.
 If the following conditions occur within 30 s after the doors are unlocked by wireless key, the vehicle
will not return to the locking state, also not lock automatically:
- PEPS switch is in a position other than OFF.
- Any door is opened.
- Engine hood is opened.

37 - DOOR LOCK
- Back door is opened.

Alarm mode
 When vehicle is in lock mode, the alarm will be triggered if the following occurs:
- Open any door, engine hood and back door manually.
 When vehicle is in alarm mode, the following occurs:
- After the alarm is triggered, turn signal lights blink and anti-theft horn sounds for 25 seconds. The
condition will occur again after an interval of 5 seconds. This process will repeat for 3 times. At
the same time, the security indicator blinks quickly to indicate system is in a state of insecurity. If
all doors/engine hood are fully closed or ignition switch is turned off during the cycle, the turn
signal lights will complete the cycle and all doors will lock again automatically after an interval of
5 seconds. At this time, the vehicle anti-theft system will be reactivated.
Alarm deactivation mode
 The following operations will deactivate the alarm mode:
- Press the unlock button on PEPS controller.
- Press the front door handle button (REK of PEPS in the detecting range of this door handle
antenna).
Back door open mode
 In the lock mode, if the back door opener switch on PEPS controller is pressed for more than 1.5
seconds, the back door will be opened but the anti-theft horn will not alarm.
37  When PEPS controller can be recognized by back door antenna, pressing the back door opener
switch can open the back door without sounding an alarm.
Specifications

Tank Upper Crossmember Deflector Fixing Nut 10 ± 1
Engine Hood Lock Assembly Fixing Nut 10 ± 1
Front Door Lock Assembly Fixing Screw 5.8 ± 0.7
Front Door Key Cylinder Cover Fixing Screw 5±1
Rear Door Lock Assembly Fixing Screw 5.8 ± 0.7
Back Door Lock Assembly Fixing Bolt 10 ± 1
1.5 ± 0.5
Front Door Outside Handle Fixing Screw 1.5
Wireless Key Upper Cover Fixing Screw 0.4 ± 0.1

37 - DOOR LOCK
Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
37
RCH0000002

37 - DOOR LOCK
Circuit Diagram
Power Door Lock System (Page 1 of 3)

BATTERY
BCM POWER INSTRUMENT

MF03 SUPPLY RF07 RF13 PANEL FUSE
60A E-061 7.5A 7.5A AND RELAY BOX A
I-007
3 7 13
RBr
RG
R
37
E1 A25 A9
BCM I-005 E-072 B-043
CAN-L1 CAN-H1 CAN-L2 CAN-H2

C4 A14 A15 A30 A31
G
OB
OB
O
6 B-048
E-070
G
2 TO CAN
SYSTEM
ANTI-THEFT
HORN
E-053
1
B
E-032
1 2 3 4 5 6 7 8 9 10 11 12 3 C1 C2 C3 C4 C5 C6 C7 C8 C9
13 14 15 16 17 18 19 20 21 22 23 24 E1
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
27 25 26 E-072
87 E-061 B-043
W
85 86 86 86 W
87 30 87 30
30 85 85
I-007 10 9 8 7 6 5 4 3 2 1
2 1
B 22 21 20 19 18 17 16 15 14 13 12 11
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 B-048 E-053

W B
I-005
ET21370010
L

37 - DOOR LOCK
BCM B-043 B-047
B3 B6 C20 C19 B20 B21

GrR
GrB
BY
Gr
W
A
BY
BY
B-040 16 10 4
F-007
B-061 B-026
11 8 16 2 L-005
H-002
BY
GrR
GrB
BY
BY
Gr
W
6 4 2 1 5 6 2
PASSENGER DR SW
FRONT
DRIVER CYL. SW
REAR
DRIVER DR SW
37
FRONT
FRT RH ACT
FRT LH ACT
RIGHT LEFT
LEFT
RR LH ACT
RL DR SW
DOOR DOOR
DOOR CONTACT CONTACT
CONTACT M M SWITCH M SWITCH
SWITCH
H-005 L-001
F-002
5 3 2 4 5 3
RY
RY
RY
B
F-007 H-002 L-005

3 7 3 5 B-061 5 1
B-040 B-026
B
B
RY
RY
RY
B
B-062 B-036
B-036
C1 C2 C3 C4 C5 C6 C7 C8 C9
B-043
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 W 6 5 2 1
4 3 F-002
12 11 8 7 B-026
10 9 6 5 4 3 2 1
Y B
B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 16 15 14 13
B-047
1 4 7 10 13 16 1 4 7 10 13 16 H-005 L-001
6 5 4 3 2 1
B-061 B-040 6 5 4 3 2 1 B
2 5 8 11 14 17 2 5 8 11 14 17 B
W W
3 6 9 12 15 18 3 6 9 12 15 18
ET21370020

37 - DOOR LOCK
BCM B-046 B-043 B-047
B4 B5 C18 B23 F1
V
YW
BG
BY
A
B
BY
B-005 B-012
R-002 16 2 4 3 15
T-004
BY
B-045
V
YW
BY
YB
1 5 3 1 2
37 REAR RIGHT
RR RH ACT
RR RH ACT
DOOR BACK
RR DR SW
RR DR SW
BACK
CONTACT DOOR DOOR
M SWITCH M LOCK SWITCH
R-004 T-012 T-006
2 4 4 2 1
B
B
RY
B
R-002 T-004
5 1 11
B-005 B-012
RY
B
B
B-062 B-017
C1 C2 C3 C4 C5 C6 C7 C8 C9 F1 1 2
B-043 R-004
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 6 5 4 3 2 1
W B-046 T-006 B
B B
B-047 T-012
6 5 4 3 2 1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 L W
1 2 3 4 5 6 7 8 B-012
6 5 2 1
B-005 9 10 11 12 13 14 15 W
12 11 4 3 8 7 Y
16 15 10 9 14 13
ET21370030

37 - DOOR LOCK
DIAGNOSIS & TESTING

HINT:
Power Door Lock Control System

Power door unlock/lock switch button -
Front left door lock assembly 37-41
Other door lock assemblies -
All doors lock/unlock functions do not
operate Passive Entry & Passive Start (PEPS)
-
controller
Power door unlock/lock switch button -
Front left door lock assembly 37-41 37
Only driver side door lock/unlock functions Passive Entry & Passive Start (PEPS)
-
do not operate controller
Front right door lock assembly 37-41
Only passenger side door lock/ unlock -
controller
functions do not operate
Rear left door lock assembly 37-47
Only rear left door lock/unlock functions do -
controller
not operate
Rear right door lock assembly 37-47
Only rear right door lock/unlock functions -
controller
do not operate

37 - DOOR LOCK

Back door lock assembly 37-51
Only back door Close/Open functions do -
controller
not operate
Wireless Door Lock Control System

Wireless key battery 37-58
Anti-theft match 37-4
Only wireless control function does not Passive Entry & Passive Start (PEPS)
-
operate controller
Turn signal lights -
Only no answer-back
37 Body Control Module (BCM) -
Diagnosis Tools
When connecting X-431 3G diagnostic tester:
 Connect X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC) for communication
with vehicle.
 DLC is located at the driver side instrument panel crossmember.
 DLC uses a trapezoidal design, which can hold 16 terminals.
Digital Multimeter
When using digital multimeter:
 Troubleshoot electrical malfunctions and wire harness system.
 Look for basic fault.
 Measure voltage, current and resistance.

 Using X-431 3G diagnostic tester to record and clear the DTCs stored in the Body Control Module (BCM).

37 - DOOR LOCK

 Inspect the mounting areas of power door lock assembly, wire harness or wire harness connector and so
on for damage, foreign matter, etc. that will cause incorrect signals.
perform a test. If DTC cannot be cleared, the Body Control Module (BCM) is malfunctioning. If DTC can be
cleared, reinstall the Body Control Module (BCM) to original vehicle.
Ground Inspection
37
Diagnosis Procedure
HINT:
Use the following procedure to troubleshoot the power door lock control system.
NEXT
NEXT

37 - DOOR LOCK
NEXT
DTC
occurs For current DTC, go to step 6
No
DTC For history DTC, go to step 7
NEXT
37 6 Troubleshoot according to Diagnostic Trouble Code (DTC) chart, then go to step 8
NEXT
NEXT
NEXT
9 Confirm troubleshooting, perform test
NEXT
10 End

37 - DOOR LOCK

B101D11 Siren Output Control Circuit Circuit Short to Ground
B101D13 Siren Output Control Circuit Circuit Open
B101D12 Siren Output Control Circuit Circuit Short to Battery
B102471 Trunk Lock Control Circuit Actuator Stuck
B102711 Battery Saver Output Control Circuit Circuit Short to Ground
37

37 - DOOR LOCK
DTC B101D11 Siren Output Control Circuit Circuit Short to Ground
DTC B101D13 Siren Output Control Circuit Circuit Open
DTC B101D12 Siren Output Control Circuit Circuit Short to Battery
BATTERY
BCM POWER
MF03 SUPPLY
60A E-061
37
R
E1
BCM
E-072
B-043
C4
G
6 B-048
E-070
G
ANTI-THEFT
HORN
E-053
1
B
E-032
10 9 8 7 6 5 4 3 2 1 3
E1 2 1
22 21 20 19 18 17 16 15 14 13 12 11
B-048 E-061 E-072 E-053

W W B
ET21370040

37 - DOOR LOCK

Condition Condition
Siren Output Control
B101D11 Circuit Circuit Short to  Fuse
Ground  Anti-theft horn
Siren Output Control  Wire harness or
B101D13 Ignition switch ON ON
Circuit Circuit Open connector
Siren Output Control  Body Control
B101D12 Circuit Circuit Short to Module (BCM)
Battery
CAUTION
Diagnosis Procedure
37
1 Check fuse MF03 (60A)

c. Pull out the fuse MF03 (60A).
NG Replace fuse MF03 (60A)
OK
2 Check anti-theft horn
a. Remove the anti-theft horn from the malfunctioning vehicle and install it to a new vehicle and perform a
test.
NG Replace anti-theft horn
OK

37 - DOOR LOCK

c. Disconnect the body wire harness connector B-043 and
B-048.
+ -
according to the table below. C1 C2 C3 C4 C5 C6 C7 C8 C9
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
Condition
B-043 (C4) -
Always Continuity
B-048 (6) 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 11

connector B-048
RT21370710
OK
37

c. Disconnect the engine compartment wire harness
+ -
E-072 according to the table below. 3
Condition
E-061 (3) - E-072

Always Continuity
(E1)
E1
E-072
RT21370700

37 - DOOR LOCK
e. Disconnect the engine compartment wire harness

E-053 according to the table below. + -
Condition 1 2 3 4 5 6 7 8 9 10
E-070
E-070 (6) - E-053
Always Continuity
(2)
2 1
E-053
RT21370720
g. Disconnect the engine compartment wire harness

37
below.
Condition 2 1
E-053

E-032
RT21370730
OK
5 Reconfirm DTCs

d. Use the X-431 3G diagnostic tester (the latest software) to record and clear the DTCs stored in the Body
e. Turn the ignition switch to LOCK and wait for a few seconds.
g. Use the X-431 3G diagnostic tester (the latest software) to read DTCs stored in the Body Control Module
(BCM) again.

37 - DOOR LOCK
Result Proceed to
DTC B101D11, B101D13 and B101D12 are output NG
No DTC is output OK
OK
System is normal
37

37 - DOOR LOCK
DOOR LOCK
DTC B102471 Trunk Lock Control Circuit Actuator Stuck
Battery Saver Output Control Circuit Circuit Short to

DTC B102711
Ground
BCM B-043 B-047
B3 B6 C20 C19 B20 B21

GrR
GrB
BY
Gr
W
A
BY
BY
B-040 16 10 4
F-007
B-061 B-026
11 8 16 2
H-002 L-005
37
BY
GrR
GrB
BY
BY
Gr
W
6 4 2 1 5 6 2
PASSENGER DR SW
FRONT
DRIVER CYL. SW
REAR
DRIVER DR SW
FRONT
FRT RH ACT
FRT LH ACT
RIGHT LEFT
LEFT
RR LH ACT
RL DR SW
DOOR DOOR
DOOR CONTACT CONTACT
CONTACT M M SWITCH M SWITCH
SWITCH
H-005 L-001
F-002
5 3 2 4 5 3
RY
RY
RY
B
F-007 H-002 L-005

3 7 3 5 B-061 5 1
B-040 B-026
B
B
RY
RY
RY
B
B-062 B-036
B-036
C1 C2 C3 C4 C5 C6 C7 C8 C9
B-043
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 W 6 5 2 1
4 3 F-002
12 11 8 7 B-026
10 9 6 5 4 3 2 1
Y B
B-047
1 4 7 10 13 16 1 4 7 10 13 16 H-005 L-001
6 5 4 3 2 1
B-061 B-040 6 5 4 3 2 1 B
2 5 8 11 14 17 2 5 8 11 14 17 B
W W
3 6 9 12 15 18 3 6 9 12 15 18
ET21370020

37 - DOOR LOCK
BCM B-047
B4
V
A
BY
B-005
R-002 16 2
BY
V
1 5
RR RH ACT REAR RIGHT

DOOR
RR DR SW
37 M
CONTACT
SWITCH
R-004
2 4
RY
B
R-002
5 1
B-005
B
RY
B-062
12 11 4 3 8 7 6 5 4 3 2 1
16 15 10 9 14 13
B-047
L B-005 R-004
Y B
ET21370050

37 - DOOR LOCK

Condition Condition
 Front door lock
Trunk Lock Control assembly
B102471
Circuit Actuator Stuck  Rear door lock
assembly
 Wire harness or
Battery Saver Output connector
 Body Control
Short to Ground
Module (BCM)
CAUTION
1 Check front door lock assembly

37
a. Remove the front door lock assembly from malfunctioning vehicle, and install it to a new vehicle to perform
a test.
NG Replace front door lock assembly
OK
2 Check rear door lock assembly
a. Remove the rear door lock assembly from malfunctioning vehicle, and install it to a new vehicle to perform
a test.
NG Replace rear door lock assembly
OK

37 - DOOR LOCK

B-040.
+ -
according to the table below. B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32
Multimeter
Specified
Condition B-047
Terminal
B-047 (B3) -
B-040 (16) 2 5 8 11 14 17
3 6 9 12 15 18
B-047 (B6) -
Always Continuity
B-040 (10)
B-040
RT21370501

37 B-061.
Multimeter
Specified
Condition
Terminal B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16
B-047 (B20) -
B-061 (11)
1 4 7 10 13 16
2 5 8 11 14 17
3 6 9 12 15 18
B-061
RT21370502

37 - DOOR LOCK

B-026.
Multimeter
Specified
Condition
B-047 (B21) -
B-026 (16)
6 5 2 1
4 3
12 11 8 7
10 9
16 15 14 13
B-026
RT21370520
i. Disconnect the body wire harness connectors B-047 and

B-005.
according to the table below. + - 37
Multimeter
Specified
Condition
B-047 (B4) -
B-005 (16)
6 5 2 1
12 11 4 3 8 7
16 15 10 9 14 13
B-005
RT21370530
k. Disconnect the body wire harness connectors B-040 and

B-043.
Multimeter
Specified
Connection Condition C1 C2 C3 C4 C5 C6 C7 C8 C9
Condition
Terminal C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-040 (5) - B-043

(C20)
1 4 7 10 13 16
2 5 8 11 14 17
3 6 9 12 15 18
B-040
RT21370540

37 - DOOR LOCK
m. Disconnect the body wire harness connectors B-043 and

B-061.
Multimeter
Specified
Condition
B-043 (C19) -
B-061(5)
B-043 (C20) -
B-061 (4) 2 5 8 11 14 17
3 6 9 12 15 18
B-061
RT21370550
o. Disconnect the body wire harness connectors B-043 and

B-026.
p. Using a digital multimeter, check for continuity between
37 according to the table below. + -
Multimeter
Specified
Condition
B-043 (C19) -
B-026 (1)
B-043 (C20) -
4 3
2 1
B-026 (2) 12 11
10 9
8 7
16 15 14 13
B-026
RT21370560
q. Disconnect the body wire harness connectors B-043 and

B-005.
r. Using a digital multimeter, check for continuity between
Multimeter
Specified
Condition
B-043 (C19) -
B-005 (1)
B-043 (C20) -
B-005 (2) 12 11 4 3 8 7
16 15 10 9 14 13
B-005
RT21370570

37 - DOOR LOCK
s. Disconnect the body wire harness connectors B-040 and

B-061.
t. Using a digital multimeter, check for continuity between
Multimeter
Specified 1 4 7 10 13 16
Condition 2 5 8 11 14 17
Terminal 3 6 9 12 15 18
B-040 (7) - B-061 B-040

Always Continuity
(5)
1 4 7 10 13 16
2 5 8 11 14 17
3 6 9 12 15 18
B-061
RT21370580
u. Disconnect the body wire harness connectors B-040 and

B-026.
v. Using a digital multimeter, check for continuity between
according to the table below. + - 37
Multimeter
Specified 1 4 7 10 13 16
Condition 2 5 8 11 14 17
Terminal 3 6 9 12 15 18
B-040 (7) - B-026 B-040

Always Continuity
(1)
6 5 2 1
4 3
12 11 8 7
10 9
16 15 14 13
B-026
RT21370590
w. Disconnect the body wire harness connectors B-040 and

B-005.
x. Using a digital multimeter, check for continuity between
Multimeter
Specified 1 4 7 10 13 16
Condition 2 5 8 11 14 17
Terminal 3 6 9 12 15 18
B-040 (7) - B-005 B-040

Always Continuity
(1)
6 5 2 1
12 11 4 3 8 7
16 15 10 9 14 13
B-005
RT21370600

37 - DOOR LOCK
y. Disconnect the body wire harness connector B-040 and

ground B-036.
z. Using a digital multimeter, check for continuity between
body wire harness connector B-040 and B-036 according
Multimeter
Specified 1 4 7 10 13 16
Condition 2 5 8 11 14 17
Terminal 3 6 9 12 15 18
B-040 (3) - B-036 Always Continuity

B-040
B-036
RT21370610
aa.Disconnect the body wire harness connector B-061 and

ground B-062.
ab.Using a digital multimeter, check for continuity between
37 to the table below. + -
Multimeter
Specified 1 4 7 10 13 16
Condition 2 5 8 11 14 17
Terminal 3 6 9 12 15 18

B-061
B-062
RT21370620
ac.Disconnect the body wire harness connector B-026 and

ground B-036.
ad.Using a digital multimeter, check for continuity between
Multimeter 6 5 2 1
Specified 4 3
Condition 10 9
Terminal 16 15 14 13
B-026 (5) - B-036 Always Continuity B-026
B-036
RT21370630

37 - DOOR LOCK
ae.Disconnect the body wire harness connector B-005 and

ground B-062.
af. Using a digital multimeter, check for continuity between
Multimeter
Specified
Condition 12 11 4 3 8 7
Terminal 16 15 10 9 14 13

B-005

connector
B-062
RT21370640
OK

37
c. Disconnect the front left door wire harness connectors 
F-007 and F-002.
+ -
d. Using a digital multimeter, check for continuity between 1 2 3 3 2 1
front left door wire harness connectors F-007 and F-002 4 5 6 6 5 4
according to the table below. 7 8 9 9 8 7
10 11 12 12 11 10
13 14 15 15 14 13
Multimeter 16 17 18 18 17 16
Specified
Condition
Terminal
F-007
F-007 (4) - F-002
Always Continuity
(2)
6 5 4 3 2 1
F-007 (7) - F-002
Always Continuity
(3) F-002
F-007 (10) - F-002 RT21370650

Always Continuity
(4)
F-007 (3) - F-002
Always Continuity
(5)
F-007 (16) - F-002
Always Continuity
(6)
NG Repair or replace front left door wire

OK

37 - DOOR LOCK

c. Disconnect the front right door wire harness connectors
H-002 and H-005.
+ -
d. Using a digital multimeter, check for continuity between 1 2 3 3 2 1
front right door wire harness connectors H-002 and  4 5 6 6 5 4
H-005 according to the table below. 7 8 9 9 8 7
10 11 12 12 11 10
13 14 15 15 14 13
Multimeter 16 17 18 18 17 16
Specified
Condition
Terminal
H-002
H-002 (3) - H-005
Always Continuity
(2)
6 5 4 3 2 1
H-002 (8) - H-005
Always Continuity
(5) H-005
H-002 (5) - H-005 RT21370660

Always Continuity
(4)
H-002 (11) -
37 H-005 (1)
Always Continuity
NG Repair or replace front right door wire

OK
6 Check rear left door wire harness and connector

c. Disconnect the rear left door wire harness connectors 
L-001 and L-005.
+ -
rear left door wire harness connectors L-001 and L-005
according to the table below. 1 2 5 6
3 4
7 8 11 12
9 10
Multimeter 13 14 15 16
Specified
Condition
Terminal L-005
L-001 (2) - L-005
Always Continuity
(2)
6 5 4 3 2 1
L-001 (3) - L-005
Always Continuity
(1) L-001
L-001 (5) - L-005 RT21370670

Always Continuity
(5)
L-001 (6) - L-005
Always Continuity
(16)

37 - DOOR LOCK
NG Repair or replace rear left door wire

OK
7 Check rear right door wire harness and connector

c. Disconnect the rear right door wire harness connectors
R-002 and R-004.
+ -
rear right door wire harness connectors R-002 and R-004
according to the table below. 1 2 5 6
3 4
7 8 11 12
9 10
Multimeter 13 14 15 16
Specified
Condition
Terminal R-002
R-002 (1) - R-004

Always Continuity
(4)
37
6 5 4 3 2 1
R-002 (2) - R-004
Always Continuity
(5) R-004
RT21370680
R-002 (5) - R-004
Always Continuity
(2)
R-002 (16) -
Always Continuity
R-004 (1)
NG Repair or replace rear right door wire

OK
8 Reconfirm DTCs

d. Use the X-431 3G diagnostic tester (the latest software) to record and clear the DTCs stored in the Body
e. Turn the ignition switch to LOCK and wait for a few seconds.
g. Use the X-431 3G diagnostic tester (the latest software) to read DTCs stored in the Body Control Module
(BCM) again.
Result Precede to
DTC B102471 and B102711 are output NG
No DTC is output OK

37 - DOOR LOCK
OK
System is normal
37

37 - DOOR LOCK
ON-VEHICLE SERVICE
Engine Hood Lock Assembly
Removal
CAUTION
 Be sure to the wear safety equipment to prevent accidents when removing engine hood lock assembly.
 Try to prevent body paint surface from being scratched when removing engine hood lock assembly.

5. Remove the tank upper crossmember deflector.
a. Remove 2 plastic clips (arrow) and the fixing nut (1)
from tank upper crossmember deflector.
b. Remove the tank upper crossmember deflector.
37
RT21370050
6. Remove the engine hood lock assembly.

a. Remove 2 fixing nuts (arrow) from engine hood lock
assembly.
RT21370060
b. Detach the engine hood cable assembly (arrow) from

clamping part, and remove the engine hood lock
assembly.
RT21370061

37 - DOOR LOCK
Installation
CAUTION
 Check if engine hood operates properly after installing engine hood lock assembly.
37

37 - DOOR LOCK
Front Door Lock Assembly

Removal
HINT:
CAUTION
 Be sure to the wear safety equipment to prevent accidents when removing front door lock assembly.
 Try to prevent interior and body paint from being scratched when removing front door lock assembly.

3. Remove the front left door protector assembly (See page 47-36).
4. Remove the front left door assist grip mounting bracket assembly (See page 47-41).
5. Remove the front left door protective film assembly (See page 47-41).
6. Remove the front left door glass rear guide rail assembly (See page 43-51).
7. Remove the front left door lock assembly.
a. Disconnect the connector (arrow) from front door lock 37
assembly.
RT21370070
b. Detach the clip (arrow) connecting front door lock

assembly and front door key cylinder lever.
RT21370080

37 - DOOR LOCK
c. Detach the cable (arrow) connecting front door lock

assembly and front door assist grip base.
RT21370090
d. Remove 3 fixing screws (arrow) from front door lock

assembly, and remove the front door lock assembly.
37
RT21370100
Inspection
1. Check front door lock assembly (fastener assembly).
a. Apply battery voltage to terminals of front door lock assembly (fastener assembly) connector and check
if front door lock assembly works properly according to the table below.
Front Left Door Lock Assembly
+ -
Specified
Measurement Condition
Condition
Battery positive (+) → Terminal 3 1 2 3 4 5 6
Lock
Unlock
RT21370110

37 - DOOR LOCK
Front Right Door Lock Assembly
Specified
Condition
Lock
Unlock
If result is not as specified, replace front door lock

assembly.
Installation
CAUTION
 Check if connector is installed correctly when installing front door lock assembly.
 Install clip and cable on the lever in place when installing front door lock assembly.
 Check if front door lock operates properly after installing front door lock assembly.
37

37 - DOOR LOCK
Front Door Key Cylinder

Removal
CAUTION
 Be sure to the wear safety equipment to prevent accidents when removing front door key cylinder.
 Try to prevent interior and body paint from being scratched when removing front door key cylinder.

6. Remove the front left door key cylinder protective cover.
a. Disconnect the clip (arrow) between front door lock
assembly and front door lock key cylinder lever.
37
RT21370080

remove the trim plug (arrow) of front door key cylinder
protective cover.
RT21370120
c. Remove the fixing screw from front door key cylinder protective cover, and remove the front left door
key cylinder protective cover.

37 - DOOR LOCK
HINT:
It is not necessary to remove the fixing screw from front left door key cylinder protective cover, because
the fixing screw is integrated with the front door key cylinder protective cover.
7. Remove the front left door key cylinder.
a. Detach the clip (arrow) from front door key cylinder
lever.
RT21370130

disengage the claws (arrow) to separate the front door
key cylinder protective cover from front door key
cylinder.
37
RT21370140
Installation
CAUTION
 Install clip on the lever in place when installing front door key cylinder.
 Check if front door key cylinder operates properly after installing front door key cylinder.

37 - DOOR LOCK
Front Door Lock Striker Assembly

Removal
HINT:
CAUTION
 Be sure to the wear safety equipment to prevent accidents when removing front door lock striker
assembly.
 Try to prevent body paint surface from being scratched when removing front door lock striker assembly.
1. Remove the front left door lock striker assembly.

a. Remove 2 fixing crews (arrow) from front left door lock
striker assembly.
b. Remove the front left door lock striker assembly.
37
RT21370150
Installation
CAUTION
 Try to prevent body paint surface from being scratched when installing front door lock striker assembly.

37 - DOOR LOCK
Rear Door Lock Assembly

Removal
HINT:
CAUTION
 Be sure to the wear safety equipment to prevent accidents when removing rear door lock assembly.
 Try to prevent interior and body paint from being scratched when removing rear door lock assembly.

3. Remove the rear left door protector assembly (See page 47-36).
4. Remove the rear left door assist grip mounting bracket assembly (See page 47-41).
5. Remove the rear left door protective film assembly (See page 47-41).
6. Remove the rear left door lock assembly.
a. Disconnect the connector (arrow) from rear door lock
assembly. 37
RT21370170
b. Detach the cable (arrow) connecting rear door lock

assembly and rear door assist grip base.
RT21370180

37 - DOOR LOCK
c. Remove 3 fixing screws (arrow) from rear door lock

assembly, and remove the rear door lock assembly.
RT21370190
Inspection
1. Check rear door lock assembly (fastener assembly).
a. Apply battery voltage to terminals of rear door lock assembly (fastener assembly) connector and check
if rear door lock assembly works properly according to the table below.
Rear Left Door Lock Assembly
37 + -
Specified
Condition
Battery positive (+) → Terminal 3 1 2 3 4 5 6
Lock
Unlock
RT21370200
Rear Right Door Lock Assembly
Specified
Condition
Lock
Unlock
If result is not as specified, replace rear door lock

assembly.

37 - DOOR LOCK
Installation
CAUTION
 Check if connector is installed correctly when installing rear door lock assembly.
 Install the cable in place when installing rear door lock assembly.
 Check if rear door lock operates properly after installing rear door lock assembly.
37

37 - DOOR LOCK
Rear Door Lock Striker Assembly

Removal
HINT:
CAUTION
 Be sure to the wear safety equipment to prevent accidents when removing rear door lock striker
assembly.
 Try to prevent body paint surface from being scratched when removing rear door lock striker assembly.
1. Remove the rear left door lock striker assembly.

a. Remove 2 fixing crews (arrow) from rear left door lock
b. Remove the rear left door lock striker assembly.
37
RT21370210
Installation
CAUTION
 Try to prevent body paint surface from being scratched when installing rear door lock striker assembly.

37 - DOOR LOCK
Back Door Lock Assembly

Removal
CAUTION
 Be sure to the wear safety equipment to prevent accidents when removing back door lock assembly.
 Try to prevent interior and body paint from being scratched when removing back door lock assembly.

4. Remove the back door lock assembly.
a. Disengage the back door lock mechanical opener
cable assembly from the slot in the direction of arrow
37
RT21370220
b. Disconnect the connector (1) from back door lock

assembly.
c. Remove 3 fixing bolts (arrow) from back door lock
assembly, and remove the back door lock assembly.
RT21370230
5. Remove the back door lock mechanical opener cable assembly.

a. Disengage the back door lock mechanical opener
cable assembly (arrow) from the slot.
1
b. Remove the back door lock mechanical opener cable
assembly (1).
RT21370240

37 - DOOR LOCK
Inspection
1. Check back door lock assembly.
continuity between terminals of back door lock
+ -
assembly according to the table below. 1 2 3 4 5 6
Switch Specified
Condition Condition
ON Continuity
Terminal 1 - Terminal 2
OFF Continuity
ON Continuity RT21370241
Terminal 3 - Terminal 4 No
OFF
continuity
If result is not as specified, replace back door lock

assembly.
2. Check back door lock assembly.
a. Apply battery voltage to the terminals of back door
-
lock assembly connector and check the operation of +
back door lock assembly according to the table below. 1 2 3 4 5 6
37 Rear Right Door Lock Assembly
Specified
Condition
ON
RT21370242
If result is not as specified, replace back door lock
assembly.
Installation
CAUTION
 Check if connector is installed correctly when installing back door lock assembly.
 Install the cable in place when installing back door lock assembly.
 Check if back door lock operates properly after installing back door lock assembly.

37 - DOOR LOCK
Back Door Lock Striker Assembly

Removal
CAUTION
 Be sure to the wear safety equipment to prevent accidents when removing back door lock striker
assembly.
 Try to prevent body paint surface from being scratched when removing back door lock striker assembly.
1. Remove the back doorsill pressure plate assembly (See page 49-13).
2. Remove the back door lock striker assembly.
a. Remove 2 fixing crews (arrow) from back door lock
b. Remove the back lock latch.
37
RT21370250
Installation
CAUTION
 Try to prevent body paint surface from being scratched when installing back door lock striker assembly.

37 - DOOR LOCK
Low Frequency Antenna

Removal
CAUTION
 Be sure to the wear safety equipment to prevent accidents when removing low frequency antenna.
 Try to prevent body paint surface from being scratched when low frequency antenna.

3. Remove the auxiliary fascia console rear cover plate assembly.
a. Remove the fixing screw from auxiliary fascia console
rear cover plate assembly.
37
RT21370480
b. Open the armrest box assembly.

up the claws on auxiliary fascia console rear cover
plate assembly, and remove the auxiliary fascia
console rear cover plate assembly.
RT21370481
4. Remove the low/medium frequency antenna.

a. Disconnect the connector (arrow) from low/medium
frequency antenna.
up the clip on low/medium frequency antenna, and
remove the low/medium frequency antenna.
RT21370490

37 - DOOR LOCK
5. Remove the anti-theft coil.

a. Remove the auxiliary fascia console assembly (See page 45-9).
HINT:
Anti-theft coil connector has been disconnected when
removing the auxiliary fascia console assembly.
RT21450181
b. Detach the claws (arrow), and remove the anti-theft

coil.
37
RT21450191
6. Remove the front low frequency antenna.

a. Disconnect the connector (arrow) from front low
frequency antenna.
up the clip on front low frequency antenna, and
remove the front low frequency antenna.
RT21370470
7. Remove the rear low frequency antenna.

a. Remove the rear left seat assembly (See page 46-25).
b. Disconnect the connector (arrow) from rear low
frequency antenna.
up the clip on rear low frequency antenna, and
remove the rear low frequency antenna.
RT21370510

9. Remove the back door opener low frequency antenna.

37 - DOOR LOCK
a. Disconnect the connector (arrow) from back door

opener low frequency antenna.
up the clip on back door opener low frequency
antenna, and remove the back door opener low
frequency antenna.
RT21370500
10.Remove the front left door protector assembly (See page 47-23).
12.Remove the front left door protective film assembly (See page 47-30).
13.Remove the front left door key cylinder protective cover (See page 37-44).
14.Remove the front left door outside handle (See page 47-31).
HINT:
Front door handle sensor connector has been
disconnected when removing the front door outside
handle.
37
RT21470390
15.Remove the front left door handle sensor (built into low frequency antenna) (take left side as an example).
a. Remove the fixing crew (arrow) from front door
outside handle.
(Tightening torque: 1.5 N·m)
RT21370450

37 - DOOR LOCK

up the claws on front door outside handle.
RT21370451
c. Separate the front door handle sensor (1) and front

door outside handle (2). 2
RT21370460
Installation 37
CAUTION
 Clip on low frequency antenna and antenna mounting bracket should be fitted properly when installing
low frequency antenna.
 Check if functions are normal after installing low frequency antenna.

37 - DOOR LOCK
Wireless Key
Removal
CAUTION
 DO NOT push the terminals with your hands when removing wireless key cover.
 Install battery positive and negative correctly when removing wireless key cover.
 DO NOT pry up the battery forcibly when removing wireless key cover, otherwise the terminals may be
damaged.
 DO NOT touch the battery with wet hands when removing wireless key cover, otherwise the water may
cause rust.
 DO NOT touch or move any components inside the transmitter when removing wireless key cover.
Failure to do so may interfere with proper operation.
1. Remove the wireless key (w/ passive entry & passive start).
a. Remove the mechanical key billet in the direction of
37
RT21370310

out the wireless key cover.
RT21370320
c. Separate the wireless key cover (1) and chip (2).
2
1
RT21370330

37 - DOOR LOCK
d. Detach the claws (arrow) on battery holder, and

remove the battery holder in the direction of arrow.
RT21370340
e. Take out the battery in the direction of arrow as shown

RT21370350
37
2. Remove the wireless key (w/o passive entry & passive start).
out the wireless key cover.
RT21370360
b. Take out the wireless key battery in the direction of

RT21370370

37 - DOOR LOCK
c. Remove 3 fixing screws (arrow) from wireless key

upper cover.
RT21370380
d. Remove the wireless key upper cover.

e. Remove the wireless key billet (1).
f. Remove the wireless key chip (2).
37 RT21370390
Installation
CAUTION
 Check that the wireless key operates properly after installing the wireless key.

INSTRUMENT CLUSTER
GENERAL INFORMATION 38-3 B1101-11 38-21
Description 38-3 B1101-15 38-21
Operation 38-4 B1103-00 38-25
Specification 38-4 B1104-41 38-28
Tools 38-4 U0100-87 38-29
Circuit Diagram 38-5 U0101-87 38-29
Instrument Cluster Terminal List 38-10 U0129-87 38-29
U0131-87 38-29
U0140-87 38-29
U0151-87 38-29
U0167-87 38-29
U0214-87 38-29
U0073-88 38-29
U1300-55 38-41
Diagnostic Trouble Code (DTC) Chart 38-16 ON-VEHICLE SERVICE 38-42
B1100-13 38-17 Instrument Cluster 38-42
B1100-16 38-17 Removal 38-42
B1100-17 38-17 Installation 38-43
38

38

38 - INSTRUMENT CLUSTER
GENERAL INFORMATION
INSTRUMENT CLUSTER
Description
Instrument Cluster
23 24 25 26 27 28 1 2 3 4 5 6 7 8 9
4 100 120
3 5 80 140
P 60 160 10
22 2 EPC
6 08:30
21 40 180 11
OFF
20 1
+ -
7
19 20 200
X1000
rpm km/h
12
123 km 220
0 8 0
C H E F
38
18 17 16 15 14 13
RT21380010
1 - Left Turn Signal Indicator 2 - Multi-information Display

3 - Right Turn Signal Indicator 4 - SRS Warning Light
5 - Driver Seat Belt Reminder Light 6 - Transmission Malfunction Warning Light (for CVT
Model)
7 - Brake System Warning Light 8 - ABS Warning Light
9 - Front Passenger Seat Belt Reminder Light 10 - Parking Brake Indicator
11 - ESP OFF Indicator (if equipped) 12 - Low Fuel Level Warning Light
13 - Speedometer 14 - Fuel Gauge
15 - Cruise Indicator (if equipped) 16 - Tachometer
17 - High Coolant Temperature Warning Light 18 - Engine Coolant Temperature Gauge
19 - Low Engine Oil Pressure Warning Light 20 - Charging System Warning Light
21 - Position Indicator 22 - Front Fog Indicator
23 - Rear Fog Indicator 24 - Headlight High Beam Indicator
25 - Engine Immobilizer System Warning Light 26 - EPC Warning Light
27 - Engine Malfunction Warning Light 28 - Maintenance Indicator

This vehicle is equipped with pointer type instrument cluster. The instrument cluster is a highly integrated
electronic instrument display system and mainly consists of engine coolant temperature gauge, tachometer,
fuel gauge, speedometer, multi-information display and warning indication symbols. The multi-information
display mainly displays vehicle information, which contains the following items: clock, trip, total mileage,
instantaneous fuel consumption and speed.
Operation
Instrument cluster is located above the upper left of instrument panel assembly, which is used to monitor and
display the operation status of each system and component in vehicle. Instrument cluster receives signals from
each sensor and switch, and displays the operation status of each system through meter, multi-information
display, indicator and warning lights. It also reminds and informs driver by flashing lights and sounding buzzer.
As a result, it will be helpful for driver to eliminate possible troubles in time, thus avoiding malfunctions or
accidents efficiently.
Specification

Instrument Cluster Fixing Screw 1.5 ± 0.5
Tools
38 Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Instrument Cluster (Page 1 of 5)

ON OR START
INSTRUMENT
PANEL
RF23 RF06 FUSE AND
10A 10A RELAY BOX A
I-007
23 6
R
P
R
16 8
R
DIAGNOSTIC
INTERFACE
I-050 38
11 13
MICROPROCESSOR
INSTRUMENT
CLUSTER
SRS I-015
CAN-L2 CAN-H2
29 30 3 5
OB
Br
B
A30 A31
CAN-L2 CAN-H2
BCM A
I-005
CAN-L1 CAN-H1
A14 A15
OB
2 17 I-003
SRS
CAN-L1 CAN-H1 CONTROL
MODULE
I-046
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-015 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 L I-046
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Gr
16 15 14 13 12 11 10 9 I-050
1 2 3 4 5 6 7 8 9 10 11 12
8 7 6 5 4 3 2 1 B
13 14 15 16 17 18 19 20 21 22 23 24
I-007
27 25 26
87
B
85 86 86 86 I-005
87 30 87 30 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 L
30 85 85
ET21380010

INSTRUMENT
I-015
LOW PARKING DRIVER BRAKE

OIL BRAKE SEAT
BELT
9 18 19 26
VW
BG
BG
Y
I-034
5 E-027
I-006 I-035 I-004
2
14 B-003 17 B-059 E-071
V
38 21
E-038
E-007
BG
BG
Y
V
1 OIL 1 PARKING 1 DRIVER 1 BREAK

PRESSURE BRAKE SEAT FLUID
SWITCH SWITCH BELT LEVEL
SWITCH SENSOR
E-001 B-019
B-039 E-082
2 2
B
B-042 E-078
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1
9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 17 16 15 14 13 12 11 10
E-001
39 35 31 26 21 16 11 6 1 I-015 I-035 W
27 22 17 12 7 2 L W
40 36 32
28 23 18 13 8 3 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
41 37 33 I-034 1
29 24 19 14 9 4 15 14 13 12 11 10 9 W 22 21 20 19 18 17 16 15 14 13 12 11
42 38 34 30 25 20 15 10 5 B-019
I-006 B
6 5 4 3 2 1 W
14 13 12 11 10 9 8 7 1 2 1 2
E-038
B-039
B I-004 E-082
B
W B
ET21380020

FUEL
GAUGE
INSTRUMENT
CLUSTER
MICROPROCESSOR
I-015
lOW FUEL CHARGING

LEVEL
21 16 31
VB
I-006 I-034
12 6
B-003 E-027
38
W
V
VB
E-038
22
E-007
1
FUEL
Q PUMP
V
MOTOR
B-038 1 6
2
Br
ALTERNATOR SPIRAL CABLE

E-003 CONNECTOR
I-012
B-032
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 22 21 20 19 18 17 16 15 14 13 12 11
I-015
I-006
L
W
39 35 31 26 21 16 11 6 1
8 7 6 5 4 3 2 1 1 2 3 4 1 2 3 27 22 17 12 7 2
15 14 13 12 11 10 9 40 36 32 E-038
B-038 E-003 28 23 18 13 8 3 B
I-034 41 37 33
B B 29 24 19 14 9 4
W
42 38 34 30 25 20 15 10 5
9 10 11 12 13 14 15 16 I-012
1 2 3 4 5 6 7 8 W
ET21380030

EPS B
CONNECTOR
I-057
CAN-L1 CAN-H1
3 2
OB
CAN-L1 CAN-H1
J105
PSE
J106 CONNECTION J1
I-029
CAN-L1 CAN-H1
OB
O
6
DIAGNOSTIC
INTERFACE
CAN-L1 CAN-H1
14
I-050
6
IMMOBILIZER
CAN-L2 CAN-H2 CONTROL
11 3 8
MODULE
I-018
A14 A15
CAN-L1 CAN-H1
BCM A
38 CAN-L2 CAN-H2
I-005
A30 A31
OB
29 30
CAN-L2 CAN-H2
INSTRUMENT
CLUSTER
MICROPROCESSOR
I-015
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 3 5 7 16 15 14 13 12 11 10 9
I-015 I-018
2 4 6 8 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 L B
I-050
B
J108 J107 J106 J105 J104 J103 J102 J101
J116 J115 J114 J113 J112 J111 J110 J109

I-029
Gr
5 4 3 2 1
10 9 8 7 6
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 L I-057
B
ET21380040

ECM-2
E-033
CAN-L1 CAN-H1
CAN-L1 CAN-H1
41 17 1
TCM
(FOR CVT
MODEL) 42
CAN-L1 CAN-H1
E-030 14
ABS
CONTROL
OB
O
26
MODULE
E-085
E-027
10 9 I-034
A14 A15
CAN-L1 CAN-H1 BCM A
I-005
CAN-L2 CAN-H2 ILLUMINTION
CAN-L2 CAN-H2
A30 A31
D3
Lg
AUDIO
ASSISTANT
D2
I-019
OB
38
29 30 12
CAN-L2 CAN-H2
INSTRUMENT
CLUSTER
MICROPROCESSOR
I-015
13 12 11 10 9 8 7 6 5 4 3 2 1
E-085
24 23 22 21 20 19 18 17 16 15 14 B
38 37 36 35 34 33 32 31 30 29 28 27 26 25
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 D8 D7 D6 D5 D4 D3 D2 D1 I-019
D16 D15 D14 D13 D12 D11 D10 D9 B
E-033 I-005
B L
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-015
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 L
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 E-027
w
E-030
B ET21380041

Instrument Cluster Terminal List

Terminal No. Definition Terminal No. Definition
1 - 17 -
2 - 18 Parking Brake Switch Signal
Driver Seat Belt Unfasten Indication
3 Ground 19
Signal
4 - 20 -
5 Ground 21 Fuel Level Indication Signal
6 - 22 -
7 - 23 -
8 - 24 -
Engine Oil Pressure Indication
9 25 -
Signal
Brake System Malfunction Indication
10 - 26
Signal
11 Battery Power Supply 27 -
12 Illumination Input 28 -
38 13 Ignition Switch Power Supply 29 CAN-L

14 - 30 CAN-H
15 - 31 Steering Wheel Key Input
16 Charging System Indication Signal 32 -

DIAGNOSIS & TESTING

HINT:

Fuse 51-36
Entire instrument cluster does not operate Wire harness or connector -
Wheel speed -
Speed display abnormal Wire harness or connector -
Engine speed sensor -
Wire harness and connector -
Tachometer abnormal
Fuel level sensor - 38
Fuel gauge abnormal Wire harness or connector -
Position light switch (combination switch) 35-65
Position indicator abnormal
Turn light switch (combination switch) 35-65
Turn signal indicator abnormal
High beam switch (combination switch) 35-65
High beam indicator abnormal
Rear fog light switch (combination switch) 35-65
Rear fog indicator abnormal


Front fog light switch (combination switch) 35-65
Front fog indicator abnormal
Alternator 16-10
Charging system warning light abnormal Wire harness or connector -
Engine oil level -
Low engine oil pressure warning light Engine oil pressure switch 13-16
abnormal Wire harness or connector -
ABS warning light abnormal Instrument cluster 38-42
Fuel amount in tank -
Fuel level sensor -
38 Low fuel level warning light abnormal
High engine coolant temperature -
Coolant temperature sensor 06-243
Coolant temperature warning light
abnormal
Communication line or connector -
Engine malfunction warning light abnormal Instrument cluster 38-42
Communication line or connector -
SRS warning light abnormal Instrument cluster 38-42
SRS control module assembly 32-72
Driver seat belt buckle switch 33-11
Driver seat belt reminder light abnormal Wire harness or connector -
Front passenger seat belt buckle switch -
Front passenger seat belt reminder light
abnormal


Low brake fluid level -
Parking brake switch assembly 26-26
Brake system warning light abnormal
Diagnosis Tools
with vehicle.
 DLC is Located on the instrument panel crossmember of driver side.
 DLC uses trapezium design and can accommodate up to 16 terminals.
Digital Multimeter
 Troubleshoot electrical problems and wiring systems.
38
 Connect the X-431 3G diagnostic tester (the latest software) to Data Link Connector (DLC), and make it
communicate with vehicle electronic module by data network.
 Turn ignition switch to ON and select "Read Code".
 If the DTC is not detected, the malfunction indicated by the DTC is intermittent. Please refer to "Intermittent
DTC Troubleshooting".

 Inspect the mounting areas of instrument cluster, wire harness or wire harness connector and so on for

 Remove the instrument cluster from the malfunctioning vehicle and install it to a new vehicle and perform a
test. If DTC cannot be cleared, the instrument cluster is malfunctioning. If the DTC can be cleared, reinstall
the instrument cluster to original vehicle.
 If multiple trouble codes were set, use the circuit diagrams to look for any common ground circuit or power
supply circuit applied to the DTC.
Ground Inspection
(rust) and oxidation can increase load resistance. This situation will seriously affect the normal operation of
6. If several wire harnesses are crimped into one ground eyelet terminal, check if they are installed correctly.
Make sure all wire harnesses are clean, securely fastened and providing a good ground path.
Diagnosis Procedure
HINT:
38 Use the following procedures to troubleshoot the instrument cluster.
NEXT
NEXT
NEXT
DTC
occurs
No 
DTC

NEXT
NEXT
NEXT
NEXT
9 Confirm troubleshooting and perform test

38
NEXT
10 End


B1100-13 Power Supply Circuit Open
B1100-16 Power Supply Circuit Voltage Below Threshold
B1100-17 Power Supply Circuit Voltage Above Threshold
B1101-11 Fuel Sensor Fault Circuit Short to Ground
B1101-15 Fuel Sensor Fault Circuit Short to Battery or Open
B1103-00 LED Airbag Fault No Subtype Information
B1104-41 EEPROM Checksum Error
U0100-87 Lost Communication with EMS
U0101-87 Lost Communication with TCM
U0114-87 Lost Communication with TMM
U0126-87 Lost Communication with SAM
U0127-87 Lost Communication with TPM
U0129-87 Lost Communication with BSM
U0131-87 Lost Communication with EPS
38 U0140-87 Lost Communication with BCM

U0151-87 Lost Communication with ICM
U0167-87 Lost Communication with IMMO
U0214-87 Lost Communication with PEPS
U0073-88 CAN Bus Off
U1300-55 Software Configuration Error, Not Configured

DTC B1100-13 Power Supply Circuit Open
DTC B1100-16 Power Supply Circuit Voltage Below Threshold
DTC B1100-17 Power Supply Circuit Voltage Above Threshold
IGNITION SWITCH
BATTERY
ON OR START
INSTRUMENT
PANEL
RF23 RF06 FUSE AND
10A 10A RELAY BOX A
I-007
23 6
R
38
11 13
INSTRUMENT
I-015
3
B
I-003
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 27 25 26
87
I-015 85 86 86 86
87 30 87 30
30 85 85
L
I-007
B
ET21380050

DTC Detection
Condition
B1100-13
Open
Power Supply Circuit  Charging system
B1100-16 Voltage Below
Threshold
 Instrument cluster
B1100-17 Voltage Above
Threshold
CAUTION
38

Diagnosis Procedure
1 Check battery
a. Using a digital multimeter, measure the voltage between positive battery terminal and negative battery
terminal.
b. The battery voltage should be between 11 and 14 V.
OK

c. Disconnect the instrument panel wire harness connector
I-015. V
+ -
e. Turn ignition switch to ON.
f. Using a digital multimeter, measure the supply voltage
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
between instrument panel wire harness connector I-015
38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
and body ground according to the value(s) in the table
below to check if system power source control circuit is I-015
normal.
Standard Voltage
Condition
I-015 (11) - Body RT21380100
ground
I-015 (13) - Body
ground
g. Turn ignition switch to LOCK.

h. Disconnect the negative battery cable.
i. Disconnect the instrument panel wire harness connectors
I-015 and I-007.
+ -
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
I-007 according to the table below. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-015
Condition
1 2 3 4 5 6 7 8 9 10 11 12
I-015 (11) -
I-007 (23)
27 25 26
87
I-015 (13) -
I-007 (6) 30 85
87 30
85
87 30
I-007
RT21380110

k. Disconnect the instrument panel wire harness connector

I-015 and ground I-003.
instrument panel wire harness connector I-015 and
ground I-003 according to the table below. + -
Multimeter Specified 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Condition
I-015 (3) - I-003 Always Continuity I-015

I-003
RT21380120
OK
3 Reconfirm DTCs

38 b. Connect the negative battery cable.
d. Use X-431 3G diagnostic tester (the latest software) to record and clear the DTCs stored in the instrument
panel control system.
g. Use X-431 3G diagnostic tester (the latest software) to read the DTCs in the instrument cluster control
system again.
h. Read the DTCs.
Result Proceed to
DTC B1100-13, B1100-16 and B1100-17 are output NG
No DTC is output OK
NG Replace instrument cluster
OK
System is normal

DTC B1101-11 Fuel Sensor Fault Circuit Short to Ground
DTC B1101-15 Fuel Sensor Fault Circuit Short to Battery or Open
FUEL
GAUGE
INSTRUMENT
I-015
lOW FUEL
LEVEL
21
VB
I-006
12
B-003
38
VB
1
FUEL
Q PUMP
MOTOR
B-038
2
Br
B-032
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 10 9 8 7 6 5 4 3 2 1
1 2 3 4 22 21 20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-015 B-038 I-006

L B W
ET21380060

DTC Detection
Condition
Fuel Sensor Fault
B1101-11
Circuit Short to Ground  Charging system
Fuel Sensor Fault Ignition switch ON  Wire harness or connector
B1101-15 Circuit Short to Battery  Instrument cluster
or Open
CAUTION
Diagnosis Procedure
1 Check fuel level sensor wire harness and connector
38 b. Disconnect the negative battery cable.

c. Disconnect the fuel level sensor and fuel pump connector
B-038.
d. Check the wire harness, connector and terminals for
deformation, bend or damage.
NG Repair or replace fuel level sensor wire

RT21380060
OK
2 Check fuel level sensor

c. Check the remaining oil amount segments from fuel
gauge in the instrument cluster. + -
d. Turn ignition switch to LOCK.

4 3 2 1
e. Disconnect the negative battery cable.
f. Disconnect the fuel level sensor and fuel pump connector
B-038.
g. Using a digital multimeter, measure the resistance RT21380050
between terminal 1 and terminal 2 of fuel level sensor.
h. Check if fuel level sensor is normal according to the
correspondence between fuel amount segments and
standard resistance of fuel level sensor as shown in the
table below.

Fuel Gauge Multimeter

Specification (Ω)
Position Connection
E 1-2 275 ± 5
1/4 1-2 165 ± 5
1/2 1-2 97 ± 4
3/4 1-2 79 ± 3
F 1-2 32 ± 3

I-015 and I-006.
+ -
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Condition
I-015 (21) -
10 9 8 7 6 5 4 3 2 1 38
I-006 (12)
I-006

RT21380130
OK

B-038.
+ -
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
Condition
B-003 (12) -
Always Continuity
B-038 (1)
1 2 3 4
B-038
RT21380140

e. Disconnect the body wire harness connector B-038 and

ground B-032.
Condition
1 2 3 4
B-038

connector
B-032
RT21380150
OK
5 Reconfirm DTCs

38 b. Connect the negative battery cable.
g. Use X-431 3G diagnostic tester (the latest software) to read the DTCs in the instrument cluster system
again.
h. Read the DTCs.
Result Proceed to
DTC B1101-11 and B1101-15 are output NG
No DTC is output OK
OK
System is normal

DTC B1103-00 LED Airbag Fault No Subtype Information
MICROPROCESSOR
INSTRUMENT
CLUSTER
SRS I-015
CAN-L2 CAN-H2
29 30
OB
A30 A31
CAN-L2 CAN-H2
BCM A
38
I-005
CAN-L1 CAN-H1
A14 A15
OB
2 17
CAN-L1 SRS
CAN-H1
CONTROL
MODULE
I-046
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-015
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 L
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
I-046
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Gr
I-005
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 L
ET21380080

DTC Detection
Condition
 Airbag system
LED Airbag Fault No
B1103-00 Ignition switch ON  Wire harness or connector
Subtype Information
 Instrument cluster
CAUTION
Diagnosis Procedure
1 Check driver airbag
a. Remove the driver airbag from the malfunctioning vehicle. Install it to a new vehicle and perform a test.
NG Repair or replace driver airbag
38 OK

I-015 and I-005.
+ -
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Condition
I-015 (29) - A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32
Always Continuity
I-005 (A30) A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16
I-015 (30) - I-005

Always Continuity
I-005 (A31)
RT21380160

e. Disconnect the instrument panel wire harness connectors

I-005 and I-046.
Condition A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32
Connection Condition A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16
I-015 (A14) - I-005

Always Continuity
I- 046 (2)
I-015 (A15) -
I- 046 (17) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-046
RT21380210
OK
3 Reconfirm DTCs

38
system again.
h. Read the DTCs.
Result Proceed to
DTC B1103-00 is output NG
No DTC is output OK
OK
System is normal

DTC B1104-41 EEPROM Checksum Error

DTC Detection
Condition
EEPROM Checksum
B1104-41 Ignition switch ON  Instrument cluster
Error
CAUTION
Diagnosis Procedure
1 Reconfirm DTCs
a. Use X-431 3G diagnostic tester (the latest software) to clear the DTCs stored in the instrument cluster
control system.
38 b. Turn ignition switch to LOCK and wait for a few seconds.
d. Use X-431 3G diagnostic tester (the latest software) to read the DTCs in the instrument cluster control
system again.
e. Read the DTCs.
Result Proceed to
DTC B1103-00 is output NG
No DTC is output OK
OK
System is normal

DTC U0100-87 Lost Communication with EMS
DTC U0101-87 Lost Communication with TCM
DTC U0129-87 Lost Communication with BSM
DTC U0131-87 Lost Communication with EPS
DTC U0140-87 Lost Communication with BCM
DTC U0151-87 Lost Communication with ICM
DTC U0167-87 Lost Communication with IMMO
DTC U0214-87 Lost Communication with PEPS
DTC U0073-88 CAN Bus Off

38

EPS B
CONNECTOR
CAN-L1 CAN-H1 I-057
3 2
OB
CAN-H1 CAN-L1
J105
PSE
CONNECTION J1
J106
I-029
CAN-H1 CAN-L1
6
DIAGNOSTIC
INTERFACE 14
CAN-H1 CAN-L1
I-050
6
CAN-L2 CAN-H2 IMMOBILIZER
CONTROL
11 3 8
MODULE
I-018
A14 A15
CAN-L1 CAN-H1 BCM A
I-005
38 A30 A31
OB
29 30
CAN-L2 CAN-H2
INSTRUMENT
CLUSTER
MICROPROCESSOR
I-015
J108 J107 J106 J105 J104 J103 J102 J101 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32
5 4 3 2 1
J116 J115 J114 J113 J112 J111 J110 J109 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16
10 9 8 7 6
I-005
I-057 I-029
L
B
16 15 14 13 12 11 10 9
1 3 5 7 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
8 7 6 5 4 3 2 1
2 4 6 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-018
I-050 I-015
B
B L
ET21380070

ECM-2
E-033
CAN-L1 CAN-H1
CAN-H1 CAN-L1
41 17 1
42
E-030
CAN-H1 CAN-L1
14
ABS
CONTROL
OB
O
26
MODULE
E-085
E-027
10 9 I-034
CAN-H1 CAN-L1
2 SRS
CONTROL
17 MODULE
I-046
A14 A15
CAN-L1 CAN-H1 BCM A
I-005
CAN-L2 CAN-H2
CAN-H2 CAN-L2
A30 A31
3
AUDIO ASSISTANT
OB
2 I-019
29 30 38
CAN-L2 CAN-H2
INSTRUMENT
CLUSTER
MICROPROCESSOR
I-015
13 12 11 10 9 8 7 6 5 4 3 2 1
E-085
24 23 22 21 20 19 18 17 16 15 14
B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 38 37 36 35 34 33 32 31 30 29 28 27 26 25
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-015
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 L
I-005
E-033 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
B I-046
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Gr
D8 D7 D6 D5 D4 D3 D2 D1 I-019
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 B
D16 D15 D14 D13 D12 D11 D10 D9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 E-027
w
E-030
B ET21380071

DTC Detection
Condition
Lost Communication
U0100-87
with EMS
Lost Communication
U0101-87
with TCM
Lost Communication  Engine Control Module (ECM)
U0129-87
with BSM  Transmission Control Module (TCM)
Lost Communication  ABS control module
U0131-87
with EPS  EPS control module
Lost Communication Ignition switch ON  Body Control Module (BCM)
U0140-87
with BCM  SRS control module
Lost Communication  Anti-theft control module
U0151-87
with ICM  Instrument cluster
Lost Communication  CAN line communication
U0167-87
with IMMO
Lost Communication
U0214-87
with PEPS
U0073-88 CAN Bus Off
38
CAUTION
Diagnosis Procedure
1 Check connector and terminal

c. Disconnect the Engine Control Module (ECM) connector
E-033.
RT21380241


c. Disconnect the Transmission Control Module (TCM)
connector E-030.
RT21380240

c. Disconnect the ABS control module connector E-085.
38
RT21250070

c. Disconnect the EPS control module connector I-057.
RT21380080

B-047.
RT21380242


c. Disconnect the immobilizer control module connector 
I-018.
RT21380290

c. Disconnect the SRS control module connector I-046.
38
RT21380070

c. Disconnect instrument panel wire harness connector 
I-015.
d. Check wire harness, connector and terminals for
RT21380030


c. Disconnect instrument panel wire harness connectors 
I-015 and I-005.
+ -
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Condition
I-015 (29) - A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32
Always Continuity
I-005 (A30) A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16
I-005
I-043 (30) -
Always Continuity
I-005 (A31)
RT21380160
e. Disconnect instrument panel wire harness connectors 

I-015 and I-019.
38
Multimeter Specified 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Condition
I-015 (29) - I-015

Always Continuity
I-019 (D3)
I-015 (30) -
Always Continuity D8 D7 D6 D5 D4 D3 D2 D1
I-019 (D2) D16 D15 D14 D13 D12 D11 D10 D9
I-019
RT21380161

g. Disconnect instrument panel wire harness connectors 

I-005 and I-034.
Condition
I-005 (A14) -
Always Continuity A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16
I-034 (10)
I-005
I-005 (A15) -
Always Continuity
I-034 (9)
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
I-034
RT21380250
i. Disconnect instrument panel wire harness connectors 

I-005 and I-057.
Condition

I-005 (A14) -
Always Continuity
I-057 (3) I-005
I-005 (A15) -
Always Continuity
I-057 (2)
5 4 3 2 1
10 9 8 7 6
I-057
RT21380230
k. Disconnect instrument panel wire harness connectors 

I-005 and I-029.
Condition

I-005 (A14) -
Always Continuity
I-029 (J105) I-005
I-005 (A15) -
Always Continuity
I-029 (J106) J108 J107 J106 J105 J104 J103 J102 J101
J116 J115 J114 J113 J112 J111 J110 J109
I-029
RT21380220

m. Disconnect instrument panel wire harness connectors 

I-005 and I-018.
I-005 (A14) -
Always Continuity
I-018 (6) I-005
I-005 (A15) -
Always Continuity
I-018 (8) 1 3 5 7
2 4 6 8
I-018
RT21380200
o. Disconnect instrument panel wire harness connectors 

I-005 and I-046.
p. Using a digital multimeter, check for continuity between
Multimeter Specified 38
I-005 (A14) - I-005

Always Continuity
I-046 (2)
I-005 (A15) -
I-046 (17) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-046
RT21380210
q. Disconnect instrument panel wire harness connectors 

I-015 and I-050.
r. Using a digital multimeter, check for continuity between
Condition
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
I-015 (29) -
I-050 (11)
I-015
I-015 (30) -
Always Continuity
I-050 (3)
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
I-050
RT21380162

s. Disconnect instrument panel wire harness connectors 

I-005 and I-050.
t. Using a digital multimeter, check for continuity between
Multimeter Specified A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32
Condition
I-005 (A14) -
I-050 (14)
16 15 14 13 12 11 10 9
I-005 (A15) -
Always Continuity 8 7 6 5 4 3 2 1
I-050 (6)
I-050

RT21380163
OK
10 Check engine compartment wire harness and connector

38 b. Disconnect the negative battery cable.
c. Disconnect engine compartment wire harness
+ -
d. Using a digital multimeter, check for continuity between 1 2 3 4 5 6 7 8
engine compartment wire harness connectors E-027 and 9 10 11 12 13 14 15
E-033 according to the table below.
E-027
Condition
E-027 (10) - 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
E-033 (17) 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
E-027 (9) -
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Always Continuity
E-033 (1)
E-033
RT21380260

e. Disconnect engine compartment wire harness

1 2 3 4 5 6 7 8
Multimeter Specified 9 10 11 12 13 14 15
Condition
E-027 (10) - E-027
Always Continuity
E-030 (42)
E-027 (9) - 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
Always Continuity
E-030 (41) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
E-030
RT21380270
g. Disconnect engine compartment wire harness

1 2 3 4 5 6 7 8 38
Condition 9 10 11 12 13 14 15
E-027 (10) -
E-085 (14)
E-027 (9) -
Always Continuity 13 12 11 10 9 8 7 6 5 4 3 2 1
E-085 (26) 24 23 22 21 20 19 18 17 16 15 14
38 37 36 35 34 33 32 31 30 29 28 27 26 25
NG Replace or repair engine compartment

wire harness and connector E-085
RT21380280
OK
11 Reconfirm DTCs

d. Use the X-431 3G diagnostic tester (the latest software) to record and clear the DTCs stored in the
instrument panel control system.
system again.
h. Read the DTCs.

Result Proceed to
DTC U0100-87, U0101-87, U0129-87, U0131-87,
U0140-87, U0151-87, U0167-87, U0214-87 and NG
U0073-88 are output
No DTC is output OK
OK
System is normal
38

DTC U1300-55 Software Configuration Error, Not Configured

DTC Detection
Condition
Software Configuration
U1300-55 Ignition switch ON  Instrument cluster
Error, Not Configured
CAUTION
Diagnosis Procedure
1 Reconfirm DTCs
a. Use X-431 3G diagnostic tester (the latest software) to clear the DTCs stored in the instrument cluster
control system.
b. Turn ignition switch to LOCK and wait for a few seconds. 38
d. Use X-431 3G diagnostic tester (the latest software) to read the DTCs in the instrument cluster control
system again.
e. Read the DTCs.
Result Proceed to
DTC U1300-55 is output NG
No DTC is output OK
OK
System is normal

ON-VEHICLE SERVICE
Instrument Cluster
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing instrument cluster.
 Operate carefully to prevent components from being damaged when removing instrument cluster.
 DO NOT scratch interior and body paint when removing instrument cluster.

3. Lower the steering wheel in the direction of arrow as
38
RT21380040

5. Remove the instrument cluster.
a. Remove 2 fixing screws (arrow) from instrument
cluster.
RT21380020

up the clips on instrument cluster.
RT21380021

c. Disconnect the instrument cluster connector (arrow),

and remove the instrument cluster.
RT21380030
Installation
CAUTION
 When installing instrument cluster, be sure to align instrument cluster positioning hole with instrument
panel dowel pin, and clips are clamped in place.
 When installing instrument cluster, be sure to install connector in place.
 When installing instrument cluster, be sure to tighten fixing screws in place.
 Operate carefully to prevent other components from being damaged when installing instrument cluster.
38

- MEMO -

AUDIO SYSTEM
Operation 39-4 Rear Woofer Assembly 39-17
Tool 39-4 Inspection 39-17
Audio System Control Module  Antenna Assembly 
Terminal List 39-9 (w/ Antenna Amplifier) 39-19
Removal 39-19
Inspection 39-20
Installation 39-20
ON-VEHICLE SERVICE 39-12 Multi-function Interface 39-21
No Disc DVD Assembly 39-12 Removal 39-21
Inspection 39-13 No Disc DVD Control Panel 39-22
Tweeter Assembly 39-14 Installation 39-23
Removal 39-14 Steering Wheel Quick Button 
Inspection 39-14 (if equipped) 39-24
Front Woofer Assembly 39-15 Inspection 39-26
Removal 39-15 Installation 39-26 39

39

39 - AUDIO SYSTEM
GENERAL INFORMATION
AUDIO SYSTEM
Description
3
1
2
AC C
CK
O
LO
N
STA RT
39
5
7 8
10
11
RT21390010
1 - Steering Wheel Quick Button (if equipped) 2 - No Disc DVD Control Panel
3 - No Disc DVD Assembly 4 - Multi-function Interface
5 - Right Tweeter Assembly 6 - Front Right Woofer Assembly
7 - Rear Right Woofer Assembly 8 - Left Tweeter Assembly
9 - Antenna Assembly (w/ Antenna Amplifier) 10 - Rear Left Woofer Assembly
11 - Front Left Woofer Assembly

39 - AUDIO SYSTEM
Audio system mainly indicates radio receiver assembly. Primary function of radio receiver assembly is to
receive frequency modulation and amplitude modulation broadcast signals sent from broadcast stations, and
convert these signals into audio signal.
Radio receiver assembly consists of amplitude modulation tuner (AM) that receives the amplitude modulation
broadcast signal and frequency modulation tuner (FM) that receives the frequency modulation broadcast
signal.
Radio receiver assembly configuration in this model: no disc DVD assembly.
This vehicle is equipped with 6 speakers, which includes 2 tweeter assemblies and 4 woofer assemblies.
Operation
Essentially, radio receiver is a tuner. Radio receiver demodulates the radio frequency signal received from
antenna, and outputs the low power audio signal, which is amplified by inner amplifier circuit and converted
into original sound.
Specifications

No Disc DVD Assembly Fixing Screw 2 ± 0.5
Tweeter Assembly Fixing Screw 3 ± 0.5
Front Woofer Assembly Fixing Screw 2.5 ± 0.5
Rear Woofer Assembly Fixing Screw 2.5 ± 0.5
39 Antenna Assembly Fixing Nut 5±1
No Disc DVD Control Panel Fixing Screw 2 ± 0.5
Wire Harness Fixing Screw 0.7 ± 0.2
Steering Wheel Quick Button Trim Cover Fixing
0.7 ± 0.2
Screw
Steering Wheel Quick Button Fixing Screw 0.7 ± 0.2
Tool
General Tool
Digital Multimeter
RCH0000002

39 - AUDIO SYSTEM
Circuit Diagram
Audio System (Page 1 of 4)
RADIO BUTTONS
IGNITION SWITCH R5 MODE/MUTE

BATTERY
ON OR ACC
R4
INSTRUMENT R3
RF22 RF13 PANEL FUSE
BOX A
15A 7.5A R2 VOL-
I-007
22 13
R1 VOL+ R8
INSTRUMENT
CLUSTER
ADJUST
BUTTON
RW
RL
SPIRAL
CABLE
CONNECTOR
10 12 11 6 13 5 I-012
B
39
Lg
I-003
31 G
INSTRUMENT
BrW
CLUSTER
BrY
I-015
ILLUMINTION
B16 B15 B10 B14 B13 D16
AUDIO I-020 I-019
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
I-007 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-015
27 25 26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 L
87
B
85 86 86 86
87 30 87 30
30 85 85
B8 B7 B6 B5 B4 B3 B2 B1 I-020 D8 D7
9 10 11 12 13 14 15 16 I-012 D6 D5 D4 D3 D2 D1 I-019
1 2 3 4 5 6 7 8 W B9 B10 B11 B12 B13 B14 B15 B16 B B
D9 D10 D11 D12 D13 D14 D15 D16
ET21390010

39 - AUDIO SYSTEM
AUDIO I-020
B2 B3 B4 B5
LBr
LBr
LW
LW
3 4 I-006 I-035
B-003 3 4 B-059
LBr
LW
LW
LBr
39
LBr
LW
LW
1 2 B-040 B-061
14 17
F-007 H-002
LBr
LW
LBr
LW
LBr
LBr
LW
LW
1 2 1 2 1 2 1 2
FRONT LEFT FRONT LEFT FRONT RIGHT FRONT RIGHT

SPEAKER DOOR SPEAKER SPEAKER DOOR SPEAKER
B-006 F-008 B-001 H-007
9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 B8 B7 B6 B5 B4 B3 B2 B1 I-020
I-035 I-006
18 17 16 15 14 13 12 11 10 W 22 21 20 19 18 17 16 15 14 13 12 11 B9 B10 B11 B12 B13 B14 B15 B16 B
W
1 4 7 10 13 16 1 4 7 10 13 16 1 1
B-040 B-061 1 B-001 1 B-006 F-008 H-007
2 5 8 11 14 17 2 5 8 11 14 17 2
W W 2 B 2 B 2 B B
3 6 9 12 15 18 3 6 9 12 15 18
ET21390020

39 - AUDIO SYSTEM
AUDIO I-020
B6 B7 B8 B9 B11 B1
GW
WY
GY
GB
B
5 6 I-006 I-035
B-003 5 6 10 B-059
GW
WY
GY
GB
I-037
Y
B-026 B-005
13 14 L-005 13 14 R-002
1 39
GW
WY
GY
GB
ANTENNA
POWER SUPPLY
1 2 1 2 B-014

DOOR SPEAKER DOOR SPEAKER
L-003 R-005
1 1 B-014
L-003 R-005 B8 B7 B6 B5 B4 B3 B2 B1 I-020 9 8 7 6 5 4 3 2 1 I-035 1
2 B 2 B B9 B10 B11 B12 B13 B14 B15 B16 B 18 17 16 15 14 13 12 11 10 W W
6 5 2 1 10 9 8 7 6 5 4 3 2 1
6 5 2 1 4 3 I-006
B-005 12 11 8 7 B-026 22 21 20 19 18 17 16 15 14 13 12 11
12 11 4 3 8 7 10 9 W
Y 14 13
Y
16 15
16 15 10 9 14 13
ET21390030

39 - AUDIO SYSTEM
CAMERA T-009 USB I-042
2 5 6 1 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10
NONE
RY
B
W
T-004
14 10 2 8
B-012
B
NONE
RY
B-018
TO BACK-UP
SWITCH
B-059
9 12 11
I-035
TO CAN
SYSTEM
NONE
RY
OB
39
O
D6 D5 D4 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 D1 D3 D2
CAN-L2 CAN-H2
AUDIO I-019 I-023
1 2 3 4 5 6 7 8 B-012 9 8 7 6 5 4 3 2 1
3 2 1 T-009 I-035
9 10 11 12 13 14 15 W 18 17 16 15 14 13 12 11 10 W
4 5 6 B
D8 D7 D6 D5 D4 D3 D2 D1 C2 C4 C6 C8 C10 D2 D4 D6 D8 D10
I-019 I-023 I-042
D9 D10 D11 D12 D13 D14 D15 D16 B C1 C3 C5 C7 C9 B D1 D3 D5 D7 D9 B
ET21390040

39 - AUDIO SYSTEM
Audio System Control Module Terminal List
9 10 11 12 13 14 15
16
1
8 7 6 5 4 3 2
39
RT21390260
Terminal No. Terminal Name Terminal Definition

1 GND Power Ground
2 FL+ Front Left Speaker Audio Signal+
3 FL- Front Left Speaker Audio Signal-
4 FR+ Front Right Speaker Audio Signal+
5 FR- Front Right Speaker Audio Signal-
6 RL+ Rear Left Speaker Audio Signal+
7 RL- Rear Left Speaker Audio Signal-
8 RR+ Rear Right Speaker Audio Signal+
9 RR- Rear Right Speaker Audio Signal-
10 Steer button power Steering Wheel Quick Button Operation Power
11 AMP Antenna Operation Power
12 - -
13 Steer button signal Steering Wheel Quick Button Signal
14 ILL Backlight Adjustment Signal
15 ACC Ignition Switch Power Supply
16 BATT Battery Power Supply

39 - AUDIO SYSTEM
9 10 11 12 13 14 15 16
8 7 6 5 4 3 2 1
39 RT21390270
Terminal No. Terminal Name Terminal Definition

1 Reverse Reverse Signal (DC High is effective)
2 CAN_H CAN High Signal
3 CAN_L CAN Low Signal
4 RVC_CVBS- Camera Video-
5 RVC_CVBS+ Camera Video+
6 RVC_VCC Camera Power Supply
7 - -
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
14 - -
15 - -
16 Steer button power Steering Wheel Bluetooth Button Power Supply

39 - AUDIO SYSTEM
DIAGNOSIS & TESTING

HINT:

Noise source (interference) -
Tweeter assembly (loose installation) 39-14
Noise occurs Front woofer assembly (loose installation) 39-15
Rear woofer assembly (loose installation) 39-17
No disc DVD assembly (malfunction) 39-12
Fuse (blown) 51-36
No disc DVD control panel 39-22
No disc DVD assembly does not operate
Wire harness and connector (malfunction) -
Fuse (blown) 51-36
Tweeter assembly (loose installation) 39-14
Front woofer assembly (loose installation) 39-15 39
No sound can be heard from speakers Rear woofer assembly (loose installation) 39-17
Wire harness and connector (malfunction) -
Optional equipment (interference) -
Radio broadcast signal cannot be received
(poor reception) Antenna assembly (w/ antenna amplifier)
39-19
(malfunction)
Antenna wire harness and connector
-
(malfunction)
HINT:
When checking general malfunctions of audio system, perform inspection at spacious area nearby free of
obstacles.

39 - AUDIO SYSTEM
ON-VEHICLE SERVICE
No Disc DVD Assembly
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing no disc DVD assembly.
 Appropriate force should be applied when removing no disc DVD assembly. Be careful not to operate
roughly.
 DO NOT scratch interior when removing no disc DVD assembly.

3. Remove the DVD panel assembly.
the clips on DVD panel assembly.
39
RT21430500
b. Disconnect the DVD panel assembly connectors

(arrow) and remove the DVD panel assembly.
3 80
60
2
40
1
20
ON
OFF
RT21430510
4. Remove the no disc DVD assembly.
CAUTION
 Handle and operate carefully to prevent components from being scratched or damaged when removing
no disc DVD assembly.

39 - AUDIO SYSTEM
a. Remove 4 fixing screws (arrow) and ground (1) from

the no disc DVD assembly.
RT21390020
b. Disconnect the no disc DVD assembly connectors

(arrow) and antenna (1) and remove the no disc DVD
assembly.
RT21390030
Inspection
1. Check no disc DVD assembly connectors and terminals for deformation or damage. Replace if necessary.
2. Check antenna and connectors for damage. Replace if necessary. 39
3. Check no disc DVD assembly house for deformation or damage. Replace if necessary.
Installation
CAUTION
 Operate carefully to prevent components from being damaged when installing no disc DVD assembly.
 Be sure to tighten fixing screws to the specified torque when installing no disc DVD assembly.
 Install each connector in place when installing no disc DVD assembly.
 Check no disc DVD assembly for proper operation after installation.

39 - AUDIO SYSTEM
Tweeter Assembly
Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing tweeter assembly.
 Appropriate force should be applied when removing tweeter assembly. Be careful not to operate roughly.

3. Remove the A-pillar upper protector assembly (See page 49-17).
4. Remove the left tweeter assembly.
a. Remove 3 fixing screws (arrow) from tweeter
assembly.
b. Remove the left tweeter assembly.
39
RT21490102
Inspection
1. Check tweeter connector for damage and terminals for bend or poor connection. Replace if necessary.
Installation
CAUTION
 Operate carefully to prevent components from being damaged when installing tweeter assembly.
 Be sure to tighten fixing screws to the specified torque when installing tweeter assembly.
 Install connector in place when installing tweeter assembly.
 Check tweeter assembly for proper operation after installation.

39 - AUDIO SYSTEM
Front Woofer Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing front woofer assembly.
 Appropriate force should be applied when removing front woofer assembly. Be careful not to operate
roughly.
 Never touch the cone paper and other components of front woofer assembly during removal; otherwise it
will affect sound effect or damage front woofer assembly.

4. Remove the front left woofer assembly.
a. Disconnect the front woofer connector (1).
b. Remove 3 fixing screws (arrow) from front woofer
assembly, and then remove the front left woofer
assembly.
39
RT21390040
Inspection
1. Check front woofer assembly.
a. Using a digital multimeter, measure resistance of front
woofer assembly according to the table below.
+ -
Standard Resistance
1
Condition
Terminal 1 - Approximately
Always
Terminal 2 3.6 Ω
If result is not as specified, replace the front woofer RT21390050

assembly.
2. Check cone paper of front woofer assembly for damage or deformation. Replace if necessary.
3. Check front woofer connector for damage and terminals for bend or poor connection. Replace if
necessary.

39 - AUDIO SYSTEM
Installation
CAUTION
 Operate carefully to prevent components from being damaged when installing front woofer assembly.
 Be sure to tighten fixing screws to the specified torque when installing front woofer assembly.
 Install connector in place when installing front woofer assembly.
 Check front woofer for proper operation after installing front woofer assembly.
39

39 - AUDIO SYSTEM
Rear Woofer Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rear woofer assembly.
 Appropriate force should be applied when removing rear woofer assembly. Be careful not to operate
roughly.
 Never touch the cone paper and other components of rear woofer assembly during removal; otherwise it
will affect sound effect or damage rear woofer assembly.

4. Remove the rear left woofer assembly.
a. Disconnect the rear woofer connector (1).
b. Remove 3 fixing screws (arrow) from rear woofer
assembly, and then remove the rear woofer assembly.
39
1
RT21390060
Inspection
1. Check rear woofer assembly.
a. Using a digital multimeter, measure resistance of rear
woofer assembly according to the table below.
+ -
Standard Resistance
1
Condition
Terminal 1 - Approximately
Always
Terminal 2 3.6 Ω
If result is not as specified, replace the rear woofer RT21390050

assembly.
2. Check cone paper of rear woofer assembly for damage or deformation. Replace if necessary.
3. Check rear woofer connector for damage and terminals for bend or poor connection. Replace if necessary.

39 - AUDIO SYSTEM
Installation
CAUTION
 Operate carefully to prevent components from being damaged when installing rear woofer assembly.
 Be sure to tighten fixing screws to specified torque when installing rear woofer assembly.
 Install connector in place when installing rear woofer assembly.
 Check rear woofer for proper operation after installing rear woofer assembly.
39

39 - AUDIO SYSTEM
Antenna Assembly (w/ Antenna Amplifier)

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing antenna assembly.
 Appropriate force should be applied when removing antenna assembly. Be careful not to operate
roughly.

HINT:
It is not necessary to completely remove the roof assembly during removal, but it is necessary to lower the
rear part of roof assembly so that antenna can be removed.
4. Remove the antenna assembly (w/ antenna amplifier).
a. Disconnect the antenna (1) and connectors (arrow)
from antenna assembly.
39
1
RT21390080
b. Remove the fixing nut (arrow) from antenna assembly.

RT21390090
c. Detach the attachment part between antenna

assembly and body in the direction of arrow as shown
RT21390100

39 - AUDIO SYSTEM
d. Remove the antenna assembly from roof.
RT21390110
Inspection
1. Check antenna assembly.
a. Check antenna assembly for wear, cracks, deformation or damage. Replace if necessary.
b. Check antenna assembly for looseness or disengagement. Replace if necessary.
c. Check terminals on antenna connector for deformation or bend. Replace if necessary.
Installation
HINT:
When installing antenna assembly, align the boss at end of
antenna assembly with the groove on fixing nut as shown in
the illustration, and then firmly install the antenna assembly.
39
RT21390120
CAUTION
 Operate carefully to prevent components from being damaged when installing antenna assembly.
 Always insert dowel pin into body positioning hole and set it in place when installing antenna assembly.
 Be sure to tighten fixing nuts to the specified torque when installing antenna assembly.
 Install each connector and antenna in place when installing antenna assembly.
 Check audio system for proper operation after installing antenna assembly.

39 - AUDIO SYSTEM
Multi-function Interface
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing multi-function interface.
 Appropriate force should be applied when removing multi-function interface. Be careful not to operate
roughly.

3. Remove the multi-function interface
up the claws (arrow) on multi-function interface. OFF
A/C
OU
TL
ER
ET
POW
120W
AUX 12V
iPod
AUX
iPod
RT21390130
39
b. Disconnect the multi-function interface connector
(arrow), and remove the multi-function interface. OFF
A/C
OU
TL
ER
ET
POW
120W
12V
RT21390140
Installation
CAUTION
 Operate carefully to prevent components from being damaged when installing multi-function interface.
 Install connector in place when installing multi-function interface.
 Check multi-function interface for proper operation after installation.

39 - AUDIO SYSTEM
No Disc DVD Control Panel

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing no disc DVD control panel.
 Appropriate force should be applied when removing no disc DVD control panel. Be careful not to operate
roughly.

up the clips on DVD panel assembly.
RT21430500
39
b. Disconnect the DVD panel assembly connectors
(arrow) and remove the DVD panel assembly.
3 80
60
2
40
1
20
ON
OFF
RT21430510
4. Remove the no disc DVD control panel.

a. Remove 4 fixing screws (arrow) from no disc DVD
control panel.
b. Remove the no disc DVD control panel from DVD
panel assembly.
RT21390150

39 - AUDIO SYSTEM
Installation
CAUTION
 Operate carefully to prevent components from being damaged when installing no disc DVD control
panel.
 Check no disc DVD for proper operation after installing no disc DVD control panel.
39

39 - AUDIO SYSTEM
Steering Wheel Quick Button (if equipped)

Removal
WARNING
 Be sure to read precautions for SRS airbag before removing steering wheel quick button
(See page 32-4).
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing steering wheel quick button.
 Operate carefully to prevent claws on steering wheel quick button from being damaged when removing
steering wheel quick button.

4. Remove the steering wheel quick button trim cover.
a. Disconnect the steering wheel quick button connector
(arrow).
39
RT21280060
b. Cut the wire harness band (arrow).
4 100 120
3 5 80 140
6 60 160
2
40 180
1 7
x1000
20 200
8 220
H
RES/+
VOL+ NAV1 SET

ON MENU BAND
OFF
SET/-
MODE
VOL-
L R
A/C
1 3 5
2 4 R
RT21280041

39 - AUDIO SYSTEM
c. Remove the fixing screw (arrow) from ground wire

harness.
d. Remove the wire harness fixing screw (1).
4 100 120
3 5 80 140
6 60 160
2
40 180
1 7
x1000
20 200
8 220
H
RES/+
1
VOL+ NAV1 SET
ON MENU BAND
OFF
SET/-
MODE
VOL-
L R
A/C
1 3 5
2 4 R
RT21390160
e. Remove 2 fixing screws (arrow) from steering wheel

quick button trim cover.
4 100 120
3 5 80 140
6 60 160
2
40 180
1 7
x1000
20 200
8 220
H
RES/+
VOL+ NAV1 SET

ON MENU BAND
OFF
SET/-
MODE
VOL-
L R
A/C
1 3 5
2 4 R
RT21390170
f. Using a screwdriver wrapped with protective tape, pry

up the claws on steering wheel quick button trim
cover, and remove the steering wheel quick button
trim cover. 2
1
x1000
3
4
5
8
6
7
60
40
20
80
100 120
140
160
220
180
200
39
H
RES/+
VOL+ NAV1 SET

ON MENU BAND
OFF
SET/-
MODE
VOL-
L R
A/C
1 3 5
2 4 R
RT21390180
5. Remove the steering wheel quick button.

a. Remove 6 fixing screws (arrow) from steering wheel
quick button, and remove the steering wheel quick
button.
RT21390190

39 - AUDIO SYSTEM
Inspection
1. Check steering wheel quick button.
a. Check steering wheel quick button for damage. Replace if necessary.
b. Check steering wheel quick button connector for damage or poor terminal connection. Replace if
necessary.
c. Check for continuity of wire harness between steering wheel quick button connector and audio unit (no
disc DVD assembly). Replace if necessary.
Installation
CAUTION
 Operate carefully to prevent components from being damaged when installing steering wheel quick
button.
 Install each connector in place when installing steering wheel quick button.
 Tighten fixing screws to the specified torque when installing steering wheel quick button.
39

Description 40-3 Reversing Radar Sensor 40-10
Operation 40-3 Removal 40-10
Reversing Radar Normal Alarm Display 40-4 Installation 40-11
Specification 40-4 Rear View Monitor Camera 40-12
Reversing Radar Control Module  Reversing Radar Control Module 
Assembly Terminal List 40-8 Assembly 40-13
Removal 40-13
Installation 40-13
Self-checking Function 40-9
40

40

40 - REVERSING RADAR SYSTEM
GENERAL INFORMATION
Description
3
2
1
4
7 5
6
40
RT21400010
1 - Instrument Cluster (Built-in Buzzer) 2 - Right Reversing Radar Sensor

3 - Rear View Monitor Camera 4 - Reversing Radar Control Module Assembly
5 - Left Reversing Radar Sensor 6 - Center Left Reversing Radar Sensor
7 - Center Right Reversing Radar Sensor
Operation
Reversing radar system is an auxiliary system intended to assist driver when reversing, consists of reversing
radar sensor (probe), reversing radar control module assembly and alarm device (instrument cluster built-in
buzzer). Reversing radar system is activated when shift lever is shifted to reverse range. When the reversing
radar sensor detects obstacles behind, the instrument cluster built-in buzzer will sound. This can help driver to
eliminate the blind corner and blurred vision, thus improving the driving safety when reversing.

Reversing Radar Normal Alarm Display

Reversing radar system consists of four reversing radar sensors and one reversing radar control module
assembly.
It is activated when the shift lever is shifted to R and reversing at the speed below 5 km/h with ignition switch
ON. The corresponding measured message will be displayed on multi-information display and alarm with
buzzer in instrument cluster.
The response way of reversing radar system is buzzer response. The table below shows the correspondence
between buzzer response frequency and actual obstacle distance:
Alarm Type 1st Section 2nd Section 3rd Section 4th Section 5th Section
Pre-warning
Displayed Area Safe Area Amble Area Park Area Park Area
Area
Alarm Distance
> 150 95 - 150 65 - 90 35 - 60 ≤ 35
(cm)
1Hz (ON 2Hz (ON 4Hz (ON
Buzzer Sound No Sound Continuous
500ms/OFF 250ms/OFF 125ms/OFF
Frequency (OFF) Sound
500ms) 250ms) 125ms)
Specification

Fixing Bolt Between Reversing Radar Control
5±1
Module Assembly and Body
40
Tool
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Reversing Radar System (Page 1 of 3)
MT
IGNITION IGNITION SWITCH

SWITCH ON ON OR START
INSTRUMENT ENGINE
PANEL EF34 EF28 COMPARTMENT
RF01
FUSE AND 20A 10A FUSE AND
10A RELAY BOX A RELAY BOX C
I-007 E-023
1 C8
LR
1
BACK-UP
CLOSE LIGHT
R
SWITCH
OPEN E-025
2 L
E-007
I-006 35
13 B-003 E-038
L
E-029
3 B-054
BCM (B) 40
R
B-047
B17 B25
V
L
3 1 13
REVERSE
RADAR
MODULE
B-020
1 2 3 4 5 6 7 8 9 10 11 12
42 38 34 30 25 20 15 10 5
13 14 15 16 17 18 19 20 21 22 23 24
41 37 33 29 24 19 14 9 4
C1 C2 C3 C4 C5
27 25 26 28 23 18 13 8 3
87 40 36 32
27 22 17 12 7 2 C6 C7 C8 C9 C10
85 86 86 86 39 35 31 26 21 16 11 6
87 30 87 30 1
30 85 85
E-023
I-007 E-007 L
B B
10 9 8 7 6 5 4 3 2 1
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 11 1 2 3 4 5 6 7 8
22 21 20 19 18 17 16 15 14 13 12
9 10 11 12 13 14 15 16
I-006 E-029
W B-020
W
W
B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 2 1
E-025
B-047 B
L
ET21400010

CVT
IGNITION
BATTERY
SWITCH ON
EF30 ENGINE
INSTRUMENT
RF01 RF03 PANEL 10A COMPARTMENT
FUSE AND 85 30 FUSE AND
10A 7.5A RELAY BOX A RELAY BOX
I-007 REVERSE E-023
1 3 RELAY
E-069
86 87
Y
F3 F2 C6
L
12
R
I-004 E-071 E-007
Br
35 E-038
L
I-006
13 B-003 E-029
3 B-054
Br
Br
14 8
TCU CONNECTOR A BCM (B)
(FOR CVT) B-047
R
(FOR CVT)
E-030 E-050 B17 B25
L
40
L
3 1 13
REVERSE
RADAR
MODULE
B-020
1 2 3 4 5 6 7 8 9 10 11 12
C1 C2 C3 C4 C5
13 14 15 16 17 18 19 20 21 22 23 24 6 4 2 1 5 3 1 2 3 4 5 6 7 8
27 25 26 I-007 C6 C7 C8 C9 C10 10 9 7 8 9 10 11 12 13 14 15 16
87 B E-050 B-020
85 86 86 86 E-023
85
87 30
85
87 30 B W
30 L
42 38 34 30 25 20 15 10 5
41 37 33 29 24 19 14 9 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 28 23 18 13 8 3
E-030 40 36 32
27 22 17 12 7 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B
39 35 31 26 21 16 11 6 1
E-007
B
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32
E-069 B-047
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 W B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 L
6 5 4 3 2 1
11 10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
14 13 12 11 10 9 8 7
22 21 20 19 18 17 16 15 14 13 12 22 21 20 19 18 17 16 15 14 13 12 11
E-029 I-006 I-004

W W W ET21400020

REVERSE
RADAR
MODULE
B-020
7 15 4 8 16
WG
RB
GW
RW
B
1 1 1 RIGHT 1 LEFT
CENTER CENTER
RADAR RADAR
RADAR RADAR
SENSOR SENSOR
2 2 2 SENSOR 2 SENSOR
B-027 B-023
B-033 B-030
40
B
B
B
B
B-025
2 2 2 2
1 2 3 4 5 6 7 8
1 1 1 1
9 10 11 12 13 14 15 16
B-020 B-023 B-027 B-030 B-033

W B B B B
ET21400030

Reversing Radar Control Module Assembly Terminal List

Pin No. Terminal Definition Pin No. Terminal Definition
1 Reversing Signal 9 -
2 - 10 -
3 Ignition Signal 11 -
Center Right Reversing Radar
4 12 -
Sensor Signal
Data Signal (to Body Control Module
5 - 13
(BCM))
6 - 14 -
Right Reversing Radar Sensor
7 Left Reversing Radar Sensor Signal 15
Signal
Center Left Reversing Radar Sensor
8 16 Ground
Signal
40

DIAGNOSIS & TESTING

HINT:

Back-up light switch Assembly 35-88
Reversing radar sensor -
Reversing radar system does not function Camera -
(buzzer in instrument cluster does not
sound) Reversing radar control module assembly -
Wire harness and connector -
Self-checking Function
Reversing radar system has malfunction self-checking function, and the function instructions are as follows: 
If reversing radar sensor wire harness and connector are damaged or there is a malfunction in the reversing
radar sensor body, the instrument cluster will alarm after turning ignition switch ON and shifting the shift lever
to R.
Specific alarms are as follows:
1. When system is normal, the buzzer does not sound, and reversing radar system enters normal operation
mode. 40
2. When there are malfunctions in one or more sensors, relevant reversing radar sensor malfunction will be
displayed on multi-information display, other sensors can also enter normal operation mode.

ON-VEHICLE SERVICE
Reversing Radar Sensor
Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents when removing the reversing radar
sensor.
 Operate carefully to avoid damaging the reversing radar sensor when removing the reversing radar
sensor.

HINT:
The reversing radar sensor connector (arrow) has been
disconnected when removing the rear bumper assembly.
40
RT21400060
4. Remove the reversing radar sensor.

a. Press the claws on reversing radar sensor.
b. Remove the reversing radar sensor from the rear
bumper assembly.
RT21480422

Installation
HINT:
When installing the reversing radar sensor, align the boss at
the end of reversing radar sensor with the groove on rear
bumper assembly, and then firmly install the reversing radar
sensor as shown in the illustration.
RT21400030
CAUTION
 Install connector in place when installing the reversing radar sensor.

 Check reversing radar system for proper operation after installing the reversing radar sensor.
40

Rear View Monitor Camera

Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents when removing the rear view monitor
camera.
 Appropriate force should be applied when removing the rear view monitor camera. Be careful not to
operate roughly.

3. Remove the Back Door Protector Assembly (See page 47-47).
HINT:
The rear view monitor camera connector (arrow) has
been disconnected when removing the luggage
compartment upper trim assembly.
RT21370260
40 4. Remove the rear view monitor camera.

a. Remove 2 fixing screws (arrow) from the rear view
monitor camera, and remove the rear view monitor
camera.
RT21400040
Installation
CAUTION
 Tighten fixing screws to specified torque when installing the rear view monitor camera.
 Install connector in place when installing the rear view monitor camera.
 Check reversing radar system for proper operation after installing the rear view monitor camera.

Reversing Radar Control Module Assembly

Removal
CAUTION
 Be sure to wear necessary safety equipment to prevent accidents when removing the reversing radar
control module assembly.
 Appropriate force should be applied when removing the reversing radar control module assembly. Be
careful not to operate roughly.

3. Remove the C-pillar lower protector assembly (See page 49-23).
4. Remove the C-pillar upper protector assembly (See page 49-26).
5. Remove the reversing radar control module assembly.
a. Disconnect the reversing radar control module
assembly connector (1).
b. Remove 2 fixing bolts (arrow) between reversing
radar control module assembly and body, and remove
the reversing radar control module assembly.
1
RT21400050
40
Installation
CAUTION
 Tighten fixing bolts to specified torque when installing the reversing radar control module assembly.
 Install connector in place when installing the reversing radar control module assembly.
 Check reversing radar system for proper operation after installing the reversing radar control module
assembly.

- MEMO -

HORN
GENERAL INFORMATION 41-3 Horn Fuse Inspection 41-6
Description 41-3 Horn Relay Inspection 41-7
Specification 41-4
Tool 41-4
Horn 41-8
Removal 41-8
DIAGNOSIS & TESTING 41-6 Inspection 41-8
Problem Symptoms Table 41-6 Installation 41-9
41

41

41 - HORN
GENERAL INFORMATION
HORN
Description
4 2
41
RT21410010
1 - Horn Switch 2 - Engine Compartment Fuse and Relay Box

3 - Low Pitched Horn 4 - High Pitched Horn
This vehicle is equipped with high pitched and low pitched electronic horn system.
Horn system consists of the following components:
 Horn: high pitched horn and low pitched horn are installed on front pump crossmember.
 Horn switch: horn switch is installed on steering wheel.
 Horn fuse: horn fuse is located in engine compartment fuse and relay box.
 Horn relay: horn relay is located in engine compartment fuse and relay box.

41 - HORN
Specification

Horn Fixing Bolt 16 ± 2
Tool
General Tool
Digital Multimeter
RCH0000002
41

41 - HORN
Circuit Diagram
Horn System
BATTERY
1 5
HORN ENGINE
RELAY COMPARTMENT
FUSE AND
2 3 RELAY BOX
E-067
EF25 E-068
15A
H4 D6
BL
E-071
RY
3 I-004
BL
RY
RY
BL
14 1 1
SPIRAL CABLE
I-012 HIGH HORN LOW HORN
E-045 E-048
41
BW
2 2
BL
1
A13
BCM (A)
B
HORN
PRESSED SWITCH I-005
I-056
RELEASED
E-051
H8 H7 H6 H5 H4 H3 H2 H1 1 2 3 4 5 6
7 8 9 10 11 12 13 14
H16 H15 H14 H13 H12 H11 H10 H9
E-067 E-071
W B
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 L 1 2 1 2
D1 D2 D3 D4 D5 9 10 11 12 13 14 15 16 E-045 E-048
1 2 3 4 5 6 7 8 1
Gr Gr
D6 D7 D8 D9 D10
I-012 I-056
W W
E-068
W
ET21410010

41 - HORN
DIAGNOSIS & TESTING

HINT:

Horn fuse (blown) 51-34
Low pitched horn (damaged) 41-8
High pitched horn (damaged) 41-8
Horn does not sound
Horn switch (damaged) 32-65
Spiral cable (damaged) 32-67
Wire harness (short or open) -
Horn Fuse Inspection

1. Identify the horn fuse on the engine compartment fuse
and relay box.
15A
41
RT21410030
2. Check horn fuse.

a. Using a fuse puller, remove the horn fuse (15 A).
b. Check if the fuse is blown. Replace the fuse if it is blown.
CAUTION
 Use a fuse with the same specification as the original fuse to avoid affecting normal usage of electrical
equipment.

41 - HORN
Horn Relay Inspection

1. Check horn relay.
a. Remove the relay from engine compartment fuse and relay box.
b. Measure resistance according to the table below.
+ -
3
Condition 5
2 4 1
When battery
voltage is not
Terminal 3 -
applied between No continuity
Terminal 5
terminal 2 and
terminal 1
When battery RT21410031
Terminal 3 - voltage is applied

Continuity
2 and terminal 1
If result is not as specified, replace the relay.
41

41 - HORN
ON-VEHICLE SERVICE
Horn
Removal
4. Remove the high pitched horn.
a. Disconnect the high pitched horn wire harness
connector (1). 1
b. Remove the fixing bolt (arrow) from high pitched horn
bracket, and remove the high pitched horn.
RT21410040
5. Remove the low pitched horn.

a. Disconnect the low pitched horn wire harness
connector (1). 1
b. Remove the fixing bolt (arrow) from the low pitched
horn bracket, and remove the low pitched horn.
41
RT21410041
Inspection
1. Check high pitched horn.
Apply battery voltage to the high pitched horn and check
-
the operation of high pitched horn. +
Measurement Specified 2 1
Condition
Condition Condition
Battery positive
(+) - Terminal 1
Always Sounds
Battery negative
(-) - Terminal 2
RT21410050
If result is not as specified, replace the high pitched horn.

41 - HORN
2. Check low pitched horn.

Apply battery voltage to the low pitched horn and check
-
the operation of low pitched horn. +
Measurement Specified 2 1
Condition
Condition Condition
Battery positive
(+) - Terminal 1
Always Sounds
Battery negative
(-) - Terminal 2
RT21410060
If the result is not as specified, replace the high pitched

horn.
3. Check wire harness.
Using a digital multimeter, check for an open, short or ground failure in the horn system wire harness.
Replace if necessary.
Installation
CAUTION
 Tighten fixing bolts to the specified torque.

41

- MEMO -

OTHER SYSTEM
Circuit Diagram 42-4 Backup Power Supply Assembly 42-7
Removal 42-7
Installation 42-8
Cigarette Lighter Assembly 42-5
42

42

42 - OTHER SYSTEM
GENERAL INFORMATION
OTHER SYSTEM
Description
7
6
2
3
4 1
5
42
RT21420010
1 - Auxiliary Fascia Console Assembly 2 - Cigarette Lighter End

3 - Cigarette Lighter Fixing Bush 4 - Cigarette Lighter Housing
5 - USB Panel Assembly 6 - Power Socket Cover
7 - Power Socket
Cigarette lighter assembly is located on the USB panel assembly.

This model is equipped with a 12 V backup power supply, which is located on the USB panel assembly for
charging at any time.
CAUTION
 Rated voltage of cigarette lighter socket is 12 V. DO NOT use electrical equipment with higher rated
voltage.

42 - OTHER SYSTEM
Circuit Diagram
Cigarette Lighter System
IGNITION SEITCH
BATTERY
ACC OR ON
INSTRUMENT
PANEL FUSE
RF45 RF14 AND RELAY
BOX
10A 15A
I-007
I-031
E17 14
RY
2 2
BACKUP
POWER CIGARETTE
SUPPLY LIGHTER
I-049
42
I-041
1 3
B
I-047 I-047
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
E1 E2 E3 E4 E5 E6 E7 E8
E13 E14 E15 E16 1 2
E9 E10 E11 E12 E17 E18 E19 E20 27 25 26 3 2 1
87
85 86 86 86
87 30 87 30 I-041 I-049
I-031 30 85 85
W W
W
I-007
B
ET21420010

42 - OTHER SYSTEM
ON-VEHICLE SERVICE
Cigarette Lighter Assembly
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing cigarette lighter assembly.
 Appropriate force should be applied when removing cigarette lighter assembly. Be careful not to operate
roughly.
 Try to prevent USB panel assembly from being scratched when removing cigarette lighter assembly.

3. Remove the cigarette lighter assembly.
a. Remove the cigarette lighter end in the direction of
A/C
OFF
OU
TL
ER
ET
POW
120W
AUX 12V
iPod
RT21420030
b. Using a screwdriver wrapped with protective tape, pry 42

off the clips on USB panel assembly, and remove the
cigarette lighter panel. OFF
A/C
OU
TL
ER
ET
POW
120W
AUX 12V
iPod
RT21420040
c. Disconnect the cigarette lighter connector (arrow).
A/C
OFF
RT21420050

42 - OTHER SYSTEM
d. While pressing the claws on cigarette lighter housing

in the direction of arrow as shown in the illustration,
remove the cigarette lighter fixing bush using a OFF
A/C
screwdriver wrapped with protective tape.
RT21420060
e. Press the claws on cigarette lighter housing in the

remove the cigarette lighter housing. OFF
A/C
RT21420070
Installation
HINT:
When installing cigarette lighter housing, align the protrusion
of cigarette lighter housing end with the slot on USB panel,
and install the cigarette lighter housing securely.
42
RT21420080
CAUTION
 Check the cigarette lighter for proper operation after installing cigarette lighter assembly.

42 - OTHER SYSTEM
Backup Power Supply Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing backup power supply assembly.
 Appropriate force should be applied when removing backup power supply assembly. Be careful not to
operate roughly.
 Try to prevent USB panel assembly from being scratched when removing backup power supply
assembly.

3. Remove the backup power supply assembly.
a. Open the backup power supply cover in the direction
of arrow as shown in the illustration. OFF
A/C
OU
TL
ER
ET
POW
120W
AUX 12V
iPod
RT21420090

off the backup power supply assembly. A/C
42
OFF
AUX
iPod
RT21420100
c. Disconnect the backup power supply connector

(arrow), and remove the backup power supply A/C
assembly.
OFF
AUX
iPod
RT21420110

42 - OTHER SYSTEM
d. Separate the power socket (1) and power socket

cover (2) as shown in the illustration.
1
2
RT21420130
Installation
HINT:
When installing backup power supply assembly, align the
protrusion of backup power supply assembly end with the
slot on USB panel, and install the backup power supply
assembly securely.
RT21420120
CAUTION
 Check the backup power supply assembly for proper operation after installing backup power supply
assembly.
42

GENERAL INFORMATION 43-3 Front Door Glass Rear Guide Rail 
Circuit Diagram 43-10 Front Door Power Glass Regulator 
Assembly 43-53
DIAGNOSIS & TESTING 43-13 Removal 43-53
Problem Symptoms Table 43-13 Inspection 43-54
Diagnosis Tools 43-13 Installation 43-54
DTC Confirmation Procedure 43-13 Power Glass Regulating Switch 43-55
Intermittent DTC Troubleshooting 43-14 Removal 43-55
Ground Inspection 43-14 Inspection 43-57
Diagnosis Procedure 43-15 Installation 43-57
Diagnostic Trouble Code (DTC) Chart 43-16 Rear Door Outer Weather bar 43-58
B100C13 43-17 Removal 43-58
B100C71 43-17 Installation 43-58
B100D13 43-17 Rear Door Glass Assembly 43-59
B100D71 43-17 Removal 43-59
B100E13 43-23 Installation 43-60
B100E71 43-23 Rear Door Glass Rear Guide Rail 
B100F13 43-23 Assembly 43-61
B100F71 43-23 Removal 43-61
B101071 43-30 Rear Door Power Glass Regulator 
B101113 43-30 Assembly 43-62
B101171 43-30 Removal 43-62
B101213 43-37 Inspection 43-63
Installation 43-63
B101271 43-37 43
B101313 43-37 Triangular Window Glass Assembly 43-64
B101371 43-37 Removal 43-64
Installation 43-66
ON-VEHICLE SERVICE 43-44 Front Windshield Assembly 43-70
Power Glass Regulating Control 
Removal 43-70
Master Switch 43-44
Installation 43-72
Removal 43-44
Rear Windshield Assembly 43-77
Inspection 43-45
Removal 43-77
Installation 43-46
Installation 43-79
Front Door Outer Weather bar 43-47
Rear Window Defroster 43-83
Removal 43-47
General Information 43-83
Installation 43-48
Front Door Glass Assembly 43-49
Rear Window Defroster System 43-84
Removal 43-49
Installation 43-50
Rear Window Defogger Switch 43-86
Removal 43-86
Installation 43-87

43

43 - WINDSHIELD/WINDOW GLASS
GENERAL INFORMATION
Description
1
4
2
3
7
6 8
5
43
RT21430010

1 - Front Windshield Assembly 2 - Front Left Door Glass Assembly

3 - Rear Left Door Glass Assembly 4 - Left Triangular Window Glass Assembly
5 - Rear Windshield Assembly 6 - Right Triangular Window Glass Assembly
7 - Rear Right Door Glass Assembly 8 - Front Right Door Glass Assembly
43

2
3
4
7
8
5
6
RT21430020
1 - Front Right Door Power Glass Regulating Switch 2 - Rear Right Door Power Glass Regulating Switch 43
Assembly Assembly
3 - Front Left Door Power Glass Regulating Control 4 - Rear Left Door Power Glass Regulating Switch
Master Switch Assembly Assembly
5 - Rear Left Door Power Glass Regulator Assembly 6 - Front Left Door Power Glass Regulator Assembly
7 - Rear Right Door Power Glass Regulator 8 - Front Right Door Power Glass Regulator
Assembly Assembly
Power window control system controls the power window glass UP/DOWN function by operating power glass
regulating control switch on the door inner protector assembly. Main control devices of this system include:
power glass regulating control master switch (built into driver side door) and power glass regulating switches
(built into front passenger side door and rear doors). Press the power glass regulating control master switch or
any power glass regulating switch to transmit the UP/DOWN signal to corresponding power glass regulator
motor, thus controlling the UP/DOWN operation of corresponding power window glass.

Main Components Function
Component Description
Locates on front left door inner protector assembly
and controls operations of front and rear passenger
door power window glass.
Power window lock switch When power window lock switch is in lock position,
only driver side power glass regulating control
master switch can control UP/DOWN operation of
driver side power window glass.
Locates on door inner protector assembly.
Power glass regulating switch Each power glass regulating switch controls UP/
DOWN operation of corresponding power window
glass.
Receives switch signal and performs conversion in
Power glass regulator motor order to activate power glass regulator motor to
change power window glass position.
System Function
Function Description
Power glass regulating control master switch and
power glass regulating switches have manual UP
function. Power window glass goes up when power
Manual UP function
glass regulating control master switch or any power
glass regulating switch is pulled up and stops when
switch is released.
power glass regulating switches have manual
DOWN function. Power window glass goes down
Manual DOWN function
when power glass regulating control master switch
43 or any power glass regulating switch is pressed and
held and stops when switch is released.
power glass regulating switches have automatic
DOWN function. Power window glass goes down
Automatic DOWN function
automatically when power glass regulating control
master switch or any power glass regulating switch is
pressed. To stop it partway, press switch again.
When power window lock switch is pressed,
corresponding power window glass cannot be
operated with passenger side power glass regulating
Power window LOCK function control switches. In this case, only driver side power
window glass can be operated. This function can be
canceled only when power window lock switch is
pressed again.

Operation Inspection
1. Check power window lock switch.
a. Check that front passenger side power window glass and rear door window glass cannot be operated
with front passenger side power glass regulating switch and rear door glass regulating switch when
power window lock switch is pressed.
OK: Operation for front passenger side power glass regulating switch and rear door glass
regulating switch is failed.
b. Check that front passenger side power window glass
and rear door window glass can be operated with front
passenger side power glass regulating switch and
rear door glass regulating switch when power window
lock switch is pressed again.
OK: Front passenger side power glass regulating
switch and rear door glass regulating switch can
be operated.
RT21430030
2. Check manual UP/DOWN function.

a. Check that driver side power window glass operates as follows:
OK
Power Glass
Condition Regulating Control Switch Operation Power Window Glass
Master Switch
Pulled UP (close)
Ignition switch ON Driver side
Pushed DOWN (open)
b. Check that power window glasses other than driver side power window glass operate as follows:
OK
Power Glass 43
Condition Switch Operation Power Window Glass
Regulating Switch
Pulled UP (close)
Passenger side
Pushed DOWN (open)
Ignition switch ON Pulled UP (close)
Rear left side
Window lock switch OFF Pushed DOWN (open)
Pulled UP (close)
Rear right side
Pushed DOWN (open)

3. Check remote manual UP/DOWN function.

a. Check that driver side power window glass operates as follows:
OK
Power Glass
Condition Regulating Control Switch Operation Power Window Glass
Master Switch
Fully pulled UP (close)
Ignition switch ON Driver side
Fully pushed DOWN (open)
b. Check that power window glasses other than driver side power window glass operate as follows:
OK
Power Glass
Condition Switch Operation Power Window Glass
Regulating Switch
Pulled UP (close)
Passenger side
Pushed DOWN (open)
Ignition switch ON Pulled UP (close)
Rear left side
Window lock switch OFF Pushed DOWN (open)
Pulled UP (close)
Rear right side
Pushed DOWN (open)
Specifications
2 ± 0.5
Power Glass Regulating Switch Assembly Fixing
43 Screw
2 ± 0.5
Front Door Outer Weather Bar Fixing Screw 1.3 ± 0.2

Rear Door Outer Weather Bar Fixing Screw 1.3 ± 0.2
Front Door Glass Rear Guide Rail Assembly Fixing
9±1
Bolt
9±1
Bolt
5 ± 0.5
Screw
Front Door Glass Assembly Fixing Bolt 9±1
Rear Door Glass Assembly Fixing Bolt 9±1
Front Door Power Glass Regulator Assembly Fixing
9±1
Bolt
Rear Door Power Glass Regulator Assembly Fixing
9±1
Bolt
A/C Control Panel Fixing Screw 2 ± 0.5

Tools
Special Tool
Interior Crow Plate
RCH0000025
General Tool
Digital Multimeter
RCH0000002
43

Circuit Diagram
Power Window Control System (Page 1 of 3)

BATTERY
INSTRUMENT
BCM POWER PANEL FUSE
MF03 SUPPLY RF07 RF13
AND RELAY
60A E-061 7.5A 7.5A BOX A
I-007
3 7 13
RBr
RG
R
E1 A25 A9
BCM I-005 B-044 E-072
D2 D1 D4 D3 D6 D8 D11 D12
GY
RY
BL
LY
G
P
L
8 11 B-040 8 11 B-061 B-026 B-005

4 10 4 10
F-007 H-002 L-005 R-002
GY
RY
BL
LY
G
P
L
1 2 1 2 1 2 1 2
M M M M
43 FRONT LEFT
POWER WINDOW
FRONT RIGHT
POWER WINDOW
REAR LEFT
POWER WINDOW
REAR RIGHT
POWER WINDOW
REGULATOR MOTOR REGULATOR MOTOR REGULATOR MOTOR REGULATOR MOTOR
(W/JAM PROTECTION H-001 L-004 R-001
FUNCTION)
F-006(a)
3 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 I-005 D1 D2 D3 D4 D5 B-044
E1
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 L D6 D7 D8 D9 D10 D11D12 W
E-072
W E-061
1 4 7 10 13 16 1 4 7 10 13 16 F-006(a) H-001
2 5 8 11 14 17 2 5 8 11 14 17 Gr Gr
1 2 3 4 5 6 7 8 9 10 11 12 2 1
3 6 9 12 15 18 3 6 9 12 15 18 L-004 R-001
13 14 15 16 17 18 19 20 21 22 23 24 Gr Gr
B-040 B-061
27 25 26 W W
87
85 86 86 86
87 30 87 30
30 85 85 6 5 2 1 6 5 2 1
4 3
12 11 8 7 12 11 4 3 8 7
I-007 10 9
16 15 14 13 16 15 10 9 14 13
B
B-026 B-005
Y Y ET21430010

BCM B-047
B9 B10 B12 B11 B24 B7 B19
BG
LW
LR
Gr
Gr
R
L
Lg
A
8 11 17 14 15 12 6 3 B-041
F-007
BG
LW
LR
Gr
Gr
Lg
R
L
6 5 3 4 2 1 7 13
FL WIN SW
FR WIN SW
RR WIN SW
RL WIN SW
UNLOCK
LOCK
INHIBITION SW
FRONT
LEFT
POWER
UP
UP
UP
UP
DOWN
DOWN
DOWN
DOWN
WINDOW
SWITCH
220
220
220
220
F-009
8 11 12
43
B
F-007
3
B-040
B
B-036
1 4 7 10 13 16 16 13 10 7 4 1
B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 9 10 11 12 13 14 15 16
2 5 8 11 14 17 17 14 11 8 5 2
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 8 7 6 5 4 3 2 1
3 6 9 12 15 18 18 15 12 9 6 3
B-047
L F-009 B-040 B-041
Br W Gr
ET21430020

BCM B-047
B13 B14 B15

GrR
WV
G
A ILLUMINATION
Lg
Lg
Lg
12 17 B-061 B-026 B-005
H-002 6 11 6 11 R-002
L-005
WV
BG
Lg
Lg
Lg
G
6 1 6 1 6 1
FRONT REAR REAR

RIGHT LEFT RIGHT
POWER POWER POWER
WINDOW WINDOW WINDOW
SWITCH SWITCH SWITCH
UP
UP
UP
DOWN
DOWN
DOWN
H-003 L-002 R-003

220
220
220
9 3 9 3 9 3
43
B
H-002 5 L-005 5 R-002

3 B-026 B-005
B-061
B
B-062 B-036 B-062
B-047
L H-003 L-002 R-003
B B B
6 5 2 1 6 5 2 1
1 4 7 10 13 16 4 3
12 11 8 7 12 11 4 3 8 7
2 5 8 11 14 17 10 9
3 6 9 12 15 18 16 15 14 13 16 15 10 9 14 13
B-061 B-026 B-005

W Y Y ET21430030

DIAGNOSIS & TESTING

HINT:
Use the table below to help determine the cause of the problem. Check each suspected area in order. Repair
or replace the faulty components, or adjust as necessary.

Fuse 51-37
Driver side power glass regulating control
43-44
Driver side power window cannot be switch
operated with driver side power glass
Driver side power glass regulator assembly 43-53
regulating control switch
Fuse 51-37
Passenger side power glass regulating
43-55
switch
Passenger side power window cannot be
operated with passenger side power glass Passenger side power glass regulator
43-62
regulating switch assembly
Ground -
Power window has intermittent problem
Diagnosis Tools
X-431 3G Diagnostic Tester 43
with vehicle.
 DLC is located at the driver side instrument panel crossmember.
 DLC uses a trapezoidal design which can hold 16 terminals.
Digital Multimeter
 Troubleshoot electrical malfunctions and wire harness system.



 Inspect the mounting areas of power window assembly, wire harness or wire harness connector and so on
for damage, foreign matter, etc. that will cause incorrect signals.
perform a test. If DTC cannot be cleared, the Body Control Module (BCM) is malfunctioning. If DTC can be
cleared, reinstall the Body Control Module (BCM) to original vehicle.
Ground Inspection
Grounding are very important to entire circuit system, which are normal or not can seriously affect the entire
43 1. Remove the ground bolt or nut.

Diagnosis Procedure
HINT:
Use the following procedures to troubleshoot the power window control system.
NEXT
NEXT
NEXT
DTC
occurs
No 
DTC 43
NEXT
NEXT
NEXT

NEXT
9 Confirm troubleshooting, perform test
NEXT
10 End

B100C13 FL Window Up Control Circuit Circuit Open
B100C71 FL Window Up Control Circuit Actuator Stuck
B100D13 FL Window Down Control Circuit Circuit Open
B100D71 FL Window Down Control Circuit Actuator Stuck
B100E13 FR Window Up Control Circuit Circuit Open
B100E71 FR Window Up Control Circuit Actuator Stuck
B100F13 FR Window Down Control Circuit Circuit Open
B100F71 FR Window Down Control Circuit Actuator Stuck
B101013 RL Window Up Control Circuit Circuit Open
B101071 RL Window Up Control Circuit Actuator Stuck
43 B101113 RL Window Down Control Circuit Circuit Open
B101171 RL Window Down Control Circuit Actuator Stuck
B101213 RR Window Up Control Circuit Circuit Open
B101271 RR Window Up Control Circuit Actuator Stuck
B101313 RR Window Down Control Circuit Circuit Open
B101371 RR Window Down Control Circuit Actuator Stuck

DTC B100C13 FL Window Up Control Circuit Circuit Open
DTC B100C71 FL Window Up Control Circuit Actuator Stuck
DTC B100D13 FL Window Down Control Circuit Circuit Open
DTC B100D71 FL Window Down Control Circuit Actuator Stuck
43

BATTERY
BCM POWER
MF03 SUPPLY
60A E-061
R
E1
BCM B-044 E-072 B-047
D2 D1 B9
L
B-041
G
L
8
F-007
L
8 11 B-040
6
F-007
FL WIN SW
G
L
1 2
FRONT
LEFT
M
POWER
UP
DOWN
WINDOW
220
FRONT LEFT SWITCH

POWER WINDOW F-009
REGULATOR MOTOR
(W/JAM PROTECTION
FUNCTION)
F-006(a) 8
F-007
43 3
B-040
B
B-036
B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 D1 D2 D3 D4 D5
E1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 D6 D7 D8 D9 D10 D11D12
B-047 B-044 E-072

L W W
16 13 10 7 4 1 1 4 7 10 13 16 9 10 11 12 13 14 15 16
3
17 14 11 8 5 2 2 5 8 11 14 17 8 7 6 5 4 3 2 1 2 1
18 15 12 9 6 3 3 6 9 12 15 18
F-009 F-006(a)
B-040 E-061
B-041 Br Gr
W
Gr
ET21430050


Condition Condition
FL Window Up Control  Glass regulating
B100C13
Circuit Circuit Open control master
FL Window Up Control switch
B100C71
Circuit Actuator Stuck  Power glass
FL Window Down regulator
Ignition switch ON ON assembly
B100D13 Control Circuit Circuit
Open  Wire harness or
connector
FL Window Down
B100D71 Control Circuit Actuator  Body Control
Stuck Module (BCM)
CAUTION
 When performing the circuit diagnosis and test, always refer to the circuit diagram for specific circuit and
Diagnosis Procedure
1 Check power glass regulating control master switch
a. Remove the power glass regulating control master switch from malfunctioning vehicle, and install it to a
new vehicle to perform a test.
NG Replace power glass regulating control

master switch
43
OK
2 Check front left door power glass regulator assembly
a. Remove the front left door power glass regulator assembly from malfunctioning vehicle, and install it to a
NG Replace front left door power glass

regulator assembly
OK


B-040.
+ -
D1 D2 D3 D4 D5
D6 D7 D8 D9 D10 D11D12

Condition
B-044 (D1) -
Always Continuity
B-040 (11) 1 4 7 10 13 16
2 5 8 11 14 17
B-044 (D2) - 3 6 9 12 15 18
Always Continuity
B-040 (8) B-040
RT21430550

B-041.
Condition B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32
B-047 (B9) - B-047

Always Continuity
B-041 (8)
16 13 10 7 4 1
17 14 11 8 5 2
18 15 12 9 6 3
43 B-041
RT21430560
g. Disconnect the body wire harness connector B-040 and

ground B-036.
Condition
2 5 8 11 14 17
B-040 (3) - B-036 Always Continuity 3 6 9 12 15 18
B-040

connector
B-036
RT21430660

OK

F-007 and F-006 (a).
+ -
4 5 6 6 5 4
(a) according to the table below. 7 8 9 9 8 7
10 11 12 12 11 10
Condition 16 17 18 18 17 16
F-007 (8) -
Always Continuity F-007
F-006 (a) (1)
F-007 (11) -
F-006 (a) (2)
F-006(a)
RT21430700
e. Disconnect the front left door wire harness connectors 

F-007 and F-009.
front left door wire harness connectors F-007 and F-009
1 2 3 3 2 1
10 11 12 12 11 10
F-007 (3) - 13 14 15 15 14 13
F-009 (8)
43
F-007 (8) -
F-009 (6)
9 10 11 12 13 14 15 16
NG Repair or replace front left door wire 8 7 6 5 4 3 2 1

F-009
RT21430710
OK
5 Reconfirm DTCs

d. Use X-431 3G diagnostic tester (the latest software) to record and clear DTCs stored in the Body Control
Module (BCM).


g. Use X-431 3G diagnostic tester (the latest software) to read DTCs stored in the Body Control Module
(BCM) again.
Result Proceed to
DTC B100C13, B100C71, B100D13 and B100D71
NG
are output
No DTC is output OK
OK
System is normal
43

DTC B100E13 FR Window Up Control Circuit Circuit Open
DTC B100E71 FR Window Up Control Circuit Actuator Stuck
DTC B100F13 FR Window Down Control Circuit Circuit Open
DTC B100F71 FR Window Down Control Circuit Actuator Stuck
43

BATTERY
BCM POWER
MF03 SUPPLY
60A E-061
3
R
E1
BCM B-044 E-072 B-047
D4 D3 B13 B10
Gr
ILLUMINATION
GrR
Lg
B-041
11
Y
F-007
12 17 B-061
Gr
H-002 5
B-061
BG
8 11
Lg
FR WIN SW
H-002
6 1
Y
FRONT
1 2 FRONT
LEFT
RIGHT
POWER
POWER
UP
DOWN
M WINDOW
WINDOW
SWITCH
220
SWITCH
F-009
UP
DOWN
FRONT RIGHT H-003

220
POWER WINDOW
REGULATOR MOTOR
H-001
11
9 3
F-007
B
3
B-040
B
H-002
3
B-061
B-036
B
43 B-062
B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 3
1 2 3 3 2 1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 4 5 6 6 5 4
7 8 9 9 8 7
B-047 10 11 12 12 11 10
L E-061
13 14 15 15 14 13
16 17 18 18 17 16
1 4 7 10 13 16 1 4 7 10 13 16
2 5 8 11 14 17 H-001 2 5 8 11 14 17
2 1
3 6 9 12 15 18 Gr 3 6 9 12 15 18 F-007
W
B-061 B-061
W W
9 10 11 12 13 14 15 16 6 7 8 9 10 D1 D2 D3 D4 D5
16 13 10 7 4 1 8 7 6 5 4 3 2 1 E1 1 2 3 4 5 D6 D7 D8 D9 D10 D11D12
17 14 11 8 5 2 B-041
18 15 12 9 6 3 Gr E-072 H-003 B-044
F-009
W B W
Br
ET21430060


Condition Condition
FR Window Up Control
B100E13
Circuit Circuit Open  Glass regulating
FR Window Up Control control switch
B100E71
FR Window Down regulator assembly
B100F13 Control Circuit Circuit  Wire harness or
Open connector
FR Window Down  Body Control
B100F71 Control Circuit Module (BCM)
Actuator Stuck
CAUTION
Diagnosis Procedure
1 Check power glass regulating switch
a. Remove the power glass regulating switch from malfunctioning vehicle, and install it to a new vehicle to
perform a test.
NG Replace power glass regulating switch
43
OK
2 Check front right door power glass regulator assembly
a. Remove the front right door power glass regulator assembly from malfunctioning vehicle, and install it to a
NG Replace front right door power glass

regulator assembly
OK


B-061.
+ -
according to the table below. D1 D2 D3 D4 D5
D6 D7 D8 D9 D10 D11D12

Condition
B-044 (D3) -
Always Continuity
B-061(11) 1 4 7 10 13 16
2 5 8 11 14 17
B-044 (D4) - 3 6 9 12 15 18
Always Continuity
B-061(8) B-061
RT21430570

B-061.
B-047 (B13) -
B-061 (12)
1 4 7 10 13 16
2 5 8 11 14 17
3 6 9 12 15 18
43 B-061
RT21430580

B-041.
B-047 (B10) -
B-041 (11)
16 13 10 7 4 1
17 14 11 8 5 2
18 15 12 9 6 3
B-041
RT21430590


ground B-062.
Condition
2 5 8 11 14 17
B-061
B-062
RT21430670

ground B-036.
Condition
2 5 8 11 14 17
B-040

connector
43
B-036
RT21430660
OK


F-007 and F-009.
+ -
4 5 6 6 5 4
10 11 12 12 11 10
Condition 16 17 18 18 17 16
F-007 (11) -
F-009 (5)
F-007 (3) - 9 10 11 12 13 14 15 16
Always Continuity
F-009(11) 8 7 6 5 4 3 2 1
F-009
NG Repair or replace front left door wire RT21430720
OK

c. Disconnect the front right door wire harness connectors
H-002 and H-003.
+ -
43 front right door wire harness connectors H-002 and  1 2 3 3 2 1
4 5 6 6 5 4
H-003 according to the table below. 7 8 9 9 8 7
10 11 12 12 11 10
Condition 16 17 18 18 17 16
H-002 (12) - H-002
Always Continuity
H-003 (6)
H-002 (17) -
H-003 (1) 1 2 3 4 5
H-002 (3) -
Always Continuity H-003
H-003 (9) RT21430730

e. Disconnect the front right door wire harness connectors

H-001 and H-002.
front right door wire harness connectors H-001 and 
H-002 according to the table below. + -
Condition
H-001
H-001 (1) -
Always Continuity
H-002 (8)
H-001 (2) - 1 2 3 3 2 1
Always Continuity
H-002 (11) 4
7
5
8
6
9
6
9
5 4
8 7
10 11 12 12 11 10
13 14 15 15 14 13
NG Repair or replace front right door wire 16 17 18 18 17 16

H-002 RT21430740
OK
6 Reconfirm DTCs

Module (BCM).
(BCM) again.
43
Result Proceed to
DTC B100E13, B100E71, B100F13 and B100F71
NG
are output
No DTC is output OK
OK
System is normal

DTC B101013 RL Window Up Control Circuit Circuit Open
DTC B101071 RL Window Up Control Circuit Actuator Stuck
DTC B101113 RL Window Down Control Circuit Circuit Open
DTC B101171 RL Window Down Control Circuit Actuator Stuck
43

BATTERY
BCM POWER
MF03 SUPPLY
60A E-061
3
R
E1
BCM B-044 E-072 B-047
D6 D8 B14 B11
WV ILLUMINATION
R
Lg
GY
LY
B-026 B-041
6 11 14
L-005 F-007
B-026
4 10
WV
Lg
L-005
R
6 1
GY
LY
RL WIN SW
1 2
REAR
M LEFT
POWER FRONT
REAR LEFT WINDOW LEFT
UP
DOWN
POWER WINDOW SWITCH POWER

220
UP
REGULATOR MOTOR L-002 WINDOW
SWITCH
220
L-004
F-009
9 3
B
11
F-007
5 L-005
3
B-040 43
B
B-026
B
B-036
B-036
B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 3 9 10 11 12 13 14 15 16
B-047 E1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 2 1 8 7 6 5 4 3 2 1
L
E-072 L-004 F-009

W E-061
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 Gr Br
I-005
1 4 7 10 13 16 6 5 2 1 16 13 10 7 4 1
4 3
6 7 8 9 10 2 5 8 11 14 17 12 11 8 7 17 14 11 8 5 2
D1 D2 D3 D4 D5 B-044 L-002 10 9 18 15 12 9 3
1 2 3 4 5 3 6 9 12 15 18 16 15 14 13 6
D6 D7 D8 D9 D10 D11D12 W B
B-040 B-026
B-041
W Y
Gr
ET21430070


Condition Condition
RL Window Up Control
B101013
RL Window Up Control switch
B101071
RL Window Down regulator assembly
B101113 Control Circuit Circuit  Wire harness or
Open connector
RL Window Down  Body Control
B101171 Control Circuit Module (BCM)
Actuator Stuck
CAUTION
Diagnosis Procedure
perform a test.
43
OK
2 Check rear left door power glass regulator assembly
a. Remove the rear left door power glass regulator assembly from malfunctioning vehicle, and install it to a
NG Replace rear left door power glass

regulator assembly
OK


B-026.
+ -
D6 D7 D8 D9 D10 D11D12
Condition B-044
B-044 (D6) -
B-026 (4) 12 11
4 3
8 7
10 9
B-044 (D8) - 16 15 14 13
Always Continuity
B-026 (10)
B-026
RT21430600

B-026.
Condition
B-047 (B14) -
B-026 (6)
43
6 5 2 1
4 3
12 11 8 7
10 9
16 15 14 13
B-026
RT21430610


B-041.
B-047 (B11) -
B-041 (14)
16 13 10 7 4 1
17 14 11 8 5 2
18 15 12 9 6 3
B-041
RT21430620

ground B-036.
Condition
2 5 8 11 14 17
B-040
43
B-036
RT21430660

ground B-036.
Condition
4 3
2 1
12 11 8 7
10 9
B-026 (5) - B-036 Always Continuity 16 15 14 13
B-026
connector
B-036
RT21430680

OK

F-007 and F-009.
+ -
4 5 6 6 5 4
10 11 12 12 11 10
Condition 16 17 18 18 17 16
F-007 (14) -
F-009 (4)
F-007 (3) - 9 10 11 12 13 14 15 16
Always Continuity
F-009 (11) 8 7 6 5 4 3 2 1
F-009
OK
5 Check rear left door wire harness and connector

c. Disconnect the rear left door wire harness connectors  43
L-005 and L-002.
+ -
1 2 5 6
3 4
7 8 11 12
Condition 13 14 15 16
L-005 (6) - L-005
Always Continuity
L-002 (6)
L-005 (11) - 6 7 8 9 10
L-002 (1)
L-005 (5) - L-002
Always Continuity
L-002 (9) RT21430760

e. Disconnect the rear left door wire harness connectors 

L-005 and L-004.
Condition
3 4
7 8 11 12
L-005 (4) - 9 10
L-004 (1)
L-005 (10) - L-005
Always Continuity
L-004 (2)
2 1
NG Repair or replace rear left wire harness
and connector L-004
RT21430770
OK
6 Reconfirm DTCs

Module (BCM).
(BCM) again.
43
Result Proceed to
DTC B101013, B101071, B101113 and B101171 are
NG
output
No DTC is output OK
OK
System is normal

DTC B101213 RR Window Up Control Circuit Circuit Open
DTC B101271 RR Window Up Control Circuit Actuator Stuck
DTC B101313 RR Window Down Control Circuit Circuit Open
DTC B101371 RR Window Down Control Circuit Actuator Stuck
43

BATTERY
BCM POWER
MF03 SUPPLY
60A E-061
3
R
E1
BCM B-044 E-072 B-047
D11 D12 B15 B12

Lg
G
ILLUMINATION
BG
RY
BL
B-005 B-041
6 11 17
R-002 F-007
Lg
B-005
BG
G
4 10 R-002
6 1
3
RR WIN SW
RY
BL
1 2 REAR
RIGHT
POWER
M WINDOW
FRONT
SWITCH
LEFT
UP
DOWN
REAR RIGHT R-003 POWER
UP
220
POWER WINDOW DOWN

WINDOW
220
REGULATOR MOTOR SWITCH
R-001 F-009
9 3
B
11
43 5 R-002
B-005
3
F-007
B-040
B
B
B-062 B-036
3 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32
D1 D2 D3 D4 D5 B-044 B-047
E1
D6 D7 D8 D9 D10 D11D12 W B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 L
E-072
E-061 W
6 7 8 9 10 6 5 2 1 16 13 10 7 4 1 9 10 11 12 13 14 15 16
4 3 2 1 1 4 7 10 13 16
1 2 3 4 5 12 11 8 7 17 14 11 8 5 2 8 7 6 5 4 3 2 1
2 5 8 11 14 17
16 15 10 9 14 13 18 15 12 9 6 3
3 6 9 12 15 18
F-009 R-001
R-003 B-041
B-005 Br Gr B-040
B Gr
Y W
ET21430080


Condition Condition
RR Window Up Control
B101213
RR Window Up Control switch
B101271
RR Window Down regulator assembly
B101313 Control Circuit Circuit  Wire harness or
Open connector
RR Window Down  Body Control
B101371 Control Circuit Module (BCM)
Actuator Stuck
CAUTION
Diagnosis Procedure
perform a test.
43
OK
2 Check rear right door power glass regulator assembly
a. Remove the rear right door power glass regulator assembly from malfunctioning vehicle, and install it to a
NG Replace rear right door power glass

regulator assembly
OK


B-005.
+ -
D6 D7 D8 D9 D10 D11D12
Condition B-044
B-044 (D11) -
B-005 (4) 12 11 4 3 8 7
16 15 10 9
B-044 (D12) - 14 13
Always Continuity
B-005 (10)
B-005
RT21430630

B-005.
Multimeter Specified B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32
Condition
B-047 (B15) - B-047

Always Continuity
B-005 (6)
6 5 2 1
12 11 4 3 8 7
16 15 10 9 14 13
43 B-005
RT21430640

B-041.
B-047 (B12) -
B-041 (17)
16 13 10 7 4 1
17 14 11 8 5 2
18 15 12 9 6 3
B-041
RT21430650


ground B-036.
Condition
2 5 8 11 14 17
B-040
B-036
RT21430660

ground B-062.
6 5 2 1
Condition 12 11 4 3 8 7

B-005

connector
B-062
43
RT21430690
OK


F-007 and F-009.
+ -
4 5 6 6 5 4
10 11 12 12 11 10
Condition 16 17 18 18 17 16
F-007 (17) -
F-009 (3)
F-007 (3) - 9 10 11 12 13 14 15 16
Always Continuity
F-009 (11) 8 7 6 5 4 3 2 1
F-009
OK
5 Check rear right door wire harness and connector

c. Disconnect the rear right door wire harness connectors
R-001 and R-002.
+ -
43 rear right door wire harness connectors R-001 and R-002
1 2 5 6
3 4
7 8 11 12
Condition 13 14 15 16
R-001 (1) - R-002
Always Continuity
R-002 (4)
R-001 (2) -
R-002 (10)
R-001
RT21430790

e. Disconnect the rear right door wire harness connectors

R-002 and R-003.
rear right door wire harness connectors R-002 and R-003
Condition
3 4
7 8 11 12
R-002 (6) - 9 10
R-003 (6)
R-002 (11) - R-002
Always Continuity
R-003 (1)
R-002 (9) - 6 7 8 9 10
R-003 (5)
R-003
NG Repair or replace rear right door wire RT21430800
OK
6 Reconfirm DTCs

Module (BCM).
(BCM) again.
43
Result Proceed to
DTC B101213, B101271, B101313 and B101371 are
NG
output
No DTC is output OK
OK
System is normal

ON-VEHICLE SERVICE

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing power glass regulating control
master switch.
 Appropriate force should be applied when removing power glass regulating control master switch. Be
 Try to prevent front door protector assembly from being scratched when removing power glass regulating
control master switch.

3. Remove the power glass regulating control master switch assembly.
a. Remove the cushion rubber (1) from power glass
regulating control master switch assembly.
b. Remove the fixing screw (2) from power glass
regulating control master switch assembly.
RT21430050
43 c. Using a screwdriver wrapped with protective tape, pry

up the power glass regulating control master switch
assembly.
RT21430060
d. Disconnect the connector (arrow) from power glass

regulating control master switch assembly, and
remove the power glass regulating control master
switch assembly.
RT21430070

4. Remove the power glass regulating control master

switch.
up the claws (arrow) on power glass regulating control
master switch, and remove the power glass regulating
control master switch.
RT21430080
Inspection
1. Check power glass regulating control master switch.
a. Using a digital multimeter, check for continuity of
power glass regulating control master switch
+ -
1 2 3 4 5 6 7 8
Multimeter Switch Specified 9 10111213141516
Area
Front left door UP 220 Ω

6-8
glass OFF No continuity
regulating DOWN Continuity RT21430090
switch 6-8
OFF No continuity
Front right UP 220 Ω

5 - 11
door glass OFF No continuity
regulating DOWN Continuity
switch 5 - 11
OFF No continuity
Rear left door UP 220 Ω

4 - 11
glass OFF No continuity 43
switch 4 - 11
OFF No continuity
Rear right UP 220 Ω

3 - 11
door glass OFF No continuity
switch 3 - 11
OFF No continuity
If result is not as specified, replace power glass

regulating control master switch.

2. Check power glass regulating control master switch illumination.

a. Apply battery voltage to the terminals of power glass
-
regulating control master switch connector, and check +
the operation of power glass regulating control master

switch according to the table below. 1 2 3 4 5 6 7 8
9 10111213141516
Specified
Battery positive Battery negative Condition
(+) (-)
13 12 LED comes on
RT21430091
regulating control master switch.
Installation
CAUTION
 Check if connector is correctly installed when installing power glass regulating control master switch.
 Check if switch operates normally after installing glass regulating control master switch.
43

Front Door Outer Weather bar

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing front door outer weather bar.
 Appropriate force should be applied when removing front door outer weather bar. Be careful not to
operate roughly.
 Try to prevent body paint surface from being scratched when removing front door outer weather bar.

3. Remove the outside rear view mirror assembly (See page 44-7).
4. Remove the front left door outer weather bar.
a. Remove the front left door frame weatherstrip.
HINT:
It is not necessary to remove the front left door frame weatherstrip completely. There is a fixing screw in
the front door frame weatherstrip.
b. Remove 2 fixing screws (arrow) from front door outer
weather bar.
43
RT21430160
c. Remove the front left door outer weather bar in the

RT21430170

Installation
43

Front Door Glass Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing front door glass assembly.
 Appropriate force should be applied when removing front door glass assembly. Be careful not to operate
roughly.
 When removing front door glass assembly, avoid the window glass from dropping and becomes
damaged.

6. Remove the front left door glass run.
a. Lower the front door glass assembly and pull out the
front left door glass run from the slot.
RT21430100
43
7. Remove the front left door glass assembly.

a. Raise the front door glass assembly to the proper position.
b. Remove 2 fixing bolts (arrow) from front left door glass
assembly, and remove the front left door glass
assembly.
RT21430110

Installation
43

Front Door Glass Rear Guide Rail Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing front door glass rear guide rail
assembly.
 Appropriate force should be applied when removing front door glass rear guide rail assembly. Be careful
not to operate roughly.

6. Remove the front left door glass rear guide rail assembly.
a. Remove the fixing bolt (arrow) from front door glass
rear guide rail assembly.
43
RT21430120

b. Take out the front left door glass rear guide rail
assembly from the slot.
RT21430130
Installation
CAUTION
 After glass regulating system is installed, make sure that the window glass can go up and down smoothly
and freely without any vibration, chattering or shock loading, etc.
43

Front Door Power Glass Regulator Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing front door power glass
regulator assembly.
 Appropriate force should be applied when removing front door power glass regulator assembly. Be

6. Remove the front left door glass assembly (See page 43-49).
7. Remove the front left door power glass regulator assembly.
a. Disconnect the connector (1) from front left door
power glass regulator assembly.
b. Remove 6 fixing bolts (arrow) from front left door
power glass regulator assembly, and remove the front
left door power glass regulator assembly.
43
RT21430140

Inspection
1. Check front door power glass regulator motor.
-
regulator motor connector, and check the operation of +
power glass regulator motor according to the table 1 2

below.
Specified
(+) (-)
1 2 UP smoothly
RT21430150
2 1 Down smoothly
If result is not as specified, replace front door power

glass regulator assembly.
Installation
CAUTION
 After front door power glass regulator is installed, make sure that the window glass can go up and down
smoothly and freely without any vibration, chattering or shock loading, etc.
43

Power Glass Regulating Switch

Removal
HINT:
 Use the same procedures for the front right/rear right side and rear left side.
 Procedures listed below are for the rear left side.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing power glass regulating switch.
 Appropriate force should be applied when removing power glass regulating switch. Be careful not to
operate roughly.
 Try to prevent rear door protector assembly from being scratched when removing power glass regulating
switch.

3. Remove the left power glass regulating switch assembly.
a. Remove the cushion rubber (1) from power glass
regulating switch assembly.
b. Remove the fixing screw (2) from power glass
regulating switch assembly.
43
RT21430200

up the power glass regulating switch assembly.
RT21430210

d. Disconnect the connector (arrow) from power glass

regulating switch assembly, and remove the left power
glass regulating switch assembly.
RT21430220
4. Remove the left power glass regulating switch.

up the claws (arrow) on power glass regulating switch,
and remove the left power glass regulating control
switch.
RT21430230
43

Inspection
1. Check power glass regulating switch.
a. Using a digital multimeter, check for continuity of
power glass regulating switch according to the table
+ -
below. 1 2 3 4 5
6 7 8 9 10

Area
UP 220 Ω
6-9
Front right door OFF No continuity
glass regulating
switch DOWN Continuity RT21430240
6-9
OFF No continuity
UP 220 Ω
6-9
Rear left door OFF No continuity
glass regulating
switch DOWN Continuity
6-9
OFF No continuity
UP 220 Ω
6-9
Rear right door OFF No continuity
glass regulating
switch DOWN Continuity
6-9
OFF No continuity

regulating switch.
2. Check power glass regulating switch illumination.
-
regulating switch connector, and check the operation +
of power glass regulating switch according to the table 1 2 3 4 5

below. 6 7 8 9 10
43
Specified
(+) (-)
1 3 LED comes on
RT21430241
regulating switch.
Installation
CAUTION
 Check if connector is correctly installed when installing power glass regulating switch.
 Check if switch operates normally after installing power glass regulating switch.

Rear Door Outer Weather bar

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing rear door outer weather bar.
 Appropriate force should be applied when removing rear door outer weather bar. Be careful not to
operate roughly.
 Try to prevent body paint surface from being scratched when removing rear door outer weather bar.
1. Remove the rear left door outer weather bar.

a. Remove the rear left door frame weatherstrip.
HINT:
It is not necessary to remove the rear left door weatherstrip completely. There is a fixing screw in the
rear door weatherstrip.
b. Remove 2 fixing screws (arrow) from rear door outer
weather bar.
43
RT21430180
c. Remove the rear left door outer weather bar in the

RT21430190
Installation

Rear Door Glass Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing rear door glass assembly.
 Appropriate force should be applied when removing rear door glass assembly. Be careful not to operate
roughly.
 When removing the rear door glass assembly, avoid the window glass from dropping and becomes
damaged.

3. Remove the rear door outer weather bar (See page 43-58).
7. Remove the rear door glass rear guide rail assembly (See page 43-61).
8. Remove the rear left door glass run.
a. Lower the rear door glass assembly and pull out the
rear left door glass run from the slot.
43
RT21430250

9. Remove the rear left door glass assembly.

a. Raise the rear door glass assembly to the proper position.
b. Remove 2 fixing bolts (arrow) from rear door glass
assembly, and remove the rear left door glass
assembly.
RT21430260
Installation
CAUTION
 When installing rear door glass assembly, avoid the window glass from dropping and becomes
damaged.
43

Rear Door Glass Rear Guide Rail Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing rear door glass rear guide rail
assembly.
 Appropriate force should be applied when removing rear door glass rear guide rail assembly. Be careful

6. Remove the rear left door glass rear guide rail assembly.
a. Remove the rear left door frame weatherstrip.
HINT:
It is not necessary to remove the rear left door frame weatherstrip completely. There is a fixing screw in
the rear door frame weatherstrip.
b. Remove 2 fixing screws (arrow) from rear door glass
rear guide rail assembly.
c. Remove the fixing bolt (1) from rear door glass rear
guide rail assembly, and remove the rear left door
glass rear guide rail assembly. 43
1
RT21430270
Installation
CAUTION
 After glass regulating system is installed, make sure that the window glass can go up and down smoothly
and freely without any vibration, chattering or shock loading, etc.

Rear Door Power Glass Regulator Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing rear door power glass
regulator assembly.
 Appropriate force should be applied when removing rear door power glass regulator assembly. Be

3. Remove the rear door outer weather bar (See page 43-58).
7. Remove the rear door glass rear guide rail assembly (See page 43-61).
8. Remove the rear left door glass assembly (See page 43-59).
9. Remove the rear left door power glass regulator assembly.
a. Disconnect the connector (1) from rear door power
b. Remove 6 fixing bolts (arrow) from rear door power
glass regulator assembly, and remove the rear left
door power glass regulator assembly.
43
1
RT21430280

Inspection
1. Check rear door power glass regulator motor.
-
regulator motor connector, and check the operation of +
power glass regulator motor according to the table

below. 1 2
Specified
(+) (-)
1 2 UP smoothly
RT21430290
2 1 Down smoothly
If result is not as specified, replace rear door power

Installation
CAUTION
 After rear door power glass regulator is installed, make sure that the window glass can go up and down
smoothly and freely without any vibration, chattering or shock loading, etc.
43

Triangular Window Glass Assembly

Removal
3. Remove the C-pillar upper protector assembly (See page 49-26).
4. Remove the triangular window glass trim board.
5. Remove the triangular window glass assembly.
a. Cut the adhesive with a knife.
Cut
RT21430300
CAUTION
 Try to prevent body paint surface from being scratched when cutting the adhesive.
b. Apply protective tape to the outer surface of body to prevent scratches.

c. Pass a piano wire through the seam between body and triangular window glass assembly.
d. Tie wooden blocks or similar objects to both piano
wire ends, cut off adhesive by pulling the piano wire
around triangular window glass assembly, and
remove the triangular window glass assembly.
43
RT21430310
CAUTION
 When removing triangular window glass assembly, two technicians are required.
 DO NOT drop the triangular window glass assembly when removing it.
 Leave as much adhesive on body as possible when cutting the adhesive.
 When separating the triangular window glass assembly from vehicle, be careful not to damage the body
paint or interior/exterior ornaments.

6. Clean the vehicle body.

a. Using a knife, cut away excess adhesive on the
contact surface of vehicle body as shown in the
illustration.
Adhesive
RT21430320
CAUTION
b. Clean the contact surface of vehicle body with cleaner.
CAUTION
 Even if all adhesive has been removed, cleaning of vehicle would be necessary.
7. Clean the removed glass.
CAUTION
 DO NOT touch the glass after cleaning it.

 Even if new glass is used, it is necessary to clean it with glass cleaner.
43
a. Remove the adhesive sticking to glass with a scraper.
b. Clean the outer edges of glass with glass cleaner.
RT21430330

Installation
1. Position the triangular window glass assembly.
a. Align the clip with installation hole on roof panel.
b. Check if whole contact surface of glass rim is perfectly even.
c. Place matchmarks on the triangular window glass
assembly and body at the positions shown in the
illustration.
RT21430340
d. Remove the triangular window glass assembly.

2. Apply a coat of primer M to the contact surface of body.
CAUTION
 Allow primer to dry for at least 3 minutes.

 DO NOT apply primer to the adhesive.
 DO NOT apply too much primer.
 DO NOT keep any opened primer M for later use.
a. Using a brush, apply a coat of primer M to the contact

surface of body. Primer M Primer M
b. Width of primer is 13 - 15 mm.
43
Primer M Adhesive
RT21430350

3. Clean the contact surface of triangular window glass.
CAUTION
 DO NOT touch the triangular window glass surface after cleaning it.
a. Remove any residue on the contact surface of

triangular window glass assembly with a piece of
clean cloth soaked with glass cleaner.
RT21430360
4. Apply a coat of primer G to the contact surface of triangular window glass assembly.
CAUTION

 DO NOT keep any of the opened primer G for later use.
a. Using a brush or sponge, apply a coat of primer G to

the glass rim and contact surface.
b. Use a piece of clean cloth to wipe off the excess
primer before drying. Primer G 13-15 mm
c. Width of primer is 13 - 15 mm. 43
RT21430370

5. Mix the adhesive.
CAUTION
 Adhesive should be mixed thoroughly within 5 minutes.
a. Using solvent, thoroughly clean the mixing board and scraper.

b. Using a scraper, thoroughly mix 500 g main adhesive
and 75 g hardener on the mixing board.
RT21430380
6. Apply the adhesive.

a. Cut off the tip of cartridge nozzle and add adhesive.
b. Install the cartridge to sealer gun.
c. Apply adhesive evenly to the triangular window glass
Adhesive width: 8 - 10 mm
Adhesive height: 11 - 13 mm
8-10 mm
11-13 mm
43
RT21430390
7. Install the triangular window glass assembly.
CAUTION
 Check that lower/upper clearance and right/left clearance of triangular window glass assembly are
uniform.
a. Align the matchmarks on glass and vehicle body, and

gently press in glass along the rim.
RT21430400

b. Uniformly apply adhesive to the glass rim with a

scraper.
c. Remove any excessive or spilled adhesive with a
scraper.
Adhesive
RT21430410
d. Apply tape around the triangular window glass, and remove them when the adhesive becomes hard.
8. Install the triangular window glass trim board.
9. Check and repair the sealing of glass.
a. Check the glass for leakage after adhesive has completely hardened.
b. If it leaks, seal the leaks by adding adhesive.
10.Install the C-pillar upper protector assembly.
11. Connect the negative battery cable.
43

Front Windshield Assembly

Removal
HINT:
It is not necessary to completely remove the roof assembly. Lower the front part of roof assembly so that
the front windshield assembly can be removed.
4. Remove the inside rear view mirror assembly (See page 44-11).
5. Remove the wiper arm assembly (See page 36-24).
7. Remove the front windshield weatherstrip.
8. Remove the front windshield assembly
Cut
RT21430300
CAUTION
43
CAUTION
 To prevent the instrument panel assembly from being scratched, place a plastic sheet between piano
wire and instrument panel assembly.
c. Pass a piano wire through the seam between body and front windshield assembly.
around front windshield assembly, and remove the
front windshield assembly.
RT21430420

CAUTION
 When removing front windshield assembly, 2 technicians are required.

 DO NOT drop the front windshield assembly when removing it.
 When separating the front windshield assembly from vehicle, be careful not to damage the body paint or
interior/exterior ornaments.
9. Clean the vehicle body.

illustration.
Adhesive
RT21430320
CAUTION
43

CAUTION
10.Clean the removed glass.
CAUTION


RT21430330
Installation
1. Position the front windshield assembly.
c. Place matchmarks on the front windshield and body at
43 the positions shown in the illustration.
RT21430430
d. Remove the front windshield assembly.

CAUTION


Primer M Adhesive
RT21430350
3. Clean the contact surface of the front windshield assembly.
CAUTION
 DO NOT touch the surface of front windshield after cleaning it.
a. Remove any residue on the contact surface of front

windshield assembly with a piece of clean cloth
soaked with glass cleaner.
43
RT21430360

4. Apply a coat of primer G to the contact surface of front windshield assembly.
CAUTION


c. Width of primer is 13 - 15 mm.
RT21430370
CAUTION
a. Using solvent, thoroughly clean the mixing board and scraper.

b. Using a scraper, thoroughly mix the 500 g main
adhesive and 75 g hardener on the mixing board.
43
RT21430380


a. Cut off the tip of the cartridge nozzle and add the adhesive.
c. Apply adhesive evenly to the front windshield
8-10 mm
11-13 mm
RT21430390
7. Install the front windshield assembly.
CAUTION
 Check that lower/upper clearance and right/left clearance of front windshield are uniform to ensure it is fit
well with the surrounding moulding.
a. Align the matchmarks on windshield and vehicle body,

and gently press in the windshield along the rim.
RT21430440
43
b. Uniformly apply adhesive to the windshield rim with a
scraper.
scraper.
Adhesive
RT21430410
d. Apply tape around the windshield, and remove them when the adhesive becomes hard.

8. Install the front windshield weatherstrip.

9. Check and repair the sealing of the glass.
10.Install the front windshield lower garnish assembly.
11. Install the wiper arm assembly.
12.Install the inside rear view mirror assembly.
13.Install the roof assembly.
14.Connect the negative battery cable.
43

Rear Windshield Assembly

Removal
5. Remove the rear wiper motor assembly (See page 36-33).
7. Remove the defroster wire harness assembly.
a. Disconnect the left defroster wire harness connector
(arrow).
RT21430281
b. Disconnect the right defroster wire harness connector

(arrow).
RT21430282
43
8. Remove the rear windshield weatherstrip.
9. Remove the rear windshield assembly.
Cut
RT21430300
CAUTION


c. Pass a piano wire through the seam between body and rear windshield assembly.
around rear windshield assembly, and remove the
rear windshield assembly.
RT21430341
CAUTION
 When removing the rear windshield assembly, 2 technicians are required.

 DO NOT drop the rear windshield assembly when removing it.
 When separating the rear windshield assembly from the vehicle, be careful not to damage the body paint
or interior/exterior ornaments.
10.Clean the vehicle body.

illustration.
Adhesive
43
RT21430320
CAUTION
CAUTION

11. Clean the removed glass.
CAUTION


RT21430330
Installation
1. Position the rear windshield assembly.
c. Place matchmarks on the rear windshield and body at
the positions shown in the illustration. Matchmarks
43
RT21430471
d. Remove the rear windshield assembly.

CAUTION


Primer M Adhesive
RT21430350
3. Clean the contact surface of rear windshield.
CAUTION
 DO NOT touch the surface of rear windshield after cleaning it.
a. Remove any residue on the contact surface of rear

windshield with a piece of clean cloth soaked with
glass cleaner.
43
RT21430360

4. Apply a coat of primer G to the contact surface of rear windshield assembly.
CAUTION


c. Width of primer is 13 - 15 mm.
RT21430370
CAUTION
a. Using solvent, thoroughly clean the mixing board and

scraper.
b. Using a scraper, thoroughly mix 500 g main adhesive
and 75 g hardener on the mixing board.
43
RT21430380

a. Cut off the tip of the cartridge nozzle and add adhesive.
c. Apply adhesive evenly to the rear windshield
8-10 mm
11-13 mm
RT21430390

7. Install the rear windshield assembly.
CAUTION
 Check that lower/upper clearance and right/left clearance of rear windshield are uniform to ensure it is fit
well with the surrounding moulding.
a. Align the matchmarks on windshield and vehicle body,

and gently press in the windshield along the rim. Matchmarks
RT21430470
b. Uniformly apply adhesive to the windshield rim with a

scraper.
scraper.
Adhesive
RT21430410
d. Apply tape around the windshield, and remove them when the adhesive becomes hard.
8. Install the rear windshield weatherstrip.
43 9. Check and repair the sealing of glass.
10.Install the rear spoiler assembly.
11. Install the rear wiper motor assembly.
12.Install the rear wiper arm assembly.
13.Install the back door protector assembly.
14.Connect the negative battery cable.

Rear Window Defroster

General Information
Description
Rear Window Defogger Wire
43
RT21430490
When rear window defroster switch is turned on, rear window defogger wire is heated to remove the fog, frost
or water vapors on rear windshield, thus realizing a clear view.
To turn on the rear window defogger, it is necessary to turn ignition switch to ON and press rear window
defogger switch. The rear window defogger switch indicator comes on while the rear window defogger
operation begins. The rear window defogger stops and the indicator turns off after pressing the rear window
defogger switch again.

Circuit Diagram
Rear Window Defroster System
IGNITION SEITCH
BATTERY
ON OR ACC
RF13 RF33
7.5A 25A INSTRUMENT
PANEL FUSE
AND RELAY
85 30 BOX B
DEFOGER I-031
RELAY B-060
RRLY02
86 87
E4 F13
R
13 B-012 HVAC
T-004 DEFOGGER CONTROL
SWITCH PANEL
R
1 K-002 MT
K-012 CVT
24 4
DEFROSTER
BrW
RW
NEGATIVE
T-002
BG
T-010 K-007
10 8
I-039
1
B
T-004
11 B-012 I-037
WV
B
1
B-017
43 A12 A21
BCM I-005
1 1
E1 E2 E3 E4 E5 E6 E7 E8 F1 F2 F3 F4 F5 F6 F7
E13 E14 E15 E16 F11 F12 F13 F14
E9 E10 E11 E12 E17 E18 E19 E20 F8 F9 F10 F15 F16 F17 F18 T-002 T-010
B B
I-031 B-060
W W
4 3 2 1 1 2 3 4 5 6 7 8 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 I-005
9 8 7 6 5 9 10 11 12 13 14 15 L
14 13 12 11 10
19 18 17 16 15
B-012
22 21 20 W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 K-002 K-012
I-039 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 W W
B
ET21430040


HINT:

Fuse 51-37
Rear window defogger switch is turned on Rear window defogger switch -

but does not operate (indicator on) Rear window defogger wire -
Fuse 51-37
Rear window defogger switch is turned on
Rear window defogger switch -
but does not operate (indicator off)
Rear window defogger have intermittent Ground -

problem Wire harness or connector -
43

Rear Window Defogger Switch

Removal
HINT:
Rear window defogger switch is installed on A/C control panel assembly, and cannot be disassembled.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing rear window defogger switch.
 Appropriate force should be applied when removing rear window defogger switch. Be careful not to
operate roughly.
 Try to prevent interior from being scratched when removing rear window defogger switch.

RT21430500
b. Disconnect the connectors (arrow) from DVD panel

assembly, and remove the DVD panel assembly.
43 2
1
3
60
40
20
80
ON
OFF
RT21430510

4. Remove the A/C control panel

a. Remove 2 fixing screws (arrow) from A/C control panel.
up the clips on A/C control panel.
RT21430520
c. Disconnect the connector (arrow) from A/C control

panel, and remove the A/C control panel.
RT21430530
Installation
CAUTION
 Install connectors in place when installing rear window defogger switch.

 Always operate carefully to prevent components from being damaged when installing rear window 43
defogger switch.
 Check rear window defogger switch for proper operation after installation.

- MEMO -

REAR VIEW MIRROR
GENERAL INFORMATION 44-3 Outside Rear View Mirror Housing 
Circuit Diagram 44-5 Outside Rear View Mirror Lens 
Assembly 44-10
DIAGNOSIS & TESTING 44-6 Removal 44-10
Problem Symptoms Table 44-6 Installation 44-10
Repair & Inspection Items 44-6 Inside Rear View Mirror Assembly 44-11
Installation 44-11
Outside Rear View Mirror Assembly 44-7
Removal 44-7 Rear View Mirror Adjustment Switch
Assembly 44-12
Inspection 44-8
Removal 44-12
Installation 44-8
Inspection 44-13
Installation 44-14
44

44

44 - REAR VIEW MIRROR
GENERAL INFORMATION
REAR VIEW MIRROR
Description
4
1
RT21440010
1 - Left Outside Rear View Mirror Assembly 2 - Outside Rear View Mirror Adjustment Switch
Assembly
3 - Inside Rear View Mirror Assembly 4 - Right Outside Rear View Mirror Assembly
44
This vehicle is equipped with power outside rear view mirror and inside rear view mirror.
Power outside rear view mirror: driver can control the rotation of motor by operating outside rear view mirror
adjustment switch in vehicle, thus adjusting mirror surface to achieve a required visual angle.
Power outside rear view mirror adjustment switch is located on the instrument panel lower left protector
assembly. With ignition switch ON, press power outside rear view mirror adjustment switch "L" or "R" to select
the left or right outside rear view mirror that you want to adjust, and then press the rear view mirror up or down
and left or right button to achieve a required visual angle.
It is necessary to adjust inside rear view mirror manually to desired direction. When driving at night, rear view
mirror angle can be adjusted by pulling back the glare-resistant rod to reduce glare.

Specifications

Outside Rear View Mirror Assembly Fixing Bolt 6±1
Inside Rear View Mirror Assembly Fixing Screw 1.5 ± 0.5
Tool
General Tool
Digital Multimeter
RCH0000002
44

Circuit Diagram
Power Rear View Mirror Control System
IGNITION SWITCH
ON OR START
INSTRUMENT
PANEL FUSE
RF15 AND RELAY
7.5A BOX A
I-007
15
RY
DOWN UP DOWN UP LH RH LH RH REAR VIEW

MIRROR
ADJUSTMENT
SWITCH
LH RH LH RH I-008
MIRROR MIRROR MIRROR MIRROR
4 5 7 8 6 9
BrG
BrR
BrY
BrB
BrL
B
1
I-037 7 9 8 I-006 I-035
B-003 7 8 B-059
BrG
BrR
BrY
BrB
B-041 BrL B-061
5 4 1 14 13 9
F-007 H-002
BrG
BrR
BrR
BrL
BrY
BrB
2 3 2 3
POWER REAR POWER REAR

VIEW MIRROR VIEW MIRROR
M M
MOTOR MOTOR
F-005 H-008
M M
4 13
1
13 4
1
44
WL
GR
B
F-007 F-007 H-002

3 7 15 3
B-040 B-041 B-061
B
WL BCM GR
1 B-043 1
C16 C6
B-036 B-062
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
27 25 26
10 9 8 7 6 22 21 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10
87
85 86 86 86 I-035
85
87 30
85
87 30 I-008 I-006
30 W
B W
I-007
B
7 6 5 4 3 2 1 1 4 7 10 13 16 16 13 10 7 4 1 1 4 7 10 13 16
C1 C2 C3 C4 C5 C6 C7 C8 C9 16 15 14 13 12 11 10 9 8 2 5 8 11 14 17 17 14 11 8 5 2 2 5 8 11 14 17
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 3 6 9 12 15 18 18 15 12 9 6 3 3 6 9 12 15 18
B-043 F-005 H-008 B-040 B-041 B-061

W W W W Gr W
ET21440010

DIAGNOSIS & TESTING

HINT:

Fuse 51-36
Outside rear view mirror adjustment switch
44-12
Outside rear view mirror cannot operate assembly
Outside rear view mirror assembly 44-7
Outside rear view mirror intermittent Ground 51-29

malfunction Wire harness or connector -
Repair & Inspection Items

Visual inspection can reduce unnecessary test and diagnostic time, so pay attention to inspection of the
following items:
1. Check if fuse is damaged.
2. Check if wire harnesses and connectors related to rear view mirror are worn, pierced, pinched or partially
broken.
3. Check wire harnesses and connectors related to rear view mirror for break, bend, protrusion or corroded
terminals.
4. Check if terminal contact pins of connectors related to rear view mirror are in good condition.
44

ON-VEHICLE SERVICE
Outside Rear View Mirror Assembly
Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing rear view mirror assembly.
 Operate carefully to prevent damage to the components when removing outside rear view mirror
assembly.
 Prevent the interior and body paint from being scratched when removing outside rear view mirror
assembly.

4. Remove the left outside rear view mirror assembly.
a. Disconnect the outside rear view mirror connector (1).
b. Remove 3 fixing bolts (arrow) from outside rear view
mirror assembly.
RT21440020
44
c. Remove the left outside rear view mirror assembly.

Inspection
1. Inspect the left outside rear view mirror assembly.
a. Apply battery voltage to the terminals of outside rear
-
view mirror assembly connector and check the +
operation of outside rear view mirror according to the 1 2 3 4 5 6 7
table below. 8 9 10 11 12 13 14 15 16
Specified
Condition
UP
RT21440040
DOWN
LEFT
RIGHT
If result is not as specified, replace the left outside rear view mirror assembly.
Installation
CAUTION
 When installing outside rear view mirror assembly, install connector in place and tighten fixing bolts to the
specified torque.
 Make sure outside rear view mirror assembly can move smoothly after installation.
44

Outside Rear View Mirror Housing Assembly

Removal
HINT:
CAUTION
 Avoid breaking the claw when removing outside rear view mirror housing assembly.
 Avoid damaging lens due to dropping when removing outside rear view mirror housing assembly.
 Try to prevent body paint surface from being scratched when removing outside rear view mirror housing
assembly.

3. Remove the left outside rear view mirror housing
assembly.
remove the clip from outside rear view mirror housing
assembly, and remove the left outside rear view mirror
housing assembly.
RT21440050
Installation
CAUTION
 Make sure to install outside rear view mirror housing assembly in place.
44

Outside Rear View Mirror Lens Assembly

Removal
HINT:
CAUTION
 Avoid breaking the claws when removing outside rear view mirror lens assembly.
 Avoid damaging lens due to dropping when removing outside rear view mirror lens assembly.
 Try to prevent body paint surface from being scratched when removing outside rear view mirror lens
assembly.

3. Remove the left outside rear view mirror lens assembly.
a. Press the outside rear view mirror surface to tilt it.
b. Apply protective tape around the outside rear view
mirror frame.
up the claws (arrow) of outside rear view mirror lens
assembly.
RT21440090
d. Remove the left outside rear view mirror lens assembly.
Installation
44 CAUTION
 Make sure the lens can move smoothly after installing outside rear view mirror lens assembly.

Inside Rear View Mirror Assembly

Removal
CAUTION
 Appropriate force should be applied when removing inside rear view mirror assembly, and operate
carefully.
 Avoid scratching front windshield assembly when removing inside rear view mirror assembly.
1. Remove the inside rear view mirror assembly.

a. Remove the fixing screw from inside rear view mirror.
RT21440100
b. Remove the inside rear view mirror assembly in the

RT21440110
Installation 44
CAUTION
 Make sure the inside rear view mirror assembly can move smoothly after installation.

Rear View Mirror Adjustment Switch Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing rear view mirror adjustment
switch assembly.
 Prevent instrument panel lower left protector assembly from being scratched when removing rear view
mirror adjustment switch assembly.

3. Remove the rear view mirror adjustment switch
assembly.
out the headlight adjustment switch unit panel.
RT21440120
b. Disconnect the rear view mirror adjustment switch

connector (arrow).
44
RT21440130

detach the claws (arrow) of rear view mirror
RT21440140
d. Remove the rear view mirror adjustment switch assembly.

Inspection
Check the outside rear view mirror adjustment switch
assembly.
+ -
a. Adjust the rear view mirror adjustment switch 1 2 3 4 5
assembly to "L" position. 6 7 8 9 10
b. Using a multimeter, check for continuity between LR

terminals of rear view mirror adjustment switch
assembly according to the table below.

Connection Condition Condition RT21440150
Terminal 3 - 7 UP Continuity
Terminal 4 - 5 OFF No continuity
Terminal 3 - 5 DOWN Continuity
Terminal 3 - 6 LEFT Continuity
Terminal 3 - 5 RIGHT Continuity
If result is not as specified, replace rear view mirror

c. Adjust the rear view mirror adjustment switch
assembly to "R" position.
+ -
d. Using a multimeter, check for continuity between 1 2 3 4 5
terminals of rear view mirror adjustment switch 6 7 8 9 10
assembly according to the table below.
LR

Terminal 3 - 8 UP Continuity
RT21440150 44
Terminal 3 - 5 DOWN Continuity
Terminal 3 - 9 LEFT Continuity
Terminal 3 - 5 RIGHT Continuity
If result is not as specified, replace rear view mirror


Installation
CAUTION
 Always operate carefully to prevent components from being damaged when installing the rear view
mirror adjustment switch assembly.
 Install each connector in place when installing rear view mirror adjustment switch assembly.
 Check that switch can operate normally after installing rear view mirror adjustment switch assembly.
44

INSTRUMENT PANEL
GENERAL INFORMATION 45-3 Instrument Panel Assembly 45-17
Specifications 45-7 Disassembly 45-20
Tools 45-8 Assembly 45-23
Installation 45-23
Instrument Panel Crossmember 
Auxiliary Fascia Console Assembly 45-9 Assembly 45-24
Disassembly 45-13 Installation 45-27
Assembly 45-16
Installation 45-16
45

45

45 - INSTRUMENT PANEL
GENERAL INFORMATION
INSTRUMENT PANEL
Description
Auxiliary Fascia Console Assembly
×10
20
3
16
15
19
14 4
18
13 ×4
5
×4
12
11 6
17
7
×2
×4
×2
×9
45
10 ×2
×2
RT21450010

1 - Shift Knob 2 - Auxiliary Fascia Console Front Trim Ring

3 - Gearshift Cover Plate Assembly 4 - Auxiliary Fascia Console Front Inner Protector
Assembly
5 - Front Storage Box 6 - Auxiliary Fascia Console Front Left Protector
7 - Auxiliary Fascia Console Front Right Protector 8 - Auxiliary Fascia Console Assembly
9 - Auxiliary Fascia Console Rear Cover Plate 10 - Parking Brake Garnish
Assembly
11 - Cup Holder Assembly 12 - Backup Power Supply Assembly
13 - Portable Ashtray Assembly 14 - Multifunctional Interface
15 - Cigarette Lighter Assembly 16 - USB Panel Assembly
17 - Hinge Shaft 18 - Armrest Box Assembly
19 - Armrest Inner Storage Box 20 - Armrest Box Cover Assembly
45

Instrument Panel Assembly
16
2
15 17
12
14
×2
13
11
10
×14
9
7 5
×2 3
8
×3
4
×2
6
×4
RT21450020
1 - Instrument Panel Assembly 2 - Instrument Panel Right End Panel Assembly

3 - Damper Assembly 4 - Glove Box Assembly 45
5 - Hood Grip Assembly 6 - A/C Control Panel Assembly
7 - No Disc DVD Assembly 8 - DVD Panel Assembly
9 - Fuse Box Cover 10 - Combination Light Adjust Switch Panel
11 - Instrument Panel Lower Left Protector Assembly 12 - Instrument Cluster
13 - Hazard Warning Light 14 - Engine Switch
15 - Instrument Panel Left End Panel Assembly 16 - Instrument Panel Left Outlet Assembly
17 - Instrument Panel Right Outlet Assembly

×5
1
×4
×2
2 3
4
×3
×3
×2
×6
6
5
×2
×8
7
9
45
RT21450030
1 - Instrument Panel Crossmember Assembly 2 - Instrument Panel Crossmember Lower Left

Bracket Assembly
3 - Instrument Panel Crossmember Lower Right 4 - Left Defroster Duct Assembly
Bracket Assembly
5 - Center Defroster Duct Assembly 6 - Right Defroster Duct Assembly
7 - Face Air Duct Assembly 8 - Instrument Panel Assembly
9 - Front Passenger Airbag
Instrument panel of this model consists of instrument panel assembly, auxiliary fascia console assembly and
instrument panel crossmember system.

Specifications

Auxiliary Fascia Console Front Protector Fixing Bolt 5±1
Auxiliary Fascia Console Assembly Fixing Screw 1.5 ± 0.5
Auxiliary Fascia Console Assembly Fixing Bolt 5±1
Front Storage Box Fixing Screw 1.5 ± 0.5
Armrest Box Assembly Fixing Screw 1.5 ± 0.5
1.5 ± 0.5
Cup Holder Assembly Fixing Screw 1.5 ± 0.5
Auxiliary Fascia Console Front Trim Ring Fixing
1.5 ± 0.5
Screw
Gear Backlight Fixing Screw 1.5 ± 0.5
Instrument Panel Lower Left Protector Assembly
2 ± 0.5
Fixing Screw
Front Passenger Airbag Assembly Fixing Bolt 10 ± 1
Instrument Panel Assembly Fixing Bolt 7±1
Face Air Duct Assembly Fixing Screw 1.5 ± 0.5
Defroster Duct Assembly Fixing Screw 1.5 ± 0.5
Center Defroster Duct Assembly Fixing Screw 1.5 ± 0.5
Instrument Panel Right Outlet Assembly Fixing
1.5 ± 0.5
Screw
Instrument Panel Fuse and Relay Box Fixing Bolt 7±1
Connector Mounting Bracket Fixing Bolt 7±1
Diagnostic Interface Fixing Screw 1.5
Smart Entry Start Controller Fixing Nut 7±1 45
Instrument Panel Crossmember Lower Bracket
25 ± 3
Assembly
Steering Column Assembly Fixing Nut 25 ± 3
Steering Column Assembly Fixing Bolt 25 ± 3
Blower Fixing Bolt 4±1
Ground Wire Fixing Nut 15 ± 2
25 ± 3
Bolt
7±1
Nut
7±1
Screw
Instrument Panel Crossmember Bracket Assembly
25 ± 3
Fixing Bolt

Tools
Special Tools
RCH0000014
Interior Crow Plate
RCH0000025
45

ON-VEHICLE SERVICE
Auxiliary Fascia Console Assembly
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing auxiliary fascia console
assembly.
 Appropriate force should be applied when removing auxiliary fascia console assembly. Be careful not to
operate roughly.
 DO NOT scratch interior and body paint when removing auxiliary fascia console assembly.

3. Remove the portable ashtray assembly.
a. Remove the portable ashtray assembly in the
RT21450040
4. Remove the parking brake garnish.

up the claws on parking brake garnish, and remove
the parking brake garnish.
45
RT21450050

5. Remove the USB panel assembly.

up the clips on USB panel assembly.
A/C
OFF
OU
TL
ER
ET
POW
120W
AUX 12V
iPod
RT21450060
b. Disconnect the connectors (arrow) from USB panel

assembly, and remove the USB panel assembly.
A/C
OFF
RT21450070
6. Remove the gearshift cover plate assembly (for CVT model).

a. Pull out the shift knob in the direction of arrow as
R
S
RT21450080
45 b. Using a screwdriver wrapped with protective tape, pry

up the clips on gearshift cover plate assembly. OFF ON
A/C
R
S
N
MD
RT21450090

c. Disconnect the connectors (arrow) from gearshift

cover plate assembly, and remove the gearshift cover OFF ON
A/C
plate assembly.
R
S
N
MD
RT21450100
7. Remove the gearshift cover plate assembly (for MT model).

up the clips on gearshift cover plate assembly. OFF ON
A/C
b. Pull out the gearshift cover plate assembly in the

RT21450110
8. Remove the auxiliary fascia console front left protector (take left side as an example).
a. Remove the fixing bolt (arrow) from auxiliary fascia
console front left protector.
up the claws on auxiliary fascia console front left
protector, and remove the auxiliary fascia console
front left protector.
RT21450130
9. Remove the auxiliary fascia console assembly. 45

a. Remove the fixing screw (arrow) from the side of
auxiliary fascia console assembly (take left side as an
example).
b. Remove the fixing bolt (1) from the side of auxiliary
fascia console assembly (take left side as an 1
example).
RT21450140

c. Remove 4 fixing screws (arrow) from front part of

auxiliary fascia console assembly.
OFF
A/C
RT21450150
d. Pull up the seat adjusting handle and move the front

seat assembly to the foremost position.
RT21460071
e. Remove 2 fixing bolts (arrow) from rear part of

auxiliary fascia console assembly.
RT21450170
f. Using an interior crow plate, pry up the dowel pins on

the front part of auxiliary fascia console.
OFF
A/C
45
RT21450180

g. Disconnect the anti-theft coil connector (arrow).
RT21450181
h. Remove 4 fixing screws (arrow) from front storage

box.
RT21450190
i. Remove the auxiliary fascia console assembly.
Disassembly
1. Remove the anti-theft coil (for CVT model).
a. Disengage the claws (arrow), and remove the anti-theft
coil.
RT21450191 45
2. Remove the auxiliary fascia console rear cover plate assembly.
a. Remove the fixing screw from auxiliary fascia console
rear cover plate assembly.
RT21450211

b. Open the armrest box cover assembly in the direction

RT21450200

up the claws on auxiliary fascia console rear cover
plate assembly.
d. Remove the auxiliary fascia console rear cover plate
assembly from auxiliary fascia console assembly.
RT21450210
3. Remove the armrest box cover assembly and armrest inner storage box.
a. Pull out the hinge shaft in the direction of arrow as
b. Remove the armrest box cover assembly (1) and
armrest inner storage box (2) from auxiliary fascia
console assembly.
1
RT21450220
4. Remove the armrest box assembly.

45 a. Remove 4 fixing screws from armrest box assembly.
b. Remove the armrest box assembly from auxiliary
fascia console assembly.
RT21450230

5. Remove the cup holder assembly.

a. Remove 9 fixing screws from cup holder assembly.
b. Remove the cup holder assembly from auxiliary fascia
console assembly.
RT21450240
6. Remove the auxiliary fascia console front trim ring.

a. Remove 10 fixing screws from auxiliary fascia console
front trim ring.
b. Remove the auxiliary fascia console front trim ring
from auxiliary fascia console assembly.
RT21450250
7. Remove the auxiliary fascia console front inner protector assembly.

a. Remove the auxiliary fascia console front inner
protector assembly from auxiliary fascia console
assembly.
RT21450260
45
8. Remove the gear backlight.
a. Remove 2 fixing screws (1) from gear backlight.
1
disengage the claws (arrow).
c. Remove the gear backlight from gearshift cover plate.
1
RT21450270
9. Remove the cigarette lighter assembly (See page 42-5).

10.Remove the backup power supply assembly (See page 42-7).

11. Remove the multifunctional interface.

a. Press the claws (arrow) on multifunctional interface as
b. Remove the multifunctional interface from USB panel
assembly. iPod
AUX
iPod AUX
RT21450280
Assembly
Installation
CAUTION
 Make sure to tighten fixing bolts and fixing screws to the specified torque when installing auxiliary fascia
console assembly.
 Check each electrical equipment for proper operation after installing auxiliary fascia console assembly.
45

Instrument Panel Assembly

Removal
WARNING
 Wait at least 60 seconds after disconnecting negative battery cable to disable supplementary restraint
system.
 When removing and installing instrument panel assembly, all components related to airbag should be
operated with battery power source off. It is forbidden to operate them with power source on. Because
within 60 seconds after vehicle stops or fuse removed, there is enough power inside the airbag control
module for activating the airbag, and the airbag can be accidentally activated, causing personal injury or
vehicle damage.
 DO NOT expose airbag components to hot air or flame.
 Removed airbag should be well kept. If triggered accidentally, the airbag may cause personal injury.
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing instrument panel assembly.
 DO NOT scratch interior and body paint when removing instrument panel assembly.

3. Remove the glove box assembly.
a. Open the glove box assembly in the direction of arrow
45
RT21450281
b. Rotate the lock knobs (arrow) clockwise, and remove

the lock knobs.
RT21450282

c. Disengage the claws on the lower side of glove box

assembly, and remove the glove box assembly.
RT21450283

RT21430500
b. Disconnect the connectors (arrow) from DVD panel

assembly, and remove the DVD panel assembly.
3 80
60
2
40
1
20
ON
OFF
RT21430510
5. Remove the no disc DVD assembly (See page 39-12).

45 6. Remove the A/C control panel assembly (See page 31-70).
7. Remove the combination light adjust switch panel.
out the combination light adjust switch panel.
RT21450296

b. Disconnect the connectors (arrow) from combination

light adjust switch panel, and remove the combination
light adjust switch panel.
RT21450290
8. Remove the fuse box cover.

up the claws on fuse box cover, and remove the fuse
box cover.
RT21450300
9. Remove the front door opening weatherstrip (See page 49-14).

10.Remove the instrument panel left end panel assembly (take left side as an example).
up the claws on instrument panel left end panel
assembly, and remove the instrument panel left end
panel assembly.
RT21450310
45
12.Remove the front doorsill pressure plate assembly (See page 49-11).
13.Remove the A-pillar lower protector assembly (See page 49-19).
14.Remove the hood grip assembly (See page 47-19).
15.Remove the instrument panel lower left protector assembly.
a. Remove 3 fixing screws (arrow) from instrument panel
lower left protector assembly.
RT21450320

b. Using an interior crow plate, pry up the clips on

instrument panel lower left protector assembly, and
remove the instrument panel lower left protector
assembly.
RT21450330
16.Remove the driver airbag (See page 32-64).

17.Remove the combination switch cover (See page 28-13).
18.Remove the steering wheel assembly (See page 28-10).
19.Remove the spiral cable (See page 32-67).
20.Remove the wiper switch assembly (See page 36-22).
21.Remove the headlight, turn light and fog switch assembly (See page 35-64).
22.Remove the instrument cluster (See page 38-42).
23.Remove the A-pillar upper protector assembly (See page 49-17).
24.Remove the instrument panel assembly.
a. Disconnect the front passenger airbag connector (1).
b. Remove 2 fixing bolts (arrow) from front passenger 1
airbag assembly.
c. Disconnect the engine switch connector (2). 2
d. Disconnect the hazard warning light connector (3).
3
RT21450340
e. Remove 14 fixing bolts (arrow) from instrument panel

assembly, and remove the instrument panel
assembly.
RT21450350
Disassembly
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing instrument panel assembly.
 DO NOT scratch instrument panel surface when removing instrument panel assembly.

1. Remove the engine switch.

a. Press the claws (arrow) on engine switch as shown in
the illustration.
b. Remove the engine switch from instrument panel
assembly.
RT21450360
2. Remove the hazard warning light.

a. Press the claws (arrow) on hazard warning light as
b. Remove the hazard warning light from instrument
panel assembly.
RT21450370
3. Remove the damper assembly.

a. Press the claws (arrow) as shown in the illustration.
b. Remove the damper assembly from instrument panel
assembly.
RT21450380
45
4. Remove the face air duct assembly.
a. Remove 8 fixing screws (arrow) from face air duct
assembly.
b. Remove the face air duct assembly from instrument
panel assembly.
RT21450390

5. Remove the defroster duct assembly.

a. Remove 4 fixing screws (arrow) from defroster duct
assembly.
(Tightening torque: 1.5 ± 0.5 N·m) 2 1
b. Remove the left defroster duct assembly (1) and right
defroster duct assembly (2) from instrument panel
assembly.
RT21450400
6. Remove the center defroster duct assembly.

a. Remove 6 fixing screws (arrow) from center defroster
duct assembly.
b. Remove the center defroster duct assembly from
instrument panel assembly.
RT21450410
7. Remove the instrument panel left outlet assembly.

a. Using a screwdriver wrapped with protective tape, pry up the claws on instrument panel left outlet
assembly.
b. Remove the instrument panel left outlet assembly
from instrument panel assembly.
45
RT21450421
8. Remove the instrument panel right outlet assembly.

a. Remove the fixing screw (arrow) from instrument
panel right outlet assembly.
RT21450420


up the claws on instrument panel right outlet
assembly.
c. Remove the instrument panel right outlet assembly
from instrument panel assembly.
RT21450430
9. Remove the front passenger airbag.

a. Disengage the claws from front passenger airbag.
b. Remove the front passenger airbag from instrument
panel assembly.
RT21450440
Assembly
Installation
CAUTION
 Make sure to tighten fixing bolts and fixing screws to the specified torque when installing instrument
panel assembly.
 Check airbag for proper installation after installing instrument panel assembly.
 Check each electrical equipment for proper operation after installing instrument panel assembly.
45


Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing instrument panel crossmember
assembly.
 DO NOT scratch interior and body paint when removing instrument panel crossmember assembly.

3. Remove the instrument panel assembly (See page 45-17).
4. Loosen the instrument panel fuse and relay box.
a. Remove 2 fixing bolts (arrow) from instrument panel
fuse and relay box, and loosen the instrument panel
fuse and relay box.
RT21450450
5. Loosen the connector mounting bracket.

a. Disconnect the connectors (1) from the inner part of
connector mounting bracket.
1
b. Remove 2 fixing bolts (arrow) from connector
mounting bracket, and loosen the connector mounting
bracket.
45
RT21450460
6. Loosen the diagnostic interface.

a. Remove 2 fixing screws (arrow) from diagnostic
interface, and loosen the diagnostic interface.
(Tightening torque: 1.5 N·m)
RT21450470

7. Remove the smart entry start controller.

a. Disconnect the connectors (1) from smart entry start
controller.
b. Remove 2 fixing nuts (arrow) from smart entry start
controller, and remove the smart entry start controller.
RT21450480
8. Remove the anti-theft module (for MT model).

a. Disconnect the connector (arrow) from the anti-theft
module.
b. Remove the fixing bolt (1) from the anti-theft module.
1
RT21450541
9. Remove the instrument panel crossmember lower bracket assembly.

crossmember lower bracket assemblies, and remove
the instrument panel crossmember lower bracket
assemblies.
RT21450481
45
10.Loosen the steering column assembly.
a. Remove 2 fixing nuts (arrow) from steering column
assembly.
b. Remove 2 fixing bolts (1) from steering column
assembly.
c. Separate the steering column assembly from
instrument panel crossmember.
1
RT21450490

11. Remove 2 fixing bolts (arrow) from blower.

RT21450491
12.Separate the instrument panel wire harness.

a. Disconnect the connector (1) from airbag control
module.
b. Remove the fixing nuts (2) from ground wire.
c. Remove the clips (arrow) from lower part of
instrument panel wire harness. 1 2
RT21450501
d. Remove the clips from upper part of instrument panel

wire harness, and separate the instrument panel wire
harness from instrument panel crossmember.
RT21450500
13.Remove the instrument panel crossmember assembly.

45 a. Remove the fixing bolt (arrow) from outer part of
instrument panel crossmember assembly.
RT21450530

b. Remove 4 fixing bolts (arrow) from instrument panel

c. Remove 4 fixing nuts (1) from instrument panel
d. Remove 2 fixing screws (2) from instrument panel
crossmember assembly, and remove the instrument
panel crossmember assembly.
2
(Tightening torque: 7 ± 1 N·m) RT21450520
14.Remove the instrument panel crossmember bracket assembly (take left side as an example).
crossmember bracket assembly.
b. Remove the instrument panel crossmember bracket
assembly.
RT21450540
Installation
CAUTION
 Make sure to tighten fixing bolts to the specified torque when installing instrument panel crossmember
assembly.
 Check airbag for proper installation after installing instrument panel crossmember assembly.
 Check each electrical equipment for proper operation after installing instrument panel crossmember
assembly.
45

- MEMO -

SEAT
GENERAL INFORMATION 46-3 Rear Seat Assembly 46-25
Specifications 46-9 Disassembly 46-26
Tool 46-10 Assembly 46-33
Inspection 46-34
Seat Heater Switch 46-36
Front Seat Assembly 46-12
Removal 46-36
Removal 46-12
Installation 46-36
Disassembly 46-14
Assembly 46-22
Installation 46-22
Inspection 46-22
46

46

46 - SEAT
GENERAL INFORMATION
SEAT
Description
Driver Seat Assembly
2
3
4 6
5
×2
×2
×2 7
×2
15
×2 8
×3
14
46
×2
13 ×2
12 10
11
RT21460010

46 - SEAT
1 - Driver Seat Headrest Assembly 2 - Driver Seat Headrest Guide w/o Button
3 - Driver Seat Headrest Guide w/ Button 4 - Drive Seat Inner Shield Assembly
5 - Driver Seat Belt Buckle Assembly 6 - Driver Seatback Assembly
7 - Driver Seat Rear Mounting Foot Cover Assembly 8 - Driver Seat Outer Shield Assembly
9 - Driver Seat Reclining Adjuster Handle 10 - Driver Seat Reclining Adjuster Handle Cover
11 - Driver Seat Height Adjuster Handle Cover 12 - Driver Seat Height Adjuster Handle
13 - Driver Seat Front Mounting Foot Cover 14 - Driver Seat Track Unlock Handle
Assembly
15 - Driver Seat Cushion Assembly
46

46 - SEAT
Front Passenger Seat Assembly
2
3
15
14 4
13 ×2
×2
5
12 6
×2
×3
×2
×2 ×2
46
11 10
×3
×2 8
RT21460020

46 - SEAT
1 - Front Passenger Seat Headrest Assembly 2 - Front Passenger Seat Headrest Guide w/o Button
3 - Front Passenger Seat Headrest Guide w/ Button 4 - Front Passenger Seatback Assembly
5 - Front Passenger Seat Belt Buckle Assembly 6 - Front Passenger Seat Inner Shield Assembly
7 - Front Passenger Seat Rear Mounting Foot Cover 8 - Front Passenger Seat Track Assembly
Assembly
9 - Front Passenger Seat Front Mounting Foot Cover 10 - Front Passenger Seat Track Unlock Handle
Assembly
11 - Passenger Side Seat Belt Reminder 12 - Front Passenger Seat Cushion Assembly
13 - Front Passenger Seat Outer Shield Assembly 14 - Front Passenger Seat Reclining Adjuster
Handle
15 - Front Passenger Seat Reclining Adjuster
Handle Cover
46

46 - SEAT
Rear Seat Assembly
21
×2
4
19 20
2 3
5
6
×2
×2
7
18
17
10
×2
×2 8
×2
×2
9
×2
16
×2 ×4
×4 ×2
×2 11
×2
15
12
13
14
46
RT21460030

46 - SEAT
1 - Rear Left Seat Headrest Assembly 2 - Rear Seat Headrest Guide w/o Button
3 - Rear Seat Headrest Guide w/ Button 4 - Rear Seatback Unlock Mechanism Cover
5 - Rear Seatback Unlock Mechanism Assembly 6 - Child Seat Upper Fixing Point Trim Cover
7 - Rear Left Seatback Assembly 8 - Rear Left Seat Folder Mechanism Assembly
Outer Cover
9 - Rear Left Seat Reclining Adjuster Inner Cover 10 - Rear Right Seat Reclining Adjuster Inner Cover
11 - Rear Left Seat Bracket Assembly 12 - Rear Seat Mounting Foot Cover Assembly
13 - Attachment Trim Cover Between Rear Left Seat 14 - Rear Left Seat Cushion Assembly
Cushion and Seatback
15 - Attachment Trim Cover Between Rear Right 16 - Rear Right Seat Bracket Assembly
17 - Rear Right Seat Cushion Assembly 18 - Rear Right Seat Folder Mechanism Assembly
Outer Cover
19 - Rear Right Seatback Assembly 20 - Rear Seat Armrest Assembly
21 - Rear Right Seat Headrest Assembly
The front seat assemblies can be moved forward and backward by seat track unlock handle, and can be
moved upward and downward by seat height adjuster handle, and the seatback reclining can be adjusted by
seat reclining adjuster handle.
The rear seat position is not adjustable; however, the rear seatback can be put down forward by pulling the
seatback unlock mechanism assembly to help increase the storage space of back door.
46

46 - SEAT
Specifications

Front Seat Assembly Fixing Bolt 50 ± 5
Seat Track Unlock Handle Fixing Screw 4.8 ± 0.5
Seat Front Mounting Foot Cover Assembly Fixing
4.8 ± 0.5
Screw
Seat Rear Mounting Foot Cover Assembly Fixing
4.8 ± 0.5
Screw
Seat Height Adjuster Handle Fixing Screw 4.8 ± 0.5
Seat Reclining Adjuster Handle Fixing Screw 4.8 ± 0.5
Seat Outer Shield Assembly Fixing Screw 4.8 ± 0.5
Seat Belt Buckle Assembly Fixing Nut 50 ± 5
Seat Inner Shield Assembly Fixing Screw 4.8 ± 0.5
Seat Track Assembly Fixing Bolt 24 ± 2.4
Rear Seat Assembly Fixing Bolt 50 ± 5
Attachment Trim Cover Fixing Screw Between Rear
4.8 ± 0.5
Rear Seat Armrest Assembly Fixing Screw 4.8 ± 0.5
Child Seat Upper Fixing Point Trim Cover Fixing
4.8 ± 0.5
Screw
Rear Seatback Unlock Mechanism Assembly Fixing
4.8 ± 0.5
Screw
Rear Seat Mounting Foot Cover Assembly Fixing
4.8 ± 0.5
Screw
Fixing Bolt Between Rear Seat Cushion Assembly
48 ± 4.8
and Seatback Assembly
Rear Seat Folder Mechanism Assembly Outer Cover
4.8 ± 0.5
Fixing Screw
Rear Seat Reclining Adjuster Inner Cover Fixing 46
4.8 ± 0.5
Screw
Rear Seat Bracket Assembly Fixing Bolt 48 ± 4.8

46 - SEAT
Tool
General Tool
Digital Multimeter
RCH0000002
46

46 - SEAT
Circuit Diagram
Seat System
IGNITION SWITCH
ON OR START
INSTRUMENT
RF02 RF07 PANEL FUSE
AND RELAY
20A 20A
BOX B
B-060
F2 F7
RW
R
RW
18 B-059
B-003
I-006
I-035
RW
R
RW
20
ILLUMINTION
Lg
Lg
2 3 2 3
FRONT 1 1
FRONT DRIVER DRIVER BCM
PASSENGER
PASSENGER SEAT SEAT HEAT I-005
SEAT HEATER
SEAT HEATER HEATER SWITCH
SWITCH B-047
B-065 B-071 B-067
I-044 B1 A23
2 2
1 4 1 4
B
B
GR
YR
B
YR
I-047
B-042
46
1 2 3 4 5 6 7 8 9 1 2 3 4 1 2 3 4
F1 F2 F3 F4 F5 F6 F7
F11 F12 F13 F14 10 11 12 13 14 15 16 17 18 5 6 7 8 5 6 7 8
F8 F9 F10 F15 F16 F17 F18
B-059 I-044 B-067
W B B
B-060
W
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16
I-005 B-047
L L
10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 11
2 1 2 1
3 4 3 4
I-006
B-065 B-071 W
B B ET21460010

46 - SEAT
ON-VEHICLE SERVICE
Front Seat Assembly
Removal
HINT:
 Use the same procedures for the front passenger seat assembly and driver seat assembly.
 Procedures listed below are for the driver seat assembly.
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing seat assembly.
 Avoid scratch or damage to the body paint surface and carpet when removing seat assembly.

3. Remove the driver seat headrest assembly.
a. As shown in the illustration, press the seat headrest
guide w/ button and remove the driver seat headrest
assembly.
RT21460040
4. Remove the driver seat assembly.

a. As shown in the illustration, pull up the seat track
unlock handle and move the seat assembly to the
rearmost position.
46
RT21460050

up the seat front mounting foot cover.
RT21460060

46 - SEAT
c. Remove 2 fixing bolts (arrow) on the front side of seat

assembly.
RT21460070
d. As shown in the illustration, pull up the seat track

unlock handle and move the seat assembly to the
foremost position.
RT21460071
e. Using a screwdriver wrapped with protective tape, pry

up the seat rear mounting foot cover.
RT21460080
f. Remove 2 fixing bolts (arrow) on the rear side of seat

assembly.
46
RT21460090

46 - SEAT
g. Disconnect the wire harness connector (arrow) and

clip (1) under the seat assembly (for driver seat
assembly).
RT21330080
h. Disconnect the wire harness connectors (arrow) and

clip (1) under the seat assembly (for front passenger
seat assembly).
RT21460100
i. Pull up the seat track unlock handle and move the seat assembly to the mid-position. At the same time,
operate the seat reclining adjuster handle and move the seatback to the upright position, and remove
the driver seat assembly.
Disassembly
HINT:
 Use the same procedures for the front passenger seat assembly and driver seat assembly.
 Procedures listed below are for the driver seat assembly.
CAUTION
 Be sure to wear safety equipment to prevent accidents when disassembling seat assembly.
1. Remove the driver seat track unlock handle.

46 a. Remove the fixing screw (arrow) from the seat track
unlock handle, and remove the driver seat track
unlock handle.
RT21460101

46 - SEAT
2. Remove the driver seat front mounting foot cover assembly.

a. Remove 2 fixing screws (arrow) from the seat front
mounting foot cover assembly, and remove the driver
seat front mounting foot cover assembly.
RT21460110
3. Remove the driver seat rear mounting foot cover assembly.

a. Remove 2 fixing screws (arrow) from the seat rear
mounting foot cover assembly, and remove the driver
seat rear mounting foot cover assembly.
RT21460120
4. Remove the seat height adjuster handle (for driver side).

up the seat height adjuster handle cover (1).
b. Remove 2 fixing screws (arrow) from the seat height
46
adjuster handle, and remove the seat height adjuster
handle.
RT21460130

46 - SEAT
5. Remove the power seat position adjust switch (for driver side) (if equipped).
up the claw on the power seat position adjust switch,
and remove the power seat position adjust switch.
RT21460630
6. Remove the driver seat reclining adjuster handle.

up the seat reclining adjuster handle cover (1).
b. Remove 2 fixing screws (arrow) from the seat
reclining adjuster handle, and remove the driver seat
reclining adjuster handle.
RT21460140
7. Remove the power seat reclining adjust switch (for driver side) (if equipped).
up the claw on the power seat reclining adjust switch,
and remove the power seat reclining adjust switch.
46
RT21460620

46 - SEAT
8. Remove the seat outer shield assembly (for driver side).

a. Remove 3 fixing screws from the seat outer shield
assembly.
RT21460152

up the claws on the seat outer shield assembly, and
remove the seat outer shield assembly.
RT21460150
9. Remove the seat outer shield assembly (for front passenger side).
a. Remove 2 fixing screws from the seat outer shield
assembly.
46
RT21460153

46 - SEAT

up the claws on the seat outer shield assembly, and
remove the seat outer shield assembly.
RT21460151
10.Remove the driver seat belt buckle assembly.

a. Remove the fixing nut (1) from the seat belt buckle
assembly.
b. Remove the clips (arrow) from the seat belt buckle
assembly, and remove the driver seat belt buckle
assembly.
RT21460160
11. Remove the driver seat inner shield assembly.

a. Remove 2 fixing screws from the seat inner shield
assembly.
46 b. Using a screwdriver wrapped with protective tape, pry
up the claws on the seat inner shield assembly, and
remove the driver seat inner shield assembly.
RT21460170

46 - SEAT
12.Remove the hooks (arrow) connecting the driver

seatback assembly and seat cushion assembly.
RT21460180
13.Remove the driver seat headrest guide.

a. Remove 9 hog rings (arrow) from the seatback
assembly.
RT21460190
b. Press and hold the lower part of seat headrest guide

in the direction of arrow as shown in the illustration,
and remove the driver seat headrest guide.
46
RT21460200

46 - SEAT
14.Remove the seat cushion assembly (for driver side).

a. Remove 12 hog rings (arrow) from the seat cushion
assembly.
b. Remove the driver seat cushion assembly.
RT21460210
15.Remove the seat cushion assembly (for front passenger side).

a. Remove 11 hog rings (arrow) from the seat cushion
assembly.
RT21460220
b. Disengage the clip (arrow) from the passenger side

seat belt reminder connector.
c. Remove the front passenger seat cushion assembly.
46
RT21460230

46 - SEAT
16.Remove the passenger side seat belt reminder (for front passenger side).
a. Remove 4 hog rings from the seat cushion assembly.
b. Remove the passenger side seat belt reminder (1).
RT21460231
17.Remove the seat track assembly (for front passenger side).

a. Remove 3 fixing bolts (arrow) from the left seat track
assembly.
RT21460232
b. Remove 3 fixing bolts (arrow) from the right seat track

assembly, and remove the front passenger seat track
assembly.
46
RT21460233

46 - SEAT
Assembly
CAUTION
 Be sure to wear safety equipment to prevent accidents when assembling seat.

 Be careful not to damage the seat cover during assembly.
 Replace the damaged hog rings during assembly.
 Keep the seat cover clean and tidy, and try to prevent wrinkles during assembly.
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing seat assembly.
 Be careful not to damage the body paint surface when installing seat assembly.
 Avoid scratch or damage to the carpet when installing seat assembly.
Inspection
After completing the installation of seat assembly, check the basic functions of the seat assembly, and confirm
that the following functions operates normally:
1. Manual seat assembly
a. Move the seat to the foremost and rearmost positions
by pulling up the seat track unlock handle, and check
if the seat is difficult to move, stuck, has high sliding
resistance, makes noise, etc. If the above conditions
occur, repair or replace in time.
RT21460240
46
b. Adjust the seatback reclining to the maximum and
minimum angle by pulling up the seat reclining
adjuster handle, and check if the seat is difficult to
move, stuck, etc. If the above conditions occur, repair
or replace in time.
RT21460250

46 - SEAT
c. Adjust the seat height to the highest and lowest

position by pulling up the seat height adjuster handle
(for driver side), and check if the seat is difficult to
or replace in time.
RT21460260
d. Press the headrest guide w/ button, move the

headrest up and down, and check if the headrest is
difficult to move, stuck, etc. If the above conditions
occur, repair or replace in time.
RT21460270
e. Check if the fixing bolts are set in position. Tighten to the specified torque as necessary.
f. Check the passenger side seat belt reminder (for front passenger side).
- Disconnect passenger side seat belt reminder
connector (arrow).
RT21460251
- Using a digital multimeter, measure resistance

between terminals of passenger side seat belt
reminder according to the value(s) in the table
+ - 46
below. 1 2
Condition
Terminal 1 -
No occupant ∞Ω
Terminal 2
Terminal 1 - RT21460252
With occupant ≤ 20 Ω
Terminal 2
If result is not as specified, replace passenger side

seat belt reminder.

46 - SEAT
2. Power seat assembly

a. Move the seat to the foremost and rearmost positions
by moving the seat position adjust switch back and
forth, and check if the seat is difficult to move, stuck,
has high sliding resistance, makes noise, etc. If the
above conditions occur, repair or replace in time.
RT21460590
b. Adjust the seatback reclining to the maximum and

minimum angle by pulling the seatback reclining
adjust switch, and check if the seatback is difficult to
or replace in time.
RT21460600
c. Adjust the seat height to the highest and lowest

position by pulling the seat cushion height adjust
switch, and check if the seat is difficult to move, stuck,
etc. If the above conditions occur, repair or replace in
time.
RT21460610
46

46 - SEAT
Rear Seat Assembly

Removal
HINT:
 Use the same procedures for the rear right seat assembly and rear left seat assembly.
 Procedures listed below are for the rear left seat assembly.
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rear seat assembly.
 Avoid scratch or damage to the body paint surface and carpet when removing rear seat assembly.
1. Remove the rear left seat headrest assembly.

a. As shown in the illustration, press the left seat
headrest guide w/ button and remove the rear left seat
headrest assembly.
RT21460280
2. Remove the rear left seat assembly.

a. Remove 2 fixing bolts (arrow) from the front part of
rear left seat assembly.
RT21460290
46
b. Put down the rear left seatback in the direction of
RT21460280

46 - SEAT
c. Remove 2 fixing bolts (arrow) from the rear part of

rear left seat assembly, and remove the rear left seat
assembly.
RT21460310
Disassembly
HINT:
 Use the same procedures for the rear right seat assembly and rear left seat assembly.
 Procedures listed below are for the rear left seat assembly.
CAUTION
 Be sure to wear safety equipment to prevent accidents when disassembling rear seat assembly.
1. Remove the attachment trim cover between rear left seat cushion and seatback (take left side as an
example).
a. Remove the attachment trim cover fixing screw
(arrow) between rear left seat cushion and seatback.
up the claws on the attachment trim cover between
rear left seat cushion and seatback.
c. Remove the attachment trim cover between rear left
seat cushion and seatback.
46 RT21460350

46 - SEAT
2. Remove the rear seat armrest assembly.

a. Open the rear seat armrest assembly in the direction
RT21460361

up the claw on the rear seat armrest trim cover, and
remove the rear seat armrest trim cover.
RT21460362
c. Remove the fixing screw (1) from the rear seat

armrest assembly.
d. Remove the rear seat armrest assembly from the
grooves (arrow). 1
RT21460363 46

46 - SEAT
3. Remove the child seat upper fixing point trim cover.

a. Open the child seat upper fixing point trim cover in the
RT21460370
b. Remove the fixing screw (arrow) from the child seat

upper fixing point trim cover.
up the claw on the child seat upper fixing point trim
cover.
d. Remove the child seat upper fixing point trim cover.
RT21460380
4. Remove the rear left seat headrest guide.

a. Remove 7 hog rings under the seatback.
b. Unzip the rear seatback assembly.
46
RT21460390

46 - SEAT
c. Remove 5 fixing clamps (arrow) from the rear

seatback board, and remove the rear seatback board.
RT21460400
d. Press the lower part of rear seat headrest guide in the

remove the rear left seat headrest guide.
RT21460410
5. Remove the rear seatback unlock mechanism assembly.

up the cover (arrow) of rear seatback unlock
mechanism assembly.
46
RT21460420

46 - SEAT
b. Remove the fixing screw (arrow) from the rear

seatback unlock mechanism assembly.
RT21460430
c. Disconnect the rear seatback unlock mechanism

cables (arrow), and remove the rear seatback unlock
mechanism assembly.
RT21460440
6. Remove the rear seatback unlock mechanism cable.

a. Remove the rear seatback unlock mechanism cables
(arrow) from the groove as shown in the illustration.
46
RT21460431

46 - SEAT
7. Separate the rear seat cushion assembly and seatback assembly.

a. Remove 2 fixing screws (arrow) from the rear seat
mounting foot cover assembly, and remove the rear
seat mounting foot cover assembly.
RT21460450
b. Remove the snap ring in the direction of arrow as

RT21460460
c. Pull out the coupling shaft in the direction of arrow as

RT21460470 46

46 - SEAT
d. Remove the fixing bolt (arrow) between rear seat

cushion assembly and left side of seatback assembly.
RT21460441
e. Remove the fixing bolt (arrow) between rear seat

cushion assembly and right side of seatback
assembly.
RT21460442
f. Separate the rear seat cushion assembly and seatback assembly.

8. Remove the rear left seat folder mechanism assembly outer cover (take left side as an example).
a. Remove 2 fixing screws (arrow) from the rear left seat
folder mechanism assembly outer cover.
46 b. Remove the rear left seat folder mechanism assembly
outer cover.
RT21460480

46 - SEAT
9. Remove the rear left seat reclining adjuster inner cover (take left side as an example).
a. Remove 2 fixing screws (arrow) from the rear left seat
reclining adjuster inner cover.
b. Remove the rear left seat reclining adjuster inner
cover.
RT21460500
10.Remove the rear seat bracket assembly.

a. Remove 2 fixing bolts (arrow) from the left side of rear
seat bracket assembly.
RT21460520
b. Remove 2 fixing bolts (arrow) from the right side of

rear seat bracket assembly.
c. Remove the rear seat bracket assembly.
RT21460530
Assembly
Assembly is in the reverse order of disassembly. 46
CAUTION
 Be sure to wear safety equipment to prevent accidents when assembling rear seat assembly.
 Be careful not to damage the seat cover during assembly.
 Replace the damaged hog rings during assembly.
 Keep the seat cover clean and tidy, and try to prevent wrinkles during assembly.

46 - SEAT
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing rear seat assembly.
 Be careful not to damage the body paint surface when installing rear seat assembly.
 Avoid scratch or damage to the carpet when installing rear seat assembly.
 Make sure that the seat belt buckle is not under the seat cushion when installing rear seat cushion.
Inspection
After installing the rear seat assembly, check the basic functions of rear seat assembly, and confirm that the
following functions operates normally:
1. Pull up the seatback unlock mechanism assembly, and
check if the rear seatback is difficult to move, stuck, etc.
Repair or replace as necessary.
RT21460550
2. Press the headrest guide w/ button, move the headrest

up and down, and check if the headrest is difficult to
move, stuck, etc. If the above conditions occur, repair or
replace in time.
46
RT21460540

46 - SEAT
3. Flip down the rear seat armrest assembly forward or

backward, and check if the rear seat armrest assembly is
difficult to move, stuck, etc. If the above conditions occur,
repair or replace in time.
RT21460560
4. Check if the fixing bolts are set in position. Tighten to the specified torque as necessary.
46

46 - SEAT
Seat Heater Switch

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing seat heater switch.
 Avoid scratch or damage to the shift panel assembly when removing seat heater switch.

3. Remove the seat heater switch.
up the claws on the seat heater switch.
R
S
RT21460570
b. Disconnect the seat heater switch connectors (arrow),

and remove the driver seat heater switch (1) and front
passenger seat heater switch (2).
2
1
R
S
RT21460580
Installation
46
CAUTION
 Check seat heater switch for proper operation after installation.

ENGINE HOOD/DOOR
Description 47-3 Adjustment 47-33
Tool 47-10 Rear Door Protector Assembly 47-36
Removal 47-36
Installation 47-38
Hood Assembly 47-11
Rear Door Assembly 47-39
Removal 47-11
Removal 47-39
Installation 47-13
Installation 47-44
Adjustment 47-14
Adjustment 47-44
Inspection 47-15
Inspection 47-46
Hood Hinge Assembly 47-16
Back Door Protector Assembly 47-47
Removal 47-16
Removal 47-47
Installation 47-17
Installation 47-49
Hood Cable Assembly 47-18
Back Door Assembly 47-50
Removal 47-18
Removal 47-50
Installation 47-20
Installation 47-52
Hood Air Spring Assembly 47-21
Adjustment 47-53
Removal 47-21
Inspection 47-55
Installation 47-22
Back Door Opener Switch Assembly 47-56
Front Door Protector Assembly 47-23
Removal 47-56
Removal 47-23
Installation 47-56
Installation 47-27
Back Door Air Spring Assembly 47-57
Front Door Assembly 47-28
Removal 47-57
Removal 47-28
Installation 47-58
47

47

47 - ENGINE HOOD/DOOR
GENERAL INFORMATION
ENGINE HOOD/DOOR
Description
Hood Assembly
3
5
4 6
7
×14
MAX
MIN
47
RT21470010

1 - Hood Assembly 2 - Hood Upper Adjustment Block

3 - Hood Right Air Spring Assembly 4 - Hood Right Hinge Assembly
5 - Hood Left Hinge Assembly 6 - Hood Left Air Spring Assembly
7 - Hood Sound-absorbing Pad 8 - Hood Lower Adjustment Block
47

Front Left Door Assembly
3
4
5
6
×3
18
8
7
19
17
16 20 21
×2 24
9 22
×3
×3
23 25
10
15
×6
13 14
11 27
12 26
RT21470020
47

1 - Front Door Frame Weatherstrip 2 - Front Door Glass Run

3 - Front Door Glass Assembly 4 - Front Door Assembly
5 - Outside Rear View Mirror Assembly 6 - Front Door Outer Weather Bar Assembly
7 - Front Door Key Cylinder Protective Cover 8 - Front Door Outside Handle
9 - Front Door Lock Assembly 10 - Front Door Trim Board Garnish
11 - Front Door Trim Board Assembly 12 - Front Door Buffer Block
13 - Front Door Glass Rear Guide Rail Assembly 14 - Front Door Power Glass Regulator Assembly
15 - Front Door Low Pitched Speaker 16 - Front Door Lower Hinge Assembly
17 - Front Door Outside Handle Base Assembly 18 - Front Door Upper Hinge Assembly
19 - Front Door Protective Film Assembly 20 - Front Door Assist Grip Mounting Bracket
Assembly
21 - Rubber Cushion 22 - Power Glass Regulating Control Master Switch
Assembly
23 - Front Door Inside Handle Assembly 24 - Front Door Inner Triangular Block Assembly
25 - Front Door Inside Handle Screw Cover 26 - Front Door Assist Grip Cover
27 - Front Door Protector Assembly
47

Back Door Assembly
1
×2
14
3 13
×3
11 12
7
10
8
9
47
RT21470030

1 - Back Door Assembly 2 - Back Door Locating Block

3 - Back Door Hinge Assembly 4 - Back Door Left Air Spring Assembly
5 - Back Door Right Air Spring Assembly 6 - Back Door Locating Seat
7 - Back Door Left Protector Assembly 8 - Back Door Upper Protector Assembly
9 - Back Door Right Protector Assembly 10 - Back Door Lower Protector Assembly
11 - Back Door Adjustment Block 12 - Rear Wiper Motor Assembly
13 - Back Door Opener Switch Assembly 14 - Back Door Buffer Block
The vehicle is designed as a structure with five doors & one cover (front left door, rear left door, front right
door, rear right door, back door and hood).
47

Specifications

Fixing Bolt Between Hood Assembly and Hood
23 ± 2
Hinge Assembly
Hood Lock Assembly Fixing Nut 10 ± 1
10 ± 1
Fender Assembly
23 ± 2
Body
Water Tank Upper Crossmember Deflector Fixing
10 ± 1
Nut
Hood Grip Assembly Fixing Screw 1.5 ± 0.5
Hood Air Spring Ball Pin Assembly 10 ± 1
Front Door Inside Handle Assembly Fixing Screw 1.5 ± 0.5
Front Door Protector Assembly Fixing Screw 1.5 ± 0.5
Front Door Assist Grip Assembly Fixing Screw 1.5 ± 0.5
Front Door Assist Grip Mounting Bracket Assembly
1.5 ± 0.5
Fixing Screw
Front Door Outside Handle Base Assembly Fixing
5±1
Screw
70 ± 3
Door
70 ± 3
Body
Rear Door Inside Handle Assembly Fixing Screw 1.5 ± 0.5
Rear Door Protector Assembly Fixing Screw 1.5 ± 0.5
Rear Door Assist Grip Assembly Fixing Screw 1.5 ± 0.5
Rear Door Assist Grip Mounting Bracket Assembly
1.5 ± 0.5
Fixing Screw
47
Rear Door Outside Handle Base Assembly Fixing
5±1
Screw
70 ± 3
Door
70 ± 3
Body
Back Door Grip Assembly Fixing Screw 7±1
Back Door Lower Protector Assembly Fixing Screw 1.5 ± 0.5
Back Door Locating Block Fixing Bolt 1.5 ± 1


Fixing Bolt Between Back Door Hinge Assembly and
23 ± 2
Back Door
Back Door Hinge Assembly Fixing Nut 23 ± 2
Back Door Opener Switch Assembly Fixing Bolt 10 ± 1
Back Door Air Spring Assembly Ball Pin 10 ± 1
Tool
General Tool
Interior Crow Plate
RCH0000025
47

ON-VEHICLE SERVICE
Hood Assembly
Removal
WARNING
 When removing hood assembly, an assistant is needed to hold hood. Prevent hood from dropping or
sudden closing to cause accidents during operation.
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing hood assembly.
 When removing hood assembly, prevent hood from dropping to damage the body or front windshield
during operation.

3. Remove the hood upper adjustment block.
a. Turn the hood upper adjustment blocks counterclockwise
and remove the hood upper adjustment blocks (1).
RT21470040
4. Remove the hood lower adjustment block.

a. Turn the hood lower adjustment blocks counterclockwise
and remove the hood lower adjustment blocks (1).
47
RT21470060

5. Remove the hood sound-absorbing pad.

a. Remove the clips (arrow) from the hood 
sound-absorbing pad, and remove the hood 
sound-absorbing pad.
RT21470050
6. Remove the front washer nozzle assembly (See page 36-29).

7. Remove the washer hose.
b. Remove the washer hose from the clips (arrow).
RT21470051
8. Release the hood air spring assembly.

up the clips on the upper part of hood air spring.
b. Release the hood air spring assembly.
RT21470070
9. Remove the hood assembly.

47 a. Remove 4 fixing bolts (arrow) between hood
assembly and hood hinge assembly, and remove the
hood assembly.
RT21470080

Installation
WARNING
 When installing hood assembly, an assistant is needed to hold hood. Prevent hood from dropping or
sudden closing to cause accidents during operation.
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing hood assembly.
 Try to prevent body paint surface from being scratched when installing hood assembly.
47

Adjustment
1. Adjust the hood assembly.
a. Loosen fixing bolts on hood hinge assembly.
b. Adjust clearance of hood assembly to standard range and pre-tighten fixing bolts on hood hinge
assembly.
Standard ranges of clearance between installation positions of hood assembly and each part are as
follows:
Clearance between hood assembly and radiator grille: 6.4 ± 1.5 mm.
Clearance between hood assembly and front headlight assembly: 6.5 ± 1.5 mm.
Clearance between hood assembly and front fender assembly: 4.0 ± 1.0 mm.
6.4±1.5
Hood
Hood
Radiator grille .5
6.5±1
Headlight
4.0
±1
.0
Hood
Front fender
0±
1.
0
47
RT21470090
c. After adjustment, tighten the fixing bolts between hood hinge assembly and hood assembly to the
specified torque.
d. After adjustment, tighten the fixing bolts between hood hinge assembly and body to the specified
torque.

2. Adjust the height of hood front end with adjustment block.

a. Raise or lower the hood front end by rotating the upper
adjustment blocks clockwise or counterclockwise.
RT21470091
b. Raise or lower the hood front end by rotating the lower

RT21470100
c. After adjustment, make sure alignment between hood assembly and front fender assembly is within the
standard range.
Standard alignment: 0 ± 1.0 mm
3. Adjust the hood lock assembly.
a. Slightly loosen the fixing nuts of hood lock assembly
and adjust the hood lock assembly in the direction of
RT21470110
b. Tighten the hood lock assembly fixing nuts to the specified torque after adjustment. 47
Inspection
After the hood assembly is adjusted, perform the following inspections:
1. Check hood assembly for wear or deformation during installation, and repair as necessary.
2. Check if fixing bolts and fixing nuts are set in position. Tighten them to the specified torque as necessary.
3. Check if clearance and alignment between hood assembly and front fender assembly, radiator grille and
front headlight assembly are within the specified range, and adjust as necessary.

Hood Hinge Assembly

Removal
HINT:
WARNING
 When removing hood hinge assembly, an assistant is needed to hold hood. Prevent hood from dropping
or sudden closing to cause accidents during operation.
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing hood hinge assembly.
 When removing hood hinge assembly, prevent hood from dropping to damage body or front windshield
during operation.

3. Remove the front windshield lower garnish left cover plate.
up the claws on front windshield lower garnish left
cover plate.
b. Remove the front windshield lower garnish left cover
plate.
RT21480490
4. Remove the hood left hinge assembly.

a. Remove 2 fixing bolts (arrow) between hood hinge
assembly and hood assembly.
RT21470130

b. Remove the fixing bolt (arrow) between hood hinge

assembly and front fender assembly.
RT21480250
c. Remove 2 fixing bolts (arrow) between hood hinge

RT21470150
d. Remove the hood hinge Assembly.
Installation
WARNING
 When installing hood hinge assembly, an assistant is needed to hold hood. Prevent hood from dropping
or sudden closing to cause accidents during operation.
CAUTION
 After installing hood hinge assembly, it is necessary to adjust hood.

 When installing hood hinge assembly, prevent hood from dropping to damage body or front windshield
during operation.
47

Hood Cable Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing hood cable assembly.
 Try to prevent body paint surface from being scratched when removing hood cable assembly.

5. Remove the water tank upper crossmember deflector.
a. Remove 2 plastic clips (arrow) and the fixing nut (1)
from the water tank upper crossmember deflector.
b. Remove the water tank upper crossmember deflector.
RT21370050
6. Remove the hood lock assembly.

a. Remove 2 fixing nuts (arrow) from the hood lock
assembly.
RT21370060
47
b. Disengage the hood cable assembly (arrow) from the
slot.
c. Remove the hood lock assembly.
RT21370061

7. Remove the hood grip assembly.

a. Remove 2 fixing crews (arrow) from the hood grip
assembly.
RT21470160
b. Disengage the hood grip assembly in the direction of

RT21470170
c. Disengage the hood cable (arrow) to separate it from

the hood grip assembly.
RT21470171
8. Remove the hood cable assembly.

a. Disengage the hood cable assembly from the clips.
b. Remove the hood cable assembly.
47
RT21470180

Installation
CAUTION
 Try to prevent body paint surface from being scratched when installing hood cable assembly.
 After installation of hood cable assembly is completed, make sure hood can be opened smoothly without
sticking.
47

Hood Air Spring Assembly

Removal
HINT:
WARNING
 When removing hood air spring assembly, an assistant is needed to hold hood. Prevent hood from
dropping or sudden closing to cause accidents during operation.
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing hood air spring assembly.
 Try to prevent body paint surface from being scratched when removing hood air spring assembly.
 When removing hood air spring assembly, prevent hood from dropping to damage body or front
windshield during operation.

3. Remove the hood left air spring assembly.
up the fixing clip on the upper part of hood air spring.
up the fixing clip on the lower part of hood air spring
and remove the hood left air spring assembly.
RT21470190
4. Remove the hood air spring ball pin (arrow).

47
RT21470191

Installation
WARNING
 When removing hood air spring assembly, an assistant is needed to hold hood. Prevent hood from
CAUTION
 Try to prevent body paint surface from being scratched when installing hood air spring assembly.
 Make sure hood air spring assembly and hood air spring clip are fitted closely after installing hood air
spring assembly.
47

Front Door Protector Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing front door protector assembly.
 Avoid damage to front door protector surface when removing front door protector assembly.

3. Remove the front left door inner triangular block assembly.
a. Using an interior crow plate, pry up the claws on front
door inner triangular block assembly, and remove the
front left door inner triangular block assembly.
RT21470200
4. Remove the front left door inside handle assembly.

up the front door inside handle screw cover (1).
b. Remove the fixing screw (2) from the front door inside
handle assembly.
47
RT21470210

5. Remove the front left door assist grip cover.

up the claws on front left door assist grip cover, and
remove the front left door assist grip cover.
RT21470220
6. Remove the power glass regulating control master switch assembly (See page 43-44).
7. Remove the front left door protector assembly.
up the front door protector screw cover (1).
b. Remove the fixing screw (2) from the upper part of
front door protector assembly.
RT21470240
c. Remove 2 fixing screws (arrow) from the lower part of

front door protector assembly.
47
RT21470250

d. Remove 2 fixing screws inside the front door assist

grip assembly.
RT21470230
e. Using an interior crow plate, pry off the clips from the
front door protector assembly, and release the front
door protector assembly in the direction of arrow as
RT21470260
f. Disengage the front door inside handle cable (arrow)

from the slot.
47
RT21470270

g. Disconnect the front door open warning light

connector (1).
h. Disconnect the anti-theft indicator connector (arrow)
(for left side).
i. Remove the front left door protector assembly.
RT21470280
8. Remove the front left door inside handle assembly.

a. Remove the fixing screw (arrow) from the front door
inside handle assembly.
RT21470290

up the claws on front door inside handle assembly.
c. Remove the front door inside handle assembly from
the front door protector assembly.
RT21470300
47 9. Remove the front door assist grip assembly.

a. Remove 4 fixing screws (arrow) from the front door
assist grip assembly.
b. Remove the front door assist grip assembly from the
front door protector assembly.
RT21470301

10.Remove the courtesy light cover.

up the courtesy light cover.
b. Remove the courtesy light cover from the front door
protector assembly.
RT21470310
11. Remove the front door courtesy light.

a. Turn the front door courtesy light counterclockwise.
b. Remove the front door courtesy light from the front
door protector assembly.
RT21470311
12.Remove the anti-theft indicator.

a. Press the claws (arrow) on anti-theft indicator as
b. Remove the anti-theft indicator from the front door
protector assembly.
RT21470320
Installation
47
CAUTION
 Make sure damaged clips are replaced and front door protector assembly is installed in place when
installing front door protector assembly.
 Install connector in place when installing front door protector assembly.
 Make sure each function can operate properly after installing front door protector assembly.

Front Door Assembly

Removal
HINT:
WARNING
 When removing front door assembly, an assistant is needed to hold front door to prevent front door from
dropping to cause accidents during operation.
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing front door assembly.
 Try to prevent body paint surface from being scratched when removing front door assembly.

3. Remove the front left door trim board garnish.
up the claws on front door trim board garnish.
b. Remove the front left door trim board garnish.
RT21470321
4. Remove the front left door trim board assembly.

up the clips on front door trim board assembly.
b. Remove the front door trim board assembly.
47
RT21470322

5. Disconnect the front left door connector.

up the front door dust boot.
up the claws on connector.
c. Disconnect the front left door connector (arrow).
RT21470330
6. Remove the front left door frame weatherstrip.

a. Remove the clip from the front door frame
weatherstrip, and remove the front left door frame
weatherstrip.
RT21470360
7. Remove the front left door buffer block.

remove the front door buffer blocks (arrow).
47
RT21470340
9. Remove the front left door assist grip mounting bracket assembly.

a. Remove 2 fixing screws (arrow) from the front door

assist grip mounting bracket assembly.
b. Remove the front left door assist grip mounting
bracket assembly.
RT21470350
10.Remove the front left door protective film assembly.
CAUTION
 Avoid damage to front door protective film when removing front door protective film assembly.
 Place front door protective film assembly properly after removal, and avoid adhesive sticker on front door
protective film assembly from sticking to other components.
a. Disengage the wire harness clips (arrow).
47 RT21470380

b. Remove the front left door protective film assembly by

gently pulling it along edges from one corner of the
front left door protective film assembly.
RT21470370
11. Remove the front left woofer assembly. (See page 39-15).
12.Remove the left outside rear view mirror assembly (See page 44-7).
13.Remove the front left door key cylinder protective cover (See page 37-44).
14.Remove the front left door outside handle.
a. Disconnect the connector (arrow) from the front door
outside handle.
RT21470390
b. Slide and pull the front door outside handle in the

remove it. 47
RT21470381

15.Remove the front left door outside handle base assembly.

a. Remove the fixing screw (arrow) from the front door
outside handle base assembly, and remove the front
left door outside handle base assembly.
RT21470400
16.Remove the front left door outside handle front gasket.

a. Disengage the claws from the front door outside handle front gasket, and remove the front left door
outside handle front gasket.
17.Remove the front left door outside handle rear gasket.
a. Disengage the claws from the front door outside
handle rear gasket, and remove the front left door
outside handle rear gasket.
RT21470410
18.Remove the front left door outer weather bar (See page 43-47).
19.Remove the front left door glass assembly (See page 43-49).
20.Remove the front left door glass rear guide rail assembly (See page 43-51).
47 21.Remove the front left door power glass regulator assembly (See page 43-53).
22.Remove the front left door lock assembly (See page 37-41).
23.Remove the front left door assembly.
a. Remove 3 fixing bolts (arrow) between front door
hinge assembly and door.
RT21470420

b. Remove the front left door assembly.

24.Remove the instrument panel assembly (See page 45-17).
25.Remove the instrument panel crossmember assembly (See page 45-24).
26.Remove the front left door hinge assembly.
a. Remove 4 fixing bolts (arrow) between front door
hinge assembly and body.
b. Remove the front door upper hinge assembly (1) and
front door lower hinge assembly (2).
RT21470430
Installation
WARNING
 Be sure to wear safety equipment to prevent accidents when installing front door assembly.
 When installing front door assembly, an assistant is needed to hold front door to prevent front door from
CAUTION
 Make sure damaged clips are replaced and front door protector assembly is installed in place when
installing front door protector assembly.
 Stick protective film in specified position, not in a wrong position or a asymmetric position between left
and right sides or cover the holes of other installation parts.
 DO NOT drag protective film when sticking it. It should be done under its original condition and ensure
sheet metal is clean before assembly.
 Finished protective film should have no defects, such as wrinkles, bubbles or turnups.
 Finished protective film should have powerful adherence. Protective film sticking should be finished at
one time. Avoid repeat sticking.
47
Adjustment
1. Adjust the front left door assembly.
a. Loosen the fixing bolts on the front door hinge
assemblies and adjust the front door assembly
position in the direction of arrow as shown in the
illustration.
RT21470440

b. Tighten the fixing bolts on the front door hinge

assemblies to the specified torque after adjustment.
c. Loosen the fixing bolts on the front door hinge
assemblies and adjust the front door assembly
illustration.
RT21470450
d. Tighten the fixing bolts on the front door hinge assemblies to the specified torque after adjustment.
e. Standard ranges of clearance and alignment between installation positions of front door assembly and
each part are as follows:
Clearance between front door assembly and rear door assembly: 4.0 ± 1.0 mm.
Clearance between front door assembly and front fender assembly: 4.0 ± 1.0 mm.
Clearance between apron plate assembly and front door trim board assembly: 6.0 ± 1.8 mm.
Front
door
0 +1.0
0
Rear door
4.0± 4.0
1.0 ±1.
0
Front fender
0 +1.0
0
Front door
Front door trim board

6.0±1.8
47
Apron plate
RT21470460
f. After adjustment, make sure alignment between front door assembly and rear door assembly is within
the standard range.
+1.0
Standard alignment: 0 0 mm
g. After adjustment, make sure alignment between front door assembly and front fender assembly is
within the standard range.
+1.0

2. Adjust the front left door lock striker assembly.

a. Slightly loosen the fixing screws on the front door lock
striker and tap it with a plastic hammer in the direction
of arrow as shown in the illustration to adjust the
striker position.
RT21470470
b. Tighten the fixing screws on the front door lock striker to the specified torque after adjustment.
Inspection
After front left door assembly is adjusted, perform the following inspections:
1. Check front door assembly for wear or deformation during installation, and repair it as necessary.
2. Check if fixing bolts and fixing screws are set in position. Tighten them to the specified torque as
necessary.
3. Check if clearances and alignment between front door assembly installation position and each component
are within the specified range. Adjust if necessary.
47

Rear Door Protector Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rear door protector assembly.
 Avoid damage to rear door protector surface when removing rear door protector assembly.

3. Remove the rear left door inside handle assembly.
up the rear door inside handle screw cover (1).
b. Remove the fixing screw (2) from the rear door inside
handle assembly.
RT21470540
4. Remove the rear left door assist grip cover.

up the claws on rear door assist grip cover, and
remove the rear left door assist grip cover.
47
RT21470550
5. Remove the rear left door power glass regulator switch assembly (See page 43-55).
6. Remove the rear left door protector assembly.

a. Remove 2 fixing screws from the rear door assist grip

assembly.
RT21470560
b. Using an interior crow plate, pry off the clips from the
rear door protector assembly, and remove the rear
door protector assembly in the direction of arrow as
RT21470570
c. Disengage the rear door inside handle cable (arrow)

from the slot.
d. Remove the rear left door protector assembly.
47
RT21470580

7. Remove the rear left door inside handle assembly.

a. Remove the fixing screw (arrow) from the rear door
inside handle assembly.
RT21470590

up the claws on rear door inside handle assembly.
c. Remove the rear door inside handle assembly from
the rear door protector assembly.
RT21470600
8. Remove the rear door assist grip assembly.

a. Remove 4 fixing screws (arrow) from the rear door
assist grip assembly.
b. Remove the rear door assist grip assembly from the
rear door protector assembly.
RT21470610
Installation
47 CAUTION
 Make sure damaged clips are replaced and rear door protector assembly is installed in place when
installing rear door protector assembly.
 Make sure inside handle assembly can operate properly after installing rear door protector assembly.

Rear Door Assembly

Removal
HINT:
WARNING
 When removing rear door assembly, an assistant is needed to hold rear door to prevent rear door from
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rear door assembly,.
 Try to prevent body paint surface from being scratched when removing rear door assembly.

3. Remove the rear left door trim board garnish.
up the claws on rear door trim board garnish.
b. Remove the rear left door trim board garnish.
RT21470641
4. Remove the rear left door trim board assembly.

up the clips on rear door trim board assembly.
b. Remove the rear left door trim board assembly.
47
RT21470642

5. Disconnect the rear left door connector.

remove the rear door dust boot.
up the claws on connector.
c. Disconnect the rear left door connector (arrow).
RT21470621
6. Remove the rear left door frame weatherstrip.

a. Remove the clip from the rear door frame weatherstrip,
and remove the rear left door frame weatherstrip.
RT21470640
7. Remove the rear left door buffer block.

remove the rear door buffer block (arrow).
47
RT21470650

9. Remove the rear left door assist grip mounting bracket assembly.
a. Remove 3 fixing screws (arrow) from the rear door
assist grip mounting bracket assembly.
b. Remove the rear left door assist grip mounting
bracket assembly.
RT21470620
10.Remove the rear left woofer assembly (See page 39-17).

11. Remove the rear left door protective film assembly.
CAUTION
 Avoid damage to rear door protective film when removing rear door protective film assembly.
 Place rear door protective film assembly properly after removal, and avoid adhesive sticker on rear door
protective film assembly from sticking to other components.
a. Remove the rear left door protective film assembly by

rear left door protective film assembly.
47
RT21470630

12.Remove the protective cover without key cylinder from the rear left door.
remove the plug of protective cover (arrow) without
key cylinder from the rear left door.
RT21470635
b. Remove the fixing screw from the protective cover without key cylinder, and remove the protective
cover without key cylinder from the rear left door.
HINT:
It is not necessary to remove the fixing screw for protective cover without key cylinder of rear door,
because it is integrated with the protective cover without key cylinder of rear door.
13.Remove the rear left door outside handle.
a. Slide and pull the rear door outside handle in the
remove it.
RT21470636
14.Remove the rear left door outside handle base assembly.

a. Remove the fixing screw (arrow) from the rear left
door handle base assembly.
b. Remove the rear left door outside handle base
assembly.
RT21470660
15.Remove the rear left door outside handle front gasket.

a. Disengage the claws from the rear door outside handle front gasket, and remove the rear left door
outside handle front gasket.
16.Remove the rear left door outside handle rear gasket.

a. Disengage the claws from the rear door outside

handle rear gasket, and remove the rear left door
outside handle rear gasket.
RT21470410
17.Remove the rear left door outer weather bar (See page 43-58).
18.Remove the rear left door glass assembly (See page 43-59).
19.Remove the rear left door glass rear guide rail assembly (See page 43-61).
20.Remove the rear left door power glass regulator assembly (See page 43-62).
21.Remove the rear left door lock assembly (See page 37-47).
22.Remove the rear left door assembly.
a. Remove 3 fixing bolts (arrow) between rear door
hinge assembly and door.
RT21470670
b. Remove the rear left door assembly.

23.Remove the B-pillar lower protector assembly (See page 49-20). 47
24.Remove the rear left door hinge assembly.
a. Remove 4 fixing bolts (arrow) between rear door
hinge assembly and body.
b. Remove the rear door upper hinge assembly (1) and
rear door lower hinge assembly (2).
RT21470680

Installation
WARNING
 Be sure to wear safety equipment to prevent accidents when installing rear door assembly,.
 When installing rear door assembly, an assistant is needed to hold rear door to prevent rear door from
CAUTION
 Make sure damaged clips are replaced and rear door protector assembly is installed in place when
installing rear door protector assembly.
 Stick protective film in specified position, not in a wrong position or a asymmetric position between left
and right sides or cover the holes of other installation parts.
 DO NOT drag protective film when sticking it. It should be done under its original condition and ensure
sheet metal is clean before assembly.
 Finished protective film should have no defects, such as wrinkles, bubbles or turnups.
 Finished protective film should have powerful adherence. Protective film sticking should be finished at
one time. Avoid repeat sticking.
Adjustment
1. Adjust the rear left door assembly.
a. Loosen the fixing bolts on the rear door hinge
assemblies and adjust the rear door assembly
illustration.
RT21470690
b. Tighten the fixing bolts on the rear door hinge

47 assemblies to the specified torque after adjustment.
c. Loosen the fixing bolts on the rear door hinge
assemblies and adjust the rear door assembly
illustration.
RT21470691
d. Tighten the fixing bolts on the rear door hinge assemblies to the specified torque after adjustment.

e. Standard ranges of clearance between installation positions of rear door assembly and each part are as
follows:
Clearance between rear door assembly and front door assembly: 4.0 ± 1.0 mm.
+1.0
Clearance between rear door assembly and rear body outer panel: 4 - 0.5 mm.
Clearance between apron plate assembly and rear door trim board assembly: 6.0 ± 1.8 mm.
4.0 +1.0
-0.5
0 +1.
0 0
Rear door Rear body
outer panel
Front
door
0 +1.0
0
Rear door
4.0 +1
-0.5.0
Rear door trim board

6±1.8//2.0
Apron plate
RT21470692
f. After adjustment, make sure alignment between rear door assembly and front door assembly is within
the standard range.
+1.0
g. After adjustment, make sure alignment between rear door assembly and rear body outer panel is within
the standard range. 47
+1.0
2. Adjust the rear left door lock striker assembly.
a. Slightly loosen the fixing screws on the rear door lock
striker and tap it with a plastic hammer in the direction
of arrow as shown in the illustration to adjust the
striker position.
RT21470693

b. Tighten the fixing screws on the rear door lock striker to the specified torque after adjustment.
Inspection
After rear left door assembly is adjusted, perform the following inspections:
1. Check rear door assembly for wear or deformation during installation, and repair as necessary.
2. Check if fixing bolts and fixing screws are set in position. Tighten them to the specified torque as
necessary.
3. Check if clearances and alignment between rear door assembly installation position and each component
are within the specified range. Adjust them if necessary.
47

Back Door Protector Assembly

Removal
CAUTION
 Be sure to wear safety equipment when removing back door protector assembly.
 Try to prevent body paint surface from being scratched when removing back door protector assembly.

3. Remove the back door upper protector assembly.
a. Using an interior crow plate, pry off the clips from the
back door upper protector assembly.
b. Remove the back door upper protector assembly.
RT21470700
4. Remove the back door left protector assembly (take left side as an example).
back door left protector assembly.
b. Remove the back door left protector assembly.
RT21470710
5. Remove the back door lock mechanical opener cable service cover.
a. Using a screwdriver wrapped with protective tape, pry 47
up the claws on back door lock mechanical opener
cable service cover.
b. Remove the back door lock mechanical opener cable
service cover.
RT21470711

6. Remove the left and right back-up light service covers.

up the claws on back-up light service covers.
b. Remove the left back-up light service cover (1) and
right back-up light service cover (2).
1 2
RT21470720
7. Remove the back door grip assembly.

a. Remove the fixing screw (arrow) from the back door grip
assembly.
RT21470730

up the claw on back door grip assembly and remove
the back door grip assembly.
RT21470740
8. Remove the back door lower protector assembly.

a. Remove 6 fixing screws (1) and 4 plastic clips (arrow)
from the back door lower protector assembly.
47 (Tightening torque: 1.5 ± 0.5 N·m)
1
1
RT21470750

back door lower protector assembly.
c. Remove the back door lower protector assembly.
RT21470760
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing back door protector assembly.
 Try to prevent body paint surface from being scratched when installing back door protector assembly.
47

Back Door Assembly

Removal
WARNING
 When removing back door assembly, an assistant is needed to hold back door. Prevent back door from
CAUTION
 Be sure to wear safety equipment when removing back door assembly.

 Try to prevent body paint surface from being scratched when removing back door assembly.

3. Remove the back door adjustment block.
a. Turn the back door adjustment blocks (1) counterclockwise and remove the back door adjustment
blocks.
4. Remove the back door buffer block.
remove the back door buffer blocks (2).
2
1
RT21470761
5. Remove the back door locating seat.

a. Remove 4 fixing bolts (arrow) from the back door
locating seat.
47 b. Remove the left back door locating seat (1) and right
back door locating seat (2).
1 2
RT21480380

6. Remove the left back door locating block (take left side as an example).
locating block.
b. Remove the left back door locating block.
RT21470770

9. Remove the rear wiper motor assembly (See page 36-33).
10.Remove the rear nozzle assembly (See page 36-35).
12.Remove the back door upper trim board assembly (See page 48-45).
13.Remove the back door lock assembly (See page 37-51).
14.Remove the back door opener switch assembly (See page 47-56).
15.Remove the rear combination light assembly (movable part) (See page 35-76).
16.Remove the back door weatherstrip (See page 49-16).
17.Remove the roof assembly (See page 49-30).
HINT:
It is not necessary to remove the roof assembly completely, because the rear part of roof assembly needs
to be lowered for disconnecting the back door connector.
18.Remove the back door assembly.
a. Disconnect the back door connector (arrow).
b. Disconnect the washer line (1).
47
RT21470780

off the back door air spring upper clips and remove
the back door air spring.
RT21470790


up the back door dust boot (1).
e. Remove 4 fixing bolts (arrow) between back door
1
hinge assembly and back door.
RT21470800
f. Remove the back door assembly.

19.Remove the back door hinge assembly.
a. Remove 4 fixing nuts (arrow) from the back door
hinge assembly.
RT21470810
b. Remove the back door hinge assembly.
Installation
WARNING
 When installing back door assembly, an assistant is needed to hold back door. Prevent back door from
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing back door assembly.
47  Try to prevent body paint surface from being scratched when installing back door assembly.

Adjustment
1. Adjust the back door assembly.
a. Loosen the fixing nuts on the back door assembly and
adjust the position of back door assembly in the
RT21472000
b. Tighten the fixing nuts on back door assembly to the specified torque after adjustment.
c. Loosen the fixing bolts on back door assembly and
adjust the position of back door assembly in the
RT21472001
d. Tighten the fixing bolts on back door assembly to the specified torque after adjustment.
e. Standard ranges of clearance between installation positions of back door assembly and each part are
as follows:
Clearance between back door assembly and rear combination light assembly: 4.0 ± 1.5 mm.
Clearance between back door assembly and rear bumper assembly: 7.0 ± 2.0 mm.
47

4±1.5
0.7±1.2
Back door Rear combination

light
Back door
Rear bumper
.0
.0//2
7±2
RT21470811
f. After adjustment, tighten fixing bolts between back door hinge assembly and back door assembly to the
specified torque.
g. After adjustment, tighten fixing bolts between back door hinge and body to the specified torque.
2. Adjust the height of back door with the back door adjustment block.
a. Lower or raise the back door by rotating the back door
47
RT21470815

3. Adjust the back door lock striker assembly.

a. Slightly loosen the fixing screws on back door lock
striker assembly and tap it with a plastic hammer in
the direction of arrow as shown in the illustration to
adjust the striker position.
RT21470817
b. Tighten the fixing screws on back door lock striker assembly to the specified torque after adjustment.
Inspection
After back door assembly is adjusted, perform the following inspections:
1. Check back door for wear or deformation during installation, and repair as necessary.
2. Check if fixing bolts and fixing nuts are set in position. Tighten them to the specified torque as necessary.
3. Check if clearances and alignment between back door assembly and rear bumper are within the specified
range. Adjust if necessary.
47

Back Door Opener Switch Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing back door opener switch
assembly.
 Try to prevent body paint surface from being scratched when removing back door opener switch
assembly.

4. Remove the back door upper trim board assembly (See page 48-45).
5. Remove the back door opener switch assembly.
a. Disconnect the back door opener switch connector
(arrow).
RT21370261
b. Remove 2 fixing bolts from the back door opener

switch assembly, and remove the back door opener
switch assembly.
47
RT21370300
Installation
CAUTION
 Make sure damaged clips are replaced and back door opener switch assembly is installed in place when
installing back door opener switch assembly.
 Install connector in place when installing back door opener switch assembly.
 Make sure each function can operate properly after installing back door opener switch assembly.

Back Door Air Spring Assembly

Removal
HINT:
WARNING
 When removing back door air spring assembly, an assistant is needed to hold back door. Prevent back
door from dropping or sudden closing to cause accidents during operation.
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing back door air spring assembly.
 Try to prevent body paint surface from being scratched when removing back door air spring assembly.
 When installing back door air spring assembly, prevent back door from dropping to damage body during
operation.

3. Remove the back door left air spring assembly.
off the back door air spring upper clip.
off the back door air spring lower clip and remove the
back door left air spring assembly.
RT21470820
4. Remove the back door air spring ball pin (arrow).

47
RT21470830

Installation
WARNING
 When removing back door air spring assembly, an assistant is needed to hold back door. Prevent back
door from dropping or sudden closing to cause accidents during operation.
CAUTION
 Try to prevent body paint surface from being scratched when installing back door air spring assembly.
 Make sure back door air spring and back door air spring assembly clip are fitted closely after installing
back door air spring assembly.
47

EXTERIOR
Description 48-3 Engine Lower Protector Assembly 48-29
Rear Bumper Assembly 48-30
Removal 48-30
Radiator Grille Assembly 48-8
Disassembly 48-32
Removal 48-8
Assembly 48-33
Installation 48-9
Installation 48-33
Water Tank Upper Crossmember 
Rear Bumper Mounting Bracket 
Trim Board 48-10
Assembly 48-34
Removal 48-10
Removal 48-34
Installation 48-10
Installation 48-34
Front Bumper Assembly 48-11
Rear Bumper Crossmember 
Removal 48-11 Assembly 48-35
Disassembly 48-12 Removal 48-35
Assembly 48-14 Installation 48-36
Installation 48-15 Front Wheel House Protector 
Front Bumper Stiffener Bracket  Assembly of Rear Wheel 48-37
Assembly 48-16 Removal 48-37
Installation 48-16 Rear Wheel House Protector 
Front Bumper Mounting Bracket  Assembly 48-38
Installation 48-18 Front Windshield Lower Garnish 
Front Bumper Crossmember  Assembly 48-39
Installation 48-19 Roof Rack Assembly 48-41
Wheel Flare Assembly 48-20 Removal 48-41
Installation 48-21 Rear Spoiler Assembly 48-43
Apron Plate Assembly 48-22 Removal 48-43
Installation 48-23 Back Door Upper Trim Board 
Front Wheel House Protector  Assembly 48-45 48
Installation 48-24 Name Plate 48-48
Fender Assembly 48-25 Removal 48-48

48

48 - EXTERIOR
GENERAL INFORMATION
EXTERIOR
Description
2
3
21
6 7
×3
×18
9
×3 ×6
×3 8
10 18 20
×6
×3 ×4
×6 11
×12
12 ×2
×8 ×14
17 19
13
15
14 16
RT21480010 48

48 - EXTERIOR
1 - Front Windshield Lower Garnish Assembly 2 - Right Fender Assembly

3 - Front Right Wheel Flare Assembly 4 - Front Bumper Right Mounting Bracket Assembly
5 - Front Right Wheel House Protector Assembly 6 - Engine Lower Right Protector Assembly
7 - Front Bumper Upper Right Mounting Bracket 8 - Front Bumper Center Stiffener Bracket Assembly
Assembly
9 - Front Bumper Upper Left Mounting Bracket 10 - Front Bumper Crossmember Assembly
Assembly
11 - Front Bumper Energy Absorber 12 - Radiator Grille Assembly
13 - Front Bumper Assembly 14 - Front Bumper Lower Right Mounting Bracket
Assembly
15 - Front Bumper Lower Stiffener Bracket Assembly 16 - Front Bumper Lower Left Mounting Bracket
Assembly
17 - Engine Lower Left Protector Assembly 18 - Front Bumper Left Mounting Bracket Assembly
19 - Front Left Wheel House Protector Assembly 20 - Front Left Wheel Flare Assembly
21 - Left Fender Assembly
48

48 - EXTERIOR
2
×3 1
4 ×5
5
×3
×5 ×4
20
3 19
18
×6
6 17
×8
×2
16
×8
15
7
×3
×3
8 ×2
12
9 ×2
10 13
11
14
RT21480020
1 - Rear Spoiler Assembly 2 - Right Roof Rack Assembly

3 - Roof Rack Rear Trim Cover 4 - Left Roof Rack Assembly
5 - Roof Rack Front Trim Cover 6 - Left Apron Plate Cover Assembly
7 - Left Apron Plate Assembly 8 - Rear Left Wheel Flare Assembly
9 - Front Wheel House Protector Assembly of Rear 10 - Rear Bumper Left Mounting Bracket Assembly
48
Left Wheel
11 - Rear Left Wheel House Protector Assembly 12 - Rear Bumper Crossmember Assembly
13 - Rear Bumper Energy Absorber 14 - Rear Bumper Assembly
15 - Rear Right Wheel House Protector Assembly 16 - Front Wheel House Protector Assembly of Rear
Right Wheel
17 - Rear Bumper Right Mounting Bracket Assembly 18 - Rear Right Wheel Flare Assembly
19 - Right Apron Plate Assembly 20 - Right Apron Plate Cover Assembly

48 - EXTERIOR
Bumper assembly and bumper crossmember assembly are safety devices to protect the front and rear body,
which mainly absorb and reduce outside shock. The exterior mainly includes front bumper assembly, radiator
grille assembly, front bumper stiffener bracket assembly, front bumper mounting bracket assembly, front
bumper crossmember assembly, wheel flare assembly, apron plate assembly, front wheel house protector
assembly, fender assembly, engine lower protector assembly, rear bumper assembly, rear bumper mounting
bracket assembly, rear bumper crossmember assembly, front wheel house protector assembly of rear wheel,
rear wheel house protector assembly, front windshield lower garnish assembly, roof rack assembly, rear
spoiler assembly and back door upper trim board assembly.
Specifications

Front Name Plate CAC Assembly Fixing Screw 2.5 ± 0.5
Front Bumper Upper Grille Fixing Screw 2.5 ± 0.5
Front Bumper Assembly Fixing Screw 3±1
Front Bumper Assembly Fixing Bolt 10 ± 1
Front Bumper Mounting Bracket Assembly Fixing
10 ± 1
Bolt
Headlight Fixing Bolt 3.5 ± 0.5
Front Bumper Upper Mounting Bracket Assembly
10 ± 1
Fixing Bolt
Front Bumper Lower Mounting Bracket Assembly
10 ± 1
Fixing Bolt
Front Bumper Crossmember Assembly Fixing Nut 23 ± 2
Apron Plate Cover Assembly Fixing Screw 3±1
Apron Plate Assembly Fixing Screw 3±1
Front Bumper Center Stiffener Bracket Assembly
10 ± 1
Fixing Bolt
Front Bumper Lower Stiffener Bracket Assembly
10 ± 1
Fixing Nut
Front Wheel House Protector Assembly Fixing
3±1
Screw
Fender Assembly Fixing Bolt 10 ± 1
48 Engine Lower Protector Assembly Fixing Bolt 10 ± 1
Engine Lower Protector Assembly Fixing Screw 3±1
Rear Bumper Assembly Fixing Screw 3±1
Rear Bumper Assembly Fixing Bolt 3±1
Rear Bumper Mounting Bracket Assembly Fixing
3±1
Screw
Rear Bumper Crossmember Assembly Fixing Bolt 23 ± 2
Front Wheel House Protector Assembly of Rear
3±1
Wheel Fixing Screw

48 - EXTERIOR

Rear Wheel House Protector Assembly Fixing Screw 3±1
Front Windshield Lower Garnish Assembly Fixing
3±1
Screw
Roof Rack Assembly Fixing Bolt 9±1
Rear Spoiler Assembly Fixing Nut 5±1
Rear Bumper Energy Absorber Fixing Bolt 23 ± 2
Rear Fog Light Fixing Screw 1.5 ± 0.5
Camera Fixing Screw 6 ± 0.5
Tool
General Tool
Interior Crow Plate
RCH0000025
48

48 - EXTERIOR
ON-VEHICLE SERVICE
Radiator Grille Assembly
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing radiator grille assembly.
 Appropriate force should be applied when removing radiator grille assembly, and operate carefully.
 Try to prevent body paint surface from being scratched when removing radiator grille assembly.
1. Remove the radiator grille assembly.

a. Remove 6 plastic clips (arrow) from the radiator grille
assembly.
RT21480030

up the claw on radiator grille assembly.
c. Remove the radiator grille assembly.
RT21480040
2. Remove the front name plate CAC assembly.

a. Remove 6 fixing crews (arrow) from the front name
plate CAC assembly.
b. Remove the front name plate CAC assembly from the
radiator grille assembly.
RT21480042

48 - EXTERIOR
3. Remove the front bumper upper grille.

a. Remove 14 fixing screws (arrow) from the front
bumper upper grille.
b. Remove the front bumper upper grille from the
radiator grille assembly.
RT21480043
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing radiator grille assembly.
 Try to prevent body paint surface from being scratched when installing radiator grille assembly.
 Make sure that radiator grille is installed correctly and fitting clearance between radiator grille and front
bumper is appropriate when installing radiator grille assembly.
48

48 - EXTERIOR
Water Tank Upper Crossmember Trim Board

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing water tank upper
crossmember trim board.
 Appropriate force should be applied when removing water tank upper crossmember trim board. Be
 Try to prevent body paint surface from being scratched when removing water tank upper crossmember
trim board.

2. Remove the water tank upper crossmember trim board.
a. Remove 8 plastic clips (arrow) from the water tank
upper crossmember trim board.
b. Remove the water tank upper crossmember trim
board.
RT21480041
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing water tank upper crossmember
trim board.
 Try to prevent body paint surface from being scratched when installing water tank upper crossmember
trim board.
48

48 - EXTERIOR
Front Bumper Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing front bumper assembly.
 Appropriate force should be applied when removing front bumper assembly. Be careful not to operate
roughly.
 Try to prevent body paint surface from being scratched when removing front bumper assembly.

4. Remove the front bumper assembly.
a. Raise the vehicle with a lifter, and remove 5 fixing
screws (arrow) between front bumper assembly and
front wheel house protector assembly (take left side
as an example).
RT21480211
b. Remove 3 plastic clips (arrow) from the lower part of

front bumper assembly.
c. Remove 2 fixing screws (1) from the lower part of front
bumper assembly.
1 1
d. Remove 2 fixing bolts (2) from the lower part of front
bumper assembly.
2 RT21480050
e. Lower the vehicle to a proper position, and remove 6

fixing bolts (arrow) from the upper part of front bumper 48
assembly.
RT21480060

48 - EXTERIOR
f. Disengage the claws from the front bumper assembly

(take left side as an example).
RT21480070
CAUTION
 Avoid breaking the claws when removing the front bumper assembly.
g. Disconnect the front fog light connectors (arrow), and

remove the front bumper assembly.
RT21480080
Disassembly
CAUTION
 Be sure to wear safety equipment to prevent accidents when disassembling front bumper assembly.
 Appropriate force should be applied when disassembling front bumper assembly. Be careful not to
operate roughly.
 Avoid breaking the claws when disassembling front bumper assembly.
48

48 - EXTERIOR
1. Remove the front towing hook cover plate.

remove the front towing hook cover plate claw
(arrow).
b. Remove the front towing hook cover plate from the
RT21480081
2. Remove the front bumper energy absorber.

a. Remove the clamping washers (arrow) from the front
bumper energy absorber.
b. Remove the front bumper energy absorber from the
RT21480090
3. Remove the front bumper upper center grille.

up the claws on front bumper upper center grille.
b. Remove the front bumper upper center grille from the
RT21480100
4. Remove the front bumper lower center grille.

up the claws on front bumper lower center grille.
b. Remove the front bumper lower center grille from the
front bumper assembly. 48
RT21480110

48 - EXTERIOR
5. Remove the front fog light assembly.

a. Remove 6 fixing crews (arrow) from the front fog light
assembly.
2
b. Remove the front left fog light assembly (1) and front
right fog light assembly (2) from the front bumper
assembly.
RT21480120
6. Remove the front left fog light cover garnish (take left side as an example).
up the claws on front left fog light cover garnish.
b. Remove the front left fog light cover garnish from the
RT21480130
7. Remove the front left fog light cover (take left side as an example).
up the claws on front left fog light cover.
b. Remove the front left fog light cover from the front
bumper assembly.
RT21480140
Assembly
CAUTION
48
 Be sure to wear safety equipment to prevent accidents when installing front bumper assembly.
 Try to prevent body paint surface from being scratched when installing front bumper assembly.

48 - EXTERIOR
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing front bumper assembly.
 Try to prevent body paint surface from being scratched when installing front bumper assembly.
 Make sure that front bumper is installed correctly and fitting clearance between front bumper and body is
appropriate when installing front bumper assembly.
48

48 - EXTERIOR
Front Bumper Stiffener Bracket Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing front bumper stiffener bracket
assembly.
 Try to prevent body paint surface from being scratched when removing front bumper stiffener bracket
assembly.

4. Remove the front bumper center stiffener bracket assembly.
a. Remove 2 fixing bolts (arrow) from the front bumper
center stiffener bracket assembly.
b. Remove the front bumper center stiffener bracket
assembly.
RT21480200
5. Remove the front bumper lower stiffener bracket assembly.

a. Remove 2 fixing nuts (arrow) from the front bumper
lower stiffener bracket assembly.
b. Remove the front bumper lower stiffener bracket
assembly.
RT21480201
48 Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing front bumper stiffener bracket
assembly.
 Try to prevent body paint surface from being scratched when installing front bumper stiffener bracket
assembly.

48 - EXTERIOR
Front Bumper Mounting Bracket Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing front bumper mounting bracket
assembly.
 Try to prevent body paint surface from being scratched when removing front bumper mounting bracket
assembly.

4. Remove the front bumper left mounting bracket assembly.
left mounting bracket assembly.
b. Remove the front bumper left mounting bracket
assembly.
RT21480150
5. Remove the front bumper center stiffener bracket assembly (See page 48-16).
6. Remove the front bumper left mounting bracket assembly (take left side as an example).
a. Remove 3 fixing bolts (arrow) from the headlight. 
48
RT21480151

48 - EXTERIOR
b. Remove 3 fixing bolts (arrow) from the front bumper

upper mounting bracket assembly.
c. Remove the front bumper upper mounting bracket
assembly.
RT21480160
7. Remove the front bumper lower stiffener bracket assembly (See page 48-16).
8. Remove the front bumper lower left mounting bracket assembly (take left side as an example).
lower mounting bracket assembly.
b. Remove the front bumper lower left mounting bracket
assembly.
RT21480170
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing front bumper mounting bracket
assembly.
 Try to prevent body paint surface from being scratched when installing front bumper mounting bracket
assembly.
48

48 - EXTERIOR
Front Bumper Crossmember Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing front bumper crossmember
assembly.
 Try to prevent body paint surface from being scratched when removing front bumper crossmember
assembly.

4. Remove the horn assembly (See page 41-8).
5. Remove the front bumper crossmember assembly.
a. Disengage the wire harness clips from the front
bumper crossmember assembly.
RT21480180
b. Remove 6 fixing nuts (arrow) from the front bumper

c. Remove the front bumper crossmember assembly.
RT21480190
Installation 48
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing front bumper crossmember
assembly.
 Try to prevent body paint surface from being scratched when installing front bumper crossmember
assembly.
 Front bumper crossmember assembly should not be loose, shaking and deformed after installing it.

48 - EXTERIOR
Wheel Flare Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing wheel flare assembly.
 Appropriate force should be applied when removing the wheel flare assembly, and operate carefully.
 Try to prevent body paint surface from being scratched when removing wheel flare assembly.
1. Remove the front left wheel flare assembly.

a. Remove the clips from the front left wheel flare
assembly.
b. Remove the front left wheel flare assembly.
RT21480191
2. Remove the rear left wheel flare assembly.

a. Remove the clips from the rear left wheel flare
assembly.
b. Remove the rear left wheel flare assembly.
RT21480192
48

48 - EXTERIOR
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing wheel flare assembly.
 Try to prevent body paint surface from being scratched when installing wheel flare assembly.
 Make sure damaged clips are replaced and wheel flare assembly is installed in place when installing
wheel flare assembly.
48

48 - EXTERIOR
Apron Plate Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing apron plate assembly.
 Appropriate force should be applied when removing apron plate assembly. Be careful not to operate
roughly.
 Try to prevent body paint surface from being scratched when removing apron plate assembly.
1. Remove the front left wheel flare assembly (See page 48-20).
2. Remove the left apron plate cover assembly.
a. Remove the fixing crew (1) from the left apron plate
cover assembly.
b. Remove the plastic clip (arrow) from the left apron
plate cover assembly.
RT21480310
c. Using an interior crow plate, pry off the clip from the
left apron plate cover assembly.
d. Remove the left apron plate cover assembly in the
RT21480320
48 3. Remove the left apron plate assembly.

a. Remove 2 fixing crews (arrow) from the left apron
plate assembly.
RT21480330

48 - EXTERIOR
b. Remove 7 plastic clips (arrow) from the left apron

plate assembly, and remove the left apron plate
assembly.
RT21480331
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing apron plate assembly.
 Try to prevent body paint surface from being scratched when installing apron plate assembly.
 Make sure damaged clips are replaced and apron plate assembly is installed in place when installing
apron plate assembly.
48

48 - EXTERIOR
Front Wheel House Protector Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing front wheel house protector
assembly.
 Try to prevent body paint surface from being scratched when removing front wheel house protector
assembly.
1. Remove the front left wheel house protector assembly.

a. Remove 5 fixing crews (arrow) from the front left
wheel house protector assembly.
RT21480210
b. Remove 2 fixing screws from the front left wheel

house protector assembly.
c. Remove 6 plastic clips from the front left wheel house
protector assembly.
d. Remove the front left wheel house protector
assembly.
RT21480220
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing front wheel house protector
assembly.
 Try to prevent body paint surface from being scratched when installing front wheel house protector
assembly.
 Make sure damaged clips are replaced and front wheel house protector assembly is installed in place
when installing front wheel house protector assembly.

48 - EXTERIOR
Fender Assembly
Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing fender assembly.
 Try to prevent body paint surface from being scratched when removing fender assembly.

3. Remove the front left wheel flare assembly (See page 48-20).
4. Remove the left apron plate cover assembly (See page 48-22).
6. Remove the front bumper left mounting bracket assembly (See page 48-17).
7. Remove the front windshield lower garnish left cover plate.
cover plate.
plate.
RT21480490
8. Remove the left outer triangular block assembly.

left outer triangular block assembly, and remove the
left outer triangular block assembly.
48
RT21480230

48 - EXTERIOR
9. Remove the left fender assembly.

a. Remove 3 fixing bolts (arrow) between the upper part
of fender assembly and body.
RT21480240
b. Remove the fixing bolt (arrow) between fender

assembly and engine hood hinge.
RT21480250
c. Remove the fixing bolt (arrow) between fender

RT21480260
d. Remove the fixing bolt (arrow) between front part of

fender assembly and body.
48
RT21480270

48 - EXTERIOR
e. Remove 2 fixing bolts (arrow) between inner part of

RT21480280
f. Remove the fixing bolt (arrow) between lower part of

RT21480290
g. Remove the clip from the front windshield lower

garnish weatherstrip, and remove the left fender
assembly.
RT21480241
10.Remove the left fender sponge.
48
RT21480300

48 - EXTERIOR
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing front fender.
 Try to prevent body paint surface from being scratched when installing front fender.
 Make sure that front fender is installed correctly and fitting clearance between front fender and body is
appropriate when installing front fender.
48

48 - EXTERIOR
Engine Lower Protector Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing engine lower protector assembly.
 Try to prevent body paint surface from being scratched when removing engine lower protector assembly.
1. Remove the engine lower left protector assembly.

a. Remove 4 fixing bolts (arrow) from the engine lower
left protector assembly.
b. Remove the fixing screw (1) from the engine lower left
protector assembly. 1
RT21480340
c. Remove 2 plastic clips (arrow) from the engine lower

left protector assembly, and remove the left engine
lower left protector assembly.
RT21480350
Installation
CAUTION
48
 Be sure to wear safety equipment to prevent accidents when installing engine lower protector assembly.
 Try to prevent body paint surface from being scratched when installing engine lower protector assembly.

48 - EXTERIOR
Rear Bumper Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rear bumper assembly.
 Appropriate force should be applied when removing rear bumper assembly. Be careful not to operate
roughly.
 Try to prevent body paint surface from being scratched when removing rear bumper assembly.

3. Remove the back door locating seat.
locating seat.
b. Remove the back door left locating seat (1) and back
door right locating seat (2).
1 2
RT21480380
4. Remove the rear combination light assembly (fixed part) (See page 35-74).
5. Remove the rear bumper assembly.
a. Raise the vehicle with a lifter, and remove the fixing
screw (1) between rear bumper assembly and rear
wheel house protector assembly (take left side as an 1
example).
b. Remove 3 plastic clips (arrow) between rear bumper
assembly and rear wheel house protector assembly
RT21480360
48 c. Remove 4 plastic clips (arrow) from the lower part of

rear bumper assembly.
RT21480370

48 - EXTERIOR
d. Lower the vehicle, and remove 4 fixing screws (arrow)

1
from the upper part of rear bumper assembly.
e. Remove 2 fixing bolts (1) from the upper part of rear
bumper assembly.
RT21480390
f. Disengage the claws from the rear bumper assembly

RT21480400
CAUTION
 Avoid breaking claws when removing rear bumper assembly.
g. Disconnect the connectors (arrow) from the rear

bumper assembly, and remove the rear bumper
assembly.
RT21480410
48

48 - EXTERIOR
Disassembly
CAUTION
 Be sure to wear safety equipment to prevent accidents when disassembly rear bumper assembly.
 Appropriate force should be applied when dissembling rear bumper assembly. Be careful not to operate
roughly.
 Avoid breaking claws when disassembly rear bumper assembly.
1. Remove the rear towing hook cover plate.

remove the rear towing hook cover plate claws
(arrow).
b. Remove the rear towing hook cover plate from the
rear bumper assembly.
RT21480420
2. Remove the rear fog light.

a. Remove 8 fixing crews (arrow) from the rear fog light.
b. Remove the rear left fog light (1) and rear right fog
light (2) from the rear bumper assembly.
2 1
RT21480421
3. Remove the reversing radar sensor.

a. Press the claws on the reversing radar sensor.
b. Remove the reversing radar sensor from the rear
bumper assembly.
48
RT21480422

48 - EXTERIOR
Assembly
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing rear bumper assembly.
 Try to prevent body paint surface from being scratched when installing rear bumper assembly.
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing rear bumper assembly.
 Try to prevent body paint surface from being scratched when installing rear bumper assembly.
 Make sure rear bumper is installed correctly and fitting clearance between rear bumper and body is
appropriate when installing rear bumper assembly.
48

48 - EXTERIOR
Rear Bumper Mounting Bracket Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rear bumper mounting bracket
assembly.
 Try to prevent body paint surface from being scratched when removing rear bumper mounting bracket
assembly.

4. Remove the rear bumper left mounting bracket assembly.
a. Remove 3 fixing screws (arrow) from the rear bumper
left mounting bracket assembly.
b. Remove the rear bumper left mounting bracket
assembly.
RT21480430
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing rear bumper mounting bracket
assembly.
 Try to prevent body paint surface from being scratched when installing rear bumper mounting bracket
assembly.
48

48 - EXTERIOR
Rear Bumper Crossmember Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rear bumper crossmember
assembly.
 Try to prevent body paint surface from being scratched when removing rear bumper crossmember
assembly.

4. Remove the rear bumper energy absorber.
a. Remove 2 fixing bolts (arrow) from the rear bumper
energy absorber, and remove the rear bumper energy
absorber.
RT21480441
5. Remove the back door handle sensor.

a. Disconnect the back door handle sensor (arrow).
up the clip and remove the back door handle sensor.
RT21480440
6. Remove the rear bumper crossmember assembly. 48

up the wire harness clips.
RT21480451

48 - EXTERIOR
b. Remove 6 fixing bolts (arrow) from the rear bumper

c. Remove the rear bumper crossmember assembly.
RT21480450
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing rear bumper crossmember
assembly.
 Try to prevent body paint surface from being scratched when installing rear bumper crossmember
assembly.
 Front bumper crossmember assembly should not be loose, shaking and deformed after installing it.
48

48 - EXTERIOR
Front Wheel House Protector Assembly of Rear Wheel

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing front wheel house protector
assembly of rear wheel.
 Try to prevent body paint surface from being scratched when removing front wheel house protector
1. Remove the front wheel house protector assembly of rear left wheel.
a. Remove 4 fixing screws (arrow) from front wheel
house protector assembly of rear left wheel.
b. Remove the front wheel house protector assembly of
rear left wheel.
RT21480460
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing front wheel house protector
 Try to prevent body paint surface from being scratched when installing front wheel house protector
48

48 - EXTERIOR
Rear Wheel House Protector Assembly

Removal
HINT:
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rear wheel house protector
assembly.
 Try to prevent body paint surface from being scratched when removing rear wheel house protector
assembly.
1. Remove the rear left wheel house protector assembly.

a. Remove 4 plastic clips (arrow) from the rear left wheel
house protector assembly.
1
b. Remove the fixing screw (1) from the inner part of rear
left wheel house protector assembly.
RT21480470
c. Remove the fixing screw (arrow) from the outer part of

rear left wheel house protector assembly.
d. Remove the rear left wheel house protector assembly.
RT21480480
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing rear wheel house protector
assembly.
 Try to prevent body paint surface from being scratched when installing rear wheel house protector
assembly.
 Make sure damaged clips are replaced and rear wheel house protector assembly is installed in place
when installing rear wheel house protector assembly.

48 - EXTERIOR
Front Windshield Lower Garnish Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing front windshield lower garnish
assembly.
 Try to prevent body paint surface from being scratched when removing front windshield lower garnish
assembly.
1. Remove the front windshield lower garnish left cover plate (take left side as an example).
cover plate.
plate.
RT21480490

3. Remove the front windshield lower garnish weatherstrip.
a. Remove the clip from the front windshield lower
garnish weatherstrip.
b. Remove the front windshield lower garnish
weatherstrip.
RT21480500
4. Remove the front windshield lower garnish assembly.

a. Remove 5 fixing screws (arrow) from the front
windshield lower garnish assembly, and remove the
front windshield lower garnish assembly.
48
RT21480510

48 - EXTERIOR
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing front windshield lower garnish
assembly.
 Try to prevent body paint surface from being scratched when installing front windshield lower garnish
assembly.
48

48 - EXTERIOR
Roof Rack Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing roof rack assembly.
 Try to prevent body paint surface from being scratched when removing roof rack assembly.
1. Remove the roof rack assembly.

up the claws on roof rack center trim cover and
remove the roof rack center trim cover.
RT21480520

up the claws on roof rack front/rear trim cover and
remove the roof rack front/rear trim cover.
RT21480521
c. Remove 5 fixing bolts (arrow) from the roof rack

assembly, and remove the roof rack assembly.
48
RT21480530

48 - EXTERIOR
2. Remove the roof rack front cushion.

up the claws (arrow) on roof rack front cushion.
b. Remove the roof rack front cushion from the roof rack
assembly.
RT21480531
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing roof rack assembly.
 Try to prevent body paint surface from being scratched when installing roof rack assembly.
48

48 - EXTERIOR
Rear Spoiler Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing rear spoiler assembly.
 Try to prevent body paint surface from being scratched when removing rear spoiler assembly.

4. Remove the rear spoiler assembly.
a. Disconnect the high mounted stop light connector (1).
b. Using a screwdriver wrapped with protective tape, pry 1
up the inside rubber covers (2).
c. Remove 4 fixing nuts (arrow) from the rear spoiler
assembly.
2
RT21480540

up the outside rubber covers (arrow) and remove the
rear spoiler assembly.
RT21480541
48

48 - EXTERIOR
5. Remove the high mounted stop light.

a. Remove 3 fixing nuts (arrow) from the high mounted
stop light.
b. Remove the high mounted stop light from the rear
spoiler assembly.
RT21480542
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing rear spoiler assembly.
 Try to prevent body paint surface from being scratched when installing rear spoiler assembly.
48

48 - EXTERIOR
Back Door Upper Trim Board Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing back door upper trim board
assembly.
 Try to prevent body paint surface from being scratched when removing back door upper trim board
assembly.

4. Remove the back door upper trim board assembly.
a. Remove 2 fixing screws (1) from the back door upper
trim board assembly.
b. Remove 6 fixing nuts (arrow) from the back door
upper trim board assembly.
1 1
RT21370270

off the clips from the back door upper trim board
assembly.
48
RT21370280

48 - EXTERIOR
d. Disconnect the camera connector (arrow).
RT21370260
e. Disconnect the license plate light connector (arrow),

and remove the back door upper trim board assembly.
RT21370290
5. Remove the license plate light.

a. Press the claws on license plate light in the direction
b. Remove the license plate light from the back door
upper trim board assembly.
RT21480610
6. Remove the camera.

48 a. Remove 2 fixing screws (arrow) from the camera, and
remove the camera.
b. Remove the camera from the back door upper trim
board assembly.
RT21480600

48 - EXTERIOR
Installation
CAUTION
 Be sure to wear safety equipment to prevent accidents when installing back door upper trim board
assembly.
 Try to prevent body paint surface from being scratched when installing back door upper trim board
assembly.
48

48 - EXTERIOR
Name Plate
Removal
HINT:
 Use the same operation procedures for rear name plate "CAC", name plate "DVVT", name plate "Tiggo5"
and name plate "CHERY".
 Procedures listed below are for name plate "CHERY".
CAUTION
 If name plate "CHERY" is to be reused, be careful not to damage it.

 When removing name plate "CHERY", prevent the interior and body paint from being scratched.
1. Remove the name plate "CHERY".

a. Attach protective tape around the name plate
"CHERY".
b. Insert a piano wire between body and name plate
"CHERY".
c. Tie both piano wire ends to objects (such as wooden
blocks) that can serve as handles.
d. Pull the piano wire to remove the double-sided tape
that holds the name plate on the body.
RT21480550
e. Remove the name plate "CHERY".
Installation
1. Clean the body surface.
a. Using a heat light, heat body surface, and remove double-sided tape on the body.
b. Wipe off all tape adhesive residues with cleaner.
2. Clean name plate "CHERY" (if name plate "CHERY" is to be reused).
a. Using a heat light, heat name plate, and remove double-sided tape on name plate "CHERY".
b. Wipe off all tape adhesive residues with cleaner.
c. Apply new double-sided tape to name plate "CHERY".
3. Install name plate "CHERY".
a. Using a heat light, heat body and name plate "CHERY".
48 b. Remove release paper from name plate "CHERY" and install name plate "CHERY" in place.
CAUTION
 DO NOT overheat the body and name plate.

 DO NOT remove release paper on name plate in advance.
 DO NOT touch name plate adhesive surface with hands.
 After removing release paper, prevent foreign matter from attaching on outside adhesive.

48 - EXTERIOR
4. Installation distance ranges for name plate "CHERY" are as follows:

a. When attaching name plate "CHERY", keep it horizontal and centered.
b. Vertical distance "a" between left side of name plate
"CHERY" and left side of back door door is 3.3 ± 2 mm.
c. Vertical distance "b" between lower side of name
plate "CHERY" and lower side of back door door is
10.1 ± 2 mm. a
RT21480560
5. Installation distance ranges for rear name plate "CAC" are as follows:
a. When attaching rear name plate "CAC", keep it horizontal and centered.
b. Vertical distance "a" between upper side of name
plate "CAC" and upper side of back door upper trim
board is 3.0 ± 2 mm.
c. Vertical distance "b" between lower side of name plate
"CAC" and lower side of back door upper trim board is a
4.4 ± 2 mm.
RT21480570
6. Installation distance ranges for name plate "Tiggo5" are as follows:

a. When attaching "Tiggo5" name plate, keep it horizontal and centered.
b. Vertical distance "a" between lower side of name plate
"Tiggo5" and lower side of back door door is 9.0 ± 2 mm.
c. Vertical distance "b" between right side of name
plate "Tiggo5" and right side of back door door is
3.7 ± 2 mm. b
a
RT21480580
7. The installation distance ranges for the name plate "DVVT" are as follows:
48
a. When attaching "DVVT" name plate, keep it horizontal and centered.
b. Vertical distance "a" between lower side of name plate
"DVVT" and lower side of back door door is 5.8 ± 2 mm.
c. Vertical distance "b" between right side of name plate
"DVVT" and right side of back door door is 3.0 ± 2 mm.
b
a
RT21480590

- MEMO -

INTERIOR
GENERAL INFORMATION 49-3 B-pillar Lower Protector Assembly 49-20
Tool 49-8 B-pillar Upper Protector Assembly 49-21
Removal 49-21
Installation 49-22
Front Door Scuff Plate Assembly 49-9
C-pillar Lower Protector Assembly 49-23
Removal 49-9
Removal 49-23
Installation 49-9
Installation 49-25
Rear Door Scuff Plate Assembly 49-10
C-pillar Upper Protector Assembly 49-26
Removal 49-10
Removal 49-26
Installation 49-10
Installation 49-27
Front Doorsill Pressure Plate 
Sun Visor Assembly 49-28
Assembly 49-11
Removal 49-28
Removal 49-11
Installation 49-28
Installation 49-11
Passenger Grip Assembly 49-29
Rear Doorsill Pressure Plate 
Installation 49-12 Roof Assembly 49-30
Back Doorsill Pressure Plate  Removal 49-30
Assembly 49-13 Installation 49-33
Removal 49-13 Front Floor Carpet Assembly 49-34
Front Door Opening Weatherstrip 49-14 Installation 49-35
Removal 49-14 Luggage Compartment Carpet 
Rear Door Opening Weatherstrip 49-15 Removal 49-36
Installation 49-15 Tonneau Cover Assembly 49-37
Back Door Weatherstrip 49-16 Removal 49-37
Installation 49-16 Fuel Filler Cap Cable Assembly 49-38
A-pillar Upper Protector Assembly 49-17 Removal 49-38
Installation 49-18 Rear Wheel House Sound 
Insulation Pad 49-41
A-pillar Lower Protector Assembly 49-19
Removal 49-41
Removal 49-19
Installation 49-41 49
Installation 49-19

49

49 - INTERIOR
GENERAL INFORMATION
INTERIOR
Description
7 11 13
3
×3
×2
9
×5
12
10 14
15
8
×3
6 19
49
×5
4 16
×3
17
20
23
21
22
24 18
RT21490010

49 - INTERIOR
1 - Roof Assembly (w/o Sunroof) 2 - Roof Assembly (w/ Sunroof)

3 - Right A-pillar Upper Protector Assembly 4 - Right A-pillar Lower Protector Assembly
5 - Front Right Door Scuff Plate Assembly 6 - Front Right Doorsill Pressure Plate Assembly
7 - Right B-pillar Upper Protector Assembly 8 - Right B-pillar Lower Protector Assembly
9 - Rear Right Door Scuff Plate Assembly 10 - Rear Right Doorsill Pressure Plate Assembly
11 - Right C-pillar Upper Protector Assembly 12 - Right C-pillar Lower Protector Assembly
13 - Back Doorsill Pressure Plate Assembly 14 - Back Door Baffle Plate Assembly
15 - Left C-pillar Upper Protector Assembly 16 - Left C-pillar Lower Protector Assembly
17 - Rear Left Doorsill Pressure Plate Assembly 18 - Rear Left Door Scuff Plate Assembly
19 - Left B-pillar Upper Protector Assembly 20 - Left B-pillar Lower Protector Assembly
21 - Front Left Doorsill Pressure Plate Assembly 22 - Front Left Door Scuff Plate Assembly
23 - Left A-pillar Upper Protector Assembly 24 - Left A-pillar Lower Protector Assembly
49

49 - INTERIOR
4 2
×2
8
7
12
14
×2
9
13
×2
10
×3
11 49
RT21490020

49 - INTERIOR
1 - Roof Assembly (w/o Sunroof) 2 - Roof Assembly (w/ Sunroof)

3 - Rear Right Passenger Grip Assembly 4 - Front Right Passenger Grip Assembly
5 - Rear Left Passenger Grip Assembly 6 - Right Sun Visor Holder B
7 - Right Sun Visor Assembly 8 - Left Sun Visor Holder B
9 - Left Sun Visor Assembly 10 - Interior Front Dome Light Assembly
11 - Interior Front Dome Light Cover 12 - Interior Rear Dome Light Assembly
13 - Interior Rear Dome Light Cover 14 - Center Seat Belt Outer Trim Cover
49

49 - INTERIOR
5
1
RT21490030
1 - Front Right Door Opening Weatherstrip 2 - Rear Right Door Opening Weatherstrip
3 - Front Floor Carpet Assembly 4 - Luggage Compartment Carpet Assembly
5 - Tonneau Cover Assembly 6 - Back Door Weatherstrip
49
7 - Front Left Door Opening Weatherstrip 8 - Rear Left Door Opening Weatherstrip
The interior includes following parts: roof assembly, door scuff plate assembly, doorsill pressure plate
assembly, sun visor assembly, door opening weatherstrip, passenger grip assembly, pillar protector assembly,
tonneau cover assembly and carpet assembly, etc.

49 - INTERIOR
Specifications

A-pillar Lower Protector Assembly Fixing Nut 5±1
B-pillar Upper Protector Assembly Fixing Screw 1.5 ± 1
Back Door Baffle Plate Assembly Fixing Screw 1.5 ± 1
Back Door Baffle Plate Assembly Fixing Nut 1.5 ± 1
C-pillar Lower Protector Assembly Fixing Screw 1.5 ± 1
C-pillar Upper Protector Assembly Fixing Screw 1.5 ± 1
Sun Visor Assembly Fixing Screw 3 ± 0.5
Sun Visor Holder B Fixing Screw 3 ± 0.5
Front Seat Belt Assembly Lower Fixing Bolt 50 ± 5
Rear Seat Belt Lower Fixing Bolt 50 ± 5
Passenger Grip Assembly Fixing Bolt 5±1
Interior Front Dome Light Assembly Fixing Screw 1.5 ± 0.5
Interior Rear Dome Light Assembly Fixing Screw 1.5 ± 0.5
High Pitched Speaker Fixing Screw 3 ± 0.5
Fuel Tank Opening Bracket Assembly Fixing Bolt 10 ± 1
Ground Wire Harness Fixing Nut 15 ± 2
Tool
General Tool
Interior Crow Plate
RCH0000025
49

49 - INTERIOR
ON-VEHICLE SERVICE
Front Door Scuff Plate Assembly
Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the front door scuff plate
assembly.
 Appropriate force should be applied when removing the front door scuff plate assembly. Be careful not to
operate roughly.
 Prevent interior and body paint from being scratched when removing the front door scuff plate assembly.
1. Remove the front left door scuff plate assembly.

a. Using an interior crow plate, pry up the claws of front
door scuff plate assembly, and remove the front left
door scuff plate assembly.
RT21490040
Installation
CAUTION
 Make sure front door scuff plate assembly is installed in place during installation.
49

49 - INTERIOR
Rear Door Scuff Plate Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear door scuff plate
assembly.
 Appropriate force should be applied when removing the rear door scuff plate assembly. Be careful not to
operate roughly.
 Prevent interior and body paint from being scratched when removing the rear door scuff plate assembly.
1. Remove the rear left door scuff plate assembly.

a. Using an interior crow plate, pry up the claws of rear
door scuff plate assembly, and remove the rear left
door scuff plate assembly.
RT21490041
Installation
CAUTION
 Make sure rear door scuff plate assembly is installed in place during installation.
49

49 - INTERIOR
Front Doorsill Pressure Plate Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the front door scuff plate
assembly.
 Appropriate force should be applied when removing the front door scuff plate assembly. Be careful not to
operate roughly.
 Prevent interior and body paint from being scratched when removing the front door scuff plate assembly.
1. Remove the front left doorsill pressure plate assembly.

a. Using an interior crow plate, pry up the claws of front
doorsill pressure plate assembly, and remove the front
left doorsill pressure plate assembly.
RT21490050
Installation
CAUTION
 Make sure front doorsill pressure plate assembly is installed in place during installation.
 Make sure to check the fitting gap between front doorsill pressure plate assembly and B-pillar lower
protector assembly, A-pillar lower protector assembly for uniformity after installing front doorsill pressure
plate assembly.
49

49 - INTERIOR
Rear Doorsill Pressure Plate Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear doorsill pressure plate
assembly.
 Appropriate force should be applied when removing the rear doorsill pressure plate assembly. Be careful
 Prevent interior and body paint from being scratched when removing the rear doorsill pressure plate
assembly.

3. Remove rear left doorsill pressure plate assembly.
a. Using an interior crow plate, pry up the claws of rear
doorsill pressure plate assembly, and remove the rear
left doorsill pressure plate assembly.
RT21490060
Installation
CAUTION
 Make sure rear doorsill pressure plate assembly is installed in place during installation.
 Make sure to check the fitting gap between rear doorsill pressure plate assembly and B-pillar lower
protector assembly, C-pillar lower protector assembly for uniformity after installing the rear doorsill
pressure plate assembly.
49

49 - INTERIOR
Back Doorsill Pressure Plate Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the back doorsill pressure
plate assembly.
 Appropriate force should be applied when removing the back doorsill pressure plate assembly. Be
 Prevent interior and body paint from being scratched when removing the back doorsill pressure plate
assembly.
1. Remove the back door weatherstrip (See page 49-16).

2. Remove the luggage compartment carpet assembly (See page 49-36).
3. Remove the back doorsill pressure plate assembly.
a. Remove 2 plastic clips (arrow) from the back doorsill
pressure plate assembly.
RT21490070
back doorsill pressure plate assembly and remove the
back doorsill pressure plate assembly.
RT21490080
Installation
49
CAUTION
 Make sure damaged clips are replaced and back doorsill pressure plate assembly is installed in place
when installing back doorsill pressure plate assembly.

49 - INTERIOR
Front Door Opening Weatherstrip

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the front door opening
weatherstrip.
 Appropriate force should be applied when removing the front door opening weatherstrip, and avoid
operating roughly.
 DO NOT damage the front door opening weatherstrip when removing it.
1. Remove the front left doorsill pressure plate assembly (See page 49-11).
2. Remove the front left door opening weatherstrip.
a. Remove the front left door opening weatherstrip by
front door opening weatherstrip.
RT21490180
Installation
CAUTION
 The front door opening weatherstrip and body should be properly fitted with a certain degree of gripping
force and the weatherstrip should not fall off easily when installing the front door opening weatherstrip.
49  When installing the front door opening weatherstrip, tap all around uniformly with a rubber hammer to
install it in place. The surface of weatherstrip should have no defects, such as tapped dents, deformation
and warpage after installation.
 After installing the front door opening weatherstrip, do not remove or install it unless it is necessary.
Otherwise the weatherstrip holding force of installation may be reduced.

49 - INTERIOR
Rear Door Opening Weatherstrip

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear door opening
weatherstrip.
 Appropriate force should be applied when removing the rear door opening weatherstrip, and avoid
operating roughly.
 DO NOT damage the rear door opening weatherstrip when removing it.
1. Remove the rear left doorsill pressure plate assembly (See page 49-12).
2. Remove the rear left door opening weatherstrip.
a. Remove the rear left door opening weatherstrip by
rear door opening weatherstrip.
RT21490190
Installation
CAUTION
 The rear door opening weatherstrip and body should be properly fitted with a certain degree of gripping
force and the weatherstrip should not fall off easily when installing the rear door opening weatherstrip.
 When installing the rear door opening weatherstrip, tap all around uniformly with a rubber hammer to 49
install it in place. The surface of weatherstrip should have no defects, such as tapped dents, deformation
and warpage after installation.
 After installing the rear door opening weatherstrip, do not remove or install it unless it is necessary; or the
weatherstrip holding force of installation may be reduced.

49 - INTERIOR
Back Door Weatherstrip

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the back door weatherstrip.
 Appropriate force should be applied when removing the back door weatherstrip, and avoid operating
roughly.
 DO NOT damage the back door weatherstrip when removing it.
1. Remove the back door weatherstrip.

a. Remove the back door weatherstrip by gently pulling it
along edges from one corner of the back door
weatherstrip.
RT21490200
Installation
CAUTION
 The back door weatherstrip and body should be properly fitted with a certain degree of gripping force and
the weatherstrip should not fall off easily when installing the back door weatherstrip.
 When installing the back door weatherstrip, tap all around uniformly with a rubber hammer to install it in
place. The surface of weatherstrip should have no defects, such as tapped dents, deformation and
warpage after installation.
 After installing the back door weatherstrip, do not remove or install it unless it is necessary; or the
weatherstrip holding force of installation may be reduced.
49

49 - INTERIOR
A-pillar Upper Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the A-pillar upper protector
assembly.
 Appropriate force should be applied when removing the A-pillar upper protector assembly. Be careful not
to operate roughly.
 Prevent interior and body paint from being scratched when removing the A-pillar upper protector
assembly.
1. Remove the front left door opening weatherstrip (See page 49-14).
2. Remove the left A-pillar upper protector assembly.
A-pillar upper protector assembly.
RT21490100
b. Disconnect the high pitched speaker connector

(arrow), and remove the left A-pillar protector
assembly.
3 4
2 5
1
RT21490101
c. Remove 3 fixing screws (arrow) from the high pitched 49

speaker assembly.
d. Remove the high pitched speaker assembly from the
A-pillar protector assembly.
RT21490102

49 - INTERIOR
Installation
CAUTION
 Make sure damaged clips are replaced and A-pillar upper protector assembly is installed in place when
installing A-pillar upper protector assembly.
 A-pillar upper protector assembly and front door opening weatherstrip should be fitted closely after
 A-pillar upper protector assembly and instrument panel and roof headlining should be fitted closely after
49

49 - INTERIOR
A-pillar Lower Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the A-pillar lower protector
assembly.
 Appropriate force should be applied when removing the A-pillar lower protector assembly. Be careful not
to operate roughly.
 Prevent interior and body paint from being scratched when removing the A-pillar lower protector
assembly.
3. Remove the left A-pillar lower protector assembly.
a. Remove the fixing nut (arrow) from the A-pillar lower
protector assembly.
b. Using an interior crow plate, pry up the claws of 
A-pillar lower protector assembly, and remove the 
A-pillar lower protector assembly.
RT21490110
Installation
CAUTION
 A-pillar lower protector assembly and front door opening weatherstrip should be fitted closely after
installing A-pillar lower protector assembly.
49

49 - INTERIOR
B-pillar Lower Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the B-pillar lower protector
assembly.
 Appropriate force should be applied when removing the B-pillar lower protector assembly. Be careful not
to operate roughly.
 Prevent interior and body paint from being scratched when removing the B-pillar lower protector
assembly.
4. Remove the rear left door opening weatherstrip (See page 49-15).
5. Remove the left B-pillar lower protector assembly.
B-pillar protector assembly, and remove the left 
B-pillar lower protector assembly.
RT21490120
Installation
CAUTION
 Make sure damaged clips are replaced and B-pillar lower protector assembly is installed in place when
installing B-pillar lower protector assembly.
 B-pillar lower protector assembly and front and rear door opening weatherstrips should be fitted closely
49 after installing B-pillar lower protector assembly.
 B-pillar lower protector assembly and front and rear doorsill pressure plate assemblies should be fitted
closely after installing B-pillar lower protector assembly.

49 - INTERIOR
B-pillar Upper Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the B-pillar upper protector
assembly.
 Appropriate force should be applied when removing the B-pillar upper protector assembly. Be careful not
to operate roughly.
 Prevent interior and body paint from being scratched when removing the B-pillar upper protector
assembly.
5. Loosen the lower part of front seat belt assembly.
off the front seat belt assembly lower bolt protective
cap (arrow).
RT21490330

49
RT21490340

49 - INTERIOR
7. Remove the left B-pillar upper protector assembly.

a. Remove 2 fixing screws (arrow) from the B-pillar
upper protector assembly.
b. Using an interior crow plate, pry off the clip from the 
B-pillar upper protector assembly, pull out the front
seat belt from the B-pillar upper protector assembly,
and remove the left B-pillar upper protector assembly.
RT21490130
Installation
CAUTION
 Make sure damaged clip are replaced and B-pillar upper protector assembly is installed in place when
installing B-pillar upper protector assembly.
 B-pillar upper protector assembly and front and rear door opening weatherstrips should be fitted closely
after installing B-pillar upper protector assembly.
 B-pillar upper protector assembly and B-pillar lower protector assembly and roof headlining should be
fitted closely after installing B-pillar upper protector assembly.
49

49 - INTERIOR
C-pillar Lower Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the C-pillar lower protector
assembly.
 Appropriate force should be applied when removing the C-pillar lower protector assembly. Be careful not
to operate roughly.
 Prevent interior and body paint from being scratched when removing the C-pillar lower protector
assembly.
4. Remove the rear left seat assembly (See page 49-15).
5. Remove the back door baffle plate assembly.
a. Remove 2 fixing nuts (1) from the back door baffle
plate assembly. 1
b. Remove 2 fixing screws (arrow) from the back door
baffle plate assembly and remove the back door baffle
plate assembly.
RT21490141
6. Remove the left C-pillar lower protector assembly.

a. Remove the fixing bolt (arrow) from the lower part of
front seat belt.
49
RT21490140

49 - INTERIOR
b. Remove the warning triangle box (for right side) in the

RT21490161

off the back door light cover (for right side).
RT21490162
d. Disconnect the back door light connector (arrow) and

remove the back door light.
RT21490163
e. Using a screwdriver wrapped with protective tape, pry

off the rear shock absorber service cover and remove
the rear shock absorber service cover.
49 RT21490152

49 - INTERIOR
f. Using a screwdriver wrapped with protective tape, pry

off the rear combination light service cover and
remove the rear combination light service cover.
RT21490153
g. Remove 5 fixing screws (arrow) from the C-pillar

lower protector assembly.
RT21490150
h. Using an interior crow plate, pry off the clips from the
C-pillar lower protector assembly, and remove the left
C-pillar lower protector assembly.
RT21490151
Installation
CAUTION
 Make sure the damaged clips are replaced and the C-pillar lower protector assembly is installed in place
when installing the C-pillar lower protector assembly.
 The C-pillar lower protector assembly, C-pillar upper protector and rear door opening weatherstrip should
be fitted closely after installing the C-pillar lower protector assembly.
49

49 - INTERIOR
C-pillar Upper Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the C-pillar upper protector
assembly.
 Appropriate force should be applied when removing the C-pillar upper protector assembly. Be careful not
to operate roughly.
 Prevent interior and body paint from being scratched when removing the C-pillar upper protector
assembly.
4. Remove the rear left seat assembly (See page 46-25).
6. Remove the left C-pillar upper protector assembly.
a. Remove 3 fixing screws (arrow) from the C-pillar
upper protector assembly.
RT21490160
C-pillar upper protector assembly, pull out the rear
seat belt from the C-pillar upper protector assembly,
and remove the left C-pillar upper protector assembly.
49
RT21490170

49 - INTERIOR
Installation
CAUTION
 Make sure damaged clips are replaced and C-pillar upper protector assembly is installed in place when
installing C-pillar upper protector assembly.
 C-pillar upper protector assembly and rear door opening weatherstrip should be fitted closely after
installing C-pillar upper protector assembly.
 C-pillar upper protector assembly, C-pillar lower protector assembly and roof headlining should be fitted
closely after installing C-pillar upper protector assembly.
49

49 - INTERIOR
Sun Visor Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the sun visor assembly.
 Appropriate force should be applied when removing the sun visor assembly. Be careful not to operate
roughly.
 Avoid damage to the interior and roof when removing the sun visor assembly.
1. Remove the left sun visor assembly.

a. Disengage one side of the sun visor assembly from
1
holder B (1).
b. Remove 2 fixing screws (arrow) from the sun visor
assembly.
c. Remove the left sun visor assembly.
RT21490210
2. Remove the left sun visor holder B.

a. Remove the fixing screw from the sun visor holder B.
b. Remove the left sun visor holder B.
RT21490220
Installation
49
CAUTION
 Make sure to wear safety equipment to prevent accidents when installing the sun visor assembly.
 Avoid damage to the interior and roof when installing the sun visor assembly.

49 - INTERIOR
Passenger Grip Assembly

Removal
HINT:
 Use the same procedures for rear left/rear right side and front right side.
 Procedures listed below are for the front right side.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the passenger grip assembly.
 Appropriate force should be applied when removing the passenger grip assembly. Be careful not to
operate roughly.
 Avoid damage to the interior and roof when removing the passenger grip assembly.
1. Remove the front right passenger grip assembly.

remove the passenger grip covers (arrow).
RT21490230
b. Remove 2 fixing screws (arrow) from the passenger

grip assembly, and remove the front right passenger
grip assembly.
RT21490240
Installation
CAUTION 49
 Make sure to wear safety equipment to prevent accidents when installing the passenger grip assembly.
 Avoid damage to the interior and roof when installing the passenger grip assembly.

49 - INTERIOR
Roof Assembly
Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the roof assembly.
 Appropriate force should be applied when removing the roof assembly. Be careful not to operate roughly.
 Avoid damage to the interior and body paint when removing the roof assembly.

3. Remove the interior front dome light assembly.
a. Open the glasses box in the direction of arrow as
RT21490250

remove the interior front dome light cover.
RT21490260
c. Remove 3 fixing screws (arrow) from the interior front

dome light assembly.
49
RT21490270

49 - INTERIOR
d. Disconnect the interior front dome light connector

(arrow), and remove the interior front dome light
assembly.
RT21490280
4. Remove the interior rear dome light assembly.

remove the interior rear dome light cover.
RT21490290
b. Remove 2 fixing screws (arrow) from the interior rear

dome light assembly.
RT21490300
c. Disconnect the interior rear dome light connector

(arrow), and remove the interior rear dome light
assembly.
49
RT21490310

49 - INTERIOR
5. Remove the center seat belt outer trim cover.

up the clips of center seat belt outer trim cover, and
remove the center seat belt outer trim cover.
RT21490311
6. Remove the sunroof weatherstrip (if equipped).

a. Open the sunroof in the direction of arrow as shown in
the illustration.
RT21470460
b. Remove the sunroof weatherstrip (1) by gently pulling

it along edges from one corner of the sunroof
weatherstrip.
RT21490470
7. Remove the sun visor assembly (See page 49-28).

8. Remove the passenger grip assembly (See page 49-29).
9. Remove the front doorsill pressure plate assembly (See page 49-11).
10.Remove the front door opening weatherstrip (See page 49-14).
11. Remove the rear doorsill pressure plate assembly (See page 49-12).
12.Remove the rear door opening weatherstrip (See page 49-15).
49 13.Remove the A-pillar upper protector assembly (See page 49-17).
14.Remove the B-pillar upper protector assembly (See page 49-21).
15.Remove the C-pillar upper protector assembly (See page 49-26).

49 - INTERIOR
16.Remove the roof assembly.

a. Remove 4 clips (arrow) from the roof assembly.
RT21490320
b. Take out the roof assembly from the back door.
Installation
CAUTION
 Make sure damaged clips are replaced and roof assembly is installed in place when installing roof
assembly.
 Roof assembly and pillar upper protectors should be fitted closely when installing roof assembly.
 Roof assembly and door opening weatherstrips should be fitted closely after installing roof assembly.
49

49 - INTERIOR
Front Floor Carpet Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the front floor carpet assembly.
 Appropriate force should be applied when removing the front floor carpet assembly. Be careful not to
operate roughly.
 Avoid damage to the interior and body paint when removing the front floor carpet assembly.

up the front seat belt assembly lower bolt protective
cap (arrow).
RT21490330

RT21490340

5. Remove the front seat assembly (See page 46-12).
7. Remove the front doorsill pressure plate assembly (See page 49-11).
49
8. Remove the front door opening weatherstrip (See page 49-14).
10.Remove the rear door opening weatherstrip (See page 49-15).
11. Remove the A-pillar lower protector assembly (See page 49-19).
12.Remove the B-pillar lower protector assembly (See page 49-20).

49 - INTERIOR
13.Remove the front floor carpet assembly.

a. Take out the front floor carpet assembly from the back
door.
RT21490351
14.Remove the front left floor shock pad assembly (take left
side as an example).
a. Remove the front left shock pad assembly (1) from the
front floor.
15.Remove the driver side foot rest assembly. 2
1
a. Rotate the clip (arrow) on the driver side foot rest
assembly counterclockwise.
b. Remove the driver side foot rest assembly (2).
RT21490350
Installation
CAUTION
 Always pay attention to the flatness around front floor carpet assembly and the routing of relative body
wire harness when installing the front floor carpet assembly.
 Spread the front floor carpet assembly according to the bottom shape without obvious bumps and
unevenness. Expose the seat installation holes, and the front floor carpet should be firmly abutted
against the bottom.
49

49 - INTERIOR
Luggage Compartment Carpet Assembly

Removal
1. Remove the luggage compartment carpet assembly.
a. Lift up the band in the rear center part of luggage
compartment carpet and remove the luggage
compartment carpet assembly by pulling it outward.
RT21490360
Installation
CAUTION
 Make sure that the left and right sides of luggage compartment carpet are fitted in place after installing
the luggage compartment carpet assembly.
49

49 - INTERIOR
Tonneau Cover Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the tonneau cover assembly.
 Appropriate force should be applied when removing the tonneau cover assembly. Be careful not to
operate roughly.
 Prevent interior and body paint from being scratched when removing the tonneau cover assembly.
1. Remove the tonneau cover assembly.

a. Release the clamping part in the direction of arrow as
shown in the illustration to retract the tonneau cover.
RT21490390
b. Retract both ends of the tonneau cover assembly in

remove the tonneau cover assembly.
RT21490400
Installation
CAUTION
 Prevent interior and body paint from being scratched when installing the tonneau cover assembly.
 The tonneau cover assembly and C-pillar lower protector assembly should be fitted closely when 49
installing the tonneau cover assembly.

49 - INTERIOR
Fuel Filler Cap Cable Assembly

Removal
CAUTION
 Make sure to wear safety equipment when removing the fuel filler cap cable assembly.
 Avoid damage to the interior and body paint when removing the fuel filler cap cable assembly.

up the front seat belt assembly lower bolt protective
cap.
RT21490330

RT21490340
4. Remove the front left doorsill pressure plate assembly (See page 49-11x).
49 9. Remove the back doorsill pressure plate assembly (See page 49-13).
10.Remove the C-pillar lower protector assembly (See page 49-23).

49 - INTERIOR
11. Remove the fuel filler cap cable assembly.

a. Remove 2 fixing bolts (arrow) from the fuel tank
opening bracket assembly.
RT21490401
b. Remove the fuel filler cap cable from the fuel tank
opening bracket assembly in the direction of arrow as
RT21490410
c. Remove the fuel filler cap cable on the other side in

the direction of arrow as shown in the illustration.
RT21490440
d. Remove the clips (arrow) on the side of fuel filler cap

cable.
49
RT21490420

49 - INTERIOR
e. Remove the clips (arrow) on the rear part of fuel filler

cap cable and remove the fuel filler cap cable.
RT21490430
Installation
CAUTION
 Prevent interior and body paint from being scratched when installing fuel filler cap cable.
 Make sure damaged clips are replaced and fuel filler cap cable is installed in place when installing fuel
filler cap cable.
 Check that fuel filler cap cable can operate properly after installing fuel filler cap cable.
49

49 - INTERIOR
Rear Wheel House Sound Insulation Pad

Removal
HINT:
 Use the same procedures for the rear left/rear right side and front right side.
 Procedures listed below are for the front right side.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear wheel house sound
insulation pad assembly.
 Appropriate force should be applied when removing the rear wheel house sound insulation pad
assembly. Be careful not to operate roughly.

4. Remove the rear wheel house sound insulation pad.
a. Remove the fixing nut (1) from the ground wire
harness. 
b. Remove the clips (arrow) from the rear wheel house
sound insulation pad.
c. Remove the clamping washer (2) from the rear wheel 1
house sound insulation pad, and remove the rear
wheel house sound insulation pad. 2
RT21490450
Installation
49

- MEMO -

BODY DIMENSIONS
GENERAL INFORMATION 50-3 Body Opening Dimensions (Top View) 50-8
Description 50-3 Body Frame Dimensions 50-9
Engine Compartment Dimensions 50-4 Body Assembly Dimensions 50-10
Body Opening Dimensions (Front View) 50-5 Front Body Assembly Dimensions 50-11
Body Opening Dimensions (Side View) 50-6 Rear Body Assembly Dimensions 50-20
Body Opening Dimensions (Rear View) 50-7
50

50

50 - BODY DIMENSIONS
GENERAL INFORMATION
BODY DIMENSIONS
Description
 All measurements should be made from the bare metal. Remove the trim and bumper covers as
necessary.
 Repair the badly damaged areas before taking measurements for underbody alignment.
 Monitor the upper body structure for excessive stress or movement while making any corrections to the
underbody structure.
 Remove all the necessary glasses to prevent breakage.
 All dimensions are shown in millimeters (mm).
50

Engine Compartment Dimensions
mm m
874 5m
154
1127.1 mm
5 mm 1517
27 mm
1545
mm
RT21500010
50

Body Opening Dimensions (Front View)
m
4m
148
790 mm
148
4m
m
RT21500020
50

Body Opening Dimensions (Side View)
92
mm
2.
6
.7
m
m
55
m
m
12
.7
25
14
94
7
m 898.8 mm
m
923.7 mm
RT21500030
50

Body Opening Dimensions (Rear View)
m
1003 mm
12
m
54
54
m
12
m
1080 mm
RT21500040
50

Body Opening Dimensions (Top View)
1237.4 mm
mm
22
22
.3
.3
22
mm
22
927.3 mm
50 RT21500050

Body Frame Dimensions
912.9 mm
m
.6 m
952
890 mm
mm
5.1
2058.1 mm
215
460 mm
354 mm
50
RT21500090

Body Assembly Dimensions

1. Gap is indicated by the standard distance measurement symbol .
2. Flush measurement method and instructional symbol description:
a. Reference surface is indicated by .
b. Pointed surface is indicated by .
c. If the level is higher than the reference surface, the number is positive, whereas negative.
50

Front Body Assembly Dimensions
A A
2
1
A
3
A
21
A
A 22
A
23
24
26
A
A
A 4 25
A 9 A
A A A 8
5
A 6
14
19 A A
A 15 A
A A
A 10
13
A A 7
20
18 16 A 12
31 11
17
A A
27 28
29
A
A 30
RT21500710
Flush between roof and front windshield at A-1: -4.0 ± 2.0 mm
-4.0±2.0
FRONT WINDSHIELD
ROOF
RT21500130
50

Clearance between trim panel garnish and front door at A-2:

4.5 ± 1.2 mm
4.5±1.2
TRIM PANEL
GARNISH
FRONT DOOR
RT21500140
+1.5
Clearance between front door and rear door at A-3: 4.0 -1.0 mm
+1.2
Flush between front door and rear door at A-3: 0 -0.5 mm 0 +1.2
-0.5
REAR DOOR
4.0 +1.5
-1.0
FRONT DOOR
RT21500160
+1.0
Clearance between front door and rear door at A-4: 4.0 -0.5 mm
+1.0
Flush between front door and rear door at A-4: 0 0 mm
0 +1.0
0
FRONT DOOR
REAR DOOR
4.0 +1.0
-0.5
RT21500200
Clearance between front door trim board and rear door trim
board at A-5: 7.8 ± 2.0 mm REAR DOOR TRIM BOARD
7.8±2.0
Flush between front door trim board and rear door trim board
at A-5: 3.0 ± 2.0 mm FRONT DOOR TRIM BOARD
3.0±2.0
RT21500210
50

Clearance between front door and front door trim board at 

+1.0
A-6: 0 0 mm FRONT DOOR
0 +1.0
0
FRONT DOOR TRIM BOARD
RT21500220
Clearance between rear apron plate and front door trim

board at A-7: 6.0 ± 1.8 mm
FRONT DOOR TRIM BOARD
6.0±1.8
REAR APRON PLATE
RT21500230
+1.0
Clearance between front door and fender at A-8: 4.0 -0.5 mm
0
Flush between front door and fender at A-8: 0 -1.0 mm
4.0 +1.0
FENDER -0.5
00
-1.0
FRONT DOOR
RT21500100
Clearance between fender and hood at A-9: 4.0 ± 1.0 mm

Flush between fender and hood at A-9: 0 ± 1.0 mm
4.0
±1.
0
HOOD
FENDER
0±
1.0
RT21500400
50

Clearance between fender and front wheel flare trim board

at A-10: 0.5 ± 0.5 mm
FENDER
0.5
±0
.5
FRONT WHEEL
FLARE TRIM BOARD
RT21500390
Clearance between front wheel flare trim board and front

bumper at A-11: 1.0 ± 1.0 mm FRONT WHEEL
FLARE TRIM BOARD
Flush between front wheel flare trim board and front bumper
at A-11: 0 ± 1.0 mm
0±1.0
1.0±1.0
FRONT BUMPER
RT21500280
Clearance between fender and front bumper at A-12: 

0.5 ± 0.5 mm
Flush between fender and front bumper at A-12: -0.7 ± 1.0 mm
1.0
7±
-0. ±0
.5
0.5
FENDER
FRONT BUMPER
RT21500290
Clearance between fender and headlight at A-13: 2.0 ± 1.0 mm
FENDER
.0
±1
2.0
HEADLIGHT
RT21500310
50

Clearance between fender and headlight at A-14: 2.4 ± 1.0 mm
2.4
±1.
0
HEADLIGHT
FENDER
RT21500380
Clearance between hood and headlight at A-15: 6.5 ± 1.5 mm
HOOD
HEADLIGHT
.5
6.5±1
RT21500330
Clearance between front bumper and headlight at A-16: 

2.2 ± 1.2 mm
HEADLIGHT
2.2±1.2
FRONT BUMPER
RT21500320
Clearance between front fog light cover and front bumper at

A-17: 0.5 ± 0.5 mm
FRONT BUMPER
.5
±0
0.5
FRONT FOG LIGHT COVER
RT21500300
50

Clearance between radiator grille and headlight at A-18: 

2.7 ± 1.0 mm
0
±1.
2.7
RADIATOR GRILLE
HEADLIGHT
RT21500340
Clearance between radiator grille and hood at A-19: 

6.4 ± 1.5 mm
HOOD
6.4±1.5
RADIATOR GRILLE
RT21500370
Clearance between radiator grille and front bumper at A-20:

2.0 ± 1.0 mm
RADIATOR GRILLE
FRONT BUMPER
1.0
2.0±
RT21500360
Clearance between trim panel garnish and rear view mirror

base at A-21: 5.0 ± 1.5 mm
Flush between trim panel garnish and rear view mirror base 1.5
5.0±
at A-21: 0 ± 1.5 mm REAR VIEW
MIRROR BASE
TRIM PANEL GARNISH
.5
0±1
RT21500150
50

Clearance between front triangular block and rear view

mirror base at A-22: 4.0 ± 1.2 mm
Flush between front triangular block and rear view mirror +1.0
+1.0 FRONT
base at A-22: 0 -1.5 mm TRIANGULAR BLOCK
0 -1.5
REAR VIEW
MIRROR BASE
4.0±1.2
RT21500120
Clearance between side body outer panel and fender at 

A-23: 2.3 ± 1.2 mm
SIDE BODY
Flush between side body outer panel and fender at A-23:  OUTER PANEL
0 ± 1.2 mm 0±
1.2
FENDER
.2
2.3±1
RT21500110
Flush between rear view mirror base and front door weather
bar at A-24: 1.2 ± 1.5 mm
1.2±1.5
REAR VIEW
MIRROR BASE
FRONT DOOR
WEATHER BAR
RT21500170
Clearance between front door handle and front door at A-25:

3.7 ± 1.0 mm FRONT DOOR HANDLE
3.7±1.0
FRONT DOOR
RT21500190
50

Clearance between front door handle and front door handle

base at A-26: 1.0 ± 0.5 mm
Flush between front door handle and front door handle base FRONT DOOR 1.0
at A-26: 0 ± 1.0 mm HANDLE BASE
0±1
±0
.5
.0
FRONT DOOR HANDLE
RT21500180
Clearance between front wheel flare trim board and front

apron plate at A-27: 2.0 ± 1.0 mm FRONT WHEEL FLARE TRIM
BOARD
2.0
±1
.0
FRONT APRON PLATE
RT21500250
Clearance between fender and front apron plate at A-28:

+1.0
0 0 mm
FENDER FRONT APRON PLATE

0 .0
0 +1
RT21500240
Clearance between front door trim board and front apron

plate at A-29: 5.6 ± 1.0 mm
.0
Flush between front door trim board and front apron plate at 5.6
±1
A-29: 0 ± 1.0 mm
FRONT DOOR
FRONT APRON PLATE TRIM BOARD
1.0
0±
RT21500260
50

Clearance between front apron plate and rear apron plate at

A-30: 8.0 ± 3.0 mm
Flush between front apron plate and rear apron plate at  8.0
±3.
0
+1.0
A-30: 0 0 mm
0 +1
0 .0
REAR APRON PLATE
FRONT APRON PLATE
RT21500270
Clearance between front towing hook cover plate and front

bumper at A-31: 0.8 ± 0.5 mm
Flush between front towing hook cover plate and front 0.8 ±0.5
bumper at A-31: -0.5 ± 0.5 mm 0.5

-0.5 ±
FRONT TOWING FRONT BUMPER

HOOK COVER PLATE
RT21500350
50

Rear Body Assembly Dimensions
B
B
B B
B
1 2
B
3 7
4
5 6
B
B 8
B
B 28
B
9 B
12 B 13
B 11
B 17
10 B
B
16
18 B
B 15
14 B
B B
23 B
22
19 B 27
B
B 24
B
20 B 25 26
21
RT21500720
Clearance between rear spoiler and roof at B-1: 8.9 ± 2.0 mm
REAR SPOILER ROOF
8.9±
2.0
RT21500420
Clearance between rear spoiler and back door at B-2:

+1.0
1.5 -1.5 mm
Flush between rear spoiler and back door at B-2: -1.5 ± 1.0 mm REAR SPOILER -1.
5±
1.0
1.5
+1 .5
-1
.0
50 BACK DOOR
RT21500430

Clearance between back door and roof at B-3: 8.9 ± 2.0 mm

Flush between back door and roof at B-3: -2.0 ± 2.0 mm
8.9
±2.
0
-2.0
±2.
0
BACK DOOR
ROOF
RT21500450
Clearance between rear spoiler and rear windshield at B-4:

4.0 ± 2.0 mm
REAR SPOILER
4.0
±2.
0
REAR WINDSHIELD
RT21500410
Clearance between rear spoiler and high mounted stop light

at B-5: 1.0 ± 1.0 mm
Flush between rear spoiler and high mounted stop light at  REAR SPOILER
1.0±1.0
B-5: -1.0 ± 1.0 mm
1.0
HIGH MOUNTED STOP LIGHT
-1.0±
RT21500440
Clearance between side body outer panel and rear spoiler at

B-6: 8.0 ± 2.0 mm
8.0±
REAR SPOILER
2.0
SIDE BODY OUTER PANEL
RT21500470
50

Clearance between side body outer panel and trim panel

garnish at B-7: 4.5 ± 1.2 mm
Flush between side body outer panel and trim panel garnish SIDE BODY TRIM PANEL GARNISH
at B-7: 1.6 ± 1.2 mm OUTER PANEL
4.5
1.6
±
1.2
±
1.2
RT21500480
Clearance between rear door and triangular block at B-8: 

0.3 ± 0.2 mm TRIANGULAR BLOCK
Flush between rear door and triangular block at B-8: 
1.0 ± 0.7 mm
0.7
2
±0.
±
1.0
0.3
REAR DOOR
RT21500490
Clearance between rear windshield and back door upper

trim board at B-9: 3.0 ± 1.5 mm
REAR WINDSHIELD
.5
±1
3.0
BACK DOOR UPPER TRIM BOARD
RT21500670
Clearance between rear combination light and rear fog light

at B-10: 4.0 ± 2.0 mm
Flush between rear combination light and rear fog light at 
4.0±2.0
B-10: -0.8 ± 2.0 mm
-0.8±2.0
REAR
REAR FOG LIGHT COMBINATION LIGHT
RT21500660
50

Clearance between rear combination light and back door

upper trim board at B-11: 4.0 ± 1.5 mm
Flush between rear combination light and back door upper
trim board at B-11: 0.7 ± 1.2 mm 4.0±1.5
0.7±1.2
BACK DOOR
UPPER TRIM BOARD REAR
COMBINATION LIGHT
RT21500680
Clearance between side body outer panel and rear

combination light at B-12: 2.0 ± 1.0 mm
Flush between side body outer panel and rear combination SIDE BODY
OUTER PANEL -1.0±1.0
light at B-12: -1.0 ± 12.0 mm
REAR
COMBINATION LIGHT
2.0±1.0
RT21500460
Clearance between rear combination light and side body

outer panel at B-13: 2.0 ± 1.0 mm
Flush between rear combination light and side body outer -0.8±1.0
panel at B-13: -0.8 ± 1.0 mm
REAR
SIDE BODY
COMBINATION LIGHT
OUTER PANEL
2.0
±1.
0
RT21500500
Clearance between rear bumper and back door at B-14: 

4.0 ± 1.5 mm
Flush between rear bumper and back door at B-14: 
-0.7 ± 1.5 mm
1.5
4.0± -0.7±
1.5
BACK DOOR REAR BUMPER
RT21500620
50

Clearance between rear bumper and rear combination light

at B-15: 2.0 ± 1.0 mm
REAR COMBINATION LIGHT
1.0
2.0±
REAR BUMPER
RT21500630
Clearance between rear combination light and side body

outer panel at B-16: 2.5 ± 1.0 mm
2.5±1.0
Flush between rear combination light and side body outer
panel at B-16: 2.0 ± 1.0 mm REAR
COMBINATION LIGHT
SIDE BODY
OUTER PANEL
2.0±1
.0
RT21500570
Clearance between fuel filler door and side body outer panel
at B-17: 3.0 ± 0.8 mm
Flush between fuel filler door and side body outer panel at 
+1.0 3.0±0.8
B-17: -1.0 -0.2 mm
SIDE BODY +1.0
-1.0 -2.0
OUTER PANEL
FUEL FILLER DOOR
RT21500510
Clearance between side body outer panel and rear bumper

at B-18: 0.5 ± 0.5 mm
Flush between side body outer panel and rear bumper at 
.0
B-18: -0.7 ± 1.0 mm -0.7±1
REAR BUMPER
0.5±0.5
RT21500590
50

Clearance between rear bumper and back door at B-19: 

7.0 ± 2.0 mm
BACK DOOR
REAR BUMPER
2.0
7.0±
RT21500640
Clearance between rear towing hook cover plate and rear

bumper at B-20: 0.8 ± 0.5 mm
Flush between rear towing hook cover plate and rear -0.5
±0.5
bumper at B-20: -0.5 ± 0.5 mm
0.8
±0
REAR TOWING .5
HOOK COVER PLATE
REAR BUMPER
RT21500650
Clearance between rear fog light and rear bumper at B-21:

1.3 ± 1.0 mm
REAR FOG LIGHT

0
±1.
1.3
REAR BUMPER
RT21500610
Clearance between rear wheel flare trim board and rear

bumper at B-22: 1.0 ± 1.0 mm
REAR WHEEL
Flush between rear wheel flare trim board and rear bumper FLARE TRIM BOARD
at B-22: 0 ± 1.0 mm 0±1
.0
REAR BUMPER
1.0
1.0±
RT21500580
50

Clearance between rear wheel flare trim board and side

+1.0
body outer panel at B-23: 0 0 mm

0 +1
0 .0
REAR WHEEL
FLARE TRIM BOARD
RT21500560
Clearance between rear wheel flare trim board and rear

apron plate at B-24: 2.0 ± 1.0 mm
Flush between rear wheel flare trim board and rear apron REAR WHEEL FLARE TRIM BOARD
plate at B-24: 3.0 ± 1.0 mm
2.0±1.0
.0
3.0±1
REAR APRON PLATE
RT21500540
Clearance between rear door trim board and rear apron

plate at B-25: 4.6 ± 2.0 mm
REAR DOOR TRIM BOARD
4.6
REAR APRON PLATE
±2.
0 RT21500550
Clearance between rear door trim board and rear apron

plate at B-26: 6.0 ± 1.8 mm
REAR APRON PLATE
6.0±1.8
RT21500530
50

Clearance between rear door and rear door trim board at 

+1.0
B-27: 0 0 mm
REAR DOOR
0 +1.0
0
RT21500520
Clearance between side body outer panel and rear

windshield at B-28: 4.0 ± 1.5 mm
SIDE BODY
OUTER PANEL
REAR WINDSHIELD
4.0±1.5
RT21500600
50

- MEMO -

WIRE HARNESS
WIRE HARNESS INFORMATION 51-3 VEHICLE FUSE & RELAY 51-33
General Information 51-3 General Information 51-33
Description 51-3 Description 51-33
Circuit Diagram Information 51-3 Fuse & Relay 51-34
Circuit Diagram Instruction 51-4 Engine Compartment Fuse and Relay 
Electrical Troubleshooting 51-7 Box 51-34
Wire Harness Troubleshooting 51-7 Instrument Panel Fuse and Relay 
Voltage Test 51-7 Box A 51-36
Circuit Continuity Test 51-7 Instrument Panel Fuse and Relay 
Box B 51-37
Short Circuit Test 51-7
Electrical Troubleshooting Tools 51-8 VEHICLE WIRE HARNESS LAYOUT 51-38
Electrical Repair 51-9 General Information 51-38
Wire Harness Repair 51-9 Description 51-38
Fuse Replacement 51-9 Vehicle Wire Harness Layout 51-39
Electrical Components 51-10 Entire Vehicle Wire Harness Layout 51-39
Engine Wire Harness 51-40
VEHICLE POWER DISTRIBUTION 51-12
Engine Compartment Wire Harness 51-42
General Information 51-12
Instrument Panel Wire Harness 51-45
Description 51-12
Body Wire Harness 51-48
Front Left Door Wire Harness 51-52
Circuit Distribution 51-13
Front Right Door Wire Harness 51-53
VEHICLE GROUND DISTRIBUTION 51-26 Rear Right Door Wire Harness 51-54
General Information 51-26 Rear Right Door Wire Harness 51-55
Description 51-26 Back Door Wire Harness 51-56
Circuit Diagram 51-27 A/C Wire Harness 
Ground Distribution 51-27 (for Electrical A/C System) 51-57
A/C Wire Harness 
(for Automatic A/C System) 51-58
Battery/Ground Wire Harness 51-59
51

51

51 - WIRE HARNESS
WIRE HARNESS INFORMATION

WIRE HARNESS
General Information
Description
Wire harness information contains basic introductions of circuit diagrams, inspection methods of cables and
connectors, as well as layout of connector positions and wire harness positions, etc.
Circuit Diagram Information

Circuit diagrams are classified into each chapter in Service Manual. If a component appears in a specific
system, its related information (such as wire harness, connector, terminal, etc.) will appear in the circuit
diagram and be introduced in detail. For example, the information of Engine Control Module (ECM) is mainly
introduced in chapter 6. If the component wire harnesses involve other systems, the component information
will also appear in the corresponding systems.
Chery automobile offers related circuit diagram information of the vehicle electrical equipment to help
technicians determine and detect the vehicle malfunction effectively.
Functions and features of circuit diagram:
 Power supply circuit is on the top of the page, while ground circuit is at the bottom.
 Components (such as switches and fuses) are displayed on the circuit diagram in the form of simple icon.
51

51 - WIRE HARNESS
Circuit Diagram Instruction
EXAMPLE
[1] BATTERY
IGNITION SWITCH
ON OR START [14]
ENGINE
EF05 COMPARTMENT [15]
[2] FUSE AND RELAY BOX
30A
E-049
D3
[3] A
A11 A13
2 3
INSTRUMENT
[4] MAIN
RF14 PANEL FUSE [16]
RELAY AND RELAY BOX
10A
1 5 I-004
RF19
15A
A4 A3 A1 A2 [13]
VR
SENSOR
I-003
MT CVT [12]
1 2
G
B
I-013
BW
[5] [6] 2 3 E-010

[17]
RW
RW
[8]
10 13 11 3 4
1 CONTROL
MODULE
I-001
MOTOR 7 8 9
[7] M E-011
GR
TO BACKLIGHT [18]
V
POWER SUPPLY
2 1 6
SWITCH
[9]
B
I-009
[11] TO CAN
[19] SYSTEM
[10]
E-014 3 5
[20]
I-006
D1 D2 D3 D4 D5
1 2 3 4 5 6 7 8 9 10 11 12 13 A16 A15 A14 A9 A8 A7
14 15 16 17 18 19 20 21 22 23 24 25 26
A6 A5 A4
A13 A12 A11 A10
A3 A2 A1
[21] D6 D7 D8 D9 D10 D11 D12
E-049
I-001 I-004 [22] W
W W
51 1 2 3 4 5 6 7 8
1 2
4 5 6 1 2
1 2 3
9 10 11 12 13 14 15 16
I-009 I-003
I-013
E-011 W W
W
Gr ET21020000

51 - WIRE HARNESS
The following is a list of symbols defined in the circuit diagram.

It indicates the power supply from battery positive to electrical
[1] Battery
equipment.
This symbol indicates a fuse; "EF05" indicates the fuse number;
[2] Fuse
"30A" indicates the rated amperage of the fuse.
[3] Splice Point The solid circle indicates that each intersecting wire is interconnected.
This symbol indicates a relay; "MAIN RELAY" indicates the relay
[4] Relay
name; "1", "2", "3" and "5" indicate the terminal numbers of the relay.
It indicates the color of this wire. The color codes are as follows:
B = Black;
W = White;
R = Red;
G = Green;
L = Blue;
Y = Yellow;
[5] Color Br = Brown;
O = Orange;
Gr = Gray;
P = Pink;
V = Violet;
Lg = Light Green.
For example: "BrR" indicates that the main color is brown in the wire
color, and the second color is red.
It indicates the junction connectors. "Λ" is the female connector, and 
"I-013" is the applicable number; "◊" is the male connector, and "E-010"
[6] Connector is the applicable number. The number "2" and "3" inside the male
connector indicates the terminal number. "----" indicates different
terminals come from the same junction connectors.
[7] Motor This symbol indicates a motor.
[8] Component Name It indicates the name of the component.
51

51 - WIRE HARNESS

"E-011" indicates the connector number of this component, and the
letter "E" indicates the wire harness code in which the connector is
located. The connector codes are as follows:
E = Engine Compartment Wire Harness;
E = Engine Wire Harness;
I = Instrument Panel Wire Harness;
B = Body Wire Harness;
F = Front Left Door Wire Harness;
[9] Connector No. H = Front Right Door Wire Harness;
L = Rear Left Door Wire Harness;
R = Rear Right Door Wire Harness;
T = Back Door Wire Harness;
P = Battery Wire Harness;
U = Automatic Transmission Wire Harness (For CVT);
N = Ground Wire Harness;
K = A/C Wire Harness.
[10] Ground Point It indicates the ground connection.
[11] Switch This symbol indicates a switch.
[12] Vehicle Model "CVT" indicates it is for CVT model; "MT" indicates it is for MT model.
[13] Terminal No. It indicates the terminal number in the connector of this component.
It indicates the power supply from ignition switch to electrical
[14] Ignition Switch
equipment.
It indicates that the wire harness is connected to the circuit diagram
[15] Connected to on next page. The letter "A" is connected with "A" in the circuit
diagram on the next page.
[16] Fuse and Relay Box Name It indicates the name of the fuse and relay box.
[17] Twisted-pair It indicates that two wires are twisted.
It indicates the illumination power supply output from backlight
[18] Backlight Power Supply
adjustment dial.
It is used for indicators, warning lights or illuminations in the switches
[19] LED
or instrument cluster.
It indicates CAN wire in the electrical schematics. It is connected to
[20] CAN
CAN system.
It indicates the cross section of connector and description of terminal
[21] Connector View
number.
The letter "W" indicates the color of connector. The color codes are
[22] Connector Color
the same as above.
51

51 - WIRE HARNESS
Electrical Troubleshooting
Wire Harness Troubleshooting
The following 6 steps help to troubleshoot the wire harness. Be sure to check the non-original components
added to the vehicle before performing any diagnosis. If the vehicle is equipped with these components,
disconnect them to verify these added components are not the cause of problem.
Perform following steps when troubleshooting wire harness:
1. Verify problem.
2. Look for any related symptom (by inspecting components in the same circuit).
3. Analyze symptom (use the wire harness diagram to determine the layout of the circuit, the area where
problems most likely occur and the area where diagnosis will continue).
4. Isolate problem area.
5. Repair problem area.
6. Check for proper operation (in this step, check all items in the repaired circuit for proper operation).
Voltage Test
1. Ground the negative probe (black) of voltmeter.
2. Connect the positive probe (red) of voltmeter to the selected measuring point (turn ignition switch on as
necessary). Check voltage value displayed on the voltmeter.
Circuit Continuity Test

1. Turn off all the electrical equipment and ignition switch, and disconnect the negative battery cable.
2. Remove the circuit to be tested.
3. Connect two probes of ohmmeter to two ends of the circuit to be tested respectively, and check the circuit
continuity (low resistance means there is good continuity in the circuit).
Short Circuit Test

1. Measure and record battery voltage.
2. Pull out the fuse of circuit to be tested or disconnect power supply end of the test circuit.
3. Connect the positive probe (red) of voltmeter to the positive battery terminal and the negative probe (black)
to the power supply end of the circuit.
4. Check voltage value displayed on the voltmeter. If the voltage value of battery is displayed, it indicates that
the test circuit is shorted to ground.
51

51 - WIRE HARNESS
Electrical Troubleshooting Tools

1. Jumper Wire
Jumper wire is used to create a temporary circuit.
Connect the jumper wire between terminals of a circuit to
bypass the switch.
RT21510010
CAUTION
 DO NOT connect a jumper wire from power supply end to body ground, as this may damage the wire
harnesses or electrical components.
2. Voltmeter
Power circuit
Voltmeter is used to measure circuit voltage. The Voltmeter
measurement range should be higher than 15 V.
Measure the voltage by connecting the positive probe Black
V
- +
(red) of voltmeter to the positive lead of the test
component and the negative probe (black) to the
negative lead or body ground.
Ground Red RT21510020
3. Ohmmeter
Ohmmeter is used to measure resistance between two
points in a circuit, or to check the circuit for an open or Power Supply
Line
short.
Ground Line
- +
Ohmmeter
RT21510030
CAUTION
 DO NOT connect ohmmeter to the circuit when applying voltage to the circuit, as this may result in
inaccurate measured data or even damaging the ohmmeter.
51

51 - WIRE HARNESS
Electrical Repair
Wire Harness Repair
CAUTION
 Measure the length of lead to be repaired and select a proper substitute lead before servicing.
 If there are several leads to be repaired, please stagger the repaired parts.
1. Peel off 0.5 inch insulating layer from the lead to be repaired and the substitute lead.
2. Connect the original lead to the substitute lead with the heat shrink tube and compress the metal core of
heat shrink tube with a tool, so that the original lead and the substitute lead can be connected firmly.
3. Heat the heat shrink tube to shrink the outer rubber layer and ensure that the sealing of repaired area is in
good condition.
4. Wrap the repaired lead with insulating tape.
Fuse Replacement
CAUTION
 Energizing test should be performed after replacing the fuse. If the fuse is blown again, check the
corresponding circuit for short. If any electrical equipment or additional device which exceeds the rated
current is installed, replace it with the fuse with higher amperes.
1. Turn off all the electrical equipment and ignition switch before servicing.
2. Remove the blown fuse with a fuse puller.
3. Replace the fuse with a new one which has the same
specification. Pull
Puller
Fuse
RT21510040
51

51 - WIRE HARNESS
Electrical Components
1. Battery cable
Disconnect the negative battery cable (arrow) before
servicing electrical components.
RT21020200
2. Sensor, switch and relay

Do not drop or tap the sensor, switch or relay to avoid
damaging components during servicing.
RT21510060
CAUTION
 Use the relay of the same specification with the original one during replacement.
3. Connector
a. Disconnect the connector.
Hold the connector by hand and press the connector
clip to disconnect it.
RT21510070
CAUTION
 DO NOT pull the wire harness forcibly to avoid damaging components when disconnecting the
connector.
51

51 - WIRE HARNESS
There are a variety of ways to fix connector clips, and

common disconnection methods are shown in the
illustration.
RT21510080
b. Install the connector.

A "click" can be heard when the connector is installed
in place.
ick
Cl
RT21510090
c. Replace the connector terminal.

As shown in the illustration (1), insert a suitable tool 1
into the terminal to lift up the fixing clip, and then pull
out the terminal from behind.
During installation, push the terminal from the back of
the connector to ensure that the fixing clip is installed 2
in place as shown in the illustration (2).
RT21510100
d. Check the connector terminal.

Pull a single wire harness terminal gently to check if it
is installed in place.
RT21510110
51

51 - WIRE HARNESS
VEHICLE POWER DISTRIBUTION

General Information
Description
Power distribution system provides secure, reliable and efficient power for all electrical equipment on the
vehicle.
Power distribution system consists of the following components:
 Battery
 Engine compartment fuse and relay box
 Instrument panel fuse and relay box
 Ignition switch
 Fuse
 Relay
51

51 - WIRE HARNESS
Circuit Diagram
Circuit Distribution
Power Distribution (Page 1 of 13)
CVT
BATTERY
A
- +
BODY TRANSMISSION
30 85
STARTER ENGINE
RELAY MF07
COMPARTMENT
FUSE AND
87 86 150A
RELAY BOX
EF41 E-069
30A E-067
E-022
L1 H5 F13
E-078
CONNECTOR A
STARTER CONTROL PSE CONNECTION ALTERNATOR WIRE HARNESS
H8 H7 H6 H5 H4 H3 H2 H1 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1

E-022
51
L2 L1
H16 H15 H14 H13 H12 H11 H10 H9 W
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
E-067
E-069
W
W
ET21510010

51 - WIRE HARNESS
MT
BATTERY
A
- +
BODY TRANSMISSION
30 85
STARTER ENGINE
RELAY MF07
COMPARTMENT
FUSE AND
87 86 150A
RELAY BOX
EF41 E-069
30A E-067
E-022
L1 H5 F13
STARTER CONTROL EMS 2 ALTERNATOR WIRE HARNESS
H8 H7 H6 H5 H4 H3 H2 H1 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1

L2 L1 E-022
H16 H15 H14 H13 H12 H11 H10 H9 W
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
E-067
51 W
E-069
W
ET21510020

51 - WIRE HARNESS
B B
A A
EF46 EF19 85 30
20A 10A EMS
MAIN
RELAY ENGINE
85 30
86 87 COMPARTMENT
TCU FUSE AND
C
RELAY RELAY BOX
ERLY12
EF40 EF39 E-076
86 87
EF07 E-023
10A 10A
15A E-069
E-066
F16 J2 A2 F14 A6 A7 C4
REAR OXYGEN SENSOR

FRONT OXYGEN SENSOR
TCU
ECM-2 IGNITION COIL
A1 A2 A3 A4 A5 C1 C2 C3 C4 C5 J2 J1
E-076 E-023
A6 A7 A8 A9 A10 Gr C6 C7 C8 C9 C10
L E-066
B
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1

E-069
51
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 W
ET21510030

51 - WIRE HARNESS
B B
A A
C C
85 30
ENGINE
HORN
COMPARTMENT
EF27 EF26 EF08 RELAY
FUSE AND
10A 10A 15A 86 87 RELAY BOX
E-068
EF25 E-067
15A E-023
C9 C10 C3 H4 D6
ELECTRICAL HEATING
INJECTOR 1 SPIRAL CABLE

INJECTOR 2
INJECTOR 3
AIR FLOW METER INJECTOR 4
HIGH HORN
LOW HORN
CANISTER SOLENOID VALVE VARIABLE CAMSHAFT TIMING (INTAKE)

VARIABLE CAMSHAFT TIMING (EXHAUST)
C1 C2 C3 C4 C5 H8 H7 H6 H5 H4 H3 H2 H1
D1 D2 D3 D4 D5
C6 C7 C8 C9 C10 H16 H15 H14 H13 H12 H11 H10 H9
D6 D7 D8 D9 D10
E-067
51
E-023
W E-068
L
W
ET21510040

51 - WIRE HARNESS
B B
A A
ENGINE
85 30 85 30 85 30 COMPARTMENT
A/C FUEL FUSE AND
PUMP FAN
CLUTCH EF38 RELAY BOX
RELAY RELAY
RELAY E-023
7.5A
86 87 86 87 86 87 E-069
E-073
EF10 EF35 MF02 E-076
10A 15A 60A
F1 F7 C1 A8 F6 B6 F21 F22
E-078
EMS 2 A/C COMPRESSOR FUEL PUMP MOTOR FAN CONTROLLER
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13
E-069
W
C1 C2 C3 C4 C5 A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 51
C6 C7 C8 C9 C10 A6 A7 A8 A9 A10 B6 B7 B8 B9 B10
E-023 E-076 E-073

L Gr Y
ET21510050

51 - WIRE HARNESS
B B
A A
LOW HIGH ENGING

BEAM BEAM COMPARTMENT
RELAY RELAY FUSE AND
EF47 RELAY BOX
MF01 25A E-067
40A E-068
EF04 EF02 EF03 EF01
E-074
20A 20A 20A 20A
I1 D2 D4 D3 D5 H2 H1
BCM
FRONT LEFT HEADLIGHT
ABS CONTROL MODULE FRONT RIGHT HEADLIGHT
D1 D2 D3 D4 D5 H8 H7 H6 H5 H4 H3 H2 H1
I2 I1
D6 D7 D8 D9 D10 H16 H15 H14 H13 H12 H11 H10 H9
E-074
E-067 Gr
E-068
W
W
51
ET21510060

51 - WIRE HARNESS
MT : *1
CVT : *2
B B
A A
ENGINE
30 85 EF30
FRONT COMPARTMENT
FOG 10A FUSE AND
RELAY RELAY BOX
MF03 MF09 MF04
ERLY03 85 30 E-064 E-067
60A 87 86 80A 60A
REVERSE E-061 E-023
RELAY E-062 E-069
EF05 ERLY6
E-068
15A 86 87
3 H3 D1 6 4 F3 F2 C6
TO BACK-UP SWITCH
TCU (*2)
BCM EPS
FRONT LEFT FOG LIGHT

FRONT RIGHT FOG LIGHT
6 3 4
D1 D2 D3 D4 D5 H8 H7 H6 H5 H4 H3 H2 H1 E-067
E-068
W W
D6 D7 D8 D9 D10 H16 H15 H14 H13 H12 H11 H10 H9
E-064 E-061 E-062
F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1

51
C1 C2 C3 C4 C5
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 C6 C7 C8 C9 C10
E-069 E-023
W L
ET21510070

51 - WIRE HARNESS
CVT
A A
B B
D D
E E
ENGINE
RELAY BOX
85 30 85 30 85 30 E-065
IGN2 ACC IGN1 E-067
86 87 86 87 86 87 E-074
F4 F5 B1 F18 F17 I2 H7 H6 K1
E-078 E-078 E-078
PSE CONNECTION IGNITION SWITCH
B1 B2 B3 B4 B5 K2 K1 I2 I1
E-073
B6 B7 B8 B9 B10 Y E-065 E-074
B Gr
51 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 H8 H7 H6 H5 H4 H3 H2 H1
F24 F23 F22 F21 F20 F19 F18 F17 F16 F15 F14 F13 H16 H15 H14 H13 H12 H11 H10 H9
E-069 E-067
W W
ET21510080

51 - WIRE HARNESS
MT : *1
CVT : *2
A A
B B
D D
E E
B7
ENGINE
COMPARTMENT
MF05 FUSE AND
30A RELAY BOX
E-063
85 30 EF34 E-069
BLOWER 20A EF17 EF29 E-076
RELAY EF36 EF28
10A 10A E-023
ERLY15 10A 10A
E-073
86 87
E-063
F8 F9 5 A10 C8 A4 C7
E-027
7
I-034
SPEED RESISTOR
BACK-UP LIGHT EMS

SWITCH
TCU (*2)
HVAC CONTROL
ABS CONTROL ALTERNATOR
PANEL
MODULE WIRE HARNESS
B1 B2 B3 B4 B5 5
A1 A2 A3 A4 A5 C1 C2 C3 C4 C5
F1 F2 F3 F4 F5 F6 F7
F11 F12 F13 F14 B6 B7 B8 B9 B10
F8 F9 F10 F15 F16 F17 F18 A6 A7 A8 A9 A10 C6 C7 C8 C9 C10
E-063
E-076 E-023 E-073
B-060
51
Gr L Y
W
ET21510090

51 - WIRE HARNESS
MT : *1
CVT : *2
A
E E
INSTRUMENT
PANEL FUSE
RF46 RF27 RF21 RF03 RF30 AND RELAY
25A 20A BOX
15A 10A 7.5A
I-007
I-031
E14 E7 21 3 E15 27
12 I-004
E-071
AM1 IG1 ACC AM2 IG2 ST2

240W 120W 120W 120W
IGNITION HVAC CONTROL
LOCK
SWITCH PANEL (*2)
ACC （*1）
ON I-013
START
1 2 3 6 5 4
H
F F
G G
1 2 3 4 5 6 7 8 9 10 11 12
6 5 4
3 2 1 E5 E6 E7 E8 13 14 15 16 17 18 19 20 21 22 23 24
E1 E2 E3 E4
E13 E14 E15 E16
E9 E10 E11 E12 E17 E18 E19 E20 27 25 26
I-013 87
Lg 85 86 86 86
51
87 30 87 30
I-031 30 85 85
W
I-007
B
ET21510100

51 - WIRE HARNESS
MT : *1
CVT : *2
D D
F F
H H
I I
J J
RF13 RF33
INSTRUMENT
7.5A 25A PANEL FUSE
AND RELAY
RF10 85 30 BOX
RF47 RF09 RF06
7.5A I-007
DEFOGER 10A 7.5A 10A
RF42 RELAY I-031
10A RRLY02 B-060
86 87
10 F10 F9 13 E3 E4 F13 E10 9 6
INSTRUMENT
CLUSTER
G
DIAGNOSTIC
INTERFACE
PSE CONNECTION (*2)
IMMOBILIZER
HVAC CONTROL PANEL BCM DEFROSTER BRAKE SWITCH
CONTROL MODULE
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
F1 F2 F3 F4 F5 F6 F7
I-007 F11 F12 F13 F14
27 25 26 F8 F9 F10 F15 F16 F17 F18
87 B
85 86 86 86
87 30 87 30
30 85 85 B-060
W
51
E1 E2 E3 E4 E5 E6 E7 E8
E13 E14 E15 E16
E9 E10 E11 E12 E17 E18 E19 E20
I-031
ET21510110
W

51 - WIRE HARNESS
MT : *1
CVT : *2
F F
I I
J J
INSTRUMENT
PANEL FUSE
RF23 RF45 RF22 RF24 RF35 RF21 AND RELAY
10A 15A 7.5A 10A 10A BOX
10A
I-007
B-060
I-031
23 E17 22 24 F18 21
BACKUP
POWER
SUPPLY
KEY REMINDER HVAC CONTROL

SWITCH （*1） PANEL (*2)
DIAGNOSTIC
INTERFACE
INSTRUMENT CLUSTER AUDIO BRAKE SWITCH
1 2 3 4 5 6 7 8 9 10 11 12
F1 F2 F3 F4 F5 F6 F7 13 14 15 16 17 18 19 20 21 22 23 24
F11 F12 F13 F14
F8 F9 F10 F15 F16 F17 F18
27 25 26
87
85 86 86 86
B-060 87 30 87 30
30 85 85
W
I-007
51 B
E1 E2 E3 E4 E5 E6 E7 E8
E13 E14 E15 E16
E9 E10 E11 E12 E17 E18 E19 E20
I-031
W ET21510120

51 - WIRE HARNESS
MT : *1
CVT : *2
INSTRUMENT
PANEL FUSE
RF08 RF14 RF15 RF01 RF02 RF07 AND RELAY
10A 15A 7.5A 10A 10A 7.5A BOX
I-007
I-031
8 14 15 1 2 7
CIGARETTE LIGHTER REVERSE PSE CONNECTION (*2)

RADAR MODULE
DIAGNOSTIC REAR VIEW MIRROR HEADLIGHT ADJUSTMENT

INTERFACE ADJUSTMENT SWITCH SWITCH
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
27 25 26
87
85 86 86 86
87 30 87 30
30 85 85
I-007
B 51
ET21510130

51 - WIRE HARNESS
VEHICLE GROUND DISTRIBUTION

General Information
Description
Ground distribution system provides the centralized and convenient information about ground positions for
electrical equipment on entire vehicle. Technicians can find relevant electrical equipment quickly through the
ground points and solve problem accurately and efficiently.
51

51 - WIRE HARNESS
Circuit Diagram
Ground Distribution
Ground Distribution (Page 1 of 6)
1 ELECTRICAL HEATING
E-004
E-019 2 A/C COMPRESSOR

E-002
63
ECM-2
E-033
64
E-026
47
ECM-1
E-035
48
E-028
5
FRONT RIGHT
E-031 HEADLIGHT
6
E-034
9
1 FRONT RIGHT
FOG LIGHT
E-037
2 FRONT WASHER MOTOR

E-039
E-032 2 REAR WASHER MOTOR

E-040
1 ANTI-THEFT HORN
E-053
13
ABS CONTROL MODULE
38 E-085
E-042
51
3 FAN CONTROLLER
E-046
E-051 2 HIGH PITCHED HORN

E-045
2 LOW PITCHED HORN

E-048
ET21510140

51 - WIRE HARNESS
MT : *1
CVT : *2
1
5
FRONT LEFT
E-058 HEADLIGHT
6
E-056
9
1 FRONT LEFT
FOG LIGHT
E-055
1 HOOD CONTACT
SWITCH
E-044
F4 (*2)
ENGINE
F13 (*2) COMPARTMENT
FUSE AND
E-078 F18 (*2) RELAY BOX (F)
E-069
F22
H6 ENGINE COMPARTMENT
FUSE AND RELAY BOX (H)
E-067 (*2)
2 BREAK LIQUID LEVEL SENSOR

E-082
4 FRONT WIPER MOTOR

E-077
A2 FRONT WIPER MOTOR

E-077
E-081 (*2)
24
25
TCU
E-087 (*2) 26 E-030
49
51
7 CONNECTOR A
E-050
ET21510150

51 - WIRE HARNESS
MT : *1
CVT : *2
IMMOBILIZER CONTROL
2
MODULE
I-018 (*1)
HEADLIGHT ADJUSTMENT
I-003 8
SWITCH
I-009
5 SPIRAL CABLE
I-012
3
INSTRUMENT CLUSTER
5 I-015
4
DIAGNOSTIC INTERFACE
5 I-050
2
HAZARD SWITCH
5 I-001
1 AUDIO B
I-020
REAR VIEW MIRROR

I-037 4 ADJUSTMENT SWITCH
I-008
4 HVAC CONTROL PANEL

8 K-002 (*1) K-012 (*2)
I-039 K-007
J116 PSE CONNECTION (J1)
I-029 (*2)
6 SPEED RESISTOR
17
K-004
I-039 K-007
I-038
SRS CONTROL
16
MODULE
I-046
I-006
11 B-003
I-045 2 SEAT BELT REMINDER
B-049
2
FRONT PASSENGER
SEAT BELT SWITCH
51
B-050
ET21510160

51 - WIRE HARNESS
1 BACKUP POWER SUPPLY

I-041
I-047 3 CIGARETTE LIGHTER

I-049
1 FRONT ROOM LIGHT

B-008
B-007
1 DEFROSTER NEGATIVE
11
T-002
B-012 T-004
B-017 1 BACK DOOR SWITCH

T-006
1 REAR WIPER MOTOR

T-007
2
BACK DOOR LOCK
4 T-012
REAR RIGHT
1
COMBINATION LIGHT
B-016
B-018 2 RIGHT LICENSE PLATE LIGHT

8 T-003
B-012 T-004
2 LEFT LICENSE PLATE LIGHT

T-008
1 HIGH MOUNTED STOP LIGHT

T-005
1 REAR RIGHT
COMBINATION LIGHT
T-001
REAR LEFT
1
COMBINATION LIGHT
T-011
1 CAMERA
51 T-009
ET21510170

51 - WIRE HARNESS
REAR LEFT
1
COMBINATION LIGHT
B-021
B-022 1 REAR LEFT FOG LIGHT

B-028
1 REAR RIGHT FOG LIGHT

B-037
16 REVERSE RADAR MODULE

B-020
B-025 2 REAR RIGHT RADAR SENSOR

B-023
2 REAR LEFT RADAR SENSOR

B-027
2 LEFT CENTER RADAR SENSOR

B-030
2 RIGHT CENTER RADAR SENSOR

B-033
4 FUEL PUMP MOTOR

B-038
FRONT LEFT DOOR

B-036 5
3 CONTACT SWITCH
F-002
B-040 F-007
2 ANTI-THEFT INDICATOR
F-004
POWER REAR VIEW

4
MIRROR MOTOR
F-005
8
FRONT LEFT POWER
11
WINDOW SWITCH
F-009
12
5 REAR LEFT DOOR

5 CONTACT SWITCH
L-001
B-026 L-005
3 REAR LEFT POWER 51

WINDOW SWITCH
9
L-002
ET21510180

51 - WIRE HARNESS
MT : *1
CVT : *2
2 FUEL PUMP MOTOR

B-038
B-032
2 DRIVER SEAT BELT SWITCH

B-039
B-042 2 CLUTCH SWITCH

B-051 (*1)
9 COMMAND GEAR SHIFT

B-004 (*2)
F1 BCM (F)
B-046
B-045
2 FRONT RIGHT DOOR

3 CONTACT SWITCH
H-005
B-061 H-002
POWER REAR VIEW
B-062 4
MIRROR MOTOR
H-008
3
FRONT RIGHT POWER
WINDOW SWITCH
9
H-003
REAR RIGHT DOOR

2
5 CONTACT SWITCH
R-004
B-005 R-002
3
REAR RIGHT POWER
WINDOW SWITCH
9
R-003
51
ET21510190

51 - WIRE HARNESS
VEHICLE FUSE & RELAY

WIRE HARNESS
General Information
Description
Each system should be equipped with fuses and relays to ensure normal operation of vehicle electrical
system. The fuses and relays are integrated into fuse and relay boxes which are installed in the following
specific positions of vehicle:
Engine compartment fuse and relay box: located on the left side of engine compartment and the rear side of
left headlight.
Instrument panel fuse and relay box A: located on the lower left side of instrument panel.
Instrument panel fuse and relay box B: located on the lower right side of instrument panel.
51

51 - WIRE HARNESS
Fuse & Relay

Engine Compartment Fuse and Relay Box
ERLY08 ERLY07 ERLY06 ERLY05 ERLY04 ERLY03 ERLY02 ERLY01

Fuel relay IGN2 relay Back-up light A/C Horn relay Front fog Low beam High beam
relay compressor light relay relay relay
(CVT model)
EF20 10A
EF19 10A
EF18 15A
EF17 10A
EF15 15A
EF10 10A
EF08 15A
EF07 15A
EF05 15A
EF04 20A
EF03 20A
EF02 20A
EF01 20A
EF16
EF14
EF13
EF12
EF11
EF09
EF06
EF38 7.5A
EF40 10A
EF39 10A
EF37 10A
EF36 10A
EF35 15A
EF34 20A
EF30 10A
EF29 10A
EF28 10A
EF27 10A
EF26 10A
EF25 15A
EF33
EF32
EF31
EF24
EF23
EF22
EF21
ERLY13 ERLY12 ERLY11 ERLY10 ERLY09
ACC relay TCU relay Main relay IGN1 relay Starter relay
(CVT model)
EF48 EF47 EF46 EF45 EF44 EF43 EF42 EF41

20A 25A 20A 20A 30A
ERLY16 Fuse
ERLY15 ERLY14
Cooling fan relay

puller Blower relay
RT21510120
51

51 - WIRE HARNESS
No. Description No. Description

EF01 Right Headlight High Beam EF25 Horn
EF02 Left Headlight High Beam EF26 Spare
EF03 Right Headlight Low Beam EF27 Air Flow Meter/Canister
EF04 Left Headlight Low Beam EF28 Back-up Light Switch (for MT Model)
EF05 Front Fog Light EF29 Alternator Excitation
Back-up Light/Reversing Radar (for
EF06 - EF30
CVT Model)
EF07 Ignition Coil EF31 -
EF08 Injector/Camshaft Timing EF32 -
EF09 - EF33 -
EF10 A/C Compressor EF34 IGN Power Supply
EF11 - EF35 Fuel Pump
EF12 - EF36 ABS/ESP
EF13 - EF37 Spare
Fuel Pump Relay Coil/Fan Relay
EF14 - EF38
Coil
EF15 IGN2 EF39 Oxygen Sensor
EF16 - EF40 ECM
EF17 ECM/TCU (for CVT Model) EF41 Starter
EF18 Spare EF42 -
EF19 TCU (for CVT Model)/ECM EF43 IGN1
EF20 Spare EF44 -
EF21 - EF45 -
EF22 - EF46 TCU (for CVT Model)
EF23 - EF47 ABS/ESP
EF24 - EF48 ACC
51

51 - WIRE HARNESS
Instrument Panel Fuse and Relay Box A
RF03 7.5A
RF07 7.5A
RF09 7.5A
RF10 7.5A
RF01 10A
RF02 10A
RF06 10A
RF08 10A
RF04
RF05
RF11
RF12
RF13 7.5A
RF15 7.5A
RF24 7.5A
RF14 15A
RF21 10A
RF22 15A
RF23 10A
RF16
RF17
RF18
RF19
RF20
RF25
RF26
15A
Memory fuse
RT21510130

RF01 Reversing Radar RF14 Cigarette Lighter
SPORT Switch Backlight (for CVT Outside Rear View Mirror
RF02 RF15
Model)/Headlight Leveling Dial Adjustment Switch/Sunroof Switch
Back-up Light Relay Coil (for CVT
RF03 RF16 -
Model)
RF04 - RF17 -
RF05 - RF18 -
Yaw Sensor/Steering Angle Sensor/
Instrument Cluster/Front Passenger
RF06 Seat Belt Reminder Light/Diagnosis RF19 -
Connector/Engine Immobilizer/ESP
Indication
RF07 BCM/EPS/PEPS RF20 -
RF08 Airbag RF21 Automatic A/C Control Panel
RF09 Brake Switch RF22 Audio System
Instrument Cluster/Diagnosis
RF10 A/C Control Panel RF23
Connector
51 RF11 - RF24 Key Switch
RF12 - RF25 -
Relay Coils of Rear Defroster,
RF13 Blower, Seat Heater/Audio System/ RF26 -
BCM

51 - WIRE HARNESS
Instrument Panel Fuse and Relay Box B
RF27 15A
RF32 20A
RF34 10A
RF35 10A
RF36 10A
RF37 10A
RF30 RF33
RF28
RF29
RF31
RF38
RF39
20A 25A
RRL Y02 RRL Y03 RRL Y04

Fuse
Rear defroster puller Left seat Right seat
relay heater relay heater relay
RF42 10A
RF40 RF41
30A 30A
+
RF45 10A
RF47 10A
RF49 20A
RF46
RF43
RF44
RF48
RF50 RF51
25A
RT21510140

RF27 Spare RF40 Right Window Jam Protection
RF28 - RF41 Left Window Jam Protection
Outside Rear View Mirror Heating/
RF29 - RF42
Defrosting Feedback Signal
RF30 IP Fuse and Relay Box A RF43 -
RF31 - RF44 -
RF32 Power Seat Adjustment RF45 Backup Power Supply
RF33 Rear Defroster RF46 Ignition Switch
RF34 Left Seat Heater RF47 PEPS
RF35 Brake Light Switch RF48 -
RF36 Reserve RF49 Sunroof
RF37 Right Seat Heater RF50 -
RF38 - RF51 -
RF39 - 51

51 - WIRE HARNESS
VEHICLE WIRE HARNESS LAYOUT

General Information
Description
Wire harness layout introduces location information of vehicle wire harness and electrical components in the
form of graphic. Entire vehicle wire harnesses are divided into the following parts:
 Engine Wire Harness
 Engine Compartment Wire Harness
 Instrument Panel Wire Harness
 Body Wire Harness
 Front Left Door Wire Harness
 Front Right Door Wire Harness
 Rear Left Door Wire Harness
 Rear Right Door Wire Harness
 Back Door Wire Harness
 A/C Wire Harness (for Electrical A/C System)
 A/C Wire Harness (for Automatic A/C System)
 Battery/Ground Wire Harness
51

51 - WIRE HARNESS
Vehicle Wire Harness Layout

Entire Vehicle Wire Harness Layout
Rear Right Door

A/C Wire Harness Back Door Wire
Wire Harness
Engine Wire Harness Harness Layout
Front Right Door
Engine Compartment Wire Harness
Wire Harness
Front Left Door

Wire Harness
Battery Wire Ground Wire Instrument Panel Body Wire Rear Left Door
Harness Harness Wire Harness Harness Wire Harness
ET21510191
51

51 - WIRE HARNESS
Engine Wire Harness
E-008 E-009 E-010 E-011 E-012 E-013 E-014 E-015
E-016
E-017
E-018
E-019
E-020
E-007 E-021
E-038 E-022
E-006 E-023
E-005 E-024
E-004 E-025
E-003
E-002
E-001
ET21510200
51

51 - WIRE HARNESS
Connector Code Connector Color/Pin Connector Name

E-001 W/1 Oil Pressure Switch
E-002 B/2 A/C Compressor
E-003 B/3 Alternator
E-004 B/2 Electrical Heating
E-005 B/3 Knock Sensor
E-006 B/2 Variable Camshaft Timing (Intake)
E-007 B/42 to Engine Compartment Wire Harness Connector E-038
E-008 B/2 Variable Camshaft Timing (Exhaust)
E-009 B/6 Electronic Throttle
E-010 B/2 Injector 1
E-014 B/1 Starter Control
E-015 B/3 Camshaft Position Sensor(Exhaust)
E-016 B/3 Engine Speed Sensor
E-017 B/5 Air Flow Meter
E-018 B/4 Ignition Coil
E-019 - Ground
E-020 B/3 Camshaft Position Sensor (Intake)
E-021 L/2 Coolant Temperature Sensor
E-022 W/2
(L)
E-023 L/10
(C)
E-024 B/2 Canister Solenoid Valve
E-025 B/2 Back-up Light Switch
51

51 - WIRE HARNESS
Engine Compartment Wire Harness
E-087 E-086 E-085 E-084 E-083 E-082 E-081 E-080 E-079 E-078 E-077 E-076 E-075 E-074 E-073 E-072 E-071 I-004 E-070
E-026
E-027
I-034
B-048
E-069
E-028
E-068
E-029
B-054 E-067
E-030 E-066
E-065
E-031
E-064
E-032
E-063
E-033
E-062
E-034 E-061
E-035
E-060
E-036
E-059
E-037
E-058
E-038
E-007
E-039
E-040 E-041 E-042 E-043 E-044 E-045 E-046 E-047 E-048 E-049 E-050 E-051 E-052 E-053 E-054 E-055 E-056 E-057
ET21510210
51

51 - WIRE HARNESS

E-026 - Ground
to Instrument Panel Wire Harness
E-027 W/15
Connector I-034
E-028 - Ground
E-029 W/22 to Body Wire Harness Connector B-054
E-030 B/56 TCU (for CVT Model)
E-031 - Ground
E-032 - Ground
E-033 B/64 ECM-2
E-034 B/10 Front Right Headlight
E-035 B/48 ECM-1
E-036 B/2 Front Right Wheel Speed Sensor
E-037 B/2 Front Right Fog Light
E-038 B/42 to Engine Wire Harness Connector E-007
E-039 Gr/2 Front Washer Motor
E-040 Gr/2 Rear Washer Motor
E-041 B/3 A/C Pressure Sensor
E-042 - Ground
E-043 B/4 Downstream Oxygen Sensor
E-044 W/3 Hood Contact Switch
E-045 Gr/2 High Pitched Horn
E-046 Gr/3 Fan Controller
E-047 B/2 Outside Temperature Sensor
E-048 Gr/2 Low Pitched Horn
E-049 B/3 Clutch Speed Sensor (for CVT Model)
E-050 B/10 Connector A (for CVT Model)
E-051 - Ground
E-052 Gr/10 Connector B (for CVT Model)
E-053 B/2 Anti-theft Horn
E-054 W/3 Primary Shaft Pressure Sensor
E-055 B/2 Front Left Fog Light
E-056 B/10 Front Left Headlight
E-057 - ABS Power Supply 51
E-058 - Ground
E-059 - Fan Power Supply
E-060 B/2 Front Left Wheel Speed Sensor
E-061 - BCM Power Supply

51 - WIRE HARNESS

E-062 - IP Box Power Supply
E-063 - Blower Power Supply
E-064 - EPS Power Supply
E-065 B/2
(K)
E-066 B/2
(J)
E-067 W/16
(H)
E-068 W/10
(D)
E-069 W/24
(F)
E-070 W/22 to Body Wire Harness Connector B-048
to Instrument Panel Wire Harness
E-071 B/14
Connector I-004
E-072 W/1 BCM (E)
E-073 Y/10
(B)
E-074 Gr/2
(I)
E-075 L/2 EPS
E-076 Gr/10
(A)
E-077 B/4 Front Wiper Motor
E-078 - Ground
Secondary Shaft Speed Sensor
E-079 B/3
(for CVT Model)
E-080 B/3
(for CVT Model)
E-081 - Ground
E-082 B/2 Break Fluid Level Sensor
E-083 B/3 Primary shaft speed sensor (for CVT Model)
E-084 B/4 Upstream Oxygen Sensor
51 E-085 B/38 ABS Control Module
E-086 - IP Box
E-087 - Ground

51 - WIRE HARNESS
Instrument Panel Wire Harness
I-054 I-055 I-014 I-015 I-056 I-016 I-017 I-018 I-019 I-020 I-021 I-022 I-023 I-024 I-025 I-026 I-027 I-028 I-029
I-012
I-030
I-013
I-031
I-011
I-032
I-010
I-033
I-009
I-034
I-008
E-027
I-007
I-035
I-005
B-059
I-004
B-055
I-003
I-036
E-071
I-037
I-006
I-038
B-003
I-057
I-002
I-001
I-053 I-052 I-051 I-050 I-049 I-048 I-047 I-046 I-045 I-044 I-043 I-042 I-041 I-040 K-007 I-039
ET21510220
51

51 - WIRE HARNESS

I-001 B/6 Hazard Switch
I-002 B/4 Key Reminder Switch (for MT Model)
I-003 - Ground
I-004 W/14 to Engine Compartment Wire Harness Connector E-071
I-005 L/32 BCM (A)
I-006 W/22 to Body Wire Harness Connector B-003
I-007 B/ Instrument Panel Fuse and Relay Box A
I-008 B/10 Rear View Mirror Adjustment Switch
I-009 Br/16 Headlight Adjustment Switch
I-010 B/6 Steering Angle Sensor
I-011 B/10 Combination Light Switch
I-012 W/16 to Spiral Cable Connector I-054
I-013 Lg/6 Ignition Switch (w/o Passive Entry & Passive Start)
I-014 B/10 Wiper Switch
I-015 L/32 Instrument Cluster
I-016 B/2 Key Lamp (w/o Passive Entry & Passive Start)
I-017 W/8 Engine Switch (w/ Passive Entry & Passive Start)
Immobilizer Control Module (w/o Passive Entry &
I-018 B/8
Passive Start)
I-019 B/16 Audio Assistant
I-020 B/16 Audio B
I-021 B/4 Sun Sensor
I-022 B/8 Navigation
I-023 B/10 USB
I-024 Gr/1 GPS
I-025 B/1 Antenna
I-028 Gr/2 Front Passenger Airbag
I-029 Gr/16 PEPS (J1)
I-030 B/16 PEPS (J2)
I-031 W/20 Instrument Panel Fuse and Relay Box B (E)
I-032 Gr/1 GPS
I-033 B/1 Antenna
51 I-034 W/15 to Engine Compartment Wire Harness Connector E-027

I-037 - Ground
I-038 - Ground

51 - WIRE HARNESS

I-039 B/22 to A/C Wire Harness Connector K-007
I-041 W/2 Backup Power Supply
I-042 B/10 USB
I-043 B/2 Low Frequency Antenna 1
I-044 B/8 Passenger Seat Heater Switch
I-045 - Ground
SRS Control Module (belong to Instrument Panel Wire
I-046 Gr/32
Harness)
I-047 - Ground
I-048 G/2 Immobilizer Coil (w/o Passive Entry & Passive Start)
I-049 W/3 Cigarette Lighter
I-050 B/16 Diagnostic Interface
I-051 - Ground
I-055 B/2 Driver Airbag
I-056 W/1 Horn Switch
I-057 B/10 EPS B Connector
51

51 - WIRE HARNESS
Body Wire Harness
B-001 B-002 B-003 B-004 R-002 B-005 B-006 B-007 B-008 B-009 B-010 B-011 B-012 T-004 B-013 B-014 B-015
B-016
B-017
B-018
B-019
B-062 B-020
H-002 B-021
B-061 B-022
E-029 B-023
B-060 B-024
I-035 B-025
B-059 L-005
B-058 B-026
B-027
B-057 B-028
B-056 B-029
I-036 B-030
B-055 B-031
B-032
B-033
B-034
B-035
B-036
B-037
B-038
F-007
B-039
B-054 B-053 B-052 B-051 B-050 B-049 B-048 E-070 I-006 B-047 B-046 B-045 B-044 B-043 B-042 B-041 B-040
ET21510230
51

51 - WIRE HARNESS

B-001 B/2 Front Right Speaker
B-002 B/2 Front Passenger Seat Belt Pre-tensioner
B-003 W/22 to Instrument Panel Wire Harness Connector I-006
B-004 W/11 Command Gear Shift
B-005 Y/16 to Rear Right Door Wire Harness Connector R-002
B-006 B/2 Front Left Speaker
B-007 - Ground
B-008 W/6 Front Room Light
B-009 B/2 Rear Right Wheel Speed Sensor
B-010 W/2 Rear Room Light
B-011 B/2 Luggage Compartment Light
B-012 W/15 to Back Door Wire Harness Connector T-004
B-013 B/1 Antenna
B-014 W/1 Antenna Power Supply
B-015 Gr/1 GPS
B-016 B/6 Rear Right Combination Light
B-017 - Ground
B-018 - Ground
B-019 B/1 Parking Brake Switch
B-020 W/16 Reverse Radar Module
B-021 B/6 Rear Left Combination Light
B-022 - Ground
B-023 B/2 Rear Right Radar Sensor
B-024 B/2 Low Frequency Antenna 2
B-025 - Ground
B-026 Y/16 to Rear Left Door Wire Harness Connector L-005
B-027 B/2 Rear Left Radar Sensor
B-028 B/2 Rear Left Fog Light
B-029 B/2 Rear Left Wheel Speed Sensor
B-030 B/2 Left Center Radar Sensor
B-031 B/2 Rear Bumper Low Frequency Antenna
B-032 - Ground
B-033 B/2 Right Center Radar Sensor 51
B-034 B/2 Driver Seat Belt Pre-tensioner
B-035 B/2 Low Frequency Antenna 3
B-036 - Ground
B-037 B/2 Rear Right Fog Light

51 - WIRE HARNESS

B-038 B/4 Fuel Pump Motor
B-039 B/2 Driver Seat Belt Switch
B-040 w/18 to Front Left Door Wire Harness Connector F-007
B-041 Gr/18 to Front Left Door Wire Harness Connector F-007
B-042 - Ground
B-043 W/20 BCM (C)
B-044 W/12 BCM (D)
B-045 - Ground
B-046 B/1 BCM (F)
B-047 L/32 BCM (B)
B-048 W/22 to Engine Compartment Wire Harness Connector E-070
B-049 W/2 Front Passenger Seat Belt Reminder Switch
B-050 B/2 Front Passenger Seat Belt Switch
B-051 B/2 Clutch Switch
B-052 Lg/4 Brake Switch
B-053 B/4 Electronic Accelerator Pedal
B-054 W/22 to Engine Compartment Wire Harness Connector E-029
B-056 B/8 PEPS (J3)
B-057 Gr/1 GPS
B-058 B/1 Antenna
B-060 W/18 Instrument Panel Fuse and Relay Box B (F)
B-061 W/18 to Front Right Door Wire Harness Connector H-002
B-062 - Ground
51

51 - WIRE HARNESS
B-063
B-064 B-065 B-066 B-067 B-068 B-069 B-070 B-071 B-072
ET21510240
B-063 B/6 Sunroof

B-064 B/2 Front Right Doorsill Light
B-065 B/4 Front Passenger Seat Heater
B-066 B/4 Steering Angle Sensor
B-067 B/8 Driver Seat Heater switch
B-068 - Ground
B-069 B/2 Front Left Doorsill Light
B-070 B/4 Driver Seat Power Adjustment Switch
B-071 B/4 Driver Seat Heater
B-072 B/32 SRS Control Module (belong to Body Wire Harness)
51

51 - WIRE HARNESS
Front Left Door Wire Harness
F-004 F-005
F-003 F-006
B-040
F-002 B-041
F-007
F-001
F-009 F-008
ET21510250

F-001 W/2 Front Left Door Courtesy Light
F-002 B/6 Front Left Door Contact Switch
F-003 B/2 Left Handle Sensor
F-004 W/2 Anti-theft Indicator
F-005 W/16 Power Rear View Mirror Motor
Front Left Power Window Regulator Motor (w/o jam
F-006 (a) Gr/2
protection function)
Front Left Power Window Regulator Motor (w/ jam
F-006 (b) Gr/6
51 protection function)
F-007 W/32 to Body Wire Harness Connector B-040, B-041
F-008 B/2 Front Left Door Speaker
F-009 Br/16 Front Left Power Window Switch

51 - WIRE HARNESS
Front Right Door Wire Harness
H-003
H-002 H-004
H-005
B-061
H-006
H-001 H-008 H-007
ET21510260

H-001 Gr/2 Front Right Power Window Regulator Motor
H-002 W/32 to Body Wire Harness Connector B-061
H-003 B/10 Front Right Power Window Switch
H-004 B/2 Right Handle Sensor
H-005 B/6 Front Right Door Contact Switch
H-006 W/2 Front Right Door Courtesy Light
H-007 B/2 Front Right Door Speaker
H-008 W/16 Power Rear View Mirror Motor
51

51 - WIRE HARNESS
Rear Right Door Wire Harness
L-005
L-001 B-026
L-002 L-003 L-004

R-003
ET21510270

L-001 B/6 Rear Left Door Contact Switch
L-002 B/10 Rear Left Power Window Switch
L-003 B/2 Rear Left Door Speaker
L-004 Gr/2 Rear Left Power Window Regulator Motor
L-005 W/16 to Body Wire Harness Connector B-026
51

51 - WIRE HARNESS
Rear Right Door Wire Harness
R-003
B-005 R-004
R-002 R-001 R-005

R-003
ET21510280

R-001 Gr/2 Rear Right Power Window Regulator Motor
R-002 W/16 to Body Wire Harness Connector B-005
R-003 B/10 Rear Right Power Window Switch
R-004 B/6 Rear Right Door Contact Switch
R-005 B/2 Rear Right Door Speaker
51

51 - WIRE HARNESS
Back Door Wire Harness
T-012
T-011
T-010 T-009 T-008 T-007 T-006 T-005 T-004 B-012 T-003 T-002 T-001
ET21510290

T-001 B/2 Rear Right Combination Light
T-002 B/1 Defroster Negative
T-003 W/2 Right License Plate Light
T-004 W/15 to Body Wire Harness Connector B-012
T-005 W/2 High Mounted Stop Light
T-006 B/2 Back Door Switch
T-007 W/3 Rear Wiper Motor
T-008 W/2 Left License Plate Light
51 T-009 B/6 Camera
T-010 B/1 Defroster Positive
T-011 B/2 Rear Left Combination Light
T-012 W/6 Back Door Lock

51 - WIRE HARNESS
A/C Wire Harness (for Electrical A/C System)
K-001 K-002 K-003 K-004 K-005 K-006
K-008 I-027 K-007
ET21510300

K-001 B/6 Mode Damper Motor
K-002 W/40 HVAC Control Panel
K-003 B/6 Mixed Damper Motor
K-004 B/6 Speed Resistor
K-005 W/2 Evaporator Temperature Sensor
K-006 B/6 Inner and Outer Circulation Motor
K-007 W/22 to Instrument Panel Wire Harness Connector I-039
K-008 W/2 Blower
51

51 - WIRE HARNESS
A/C Wire Harness (for Automatic A/C System)
K-009 K-010 K-011 K-012 K-001 K-002 K-003 K-004 K-005 K-006
K-008 I-027 K-007
ET21510310

K-001 W/2 Right Room Temperature Sensor
K-002 W/2 Heater Core Sensor
K-003 B/6 Right Mixed Damper Motor
K-004 B/6 Speed Resistor
K-005 W/2 Evaporator Temperature Sensor
K-006 B/6 Inner and Outer Circulation Motor
K-007 W/22 to Instrument Panel Wire Harness Connector I-039
K-008 W/2 Blower
51 K-009 B/6 Mode Damper Motor
K-010 B/6 Left Mixed Damper Motor
K-011 W/2 Left Room Temperature Sensor
K-012 W/40 HVAC Control Panel

51 - WIRE HARNESS
Battery/Ground Wire Harness
P-001 P-002 P-003 P-004 P-005 N-001 N-002 P-006 P-007
ET21510320

P-001 - Alternator
P-002 - Starter
P-003 - Battery Positive
P-004 - Body Ground
P-005 Battery Negative
P-006 - Engine Compartment Fuse Box Power Supply 2
P-007 - Alternator Power Supply
N-001 - Body Ground
N-002 Engine Ground
51

- MEMO -

INDEX
A D
Abbreviation Table,  Diagnosis & Testing, 
Introduction..................................................02-28 Air Conditioning ...........................................31-15
Adjustment Item,  Diagnosis & Testing, 
Maintenance ..................................................05-7 Audio System............................................... 39-11
Air Conditioning................................................31-1 Diagnosis & Testing, 
Air Conditioning,  Axle................................................................22-8
Preparation ..................................................03-35 Diagnosis & Testing, 
Air Conditioning,  Brake .............................................................26-9
Service Specifications..................................04-41 Diagnosis & Testing, 
Audio System ...................................................39-1 Brake Control System..................................25-14
Audio System,  Diagnosis & Testing, 
Preparation ..................................................03-43 Clutch.............................................................19-7
Audio System,  Diagnosis & Testing, 
Service Specifications..................................04-49 Differential......................................................21-6
Axle ..................................................................22-1 Diagnosis & Testing, 
Door Lock ....................................................37-17
Axle, 
Electronic Power Steering..............................30-8
Axle, 
Engine Immobilizer ........................................34-7
B Diagnosis &Testing, 
Horn ...............................................................41-6
Body Dimensions .............................................50-1 Diagnosis & Testing, 
Brake................................................................26-1 Hydraulic Assist Steering ...............................29-6
Brake Control System ......................................25-1 Diagnosis & Testing, 
Instrument Cluster ....................................... 38-11
Brake Control System, 
Lighting System ...........................................35-22
Brake Control System, 
Parking Brake ................................................27-7
Brake, 
QR019CHB CVT..........................................18-21
Brake, 
QR525MHE Transmission ...........................17-12
C Diagnosis & Testing, 
Rear View Mirror............................................44-6
Circuit Diagnosis Information,  Diagnosis & Testing, 
Introduction..................................................02-15 Reversing Radar System...............................40-9
Circuit Information,  Diagnosis & Testing, 
Introduction..................................................02-22 Seat Belt ........................................................33-7
Clutch ...............................................................19-1 Diagnosis & Testing, 
Clutch,  SQR484F Charging System ..........................16-6
Clutch,  SQR484F Cooling System...........................12-10
SQR484F Emission Control System..............09-6
Chery Automobile Co., Ltd. ID–1

INDEX
Diagnosis & Testing,  Engine Hood/Door, 

SQR484F Engine Management System .....06-18 Preparation ..................................................03-50
Diagnosis & Testing,  Engine Hood/Door, 
SQR484F Engine Mechanical .....................07-19 Service Specifications..................................04-57
Diagnosis & Testing,  Engine Immobilizer...........................................34-1
SQR484F Exhaust System............................ 11-6 Engine Immobilizer, 
Diagnosis & Testing,  Preparation ..................................................03-38
SQR484F Fuel Supply System......................08-9 Engine Unit Repair, 
Diagnosis & Testing,  SQR484F Engine Mechanical .....................07-70
SQR484F Ignition System .............................14-6 Exterior .............................................................48-1
Diagnosis & Testing,  Exterior, 
SQR484F Intake System...............................10-9 Preparation ..................................................03-51
Diagnosis & Testing,  Exterior, 
SQR484F Lubrication System .......................13-8 Service Specifications..................................04-59
Diagnosis & Testing, 
SQR484F Starting System ..........................15-14 G
Diagnosis & Testing, 
Steering Column ............................................28-7 General Information, 
Diagnosis & Testing,  Air Conditioning .............................................31-3
Supplemental Restraint System ..................32-10 General Information, 
Diagnosis & Testing,  Audio System.................................................39-3
Suspension..................................................23-10 General Information, 
Diagnosis & Testing,  Axle................................................................22-3
Tire And Wheel ..............................................24-5 General Information, 
Diagnosis & Testing,  Body Dimensions...........................................50-3
Windshield/Window Glass ...........................43-13 General Information, 
Diagnosis & Testing,  Brake .............................................................26-3
Wiper And Washer ........................................36-8 General Information, 
Differential ........................................................21-1 Brake Control System....................................25-3
Differential,  General Information, 
Preparation ..................................................03-25 Clutch.............................................................19-3
Differential,  General Information, 
Service Specifications..................................04-27 Differential......................................................21-3
Door Lock.........................................................37-1 General Information, 
Door Lock ......................................................37-3
Door Lock, 
Preparation ..................................................03-41 General Information, 
Drive Shaft .....................................................20-3
Door Lock, 
Service Specifications..................................04-47 General Information, 
Electronic Power Steering..............................30-3
Drive Shaft .......................................................20-1
General Information, 
Drive Shaft, 
Engine Hood/Door .........................................47-3
Service Specifications..................................04-26
Engine Immobilizer ........................................34-3
E
Electronic Power Steering ................................30-1 Exterior ..........................................................48-3
Electronic Power Steering,  General Information, 
Preparation ..................................................03-34 Horn ...............................................................41-3
Electronic Power Steering,  General Information, 
Service Specifications..................................04-40 Hydraulic Assist Steering ...............................29-3
Engine Hood/Door............................................47-1
ID–2 Chery Automobile Co., Ltd.

INDEX
General Information,  General Information, 

Instrument Cluster .........................................38-3 Tire And Wheel ..............................................24-3
Instrument Panel ...........................................45-3 Windshield/Window Glass .............................43-3
Interior ...........................................................49-3 Wiper And Washer.........................................36-3
Lighting System .............................................35-3 H
Other System.................................................42-3 Horn .................................................................41-1
General Information,  Horn, 
Parking Brake ................................................27-3 Preparation ..................................................03-45
General Information,  Horn, 
QR019CHB CVT ...........................................18-3 Service Specifications..................................04-51
General Information,  Hydraulic Assist Steering .................................29-1
QR525MHE Transmission .............................17-3 Hydraulic Assist Steering, 
General Information,  Preparation ..................................................03-33
Rear View Mirror............................................44-3 Hydraulic Assist Steering, 
General Information,  Service Specifications..................................04-39
Reversing Radar System...............................40-3
General Information,  I
Seat ...............................................................46-3
Inspection Items, 
General Information,  Maintenance ..................................................05-8
Seat Belt ........................................................33-3
Instrument Cluster ............................................38-1
SQR484F Charging System ..........................16-3 Instrument Cluster, 
Preparation ..................................................03-42
SQR484F Cooling System ............................12-3 Instrument Panel ..............................................45-1
General Information,  Instrument Panel, 
SQR484F Emission Control System .............09-3 Preparation ..................................................03-48
General Information,  Instrument Panel, 
SQR484F Engine Management System .......06-3 Service Specifications..................................04-54
General Information,  Interior ..............................................................49-1
SQR484F Engine Mechanical .......................07-3 Interior, 
General Information,  Preparation ..................................................03-52
SQR484F Exhaust System............................ 11-3 Interior, 
General Information,  Service Specifications..................................04-61
SQR484F Fuel Supply System......................08-3 Introduction ......................................................02-1
SQR484F Ignition System .............................14-3 L
Lighting System................................................35-1
SQR484F Intake System...............................10-3
Lighting System, 
Preparation ..................................................03-39
SQR484F Lubrication System .......................13-3
Lighting System, 
SQR484F Starting System ............................15-3
Steering Column ............................................28-3
M
General Information,  Maintenance.....................................................05-1
Supplemental Restraint System ....................32-3
Maintenance Items, 
General Information,  Maintenance ..................................................05-3
Suspension....................................................23-3

INDEX
On-vehicle Service, 
N QR019CHB CVT........................................ 18-110
Nstrument Cluster, 
QR525MHE Transmission ...........................17-14
Rear View Mirror............................................44-7
O
On-vehicle Service,  Reversing Radar System.............................40-10
Air Conditioning ...........................................31-63 On-vehicle Service, 
On-vehicle Service,  Seat .............................................................46-12
Audio System ..............................................39-12 On-vehicle Service, 
On-vehicle Service,  Seat Belt ........................................................33-8
Axle................................................................22-9 On-vehicle Service, 
On-vehicle Service,  SQR484F Charging System ..........................16-7
Brake ...........................................................26-12 On-vehicle Service, 
On-vehicle Service,  SQR484F Cooling System...........................12-13
Brake Control System..................................25-70 On-vehicle Service, 
On-vehicle Service,  SQR484F Emission Control System..............09-7
Clutch ............................................................19-8 On-vehicle Service, 
On-vehicle Service,  SQR484F Engine Management System....06-242
Differential .....................................................21-7 On-vehicle Service, 
On-vehicle Service,  SQR484F Engine Mechanical .....................07-23
Door Lock ....................................................37-39 On-vehicle Service, 
On-vehicle Service,  SQR484F Exhaust System............................ 11-7
Drive Shaft.....................................................20-5 On-vehicle Service, 
On-vehicle Service,  SQR484F Fuel Supply System....................08-12
Electronic Power Steering ...........................30-22 On-vehicle Service, 
On-vehicle Service,  SQR484F Ignition System .............................14-8
Engine Hood/Door ....................................... 47-11 On-vehicle Service, 
On-vehicle Service,  SQR484F Intake System .............................10-10
Engine Immobilizer ......................................34-26 On-vehicle Service, 
On-vehicle Service,  SQR484F Lubrication System ..................... 13-11
Exterior ..........................................................48-8 On-vehicle Service, 
On-Vehicle Service,  SQR484F Starting System...........................15-64
Horn...............................................................41-8 On-vehicle Service, 
On-vehicle Service,  Steering Column ..........................................28-10
Hydraulic Assist Steering.............................29-10 On-vehicle Service, 
On-vehicle Service,  Supplemental Restraint System ..................32-64
Instrument Cluster .......................................38-42 On-vehicle Service, 
On-vehicle Service,  Suspension ..................................................23-12
Instrument Panel ...........................................45-9 On-vehicle Service, 
On-vehicle Service,  Tire And Wheel ..............................................24-7
Interior ...........................................................49-9 On-vehicle Service, 
On-vehicle Service,  Windshield/Window Glass ...........................43-44
Lighting System ...........................................35-64 On-vehicle Service, 
On-vehicle Service,  Wiper And Washer.......................................36-22
Other System.................................................42-5 Other System ...................................................42-1
Parking Brake ................................................27-8

INDEX
Service Specifications ......................................04-1

P SQR484F Charging System.............................16-1
Parking Brake...................................................27-1 SQR484F Charging System, 
Preparation ..................................................03-20
Parking Brake, 
Preparation ..................................................03-31 SQR484F Charging System, 
Parking Brake, 
Service Specifications..................................04-37 SQR484F Cooling System ...............................12-1
Preparation.......................................................03-1 SQR484F Cooling System, 
Preparation ..................................................03-16
Q SQR484F Cooling System, 
QR019CHB CVT ..............................................18-1 SQR484F Emission Control System ................09-1
QR019CHB CVT,  SQR484F Emission Control System, 
Preparation ..................................................03-23 Preparation ..................................................03-13
QR019CHB CVT,  SQR484F Emission Control System, 
Service Specifications..................................04-23 Service Specifications..................................04-13
QR525MHE Transmission ...............................17-1 SQR484F Engine Management System ..........06-1
QR525MHE Transmission,  SQR484F Engine Management System, 
Preparation ..................................................03-21 Preparation ....................................................03-3
QR525MHE Transmission,  SQR484F Engine Management System, 
Service Specifications..................................04-22 Service Specifications....................................04-3
SQR484F Engine Mechanical ..........................07-1
R SQR484F Engine Mechanical, 
Preparation ....................................................03-5
Rear View Mirror ..............................................44-1
SQR484F Engine Mechanical, 
Rear View Mirror, 
Service Specifications....................................04-4
Preparation ..................................................03-47
SQR484F Exhaust System .............................. 11-1
Rear View Mirror, 
Service Specifications..................................04-53 SQR484F Exhaust System, 
Preparation ..................................................03-15
Replacement Instruction, 
Maintenance ..................................................05-6 SQR484F Exhaust System, 
Reversing Radar System .................................40-1
SQR484F Fuel Supply System ........................08-1
Reversing Radar System, 
Preparation ..................................................03-44 SQR484F Fuel Supply System, 
Preparation ..................................................03-12
Reversing Radar System, 
Service Specifications..................................04-50 SQR484F Fuel Supply System, 
S SQR484F Ignition System................................14-1
SQR484F Ignition System, 
Seat..................................................................46-1 Preparation ..................................................03-18
Seat,  SQR484F Ignition System, 
Preparation ..................................................03-49 Service Specifications..................................04-19
Seat Belt ..........................................................33-1 SQR484F Intake System..................................10-1
Seat Belt,  SQR484F Intake System, 
Preparation ..................................................03-37 Preparation ..................................................03-14
Seat Belt,  SQR484F Intake System, 
Service Specifications..................................04-44 Service Specifications..................................04-14
Seat,  SQR484F Lubrication System..........................13-1
Service Specifications..................................04-56 SQR484F Lubrication System, 
Service Information,  Preparation ..................................................03-17
Introduction....................................................02-3

INDEX
SQR484F Lubrication System,  Wiper And Washer, 

Service Specifications..................................04-18 Preparation ..................................................03-40
SQR484F Starting System ...............................15-1 Wiper And Washer, 
SQR484F Starting System,  Service Specifications..................................04-46
Preparation ..................................................03-19 Wire Harness ...................................................51-1
SQR484F Starting System,  Wire Harness Information, 
Service Specifications..................................04-20 Wire Harness .................................................51-3
Steering Column ..............................................28-1
Steering Column, 
Preparation ..................................................03-32
Steering Column, 
Supplemental Restraint System.......................32-1
Supplemental Restraint System, 
Preparation ..................................................03-36
Supplemental Restraint System, 
Suspension ......................................................23-1
Suspension, 
Preparation ..................................................03-28
Suspension, 
T
Tire And Wheel ................................................24-1
Tire And Wheel, 
V
Vehicle Fuse & Relay, 
Wire Harness...............................................51-33
Vehicle Ground Distribution, 
Wire Harness...............................................51-26
Vehicle Information, 
Introduction.................................................. 02-11
Vehicle Power Distribution, 
Wire Harness...............................................51-12
Vehicle Wire Harness Layout, 
Wire Harness...............................................51-38
W
Wheel Alignment, 
Suspension..................................................23-47
Windshield/Window Glass................................43-1
Windshield/Window Glass, 
Preparation ..................................................03-46
Windshield/Window Glass, 
Wiper And Washer ...........................................36-1

CHERY Tiggo5 T21 Service Manual EN1

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CHERY T21 CAUTION:

This manual is only for specialized

2014 without proper equipment and tools, it may

In order to prevent dangerous operation and

All Rights Reserved © 2014

VEHICLE INFORMATION 02-11

Chery Automobile Co., Ltd. 02–1

02–2 Chery Automobile Co., Ltd.

How to Use This Manual

Chery Automobile Co., Ltd. 02–3

02–4 Chery Automobile Co., Ltd.

 Always wear a clean uniform.

Chery Automobile Co., Ltd. 02–5

2. Jacking up and supporting vehicle

02–6 Chery Automobile Co., Ltd.

b. Precautions for using a plate type lifter

Chery Automobile Co., Ltd. 02–7

02–8 Chery Automobile Co., Ltd.

8. Lubrication and seal

Seal Lock Adhesive

11. Rubber parts and rubber hoses

Chery Automobile Co., Ltd. 02–9

 Cool the exhaust pipe with a fan.

02–10 Chery Automobile Co., Ltd.

VIN is also stamped on deck board under the front

Vehicle Identification Number (VIN)

WMI VDS VIS

ƶƶƶ ƶƶƶƶƶƶ ƶƶƻƻƻƻƻƻ

□: represents a letter or a number (letters I, O and Q cannot be used); ○: represents a number.

Chery Automobile Co., Ltd. 02–11

 The first three digits of VIN represent world manufacturer identifier.

No. WMI Code Vehicle Category

 The fourth digit of VIN represents vehicle type.

02–12 Chery Automobile Co., Ltd.

The transmission number (for CVT model) is stamped on

Chery Automobile Co., Ltd. 02–13

1 - Charging System Warning Light 2 - Daytime Running Light Indicator

02–14 Chery Automobile Co., Ltd.

CIRCUIT DIAGNOSIS INFORMATION

ECM Control System Troubleshooting

Chery Automobile Co., Ltd. 02–15

Diagnosis and Troubleshooting

Procedure Types Details Troubleshooting Methods

2. Detailed troubleshooting steps

02–16 Chery Automobile Co., Ltd.

Circuit Simulation Test

When monitoring whether the system has

Chery Automobile Co., Ltd. 02–17

 DO NOT heat components to a temperature higher than 60°C (140°F).

02–18 Chery Automobile Co., Ltd.

6. Cold/hot start test

Precautions for Control Module and Electrical Components

Chery Automobile Co., Ltd. 02–19

 If fuse wire is blown, confirm that there is no short in the circuit.

02–20 Chery Automobile Co., Ltd.

How to Check Connector

1. Check connector with a digital multimeter

Chery Automobile Co., Ltd. 02–21

 The terminal side view in circuit diagram is shown at

Connector Symbol Connector

MANUAL TRANSMISSION AUTO TRANSMISSION

02–22 Chery Automobile Co., Ltd.

3. Circuit diagram example

[5] [6] 2 3 E-010