Rodius Service Manual

GASOLIN ENGINE
CONTENTS
GENERAL INFORMATION................... SECTION 1A
ENGINE MECHANICAL ...................... SECTION 1B
ENGINE COOLING ............................... SECTION 1D
ENGINE ELECTRICAL ..........................SECTION 1E
ENGINE CONTROLS ............................ SECTION 1F
ENGINE INTAKE & EXHAUST ............. SECTION 1G

SECTION 1A
GENERAL
INFORMATION
1A-1
SECTION
00 1A
GENERAL INFORMATION
Table of Contents
DESCRIPTION AND OPERATION .................................. 1A-2
Cleanliness and care ................................................. 1A-2
On-engine service ..................................................... 1A-2
COMPONENT LOCATOR ............................................... 1A-3
Front view .................................................................. 1A-3
Side view .................................................................... 1A-4
DIAGNOSTIC INFORMATION AND PROCEDURE ....... 1A-5
Oil leak diagnosis ....................................................... 1A-5
Compression pressure test ....................................... 1A-6
Cylinder pressure leakage test ................................. 1A-8
General diagnosis .................................................... 1A-10
SPECIFICATIONS ......................................................... 1A-15
Engine specifications ............................................... 1A-15
Performance curve .................................................. 1A-16
SPECIAL TOOLS AND EQUIPMENT ........................... 1A-17
GENERAL INFORMATION CHANGED BY

M162 GSL ENG SM - 2005.7 EFFECTIVE DATE
AFFECTED VIN
1A-2
DESCRIPTION AND OPERATION

CLEANLINESS AND CARE ON-ENGINE SERVICE
An automobile engine is a combination of many Caution
machined, honed, polished and lapped surfaces with Disconnect the negative battery cable before removing
tolerances that are measured in the ten-thousanths of or installing any electrical unit, or when a tool or
an inch. When any internal engine parts are serviced, equipment could easily come in contact with exposed
care and cleanliness are important. A liberal coating of electrical terminals. Disconnecting this cable will help
enigne oil should be applied to friction areas during prevent personal injury and damage to the vehicle.
assembly, to protect and lubricate the surfaces on initial The ignition must also be in LOCK unless otherwise
operation. Proper cleaning and protection of machined noted.
surfaces and friction areas is part of the repair
procedure. This is considered standard shop practice Notice
even if not specifically stated. Any time the air cleaner is removed, the intake opening
Whenever valve train components are removed for should be covered. This will protect against accidental
service, they should be kept in order. They should be entrance of foreign material, which could follow the
installed in the same locations, and with the same mat- intake passage into the cylinder and cause extensive
ing surfaces, as when they were removed. damage when the engine is started.
Battery cables should be disconnected before any ma-
jor work is performed on the engine. Failure to discon-
nect cables may result in damage to wire harness or
other electrical parts.
CHANGED BY GENERAL INFORMATION

EFFECTIVE DATE M162 GSL ENG SM - 2005.7
AFFECTED VIN
1A-3
COMPONENT LOCATOR
FRONT VIEW
1. HFM sensor 9. Valve tappet 16. Engine mounting bracket

2. Intake air duct 10. Injector 17. Starter
3. Resonance flap 11. Exhaust valve 18. Crankcase
4. Cylinder head cover 12. Intake manifold 19. Oil pump sprocket
5. Exhaust camshaft 13. Connecting rod 20. Oil strainer
6. Intake camshaft 14. Exhaust manifold 21. Oil pan
7. Cylinder head 15. Crankshaft 22. Drain plug
8. Spark plug connector

AFFECTED VIN
1A-4
SIDE VIEW
23. Camshaft adjuster 27. Oil pump drive chain

24. Cooling fan and viscous clutch 28. Oil return pipe
25. Piston 29. Timing chain
26. Flywheel of drive plate

AFFECTED VIN
1A-5
DIAGNOSTIC INFORMATION AND PROCEDURE

OIL LEAK DIAGNOSIS Black Light and Dye Method
Most fluid oil leaks are easily located and repaired by A dye and light kit is available for finding leaks, Refer
visually finding the leak and replacing or repairing the to the manufacturer's directions when using the kit.
necessary parts. On some occasions a fluid leak may 1. Pour the specified amount of dye into the engine oil
be difficult to locate or repair. The following procedures fill tube.
may help you in locating and repairing most leaks.
2. Operate the vehicle normal operating conditions as
directed in the kit.
Finding the Leak
3. Direct the light toward the suspected area. The dyed
1. Identify the fluid. Determine whether it is engine oil, fluid will appear as a yellow path leading to the
automatic transmission fluid, power steering fluid, source.
etc.
2. Identify where the fluid is leaking from. Repairing the Leak
2.1 After running the vehicle at normal operating Once the origin of the leak has been pinpointed and
temperature, park the vehicle over a large sheet traced back to its source, the cause of the leak must
of paper. be determined in order for it to be repaired properly. If
2.2 Wait a few minutes. a gasket is replaced, but the sealing flange is bent, the
2.3 You should be able to find the approximate new gasket will not repair the leak. The bent flange
location of the leak by the drippings on the must be repaired also. Before attempting to repair a
paper. leak, check for the following conditions and correct them
as they may cause a leak.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas Gaskets
that are hard to reach. • The fluid level/pressure is too high.
4. If the leak still cannot be found, it may be necessary • The crankcase ventilation system is malfunctioning.
to clean the suspected area with a degreaser, steam • The fasteners are tightened improperly or the
or spray solvent. threads are dirty or damaged.
4.1 Clean the area well. • The flanges or the sealing surface is warped.
4.2 Dry the area. • There are scratches, burrs or other damage to the
4.3 Operate the vehicle for several miles at normal sealing surface.
operating temperature and varying speeds. • The gasket is damaged or worn.
4.4 After operating the vehicle, visually check the • There is cracking or porosity of the component.
suspected component.
• An improper seal was used (where applicable).
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method. Seals
Powder Method • The fluid level/pressure is too high.
• The crankcase ventilation system is malfunctioning.
1. Clean the suspected area.
• The seal bore is damaged (scratched, burred or
2. Apply an aerosol-type powder (such as foot powder)
nicked).
to the suspected area.
• The seal is damaged or worn.
3. Operate the vehicle under normal operating
conditoins. • Improper installation is evident.
4. Visually inspect the suspected component. You • There are cracks in the components.
should be able to trace the leak path over the • The shaft surface is scratched, nicked or damaged.
white powder surface to the source. • A loose or worn bearing is causing excess seal wear.

AFFECTED VIN
1A-6
COMPRESSION PRESSURE TEST
1. Compression pressure tester 3. Adaptor

2. Diagram sheet 4. Sealing cone
Standard Service Data

Application M162 Engine
Compression ratio 10 : 1
Normal engine temperature 80°C (176°F)
Normal compression pressure Normal Min. 10 bar, Max. 14 bar
Optimized fuel pressure Min. 6 bar, Max. 10 bar
Permissible pressure difference between
Max. 1.5 bar
individual cylinders

AFFECTED VIN
1A-7
Tools Required 6. Compare the measurements of compression pressure

A9912 0012B Compression Pressure Tester tester A9912 0012B (001 589 76 21 00) with the
(001 589 76 21 00) specifications.
7. Measure the compression pressure of the other
cylinders in the same way.
Measuring Procedure
8. If measured value is not within the specifications,
1. Warm the engine up to normal operating temperature. perform the cylinder pressure leakage test.
2. Remove the spark plugs using the spark plug wrench.
Notice
3. Place the diagram sheet to compression pressure
• Discharge the combustion residues in the
tester A9912 0012B (001 589 76 21 00).
cylinders before testing the compression
4. Connect the adaptor to compression pressure tester pressure.
A9912 0012B (001 589 76 21 00) and install it into
• Apply the parking brake before cranking the
the spark plug hole.
engine.
5. Crank the engine approx. eight revolutions by using
the start motor.

AFFECTED VIN
1A-8
CYLINDER PRESSURE LEAKAGE TEST
1. Engine oil filler cap 3. Cylinder pressure leakage tester with connecting hose
2. Vibration damper
Permissible Pressure Leakage

At whole engine Max. 25 %
At valve and cylinder head gasket Max. 10 %
At piston and piston ring Max. 20 %
Cylinder Number by Mark on Vibration Damper at TDC

TDC Mark OT (TDC) a (120°) b (240°)
Cylinder number 1, 6 2, 5 3, 4
Universal Tool
Cylinder pressure leakage tester Bosch, EFAW 210A
Sun, CLT 228

AFFECTED VIN
1A-9
Leakage Test
1. Warm the engine up to normal operating temperature.
2. Disconnect the negative battery cable.
3. Remove the spark plugs.
4. Check the coolant level by opening the coolant
reservoir cap and replenish if insufficient.
5. Open the engine oil filler cap.
6. Connect the tester to air pressure line and adjust the
scale of tester.
7. Install the connecting hose to spark plug hole.
8. Position the piston of No.1 cylinder at TDC by rotating
the crankshaft.
9. Connect the connecting hose to tester and measure the

leakage volume after blowing up 5 bar of compressed
air.
Notice
Measure the leakage volume in the completely
opening condition of throttle valve by pulling the
acceleration cable.
10. Perform the pressure test according to the firing order.

Notice
Firing Order: 1 - 5 - 3 - 6 - 2 - 4.
11. Compare the leakage pressure with the specifications.

AFFECTED VIN
1A-10
GENERAL DIAGNOSIS
Condition Probable Cause Correction
Hard starting Malfunction of igni- • Faulty fuse. • Replace the fuse.
(With normal tion system • Faulty spark plug. • Clean, adjust the plug gap or
cranking) replace.
• Electric leakage at the high • Replace the cable.
tension cable.
• Poor connection of the high • Replace the cable or wires.
tension cable or lead wires.
• Improper ignition timing. • Adjust the ignition timing.
• Faulty ignition coil. • Replace the ignition coil.
Malfunction of fuel • Lock of fuel in the fuel tank. • Feed the fuel.
system • Dirty or clogged fuel filter. • Replace the filter.
• Clogged fuel pipe. • Clean the fuel pipe.
• Malfunction of the fuel pump. • Replace the fuel pump.
• Malfunction of the fuel injector. • Replace the injector.
• The foreign material in the fuel • Clean the fuel tank.
tank.
Decline of com- • Poor tightening spark plug. • Tighten to the specified torque.
pression pressure Compression
• Cracked cylinder head gasket. • Replace the gasket.
• Inadequate the valve clearance. • Adjust the clearance.
• Leakage of the valve clearance. • Repair the valve.
• Interference of the valve stem. • Replace the valve or the valve
guide.
• Low elasticity or damage of the • Replace the valve spring.
valve spring.
• Abnormal interference of pistons • Replace the piston ring.
and cylinders.
• Excessive wear of pistons, rings, • Replace the ring or the piston and
or cylinders. boring or replace the cylinder.
Others • Broken timing belt. • Replace the belt.
• Loosening, damage or leakage of • Connect the hose correctly or
the vacuum hose. replace it.
• Leakage of intake system. • Replace intake system.
Lack of engine Decline of com- • Refer to above in this page. • Refer to above in this page.
power pression pressure
Malfunction of • Improper ignition timing. • Adjust the ignition timing.
ignition system • Faulty spark plug. • Adjust or replace the spark plug.
• Electric leakage or poor connec- • Connect the cable correctly or
tion of the high tension cable. replace it.

AFFECTED VIN
1A-11
General Diagnosis (Cont’d)

Lack of engine Malfunction of fuel • Clogged fuel pipe. • Clean the pipe.
power system • Clogged or contaminated fuel filter. • Replace the filter.
Others • Clogged exhaust system. • Check and repair the system.
• Clogged or contaminated air • Clean or replace the air cleaner
cleaner element. element.
• Leak of the intake manifold gasket. • Replace the gasket.
• Dragging brakes. • Repair or replace the brakes.
Rough engine Decline of com- • Refer to “Page 1A-6”. • Refer to “Page 1A-6”.
idling pression pressure
Malfunction of fuel • Clogged fuel pipe. • Clean the pipe.
system • Clogged or contaminated fuel filter. • Replace the filter.
• Malfunction of the fuel pressure • Replace the regulator.
regulator.
Malfunction of igni- • Malfunction of the spark plug. • Adjust or replace the spark plug.
tion system • Electric leakage or poor connection • Connect the cable correctly or
of the high tension cable. replace it.
• Poor ignition timing. • Adjust the ignition timing.
• Malfunction of the ignition coil. • Replace the ignition coil.
Others • Clogged or contaminated air • Clean or replace the air cleaner
• Poor connection or damage or • Connect the hose correctly or
leakage of the vacuum hose. replace it.
Engine hesitate Decline of com- • Refer to “Page 1A-6”. • Refer to “Page 1A-6”.
(Upon pressing pression pressure
accelerating Malfunction of igni- • Poor ignition timing. • Adjust the ignition timing.
pedal, the engine tion system • Poor spark plug or Poor adjustment • Replace the plug or adjust the gap.
makes delayed
of the plug gap.
response This
situation is • Electric leakage or poor connection • Connect the cable correctly or
remarkable when of the high tension cable. replace it.
cruising or Others • Malfunction of the air cleaner • Clean or replace the air cleaner
starting.) system. system.

AFFECTED VIN
1A-12

Engine surging Decline of • Refer to “Page 1A-6”. • Refer to “Page 1A-6”.
(Engine power compression
makes pressure
fluctuation in a Malfunction of • Clogged fuel pipe. • Clean the pipe.
fixed speed and fuel system • Clogged or contaminated fuel filter. • Replace the filter.
speed changes
• Malfunction of the fuel pressure • Replace the fuel pressure regulator.
without
operating the regulator.
accelerating Malfunction of • Malfunction of the spark plug. • Adjust or replace the spark plug.
pedal.) ignition system • Electric leakage or poor connection • Connect the cable correctly or
Others • Leak of the intake manifold gasket. • Clean or replace the gasket.
• Leakage of the vacuum hose. • Connect the hose correctly or
replace it.
Excessive Overtheated • Refer to “Overheat” in this page. • Refer to “Overheat” in this page.
detonation engine
(According to the Malfunction of • Abnormal spark plug. • Replace the spark plug.
opening range of fuel system • Poor ignition timing. • Adjust the ignition timing
Malfunction of
• Electric leakage or poor connection • Connect the cable correctly or
metallic is made
with abnormal
explosion) Malfunction of • Clogged or contaminated fuel filter • Clean or replace the fuel filter and
ignition system and fuel pipe. the fuel pipe.
Others • Leak of the intake manifold gasket. • Replace the gasket.
• Excessive carbon deposit due to • Remove the carbon.
abnormal combustion.
Overheat Malfunction of • Lack of coolant. • Refill coolant.
cooling system • Malfunction of the thermostat. • Replace the thermostat.
• Malfunction of the cooling fan. • Check or replace the cooling fan.
• Poor water pump performance. • Replace the pump.
• Clogged or leaky radiator. • Clean, repair or replace the
radiator.
Malfunction of • Poor engine oil. • Replace engine oil with the speci-
lubrication fied one.
system • Blocking oil filter or strainer. • Clean or repair the oil filter or the
strainer.
• Lack of engine oil. • Refill oil.
• Poor oil pump performance. • Replace or repair the pump.
Other • Leakage of oil • Repair.
• Damaged cylinder head gasket. • Replace the gasket.

AFFECTED VIN
1A-13

Poor fuel con- Decline of • Refer to “Page 1A-6”. • Refer to “Page 1A-6”.
sumption compression
pressure
Malfunction of • Leakage of the fuel tank or the fuel • Repair or replace the fuel tank or
fuel system pipe. the fuel pipe
ignition system • Abnormal spark plug • Replace the plug.
(Excessive carbon deposit,
inadequate gap, burnt electrode).
• Electric leakage or poor connection • Connect the cable normally or
Malfunction of • Malfunction of the thermostat. • Repair the thermostat.
cooling system
Others • Improperly installed valve. • Repair or replace the valve.
• Low pressure of tires. • Adjust the pressure of tires.
Excessive Leakage of • Loosened oil drain plug. • Tighten the plug.
consumption of engine oil • Loosened oil pan bolt. • Tighten the bolt. Engine Oil
engine oil
• Loosened oil filter. • Tighten the filter.
• Loosened oil pressure switch. • Tighten the switch.
• Leakage of camshaft front oil seal. • Replace the seal.
• Leakage of crankshaft front oil seal. • Replace the seal.
• Leakage at the cylinder head cover • Replace the gasket.
gasket.
• Damage of the cylinder head • Replace the gasket.
gasket.
Oil mixing in • Stuck piston ring. • Remove carbon and replace the
combustion ring.
chamber • Worn piston or cylinder. • Replace the piston or the cylinder.
• Worn piston ring or ring groove. • Replace the piston or ring.
• Inadequate position of the piston • Adjust the position.
ring cutting part.
• Abrasion or damage of the valve • Replace the valve system.
system.
Low oil Malfunction of • Inadequate oil viscosity. • Replace with the specified one.
pressure lubrication • Loosening of the oil pressure • Tighten the switch.
system switch.
• Blocking oil strainer. • Clean the strainer.
• Lowered function of the oil pump. • Replace the pump.
• Abrasion or damage of the oil pump • Replace the valve.
relief valve.

AFFECTED VIN
1A-14

Engine noise Valve noise • Inadequate valve clearance • Adjust the valve clearance.
• Abrasion of valve stem or guide. • Replace the valve stem or the
guide.
• Weak valve spring. • Replace the spring.
Piston, ring, cylin- • Abrasion of the piston, the ring or • Boring the cylinder or replace the
der noise the cylinder. piston, the ring or the cylinder.
Connecting rod • Abrasion of the connecting rod • Replace the bearing.
noise bearing.
• Loosened the connecting rod nut. • Tighten to the specified torque
Crankshaft noise • Abrasion of the crankshaft bearing. • Replace the bearing.
• Abrasion of the crankshaft journal. • Grind or replace the crankshaft
journal.
• Loosened bearing cap bolt. • Tighten to the specified torque.
• Excessive clearance of the crank- • Adjust or replace.
shaft thrust bearing.
• Low oil pressure. • Refer to “Page 1A-13” in this
section.

AFFECTED VIN
1A-15
SPECIFICATIONS
ENGINE SPECIFICATIONS
Application M162 Engine
Engine model M162.990
Displacement (CC) 3199
Cylinder (Bore x Stroke) (mm) 89.9 x 84.0
Fuel injection / Ignition system MSE 3.63D
Number of cylinders 6
Camshaft valve arrangement DOHC
Camshaft drive type Chain-Driven
Max. output (ps/rpm) 220 / 6000
Max. torque (kg•m/rpm) 31.6 / 3900
Firing order 1-5-3-6-2-4
Ignition type Distributorless double ignition
Ignition timing BTDC 8°
Valve timing Intake Open/Close ATDC 11° / ABDC 34°
Exhaust Open/Close BBDC 31° / BTDC 14°
Valve clearance adjustment Automatic control
Idle speed (rpm) 700 ± 50
Fuel injection pressure (kg/cm²) 3~4
Oil capacity (liter) 9
Lubrication type Forced by gear pump
Oil filter type Full flow with paper filter
Fuel Unleaded gasoline
MSE: Engine Control Module

3.63D: 6 Cylinder Version

AFFECTED VIN
1A-16
PERFORMANCE CURVE

AFFECTED VIN
1A-17
SPECIAL TOOLS AND EQUIPMENT
Name and Part Number
A9912 0012B (001 589 76 21 00)

Compression Pressure Tester

AFFECTED VIN
1B-2
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
ENGINE ASSEMBLY
1. Engine assembly
Tools Required
A9946 0012A (000 589 40 37 00) Hose Clamp
W9936 0160A (112 589 00 72 00) Oil Extractor
CHANGED BY ENGINE MECHANICAL

AFFECTED VIN
1B-3
Removal & Installation Procedure

1. Disconnect the negative terminal of battery.
2. Remove the hood & front bumper.
3. Remove the under cover.
Installation Notice
28 ~ 47 Nm
Tightening torque
(21 ~ 35 lb-ft)
4. Disconnect the Hot Film Air Mass (HFM) sensor

connector.
5. Disconnect the HFM sensor from the air filter housing.
6. Remove the intake air duct mounting nuts.
Installation Notice
9 ~ 11 Nm
Tightening torque
(80 ~ 97 lb-in)
7. Remove the air cleaner cover. Remove the mounting bolts

and air cleaner housing and element assembly.
8. Remove the hood latch cable and remove the radiator

support upper member.
ENGINE MECHANICAL CHANGED BY

AFFECTED VIN
1B-4
9. Disconnect the each connector.

(Electric fans, AQS sensor, ambient temperature switch,
receiver drier)
10. Disconnect the each hose / A/C pipe.
11. Disconnect the hoses from the radiator and remove the
cooling fan shroud.
12. Remove the automatic transmission oil cooler line.

Installation Notice
25 ~ 35 Nm
Tightening torque
(18 ~ 26 lb-ft)

AFFECTED VIN
1B-5
13. Remove the radiator assembly.
14. Remove the hydraulic pipe of power steering.

Installation Notice
40 ~ 50 Nm
Tightening torque
(30 ~ 37 lb-ft)
Completely drain the oil.
15. Discharge the refrigerant from A/C system, and

disconnect the discharge pipe and suction pipe from
the compressor. Refer to Section 7B, Manual Control
Heating, Ventilation, and Air Conditioning System.
Installation Notice
20 ~ 30 Nm
Tightening torque
(15 ~ 22 lb-ft)
16. Remove the fuel feed and return line.

Installation Notice
21 ~ 25 Nm
Tightening torque
(15 ~ 18 lb-ft)
Before removing the fuel lines, release the pressure in

the fuel system.

AFFECTED VIN
1B-6
17. Separate the vacuum hose for brake booster.

18. Separate the other vacuum hoses.
19. Separate the hose toward engine from canister purge

solenoid valve.
20. Disconnect the terminal from starter motor and remove

the starter motor.
21. Disconnect the engine main harness ground.
22. Disconnect the engine ground wire.

AFFECTED VIN
1B-7
23. Disconnect the terminals from the alternator.
24. Disconnect engine main wiring connector.
25. Remove the service hole cover in the engine block.

26. Put the alignment mark for installation, and remove the
six mounting bolts for torque converter from drive plate
through the service hole by rotating the engine and
remove the torque converter.
Installation Notice
Tightening torque 42 Nm (31 lb-ft)
• Screw the six bolts mounting the torque converter

through the service hole by using a mirror and
rotating the engine.
27. Remove the exhaust manifold and exhaust pipe.

Installation Notice

AFFECTED VIN
1B-8
28. Remove the transmission mounting bolts and separate

the transmission from the engine.
Installation Notice
54 ~ 68 Nm
Tightening torque
(40 ~ 50 lb-ft)
29. Install a chain to the bracket of engine, by using a hoist

or crane.
30. Remove the engine mounting bracket nuts.
Installation Notice
Upper: 70 Nm (52 lb-ft)
Tightening torque
Lower: 38 Nm (28 lb-ft)
31. Carefully separate the engine assembly from the

vehicle.
32. Installation should follow the removal procedure in the
reverse order.

AFFECTED VIN
1B-9
POLY V-BELT AND TENSIONING DEVICE

POLY V-BELT
Preceding Work: Removal of cooling fan
1. Poly V-belt 2. Belt tensioning pulley

1. Release the belt tension by turning the belt tensioning
pulley nut clockwise.
Installation Notice
40.5 ~ 49.5 Nm
Tightening torque
(29.9 ~ 36.5 lb-ft)
2. Remove the poly v-belt.

Notice
Check the belt for damage and tensioning pulley
bearing point for wear and replace them if necessary.
3. Install the belt by turning the nut of tensioning pulley

clockwise.
AFFECTED VIN
1B-10
Poly V-Belt Arrangement
1. Belt tensioning pulley 5. Generator pulley

2. Crankshaft belt pulley 6. Idler
3. A/C compressor pulley 7. Power steering pump pulley
4. Cooling fan pulley 8. Cooling fan and water pump pulley

AFFECTED VIN
1B-11
POLY V-BELT INSPECTION

• Make marks on the belt with chalk.
• Rotate the engine and check the belt for damage.
Notice
If one of the following types of damages is found,
replace the belt.
1. Rubber lumps in the base of rib.

2. Dirt or grit ingrained.
3. Pointed rib.
4. Belt cord visible in the base of rib.
5. Cord torn out at the side.

6. Outer cords frayed.

AFFECTED VIN
1B-12
7. Rib detached from the base of belt.
8. Splits across the rib.

9. Sections of rib torn out.
10. Splits across several ribs.
11. Splits across the back of the belt.

AFFECTED VIN
1B-13
TENSIONING DEVICE
Preceding Work: Removal of poly v-belt
1. Belt (L = 2245) 3. Water pump pulley

2. Bolt combi (M8 x 14, 3 pieces) + Washer 4. Nut
............................ 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft) 5. Belt tensioning pulley

AFFECTED VIN
1B-14

1. Remove the poly v-belt.
2. Remove the tensioning pulley by turning its mounting
nut counter clockwise as shown in figure.
Installation Notice
40.5 ~ 49.5 Nm
Tightening torque
(29.9 ~ 36.5 lb-ft)
3. Remove the bolts and remove the water pump pulley.

Installation Notice
22.5 ~ 27.5 Nm
Tightening torque
(16.6 ~ 20.3 lb-ft)
4. Remove the mounting bolts (M8 x 30, 3 pieces) at the

tensioning device, and remove the tensioning device.
Installation Notice
Tightening torque 26 ~ 32 Nm (19 - 24 lb-ft)

reverse order.

AFFECTED VIN
1B-15
CRANK CASE AND CYLINDER HEAD

CRANKCASE VENTILATION SYSTEM
1. Crankcase 9. Air admission line 17. Air admission and vent connection
2. Air admission port in crankcase 10. Vent line 18. Air admission and vent connection
3. Oil drain port 11. Restriction hole (diameter = 2 mm) 19. Throttle valve
4. Filter 12. Intake manifold 20. Vent line
5. Gasket 13. Intake air duct (cross pipe)
6. A/C bracket 14. Cylinder head cover A. Fresh air
7. Oil drain pipe 15. Oil separator B. Blowby gas in partial load
8. Oil pan 16. Oil separator C. Blowby gas in full load

AFFECTED VIN
1B-16
Operation at Idling and Mid-Load

• It show that the throttle valve (19) is closed or very partially
opened and the vacuum pressure in intake manifold is high.
The blowby gas in the crankcase in partial load flows into
the intake manifold through the vent line (20) after passing
the air conditioner bracket (6) and the filter (4). The air
reentered into the intake manifold will be dilluted on the
flow through the restriction hole (11) in the vent line (10).
The circulated engine oil is separated at the air conditioner
bracket (6) and then returns into the oil pan through the
drain pipe (7).
The vacuum pressure generated at the crankcase sucks
fresh air from intake air line (13) through the air admission
and vent connection (17, 18).
The fresh air prevents engine oil from being contaminated
and the air admission and vent connection (17, 18) is
designed to control the rapid pressure changes in intake
air line (13).
Operation at Full-Load
• The throttle valve (19) is fully opened.
All the blowby gases flow into the intake air duct (13) after
passing through the oil separator (15, 16) of the cylinder
head cover (14) when fully loaded. This dilluted air will be
supplied to the combustion chamber through the intake
manifold (12).

AFFECTED VIN
1B-17
ALTERNATOR
1. Nut (M8) ............ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft) 4. Bolt (M8 x 70, 1 piece)
2. Bolt (M8 x 30, 3 pieces) ............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)
............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft) 5. Bolt (M8 x 75, 1 piece)
3. Bolt (M8 x 40, 1 piece) ............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)
............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)

1. Remove the drive belt.
2. Remove the alternator.
3. Unscrew the alternator carrier bolts and remove the
carrier.
Installation Notice

reverse order.

AFFECTED VIN
1B-18
POWER STEERING PUMP AND A/C BRACKET

Preceding Work: Removal of cooling fan and shroud
1. Vent hose 7. Bolt (M8 x 40, 3 pieces, M8 x 95, 2 pieces)

2. Bolt (M8 x 91, 2 pieces) ............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)
............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft) 8. A/C bracket
3. Power steering pump 9. Gasket .......................................................... Replace
4. Bolt (M8 x 105, 4 pieces) 10. Bracket
............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft) 11. Bolt (M8 x 22, 2 pieces)
5. Washer ............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)
6. A/C compressor 12. Tensioning pulley
13. Nut ...................... 40.5 ~ 49.5 Nm (29.9 ~ 36.5 lb-ft)

AFFECTED VIN
1B-19

1. Remove the belt tensioning pulley.
Installation Notice
40.5 ~ 49.5 Nm
Tightening torque
(29.9 ~ 36.5 lb-ft)
Pull the tensioning pulley clockwise as shown in the

figure.
2. Disconnect the hydraulic pipe of the power steering pump

and drain the oil.
3. Unscrew the bolts and remove the steering pump.

Installation Notice
22.5 ~ 27.5 Nm
Tightening torque
(16.6 ~ 20.3 lb-ft)
4. Remove the compressor after disconnecting the wiring

connector and refrigerant pipe of A/C compressor.
Notice
Discharge all the refrigerant before removing the
pipes.

AFFECTED VIN
1B-20
5. Disconnect the vent hose from the A/C bracket.

Installation Notice
20 ~ 30 Nm
Tightening torque
(15 ~ 22 lb-ft)
6. Unscrew all the mounting bolts and remove the

A/C bracket and the gasket.
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;;;;;;;;;
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;;;;;;;;;
Installation Notice
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;;;;;;;;;
yyyyyyyyy
;;;;;;;;; 22.5 ~ 27.5 Nm
yyyyyyyyy
;;;;;;;;;
yyyyyyyyy
;;;;;;;;;
Tightening torque
(16.6 ~ 20.3 lb-ft)
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;;;;;;;;;
yyyyyyyyy
;;;;;;;;;
yyyyyyyyy
;;;;;;;;;
yyyyyyyyy
;;;;;;;;;
yyyyyyyyy
;;;;;;;;;
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;;;;;;;;;
7. Clean the sealing surface.

8. Replace the gasket with new one.
reverse order.
10. Check the oil leakage by operating the engine after
installation.

AFFECTED VIN
1B-21
ENGINE MOUNT

AFFECTED VIN
1B-22
Removal and Installation Procedure

1. Unscrew the upper engine mounting nut.
Installation Notice
2. Unscrew the lower engine mounting nut.

Installation Notice
3. Remove the hydraulic engine mounting insulator.

Notice
If the insulator is spotted with oil, replace the
hydraulic insulator asseambly.

reverse order.

AFFECTED VIN
1B-23
CYLINDER HEAD COVER
1. Ignition cable dust cover 6. Cylinder head cover

2. Bolt (M6 x 65, 8 pieces) .... 9 ~ 11 Nm (80 ~ 97 lb-in) 7. Gasket .......................................................... Replace
3. Bolt (M6 x 50, 4 pieces) .... 9 ~ 11 Nm (80 ~ 97 lb-in) 8. Spart plug hole seal ..................................... Replace
4. Spacer sleeve 9. Camshaft seal .............................................. Replace
5. Thrust piece
Composition of The Cylinder Head

Cover Bolts
A. M6 x 50, 4 Pieces - Bolts + Washers
B. M6 x 65, 8 Pieces - Bolts + Washers

AFFECTED VIN
1B-24

1. Remove the intake air duct.
Installation Notice
9 ~ 11 Nm
Tightening torque
(80 ~ 97 lb-in)
2. Remove the spark plug cover.

Installation Notice
9 ~ 11 Nm
Tightening torque
(80 ~ 97 lb-in)
Unscrew the seven (M6 x 60) bolts and remove the spark
plug cover.
3. Remove the spark plug connector and ignition cable.
4. Unscrew all the bolts (2, 3) and remove the head cover
and the gasket.
Installation Notice
9 ~ 11 Nm
Tightening torque
(80 ~ 97 lb-in)
Replace the gasket with a new one if necessary.

reverse order.
6. Check for oil leaks by operating the engine.

AFFECTED VIN
1B-25
CYLINDER HEAD FRONT COVER

Preceding Work: Removal of cylinder head cover
Removal of coolant connection fitting
1. Camshaft position sensor 5. Bolt (M8 x 80, 3 pieces)

2. Camshaft actuator ............................ 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
3. Upper guide rail 6. Front cover
4. Bolt (M6 x 60, 3 pieces) 7. Rubber gasket .............................................. Replace
............................ 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft) 8. Bolt (M6 x 16, 3 pieces)
.......................................... 9 ~ 11 Nm (80 ~ 97 lb-in)

1. Remove the camshaft actuator.
Installation Notice
9 ~ 11 Nm
Tightening torque
(80 ~ 97 lb-in)

AFFECTED VIN
1B-26
2. Remove the cylinder head front cover (6).

Installation Notice
22.5 ~ 27.5 Nm
Tightening torque
(16.6 ~ 20.3 lb-ft)
Apply the sealant at the mating surface of the cylinder

head and the front cover.
3. Remove the upper guide rail pin and the guide rail (3).
Notice
Install it while the chain tensioner is loose.
4. Remove the gasket (arrow).

Notice
Replace the gasket with new one and apply the
sealant.

reverse order.

AFFECTED VIN
1B-27
CYLINDER HEAD
Removal of cylinder head front cover
Removal of upper intake manifold
1. Cylinder head bolt (14 pieces) 4. Exhaust camshaft sprocket

......................... 1st step: 55 Nm (141 lb-ft) 5. Cylinder head
2nd step: 90° 6. Gasket .......................................................... Replace
3rd step: 90° 7. Dowel sleeve
2. Washers (14 pieces)
3. Flange bolts (3 pieces)
......................... 1st step: 18 ~ 22 Nm (13 ~ 16 lb-ft)
2nd step: 90° ± 5°

AFFECTED VIN
1B-28
Tools Required
A9913 0061B (116 589 01 34 00) Threaded Pin
A9913 0080B (116 589 20 33 00) Sliding Hammer
A9912 0080B (617 589 00 10 00) Allen Wrench Socket

1. Rotate the crankshaft so that the piston of number 1
cylinder is at TDC.
Notice
Rotate the crankshaft in the normal engine direction.
2. Put the alignment marks (arrows) on the timing chain

and camshaft sprocket.
3. Drain the coolant from the crankcase.
4. Remove the three flange bolts in the exhaust camshaft

sprocket.
Installation Notice
1st step: 18 ~ 22 Nm
Tightening torque (13 ~ 16 lb-ft)
2nd step: 90° ± 5°
Do not reuse the removed bolts.
5. Separate the chain from the camshaft sprockrt.

Notice
Be careful not to drop the chain into the timing case.

AFFECTED VIN
1B-29
6. Remove the guide rail fixing pin from the cylinder head
using the threaded pin A9913 0061B (116 589 01 34 00)
(1) and sliding hammer A9913 0080B (116 589 20 33 00)
(2).
7. Remove the cylinder head bolts in numerical order using

allen wrench socket A9912 0080B (617 589 00 10 00).
Installation Notice
1st step: 55 Nm (41 lb-ft)
Tightening torque 2nd step: 90°
3rd step: 90°
8. Check the length of the cylinder head bolt.

Installation Notice
New 160 ± 0.8 mm

Length (L)
Max. 162 ± 0.7 mm
• Replace the bolt if the measured length exceed the

max. length.
• Apply the oil to the thread surface of bolt.
9. Carefully remove the cylinder head and check the mating

surface.
reverse order.

AFFECTED VIN
1B-30
OIL PAN
1. Gasket ...................................................... Replace 5. Bolt (M6 x 85, 3 pieces)

2. Bolt (M6 x 22, 6 pieces) ...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
...................................... 9 ~ 11 Nm (80 ~ 97 lb-in) 6. Bolt (M8 x 40, 4 pieces)
3. Drain plug ...... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft) ....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
4. Bolt (M6 x 20, 22 pieces) 7. Bolt (M10) ................................... 40 Nm (30 lb-ft)
...................................... 9 ~ 11 Nm (80 ~ 97 lb-in) 8. Oil pan

AFFECTED VIN
1B-31

1. Remove the drain plug and drain the oil completely.
2. Unscrew the bolts and remove the oil pan and gasket.
Notice
Arrange the bolts according to each size.
3. Clean the inside of oil pan and sealing surface, then apply
the sealant.
5. Install the oil pan with gasket, and tighten each bolt in
specified torque.
6. Check for oil leaks while running the engine. M8 X 40, 4 pieces
M6 X 85, 3 pieces
M6 X 35, 3 pieces
M6 X 22, 6 pieces
Others M6 X 20, 28 pieces

AFFECTED VIN
1B-30
OIL PAN
1. Gasket ...................................................... Replace 5. Bolt (M6 x 85, 3 pieces)

2. Bolt (M6 x 22, 6 pieces) ...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
3. Drain plug ...... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft) ....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
4. Bolt (M6 x 20, 22 pieces) 7. Bolt (M10) ................................... 40 Nm (30 lb-ft)
...................................... 9 ~ 11 Nm (80 ~ 97 lb-in) 8. Oil pan

AFFECTED VIN
1B-31

1. Remove the drain plug and drain the oil completely.
2. Unscrew the bolts and remove the oil pan and gasket.
Notice
Arrange the bolts according to each size.
3. Clean the inside of oil pan and sealing surface, then apply
the sealant.
5. Install the oil pan with gasket, and tighten each bolt in
specified torque.
6. Check for oil leaks while running the engine. M8 X 40, 4 pieces
M6 X 85, 3 pieces
M6 X 35, 3 pieces
M6 X 22, 6 pieces
Others M6 X 20, 28 pieces

AFFECTED VIN
1B-32
TIMING GEAR CASE COVER

Preceding Work: Removal of cylinder head front cover
Removal of generator bracket
Removal of tensioning device
Removal of belt pulley and vibration damper
1. Bolt (M8 x 60, 3 pieces) 5. Bolt (M8 x 60, 1 piece)

....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft) ....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
2. A/C bracket 6. Seal
3. Bolt (M8 x 65, 3 pieces) 7. Timing gear case cover
....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft) 8. Roll pin
4. Bolt (M8 x 40, 1 piece) 9. Bolt (M6 x 22, 6 pieces)
....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft) ...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)

AFFECTED VIN
1B-33

1. Put the alignment marks (arrows) on the timing chain
and camshaft sprocket.
2. Unscrew the A/C bracket bolts (1) and remove the
bracket.
Installation Notice
22.5 ~ 27.5 Nm
Tightening torque
(16.6 ~ 20.3 lb-ft)
3. Remove the cooling fan and the viscous clutch. Unscrew

the three bolts from the cooling fan bracket and remove
the bracket.
Installation Notice
22.5 ~ 27.5 Nm
Tightening torque
(16.6 ~ 20.3 lb-ft)
4. Remove the timing gear case cover after unscrewing the

bolts (3) and (4) from the timing gear case cover and the
bolt (9) from the oil pan.
Notice
Be careful not to damage the oil pan gasket.
Installation Notice
22.5 ~ 27.5 Nm
Bolt (3, 4)
(16.6 ~ 20.3 Ib-ft)
Tightening torque
9 ~ 11 Nm
Bolt (9)
(80 ~ 97 Ib-ft)
• Apply the sealant after cleaning the timing gear case

cover surface.
• Be careful not to stain the oil chamber of chain
tensioner with the sealant.

reverse order.
6. Warm up the engine and check for oil leaks.

AFFECTED VIN
1B-34
CRANKSHAFT SEALING REAR COVER

Preceding Work: Removal of the automatic transmission drive plate
1. Bolt (M6 x 20, 6 pieces) 4. Sleeve

2. Radial shaft seal ...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
3. Rear cover 6. Washer

AFFECTED VIN
1B-35
Tools Required
W9911 0020B (601 589 03 43 00) Crankshaft Rear Seal Installer

1. Unscrew the bolts (1) and (5) and remove the closing
cover by pulling the rear cover lug (arrows).
Notice
Be careful not to damage the oil pan gasket.
2. Clean the sealing surface of the crankcase and the rear

sealing cover.
3. Check the radial shaft seal and replace it if necessary.
4. Apply the Loctite 573 to the rear cover sealing surface.
5. Apply the engine oil to the dust lip of the radial shaft
seal.
Notice
Do not use the grease.
6. Install the crankshaft rear radial seal and the crankshaft

sealing rear cover, using crankshaft rear seal installer
W9911 0020B (601 589 03 43 00).
7. Install the crankshaft sealing rear cover mounting bolts

and remove the crankshaft rear seal installer W9911
0020B (601 589 03 43 00).
Installation Notice
9 ~ 11 Nm
Tightening torque
(80 ~ 97 lb-in)

AFFECTED VIN
1B-36
CRANKSHAFT ASSEMBLY
BELT PULLEY AND VIBRATION DAMPER
Preceding Work: Removal of cooling fan and viscous clutch
Removal of fan shroud
Removal of drive belt
1. Center bolt (M18 x 50) 4. Vibration damper assembly

............. 1st step: 80 ~ 220 Nm (133 ~ 162 lb-ft) 5. Woodruff key
2nd step: 90° + 10° 6. Bolt (M6 x 12, 4 pieces)
2. Vibration damper disk ...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
3. Bolt (M6 x 20, 6 pieces) 7. Cooling fan pulley
........................... 7.7 ~ 9.5 Nm (68.1 ~ 84.1 lb-in)

AFFECTED VIN
1B-37
Components
1. Center bolt (M18 x 50) 7. Crankshaft sprocket (camshaft driven)

2. Vibration damper disk 8. Crankshaft sprocket (oil pump driven)
3. Vibration damper and pulley assembly 9. Crankshaft
4. Woodruff key 10. Oil pan
5. Crankshaft front seal 11. Oil pan gasket
6. Timing gear case cover 12. Oil pan mounting bolt (M6 x 22)
Service Data Standard

Radial Runout 0.6 mm
Permissble Deviation of The Vibration Damper
Axial Runout 0.6 mm

AFFECTED VIN
1B-38
Tools Required
A9910 0150B (602 589 00 40 00) Engine Lock

1. Adjust the piston of number 1 cylinder to the TDC.
2. Remove the start motor and install the engine lock A9910
0150B (602 589 00 40 00) to the flywheel ring gear.
3. Remove the vibration damper center bolt.
Installation Notice
1st step: 180 ~ 220 Nm
2nd step: 90° + 10°
4. Remove the vibration damper assembly using the puller.

reverse order.
Notice
If possible, don’t separate the vibration damper and
the pulley.

AFFECTED VIN
1B-39
CRANKSHAFT FRONT RADIAL SEAL

Preceding Work: Removal of belt pulley and vibration damper
1. Center bolt (M18 x 50) 3. Sleeve (special tool)

.......... 1st step: 180 ~ 220 Nm (133 ~ 162 lb-ft) 4. Crankshaft front seal
2nd step: 90°+10° 5. Key
2. Center bolt washer

AFFECTED VIN
1B-40
Tools Required
A9911 0060B (601 589 03 14 00)
Crankshaft Front Seal Installer
Replacement Procedure
1. Remove the radial seal with a screw driver.
Notice
Use a clean cloth not to damage the radial seal
mounting hole and the crankshaft.
2. Coat the radial sealing lip with engine oil.

3. Using the crankshaft front seal installer A9911 0060B
(601 589 03 14 00), assemble the radial seal.
4. Align the sleeve groove and the woodruff key and tighten
the center bolt until the center bolt and the damper disk
stop in the movement.
Installation Notice
1st step: 180 ~ 220 Nm
2nd step: 90° + 10°
5. Remove the crankshaft front seal installer A9911 0060B

(601 589 03 14 00), and install the belt pulley and the
vibration damper.
6. Check for leaks while operating the engine.

AFFECTED VIN
1B-41
CRANKSHAFT REAR RADIAL SEAL

Preceding Work: Removal of flywheel or drive plate
1. Special tool 3. Crankshaft rear seal

2. Special tool

AFFECTED VIN
1B-42
Tools Required
W9911 0020B (601 589 03 43 00)
Crankshaft Rear Seal Installer
Replacement Proceudre
1. Remove the radial seal with a screw driver.
Notice
Use a clean cloth not to damage the radial seal
mounting hole and the crankshaft.
2. Install the crankshaft rear seal installer W9911 0020B

(601 589 03 43 00) (2) to the crankshaft.
3. Apply the engine oil on the crankshaft rear seal installer
W9911 0020B (601 589 03 43 00) (2).
Notice
Do not use the grease.
4. Install the radial seal on the inner parts assembler.

5. Press in the crankshaft rear seal installer W9911 0020B
(601 589 03 43 00) (1) until the radial seal is stopped.
6. Check for leaks while operating the engine.

AFFECTED VIN
1B-43
CRANKSHAFT
Preceding Work: Removal of engine assembly
Removal of timing gear case cover
Removal of cylinder head
Removal of crankshaft sealing rear cover
Removal of oil pan
Removal of oil pump
Removal of baffle plate
1. Crankshaft bearing cap bolt (M8 x 55, 14 pieces) 3. Crankshaft lower main bearing
................... 1st step: 50 ~ 60 Nm (37 ~ 44 lb-ft) 4. Crankshaft lower thrust bearing
2nd step: 90° + 5° 5. Crankshaft
2. Crankshaft bearing cap

AFFECTED VIN
1B-44
Arrangement of the Thrust Bearing and the Main Bearing
1. Upper main bearing A. Crankcase side

2. Upper thrust bearing B. Bearing cap side (oil pan side)
3. Crankshaft C. Axial fit bearing (number 5 bearing point)
4. Lower main bearing D. Radial bearing
5. Lower thrust bearing
1 - 12 Weight Balance/Color Marking Point

j1 - j7 Journal Main Bearing #1 - #7
• Color Dot Marking
The color dot marking are put on the 1 , 2 , 4 , 6 , 8 , 10 ,

12 and it indicates the diameter of crankshaft journal by
color as below.

AFFECTED VIN
1B-45
Color Dot Marking Crankshaft Journal Diameter (mm)

Blue 57.960 ~ 57.965
Yellow 57.955 ~ 57.960
Red 57.950 ~ 57.955
White 57.945 ~ 57.950
Violet 57.940 ~ 57.945
Selection of Crankshaft Main Bearing

1. Crankcase Side
There are seven punching marks on the mating surface
to oil pan. This mark is correspondent to the bearing
distinguished by color. Select the relevant bearing
according to the punching mark when repaired.
Punching Mark Bearing Color Selected

• Blue
•• Yellow
••• Red
2. Crankshaft Bearing Cap Side

Select the crankshaft main bearing according to the
marking letter on the crankshaft main journal when
repaired.
Marking Letter Bearing Color Selected

B Blue
Y Yellow
R Red
W White
V Violet
Service Data
Unit: mm
Crankshaft Crankshaft Connecting Rod Connecting Rod

Crankshaft Standard Thrust Washer
Bearing Journal Journal Width Bearing Journal Bearing Jourmal
and Repair Size Thickness
Diameter at fit bearing Diameter Width
Standard size 57.950 ~ 57.965 2.15 or 2.20 24.50 ~ 24.533 47.94 ~ 47.96 27.958 ~ 28.042
1st repair size 57.700 ~ 57.715 47.75
2.25 or
2nd repair size 57.450 ~ 57.465 - 47.50 -
2.35 or
3rd repair size 57.200 ~ 57.215 47.25
2.40
4th repair size 56.950 ~ 56.965 47.00

AFFECTED VIN
1B-46

1. Unscrew the connecting rod bearing cap bolt and remove
the bearing cap.
Installation Notice
1st step: 40 + 5 Nm
Tightening torque (30 + 3.7 lb-ft)
2nd step: 90° + 10°
• Make sure that the upper and lower bearing shells do

not change each other.
• Coat the bearing shell with engine oil.
• Install the bearing cap according to the consecutive
number.
2. Unscrew the crankshaft bearing cap bolts and separate

the upper and lower bearing shells and thrust washers.
Installation Notice
2nd step: 90°
• Remove the bearing cap from front (pulley side) to rear.

• Make sure that the upper and lower bearing shells do
not change each other and coat with engine oil.
Part No. : 601 030 00 62 2.15 mm
• The oil grooves (arrows) in the thrust washers must face
Part No. : 601 030 01 62 2.20 mm outward and insert the thrust bearing into the bearing
Part No. : 601 030 02 62 2.25 mm cap.
Part No. : 601 030 03 62 2.30 mm • There are five kinds of thrust washers by thickness.
Part No. : 601 030 04 62 2.40 mm Select the proper washer when repaired.
3. Remove the crankshaft.
reverse order.
5. After completion of the installation, check for the rotating
condition of the crankshaft.
Notice
• Make sure the crankshaft bearing cap properly
seated in place in the crankcase side. When perfectly
installed, the projected part (arrow) locates in the
left side (intake manifold side).
• Assemble so that the projected part of the cap and
crankcase face the same direction.

AFFECTED VIN
1B-47
Inspection
1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds
63.8 mm, replace it.
2. Make sure the crankshaft bearing cap is properly seated

on the cylinder block (arrows).
3. Measure and record the inner diameter of the crankshaft

bearing.
Notice
• Measure at 2 points (1, 2).
• Measure ‘A’,‘B’and ‘C’ as shown. If average value
of ‘B’ and ‘C’is less than value ‘A’, then the average
value of ‘B’ and ‘C’ is actual average value. If average
value of ‘B’ and ‘C’ is more than value ‘A’, then the
value ‘A’ is actual average value.
4. Measure and record the diameter of the crankshaft

bearing journal.
Notice
• Record the mean value when measured at 3 points
(A, B, C).
• Measure the inner diameter of bearing and the
diameter of journal and if it is out of the standard
data, replace the bearing shell.

AFFECTED VIN
1B-48

(Crankshaft Main Bearing Gap)
Item Measuring Position Gap (mm)
Static condition: 0.015 ~ 0.039
Main Bearing Journal Radial Dynamic condition: 0.031 ~ 0.051
(NO. 1, 5, 7) (Consider the expansion 0.011 ~ 0.016)
Axial 0.010 ~ 0.254
Static condition: 0.011 ~ 0.039
Main Bearing Journal Radial Dynamic condition: 0.031 ~ 0.051
(NO. 3, 4, 6) (Consider the expansion 0.015 ~ 0.022)
Axial 0.010 ~ 0.254
(Connecting Rod Bearing Gap)

Item Measuring Position Gap (mm)
Connecting Rod Bearing Radial 0.030 ~ 0.050

AFFECTED VIN
1B-49
CONNECTING ROD
Preceding Work: Removal of piston
1. Connecting rod bushing 5. Fit sleeve

2. Oil gallery 6. Upper connecting rod bearing
3. Balance weight 7. Lower connecting rod bearing
4. Connecting rod bolt (M9 x 52, 12 pieces) 8. Bearing shell lug
...................... 1st step 40 + 5 Nm (30 + 3.7 lb-ft) 9. Marking [Indication ( ) or numbers]
2nd step 90° + 10°

Distance (L) from the connecting rod bearing bore center to the bushing bore center 145 ± 0.05 mm
Width of the connecting rod (B) at bearing bore 21.940 ~ 22.000 mm
Width of the connecting rod (b) at bushing bore 21.940 ~ 22.000 mm
Basic bore at the bearing shell (D1) 51.600 ~ 51.614 mm
Basic bore at the bushing (d1) 24.500 ~ 24.571 mm
Bushing inner diameter (d) 22.007 ~ 22.013 mm
Clearance between the piston pin and the bushing 0.007 ~ 0.018 mm
Peak-to-valley height of connecting rod bushing on inside 0.005 mm
Permissible twist of connecting rod bearing bore to connecting rod bushing bore 0.15 mm
Permissible deviation of axial paralleism of connecting rod bearing bore to connecting rod 0.07 mm
bushing core
Permissible deviation of connecting rod bearing bore from concentricity 0.01 mm
Permissible difference of each connecting rod in weight 0.4 g

AFFECTED VIN
1B-50
Inspection
1. Measure the basic bore of the connecting rod bearing.
Notice
If the basic bore exceeds the value of 51.614 mm,
replace the bearing or check the connecting rod.
2. Check connecting rod bolts.
Length when new (L) 51.7 ~ 52 mm

Max. Length (L) 52.9 mm
Tightening torque 1st step: 40 + 5 Nm
(30 + 3.7 lb-ft)
2nd step: 90° + 10°
Notice
If the length exceeds max. length, replace it.
3. Check the assembly mark (indication//or number: arrow)

of the connecting rods and the bearing cap when
installing.
Notice
• Make sure it doesn’t exceed over 4g with other
connecting rods when replacing the connecting
rods.
• Check if the connecting rod and the bearing cap
are accurately seated on the groove when replacing
the bearing.

AFFECTED VIN
1B-51
PISTON
Preceding Work: Removal of engine
Removal of cylinder head
Removal of oil pan
Removal of oil pump
Removal of baffle plate
1. Connecting rod bearing cap 4. Piston

2. Connecting rod 5. Snap ring
3. Connecting rod bearing cap bolt 6. Piston pin
(M9 x 52, 12 pieces)
...................... 1st step: 40 + 5 Nm (30 + 3.7 lb-ft)
2nd step: 90° + 10°

AFFECTED VIN
1B-54
PISTON RING
Preceding Work: Removal of piston
1. Piston compression ring 4. Coil spring and control ring

2. Piston compression ring 5. Hook spring
3. Piston oil ring

AFFECTED VIN
1B-55
1. Measure the piston ring’s gap.
Groove 1 0.20 ~ 0.40 mm
End Gap of the
Groove 2 0.20 ~ 0.40 mm
Piston Ring
Groove 3 0.20 ~ 0.45 mm
Gap between the Groove 1 0.015 ~ 0.050 mm
Piston and the Groove 2 0.020 ~ 0.040 mm
Piston Ring Groove 3 0.010 ~ 0.045 mm
Notice
If out of specification, replace the piston ring.
2. Remove the piston ring with a pliers.
3. For installation, position the piston ring to be the ‘TOP’

mark on the piston ring upward and arrange the piston
ring ends to be 120° apart.
4. Adjust the hook spring joint in the oil ring 180° away
from the ring end.

AFFECTED VIN
1B-56
FLYWHEEL/DRIVEN PLATE
Preceding Work: Removal of manual or automatic transmission
1. Flywheel mounting bolt (M10 x 22, 8 pieces) 3. Driven plate (A/T)

..................... 1st step: 45 + 5 Nm (33 + 3.7 lb-ft) 4. Dowel pin
2nd step: 90° + 10°
2. Plate
Service Data Standard (Stretch Bolt)

Nominal size D - M x 1.5
Stretch side diameter d When new 8.5 ~ 0.2 mm
Min. diameter 8.0 mm
Bolt length L When new 21.8 ~ 22.2 mm
Tightening torque 1st step: 45 + 5 Nm (33 + 3.7 lb-ft),
2nd step: 90° + 10°

AFFECTED VIN
1B-57

1. Unscrew the driven plate mounting bolt.
Installation Notice
1st step: 40 + 5 Nm
Tightening torque (30 + 3.7 lb-ft)
2nd step: 90° + 10°
• Replace the bolt when the stretch side diameter (d)

of the driven plate mounting bolt is less than 8.0 mm.
• For the stretch bolt tightening, keep the socket
wrench and Tommy-bar to be 90° and tighten as
specified.
2. Remove the driven plate (3), and plate (2) for automatic
transmission vehicle.
reverse order.

AFFECTED VIN
1B-58
Sectional View
1. Oil pan 8. Washer

2. Cover 9. Bolt
3. Crankshaft front seal 10. Front drive plate
4. Flywheel mounting bolt 11. Rear drive plate
5. Crankshaft 12. Rivet
6. Dowel pin 13. Segment
7. Washer (thickness = 3.5 mm) 14. Ring gear

AFFECTED VIN
1B-64
CAMSHAFT SPROCKET BOLT

Intake Flange Shaft Bolt
Installation Notice
Tightening Torque (13 ~ 16 lb-ft)
2nd step: 90° ± 5°
The sprocket bolts are designed to be used only once, so

always replace with new one.
C. M7 x 13 Collar Bolt Torx-T30

e. 6.8 mm
16. Flange shaft
18. Control piston
22. Intake camshaft
Exhaust Camshaft Sprocket Bolt

Installation Notice
2nd step: 90° ± 5°
The sprocket bolts are designed to be used only once, so

always replace with new one.
E. M7 x 13 Collar Bolt Torx-T30

e. 6.8 mm
13a. Camshaft sprocket
22a. Exhaust camshaft
CHANGED BY FUEL SYSTEM

AFFECTED VIN
1B-65
CAMSHAFT
Removal of coolant connection fitting
1. Chain tensioner assembly 4. Cylinder head front cover

.................................... 72 ~ 88 Nm (53 ~ 65 lb-ft) 5. Intake camshaft sprocket
2. Exhaust camshaft sprocket 6. Chain
3. Upper guide rail 7. Wrench
FUEL SYSTEM CHANGED BY

M162 GSLENG SM - 2005.7 EFFECTIVE DATE
AFFECTED VIN
1B-66
Tools Required
A9917 0012B (DW 110-120) Holding Pin
Removal Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston
at BTDC 30°.
2. Remove the Alternator.
3. Remove the chain tensioner. Refer to “Chain Tensioner”
in this section.
4. Remove the cylinder head front cover and the upper guide
rail.
5. Put the alignment marks (arrows) on the camshaft

sprocket (2, 5) and the timing chain (6).
6. Unscrew the exhaust camshaft sprocket bolt and remove

the sprocket.
7. Separate the chain from the intake camshaft sprocket
and put the chain not to be dropped into timing case.

AFFECTED VIN
1B-67
8. Unscrew the intake side bolts (8, 11, 13, 14) and the
exhaust side bolts (1, 4, 6, 7).
9. Loosen the remaining bolts and unscrew the intake and
exhaust side camshaft bearing cap bolts.
Notice
Number the camshaft bearing cap bolts when
removing them, so that they don’t get mixed up.
10. Remove the intake and exhaust camshafts.
Installation Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston
at BTDC 30°.
Notice
Turn the crankshaft in the direction of engine rotation.
2. Install the exhaust camshaft bearing caps (2, 3, 5) and

the intake camshaft bearing caps (9, 10, 12). Tighten
the bolts with specified torque and install the remaining
bearing caps.
Installation Notice
22.5 ~ 27.5 Nm
Tightening torque
(16.6 ~ 20.3 lb-ft)
Install the bearing caps according to the numbers on the

bearing caps.
3. Turn the camshaft using the wrench so that the intake

camshaft adjustment hole lines up with the cylinder head
upper side (3 o’clock direction at the intake, 9 o’clock
direction at the exhaust).
Notice
Turn the crankshaft and adjust it to OT so that No. 1
cylinder’s piston would be at TDC.

AFFECTED VIN
1B-68
4. Align the holes on intake and exhaust camshaft to the

hole on cylinder head. Insert the holding pin A9917 0012B
(DW 110-120) into the holes.
5. Turn the intake camshaft adjuster to the direction of

camshaft rotation by hard until it stops and then install
the chain.
Notice
• Make sure that the camshaft sprocket and timing
chain are aligned with marks.
• Intake camshaft adjuster should be in retarded
position.
6. Install the chain on the exhaust sprocket and tighten the

sprocket bolts.
Installation Notice
2nd step: 90° ± 5°
• Make sure that the camshaft sprocket and timing

chain are aligned with marks.
• Replace the sprocket bolt with new one.
7. Install the chain tensioner screw plug (1) and chain

tensioner assembly (2) and tighten it as specified.
Installation Notice
(1) : 40 Nm (30 lb-ft)
Tightening torque (2) : 72 ~ 88 Nm
(53 ~ 65 lb-ft)

AFFECTED VIN
1B-69
8. Rotate the crankshaft 2 revolutions and check followings:

- TDC of no. 1 cylinder: OT
- Alignment between camshaft adjustment hole and
cylinder head surface.
- Alignments between timing chain and sprocket
marks.
Notice
• Turn the crankshaft in the direction of engine
rotation.
• Read just if not aligned.
9. Install the upper guide rail and cylinder head front cover.
10. Install the Alternator.

AFFECTED VIN
1B-70
CAMSHAFT TIMING POSITION

1. Chain tensioner assembly 4. Cylinder head front cover

2. Exhaust camshaft sprocket 5. Wrench
3. Upper guide rail 6. Holding pin A9917 0012B (DW 110-120)

AFFECTED VIN
1B-71
Tools Required
A9917 0012B (DW 110-120) Holding Pin
Inspection
1. Position the No.1 cylinder piston to TDC (OT) by turning
the crankshaft.
Notice
When the OT mark on vibration damper is aligned
with timing gear case cover, the intake and exhaust
cam of cylinder will make the slope to the center and
will face up. In this way, the adjustment hole of the
intake and exhaust camshaft will match in line with
the cylinder head upper end, at 3 o’clock, and 9
o’clock direction each other.
2. Check the timing as below procedure;

- Check if the camshaft adjustment hole is positioned
to 3 o’clock direction at the intake side and to 9
o’clock direction at the exhaust side, respectively
and align with the cylinder head mating surface.
- At this condition, check if the OT mark on vibration
damper aligns with the marker on the timing gear
case.
Adjustment Procedure
1. Position the No.1 cylinder to BTDC 30°.
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. Align the intake and exhaust camshaft flange hole with
the cylinder head upper surface.
• Intake Side: 3 o’clock direction
• Exhaust Side: 9 o’clock direction
5. Align the holes on intake and exhaust camshaft to the
hole on cylinder head. Insert the holding pin A9917 0012B
(DW 110-120) into the hole.
6. Secure the intake and exhaust camshaft.
7. Position the piston of No.1 cylinder at TDC (OT) by
turning the crankshaft.
8. Turn the camshaft adjuster of the intake camshaft to the
left as much as possible (cam adjuster ‘retarded’
position).
9. Install the chain to the intake camshaft sprocket.
Notice
Timing chain must be placed on the guide rail in
gear case cover.

AFFECTED VIN
1B-72
10. Install the chain to the exhaust camshaft sprocket and

install it to the camshaft.
Installation Notice
2nd step: 90° ± 5°
The sprocket bolt is designed to be used only once, so

replace with new one.
11. Install the chain tensioner.

Installation Notice
Screw plug 40 Nm (30 lb-ft)
Tightening torque Tensioner 72 ~ 88 Nm
assembly (53 ~ 65 lb-ft)
12. Check the camshaft timing.

AFFECTED VIN
1B-73
VALVE SPRING
Preceding Work: Removal of camshaft
Removal of spark plug
1. Valve cotter 6. Connecting hose .... A9911 0012B (DW 110-090)

2. Upper retainer 7. Thrust piece ........... A9917 0121B (111 589 25 63 00)
3. Valve spring ............. Check, replace if necessary 8. Lever pusher ........... A9917 0111B (111 589 18 61 00)
4. Valve stem seal 9. Supporting bar ........ A9917 0101B (111 589 01 59 00)
5. Lower retainer

AFFECTED VIN
1B-74
Tools Required
A9917 0101B (111 589 01 59 00) Supporting Bar
A9917 0111B (111 589 18 61 00) Lever Pusher
A9917 0121B (111 589 25 63 00) Thrust Piece
A9910 0150B (602 589 00 40 00) Engine Lock
A9911 0012B (DW 110-090) Connecting Hose

1. Place the supporting bar A9917 0101B (111 589 01 59
00) (12) at the camshaft bearing cap and tighten them
with the bearing cap bolt.
Installation Notice
22.5 ~ 27.5 Nm
Tightening torque
(16.6 ~ 20.3 lb-ft)
2. Turn the crankshaft to position the each cylinder piston

at TDC.
Mark on The Vibration Damper Cylinder

OT 1, 6
120° 2, 5
240° 3, 4
Notice
• Remove the valve spring only at TDC.
• Always rotate the crankshaft by holding the chain
to prevent from timing chain damage and tangling,
and for smooth rotation.
3. Remove the valve tappet (1) using the valve tappet remover.
4. Install the connecting hose A9911 0012B (DW 110-090)
to the spark plug hole.

AFFECTED VIN
1B-75
5. Install the engine lock to the ring gear to prevent the

crankshaft from rotating.
6. Blow up with compressed air.
7. Install the lever pusher A9917 0111B (111 589 18 61 00)

(8) and the thrust piece 111 589 25 63 00 (7).
8. Mount the thrust piece A9917 0121B (111 589 25 03 00)
(7) vertically to the valve spring retainer (2).
9. Press the valve spring (3) by using the lever pusher A9917
0111B (111 589 18 61 00) (8).
10. Remove the valve cotter (1) using the pincette.
11. Remove the upper retainer (2) and the valve spring (3).
12. Remove the valve stem seal (4).

Notice
Check the valve stem seal for damage and replace if
necessary.
13. Remove the lower retainer (5).

Notice
Check the retainer for damages and replace with a
new one if necessary.

reverse order.

AFFECTED VIN
1B-76
Test (Upper and Lower Valve

Tappet and Valve Cotter)
• Upper Valve Spring Retainer
(d) 8.5
Size (mm)
(D) 12.3
• Lower Valve Spring Retainer
Thickness (mm) (a) 0.8 ~ 1.0
• Valve Cotter
(B) 9.0
Size (mm)
(H) 9.2 ~ 9.8

AFFECTED VIN
1B-77
VALVE STEM SEAL

Preceding Work: Removal of valve spring
1. Drift A9917 0171B (119 589 00 43 00) 3. Protective sleeve

2. Valve stem seal
Tools Required
A9917 0171B (119 589 00 43 00) Drift
1. Remove the valve stem seal (2) using the pliers.
Notice
Check the valve stem seal for damage and replace if
necessary.
2. Coat the valve stem seal with oil and assemble it with
the protective sleeve.
3. Insert the valve stem seal by pressing it with the drift
A9917 0171B (119 589 00 43 00).

AFFECTED VIN
1B-78
CHAIN TENSIONER
1. Screw plug .................................. 40 Nm (30 lb-ft) 6. Thrust pin

2. Seal 7. Chain tensioner housing
3. Filler pin .................................... 72 ~ 88 Nm (53 ~ 65 lb-ft)
4. Compression spring 8. Seal
5. Snap ring

AFFECTED VIN
1B-79
Removal Procedure
1. Position the No.1 cylinder to TDC (OT).
Notice
Remove the oil filler cap at adjustment position, and
check whether the intake camshaft cam’s lobe (arrow)
stays in the upper side.
2. Cover the generator with a clean cloth.

3. Release the tension by unscrewing the screw plug once.
Notice
In case that the tension is reduced by unscrewing the
screw plug, reinstall after completely removing the
chain tensioner. If the chain tensioner is tightened
again without completely reducing its tension, then
the detent spring doesn’t return to the original
position and the tension gets exceeded.
4. Carefully unscrew the screw plug (1), and remove the

seal (2).
Notice
• For the removal of screw plug, be careful that it
can be jumped out due to the force of compression
spring.
• Remove the screw plug only when the seal and
compression spring are damaged.
5. Carefully remove the filler pin (3), compression spring

(4), snap ring (5), and the thrust pin (6).
6. Remove the chain tensioner housing (7) and the seal (8).

AFFECTED VIN
1B-80
Installation Procedure
1. Connect the thrust pin (6) and the snap ring (5) to the
chain tensioner housing (7).
Notice
When connecting the thrust pin, push in the thrust
pin far enough so that it doesn’t protrude at the chain
tensioner housing.
2. Install the chain tensioner housing (7), thrust pin (6), snap
ring (5), and the seal (8).
Installation Notice
72 ~ 88 Nm
Tightening torque
(53 ~ 65 lb-ft)
3. Insert the compression spring (4) with the filler pin (3)
into chain tensioner housing.
4. Lightly apply the grease to the seal (2) and install the
screw plug (1).
Installation Notice
Specified value 40 Nm (30 lb-ft)
5. Check for leaks by operating the engine.

AFFECTED VIN
1B-81
Sectional View
1. Screw plug 13. Chain tensioner housing

2. Ball (nonreturn valve) 14. Seal
3. Compression spring 15. Timing gear case cover
4. Ball guide 16. Cylinder head
5. Seal (aluminum) 17. Bolt/Washer
6. Filler pin 18. Tensioning rail
7. Compression spring 19. Cylinder head gasket
8. Snap ring 20. Timing chain
9. Thrust pin 21. Tensioning rail base (sliding surface)
10. Ball (nonreturn valve)
11. Compression spring A. Oil supply hole
12. Thrust piece B. Chain tensioner oil storage hole

AFFECTED VIN
1B-82
TIMING CHAIN
Removal of spark plug
1. Pin 5. Link
2. New timing chain 6. Center plate
3. Timing chain (used) 7. Outer plate
4. Wedge

AFFECTED VIN
1B-83
Tools Required
A9913 0010B (000 589 58 43 00) Chain Assembly
A9917 0012B (DW 110-120) Holding Pin
1. Position the No.1 cylinder to TDC (OT).
2. Insert the holding pin A9917 0012B (DW 110-120) to the

intake and exhaust camshaft flange not to rotate
camshaft.
4. Mount the wedges to both sides of the camshaft sprocket

as shown in the figure.
5. Cover the chain housing with a clean cloth, and grind off
the timing chain pin from the intake camshaft sprocket
with the grinder.

AFFECTED VIN
1B-84
6. Remove the outer plate (7) with the screw driver and
remove the link.
7. Connect the new timing chain (2) to the used timing chain
(3) with the link (5), center plate (6, thickness 1.6 mm),
and the outer plate (7).
8. Rotate the crankshaft in the direction if engine revolution
by pressing the new timing chain against the exhaust
camshaft sprocket to prevent it to be tangled.
Notice
Be sure to remove the wedge before cranking the
engine.
9. Take out the used timing chain out from the chain housing.
10. Connect both separators of the new timing chain with
the link (5) and the center plate (6).
11. Install the jaw (a) and the thrust piece (b) to the assembly
tool as shown in the figures.

AFFECTED VIN
1B-85
12. Place the outer plate (7, thickness 1.2 mm) inside the
thrust piece (b).
13. Install the chain assembly A9913 0010B (000 589 58 43

00) above the link and tighten the spindle (c) until a block
is felt.
14. Place the chain assembly A9913 0010B (000 589 58 43
00).
15. Replace the thrust piece (b) as shown in the figure.
16. Install the chain assembly A9913 0010B (000 589 58 43

00) to the link pin and tighten the spindle (c).
Installation Notice

AFFECTED VIN
1B-86
17. Rivet the link pin.

Check the condition and it again if necessary.
Installation Notice
Screw plug 40 Nm (30 lb-ft)
assembly (53 ~ 65 lb-ft)
19. Check the camshaft timing position.

AFFECTED VIN
1B-87
TENSIONING RAIL
Preceding Work: Removal of timing gear case cover
1. Tensioning rail 3. Tensioning rail pin

2. Plastic guide 4. Guide rail

1. Put the assembly mark at the camshaft sprocket and
the timing chain with the paint (arrow).
3. Remove the tensioning rail (1) from the tensioning rail
pin (3).
Notice
• Replace the plastic guide (2) if it is damaged.
• For installation, exactly align the plastic guide (2)
with the tensioning rail (1).

reverse order.

AFFECTED VIN
1B-88
CYLINDER HEAD GUIDE RAIL

1. Chain tensioner 3. Upper guide rail pin

2. Upper guide rail 4. Wrench (special tool)

1. Remove the chain tensioner (1).
2. Turn the exhaust camshaft to the camshaft rotating
direction using the wrench (4) and loosen the timing chain
at upper guide rail (2).
3. Pull out the upper guide rail pin from the guide rail (2).
4. Turn the exhaust camshaft to the opposite direction of
rotation using the wrench.
5. Check for damages at the upper sliding rail and replace
it if necessary. Install the upper guide rail pin.
Installation Notice
Screw Plug 40 Nm (30 lb-ft)
Assembly (53 ~ 65 lb-ft)

AFFECTED VIN
1B-89
CRANKCASE GUIDE RAIL

1. Guide rail 3. Guide rail pin

2. Plastic guide 4. Tensioning rail

1. Put the assembly mark at the camshaft sprocket and
the timing chain with the paint (arrow).
3. Remove the guide rail (1) from the guide rail pin (3).
Notice
• Replace the plastic guide (2) if damaged.
• Connect the plastic guide (2) and the guide rail (1)
by aligning them accurately when installing.

reverse order.

AFFECTED VIN
1B-90
CRANKSHAFT SPROCKET
Preceding Work: Removal of oil pan
Removal of tensioning rail
Removal of crankcase guide rail
1. Oil pump chain tensioner 6. Bolt (M8 x 20, 1 piece) / Washer

2. Oil pump chain bushing .................................... 29 ~ 35 Nm (21 ~ 26 lb-ft)
3. Oil pump chain spring 7. Oil pump sprocket
4. Crankshaft sprocket 8. Oil pump
5. Key 9. Oil pump roller chain
10. Timing chain

AFFECTED VIN
1B-91
Tools Required
W9911 0050B (615 589 01 33 00) Crankshaft Sprocker Puller

1. Put the assembly mark at the crankshaft sprocket (4)
and the timing chain (10) with the paint (arrow).
Notice
Align the assembly marks on cranshaft sprocket and
timing chain. Also, align the assembly marks on
camshaft sprocket and timing chain when installing.
2. Unscrew the bolt (6) and remove the oil pump sprocket
(7) from the oil pump.
Installation Notice
29 ~ 35 Nm
Tightening torque
(21 ~ 26 lb-ft)
3. Remove the oil pump roller chain (9).

4. Remove the oil pump chain tensioner (1), oil pump chain
bushing (2), and the oil pump chain spring (3).
5. Remove the crankshaft sprocket (4) using the crankshaft

sprocket puller W9911 0050B (615 589 01 33 00).
Notice
• Make sure not to lose the crankshaft pulley key (5)
when removing.
• Install the crankshaft sprocket (4) after warming it
up.

reverse order.

AFFECTED VIN
1B-92
LUBRICATION SYSTEM
ENGINE OIL SPECIFICATION
1. Drain plug .................................... 25 Nm (18 lb-ft) 3. Engine oil filler cap

2. Oil filter 4. Dipstick gauge
Specifications
Application Descrition
Capacity Min: 7.0L, Max: 9.0L
Quality • API SH or above grade
• ACEA: A2 or A3
• Approved oil by MB Sheet 229.1
Viscosity • Approved oil by MB Sheet 224.1
Replacemant • Initial at 1000 ~ 1500 km, Replace every 15000 km

AFFECTED VIN
1B-93
REPLACEMENT
1. Install the socket wrench A9910 0050A (103 589 02 09
00) on the oil filter cover (2).
Notice
Tighten the bolts on the socket wrench to remove
the screw cover.
2. Set a wrench on the bolt on the top of socket wrench

and turn it to remove the oil filter cover.
3. Remove the oil filter element.
Notice
Wrap the used filter element with a shop cloth so
that the oil cannot drop on the floor.
4. Remove the drain plug (1) and drain the engine oil
completely.
Notice
To drain the oil easily, remove the oil filler cap (3).
5. Clean the drain plug and reinstall it.

Installation
Tightening torque 25 Nm
Notice
Replace the seal washer with new one.
6. Replace the O-ring (5) on the oil filter cover with new
one.
Notice
When replacing, apply the engine oil on the O-ring.
7. Insert new oil filter element into the oil filter housing.
8. Temporarily tighten the oil filter cover (2) by hands and
then tighten it with the socket wrench A9910 0050A
(103 589 02 09 00).
Installation
9. Pour the engine oil through the engine oil filler hole.
10. Run the engine and check for oil leakage at normal
operating temperature.
11. Stop the engine and wait for 5 minutes. Check the oil
level and add if necessary.

AFFECTED VIN
1B-94
OIL CIRCULATION
1. Oil pump 19. Oil supply (to intake camshaft)

2. Oil gallery (to oil filter) 20. Oil supply (to exhaust camshaft bearing)
3. Oil filter 21. Oil supply (to intake camshaft bearing)
4. Oil pressure switch 22. Oil gallery (oil supply to exhaust valve tappet)
5. Main oil gallery 23. Oil gallery (oil supply to intake valve tappet)
6. Cylinder head closing cover 24. Camshaft closing cover
7. Oil gallery (at chain tensioner) 25. Ball (φ 8 mm)
8. Oil non-return valve 26. Screw plug
9. Chain tensioner 27. Camshaft adjuster
10. Vent (chain tensioner) 28. Front closing cover (intake camshaft)
11. Front closing cover (φ 17 mm) 29. Front treaded bushing (exhaust camshaft)
12. Oil gallery (perpendicular to the shaft) 30. Valve tappet
13. Ball (φ 6 mm)
14. Oil spray nozzle (timing chain) a. Oil gallery (from oil pump to oil filter)
15. Oil gallery (at cylinder head) b. Main oil gallery
16. Ball (φ 15mm) c. Oil return line (oil returns to the oil pan when
17. Oil restriction inner (φ 4mm) replacing the filter element)
18. Oil supply (to exhaust camshaft)

AFFECTED VIN
1B-95
ENGINE OIL AND OIL FILTER ELEMENT

Tools Required
A9910 0050A (103 589 02 09 00) Oil Filter Remover
1. Install the oil filter remover A9910 0050A (103 589 02 09
00) on the oil filter cover.
Notice
Make the screw cover removable by tightening the
bolt at the side of the oil filter remover A9910 0050A
(103 589 02 09 00).
2. Install the wrench to the upper bolt in the oil filter remover
A9910 0050A (103 589 02 09 00) and remove the oil cover
by turning it.
3. Remove the oil filter element.
Notice
Work with a cloth under the vehicle when removing
the oil filter element to not drain the oil.
4. Remove the drain plug (1) and drain the engine oil.
Notice
Leave the oil filler cap open to ease the engine oil
discharge.
5. Tighten the engine oil drain plug after cleaning it.

Installation Notice
Replace the seal washer with new one.
6. Replace the O-ring in the oil filter cover with new one.
Notice
Apply the engine oil to the O-ring.
7. Insert new oil filter element into the oil filter housing.
8. Temporarily tighten the oil filter cover. Install the oil filter
remover A9910 0050A (103 589 02 09 00), and then
completely tighten it.
Installation Notice

AFFECTED VIN
1B-96
9. Fill up engine oil through the engine oil filler opening (3).
10. Check for oil leaks at normal engine temperature after
starting the engine.
11. Stop the engine and wait 5 minutes.
Check the oil level and fill up as specified if necessary.

AFFECTED VIN
1B-97
OIL FILTER
Preceding Work: Removal of starter motor
Removal of upper intake manifold
1. Coolant line 5. Bolt ................ 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)

2. O-ring ........................................................ Replace 6. Oil filter
3. Clip 7. Gasket ...................................................... Replace
4. Hose

AFFECTED VIN
1B-98

1. Drain the coolant from the crankcase.
2. Remove the each coolant line and hose.
3. Remove the oil filter bolt and then remove the oil filter.
Installation Notice
22.5 ~ 27.5 Nm
Tightening torque
(16.6 ~ 20.3 lb-ft)
Replace the oil filter gasket.

reverse order.
5. Check engine oil level.
6. Run the engine at idle and check the engine for leaks.

AFFECTED VIN
1B-99
OIL PUMP
1. Bolt (M8 x 20, 1 piece) 3. Bolt (M8 x 35, 3 pieces)

.................................... 29 ~ 35 Nm (21 ~ 26 lb-ft) ....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
2. Sprocket (Oil pump drive) 4. Spring pin
5. Oil pump

1. Remove the bolt (1) from the oil pump drive sprocket (2)
and separate the gear and the oil pump drive chain.
Installation Notice
29 ~ 35 Nm
Tightening torque
(21 ~ 26 lb-ft)
2. Unscrew the oil pump mounting bolts (3).

Installation Notice
22.5 ~ 27.5 Nm
Tightening torque
(16.6 ~ 20.3 lb-ft)
Tighten the baffle plate and the oil pump with the two
bolts in right side first, and then tighten the other bolt.
3. Remove the oil pump and oil strainer assembly.

4. Replace the strainer in oil pump if necessary.
reverse order.

AFFECTED VIN
1B-100
OIL PRESSURE RELIEF VALVE

1. Screw plug .................................. 50 Nm (37 lb-ft) 3. Guide pin

2. Compression spring 4. Piston

1. Remove the screw plug (1).
Installation Notice
2. Remove the spring (2), guide pin (3) and the piston (4).
reverse order.
Notice
Don’t use the seal for the screw plug.

AFFECTED VIN
1B-101
OIL NON-RETURN VALVE

1. Oil Non-return valve
Functions
The non-return valve prevents the oil in the chain
tensioner from drying up. In other words, it stops
oil-returning in order to prevent the oil in the chain
tensioner from getting dry. As a result, the chain
tensioner can be activated with oil in itself.
1. Remove the non-return valve using a pliers.
2. Insert new non-return valve with hand.

AFFECTED VIN
1B-102
OIL DIPSTICK GUIDE TUBE
1. Oil dipstick level gauge 3. O-ring

2. Oil dipstick guide tube 4. Bolt (M6 x 12, 1 piece) 9 ~ 11 Nm (80 ~ 97 lb-in)

1. Pull out the oil dipstick level gauge (1).
2. Remove the bolt (4) in the upper intake manifold and
remove the oil dipstick guide tube.
Installation Notice
9 ~ 11 Nm
Tightening torque
(80 ~ 97 lb-in)
3. Install new O-ring to the dipstick guide tube.

reverse order.
5. Check for leaks by starting the engine.

AFFECTED VIN
1B-103
UNIT REPAIR
OIL GALLERY IN CRANKCASE
Preceding Work: Removal of crankshaft
Removal of oil spray nozzle
1. Plug 3. Round bar ...................................... φ 11 x 750 mm

2. Steel ball
Cleaning Procedure
1. Remove the plug (1) with a screwdriver.
2. Using a round bar (3) and hammer, remove the steel ball
(2).
3. Using the compressed air, blow into the oil galleries and
clean it off.

AFFECTED VIN
1B-104
1. Plug ........................................................... replace 4. Main oil gallery

2. - 5. Screw plug
3. -
Tools Required
A9911 0050B (102 589 12 15 00) Drift
Sealing Procedure
1. Enlarge the end of main oil gallery (4) to be diameter of
16 mm, depth of 15 mm.
2. Using an M16 x 1.5 thread (tap), make the thread at the
end of main oil gallery (4).
3. Throughly clean the oil gallery with compressed air and
tighten the screw plug (M16 x 1.5) after applying sealing
bond on it.
4. Apply Loctite 270 on new plug and tighten to the hole
until the drift A9911 0050B (102 589 12 15 00) is stopped
after inserting new plug into the drift.

AFFECTED VIN
1B-105
OIL GALLERY IN CYLINDER HEAD

Preceding Work: Removal of cylinder head
Removal of camshaft
Removal of tappet
1. Screw plug ................................... 15 Nm (11 lb-ft) 3. Steel ball (φ 8 mm)

2. Seal
Cleaning Procedure
1. Remove the screw plug (1) and the seal (2).
Installation
Replace the seal with new one.
2. Clean the oil gallery using the compressed air.

AFFECTED VIN
1B-106
Sealing Procedure
1. Remove the screw plug (1) and the seal.
Installation
2. Remove the steel ball from the oil gallery (4), (5), (6) and
(7) using the round bar (12, φ 6 x 700 mm).
3. Remove the plug (8) using the screw driver.
4. Enlarge the oil gallery at the rear of the cylinder head to

be diameter 9mm, depth 8mm.
5. Tap in the steel ball (3) from the side to the oil gallery
using the punch (13).
6. Pull out the steel ball (3) using the round bar (12).
7. Enlarge the oil gallery to be diameter 9mm, depth 8 mm.

AFFECTED VIN
1B-107
8. Make a screw hole at the oil gallery using M10 x 1 thread.

9. All the oil gallery should be cleaned with the compressed air.
10. Apply the Loctite 270 to new plug and press in using a suitable
drift (arrow).
11. Tighten the screw plug with the seal (arrow).

AFFECTED VIN
1B-108
CORE PLUGS IN CRANKCASE

Preceding Work: Draining of the coolant
1. Core plug ................................................... replace

AFFECTED VIN
1B-109
Tools Required
W9911 0010B (102 589 00 15 00) Drift
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side comes
out using the screw driver.
3. Pull out the plug carefully using a pliers.
4. Clean the sealing surface and apply Loctite 241.
5. Press in new plug using a drift W9911 0010B (102 589

00 15 00).
Notice
Wait for about 45 minutes before filling the coolant
so that the Loctite hardens.
6. Warm up the engine and check the coolant for leaks.

AFFECTED VIN
1B-110
CYLINDER BORE
Group Code Letter and Cylinder Bore Size

Group Code Letter of Cylinder Piston Type to be Used Cylinder Bore Size (mm)
A A or X φ 89.900 ~ φ 90.906
X A, X or B φ 89.906 ~ φ 89.912
B X or B φ 89.912 ~ φ 89.918
X+5 X+5 φ 89.950 ~ φ 89.968
X + 10 X + 10 φ 90.000 ~ φ 90.018
Repair Size
Type Group Code Letter1) Cylinder Bore Size (mm)
Standard size φ 89.9 A φ 89.900 ~ φ 90.906
X φ 89.906 ~ φ 89.912
B φ 89.912 ~ φ 89.918
1st repair size A φ 90.150 ~ φ 90.156
(Standard size + 0.25) X φ 89.156 ~ φ 90.162
B φ 90.162 ~ φ 90.168
2nd repair size A φ 90.400 ~ φ 90.406
(Standard size + 0.5) X φ 90.406 ~ φ 90.412
B φ 90.412 ~ φ 90.418
1)
The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.

AFFECTED VIN
1B-111

Wear limit in longitudinal and transverse direction 0.1 mm
Permissible deviation of cylinder out-of-round When new 0.007 mm
Wear limit 0.05 mm
Permissible deviation of rectangular cylinder height (except chamfered area) 0.05 mm
Basic peak-to-valley height after final honing and brushing 0.003 ~ 0.006 mm
Chamfer angle 60°
Honing angle 50° ± 10°
Measurement of Cylinder Bore

1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore size
in axial and transverse direction at three points (1, 2, 3).
1,2,3. Measuring points

A. Axial direction
B. Transverse direction
a. Location of the No.1 piston ring at TDC
b. Location of the piston BDC
c. Location of the oil ring at BDC
Chamfer Angle

AFFECTED VIN
1B-112
CRANKCASE MATING SURFACE

Height of the crankcase “H” (when new) 282.25 ~ 282.35 mm
Minimum height after milling 281.95 mm
Flatness Crankcase upper mating surface 0.03 mm
Crankcase lower mating surface 0.04 mm
Permissible deviation of parallelism of the Axial direction 0.1 mm
upper to lower mating surface Transverse direction 0.05 mm
Peak-to-valley height Crankcase upper mating surface 0.005 ~ 0.020 mm
Crankcase lower mating surface 0.025 mm

AFFECTED VIN
1B-113
Chamfering Procedure
1. Chamfer angle : 60°
2. Polish the lower chamfered area evenly with a grinder

after finishing the chamfering with a suitable tool (e.g.,
hand milling cutter).

AFFECTED VIN
1B-114
CYLINDER HEAD MATING SURFACE

Preceding Work: Removal of valves

Overall height of cylinder head 135.9 ~ 136.0 mm
Minimum height after machining 135.5 mm
Flatness Axial direction 0.08 mm
Transverse direction 0.0 mm
Distance ‘T’ Standard size Intake 24.21 ~ 24.75 mm
(between camshaft bearing Exhaust 22.21 ~ 22.75 mm
and valve stem) Repair size Intake 23.96 ~ 24.51 mm
Exhaust 21.96 ~ 22.51 mm
Notice
Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.

AFFECTED VIN
1B-115
Measurement of Mating Surface

1. Measure the height (H) of the cylinder head (refer to
Service data standard).
2. Check the mating surface of the cylinder head.
3. Mill the sharp edge of the combustion chamber.
4. Re-measure the height (H) of the cylinder head.
5. Seal the intake and exhaust valves.
6. Measure the dimension (T) between the camshaft bearing
and the valve system (refer to Service data standard).
7. Mill the cylinder head valve seat (refer to Service data
standard).
Universal Tool
Sceledum, Type RTY
Surface Grinding Machine Roaro
Schio/Italy

AFFECTED VIN
1B-116
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
A/C bracket bolt 22.5 ~ 27.5 16.6 ~ 20.3 -
Armature bolt in camshaft actuator 35 26 -
Belt tensioning pulley nut 40.5 ~ 49.5 29.9 ~ 36.5 -
Camshaft actuator bolt 9 ~ 11 - 80 ~ 97
Camshaft adjuster mounting nut 60 ~ 70 44 ~ 52 -
Camshaft bearing cap bolt 22.5 ~ 27.5 16.6 ~ 20.3 -
Chain tensioner assembly 72 ~ 88 53 ~ 65 -
Chain tensioner screw plug 40 30 -
Connecting rod bearing cap bolt 40 + 5 30 + 3.7
-
90° + 10° 90° + 10°
Cooling fan bracket bolt 22.5 ~ 27.5 16.6 ~ 20.3 -
Crankshaft bearing cap bolt 50 ~ 60 37 ~ 44
-
90° + 5° 90° + 5°
Crankshaft sealing rear cover mounting bolt 9 - 11 - 80 ~ 97
Cylinder block drain plug 30 22 -
Cylinder head bolt 55 41
+90° +90° -
+90° +90°
Cylinder head cover bolt 9 ~ 11 - 80 ~ 97
Cylinder head front cover bolt 22.5 ~ 27.5 16.6 ~ 20.3 -
Engine mounting bracket nut 70 52 -
Exhaust camshaft sprocker bolt 18 ~ 22 13 ~ 16
-
90° ± 5° 90° ± 5°
Exhaust manifold and pipe 30 22 -
Flywheel mounting bolt 45 + 5 33 + 3.7
-
90° + 10° 90° + 10°
Fuel feed and return hose to fuel rail 21 ~ 25 15 ~ 18 -
Generator carrier bolt 25 18 -
Intake air duct nut 9 ~ 11 - 80 ~ 97
Intake flange shaft bolt 18 ~ 22 13 ~ 16
-
90° ± 5° 90° ± 5°
Lower engine mounting nut 38 28 -
Oil dipstick guide tube bolt 9 ~ 11 - 80 ~ 97
Oil drain plug 22.5 ~ 27.5 16.6 ~ 20.3 -

AFFECTED VIN
1B-117
Fastener Tightening Specifications (Cont’d)

Oil filter bolt 22.5 ~ 27.5 16.6 ~ 20.3 -
Oil filter cover 25 18 -
Oil gallery screw plug in cylinder head 15 11 -
Oil pan bolt M10 40 30 -
M8 22.5 ~ 27.5 16.6 ~ 20.3 -
M6 9 ~ 11 - 80 ~ 97
Oil pressure relief valve screw plug 50 37 -
Oil pump drive sprocket bolt 29 ~ 35 21 ~ 26 -
Oil pump mounting bolt 22.5 ~ 27.5 16.6 ~ 20.3 -
Oil pump sprocket bolt 29 ~ 35 21 ~ 26 -
Spark plug cover bolt 9 ~ 11 - 80 ~ 97
Steering pump bolt 22.5 ~ 27.5 16.6 ~ 20.3 -
Tensioning device bolt 26 ~ 32 19 ~ 24 -
Timing gear case cover bolt M8 22.5 ~ 27.5 16.6 ~ 20.3 -
M6 9 ~ 11 - 80 ~ 97
Torque converter mounting bolt 42 31 -
Transmission mounting nut 54 ~ 68 40 ~ 50 -
Under cover 28 ~ 47 21 ~ 35 -
Upper engine mounting nut 70 52 -
Vibration damper center bolt 180 ~ 220 133 ~ 162
-
90° + 10° 90° + 10°
Water pump pulley bolt 22.5 ~ 27.5 16.6 ~ 20.3 -

AFFECTED VIN
1B-118
Name and Part Number Name and Part Number
000 589 58 43 00 A9917 0101B (111 589 01 59 00)

Chain Assembly Supporting Bar
W9911 0010B (102 589 00 15 00) A9917 0111B (111 589 18 61 00)
Drift Lever Pusher
A9911 0050B (102 589 12 15 00) A9917 0121B (111 589 25 63 00)
Drift Thrust Piece
A9910 0050A (103 589 02 09 00) A9913 0061B (116 589 01 34 00)
Oil Filter Remover Threaded Pin

AFFECTED VIN
1B-119
A9917 0171B (119 589 00 43 00) A9910 0150A (603 589 00 40 00)
Drift Fan Clutch Holder
A9911 0060B (601 589 03 14 00) W9910 0150A (615 589 01 33 00)
Crankshaft Front Seal Installer Crankshaft Sprocket Puller
A9910 0150B (602 589 00 40 00) A9912 0080B (617 589 00 10 00)
Engine Lock Allen Wrench Socket
W9911 0020B (601 589 03 43 00) A9911 0012B (DW110-090)

Crankshaft Rear Seal Installer Connecting Hose

AFFECTED VIN
1B-120
A9917 0012B (DW110-120)

Holding Pin

AFFECTED VIN
1D-1
SECTION
00 1D
ENGINE COOLING
Table of Contents
DESCRIPTION AND OPERATION ......... 1D-2 REPAIR INSTRUCTIONS ....................... 1D-8
General description .......................... 1D-2 ON-VEHICLE SERVICE ......................... 1D-8
Radiator ............................................ 1D-2
Coolant drain and fill up ................... 1D-8
Coolant reservoir .............................. 1D-2
Coolant connection fitting ............... 1D-10
Thermostat ........................................ 1D-2
Water pump ..................................... 1D-12
Water pump ....................................... 1D-3
Oil cooler pipe line .......................... 1D-14
Electric cooling fan ........................... 1D-3
Thermostat ...................................... 1D-15
A/C Off or Non-AC model ................. 1D-3
Cooling fan and viscous clutch ....... 1D-16
A/C On .............................................. 1D-3
Cooling fan shroud ......................... 1D-18
Engine coolant temperature sensor . 1D-3
Radiator .......................................... 1D-20
Coolant temperature gauge ............. 1D-3
General specifications .................... 1D-22
COMPONENT LOCATOR ...................... 1D-4
SPECIFICATION .................................. 1D-23
Gasoline engine ................................ 1D-4
Fastener tightening specifications . 1D-23
DIAGNOSTIC INFORMATION AND
SPECIAL TOOLS AND EQUIPMENT .. 1D-24
PROCEDURE ........................................ 1D-5
Cooling system diagnosis ................. 1D-5
Thermostat test ................................. 1D-7
System leakage test ......................... 1D-7

AFFECTED VIN
1D-2

GENERAL DESCRIPTION the coolant reservoir. The air trapped in the radiator and
the engine is degassed into the coolant reservoir.
The cooling system maintains the engine temperature at
When the engine stops, the engine coolant cools and
an efficient level during all engine operating conditions.
When the engine is cold, the cooling system cools the contracts. The displaced engine coolant is then drawn
back into the radiator and the engine. This keeps the
engine slowly or not at all. This slow cooling of the engine
radiator filled with the coolant to the desired level at all
allows the engine to warm up quickly.
times and increases the cooling efficiency.
The cooling system includes a radiator and recovery
subsystem, cooling fans, a thermostat and housing, a Maintain the coolant level between the MIN and MAX
marks on the coolant reservoir when the system is cold.
water pump, and a water pump drive belt. The timing belt
drives the water pump.
All components must function properly for the cooling THERMOSTAT
system to operation. The water pump draws the coolant A wax pellet-type thermostat controls the flow of the en-
from the radiator. The coolant then circulates through water gine coolant through the engine cooling system. The ther-
jackets in the engine block, the intake manifold, and the mostat is mounted in the thermostat housing to the front
cylinder head. When the coolant reaches the operating of the cylinder head.
temperature of the thermostat, the thermostat opens. The The thermostat stops the flow of the engine coolant from
coolant then goes back to the radiator where it cools. the engine to the radiator to provide faster warm-up, and
This system directs some coolant through the hoses to to regulate the coolant temperature. The thermostat re-
the heat core. This provides for heating and defrosting. mains closed while the engine coolant is cold, preventing
The coolant reservoir is connected to the radiator to recirculation of the engine coolant through the radiator. At
cover the coolant displaced by expansion from the high this point, the engine coolant is allowed to circulate only
temperatures. The coolant reservoir maintains the cor- throughout the heater core to warm it quickly and evenly.
rect coolant level. As the engine warms, the thermostat opens. This allows
The cooling system for this vehicle has no radiator cap or the engine coolant to flow through the radiator where the
filler neck. The coolant is added to the cooling system heat is dissipated. This opening and closing of the ther-
through the coolant reservoir. mostat permits enough engine coolant to enter the radia-
tor to keep the engine within proper engine temperature
RADIATOR operating limits.
The wax pellet in the thermostat is hermetically sealed in
This vehicle has a lightweight tube-and-fin aluminum
radiator. Plastic tanks are mounted on the upper and the a metal case. The wax element of the thermostat ex-
pands when it is heated and contracts when it is cooled.
lower sides of the radiator core.
As the vehicle is driven and the engine warms, the engine
On vehicles equipped with automatic transaxles, the
coolant temperature increases. When the engine coolant
transaxle fluid cooler lines run through the radiator tank.
A radiator drain plug is on this radiator. reaches a specified temperature, the wax pellet element
in the thermostat expands and exerts pressure against
To drain the cooling system, open the drain plug.
the metal case, forcing the valve open. This allows the
engine coolant to flow through the engine cooling system
COOLANT RESERVOIR and cool the engine.
The coolant reservoir is a transparent plastic reservoir, As the wax pellet cools, the contraction allows a spring
similar to the windshield washer reservoir. to close the valve.
The coolant reservoir is connected to the radiator by a The thermostat begins to open at 82°C (180°F) and is
hose and to the engine cooling system by another hose. fully open at 95°C (203°F). The thermostat closes at 80°C
As the vehicle is driven, the engine coolant heats and (176°F).
expands. The portion of the engine coolant displaced by
this expansion flows from the radiator and the engine into

AFFECTED VIN
1D-3
WATER PUMP A/C OFF OR NON-AC MODEL

The belt-driven centrifugal water pump consists of an • The cooling fans are actuated by the engine control
impeller, a drive shaft, and a belt pulley. module (ECM) using a low-speed cooling fan relay, a
The impeller is supported by a completely sealed bearing. high-speed cooling fan relay and a cooling fan motor
relay.
The water pump is serviced as an assembly and, there-
fore, cannot be disassembled. • The ECM will turn the cooling fans on at low speed
when the coolant temperature reaches 95°C (203°F)
and at high speed when the coolant temperature
ELECTRIC COOLING FAN reaches 105°C (221°F).
Caution • The ECM will change the cooling fans from high peed
Keep hands, tools, and clothing away from the engine to low speed at 100°C (212°F) and will turn the cooling
cooling fans to help prevent personal injury. This fan fans off at 90°C (194°F).
is electric and can turn on even when the engine is
not running. A/C ON
Caution • The ECM will turn the cooling fans on at low speed
f a fan blade is bent or damaged in any way, no attempt when the A/C system is on. The ECM will change to
should be made to repair or reuse the damaged part. high speed when the high side A/C pressure reaches
A bent or damaged fan assembly should always be 1860 kPa (269.8 psi).
replaced with a new one to prevent possible injury. • The cooling fans will return to low speed when the
high side A/C pressure reaches 1378 kPa (199.8 psi).
The cooling fans are mounted behind the radiator in the
engine compartment. The electric cooling fans increase ENGINE COOLANT TEMPERA-
the flow of air across the radiator fins and across the
condenser on air conditioned (A/C)-equipped vehicles. TURE SENSOR
This helps to speed cooling when the vehicle is at idle or The Engine Coolant Temperature (ECT) sensor uses a
moving at low speeds. temperature to control the signal voltage to the Engine
Control Module (ECM).
All models have two fans. The main fan is 320 mm (12.6
inches) in diameter with seven blades to aid the airflow
through the radiator and the condenser. An electric motor COOLANT TEMPERATURE
attached to the radiator support drives the fan. The auxil- GAUGE
iary fan is 320 mm (12.6 inches) in diameter.
The coolant temperature gauge controls the instrument
panel temperature indicator. The coolant temperature
gauge is located with ECT sensor.

AFFECTED VIN
1D-4
COMPONENT LOCATOR
GASOLINE ENGINE
1. Radiator 10. Bolt (M6, 4 pieces) 19. Clamp

2. Electric fan 11. Upper radiator insulator 20. Clamp
3. Shroud 12. Lower radiator insulator 21. Make up hose holder
4. Deaeration tube 13. Plate 22. Reserver tank
5. Clamp 14. Clip 23. Bolt (M6, 2 piece)
6. Deaeration hose (radiator) 15. Inlet hose 24. Cooling fan
7. Electric fan mounting bracket 16. Outlet hose 25. Viscous clutch
8. Bolt (M6, 8 pieces) 17. 3 way hose 26. Bolt (M6, 1 piece)
9. Bolt (M6, 4 pieces) 18. Deaeration hose (reserver tank) 27. Bolt (M6, 3 piece)

AFFECTED VIN
1D-5

COOLING SYSTEM DIAGNOSIS
Engine Overheats
Checks Action
Check for a loss of the coolant Add the coolant.
Check for a weak coolant solution. Confirm that the coolant solution is a 50/50 mixture of
ethylene glycol and water.
Check the front of the radiator for any dirt, any leaves, Clean the front of the radiator.
or any insects.
Check for leakage from the hoses, the water pump, the Replace any damaged components.
heater, the thermostat housing, the radiator, the core
plugs, or the head gasket.
Check for a faulty thermostat. Replace a damaged thermostat.
Check for retarded ignition timing. Perform an ECM code diagnosis. Confirm the integrity
of the timing chain.
Check for an improperly operating electric cooling fan. Replace the electric cooling fan.
Check for radiator hoses that are plugged or rotted. Replace any damaged radiator hoses.
Check for a faulty water pump. Replace a faulty water pump.
Check for a faulty coolant reservoir cap. Replace a faulty coolant reservoir cap.
Check for a cylinder head or an engine block that is Repair the damaged cylinder head or the damage
cracked or plugged. engine block.

AFFECTED VIN
1D-6
Loss of Coolant
Checks Action
Check for a leak in the radiator. Replace a damaged radiator.
Check for a leak in the following locations: Replace the following parts, as needed.
• Coolant reservoir. • Coolant reservoir.
• Hose. • Hose.
Check for loose or damaged radiator hoses, heater Reseat the hoses.
hoses, and connections. Replace the hoses or the clamps.
Check for leaks in the water pump seal. Replace the water pump seal.
Check for leaks in the water pump gasket. Replace the water pump gasket.
Check for an improper cylinder head torque. Tighten the cylinder head bolts to specifications.
Check for leaks in the following locations: Replace the cylinder head gasket, if needed.
• Intake manifold. Repair or replace any components, as needed, to
• Cylinder head gasket. correct the leak.
• Cylinder block plug.
• Heater core.
• Radiator drain plug.
Engine Fails to Reach Normal Operating Temperature or Cool Air from

the Heater
Checks Action
Check to determine if the thermostat is stuck open or is Install a new thermostat of the correct type and heat range.
the wrong type of thermostat.
Check the coolant level to determine if it is below the Add sufficient coolant to raise the fluid to the specified
LOW mark on the coolant reservoir. mark on the coolant reservoir.

AFFECTED VIN
1D-7
SYSTEM LEAKAGE TEST

Tools Required
A9921 0012A (124 589 15 21 00) Leakage Tester
Test Procedure
1. Loosen the cap a little and release pressure and remove
the cap.
Notice
For the risk of scalding, cap must not be opened unless
the coolant temperature is below 90 °C (194 °F).
2. Fill coolant up to upper edge (arrow) of reservoir.

3. Connect the leakage tester A9921 0012A (124 589 15 21
00) to the reservoir filler cap and apply 1.4 bar of pressure.
4. If the pressure on the tester drops, check leakage at the
all coolant hoses and pipes and each connections.
Replace or retighten if necessary.
THERMOSTAT TEST
Test Procedure
1. Remove the thermostat from the vehicle. Refer to
“Thermostat” in this section.
2. Make sure the valve spring is tight when the thermostat
is closed. If the spring is not tight, replace the thermostat.
3. Suspend the thermostat and a thermometer in a pan of
50/50 mixture of ethylene glycol and water. Do not let
the thermostat or the thermometer rest on the bottom of
the pan. The uneven concentration of heat on the bottom
could result in inaccurate temperature measurements.
4. Heat the pan on a burner.
5. Use the thermometer to measure the temperature of the
heated solution.
6. The thermostat should begin to open at 82°C (180°F)
and it should be fully be fully open at 95°C (203°F).
If it does not open at these temperatures, replace the
thermostat.

AFFECTED VIN
1D-8
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
COOLANT DRAIN AND FILL UP

Draining & Filling up Procedure
1. Loosen the cap a little and release pressure and remove
the cap.
Notice
For the risk of scalding, the cap must not be opened
unless the coolant temperature is below 90°C (194°F).
2. Loosen the radiator hose and drain the coolant.

Notice
Collect coolant by using a proper container.
3. Drain the coolant from the crankcase by inserting a hose

(dia. 14 mm) onto the drain bolt on the side of crankcase
(exhaust manifold) and by loosening the plug.
Notice
• Just loosen the drain plug to drain the coolant and
do not remove the plug completely.
• Collect coolant by using proper container.
4. After complete draining of the coolant, remove the hose

connector to drain plug and reinstall the drain plug.
Installation Notice
5. Tighten the radiator lower drain cock.

AFFECTED VIN
1D-9
6. Remove the de-aeration hose clamp in the coolant pump

and remove the de-aeration hose.
7. Fill up the coolant through the coolant reservoir tank.
Notice
• Match the anti-freeze and the water ratio to
50 : 50.
• Supplement the coolant until the coolant overflows
to the de-aeration hose.
8. Insert the de-aeration hose and completely tighten the

clamp.
9. Check the coolant level in the coolant reservoir tank.
10. Warm up (until thermostat is opened) the engine and
recheck the coolant level in the reservoir tank and fill up
the coolant if necessary.

AFFECTED VIN
1D-10
COOLANT CONNECTION FITTING

Preceding Work: Removal of cooling fan shroud
1. Bolt (M8 X 100, 2 pieces) 4. O-ring

........................ 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft) 5. Hose mounting clamp
2. Engine hanger bracket 6. Hose
3. Coolant outlet port

AFFECTED VIN
1D-11

1. Drain coolant from the radiator.
2. Remove the hose mounting clamp (5) and disconnect
the coolant hose (6).
3. Remove the two bolts (1), the engine hanger bracket (2)
and coolant outlet port (3).
Installation Notice
22.5 ~ 27.5 Nm
Specified value
(16.6 ~ 20.3 lb-ft)
Replace the O-ring with new one.

reverse order.
5. Fill up the coolant as specified.
6. Check the leaks in the cooling system.

AFFECTED VIN
1D-12
WATER PUMP
Preceding Work: Removal of V-belt
Removal of air admission housing
1. Air admission housing 8. Coolant hose

2. Oil cooler pipe line 9. Inlet coolant hose
3. Seal ........................................................... replace 10. Water pump
4. Bolt ............................... 9 ~ 11 Nm (80 ~ 97 lb-in) 11. Bolt ................ 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
5. Coolant hose 12. Dowel sleeve
6. Coolant hose 13. Seal ........................................................... replace
7. Outlet coolant hose

AFFECTED VIN
1D-13

1. Drain the coolant.
2. Disconnect the water pump wire connector.
3. Loosen the hose clip and disconnect all hoses from the
water pump
4. Remove the coolant line bolts (4) and then remove the
coolant line (2).
Installation
9 ~ 11 Nm
Tightening torque
(80 ~ 97 lb-in)
Replace the seal (3).
5. Remove the mounting bolts (11) and carefully pull out

water pump (10).
Installation
22.5 ~ 27.5 Nm
Tightening torque
(16.6 ~ 20.3 lb-ft)
Replace the seal (13).

reverse order.
7. Fill up coolant.
8. Do coolant system leakage test.

AFFECTED VIN
1D-14
OIL COOLER PIPE LINE

Preceding Work: Removal of upper intake manifold
1. Bolt (M6 X 35, 1 piece) 3. Oil cooler pipe line

...................................... 9 ~ 11 Nm (80 ~ 97 lb-in) 4. O-ring ........................................................ Replace
2. Bolt (M6 X 16, 2 pieces)
...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)

2. Unscrew the bolts (1, 2) and remove the oil cooler pipe
line (3).
Installation
9 ~ 11 Nm
Tightening Torque
(80 ~ 97 lb-in)
Replace the O-ring with new one.

reverse order.
4. Fill up the coolant as specified.
5. Check the leaks in the cooling system.
AFFECTED VIN
1D-15
THERMOSTAT
1. Thermostat cover 5. Bolt (M6 X 25, 3 pieces)

2. Thermostat ...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
3. O-ring 6. Hose mounting clamp
4. Thermostat cover bracket 7. Heater hose

1. Drain the coolant from the radiator.
2. Loosen the hose mounting clamp (6) and remove the
heater hose (7).
3. Unscrew the three bolts (5) and remove the thermostat
cover bracket, thermostat cover and the thermostat in
order.
Installation
9 ~ 11 Nm
Tightening Torque
(80 ~ 97 lb-ft)
Do not separate the thermostat cover and thermostat.
4. Replace the O-ring if necessary.

5. Check the leakage in the cooling system.
AFFECTED VIN
1D-16
COOLING FAN AND VISCOUS CLUTCH

1. Cooling fan pulley 4. Bolt (M6 X 12, 4 piece)

2. Viscous clutch ...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
3. Cooling fan 5. Bolt (M10 X 45, 1 pieces)
....................... 40.5 ~ 49.5 Nm (29.8 ~ 36.5 lb-in)

AFFECTED VIN
1D-17
Tools Required
A9910 0150A (603 589 00 40 00) Fan Clutch Holder

1. Remove the engine hanger bracket bolts.
Installation
22.5 ~ 27.5 Nm
Tightening torque
(16.6 ~ 20.3 lb-ft)
2. Remove the engine hanger bracket.

3. Remove the cooling fan bolts.
Installation
9 ~ 11 Nm
Tightening torque
(80 ~ 97 lb-in)
4. Hold the cooling fan pulley using the fan clutch holder
A9910 0150A (603 589 00 40 00).
5. Remove the viscous clutch mounting bolts and viscous

clutch.
Installation
40.5 ~ 49.5 Nm
Tightening torque
(29.8 ~ 36.5 lb-ft)
Important
There are two chambers in the viscous clutch. Be
sure to make the viscous clutch stand on the ground
not to flow silicone oil into another chamber in the
viscous clutch. Do not lay down the clutch.

reverse order.

AFFECTED VIN
1D-18
COOLING FAN SHROUD
1. Fan shroud assembly 2. Bolt ................................ 3 ~ 7 Nm (27 ~ 62 lb-in)

AFFECTED VIN
1D-19

1. Pull out the 2 clips (1) from the fan shroud assembly.
2. Remove the lower fan shroud (2).
Notice
For installation, exactly align the lower fan shroud
pin into the hole of the fan shroud assembly (4) and
insert the clips.
3. Remove the bolts (3) and then remove the cooling fan
shroud assembly (4).
Installation
3 ~ 7 Nm
Tightening torque
(27 ~ 62 lb-in)

reverse order.

AFFECTED VIN
1D-20
RADIATOR
1. Deaeration hose 5. Lower radiator insulator

2. Radiator 6. Plate
3. Inlet hose 7. Clip
4. Bolt 8. Upper radiator insulator

AFFECTED VIN
1D-21

1. Drain coolant from the radiator.
2. Remove the each coolant hoses.
3. Remove the upper and lower automatic transmission oil

cooling pipes from radiator.
Installation
25 ~ 35 Nm
Tightening torque
(18 ~ 26 lb-ft)
4. Remove the mounting bolt (9) from the automatic

transmission oil cooler pipe (5) and then disconnect the
cooler pipe (5).
Installation
3 ~ 7 Nm
Tightening torque
(27 ~ 62 lb-in)
5. Remove the cooling fan shroud bolts and cooling fan

shroud.
Installation
3 ~ 7 Nm
Tightening torque
(27 ~ 62 lb-in)
6. Remove the radiator grille mounting screw and radiator

grille.
7. Remove the front and upper member mounting bolts and

front end upper member.
Installation
30 ~ 40 Nm
Tightening torque
(22 ~ 30 lb-ft)
8. Remove the radiator

9. Check the radiator pin for crack, damage, leakage and
bending and replace it if necessary.
reverse order.
11. Check for leakage in the cooling system.
AFFECTED VIN
1D-22
SPECIFICATION
GENERAL SPECIFICATIONS
Application Unit Gasoline Engine
Cooling system Type - Water cooling forced
circulation
Coolant Capacity L 11.3
Thermostat Type - Wax pellet type
Initial opening temp. °C (°F) 82 (180)
Fully opening temp. °C (°F) 95 (203)
Fully closing temp. °C (°F) 80 (176)
Stroke mm 7
Cooling fan Type - Electric cooling
Blades - 5
Diameter mm 320
Low speed ON temp. °C (°F) 95 (203)
Low speed OFF temp. °C (°F) 90 (194)
High speed ON temp. °C (°F) 105 (221)
High speed OFF temp. °C (°F) 100 (212)
High speed ON temp. (By A/C pressure) kPa (psi) 269.8 (1860)
Coolant reservoir Pressure valve opening pressure kPa (psi) 118 ~ 147 (17.1 ~ 21.3)
Vacuum valve opening pressure kPa (psi) 9.8 (1.4)
Water pump Type - Turbo centrifugal
Impeller diameter mm 65
Impeller blades - 8
Radiator Type - Cross-flow
Core width mm 701
Core height mm 372
Core thickness mm 18
Minimum radiation capability Kcal/h 45,000
Coolant temperature Resistance (at 50°C (122°F)) Ω 185.2
gauge Resistance (at 80°C (176°F)) Ω 47.4
Resistance (at 105°C (221°F)) Ω 28.2
Engine coolant Resistance (at 20°C (68°F)) K Ω 3.33 ~ 37.8
temperature sensor Resistance (at 80°C (176°F)) K Ω 0.32 ~ 0.35
Anti-freeze agent Type - ALUTEC-P78
Mixture of water and good quality ethylene
- 50 : 50
glycol-base anti-freeze

AFFECTED VIN
1D-23

Automatic transmission oil cooler pipe 20 15 -
Automatic transmission oil cooler pipe mounting bolt 3~7 - 27 ~ 62
Coolant drain plug 30 22 -
Cooling fan bolt 9 ~ 11 - 80 ~ 97
Cooling fan shroud bolt 3~7 - 27 ~ 62
Engine hanger bracket and coolant outlet port bolt 22.5 ~ 27.5 16.6 ~ 20.3 -
Radiator mounting bracket bolt 3~7 - 27 ~ 62
Thermostat cover bracket bolt 9 ~ 11 - 80 ~ 97
Viscous clutch mounting bolt 40.5 ~ 49.5 29.8 ~ 36.5 -
Water pump mounting bolt 22.5 ~ 27.5 16.6 ~ 20.3 -

AFFECTED VIN
1D-24
A9910 0060A (111 589 00 40 00) A9910 0070A (111 589 02 01 00)
Holder Open End Wrench
A9921 0012A (124 589 15 21 00) A9910 0150A (603 589 00 40 00)
Leakage Tester Fan Clutch Holder

AFFECTED VIN
1F-1
SECTION
00 1F
ENGINE CONTROLS
Table of Contents
ENGINE AND ECM PROBLEM CHECK INDUCTION SYSTEM .......................... 1F-41
REPORT ................................................. 1F-3 Throttle valve actuator ..................... 1F-40
Vehicle and customer information ..... 1F-3 Hot Film Air Mass (HFM) sensor ...... 1F-43
Mil information .................................... 1F-3 Engine Coolant Temperature
Problem description ........................... 1F-3 (ECT) sensor ................................... 1F-47
Condition when problem occurs ........ 1F-3 Accelerator pedal module ................ 1F-51
Cooling fan ....................................... 1F-54
DIAGNOSTIC INFORMATION AND
PROCEDURE ......................................... 1F-4 A/C compressor relay ...................... 1F-55
Cruise control switch ........................ 1F-56
Failure code diagnosis ...................... 1F-4
Resonance flap ................................ 1F-57
IGNITION SYSTEM ................................ 1F-8 Stop lamp switch .............................. 1F-58
Ignition coil ......................................... 1F-9
EXHAUST SYSTEM .............................. 1F-60
Crankshaft position (CKP) sensor ... 1F-11
Catalytic converter ........................... 1F-60
Camshaft position (CMP) sensor..... 1F-14
Oxygen sensor ................................. 1F-61
Camshaft actuator ........................... 1F-18
Knock Sensor (KS) .......................... 1F-20 ENGINE CONTROL MODULE ............. 1F-66
Spark plug ........................................ 1F-22 Serial data communication .............. 1F-67
System voltage ................................ 1F-24 Internal failure .................................. 1F-69
Ignition switch ................................... 1F-25 Electronic throttle controller safety
malfunction ....................................... 1F-70
FUEL SYSTEM ..................................... 1F-26
Immobilizer ....................................... 1F-72
Fuel pump ........................................ 1F-27
Fuel injector ..................................... 1F-30
Purge control valve .......................... 1F-34
Fuel rail ............................................ 1F-36
Fuel pressure regulator ................... 1F-38
ENGINE CONTROLS CHANGED BY

AFFECTED VIN
1F-2
MAINTENANCE AND REPAIR .............. 1F-73 Purge control valve .......................... 1F-84
ON-VEHICLE SERVICE ........................ 1F-73 Canister ............................................ 1F-84
Discharging the pressure in fuel Engine control module ..................... 1F-85
system .............................................. 1F-73 Camshaft position sensor ................ 1F-85
Fuel pump ........................................ 1F-73 Crankshaft position sensor .............. 1F-85
Fuel filter .......................................... 1F-74
SCHEMATIC AND ROUTING
Fuel tank .......................................... 1F-75
DIAGRAMS ........................................... 1F-86
Fuel pressure regulator ................... 1F-78
Diagnosis circuit ............................... 1F-86
Fuel rail and injectors ...................... 1F-79
ECU (GSL G32) ............................... 1F-87
Engine coolant temperature
sensor .............................................. 1F-80 SPECIFICATIONS ................................. 1F-90
Throttle body (integrated with the Engine data display table ................ 1F-90
actuator) ........................................... 1F-81
Fastener tightening specifications .. 1F-91
Hot Film Air Mass (HFM) sensor ...... 1F-82
Fuel system specification ................ 1F-92
Knock sensor ................................... 1F-82
Temperature vs resistance .............. 1F-92
Pedal position sensor ...................... 1F-83
Oxygen sensor ................................. 1F-83 SPECIAL TOOLS AND EQUIPMENT ... 1F-93
CHANGED BY ENGINE CONTROLS

AFFECTED VIN
1F-3
ENGINE AND ECM PROBLEM CHECK REPORT

VEHICLE AND CUSTOMER INFORMATION
Date Problem Occurred
Customer Name Vehicle Model
Driver Name VIN
Purchase date Engine Model
License No. Mileage Km
miles
MIL INFORMATION
Condition of MIL Remains on Sometimes illuminates Does not illuminate
DTC inspection Normal Malfunction code(s) (code )
(if available) Freeze Frame data ( )
PROBLEM DESCRIPTION
Engine Does Not Start No cranking No initial combustion No complete combustion
Hard to Start Slow cranking
Others
Poor Idling Incorrect first Idle Abnormal idle rpm High (rpm) Low (rpm)
Idling Unstable Others
Poor Driveability Hesitation Back fire Muffler explosion (after-burning)
Surging Knocking Poor performance Other
Engine Stall Soon after starting After accelerator pedal depressed
After accelerator pedal released During A/C operation
Shifting from N to D or D to N
At full steering Others
Others
CONDITION WHEN PROBLEM OCCURS

Constant Intermittent (times per day/month) Once only Others
Problem Frequency Fine Cloudy Rainy Snowy Various/Others
Weather Hot Warm Cool Cold (approx.____°F/____°C)
Ambient Temperature Highway Suburbs Inner City Uphill Downhill
Place Rough Road Others
Cold Warming Up Before warming up After warm-up
Engine Temperature Any temp. Others
Starting Just after starting (min.) Idling Racing Driving
Engine Operation Constant speed Acceleration Deceleration
A/C switch ON/OFF Other

AFFECTED VIN
1F-4
FAILURE CODE DIAGNOSIS

Clearing Failure Codes
Notice: To prevent Engine Control Module (ECM) damage, the key must be OFF when disconnecting or reconnecting
the power to the ECM (for example battery cable, ECM pigtail connector, ECM fuse, jumper cables, etc.)
Parameters listed in the table may not be exactly the same as your reading due to the type of instrument or other
factors. If a failure code is displayed during the “TROUBLE CODE” in scan tool check mode, check the circuit for the
code listed in the table below. For details of each code, turn to the page referred to under the “See Page” for the re-
spective “Failure Code” in the below table.
Failure codes should be cleared after repairs have been completed.
Failure Codes Table

Failure Code See Page Description
00 1F-56 Engine coolant temperature sensor low voltage
01 1F-56 Engine coolant temperature sensor high voltage
02 1F-56 Engine coolant temperature sensor plausibility
03 1F-52 Intake air temperature sensor low voltage
04 1F-52 Intake air temperature sensor high voltage
05 1F-52 Intake air temperature sensor plausibility
06 1F-56 Engine coolant temperature insufficient for closed loop fuel control
08 1F-28 System voltage too low
09 1F-52 Mass air flow sensor plausibility
10 1F-52 Mass air flow sensor low voltage
11 1F-52 Mass air flow sensor high voltage
17 1F-13 Crankshaft position sensor signal failure (no engine revolution signal)
18 1F-13 Crankshaft position sensor signal failure (rpm > max. value)
19 1F-17 Camshaft position senosr signal: No.1 cylinder recognition failure
20 1F-13 Crankshaft position sensor signal failure (gap recognition failure)
21 1F-79 Transmission coding failure
23 1F-77 CAN communication failure: ASR/MSR
24 1F-77 CAN communication failure: ABS
25 1F-82 Communication with transponder missing
26 1F-77 CAN communication failure: TCU (A/T only)
27 1F-78 CAN communication failure: TOD (E32 only)
29 1F-78 CAN communication failure: ID 200h not plausible
30 1F-78 CAN communication failure: ID 208h not plausible
31 1F-78 CAN communication failure: communication initialization failure
32 1F-68 Engine rpm output circuit short circuit to battery
33 1F-68 Engine rpm output circuit short circuit to ground or open
34 1F-33 Fuel pump relay short circuit to battery
35 1F-33 Fuel pump relay short circuit to ground or open

AFFECTED VIN
1F-5
Failure Codes Table (Cont’d)

40 1F-41 Purge control valve short circuit to battery
41 1F-41 Purge control valve short circuit to ground or open
44 1F-62 Cooling fan (HI) relay short circuit to power
45 1F-62 Cooling fan (HI) relay short circuit to ground or open
54 1F-41 Purge control circuit malfunction
56 1F-23 No.1 knock sensor signal failure
57 1F-23 No.2 knock sensor signal failure
58 1F-17 Camshaft position sensor signal: No.1 cylinder synchronization failure
59 1F-78 CAN communication failure: MSR data transmission not plausible
60 1F-78 CAN communication failure: ASR data transmission not plausible
62 1F-61 Clutch switch defective
64 1F-11 No ignition voltage output (No.1 ignition coil)
67 1F-13 Crankshaft position sensor adaptation failure
68 1F-25 Random/Multiple Misfire
71 1F-29 Starter signal recognition failure
72 1F-37 No.1 injector short circuit to battery
73 1F-37 No.1 injector short circuit to ground or open
76 1F1-37 No.3 injector short circuit to battery
80 1F-72 Oxygen sensor high voltage
81 1F-73 Bank 1 system short term fuel trim adaptation below lean threshold
82 1F-72 Oxygen sensor no activity detected
83 1F-72 Oxygen sensor not lean after overrun fuel shut -off
84 1F-72 Oxygen sensor slow response
85 1F-72 Oxygen sensor heater failure
86 1F-72 Oxygen sensor heater short circuit to battery
87 1F-72 Oxygen sensor heater short circuit to ground or open
89 1F-72 Oxygen sensor low voltage
93 1F-73 Bank 1 system short term fuel trim adaptation above rich threshold
96 1F-73 Bank 1 system short term fuel trim at rich stop
97 1F-73 Bank 1 system short term fuel trim at lean stop
98 1F-73 Bank 1 system idle adaptation failure (above rich threshold)
99 1F-73 Bank 1 system idle adaptation failure (below lean threshold)
100 1F-73 Bank 1 system learning control failure (rich, low load)
101 1F-73 Bank 1 system learning control failure (lean, low load)

AFFECTED VIN
1F-6

102 1F-73 Bank 1 system learning control failure (rich, high load)
103 1F-73 Bank 1 system learning control failure (lean, high load)
104 1F-47 Throttle position sensor 1 low voltage
105 1F-47 Throttle position sensor 1 high voltage
108 1F-47 Throttle position sensor 2 low voltage
109 1F-47 Throttle position sensor 2 high voltage
110 1F-80 Throttle actuator learning data fault
116 1F-47 Throttle actuator learning control failure
117 1F-80 Exceed fuel -cut safety time
119 1F-47 Throttle valve return spring failure
120 1F-80 Cruise control interruption memory failure
121 1F-47 Throttle actuator failure
122 1F-59 Accelerator pedal position sensor signal failure
123 1F-47 Different Mass air flow sensor signal with throttle position sensor
125 1F-47 Both throttle position sensors failure
126 1F-48 Throttle position sensor 1 not plausible with throttle position sensor 2
127 1F-48 High permanent throttle signal
129 1F-64 Cruise control “OFF” due to message counter failure
130 1F-64 Vehicle speed signal failure
131 1F-64 Vehicle speed signal failure
132 1F-64 Cruise control lever failure
133 1F-64 Cruise control acceleration failure
134 1F-64 Cruise control deceleration failure
135 1F-67 Stop lamp switch failure
136 1F-79 ECU failure (RAM)
137 1F-79 ECU failure (EPROM)
138 1F-80 Call monitoring
139 1F-80 Servo motor control output interruption memory failure
140 1F-80 Servo motor open/short
141 1F-82 Unprogramed ECU with immobilizer
142 1F-79 Uncoded/unprogramed ECU
143 1F-79 ECU failure (EEPROM/Flash-EPROM checksum failure)
144 1F-79 ECU failure (coding ID checksum failure)
145 1F-79 ECU failure (coding checksum failure)
146 1F-79 ECU failure (programing checksum failure)
150 1F-65 TCS input signal short circuit to battery
151 1F-65 TCS input signal short circuit to ground or open
160 1F-59 Accelerator pedal position sensor 1 low voltage
161 1F-59 Accelerator pedal position sensor 1 high voltage
162 1F-59 Accelerator pedal position sensor 2 low voltage
163 1F-59 Accelerator pedal position sensor 2 high voltage
AFFECTED VIN
1F-7

164 1F-59 Accelerator pedal position sensor 1 not plausible with pedal position sensor 2
167 1F-59 Both setpoint accelerator pedal position sensor defective
185 1F-48 Mass air flow sensor and throttle position sensor failure
186 1F-80 ECU failure (incompatible CPU)
187 1F-80 ECU failure (CPUs communication failure)
188 1F-80 ECU failure (CPU 2 configuration failure)
189 1F-80 ECU failure (CPU 2 fault)
190 1F-80 ECU failure (CPU run time failure between CPUs)
198 1F-66 Resonance flap short circuit to battery
199 1F-66 Resonance flap short circuit to ground or open
226 1F-21 Camshaft actuator short circuit to battery
227 1F-21 Camshaft actuator short circuit to ground or open
228 1F-63 A/C compressor relay short circuit to battery
229 1F-63 A/C compressor relay short circuit to ground or open
231 1F-80 ECU failure (CPU 2 cruise control message counter failure)
232 1F-80 Over decceleration limit (CPU 2)
233 1F-80 Over acceleration limit (CPU 2)
234 1F-80 Cruise control lever dual operation (CPU 2)
235 1F-80 Cruise control lever safety terminal failure (CPU 2)
236 1F-80 Unusual pedal position variation (CPU 2)
237 1F-80 Unusual throttle position variation (CPU 2)
238 1F-80 Unusual throttle controller monitor data comparison fault (CPU 2)
239 1F-81 Unusual accelerator pedal position sensor comparison fault (CPU 2)
240 1F1-81 Throttle potentiometer comparision fault (CPU 2)
241 1F-81 Unusual CPU communication (CPU 2)
242 1F-81 Unusual CPU configuration (CPU 2)
243 1F-81 A/D converter failure (CPU 2)
244 1F-81 Accelerator pedal position sensor setpoint fault between CPU 1 and CPU 2
245 1F-81 Position controller setpoint fault between CPU 1 and CPU 2
246 1F-81 MSR setpoint fault between CPU 1 and CPU 2
247 1F-81 Idle control setpoint fault between CPU 1 and CPU 2
248 1F-81 A/D converteroverflow (CPU 2)
249 1F-81 ROM f aul t (CPU 2)
250 1F-81 RAM f aul t (CPU 2)
251 1F-85 Cycle monitor fault (CPU 2)

AFFECTED VIN
1F-8
IGNITION SYSTEM
This ignition system does not use a conventional dis- These systems use the EST signal from the ECM to con-
tributor and coil. It uses a crankshaft position sensor in- trol the EST. The ECM uses the following information:
put to the Engine Control Module (ECM). The ECM then • Engine load (mass air flow sensor).
determines Electronic Spark Timing (EST) and triggers
• Engine temperature.
the electronic ignition system ignition coil.
• Intake air temperature.
This type of distributorless ignition system uses a “waste
spark” method of spark distribution. Each cylinder is paired • Crankshaft position.
with the cylinder that is opposite it (1-6 or 2-5 or 3-4). The • Engine speed (rpm).
spark occurs simultaneously in the cylinder coming upon
the compression stroke and in the cylinder coming up on
the exhaust stroke. The cylinder on the exhaust stroke
requires very little of the available energy tofire the spark
plug. The remaining energy is available to the spark plug
in the cylinder on the compression stroke.

AFFECTED VIN
1F-9
IGNITION COIL
1. Control cable connection 5a, 5b. Secondary voltage connection

2. Ignition cable E. Iron core
3. Spark plug connector L1. Secondary ignition coil
4. Coupling plug L2. Primary ignition coil
The Electronic Ignition (EI) system ignition coil is located on the cylinder head cover. The double ended coils receive the
signal for the Engine Control Module (ECM) which controls the spark advance.
Each EI system ignition coil provides the high voltage to two spark plugs simultaneously;
T1/1: cylinder 2 and 5
The EI system ignition coil is not serviceable and must be replaced as an assembly.

AFFECTED VIN
1F-10
Failure Code Description Trouble Area Maintenance Hint
No ignition voltage • Inspection the ECM pin 70 (71 and 72)

64 output about short circuit or open with bad
(No. 1 ignition coil) contact
• Inspection the power source to ignition
Malfunction of ignition • Inspection the power source to ignition coil
No ignition voltage
circuit Primary current
65 output • Inspection the ignition coil, high tension
values or secondary
(No. 2 ignition coil) cords etc.
short circuit
• Inspection the spark plug (wet, cracks,
No ignition voltage wear, improper gap, burned electrodes,
66 output heavy deposit)
(No. 3 ignition coil) • Inspection the ECM
Circuit Description
The Electronic Ignition (EI) system uses a waste spark method of spark distribution. The Crankshaft Position (CKP)
sensor sends reference pulses to the ECM. The ECM then triggers the EI system ignition coils. Once the ECM triggers
the EI system ignition coils both of the connected spark plugs fire at the same time. One cylinder is on its compression
stroke at the same time that the other is on the exhaust stroke, resulting in lower energy needed to fire the spark plugin
the cylinder on its exhaust stroke.
This leaves there remainder of the high voltage to be used to fire the spark plug in the cylinder on its compression stroke.
Since the CKP sensor is in a fixed position, timing adjustments are not possible or needed.

AFFECTED VIN
1F-11
CRANKSHAFT POSITION (CKP) SENSOR
1. Crankshaft position sensor 3. Segment

2. Bolt 4. Flywheel
This Electronic Ignition (EI) system uses inductive or pick up type magnetic Crankshaft Position (CKP) sensor. The
CKP sensor is located in the opposite side of the crankshaft pulley and triggers the pick-up wheel teeth which is
equipped 60 - 2 teeth with a gap of 2 teeth at 360 degree spacing. This sensor protrudes throughits mount to within 1.1
± 0.14 mm.
The output of the sensor is a sinusoidal signal. Each tooth of the pick-up 60 - 2 wheel generates a positive half wave.
The Engine Control Module (ECM) uses this sensor signal to generate timed ignition and injection pulses that it sends
to the ignition coils and to the fuel injectors.

AFFECTED VIN
1F-12
Failur Code Description Trouble Area Maintenance Hint

Crankshaft position Even through cam position • Monitoring the actual rpm through
17 sensor signal failure (no recognition is normal, no crank- or scan tool
engine revolution signal) shaft position signal recognition
• Inspection the ECM pin 100, 99
Crankshaft position When more than applicable about short circuit with bad
18 sensor signal failure revolution values or implausible contact
(rpm > max. value) to 60-2 teeth scan tool
• Inspection the CKP sensor
When implausible recognition of
Crankshaft position • Inspection the air gap between
cam and crank angle signal or
20 sensor signal failure sensor and drive plate
intermittent sensing the signal or
(gap recognition failure) • Inspection the drive plate (teeth
error count of undetected gap.
condition)
Crankshaft position When faulty crank angle
67 • Inspection the ECM
sensor adaptation failure sensor adaption
Circuit Description
The 58X reference signal is produced by the CKP sensor. During one crankshaft revolution, 58 crankshaft pulses will be
produced. The ECM uses the 58X reference signal to calculate engine rpm and CKP. The ECM constantly monitors the
number of pulses on the 58X reference circuit and compares them to the number of Camshaft Position (CMP) signal pulses
being received. If the ECM receives and incorrect number of pulses on the 58X reference circuit, this failure code will set.
Crankshaft Position Sensor Resistance Inspection

1. Disconnect the coupling “E” of ECM while the ignition switch is in “OFF” position.
2. Measure the resistance between the coupling terminal pin No. 99 and No. 100 using a multimeter.
Specified value 1,050 ~ 1,400 Ω
Notice
Measure the insulator resistance of the CKP sensor if out of the specified value.

AFFECTED VIN
1F-13
Crankshaft Position Sensor Output

Wave Inspection
1. Measure the output wave between the ECM terminals
No. 99 and No. 100 using the scan tool or the oscilloscope
while engine cranking (start motor activated).
Notice
Check the segment or crankshaft position sensor and
air gap if cannot get the output wave as shown in the
figure.
Crankshaft Position Sensor

Insulator Resistance Inspection
1. Disconnect the coupling from ECM while the ignition
switch is in “OFF” position.
2. Measure the resistance between the coupling terminal
pin No. 100 and No. 69 using a multimeter.
Specified value >20 kΩ
Notice
Measure the check and ground terminal of the CKP
sensor if out of the specified value.

AFFECTED VIN
1F-14
CAMSHAFT POSITION (CMP) SENSOR
1. Camshaft position sensor connector 3. Camshaft position sensor

2. Bolt 4. O-ring
The Camshaft Position (CMP) sensor sends a CMP signal to the Engine Control Module (ECM). The ECM uses this
signal as a “synchronized pulse” to trigger the injectors in the proper sequence. The ECM uses the CMP signal to
indicate the position of the #1 piston during its power stroke. This allows the ECM to calculate true sequential fuel
injection mode of operation.

AFFECTED VIN
1F-15
Camshaft position When no cam recognition signal • Inspection the source voltage of
sensor signal : No. 1 during TN 24 counts more. CMP sensor
19
cylinder recognition (maintain the constant low or • Inspection the ECM pin 106, 104
failure high level) about short circuit or open with
bad contact
Camshaft position • Inspection the CMP sensor
When synchronization fault of
sensor signal : No. 1 • Inspection the damage of sensor
58 cylinder 1
cylinder synchroniza- or sprocket
(TDC recognition)
tion failure • Inspection the ECM
Circuit Description
The CMP sensor sends a cam position signal to the ECM. If the cam position signal is lost while the engine is running,
the fuel injection system shifts to a calculated sequential fuel injection mode based on the last fuel injection pulse, and
the engine continuous to run.
Camshaft Position Sensor Signal Voltage Inspection

1. Measure the voltage between the ECM terminal No. 11 and No. 106 while the engine speed is at idle.
Specified value 1.2 ~ 1.7V
Notice
The signal voltage will be changed in the range of 1.2 ~ 1.7V.

AFFECTED VIN
1F-16
Camshaft Position Sensor Output

Wave Inspection
1. Measure the output wave between the ECM terminals
No. 104 and No. 106 using the scan tool or the
oscilloscope while engine speed is at idle.
Notice
Replace the CAM sensor if cannot get the out-put
wave as shown in the figure.
Camshaft Position Sensor Power

Supply Inspection
1. Disconnect the CMP sensor Connector.
2. Measure the voltage between the No. 1and No. 3 pin of
the CMP sensor connector while the ignition switch is in
“ON” position.
Specified value 11 ~ 14V
Notice
If the measured value is not within the specified value,
check the cable.

AFFECTED VIN
1F-18
CAMSHAFT ACTUATOR
1. Bolt 4. Armature
2. Camshaft actuator 5. Roll pin
3. Bolt 6. Nut
When the engine is running, the camshaft actuator rotates the intake camshaft hydraulically and mechanically relative
to the camshaft sprocket by 32° crank angle to the “advanced” position and back to the “retard” position.
The camshaft actuator is actuated electro-mechanically by the Engine Control Module (ECM).
The positioning time of apporx. 1 second is dependent on the engine oil pressure at the camshaft actuator and on the oil
viscosity and oil temperature, respectively.
The camshaft indicator on the camshaft sprocket provides the camshaft rotational speed to the position sensor as an
input parameter for the engine ignition control unit.
Operation Condition of Camshaft Actuator

Engine RPM Camshaft Position Effect
Engine stop Retard -
Idle speed is improved
0 ~ 1,500 rpm Retard Blow-by gas is decreased
Valve overlap is decreased
Torque is increased
1,500 ~ 4,300 rpm Advanced Fuel loss is decreased
NOx is decreased
Above 4,300 rpm Retard Engine overrun is prohibited

AFFECTED VIN
1F-19

• Monitoring the actual operational
Camshaft actuator short status through scan tool
226
circuit to battery • Inspection the ECM pin 73 about
short circuit or open
When malfunction of cam
• Inspection the power source short
phasing control
circuit or open to cam actuator
Camshaft actuator
• Inspection the magnet and
227 short circuit to ground
hardware
or open
• Inspection the ECM
Camshaft Actuator Current Consumption Inspection

1. Run the engine to reach the coolant temperature above 70 °C.
2. Increase the engine rpm up to 2000 rpm
3. Measure the current between the No. 1 and No. 2 pin of the camshaft actuator connector.
Specified value 1 ~ 1.5 A
Notice
If the measured value is not within the specified value, check the cable.

AFFECTED VIN
1F-20
KNOCK SENSOR (KS)
The Knock Sensor (KS) detects abnormal knocking in the engine. The two KS are mounted in the engine block near the
cylinders. The sensors produce an output voltage which increases with the severity of the knock. This signal is sent to
the Engine Control Module (ECM) via a shielded cable. The ECM then adjusts the ignition timing to reduce the spark
knock.

AFFECTED VIN
1F-21
When recognition in more than • Inspection the ECM pin 118,

control gain threshold at normal 117about short circuit or open with
No. 1 knock sensor
56 operational condition of other bad contact
signal failure
system during over 75 and 3,000 rpm • Inspection the KS 1 malfunction
running area (cylinder 1, 2, 3) • Inspection the ECM
When recognition in more than • Inspection the ECM pin 115, 114
control gain threshold at normal about short circuit or open with
No. 2 knock sensor bad contact
57 operational condition of other
signal failure
system during over 75 and 3,000 rpm • Inspection the KS 2 malfunction
running area (cylinder 4, 5, 6) • Inspection the ECM
Circuit Description
The KS system is used to detect engine detonation, allowing the ECM to retard the ignition control spark timing based
on the KS signal being received. The KS signal’s amplitude and frequency depend upon the amount of knock being
experienced. The ECM monitors the KS signal and can diagnose the KS sensor and circuitry.
Knock Sensor Resistance Inspection

1. Disconnect the coupling from ECM while the ignition switch is in “OFF” position.
2. Measure the resistance between the coupling terminal pin No. 118 and No. 117 and terminal pin No. 115 and No.
114 using a multimeter.
Specified value >10 MΩ
Notice
Replace the KS if the measured values is out of the specified values. Check the connector and wire connection
between ECM and the KS if the measured values are normal.

AFFECTED VIN
1F-22
SPARK PLUG
1. Ignition coil cable cover T 1/1 Ignition Coil ............................... Cylinder 2 and 5
2. Bolt T 1/2 Ignition Coil ............................... Cylinder 3 and 4
3. Spark plug T 1/3 Ignition Coil ............................... Cylinder 1 and 6

AFFECTED VIN
1F-23

• Inspection the ignition system
• Inspection the injection system
• Inspection the fuel pressure
• Inspection the compression pressure
When detection misfire of
• Inspection the valve timing or clearance
Random / Multiple multiple cylinder for source of
68 • Inspection the air flow sensor
Misfire over the emission threshold
• Inspection the crankshaft position
or catalyst damage
sensor and air gap
• Inspection the engine wiring system
• Inspection the Engine Control Module
(ECM)
Circuit Description
The ECM monitors the crankshaft and camshaft positions to detect if the engine is misfiring. The ECM looks for a quick
drop in crankshaft speed. Misfire multiple cylinder is monitored by engine roughness measuring. The actual roughness
value is compared with the actual (emission and catalyst damage) threshold.
Spark Plug Cable Resistance Inspection

1. Turn the ignition switch “OFF” position.
2. Disconnect the spark plug cables Refer to Section 1E1, Engine electrical.
3. Measure the spark plug resistance using a multimeter.
Specified value 1.8 ~ 2.2 kΩ
Notice: Replace the spark plug cable if the measured values is out of the specified values.
AFFECTED VIN
1F-24
SYSTEM VOLTAGE

• Monitoring the actual battery
voltages through the scan tool
• Inspection the Engine Control
Malfunction in recognition of
Module (ECM) pin 12, 11, 10, 5
system source voltage. Less
about short circuit or open with
08 System voltage too low than minimum 8 volts in
bad contact
2,000 rpm below, or less than 10
volts in 2,000 rpm above. • Inspection the over voltage
protection relay
• Inspection the battery
• Inspection ECM

AFFECTED VIN
1F-25
IGNITION SWITCH

Starter signal When not detection of starter Module (ECM) pin 2 circuit short
71 recognition failure signal or open with bad contact
• Inspection ECM

AFFECTED VIN
1F-26
FUEL SYSTEM
The function of the fuel metering system is to deliver the correct Run Mode
amount of fuel to the engine under all operating conditions. The run mode has two conditions called ‘‘open loop” and
The fuel is delivered to the engine by the individual fuel injec- ‘‘closed loop”.
tors mounted into the intake manifold near each cylinder.
The main fuel control sensors are the Mass Air Flow (MAF) Open Loop
sensor and the oxygen (O2) sensors. When the engine is first started and it is above 690 rpm,
The MAF sensor monitors the mass flow of the air being the system goes into “open loop” operation. In “open loop”,
drawn into the engine. An electrically heated element is the ECM ignores the signal from the O2S and calculates
mounted in the intake air stream, where it is cooled by the the air/fuel ratio based on inputs from the ECT sensor
flow of incoming air. Engine Control Module (ECM) modu- and the MAF sensor. The ECM stays in “open loop” until
lates the flow of heating current to maintain the temperature the following conditions are met:
differential between the heated film and the intake air at a • The O2 has a varying voltage output, showing that it
constant level. The amount of heating current required to is hot enough to operate properly.
maintain the temperature thus provides an index for the mass • The ECT sensor is above a specified temperature (22.
air flow. This concept automatically compensates for varia- 5°C).
tions in air density, as this is one of the factors that deter-
mines the amount of warmth that the surrounding air ab- • A specific amount of time has elapsed after starting
sorbs from the heated element. MAF sensor is located be- the engine.
tween the air filter and the throttle valve. Closed Loop
Under high fuel demands, the MAF sensor reads a high
The specific values for the above conditions vary with dif-
mass flow condition, such as wide open throttle. The ECM
ferent engines and are stored in the Electronically Eras-
uses this information to enrich the mixture, thus increas-
able programmable Read-Only Memory (EEPROM).
ing the fuel injector on—time, to provide the correct amount
When these conditions are met, the system goes into
of fuel. When decelerating, the mass flow decreases. This
“closed loop” operation. In “closed loop”, the ECM calcu-
mass flow change is sensed by the MAF sensor and
lates the air/fuel ratio (fuel injector on-time) based on the
read by the ECM, which then decreases the fuel injector
signals from the O2 sensors. This allows the air/fuel ratio
on—time due to the low fuel demand conditions.
to stay very close to 14.7 to 1.
The O2 sensors are located in the exhaust pipe before
catalytic converter. The O2 sensors indicate to the ECM Acceleration Mode
the amount of oxygen in the exhaust gas, and the ECM The ECM responds to rapid changes in throttle position
changes the air/fuel ratio to the engine by controlling the and airflow and provides extra fuel.
fuel injectors. The best air/fuel ratio to minimize exhaust
emissions is 14.7 to 1, which allows the catalytic con- Deceleration Mode
verter to operate most efficiently. Because of the con- The ECM responds to changes in throttle position and
stant measuring and adjusting of the air/fuel ratio, the airflow and reduces the amount of fuel. When decelera-
fuel injection system is called a “closed loop” system. tion is very fast, the ECM can cut off fuel completely for
The ECM uses voltage inputs from several sensors to deter- short periods of time.
mine how much fuel to provide to the engine. The fuel is
delivered under one of several conditions, called ‘‘modes”. Battery Voltage Correction Mode
Starting Mode When battery voltage is low, the ECM can compensate
for a weak spark delivered by the ignition module by us-
When the ignition is turned ON, the ECM turns the fuel ing the following methods:
pump relay on for 1 second. The fuel pump then builds
fuel pressure. The ECM also checks the Engine Coolant • Increasing the fuel injector pulse width.
Temperature (ECT) sensor and the Throttle Position (TP) • Increasing the idle speed rpm.
sensor and determines the proper air/fuel ratio for start- • Increasing the ignition dwell time.
ing the engine. This ranges from1.5 to 1 at
-36°C (-33°F) coolant temperature to 14.7 to 1 at Fuel Cut-Off Mode
94°C (201°F) coolant temperature. The ECM controls the No fuel is delivered by the fuel injectors when the ignition
amount of fuel delivered in the starting mode by changing is off. This prevents dieseling or engine run-on. Also, the
how long the fuel injector is turned on and off. This is fuel is not delivered if there are no reference pulses re-
done by ‘‘pulsing” the fuel injectors for very short times. ceived from the CKP sensor. This prevents flooding.

AFFECTED VIN
1F-27
FUEL PUMP
1. Flange and harness assembly 5. Thermistor

2. Spring 6. Float arm
3. Fuel pump 7. Thermistor housing
4. Float 8. Resistor card and wiper
Requirements for Fuel Pump

Item Specified Value Item Specified Value
System pressure 3.8 bar Minimum delivery at 8v 30 Litre/Hr
Maximum pressure 8.5 bar (12 V) Operating voltage 8V
Minimum pressure 5.0 bar (12 V) Maximum allowable current 7.5 A
Nominal voltage 12 V Ambient temperature -30 ~ +70 °C
Minimum amount of fuel 114 Liter/Hr (12 V, 3.8 bar, Maximum amount of fuel 165 Liter/Hr (12V, 3.8 bar,
supply -30 ~ +70 °C) supply -30 ~ +70 °C)

AFFECTED VIN
1F-28
Fuel pump relay When short circuit to power • Inspection the Engine Control
34
short circuit to battery source Module (ECM) pin 33 about short
circuit or open with bad contact
Fuel pump relay
When short circuit to ground or • Inspection the fuel pump relay
35 short circuit to ground
open open with bad contact • Inspection the ECM
or open
Circuit Description
When the ignition switch is turned ON, the ECM will activate the pump relay and run the in-tank fuel pump. The fuel
pump will operate as long as the engine is cranking or running and the ECMis receiving ignition reference pulses.
If there are no reference pulses, the ECM will shut off the fuel pump within 2 seconds after the ignition switch is turned
ON, engine stopped or engine stalled.
Fuel Pump Relay Inspection

Measure the voltage between the ECM terminal No. 33 and ground.
Ignition Switch: ON 0 V (for1 ~ 2 sec.)

Cranking 0V

AFFECTED VIN
1F-29
Measure the Fuel Delivery from the Fuel Pump

1. Disconnect the return pipe from fuel distributor and insert the appropriate hose into it.
2. Place the hose end into the beaker with the minimum capacity of 1 Liter
3. Turn the ignition switch to “ON” position.
4. Connect the terminal No. 33 and No. 5 of ECM with a service wire.
5. Measure the fuel delivery from the fuel pump
Specified value 1 Liter/max. 35 sec.
Notice
Check the fuel filter and fuel line when the fuel delivery is not within specified value.
Measure the Current Consumption of Fuel Pump

1. Remove the fuel pump relay from fuse and relay box in trunk, and turn the ignition switch to “ON” position.
2. Using a multimeter, measure the current consumption by connecting the terminal No. 30 and No. 87 of the fuel
pump relay connector.
Specified value 5~9A
Notice
Replace the fuel pump relay if the measured value is over 9 A.

AFFECTED VIN
1F-30
FUEL INJECTOR
1. Fuel rail 4. Injector

2. O-ring 5. O-ring
3. Injector bracket
The Multipoint Fuel Injection (MFI) assembly is a solenoid-operated device controlled by the Engine Control Module
(ECM) that meters pressurized fuel to an each individual cylinder. The injector sprays the fuel, in precise quantities at
a point in time determined by the ECM, directly to ward the cylinder intake valve. ECM energizes the fuel injector
solenoid to lift the needle valve and to flow the fuel through the orifice. This injector’s discharge orifice is calibrated to
meet the effective fuel atomization necessary for both ensuring the maximum homogeneity in the air-fuel mixture and
holding the condensation along the walls of the intake tract to a minimum.
Fuel enters the top feed injector from above and flows through its vertical axis. The lower end extends into the intake
valve. Fuel from the tip is directed at the intake valve, causing it to become further atomized and vaporized before
entering the combustion chamber.
A fuel injector which is stuck partially open would cause a loss of fuel pressure after the engineis shut down. Also, an
extended crank time would be noticed on some engines. Dieseling could also occur because some fuel could be
delivered to the engine after the ignition is turned off.

AFFECTED VIN
1F-31

• Inspection the power to injector #1
When malfunction of injector
No. 1 injector short or bad contact
72 circuit
circuit to battery • Inspection the injector
Injector #1 short circuit to power
When malfunction of injector • Inspection the ECM pin 63 about

No. 1 injector short short circuit or open with bad contact
circuit
73 circuit to ground or
Injector #1 short circuit to • Inspection the injector
open
ground or open • Inspection the ECM
74 circuit

circuit
open
76 circuit

AFFECTED VIN
1F-32

circuit
open
78 circuit

circuit
open
192 circuit

circuit
open
194 circuit

circuit
open

AFFECTED VIN
1F-33
Injector Spray Pattern Check

1. Turn the ignition switch OFF.
2. Remove the fuel injector connectors.
3. Remove the fuel distributor and injector with a unit. At
this time, do not remove the supply and return line.
Notice
Prepare the beaker for taking the fuel.
4. Connect the shop made cable to the injector with a firing

order.
5. Connect the other end of shop made cable to the positive
battery cable and negative battery cable.
6. Turn the ignition switch ON.
7. Check the injector for normal spray pattern as shown in
the figure. Check injector for leaks or later drop
Injector Resistance Inspection

2. Remove the fuel injector connectors.
3. Measure the fuel injector coil resistance using a
multimeter.
Specified value 14 ~ 17 Ω
Notice
Replace the fuel injector if the measured value is out
of the specified values. Check the connector and wire
connection between the ECM and the injector if the
measured values are normal.
Injector Pulse Width Inspection

2. Install the scan tool.
3. Turn the ignition switch ON.
4. Monitor the “INJECTION TIME” with a scan tool.
Cranking 8.0 ms
Engine Idle 3 ~ 5 ms
Wide Open Throttle (WOT) 14 ms

AFFECTED VIN
1F-34
PURGE CONTROL VALVE
1. Purge control valve 3. Line to conister

2. Line to engine
The fuel vaporization control system is in stalled to inhibit the fuel vaporized gas from discharging into the atmosphere.
The fuel vaporized gas that is accumulated in the canister abstracts through the purge control valve purification during
the engine combustion (except the decreasing mode) and coolant temperature of over 80°C. For this reason, the Engine
Control Module (ECM) transacts the engine speed, air inflow quantity, coolant temperature, and intake temperature.
The purge control valve is activated by the ECM frequency according with the engine rotating speed to adjust the
purification rate. The purification rate is determined by the continuous valve opening interval.
The purge control valve is activated by the ECM for the following conditions:
• Coolant temperature of over 80°C
• Engine speed of over 1,000 rpm
• 2 minutes after starting
• When the fuel cut-off mode is not activated

AFFECTED VIN
1F-35

Purge control valve When short circuit to power • Inspection the ECM pin 34 about
40
short circuit to battery source short circuit or open with bad
contact.
Purge control valve When short circuit to ground or
• Inspection the source power of
41 short circuit to ground open circuit or open with bad
valve
or open contact
• Inspection the purge control
Purge control circuit When malfunction of purge solenoid vale
54
malfunction control: not work vale • Inspection the ECM
Test
1. Maintain the normal temperature and idling state by
operating the engine.
2. Connect the ECM terminal No. 11 and No. 34 and check
for normal operation through the output waves using
oscilloscope.
Notice
Test during purge control valve operation after the
minimum of 1 minute after the engine turned on.
3. Connect the ECM terminal No. 34 and No.10 and check
for current consumption during the ignition switch ON.
Specified value 0.3 ~ 0.5 A
4. Remove the line to canister and measure the pressure

with the vacuum pressure gauge.
> 500 mbar
(after approx. 1 min.)
Specified value
purge control valve oper-
ates at this time
Notice
Test while at normal temperature and at idling state
by operating the engine.

AFFECTED VIN
1F-36
FUEL RAIL
1. Injector connector 5. Fuel return line

2. Injector 6. Bolt
3. Fuel rail 7. Vacuum hose
4. Fuel supply line 8. O-ring

AFFECTED VIN
1F-37
Fuel Pressure Test

Tools Required
A9922 0012A (103 589 00 21 00) Fuel Pressure Gauge
1. Turn the ignition switch to “OFF” position.

2. Remove the fuel pressure test connector.
3. Connect the fuel pressure gauge to the fuel pressure
test connector.
4. Test the fuel pressure at idling by operating the engine
using the fuel pressure gauge A9922 0012A (103 589
00 21 00).
Vacuum hose connected (bar) 3.2 ~ 3.6
Vacuum hose disconnected (bar) 3.7 ~ 4.2
5. Replace the pressure regulator diaphragm if out of the

specification.
Internal Leakage Test

1. Connect thefuel pressure gauge A9922 0012A (103 589
00 21 00) to the fuel pressure test connector.
2. Stop the engine for approximately 30 minutes and then
check the fuel pressure changes.
Pressure Change
Fuel pressure drops • Fuel leakage at the
slowly injector
• Faulty fuel pressure
regulator’s
diaphragm and O-ring
Fuel pressure drops • Faulty check valve in
rapidly the fuel pump
3. If there is no change in fuel pressure and maintain the

following pressure over 30 minutes, it is normal.
Fuel pressure (bar)

AFFECTED VIN
1F-38
FUEL PRESSURE REGULATOR
1. Vacuum hose 4. O-ring

2. Circlip 5. O-ring
3. Fuel pressure regulator
Function of the Fuel Pressure Regulator

The fuel pressure regulator maintains the fuel pressure in the
fuel line with the pressure of 3.2 bars to 3.8 bars according to
the intake manifold pressure. This operating pressure cannot
be changed, and the fuel injection volume will be only deter-
mined by the injection time.
Over supplied fuel returns to the fuel tank through the return line.
<Operating at full load>

There is no negative pressure applied to the spring chamber
(9) during the full load, and it is separated from the fuel cham-
ber (8) by the diaphragm (5).
2. Fuel return line 8. Fuel chamber When the fuel pressure goes up, the diaphragm forces the
compression spring (6) in the direction of compression. At
3. Valve 9. Spring chamber
this moment, the valve (3) sticks to the diaphragm by the fuel
5. Diaphragm A. Valves closed
pressure, and the fuel return line (2) opens. The fuel over sup-
6. Compression spring B. Valves opened plied returns to the fuel tank through the return line.
AFFECTED VIN
1F-39
The pressure difference between the fuel pressure and

the intake manifold is about 3.8 bars during the full load.
1. Fuel pressure regulator

2. Intake manifold
1. Fuel pressure regulator 3. Fuel return (to fuel tank)
2. Intake manifold 4. Fuel supply (from fuel pump)
3. Fuel return (to fuel tank) 7. Fuel pressure (approx. 3.2 bars)
4. Fuel supply (from fuel pump) 8. Intake manifold negative pressure (0.6 bars)
5. Fuel paressure (approx. 3.8 bars) <Fuel Pressure Diagram>
6. Intake manifold negative pressure (0 bar)
<Operating at Idle and partial load>

The spring chamber (9) is connected to the intake mani-
fold with the vacuum hose at the intake pipe connection
(7). The negative pressure generated in the intake mani-
fold activates the diaphragm, and thus the fuel pressure
gets reduced to the rate of the operating extent of the
diaphragm by the intake manifold’s negative pressure.
A. Fuel pressure
B. Intake manifold negative pressure
LL. Idling
TL. Partial load
VL. Full load
Consequently, the fuel pressure in the fuel distributor

changes by the intake manifold’s negative pressure, and
the injector’s fuel pressure gets reduced independently
to the throttle valve’s position. Thus, the fuel injection
volume can only be determined according to the injector’s
injecting duration.
The pressure difference between the fuel pressure and
the intake manifold is approx. 3.2 bars during idling.
AFFECTED VIN
1F-40
INDUCTION SYSTEM
THROTTLE VALVE ACTUATOR
The throttle actuator is actuated by the Engine Control Consequently, the throttle valve opening is a constant 10
Module(ECM) according to the position of the accelera- ~ 12° approximately.
tor pedal position. At no load, this produces an engine speed of about 1,800 rpm
It has two potentiometers which signal the position of the
throttle valve to the ECM to enable it to recognize the Driving
various engine load states.
When driving (part/full throttle), the servo motor controls
the throttle valve in line with the various load states and
Ignition “OFF” according to the input signals from the pedal value sen-
In the de-energized states the throttle valve position is sor according to the input signals from the pedal value
determined to be spring capsule. sensor according to the position of the accelerator pedal.
The function of the EA (electronic accelerator) in the ECM
Ignition “ON” determines the opening angle of the throttle valve through
When the ignition S/W on the servo motor in the throttle the throttle actuator. Further functions are;
actuator is operated by the ECM. The throttle valve adopts • Idle speed control
a position in line with the coolant temperature. • Cruise control
• Reducing engine torque for ASR/ABS operation
Closed Position • Electronic accelerator emergency running
In the closed throttle position, the servo motor controls • Storing faults
engine speed by operating the throttle valve further (greater
• Data transfer through CAN
mixture) or closing it further (reduced mixture), depend-
ing on coolant temperature and engine load. When this is
done, the throttle valve can be closed further by the servo
motor overcoming the force of the spring capsule (me-
chanical end stop). If the actuator is deenergized, the
throttle valve is resting against the spring capsule.

AFFECTED VIN
1F-41

Throttle position sensor TPS 1 short circuit to ground or
104
1 low voltage open
Throttle position sensor
105 TPS 1 short circuit to power
1 high voltage
Throttle position sensor TPS 2 short circuit to ground or
108
2 low voltage open
Throttle position sensor • Monitoring the actual values
109 TPS 2 short circuit to power
2 high voltage through
When actuator adaption fluctua- • Inspection the ECM pin 84, 85,
Throttle actuator
116 tion or not meet the condition 87, 112, 67, 68 about short circuit
learning control failure
scan tool or open with bad contact
Throttle valve return When return spring defective of • Inspection the throttle valve
119
spring failure actuator with bad contact actuator
When supply voltage of the • Inspection the ECM
121 Throttle actuator failure actuator short circuit to power
Inspection the ECM
Different mass air flow
123 sensor signal with When shut down of output driver
throttle position sensor
Both throttle position When defective of both potenti-
125
sensor failure ometers

AFFECTED VIN
1F-42

Throttle position sensor • Monitoring the actual values
When difference between TPS 1
126 1 not plausible with through scan tool
and TPS 2
Throttle position sensor 2 • Inspection the ECM pin 84, 85,
High permanent throttle When failure of wiring harness or 87, 112, 67, 68 about short circuit
127 or open with bad contact
signal actuator
Mass air flow sensor • Inspection the throttle valve
When difference between MAF actuator
185 and throttle position
and TPS signal
sensor failure • Inspection the ECM
Circuit Description
The ECM supplies a 5 volt reference signal and a ground to the TP sensor. The TP sensor sends a voltage signal back
to the ECM relative to the throttle plate opening. The voltage signal will vary from approximately 0.3 ~ 0.9 volts at closed
throttle, to over 4.0 ~ 4.6 volts at Wide Open Throttle (WOT).
The TP sensors serve for engine load control according to the drive pedal command. Load adjustments independent of
the drive pedal command can be implemented; such functions are, for instance, idle control, speed control, drive slip
control, load shock damping, and similar functions.
When the actuator current fails, the throttle valve is returned to emergency operating position by a spring. The throttle
valve position, thereby the actuator drive position check back is provided by two potentiometers. The motor positions the
throttle valve against the return spring force. Motor and return spring are two separate energy sources. Each of Them is
able to position the throttle valve in emergency position alone. Throttle valve position check back and monitoring is
provided by two actual value potentiometers connected to the engine control electronics.
Throttle Actuator Inspection Throttle Actuator DC Motor

1. Turn the ignition switch to “ON” position. Resistance
2. Measure the TPS 1 signal voltage at the ECM pin No. 1. Turn the ignition switch to “OFF” position.
87 and TPS 2 signal voltage at the ECM pin No. 85. 2. Measure the resistance between the ECM pin No.
Pedal Position Specified Value 67 and No. 68.
Closed 0.3 ~ 0.9V Specified value <10 Ω

TPS 1
Opened 1 4.0 ~ 4.6V
Closed 4.0 ~ 4.6V
TPS 2
Opened 0.3 ~ 0.9V
Throttle Actuator DC Motor

Inspection
2. Measure the signal voltage between the ECM pin
No. 67 and No. 68.
Application Specified Value
Ignition “ON” 0.8 ~ 2.3 v
Engine 1.0 ~ 2.5 v
status Idling (Coolant tempera-
ture is over 70 °C)

AFFECTED VIN
1F-43
HOT FILM AIR MASS (HFM) SENSOR
1. Housing 4. Connector
2. Protector net 5. Hot film air mass Sensor
3. Electronic housing 6. Measuring port
The Hot Film Air Mass (HFM) sensor with recognition of flow direction related to pulsating flow is designed for recording
load on Engine Control Module (ECM) by measuring the output voltage proportional to the reference voltage of the ECM.
Mass Air Flow Sensor

Mass Air Flow (MAF) is a thermal flow meter whose sensor element with its temperature sensors and heating area is
exposed to the MAF to be measured. A heating area located in the center of a thin membrane is controlled to an over-
temperature by a heating resistor and a temperature sensor of this membrane. And the value of over-temperature
depends on the temperature of the in-flowing air.
Two temperature sensors on upstream and downstream of the heating area show the same temperature without incom-
ing flow. With incoming flow, upstream part is cooled down but downstream temperature retains its temperature more or
less due to the air heated up in the heating area. This temperature difference in quantity and direction depends on the
direction of the incoming flow.
ECM modulates the flow of heating current to maintain the temperature differential between the heated film and the
intake air at a constant level. The amount of heating current required to maintain the temperature thus provides an index
for the MAF. This concept automatically compensates for variations in air density, as this is one of the factors that
determines the amount of warmth that the surrounding air absorbs from the heated element. MAF sensor is located
between the air filter and the throttle valve.

AFFECTED VIN
1F-44
Under high fuel demands, the MAF sensor reads a high mass flow condition, such as Wide Open Throttle (WOT). The
ECM uses this information to enrich the mixture, thus increasing the fuel injector on-time, to provide the correct amount
of fuel. When decelerating, the mass flow decreases. This mass flow change is sensed by the MAF sensor and read by
the ECM, which then decreases the fuel injector on-time due to the low fuel demand conditions.
To facilitate the installation of the HFM in the intake passage, lubricating agents may be used. However, when lubricants
are used care must be taken to ensure that they do not enter the flow passage and cannot be sucked in with the air flow.
The following tables show the relationship between MAF and output voltage.
Mass Air Flow (kg/h) Voltage (V) Mass Air Flow (kg/h) Voltage (V)
0 0.95 ~ 1.05 250 3.51
10 1.28 370 3.93
15 1.41 480 4.23
30 1.71 640 4.56
60 2.16 800 4.82
120 2.76
Intake Air Temperature

The Intake Air Temperature (IAT) sensor is a part of Hot Film Air Mass (HFM) sensor and is a thermistor, a resistor which
changes value based on the temperature of the air entering the engine. Low temperature produces a high resistance,
while high temperature causes a low resistance as the following table.
The ECM provides 5 volts to the IAT sensor through a resistor in the ECM and measures the change in voltage to
determine the IAT. The voltage will be high when the manifold air is cold and low when the air is hot. The ECM knows the
intake IAT by measuring the voltage.
The IAT sensor is also used to control spark timing when the manifold air is cold.
Temp. (°C) Ω)
R min.(Ω Ω)
R nom. (Ω Ω)
R max. (Ω
-40 35,140 39,260 43,760
-20 12,660 13,850 15,120
0 5,119 5,499 5,829
20 2,290 2,420 2,551
40 1,096 1,166 1,238
60 565 609 654
80 312 340 370
100 184 202 222
120 114 127 141
130 91 102 114

AFFECTED VIN
1F-45

Intake air temperature IAT sensor short circuit to • Monitoring the actual air tempera-
03
sensor low voltage ground or open ture through scan tool
• Inspection the ECM pin 80, 79
Intake air temperature
04 IAT sensor short circuit to power about short circuit or open with
sensor high voltage
bad contact
Intake air temperature Malfunction in recognition of IAT • Inspection the IAT sensor
05 (integrated in HFM sensor)
sensor plausibility When functional problem
Malfunction in recognition of • Monitoring the actual air mass
Mass air flow sensor
09 MAF flow through scan tool
plausibility
When air mass not plausible • Inspection the ECM pin 81, 105
Mass air flow sensor MAF sensor short circuit to
10 bad contact
low voltage ground or open
• Inspection the MAF sensor
Mass air flow sensor MAF sensor short circuit to (integrated 11 in HFM sensor)
11
high voltage power • Inspection the ECM
Circuit Description
The heated element on the MAF is a platinum film resistor (heater). It is located on a ceramic plate together with the other
elements in the bridge circuit. The temperature sensitive resistor (flow sensor) also included in the bridge. The separation
of heater and flow sensor facilitates design of the control circuitry. Saw cuts are employed to ensure thermal decoupling
between the heating element and the intake air temperature (IAT) sensor. The complete control circuitry is located on a
single layer. The voltage at the heater provides the index for the mass air flow. The MAF’s electronic circuitry then converts
the voltage to a level suitable for processing in the ECM. This device does not need a burn off process to maintain its
measuring precision over an extended period. In recognition of the fact that most deposits collect on the sensor element’s
leading edge, the essential thermal transfer elements are located downstream on the ceramic layer. The sensor element
is also design to ensure that deposits will not influence the flow pattern around the sensor.
The IAT sensor uses a thermistor to control the signal voltage to the ECM. The ECM supplies 5 volt reference and a
ground to the sensor. When the air is cold, the resistance is high; therefore the IAT signal voltage will be high. If the
intake air is warm, resistance is low; therefore the IAT signal voltage will be low.

AFFECTED VIN
1F-46
Mass Air Flow Sensor Input Voltage Inspection

2. Measure the signal voltage between the ECM pin
Application Specified Value

Ignition “ON” 0.9 ~ 1.1 v
Engine 1.3 ~ 1.7 v
status Idling (Coolant tempera-
ture is over 70 °C)
Notice
If the measured value is not within the specified value, the possible cause may be in cable or MAF sensor
in itself. Perform the 5 volt power supply inspection procedures.
Mass Air Flow Sensor 5 volt Power Supply Inspection

2. Disconnect the HFM sensor connector.
4. Measure the voltage between the ECM pin No. 108 and MAF sensor connecter terminal No. 3.
Specified value 4.7 ~ 5.2 V
Notice
If the measured value is not within the specified value, the possible cause may be in cableor ECM coupling.
Notice
If the measured value is not within the specified value, the possible cause may be in cableor ECM coupling.
Mass Air Flow Sensor 12 volt Power Supply Inspection

Specified value 11 ~ 14 V
Notice
If the measured value is not within the specified value, the possible cause may be in cable or Over Voltage
Protection Relay (OVPR).

AFFECTED VIN
1F-47
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
1. Artificial resin housing 4. Connector

2. Metal housing 5. Engine coolant temperature sensor
3. NTC (Negative Tcemperature Coefficient) resistor
Engine Coolant Temperature (ECT) sensor detects coolant temperature and supplies information to the ECM. It is
composed of metal housing with two NTC resistor, 4 pin connector. The ECM provides a 5 volt signal to the ECT sensor
through a dropping resistor. When the engine is cold, the ECT sensor provides high resistance, which the ECM detects
as a high signal voltage. As the engine warms up, the sensor resistance becomes lower, and the signal voltage drops.
At normal engine operating temperature, the ECT signal will measure about 1.5 to 2.0 volts.
The ECM uses information about coolant temperature to make the necessary calculations for:
• Fuel delivery
• Ignition control
• Knock sensor system
• Idle speed
• Torque converter clutch application
• Canister purge
• Cooling fan operation
• Others

AFFECTED VIN
1F-48
Temperature (°C) Ω)
Resistance (Ω Voltage (V)
-40 48,550 4.90
-30 27,000 4.82
-20 15,570 4.70
-10 9,450 4.52
0 5,890 4.43
10 3,790 3.96
20 2,500 3.57
30 1,692 3.14
40 1,170 2.70
50 826 2.26
60 594 1.86
70 434 1.51
80 322 1.22
90 243 0.98
100 185 0.78
110 143 0.63
120 111.6 0.50
130 88 0.40
140 71.2 0.33

AFFECTED VIN
1F-49

Engine coolant
ECT sensor short circuit to
00 temperature sensor low
ground or open
voltage
Engine coolant • Monitoring the actual coolant
ECT sensor short circuit to temperature through scan tool
01 temperature sensor
power
high voltage • Inspection the ECM pin 78, 79
Malfunction in recognition of ECT about short circuit or open with
Engine coolant
bad contact
02 temperature sensor When drop to about 50°C below
plausibility after warm up • Inspection the ECT sensor
Engine coolant • Inspection the ECM

Malfunction in recognition of ECT
temperature insufficient
06 When minimum temperature for
for closed loop fuel
lambda control after warm up
control
Circuit Description
The ECT sensor uses a thermistor to control the signal voltage to the ECM. The ECM supplies a voltage on the signal
circuit to the sensor. When the engine coolant is cold, the resistance is high; therefore the ECT signal voltage will be high.
Engine Coolant Temperature Sensor Inspection

2. Measure the voltage between the ECM pin No. 78 and No. 79.
Temperature (°C) Specified Value (V)
20 3.57
80 1.22
100 0.78

AFFECTED VIN
1F-50

4. Disconnect the ECT sensor connector.
6. Measure the resistance between the ECT sensor terminal pin No. 1 and No. 4.
Temperature (°C) Specified Value (V)
20 2,500
80 322
100 185
Notice
Replace wiring and coolant temperature sensor if out of specified value.

AFFECTED VIN
1F-51
ACCELERATOR PEDAL MODULE
1. Accelerator pedal 4. 6-pin connector

2. Accelerator pedal sensor 5. Bolt
3. Bolts
The Acceleration Pedal Position (APP) sensor is mounted on the accelerator pedal assembly. The sensor is actually
two individual APP sensors and one housing. This sensor works with the Throttle Position (TP) sensor to provide input
to the Engine Control Module (ECM) regarding driver requested accelerator pedal and throttle angle at the throttle body.
When the APP Sensor is Defected

When the APP1 or APP 2 sensor is defected condition, the engine is still running at idle condition but, the accelerator
pedal reaction is not response correctly and also, the engine rpm will be reacted to 4,000 rpm slowly. If the APP 1
sensor is out of order, the APP 2 sensor will be conducted with signal as a default signal but, the throttle valve opening
is limited 60% and delayed opening speed.
When the TP Sensor or Servo Motor is Defected

When the TP 1, 2 sensor or servo motor is defected condition, the throttle valve will be closed to the spring capsule by
spring force, at this condition, the throttle valve will open 10° ~ 20°and engine rpm will be controlled by ECM with opening
(ON/OFF) time of injector. The engine rpm will be maintaining 900 rpm (at idle) to 1,800 according to the engine load.

AFFECTED VIN
1F-52

Acceleration pedal
When malfunction of APP
122 position sensor signal
sensor
failure
Acceleration pedal
APP 1 sensor short circuit to
160 position 1 sensor low
ground or open
voltage
Acceleration pedal
161 position sensor 1 high
power
voltage • Monitoring the actual values
Acceleration pedal through scan tool
162 position sensor 2 low • Inspection the ECM pin 31, 47,
ground or open
voltage 32, 48, 59, 51 about short circuit
Acceleration pedal or open with
163 position sensor 2 high • Inspection the APP sensor
power bad contact
voltage • Inspection the ECM
Accelerator pedal
position sensor 1 not
When difference between APP 1
164 plausible with
sensor and APP 2 sensor
accelerator pedal
position sensor 2
Both setpoint
accelerator pedal When defective of both APP
167
position sensor sensor
defective

AFFECTED VIN
1F-53
Circuit Description
The ECM supplies a 5 or 2.5 volt reference signal and a ground to the APP sensor 1or 2. The ECM calculates on these
signal lines. The APP sensor output changes as the accelerator pedal is moved. The output of the APP 1and APP2
sensor are low, about 0.4 ~ 0.7 volts and 0.2 ~ 0.35 volts respectively at the closed throttle position. As pushing the
accelerator pedal, the output increases so that the output voltages will be about 4.3 ~ 4.8 volts and 2.1 ~ 2.4 volts
individually when accelerating fully with the kick down, at Wide Open Throttle (WOT).
Acceleration Pedal Position Sensor 1 Inspection

2. Measure the signal voltage between the ECM pin No. 47andNo. 31while operating the accelerator pedal as following
conditions.
• Not depress the pedal (closed throttle position)
• Fully depress the pedal (full throttle with kick down)
Condition of Throttle Valve Specified Value (V)

Closed throttle valve 0.3 ~ 0.7
Fully depressed throttle valve 4.3 ~ 4.8
Notice
If measured value is not within the specified value, check the pedal valve sensor and the supply voltage to
APP 1 sensor.
Acceleration Pedal Position Sensor 2 Inspection

2. Measure the signal voltage between the ECM pin No. 48 and No. 50 while operating the accelerator pedal as
following conditions.
• Not depress the pedal (closed throttle position)
• Fully depress the pedal (full throttle with kick down)
Condition of Throttle Valve Specified Value (V)
Closed throttle valve 0.1 ~ 0.4
Fully depressed throttle valve 2.1 ~ 2.5
Notice
If measured value is not within the specified value, check the pedal valve sensor and the supply voltage to
APP sensor 2.

AFFECTED VIN
1F-54
COOLING FAN
Cooling fan (HI) relay • Inspection the Engine Control

44 Cooling fan short circuit to power Module (ECM) pin 35 about short
short circuit to power
Cooling fan (HI) relay • Inspection the power source
Cooling fan short circuit to
45 short circuit to ground • Inspection the cooling fan
ground or open with bad contact
or open • Inspection the ECM
Circuit Description
Ignition voltage is supplied directly to the cooling fan relay coil. The ECM controls the relay by grounding the control
circuit. When the ECM is commanding a command ON, the voltage of the control circuit should be low (near 0 volt).
When the ECM is commanding the control circuit should be high (near battery voltage). If the fault detection circuit
senses a voltage other than what is expected, the fault line status will change causing the fault code to set.

AFFECTED VIN
1F-55
A/C COMPRESSOR RELAY

• Monitoring the actual operation
A/C compressor relay through scan tool
228
short circuit to battery
When malfunction of A/C Module (ECM) pin 44 about short
compressor control circuit or open with bad contact
A/c compressor relay • Inspection the relay short circuit
229 short circuit to ground or open
or open
Circuit Description
When the ECM detects that A/C has been requested, the ECM will activated the A/C clutch relay. When the relay has
been activated, voltage should be present at both the A/C clutch relay and A/C switch circuit at ECM.

AFFECTED VIN
1F-56
CRUISE CONTROL SWITCH

Cruise control “OFF”
Cruise control system
129 due to message
message counter fault
counter failure • Monitoring the actual recognition
Vehicle speed signal status and vehicle speed signal
130 When malfunction of auto-cruise
failure through scan tool
system Implausible condition of • Inspection the Engine Control
Vehicle speed signal
131 vehicle speed signal.
failure Module (ECM) pin 52 53 54 55 57
Cruise control lever Cruise control lever about short circuit or open with
132 bad contact
failure defective
• Inspection the CAN and ABS
Cruise control system Implau-
Cruise control • Inspection the cruise control lever
133 sible condition of acceleration
acceleration failure switch
signal
Cruise control system Implau- • Inspection the ECM
Cruise control
134 sible condition of deceleration
deceleration failure
signal
Circuit Description
Cruise control is an automatic speed control system that maintain a desired driving speed without using the accelerator
pedal. The vehicle speed must be greater than 40 km/h to engage cruise control.

AFFECTED VIN
1F-57
RESONANCE FLAP

status and vehicle speed signal
Resonance flap short Resonance flap short circuit to through scan tool
228
circuit to battery power
Module (ECM) pin 97 about short
• Inspection the power source short
Resonance flap short circuit or open to resonance flap
Resonance flap short circuit to
229 circuit to ground or • Inspection the resonance flap
ground or open
open solenoid and hardware
Circuit Description
A pneumatically actuated resonance flap is located on the intake manifold, and will be opened and closed by load, which
operates resonance flap according to engine and controlled by ECM and rpm.
Resonance flap is closed at idle/partial load (less than 3,800/rpm). The switch valve will be adjusted by ECM and
resonance flap will be closed. By increasing air flow passage through dividing intake air flow toward both air collection
housing. This leads to a significant increase in the torque in the lower speed range.
Resonance flap is open at full load (over 3,800/rpm). The switch valve will not be adjusted by ECM and resonance flap will
be open. The collected air in the air collection housing will not be divided and intake air passage will be shorten.

AFFECTED VIN
1F-58
STOP LAMP SWITCH

status and vehicle speed signal
through scan tool
When malfunction of stop lamp • Inspection the Engine Control
135 Stop lamp switch failure switch - implausible condition of Module (ECM) pin 49 about short
stop lamp signal input circuit or open with bad contact
• Inspection the contact condition of
stop lamp switch
Circuit Description
The stop lamp switch is normally opened. When the ignition switch ON and brake ON, the battery voltage is supplied to
the ECM. A scan tool should display ON when brake pedal is depressed and should read OFF with brake pedal released.

AFFECTED VIN
1F-60
EXHAUST SYSTEM
CATALYTIC CONVERTER These catalysts in the 3-way catalytic converter are the
rare metals platinum (Pt) and rhodium (Rh).
The purpose of the catalytic converter is to convert the
The catalytic converter consists essentially of three main
three pollutants of carbon monoxide(CO), hydrocarbons
(HC) and oxides of nitrogen (NOx) contained in the ex- elements. The exhaust gases flow through the catalytic
converter and, in so doing, coming into contact with rare
haust of gasoline engines, into the harmless compounds
metals (Pt and Rh).
of water (H2O), carbon dioxide (CO2) and nitrogen (N2).
The following chemical reaction are produced.
The catalytic converter contains a catalyst, a word com-
ing from the Greek and which designates the element CO + O2 → CO 2
essential for catalyst which triggers chemical reactions HC + O2 →CO2 + H2O
without itself being consumed. NOx →N2 + O2

AFFECTED VIN
1F-61
OXYGEN SENSOR
The oxygen sensor is unique among the engine control When the exhaust gas is rich (below 14.7 : 1), the voltage
sensors because is acts like a battery and is able to output is high, above 450 mv. When the exhaust gas is
generate its own low voltage signal. It is located the ex- lean (above 14.7 : 1 air/fuel ratio), the sensor’s voltage
haust system and monitors the amount of oxygen in the output is low, below 450 mv.
exhaust stream and provides feedback to the Engine The ECM uses oxygen sensor information for:
Control Module (ECM).
• Open loop / closed loop criteria
The electrically heated oxygen sensor warms up quickly
• Ideal air / fuel ratio
and remains hot, even at idle when the exhaust manifold
may cool down.
The ECM applies a reference voltage of 450 mv to the
oxygen sensor, the ECM compares this reference volt-
age with the voltage generated by oxygen sensor. The
amount of voltage the oxygen sensor generates is pro-
portionate to the difference between the amount of oxy-
gen in the outside air and the exhaust gases. The atmo-
sphere contains about 21% oxygen. The exhaust from a
rich air/fuel ratio contains almost no oxygen. With a large
difference between the amounts of oxygen containing the
two surface, the sensor generates less voltage.

AFFECTED VIN
1F-62

AFFECTED VIN
1F-63

When recognition the output that
Oxygen sensor high
80 more than nominal threshold,
voltage
malfunction of sensing voltage.
When recognition the output that • Monitoring the actual output
Oxygen sensor low signal through scan tool
89 more than nominal threshold,
voltage
malfunction of sensing voltage. • Inspection the ECM pin 16, 17
Oxygen sensor no When recognition the output that
82 bad contact
activity detected not active the sensor etc.
• Inspection the oxygen sensor
Oxygen sensor not lean When recognition the output that
83 after overrun fuel no lean signal after overrun fuel
shut-off shut-off
Oxygen sensor slow When slow response of sensor
84
response signal
Oxygen sensor heater When recognition the heating
85 • Monitoring the heating status
failure circuit
through scan tool
When recognition the heating • Inspection the ECM pin 9 about
Oxygen sensor heater currents that more or less than short circuit or open with bad contact
86
short circuit to battery set values (less than 0.2A or
• Inspection the heating power source
more than 2A)
• Inspection the heating circuit of
Oxygen sensor heater When recognition the heating oxygen sensor
87 short circuit to ground voltages than less than set
or open values (less than 2V)

AFFECTED VIN
1F-64

When recognition the value less
Bank 1 system short than nominal control threshold, it
term fuel trim means that when big deviation in
81
adaptation below lean control range of adaptation
threshold values through fuel and air
mixture formation
When recognition the value more
Bank 1 system short than nominal control threshold, it
term fuel trim means that when big deviation in
93
adaptation above rich control range of adaptation
threshold values through fuel and air
mixture formation
Bank 1 system short When recognition the short term
96 term fuel trim at rich fuel trim that more than nominal
stop threshold
Bank 1 system short When recognition the short term • Inspection the intake air leakage
97 term fuel trim at lean fuel trim that less than nominal
• Inspection the injection quantities
stop threshold
with injector block or leakage
Bank 1 system idle • Inspection the exhaust leakage
When recognition the long term
98 adaptation failure
fuel trim exceeds rich threshold • Inspection the ECM
(above rich threshold)
Bank 1 system idle
99 adaptation failure
fuel trim exceeds lean threshold
(below rich threshold)
Bank 1 system learning
100 control failure
fuel trim exceeds rich threshold
(rich, low load)
101 control failure
(lean, low load)
102 control failure
fuel trim exceeds rich threshold
(rich, high load)
103 control failure
(rich, low load)
Circuit Description
In order to control emissions, a catalytic converter is used to covert harmful emissions into harmless water vapor and
carbon dioxide. The ECM has the ability to monitor this process by using a oxygen sensor. The oxygen sensor produces
and output signal which indicates the storage capacity of the catalyst. This in turn indicates the catalyst’s ability to
convert exhaust emission effectively. If the oxygen sensor pig tail wiring, connector, or terminal is damaged. Do not
attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly, it must have a clean air
reference provided to it. This clean air reference is obtained by way of the oxygen sensor wire(s). Any attempt to repair
the wires, connector, or terminal and degrade the oxygen sensor performance.

AFFECTED VIN
1F-65
Oxygen Sensor Signal Voltage Inspection

1. Maintain the engine speed is at idle while the coolant temperature is over 80 °C.
2. Measure the oxygen sensor signal voltage between the ECM terminal No. 16 and No. 17.
Notice
If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor
or ECM.
Oxygen Sensor Heating Voltage Inspection

1. Maintain the engine speed is at idle while the coolant temperature is over 80 °C.
2. Measure the oxygen sensor signal voltage between the ECM terminal No. 11 and No. 9.
Specified value 11 ~ 14 V
Notice
or ECM.
Oxygen Sensor Heating Current Consumption Inspection

2. Measure the oxygen sensor heating current consumption between the ECM terminal No. 9 and No. 5.
Specified value 0.2 ~ 2.0 A
Notice
or ECM.

AFFECTED VIN
1F-66
ENGINE CONTROL MODULE
1. Cover 5. Pin
2. Plate Vehicle side: No. 13-60
3. Connector Engine side: No. 73-120
4. Flat pin A. Vehicle side connector: Black
Vehicle side: No. 1-12 B. Engine side connector: Gray
Engine side: No. 61-72
The Engine Control Module (ECM), located inside the right side kick panel, is the control center of the fuel injection
system. It constantly looks at the information from various sensors and controls the systems that affect the vehicle’s
performance. Engine rpm and air mass are used to measure the air intake quantity resulting in fuel injection metering.
The ECM also performs the diagnostic functions of the system. It can recognize operational problems, store failure code(s)
which identify the problem areas to aid the technician in making repairs.
There are no serviceable parts in the ECM. The calibrations are stored in the ECM in the Programmable Read Only
Memory (PROM).
The ECM supplies either 5 or 12 volts to power the sensors or switches. This is done through resistance in the ECM
which are so high in value that a test light will not come ON when connected to the circuit. In some cases, even an
ordinary shop voltmeter will not give and accurate reading because its resistance is too low. You must use a digital
voltmeter with a 10 Mohm input impedance to get accurate voltage readings. The ECM controls output circuits such as
the ignition coils, the fuel injectors, the fuel pump relay, the intake manifold resonance flap, the camshaft actuator, the
canister purge valve, etc., by controlling the ground circuit.

AFFECTED VIN
1F-67
SERIAL DATA COMMUNICATION

• Inspection the ASR unit with CAN
When CAN signal message connection
CAN communication missing or implausibility for • Inspection the Engine Control
23
failure: ASR/MSR ASR/MSR unit or not Module (ECM) pin 38, 37 about short
initialized condition circuit or open with bad contact
• Inspection the ABS unit with CAN

CAN communication
24 missing or implausibility for ABS • Inspection the ECM pin 38, 37 about
failure: ABS
unit or not initialized condition short circuit or open with bad contact
• Inspection the TCM unit with CAN

CAN communication
26 missing or implausibility for TCU • Inspection the ECM pin 38, 37 about
failure: TCU (A/T only)
unit or not initialized condition short circuit or open with bad contact

AFFECTED VIN
1F-68

• Inspection the TOD unit with CAN connec-
When CAN signal message tion
CAN communica-
missing or implausibility for
27 tion failure: TOD • Inspection the ECM pin 38, 37 about short
TOD unit or not initialized
(E32 only) circuit or open with bad contact
condition
• Inspection the ABS/ESP unit with CAN

CAN communica-
29 tion failure: ID 200h • Inspection the ECM pin 38, 37 about short
ABS/ESP unit or not initial-
not plausible circuit or open with bad contact
ized condition
• Inspection the ABS/ESP unit with CAN

CAN communica-
30 tion failure: ID 208h • Inspection the ECM pin 38, 37 about short
ABS/ESP unit or not
not plausible circuit or open with bad contact
initialized condition
When CAN signal message • Inspection the each control unit with CAN
CAN communica- connection
tion failure: commu-
31 each unit • Inspection the ECM pin 38, 37 about short
nication initializa-
(ABS, ASR, TCM, TOD etc.) circuit or open with bad contact
tion failure
or not initialized condition • Inspection the ECM
• Inspection the MSR unit with CAN connection

CAN communica- When CAN signal message • Inspection the Engine Control Module (ECM)
tion failure: MSR missing or implausibility for pin 38, 37 about short circuit or open with
59
data transmission MSR unit or not initialized bad contact
not plausible condition • Inspection the ECM
• Inspection the ASR unit with CAN connection
CAN communica- When CAN signal message • Inspection the Engine Control Module
tion failure: ASR missing or implausibility for (ECM) pin 38, 37 about short circuit or open
60
data transmission ASR unit or not initialized with bad contact
not plausible condition • Inspection the ECM
Circuit Description
The provision for communicating with the ECM is the Data Link Connector (DLC). It is located in the instrument panel
fuse block. The DLC is used to connect the scan tool. Battery power and ground is supplied for the scan tool through the
DLC. CAN line is used to communicate with the other module such as the Transmission Control Module (TCM) and
Transfer Case Control Unit (TCCU).
Keyword 2000 Serial Data Communications

Each bit of information can have one of two lengths: long or short. This allows vehicle wiring to be reduced by transmit-
ting and receiving multiple signals over a singles wire. The message carried on KWP 2000 data streams are also
prioritized. If two messages attempt to establish communications on the data line at the same time, only the message
with higher priority will must wait.

AFFECTED VIN
1F-69
INTERNAL FAILURE
• Inspection the coding condition
through scan tool
Transmission coding When faulty of variant coding of • Inspection the Engine Control
21
failure transmission Module (ECM)
• Inspection the CAN line
• Inspection the TCM
When malfunction of random

136 ECM failure (RAM) access memory - ECM internal • Inspection the ECM
error
When malfunction of ECM

Uncoded/unprogramed
142 coding-required ECM • Fulfill the ECM variant coding
ECM
encoding
137 ECM failure (EPROM)
ECM failure (EEPROM/

143 Flash - EPPOM
checksum failure)
When malfunction of ECM
ECM failure (coding ID • Inspection the ECM
144 internal
checksum failure)
ECM failure (coding

145
checksum failure)
ECM failure
146 (programming
checksum failure)

AFFECTED VIN
1F-70
ELECTRONIC THROTTLE CONTROLLER SAFETY MALFUNCTION

Throttle actuator
110
learning data fault
117 Exceed fuel-cut safety time
Cruise control
120
interruption memory failure
138 Call Monitoring
Servo motor control output

139
interruption memory failure
140 Servo motor open/short
ECM failure
186
(incompatible CPU)
ECM failure (CPUs communica-

187
tion failure)
ECM failure (CPU 2 configuration

188
failure)
189 ECM failure (CPU 2 fault) • Inspection the Engine Control

System internal failure
Module (ECM)
ECM failure (CPU run time
190
failure between CPUs)
ECM failure (CPU 2 cruise

231
control message counter failure)
232 Over deceleration limit (CPU 2)
233 Over acceleration limit (CPU 2)
Cruise control lever dual opera-

234
tion (CPU 2)
Cruise control lever safety

235
terminal failure (CPU 2)
Unusual pedal position variation

236
(CPU 2)
Unusual throttle position variation

237
(CPU 2)
Unusual throttle
238 controller monitoring data
comparison fault (CPU 2)

AFFECTED VIN
1F-71

Unusual accelerator pedal
239 position sensor comparison fault
(CPU 2)
240 Throttle potentiometer compari-

son fault (CPU 2)
Unusual CPU
241
communication (CPU 2)
Unusual CPU
242
configuration (CPU 2)
243 A/D converter failure (CPU 2)
Accelerator pedal position

244 sensor setpoint fault between
CPU 1 and CPU 2 (ECM) System internal failure
Module (ECM)
Position controller setpoint
245
fault between CPU 1 and CPU 2
MSR setpoint fault between CPU

246
1 and CPU 2
Idle control setpoint fault be-

247
tween CPU 1 and CPU 2
248 A/D converter overflow (CPU 2)
249 ROM fault (CPU 2)
250 RAM fault (CPU 2)
251 Cycle monitor fault (CPU 2)

AFFECTED VIN
1F-72
IMMOBILIZER

• D Inspection the Engine Control
Module (ECM) pin 13, 14 about
short circuit or open with bad contact
• Inspection the power source or
Communication with When missing the
25 ground short circuit or open of
transponder missing transponder signal
immobilizer unit
• Inspection the transponder
condition (broken etc.)
When malfunction of immobilizer

Unprogramed ECM with Required immobilizer encoding,
141 • Fulfill the immobilizer pairing
immobilizer no paired condition of immobi-
lizer even through start trial
Circuit Description
Immobilizer is a device disabling vehicle ignition unless a specific key is used and designed to help prevent vehicle theft.
Immobilizer is comprised of two devices, a key with encoded transponder and ECM with the same encoding of the
transponder. When a key is inserted into the hole to start vehicle and turned to ON, the ECM reads and decodes the
transponder code and, if the same, starts the engine, it is called immobilizer. It means immobilizer system disables
starting by stopping fuel supply if the code in the transponder does not match the code stored in ECM each other.

AFFECTED VIN
1F-73
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
DISCHARGING THE PRESSURE IN
FUEL SYSTEM
Installation
Specified value 25 Nm (18 lb-ft)
2. Remove the fuel pressure in fuel system by pressing the

service valve with a clean, pointy tool.
Notice
Place a cloth so that the fuel doesn’t stain around.

reverse order.
FUEL PUMP
Tools Required
A9922 0012A (661 589 00 46 00) Fuel Tank Cap Wrench

Caution
The fuel system is under pressure. To avoid fuel
spillage and the risk of personal injury or fire, it is
necessary to relieve the fuel system pressure before
disconnecting the fuel lines.
1. Relieve the fuel system pressure. Refer to “Discharging

the Pressure in Fuel System” in this section.
3. Remove the fuel pump wiring connectors.
4. Disconnect the fuel supply and return pipes.
5. Remove the fuel pump locking cap band.

AFFECTED VIN
1F-74
8. Using the fuel tank cap wrench 661 589 00 46 00, remove
the locking cap.
9. Remove the pump from the fuel tank.
Notice
Check the condition of the seal and replace if
necessary. Drain the fuel before removing the pump.
10. Perform an operational check of the fuel pump.

reverse order.
FUEL FILTER
Caution
2. Relieve the fuel system pressure. Refer to “Discharging

the Pressure in Fuel System” in this section.
3. Disconnect the fuel lines from the fuel filter.
Installation
4. Remove the fuel filter mounting bracket bolt.

Installation
Notice
Place the fuel pump pad. There may be a corrosion
due to the contact between the fuel filter and the
bracket.
5. Remove the fuel filter.

6. Install the fuel filter.
7. Perform a leak test of the fuel filter.
reverse order.

AFFECTED VIN
1F-75
FUEL TANK
Caution
1. Relieve the fuel pressure. Refer to “Discharging the
Pressure in Fuel System” in this section.
3. Drain the fuel tank.
4. Disconnect the return line.
5. Disconnect the supply line.
6. Disconnect the fuel tank-to-canister hose from the fuel
tank.
7. Disconnect the fuel pump wiring connector.
8. Disconnect the fuel supply hose, fuel return hose.

AFFECTED VIN
1F-76
9. Unscrew the bolts and remove the fuel filler pipe from the
fuel filler opening.
10. Install the safety jack under the fuel tank and remove the
bolts (12mm x 4) from the fuel tank.

AFFECTED VIN
1F-77
11. Carefully lower the safety jack with the fuel tank.
Caution
Be careful not to drop the fuel tank while removing
it.

AFFECTED VIN
1F-78
FUEL PRESSURE REGULATOR

Installation
Caution
3. Relieve the fuel pressure in fuel supply system by

pressing the service valve.
4. Disconnect the vacuum hose.

5. Disconnect the circlip and remove the fuel pressure
regulator.
6. Apply the oil to O-ring lightly and then replace it.
7. Perform a leak test of the fuel pressure regulator with the
engine off and the ignition on.
reverse order.

AFFECTED VIN
1F-79
FUEL RAIL AND INJECTORS

Caution
The fuel system is under pressure. To avoidfuel spillage
and the risk of personal injury or fire, it is necessary to
relieve the fuel system pressure before disconnecting the
fuel lines.
1. Discharge the fuel pressure from the fuel pressure test

connector.
3. Disconnect the vacuum hose from the fuel pressure
regulator.
4. Remove the cable guide.
5. Disconnect the Hot Film Air Mass (HFM) sensor
connector.
6. Remove the intake air duct mounting bolts.
Installation
7. Remove the intake air duct clamps.

8. Remove the intake air duct.
9. Remove the fuel return and supply line.

Notice
For removal, cover around parts with cloths not to
be stained by fuel. In case of checking the injector
only, do not remove the fuel return and supply line.
Installation
10. Remove the six injector connectors.
11. Remove the two left and two right bolts and one center
bolt of the fuel rail assembly from the intake manifold.
Installation

AFFECTED VIN
1F-80
Notice
Before removal, the fuel rail assembly may be cleaned
with as pray type cleaner, following package instructions.
Do not immerse the fuel rails in liquid cleaning solvent.
Use care in removing the fuel rail assembly to prevent
damage to the electrical connectors and injector spray
tips. Prevent dirt and other contaminants from entering
open lines and passages. Fittings should be capped and
holes plugged during service.
Important
If an injector becomes separated from the rail and remains
in the cylinder head, replace the injector O-ring seals and
the retaining clip.
12. Remove the injectors and the fuel rail carefully.

13. Remove the fuel injector retainer clips.
14. Remove the fuel injectors by pulling them down and out.
15. Discard the fuel injector O-rings.
16. Lubricate the new fuel injector O-rings with engine oil.
Install the new O-rings on the fuel injectors.
17. Perform a leak check of the fuel rail and fuel injectors.
reverse order.
ENGINE COOLANT TEMPERATURE

SENSOR
1. Relieve the coolant system pressure.
3. Disconnect the engine coolant temperature sensor
connector.
Notice
Take care when handling the engine coolant
temperature sensor. Damage to the sensor will affect
the proper operation of the fuel injection system.
4. Remove the engine coolant temperature sensor from the

pump hosing.
Installation

reverse order.

AFFECTED VIN
1F-81
THROTTLE BODY (INTEGRATED

WITH THE ACTUATOR)
2. Disconnect the mass air flow sensor connector.
3. Disconnect the mass air flow sensor from the air filter
housing.
4. Remove the intake air duct mounting bolts.
Installation
5. Remove the air inlet housing clamps.

6. Remove the inlet air housing.
7. Disconnect the throttle body electrical connector.

8. Remove the throttle body bolts.
Installation
9. Remove the vacuum hose.
10. Remove the throttle body and discard the gasket.

Important
Use care in cleaning old gasket material. Sharp tools
may damage sealing surfaces.

reverse order.

AFFECTED VIN
1F-82
HOT FILM AIR MASS (HFM) SENSOR

2. Disconnect the Hot Film Air Mass (HFM) sensor electrical
connector.
3. Remove the HFM sensor retaining screws.
4. Turn the HFM sensor coupling in the direction shown in
the figure in the left so that it gets separated from the
contact surface.
Notice
Make sure the HFM sensor coupling connects
completely with the contact surface installation.
5. Remove the HFM sensor.

reverse order.
KNOCK SENSOR
2. Disconnect the knock sensor electrical connector from
the intake manifold bracket.
3. Remove the knock sensor mounting bolt from the knock
sensor installed on the cylinder block.
Installation
4. Remove the knock sensor.

reverse order.

AFFECTED VIN
1F-83
PEDAL POSITION SENSOR

2. Disconnect the pedal position sensor connector.
3. Unscrew the bolts and nut.
Installation
4. Remove the pedal and sensor assembly.

reverse order.
OXYGEN SENSOR
Notice
The oxygen sensor uses a permanently attached
pigtail and connector. This pigtail should not be
removed from the oxygen sensor. Damage or removal
of the pigtail or the connector could affect proper
operation of the oxygen sensor. Do not drop the
oxygen sensor.
2. Disconnect the electrical connector.

3. Carefully remove the oxygen sensor from the exhaust pipe.
Installation
Important
A special anti-seize compound is used on the oxygen
sensor threads. This compound consists of a liquid
graphite and glass beads. The graphite will burn away,
but the glass beads will remain, making the sensor
easier to remove. New or serviced sensors will al-
ready have the compound applied to the threads. If a
sensor is removed from any engine and is to be rein-
stalled, the threads must have an anti-seize compound
applied before reinstallation.
4. Coat the threads of the oxygen sensor with an anti-seize

compound, if needed.
reverse order.

AFFECTED VIN
1F-84
PURGE CONTROL VALVE

2. Disconnect the purge control valve connector.
3. Disconnect the throttle body-to-purge control valve hose
from the purge control valve.
4. Disconnect the canister-to-purge control valve hose from
the purge control valve.
5. Remove the purge control valve.
reverse order.
CANISTER
Caution
Canister and vacuum hoses contain fuel vapors. Do
not smoke in the area or permit an open flame.
1. Disconnect the fuel tank-to-canister hose form the

canister.
2. Disconnect the canister-to-purge control valve hose form
the canister.
3. Remove the canister mounting bolts.

Installation
4. Remove the canister.

reverse order.

AFFECTED VIN
1F-85
CAMSHAFT POSITION SENSOR

2. Disconnect the electrical connector from the camshaft
position sensor.
3. Remove the camshaft position sensor retaining bolt.
Installation
4. Check the O-ring for damage and replace it if neces sary.

reverse order.
CRANKSHAFT POSITION SENSOR

2. Disconnect the electrical connector at the crankshaft
position sensor.
3. Remove the crankshaft position sensor retaining bolt.
Installation

reverse order.
ENGINE CONTROL MODULE

2. Remove the cowl side trim form passenger side. Refer
to Section 9G, Interior trim.
3. Remove the four securing nuts for the Engine Control
Module (ECM) from the mounting bracket.
Installation
4. Pull out the ECM from the bracket.

5. Disconnect the vehicle side coupling.
reverse order.

AFFECTED VIN
1F-86
SCHEMATIC AND ROUTING DIAGRAMS

DIAGNOSIS CIRCUIT

AFFECTED VIN
1F-87
ECU (GSL G32)

IGN COIL, CPS, AIR FLOW SENSOR, THROTTLE SENSOR, TPS

AFFECTED VIN
1F-88
O2 SENSOR, PEDAL MODULE, CRUISE CONTROL SW, STOP LAMP SW

AFFECTED VIN
1F-89
INJECTOR, KNOCK SENSOR, IMMOBILIZER, CANISTER PURGE VALVE

AFFECTED VIN
1F-90
SPECIFICATIONS
ENGINE DATA DISPLAY TABLE
Parameter Unit Value
Engine coolant temp. °C greater than 95°C after warm up
Intake air temp. °C -40 ~ 130°C (varies with ambient
temp. or engine mode)
Engine rpm rpm 700 ± 50 (P/N), 600 ± 50 (D)
Regular rpm rpm 700 ± 50 (P/N), 600 ± 50 (D)
Engine load % 18 ~ 25 %
Mass air flow meter Kg/h 16 ~ 25 Kg/h
Throttle position angle °TA 0°TA (up to 100°TA at t he wi de
open throttle)
Spark advance °CA °CA (6 ~ 9°CA)
Indicated engine torque Nm Varies with engine condition
Injection time ms 3 ~ 5 ms
Battery voltage V 13.5 ~ 14.1V (engine running)
Front axle speed Km/h 0 ~ 265 Km/h
Rear axle speed Km/h 0 ~ 265 Km/h
Accel. Pedal position 1 V 0.4 ~ 4.8 V
Accel. Pedal position 2 V 0.2 ~ 2.4 V
Throttle position 1 V 0.3 ~ 4.6 V
Throttle position 2 V 0.3 ~ 4.6 V
Fuel integrator 0.8 ~ 1.2
Oxygen sensor mv 100 ~ 900 mv
A/c s/w condition 1=ON/0=OFF -
Full load state 1=ON/0=OFF -
Shift gear state (A/T) 1=ON/0=OFF -
A/c control state 1=ON/0=OFF -
Clutch switch (M/T) 1=ON/0=OFF -
Cam actuator state 1=ON/0=OFF -
Knocking control 1=ON/0=OFF -
Protect mission 1=ON/0=OFF -
Purge control valve 1=ON/0=OFF -
Lambda function 1=ON/0=OFF -
Catalyst heating 1=ON/0=OFF -
Overrun fuel cut 1=ON/0=OFF -
Ful l fuel cut 1=ON/0=OFF -
Brake switch 1=ON/0=OFF -
Cruise control status 1=ON/0=OFF -
* Condition: Warmed up, idle, P/N or neutral

AFFECTED VIN
1F-91

Camshaft position sensor retaining bolts 10 - 89
Canister mounting bolts 6 - 53
Coolant temperature sensor 30 22 -
Crankshaft position sensor retaining bolt 10 - 89
Engine Control Module (ECM) mounting bracket nuts 10 - 89
Fuel filter mounting bracket bolt 6 - 53
Fuel filter lines 28 21 -
Fuel pressure test connector 25 18 -
Fuel rail assembly bolts 25 18 -
Fuel return and supply lines 23 17 -
Fuel tank retaining nuts 38 28 -
Intake air duct mounting bolts 9 - 80
Knock sensor mounting bolt 25 18 -
Oxygen sensor 55 41 -
Pedal position censor mounting bolts and nut 6 - 53
Throttle body bolts 12 - 106

AFFECTED VIN
1F-92
FUEL SYSTEM SPECIFICATION Do Not Use Methanol

Fuels containing methanol (wood alcohol) should not be
Use Only Unleaded Fuel Rated at used in vehicle.
89 Octane or Higher This type of fuel can reduce vehicle performance and dam-
Fuel quality and additives contained in fuel have a signifi- age components of the fuel system.
cant effect on power output, drivability, and life of theengine. Caution
Fuel with too low an octane number can cause engine Use of methanol may damage the fuel sys-tem.
knock.
Caution Vehicle Fueling from Drums or
Use of fuel with an octane number lower than 89 may Storage Containers
damage engine and exhaust system. For safety reasons (particularly when using noncom-
Notice mercial fueling systems) fuel containers, pumps and
To prevent accidental use of leaded fuel, the nozzles hoses must be properly earthed.
for leaded fuel are larger, and will not fit the fuel filler Static electricity build up can occur under certain atmo-
neck of your vehicle. spheric and fuel flow conditions if unearthed hoses, par-
ticularly plastic, are fitted to the fuel-dispensing pump.
It is therefore recommended that earthed pumps with in-
tegrally earthed hoses be used, and that storage con-
tainers be properly earthed during all noncommercial fu-
eling operations.
TEMPERATURE VS RESISTANCE
ECT Sensor IAT Sensor
°C °F
ohms (Ω)
Temperature vs Resistance Values (Approximate)
130 266 88 102
120 248 111.6 127
110 230 143 159
100 212 202 202
90 194 261 261
80 176 340 340
70 158 452 452
60 140 609 609
50 122 835 835
40 113 1166 1166
30 86 1662 1662
20 68 2420 2420
10 50 3604 3604
0 32 5499 5499
-10 14 8609 8609
-20 -4 13850 13850
-30 -22 22960 22960
-40 -40 39260 39260

AFFECTED VIN
1F-93
A9922 0012A (103 589 00 21 00)

Fuel Pressure Gauge

AFFECTED VIN
1G-1
SECTION
00 1G
ENGINE INTAKE & EXHAUST
Table of Contents
DESCRIPTION AND OPERATION .................................. 1G-2
Exhaust system .......................................................... 1G-2
Muffler ........................................................................ 1G-2
Catalytic converter ..................................................... 1G-2
Catalytic converte structure ....................................... 1G-3
Catalytic converter and temperature ......................... 1G-3
Purification of catalytic converter .............................. 1G-4
Resonance flap .......................................................... 1G-5
REPAIR INSTRUCTIONS ................................................ 1G-6
ON-VEHICLE SERVICE .................................................. 1G-6

Air cleaner and intake air duct .................................. 1G-6
Intake manifold ........................................................... 1G-9
Resonance flap ........................................................ 1G-10
Exhaust line .............................................................. 1G-11
SPECIFICATIONS ......................................................... 1G-14
Fastener tightening specifications .......................... 1G-14
ENGINE INTAKE & EXHAUST CHANGED BY

AFFECTED VIN
1G-2

EXHAUST SYSTEM CATALYTIC CONVERTER
Notice Notice
When you are inspecting or replacing exhaust system When jacking or lifting the vehicle from the body side
components, make sure there is adequate clearance rails, be certain that the lift pads do not contact the
from all points on the underbody to avoid possible catalytic converter, as this could damage the catalytic
overheating of the floor panel and possible damage converter.
to the passenger compartment insulation and trim
materials. Notice
Use of anything other than unleaded fuel will damage
the catalyst in the catalytic converter.
Check the complete exhaust system and the nearby body
The catalytic converter are emission-control devices added
areas and trunk lid for broken, damaged, missing or
to the exhaust system to reduce pollutants from the ex-
mispositioned parts, open seams, holes, loose
haust pipes.
connections, or other deterioration which could permit
exhaust fumes to seep into the trunk may be an indica- The oxidation catalyst is coated with a catalytic material
tion of a problem in one of these areas. Any defects should containing platinum and palladium, which reduces levels
be corrected immediately. of hydrocarbon (HC) and carbon monoxide (CO) from the
exhaust gas. The three-way catalyst has coatings which
contain platinum and rhodium, which additionally lower
the levels of oxides of nitrogen (NOx).
MUFFLER
Aside from the exhaust manifold connection, the exhaust
system uses a flange and seal joint design rather than a
slip joint coupling design with clamp and U-bolts. If hole,
open seams, or any deterioration is discovered upon in-
spection of the front muffler and pipe assembly, the com-
plete assembly should be replace, the complete assem-
bly should be replaced. The same procedure is applicable
to the rear muffler assembly.
Heat shields for the front and rear muffler assembly and
catalytic converter protect the vehicle and the environ-
ment from the high temperatures that the exhaust sys-
tem develops.
CHANGED BY ENGINE INTAKE & EXHAUST

AFFECTED VIN
1G-3
CATALYTIC CONVERTE STRUCTURE

The Catalytic converter of monolith type consists of 2 walled
metal bodies which is made of Cordierite.
The principal element of converter consists of the materials
like Alumina or oxidized Serume in order to apply to Ceramic
;;;
;;;;;;
;;;;;;;;;
Monolith.
;;;
;;;
;;;
;;;;
Washer coat operates first, and catalytic metal elements (Pt,
Pd, Rh) operates to washer coat next.
Monolith type is lighter than other types, easy to manufacture
;;;;
and quickly approaches to proper temperature.
Washer coat is used to make a contact surface with exhaust
gas bigger by adhering closely to small holes of inner layer.
If a lead compound or phosphorus adheres to the surface and
the temperature rises, its surface is decreased.
The total area of general monolith converter is about 45,000 ~
500,000 ft3. (10 times of a football field) ;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;
Generally Alumina (AL2 O3) is used as a raw material and its 7
phases of gamma, delta, theta have big areas and high stabil- ;;;;;;
;;;;;;;;;;;;
;;;;;;
ity for the temperature, and nowadays gamma Alumina is used
usually.
CATALYTIC CONVERTER AND TEM-

PERATURE
Catalytic converter has the normal function of purification at a
range of the temperature.
Because it has a weak point of decreasing of the purification
rate in the condition of continuous high temperature, it should
keep the temperature range of 400 to 500°C for normal condition.
HC purification rate becomes better according to the increase
of temperature in the normal range of temperature.
CO purification rate becomes the best near the temperature of
450°C, and NOx does so near the temperature of 400 to 500°C.

AFFECTED VIN
1G-4
PURIFICATION OF CATALYTIC
CONVERTER
• Adhesion of soluble organic fraction (SOF) below 180°C
• Purification of soluble organic fraction (SOF) over 180°C
Chemical reaction formula
- SOF(HC)+O2 → CO2+H2O
- 2CO+O2 → 2CO2
- 2C2H6+7O2 → 4CO2+6H20
• By catalytic action of two primary catalytic converter,
oxidation occurs in order to decrease HC and CO.
• Oxygen adheres to catalytic material : below 180°C
• Catalytic material supplies each CO and HC with O2 for

their oxidation : above 180°C
• Catalytic material conversion process by DOC

AFFECTED VIN
1G-5
Method for Reduction of NOx

NOx is generated a great deal in case that combustion tem-
perature and excess air factor are high. EGR valve can de-
crease NOx (30 to 35% decrease) by making temperature of
combustion chamber fall by means of exhaust gas re-
circulation.
• EGR valve is installed on the diesel engine of Musso,
Korando, Istana and Rexton.
And micro switch is installed together to control EGR valve.
• The setting method of micro switch is identical with the
existing one.
RESONANCE FLAP
Function
A pneumatically actuated resonance flap (5) is located on the
intake manifold, and will be opened and closed by load, which
operates resonance flap according to engine and controlled
by ECU and rpm.
Resonance flap closed (at idle/partial load: less

than 3,800 rpm)
The switch valve (7) will be adjusted by ECU and resonance
falp will be colosed. By increasing air flow passage through
dividing intaking air flow toward both air collection housing (8).
This leads to a signficant increase in the torque in the lower
speed range.
Resonance flap open (at full load: over 3,800 rpm)

The switch valve (7) will not be adjusted by ECU and reso-
nance falp (5) will be open. The collected air in the air collec-
tion housing (8) will not be divided and intaking air passage
will be shorten.

AFFECTED VIN
1G-6
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
AIR CLEANER AND INTAKE AIR DUCT
Cover
Element
Housing
Specifications
Element Type Dry-Element Type
* Initial cleaning: 5,000 km, Clean or change every 10,000 km as required.
However, change every 30,000 km.
Service Interval
* If the vehicle is operated under severe condition (short distance driving, extensive
idling or driving in dusty condition): More frequent maintenance is required.

AFFECTED VIN
1G-7
Air Cleaner Element - Replacement

Preceding Work: Disconnection of negative battery cable

2. Loosen the locking clamp and remove the intake duct.
3. Unscrew the screws and remove the air cleaner cover.
4. Remove the air cleaner element. Clean or replace the

element as required.

AFFECTED VIN
1G-8
Air Cleaner Housing - Removal and

Installation
Preceding Work: Removal of air cleaner cover
1. Set aside the return hose and remove the coolant reservoir
bolts.
2. Remove the air cleaner housing bolts.

3. Install in the reverse order of removal.
Air Cleaner Housing/Element - Check

1. Check the air cleaner body, cover and packing for
deformation, corrosion and damage.
2. Check the air duct for damage.
3. Check the air cleaner element for clogging, contamination

and damage. If the element is partially clogged, remove
the dust or foreign materials with the compressed air. If
the contamination is severe, replace it with new one. Also,
be careful not to contaminate during the replacement.
4. Check the air cleaner housing for clogging, contamination
and damage.
5. If the inside of housing is contaminated, remove the
contaminants.
Notice
When cleaning the air cleaner with compressed air,
direct the air from inside (engine) to outside (ambient
air). Otherwise, contaminants can get into the engine.
AFFECTED VIN
1G-9
INTAKE MANIFOLD
Preceding Work: Removal of fuel rail
Removal of battery
Removal of canister
1. Bolt (M6 X 40, 4 pieces) 9 ~ 11 Nm (80 ~ 97 lb-in) 13. Bolt (M6 X 40, 4 pieces) 9 ~ 11 Nm (80 ~ 97 lb-in)
2. Softcap 14. Throttle body-electric
3. Resonance flap 15. Gasket ....................................................... replace
4. Gasket ....................................................... replace 16. Lower intake manifold
5. Upper intake manifold 17. Bolt (M8 X 40, 4 pieces)
6. Bolt (M8 X 50, 9 pieces) ....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft) 18. Nipple
7. Gasket ....................................................... replace 19. Seal ring
8. Blow-by hose 20. Connector
9. Blow-by hose 21. Connection house
10. Clamp 22. Clamp
11. Blow-by nipple 23. Noise damper assembly
12. Inlet air housing 24. Tapping screw

AFFECTED VIN
1G-10
RESONANCE FLAP
1. Soft cap (2) 4. Vacuum hose

2. Bolt (M6 X 40, 4 piecesc) 5. Resonance flap
....................................... 9 ~ 11 Nm (80~ 97 lb-in) 6. Gasket ...................................................... Replace
3. O-ring

1. Remove the 2 soft caps (1).
2. Remove the upper resonance flap coupling after removing
4 bolt (2).
Installation
9 ~ 11 Nm
Tightening torque
(80 ~ 97 lb-ft)
3. Check the O-ring (3) and replace it if necessary.

4. Remove the lower resonance flap (5).
5. Replace the gasket (6).
reverse order.

AFFECTED VIN
1G-11
EXHAUST LINE
1. Front exhaust pipe 9. Heat protector No. 2

2. Muffler 10. Heat protector No. 3
3. Tail exhaust pipe 11. Heat protector No. 4
4. Gasket ....................................................... replace 12. Bolt ............................. 15 ~ 28 Nm (11 ~ 21 lb-ft)
5. Gasket ....................................................... replace 13. Nut .............................. 28 ~ 47 Nm (21 ~ 35 lb-ft)
6. Hanger 14. Nut .................................. 8 ~ 18 Nm (6 ~ 13 lb-ft)
7. Hanger 15. Screw
8. Heat protector No. 1 16. Oxygen sensor

AFFECTED VIN
1G-12

1. Disconnect the oxygen sensor electrical connectors.
2. Remove the exhaust manifold to front exhaust pipe nuts.
Installation Notice
3. Remove the oxygen sensor and hanger from the front
exhaust pipe.
15 ~ 28 Nm
Tightening torque
(11 ~ 21 lb-ft)
4. Remove the front exhaust pipe to muffler nuts.

Installation
28 ~ 47 Nm
Tightening torque
(21 ~ 35 lb-ft)
5. Remove the muffler to tail exhaust pipe nuts.

Installation
28 ~ 47 Nm
Tightening torque
(21 ~ 35 lb-ft)
6. Remove the Mounting hunger and muffler.

AFFECTED VIN
1G-13
7. Remove the mounting hanger and tail exhaust pipe.

8. Check the muffler and pipes for holes, damage, open
seams, or other deterioration. Which could permit
exhaust fumes to seep into the passenger compartment
or the trunk.
reverse order.

AFFECTED VIN
1G-14
SPECIFICATIONS
Exhaust manifold to front exhaust pipe nut 15 ~ 28 11 ~ 21 -
Front exhaust pipe to muffler nut 28 ~ 47 21 ~ 35 -
Intake air duct mounting bolt 22.5 ~ 27.5 16.6 ~ 20.3 -
Intake manifold mounting bolt 22.5 ~ 27.5 16.6 ~ 20.3 -
Muffler to tail exhaust pipe nut 28 ~ 47 21 ~ 35 -
Resonance flap mounting bolt 9 ~ 11 - 80 ~ 97

AFFECTED VIN
DI0A-1
SECTION
00 DI0A
GENERAL INFORMATION
Table of Contents
CLEANNESS ....................................... DI0A-2 While operating the vehicle ......... DI0A-30

At each fuel fill ............................. DI0A-30
STRUCTURE ...................................... DI0A-7
At least twice a month .................. DI0A-30
ENGINE CONTROLS ....................... DI0A-10 At least monthly ........................... DI0A-30
ECU related components ............. DI0A-10 At least twice a year ..................... DI0A-31
Engine and sensors ...................... DI0A-11 Each time the oil is changed ....... DI0A-31
Electrical components and pre heating At least annually .......................... DI0A-31
system .......................................... DI0A-12
STANDARD BOLTS SPECIFICATIONS
INTAKE SYSTEM ............................. DI0A-13 .......................................................... DI0A-32
Intake air flow chart ...................... DI0A-14
BASIC SPECIFICATION ................... DI0A-34
EXHAUST SYSTEM .......................... DI0A-15 Vehicle specifications ................... DI0A-34
Exhaust air flow chart ................... DI0A-16 Specifications ............................... DI0A-35
LUBRICATION SYSTEM .................. DI0A-17 Maintenance ................................ DI0A-37
COOLING SYSTEM ......................... DI0A-18 VEHICLE IDENTIFICATION .............. DI0A-39

Coolant flow chart ........................ DI0A-19 Vehicle identification number (VIN)
..................................................... DI0A-39
FUEL SYSTEM ................................. DI0A-20 Manufacturer’s plate .................... DI0A-40
Fuel supply system ...................... DI0A-21 Engine serial number ................... DI0A-40
MAINTENANCE AND REPAIR .......... DI0A-22 Transmission & transfer case number
Maintenance and lubrication ....... DI0A-22 ..................................................... DI0A-41
Guidelines for HOW TO USE AND MAINTAIN WORKSHOP
service work safety ...................... DI0A-23 MANUAL ........................................... DI0A-42
Vehicle lifting procedures ............ DI0A-28 Consists of workshop manual ...... DI0A-42
OWNER INSPECTIONS AND SERVICES Manual description ...................... DI0A-42
.......................................................... DI0A-30

DI ENG SM - 2004.9 EFFECTIVE DATE
AFFECTED VIN
DI0A-2
CLEANNESS
Cleanness of DI Engine Fuel System and Service Procedures
The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure
reaches over 1600 bar. Some components in injector and HP pump are machined at the micrometer 100 µm of
preciseness. The pressure regulation and injector operation are done by electric source from engine ECU.
Accordingly, if the internal valve is stucked due to foreign materials, injector remains open. Even in this case, the
HP pump still operates to supply high pressurized fuel. This increases the pressure to combustion chamber (over
250 bar) and may cause fatal damage to engine.
You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The right side
figure shows the clearance between internal operating elements.
Valve actuator lift: 0.028 mm

Hair
Diameter: 0.40 mm
Operating
clearance:
Nozzle hole 0.002 mm
Diameter:
2.0 mm
The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign
material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of
system problems and claims may arise.

EFFECTIVE DATE DI ENG SM - 2004.9
AFFECTED VIN
DI0A-3
Job procedures
1. Always keep the workshop and lift clean (especially, from dust).
2. Always keep the tools clean (from oil or foreign materials).
3. Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system.
Wash your hands and do not wear working gloves.
4. Follow the below procedures before starting service works for fuel system.
Carefully listen the symptoms and problems from customer.
Visually check the leaks and vehicle appearance on the wiring harnesses
and connectors in engine compartment.
Perform the diagnosis proceee with SCAN-100

(refer to “DI10 DIAGNOSIS” section in this manual).
Locate the fault. If the cause is from fuel system (from priming pump to
injector, including return line), follow the step 1 through step 3 above.
5. If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and sealing caps
to perform the diagnosis for DI engine fuel system in “DI10 DIAGNOSIS” section in this manual. At this point,
thoroughly clean the related area in engine compartment.
Notice
Clean the engine compartment before starting service works.
Tool kit for high pressure line Took kit for low pressure line Removal tool box and cap kits

AFFECTED VIN
DI0A-4
6. Follow the job procedures. If you find a defective component, replace it with new one.
Disconnect the negative battery cable.
For safety reasons: check pressure is low before opening the HP systems (pipes)
Use special tools and torque wrench to perform the correct works.
Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail
and each injector should be replaced with new ones. The pipes should be tightened to
specified tightening torques during installation. Over or under torques out of specified
range may cause damages and leaks at connections. Once installed, the pipes have been
deformed according to the force during installtion, therefore they are not reusable.
The copper washer on injector should be replaced with new one. The injector holder bolt
should be tightened to specified tightening torque as well. If not, the injection point may be
deviated from correct position, and it may cause engine disorder.
Plug the disconnected parts with sealing caps, and remove the caps immediately
before replacing the components.
Fuel pressure sensor
High pressure pump Common rail
IMV valve
Transfer pump and high Injection
pressure pump pipe
Fuel temperature sensor
Water separator
Water detection sensor
Priming
pump
Fuel filter
Injector
Cap position
Supply line
Return line
Fuel tank

AFFECTED VIN
DI0A-5
7. Plug the removed components with clean and

undamaged sealing caps and store it into the box to
keep the conditions when it was installed.
8. Clear the high pressure offset value by SCAN-100 after
replacing the high pressure pump.
9. To supply the fuel to transfer line of HP pump press

the priming pump until it becomes hard.
Warning
Do not crank engine before having filled pump.

Priming pump
10. Check the installed components again and connect

the negative battery cable. Start the engine and check
the operating status.
11. With SCAN-100, check if there are current faults and
erase the history faults.
Note
For details, refer to “DI10 Diagnosis table”.

AFFECTED VIN
DI0A-7
STRUCTURE
Front view
Rear view
1. TVD (Torsional Vibration Damper) 7. Viscos clutch 13. Oil filter

2. Air conditioner compressor 8. Auto tensioner pulley 14. Vacuum pump
3. Power steering pump pulley 9. Auto tensioner 15. Crank position sensor
4. Idle pulley 10. Poly-groove belt 16. EGR valve
5. Water pump pulley 11. Cam position sensor 17. Power steering pump
6. Alternator 12. Drive plate (M/T: DMF) 18. EGR center pipe

AFFECTED VIN
DI0A-8
Top view
19. Cylinder head cover 24. Fuel pipe 29. Booster pressure sensor
20. Intake manifold 25. Injector 30. Oil separator
21. Water outlet port 26. Fuel return line 31. Oil dipstic
22. Common rail 27. Oil filler cap 32. EGR center pipe
23. Fuel pressure sensor 28. Glow plug

AFFECTED VIN
DI0A-9
Left side view
Right side view
33. Cylinder head 38. EGR - RH pipe 42. Turbo charger booster vacuum
34. Cylinder block 39. Oil separator modulator
35. Oil pan 40. Oil dipstic 43. EGR valve vacuum modulator
36. Drain plug 41. HP pump 44. EGR valve
37. Turbo charger 45. Exhaust manifold

AFFECTED VIN
DI0A-10
ENGINE CONTROLS
ECU RELATED COMPONENTS
Fuel filter
ECU/barometric sensor Cam position sensor (water detection sensor) Accelerator pedal sensor
HFM sensor/intake air

temperature sensor
Pre heating time relay Main relay

AFFECTED VIN
DI0A-11
ENGINE AND SENSORS
Crankshaft position
Injector Common rail
sensor
Glow plug Fuel pressure sensor
Camshaft position Booster pressure sensor

sensor
HP pump Coolant temperature Knock sensor (2)

sensor

AFFECTED VIN
DI0A-12
ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM
Glow plug Pre heating time relay
Battery Fuse box
Alternator
Starter motor

AFFECTED VIN
DI0A-13
INTAKE SYSTEM
Air cleaner assembly HFM sensor Intake duct hose Intake manifold
Intake outlet hose Turbocharger Intercooler Inlet hose

AFFECTED VIN
DI0A-14
INTAKE AIR FLOW CHART
Intake valve (in combustion chamber)
Intake manifold
Air cleaner side
Turbo-
charger Engine
(compressor)
HFM sensor
Intake hose (outlet) Intercooler Intake hose (inner)

AFFECTED VIN
DI0A-15
EXHAUST SYSTEM
Muffler Exhaust manifold EGR valve
Turbocharger Catalytic converter EGR pipe Vacuum modulator

AFFECTED VIN
DI0A-16
EXHAUST AIR FLOW CHART
Catalytic converter Exhaust pipe Muffler
Ambient
air
Exhaust gas
Turbocharger
(turbine side)
EGR vacuum
modulator
To turbocharger
booster
Turbocharger
booster vacuum
modulator
Turbocharger booster EGR valve
Exhaust manifold
EGR pipe

AFFECTED VIN
DI0A-17
LUBRICATION SYSTEM
Cylinder head cover Oil dipstick Oil separator Engine oil filter
housing
Engine oil pump Oil pan Engine oil cooler Engine oil pressure
switch

AFFECTED VIN
DI0A-18
COOLING SYSTEM
Coolant reservoir Water pump
Cooling fan and fan

Radiator assembly
clutch

AFFECTED VIN
DI0A-19
COOLANT FLOW CHART
Heater
Oil cooler
Coolant reservoir Intake manifold
Thermostat
Coolant outlet port
Water pump
Inner hose Outlet hose
Cooling fan
Radiator

AFFECTED VIN
DI0A-20
FUEL SYSTEM
Fuel return hose Fuel pressure pipe Common rail Fuel filter
Injector HP pump Priming pump

AFFECTED VIN
DI0A-21
FUEL SUPPLY SYSTEM
High pressure pump Common rail
IMV valve
Low and high High
pressure
pressure pump
pipe
Fuel temperature
sensor
Water separator
Label
Fuel filter Priming pump (C2I)
Water detection
sensor
Injector
Sensors
HFM sensor
Cam position sensor
Crank position sensor
Fuel tank ECU
Knock sensor etc.
Components:
Supply line
- High pressure fuel pump - Fuel rail - Fuel pressure sensor Return line
- Fuel injectors - Electroc control unit (ECU) - Various sensors and actuators ECU communication line
According to input signals from various sensors, engine ECU calculates driver’s demand (position of the accelerator
pedal) and then controls overall operating performance of engine and vehicle on that time.
ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those
signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor deter-
mines injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal that is gener-
ated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and
sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume
changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from
coolant temperature sensor and air temperature sensor, booster pressure sensor and barometric sensor as compensa-
tion signal to respond to injection starting, pilot injection set values, various operations and variables.

AFFECTED VIN
DI0A-22
MAINTENANCE AND REPAIR

MAINTENANCE AND LUBRICATION
Normal Vehicle Use Fuel Filter Replacement
Replace the engine fuel filter every.
The maintenance instructions contained in the maintenance
schedule are based on the assumption that the vehicle • Gasoline Engine : 60,000 km (36,000 miles)
will be used for the following reasons: • Diesel Engine : 30,000 km (18,000 miles)
• To carry passengers and cargo within the limitation of
Spark Plug Replacement
the tire inflation prassure. Refer to “Wheels and Tire”
in section 4H. Replace spark plugs with same type.
• To be driven on reasonable road surfaces and within • Type : BOSCH : F8DC4

legal operating limits. BERU : 14F-8DU4
Champion : C11YCC
Explanation of Scheduled • Gap : 0.8 ± 0.1 mm
Maintenance Services Spark Plug Wire Replacement
The services listed in the maintenance schedule are fur- Clean wires and inspect them for burns, cracks or other
ther explained below. When the following maintenance damage. Check the wire boot fit at the Distributor and at
services are performed, make sure all the parts are re- the spark plugs. Replace the wires as needed.
placed and all the necessary repairs are done before driv-
Brake System Service
ing the vehicle. Always use the proper fluid and lubricants.
Check the disc brake pads or the drum brake linings. Check
Engine Oil and Oil Filter Change the pad and the lining thickness carefully.
Always use above the API SH grade or recommended en-
Tire and Wheel Inspection and Rotation
gine oil.
Check the tires for abnormal wear or damage. To equalize
Engine Oil Viscosity wear and obtain maximum tire life, rotate the tires. If ir-
Engine oil viscosity (thickness) has an effect on fuel regular or premature wear exists, check the wheel align-
economy and cold weather operation. Lower viscosity en- ment and check for damaged wheels. While the tires and
gine oils can provide better fuel economy and cold weather wheels are removed, inspect the brakes.
performance; however, higher temperature weather condi-
tions require higher viscosity engine oils for satisfactory Tire Rotation (Left-hand Drive Type)
lubrication. Using oils of any viscosity other than those
viscosities recommended could result in engine damage.
Cooling System Service

Drain, flush and refill the system with new coolant. Refer
to “Recommended Fluids And Lubricants” in this section.
Air Cleaner Element Replacement

Clean the air cleaner element every.
• Gasoline Engine : 15,000 km (10,000 miles)
• Diesel Engine : 10,000 km (6,000 miles)
Replace the air cleaner element every.
• Gasoline Engine : 60,000 km (36,000 miles)
• Diesel Engine : 30,000 km (18,000 miles)
Replace the air cleaner more often under dusty conditions.

AFFECTED VIN
DI0A-23
GUIDELINES FOR SERVICE WORK SAFETY

General Cautions on Inspection/Service
Notice
During service works, be sure to observe below general
items for your safety.
• For service works, be sure to disconnect battery
negative (-) terminal if not starting and inspection.
• While inspecting vehicle and replacing various
consumable parts, be sure to take caution not to
damage vehicle and injure people.
• Engine and transmission may be hot enough to
burn you. So inspect related locations when they
cooled down enough.
• If engine is running, keep your clothing, tools, hair
To maintain and operate the vehicle under optimum state and hands away from moving parts.
by performing safe service works, the service works should • Even when the ignition key is turned off and
be done by following correct methods and procedures. positioned to LOCK, electrical fan can be operated
Accordingly, the purpose of this manual is to prevent dif- while working on near around electrical fan or
ferences that can be caused by personal working method, radiator grille if air conditioner or coolant
skill, ways and service procedures and to allow prompt/ temperature rises.
correct service works. • Every oil can cause skin trouble. Immediately wash
out with soap if contacted.
Note, Notice
• Painted surface of the body can be damaged if
While using this manual, there are a lot of Note or Notice
spilled over with oil or anti-freeze.
having below meaning.
• Never go under vehicle if supported only with jack.
Note • Never near the battery and fuel related system to
Note means detailed description of supplementary flames that can cause fire like cigarette.
information on work procedure or skill. • Never disconnect or connect battery terminal or other
electrical equipment if ignition key is turned on.
Notice
• While connecting the battery terminals, be cautious
Notice means precautions on tool/device or part of polarities (+, –) not to be confused.
damages or personal injuries that can occur during • There are high voltage and currency on the battery
service works. and vehicle wires. So there can be fire if short-
circuited.
However, above references and cautions cannot be inclu-
• Do not park while running the engine in an
sive measures, so should have habits of taking concerns
enclosed area like garage. There can be toxication
and cautions based on common senses.
with CO, so make sufficient ventilation.
• The electrical fan works electrically. So the fan can
be operated unexpectedly during working causing
injuries if the ignition key is not in LOCK position.
Be sure to check whether ignition key is in LOCK
position before work.
• Be careful not to touch hot components like
catalytic converter, muffler and exhaust pipe when
the engine is running or just stopped. They may
burn you badly.

AFFECTED VIN
DI0A-24
Guidelines on Engine Service Fuel and lubrication system

Painted surface of the body can be damaged or rubber
To prevent personal injuries and vehicle damages that can
products (hoes) can be corroded if engine oil and fuel are
be caused by mistakes during engine and unit inspection/
spilled over. If spilled over engine, foreign materials in air
repair and to secure optimum engine performance and
can be accumulated on the engine damaging fuel system.
safety after service works, basic cautions and service work
guidelines that can be easily forgotten during engine ser- • If work on the fluid system such as fuel and oil, working
vice works are described in. area should be well ventilated and mechanic should
not smoke.
Cautions before service works • Gasket or seal on the fuel/lubrication system should
• Before work on engine and each electrical equipment, be replaced with new and bolts and nuts should be
be sure to disconnect battery negative (-) terminal. tightened as specified.
• Before service works, be sure to prepare the works by • After removal/installation works, be sure to check
cleaning and aligning work areas. whether there is leak on the connecting section.
• Always position the ignition switch to OFF if not
required. If not, there can be electrical equipment If fine dust or foreign material enters into DI engine’s
damages or personal injuries due to short-circuit or fuel system, there can be serious damages between
ground by mistake. HP pump and injectors. So, be sure to cover removed
• There should be no leak from fuel injection system fuel system components with cap and protect removed
(HP pump, fuel hose, high pressure pipe) of the D27DT parts not to be contaminated with dirt. (Refer to clean-
engine. So they should be protected from foreign ness in this manual while working on DI engine fuel
materials. system)
• While removing the engine, do not position the jack
and others under the oil pan or engine. To secure the
safety, use only safety hook on the engine. Electrical equipment
Engine and accessories Electrical equipment should be handled more carefully.
Engine has a lot of precise portions so tightening torque Currently, the engine is equipped with a lot of electrical
should be correct during disassembly/assembly and re- equipments so there can be engine performance drops,
moval/installation and service work should be done in clean incomplete combustion and other abnormals due to short
ways during disassembly/assembly. and poor contact. Mechanics should well aware of vehicle’s
electrical equipment.
Maintaining working area clean and cautious service ad-
ministration is essential element of service works while • If have to work on the electrical equipment, be sure to
working on the engine and each section of the vehicle. So disconnect battery negative (-) terminal and position
the mechanics should well aware of it. the ignition switch to off if not required.
• While removing the engine, related parts (bolts, • When replacing electrical equipment, use the same
gaskets, etc.) should be aligned as a group. genuine part and be sure to check whether ground or
connecting portions are correctly connected during
• While disassembling/assembling internal components
installation. If ground or connecting portion is loosened,
of the engine, well aware of disassembly/assembly
there can be vehicle fire or personal injury.
section in this manual and clean each component with
engine oil and then coat with oil before installation.
• While removing engine, drain engine oil, coolant and
fuel in fuel system to prevent leakage.
• During service work of removal/installation, be sure to
check each connected portions to engine not to make
interference.

AFFECTED VIN
DI0A-25
During Service Work - Inspection

1. Before lifting up the vehicle with lift, correctly support the
lifting points and lift up.
2. When using a jack, park the vehicle on the level ground
and block front and rear wheels. Position the jack under
the frame and lift up the vehicle and then support with
chassis stand before service work.
3. Before service work, be sure to disconnect battery

negative (-) terminal to prevent damages by bad wire and
short.
4. If service from interior of the vehicle, use protection cover

to prevent damage and contamination of seat and floor.
5. Brake fluid and anti-freeze can damage painted surface
of body. So carefully handle them during service work.
6. Use recommended and specified tools to increase

efficiency of service work.
7. Use only genuine spare parts.

AFFECTED VIN
DI0A-26
8. Never reuse cotter pin, gasket, O-ring, oil seal, lock

washer and self-locking nut. Replace them with new.
If reused, normal functions cannot be maintained.
9. Align the disassembled parts in clean according to
disassembling order and group for easy assembling.
10. According to installing positions, the bolts and nuts have
different hardness and design. So be careful not to mix
removed bolts and nuts each other and align them
according installing positions.
11. To inspect and assemble, clean the parts.
12. Securely clean the parts that related with oil not to be
affected by viscosity of oil.
13. Coat oil or grease on the driving and sliding surfaces
before installing parts.
14. Use sealer or gasket to prevent leakage if necessary.
15. Damaged or not, never reuse removed gasket. Replace
with new and cautious on installing directions.
16. Tighten every bolt and nut with specified torque.
17. When service work is completed, check finally whether
the work is performed properly or the problem is solved.
18. If work on the fuel line between priming pump and injector
(including return line), be sure to cover the removed parts
with cap and be careful not to expose the connecting
passage and removed parts to external foreign materials
or dust. (Refer to cleanness.)
19. If remove high pressure fuel supply pipe between HP pump
and fuel rail and high pressure fuel pipe between fuel rail
and each injector, be sure to replace them with new.

AFFECTED VIN
DI0A-27
During Service Work for Electric

Devices
Notice
Be careful not to modify or alter electrical system and

electrical device. Or there can be vehicle fire or serious
damage.
1. Be sure to disconnect battery negative (-) terminal during

every service work. Before disconnecting battery negative
(-) terminal, turn off ignition key.
2. Replace with specified capacity of fuse if there is bad,
blown or short circuited fuse. If use electrical wire or steel
wire other than fuse, there can be damages on the various
electrical systems. If replaced with over-capacity fuse,
there can be damages on the related electrical device
and fire.
3. Every wire on the vehicle should be fastened securely
not to be loosened with fixing clip.
4. If wires go through edges, protect them with tape or other
materials not to be damaged.
5. Carefully install the wires not to be damaged during

installation/removal of parts due to interference.
6. Be careful not to throw or drop each sensor or relay.
7. Securely connect each connector until hear a “click”
sound.

AFFECTED VIN
DI0A-28
VEHICLE LIFTING PROCEDURES

To raise the vehicle, place the lifting equipment only at the
points indicated. Failure to use these precise positions
may result in permanent vehicle body deformation.
Many dealer service facilities and service stations are
equipped with automative hoists that bear upon some parts
of the frame in order to lift the vehicle. If any other hoist
method is used, take special care to avoid damaging the
fuel tank, the filter neck, the exhaust system, or the
underbody.
Using Floor Jack

Front Side Rear Side
Using Jack
Front Jack Up Point Rear Jack Up Point

AFFECTED VIN
DI0A-29
Lifting Positions
1. 4-post lift
As illustrated, position the vehicle on the 4-post lift securely and block the front and rear of each tire not to move during
working.
Notice
During lifting, be sure to check whether vehicle is empty.

• Board-on lift connection device installed in front of vehicle should be positioned in front of sill locating
under the front door.
• Install lift connecting device on the edge of front and rear of board-on lift.
Warning
• Be sure to use attachment during lifting to prevent the lift from contacting with body floor.
• While lifting the vehicle, widen the lift floor as far as possible to stabilize between vehicle front and rear. When
fixing the lift floor, be careful not to contact with brake tube and fuel lines.
2. Safety jack and safety stand

If lift up the vehicle with safety jack and stand, should be more
careful during works.
Warning
• Never be under the vehicle if supported with only jack.
If have to be under the vehicle, be sure to use safety
block.
• Use wheel block in front and rear of every wheel.

AFFECTED VIN
DI0A-30
OWNER INSPECTIONS AND SERVICES

WHILE OPERATING THE VEHICLE
Horn Operation 4. Pull out the oil level indicator and look at the oil level
Blow the horn occasionally to make sure it works. Check on it.
all the button locations. 5. Add oil, if needed, to keep the oil level above the
Brake System Operation lower mark. Avoid overfilling the engine, since this
may cause engine damage.
Be alert for abnormal sounds, increased brake pedal travel
or repeated puling to one side when braking. Also, if the 6. Push the indicator all the way back down into the
brake warning light goes on, or flashes, something may engine after taking the reading.
be wrong with part of the brake system. If you check the oil level when the oil is cold, do not run
the engine first. The cold oil will not drain back to the pan
Exhaust System Operation fast enough to give a true oil level reading.
Be alert to any changes in the sound of the system or the
smell of the fumes. These are signs that the system may Engine Coolant Level and Condition
be leaking or overheating. Have the system in-spected and Check the coolant level in the coolant reservoir tank and
repaired immediately. add coolant if necessary. Inspect the coolant. Replace
dirty or rusty coolant.
Tires, Wheels and Alignment Operation
Be alert to any vibration of the steering wheel or the seats Windshield Washer Fluid Level
at normal highway speeds. This may mean a wheel needs Check the washer fluid level in the reservoir. Add fluid if
to be balanced. Also, a pull right or left on a straight, level necessary.
road may show the need for a tire pressure adjustment or
a wheel alignment. AT LEAST TWICE A MONTH
Steering System Operation Tire And Wheel Inspection and Pressure Check
Be alert to changes in the steering action. An inspection Check the tire for abnormal wear or damage. Also check
is needed when the steering wheel is hard to turn or has for damaged wheels. Check the tire pressure when the
too much free play, or is unusual sounds are noticed when tires are cold (check the spare also, unless it is a stow-
turning or parking. away).
Headlamp Aim Maintain the recommended pressures. Refer to “Wheels
Take note of the light pattern occasionally. Adjust the head- and Tire” is in section 4H.
lights if the beams seem improperly aimed.
AT LEAST MONTHLY
AT EACH FUEL FILL Lamp Operation
A fluid loss in any (except windshield washer) system may Check the operation of the license plate lamp, the head-
indicate a problem. Have the system inspected and re- lamps (including the high beams), the parking lamps, the
paired immediately. fog lamps, the taillamp, the brake lamps, the turn signals,
Engine Oil Level the backup lamps and the hazard warning flasher.
Check the oil level and add oil if necessary. The best time Fluid Leak Check
to check the engine oil level is when the oil is warm. Periodically inspect the surface beneath the vehicle for
1. After stopping the engine, wait a few minutes for the water, oil, fuel or other fluids, after the vehicle has been
oil to drain back to the oil pan. parked for a while. Water dripping from the air conditioning
2. Pull out the oil level indicator (dip stick). system after use is normal. If you notice fuel leaks or
3. Wipe it clean, and push the oil level indicator back fumes, find the cause and correct it at once.
down all the way.

AFFECTED VIN
DI0A-31
AT LEAST TWICE A YEAR Hood Latch Operation

When opening the hood, note the operation of the sec-
Power Steering System Reservoir Level ondary latch. It should keep the hood from opening all
Check the power steering fluid level. Keep the power steering the way when the primary latch is released. The hood
fluid at the proper level. Refer to Section 4G, Power Steering must close firmly.
System.
Brake Master Cylinder Reservoir Level AT LEAST ANNUALLY

Check the fluid and keep it at the proper level. A low fluid level Lap and Shoulder Belts Condition and
can indicate worn disc brake pads which may need to be Operation
serviced. Check the breather hole in the reservoir cover to be
Inspect the belt system including: the webbing, the
free from dirt and check for an open passage.
buckles, the latch plates, the retractor, the guide loops
Weather-Strip Lubrication and the anchors.
Apply a thin film silicone grease using a clean cloth. Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints
EACH TIME THE OIL IS CHANGED must stay in the desired position.
Brake System Inspection Spare Tire and Jack Storage

This inspection should be done when the wheels are removed Be alert to rattles in the rear of the vehicle. The spare
for rotation. Inspect the lines and the hoses for proper hookup, tire, all the jacking equipment, and the tools must be
binding, leaks, cracks, chafing, etc. Inspect the disc brake securely stowed at all times. Oil the jack ratchet or
pads for wear. Inspect the rotors for surface condition. Inspect the screw mechanism after each use.
other brake parts, the parking brake, etc., at the same time.
Key Lock Service
Inspect the brakes more often if habit or conditions result in
frequent braking. Lubricate the key lock cylinder.
Steering, Suspension and Front Drive Axle Boot Body Lubrication Service
And Seal Inspection Lubricate all the body door hinges including the hood,
Inspect the front and rear suspension and the steering sys- the fuel door, the rear compartment hinges and the
tem for damaged, loose or missing parts, signs of wear or latches, the glove box and the console doors, and any
lack of lubrication. Inspect the power steering line and the folding seat hardware.
hoses for proper hookup, binding, leaks, cracks, chafing, etc.
Underbody Flushing
Clean and inspect the drive axle boot and seals for damage,
tears or leakage. Replace the seals if necessary. Flushing the underbody will remove any corrosive ma-
terials used for ice and snow removal and dust control.
Exhaust System Inspection At least every spring clean the underbody. First, loosen
Inspect the complete system (including the catalytic converter the sediment packed in closed areas of the vehicle.
if equipped). Inspect the body near the exhaust system. Look Then flush the underbody with plain water.
for broken, damaged, missing, or out-of-position parts as well
Engine Cooling System
as open seams, holes, loose connections, or other conditions
which could cause heat buildup in the floor pan or could let Inspect the coolant and freeze protection fluid. If the
exhaust fumes seep into the trunk or passenger compartment. fluid is dirty or rusty, drain, flush and refill the engine
cooling system with new coolant. Keep the coolant at
Drain the Water from Fuel Filter the proper mixture in order to ensure proper freeze
When the water level inside water separator in fuel filter ex- protection, corrosion protection and engine operating
ceeds a certain level, water separator warning light comes on temperature. Inspect the hoses. Replace the cracked,
and buzzer sounds. Also, the driving force of the vehicle swollen, or deteriorated hoses. Tighten the clamps.
decreases. Clean the outside of the radiator and the air condition-
If these conditions occur, immediately drain the water from ing condenser. Wash the filler cap and the neck. Pres-
fuel filter & water separator. sure test the cooling system and the cap in order to
help ensure proper operation.

AFFECTED VIN
DI0A-32
STANDARD BOLTS SPECIFICATIONS

Torque (N•m / Ib-in)
Bolt* Standard Limit
4T 7T 9T 4T 7T 9T
M3 × 0.5 0.5 N•m 0.9 N•m 1.3 N•m 0.7 N•m 1.2 N•m 17 N•m
(4.5 lb-in) (8 lb-in) (12 lb-in) (6.3 lb-in) (11 lb-in) (15 lb-in)
M4 × 0.7 1.2 N•m 2.0 N•m 3.0 N•m 1.6 N•m 2.6 N•m 4.0 N•m
(11 lb-in) (18 lb-in) (27 lb-in) (14 lb-in) (23 lb-in) (36 lb-in)
M5 × 0.8 2.4 N•m 4.0 N•m 5.6 N•m 3.1 N•m 5.2 N•m 7.6 N•m
M6 × 1.0 4.0 N•m 6.7 N•m 9.7 N•m 5.4 N•m 9.0 N•m 12.7 N•m
M8 × 1.25 8.6 N•m 15.7 N•m 22.5 N•m 12.7 N•m 20.6 N•m 30.4 N•m
(77 lb-in) (12 lb-in) (17 lb-in) (9 lb-in) (15.2 lb-in) (22 lb-in)
M10 × 1.25 18.6 N•m 32.3 N•m 46.0 N•m 25.5 N•m 42.1 N•m 60.8 N•m
M10 × 1.5 18.6 N•m 30.4 N•m 44.1 N•m 24.5 N•m 41.2 N•m 58.8 N•m
M12 × 1.25 34.3 N•m 56.8 N•m 82.3 N•m 45.0 N•m 75.5 N•m 107.8 N•m
M12 × 1.75 32.3 N•m 53.9 N•m 77.4 N•m 43.1 N•m 71.5 N•m 98.0 N•m
M14 × 1.5 54.0 N•m 89.2 N•m 127.4 N•m 71.6 N•m 117.6 N•m 166.6 N•m
M16 × 1.5 81.3 N•m 107.8 N•m 196.0 N•m 107.8 N•m 186.2 N•m 264.6 N•m
M18 × 1.5 117.6 N•m 196.0 N•m 284.2 N•m 156.8 N•m 264.6 N•m 372.4 N•m
M20 × 1.5 166.6N•m 274.4 N•m 392.0 N•m 215.6 N•m 362.6 N•m 519.4 N•m
M22 × 0.5 225.4N•m 372.4 N•m 529.2 N•m 294.0 N•m 490.0 N•m 705.6 N•m
M24 × 1.5 284.2 N•m 480.2 N•m 686.0 N•m 382.2 N•m 637.0 N•m 921.2 N•m
M24 × 2.0 274.4 N•m 460.6 N•m 666.4 N•m 372.4 N•m 617.4 N•m 891.8 N•m
*Diameter X pitch in millimeters

AFFECTED VIN
DI0A-33
1. Metric bolt strength is embossed on the head of each 3. Determine extra proper tightening torque if tightens
bolt. The strength of bolt can be classified as 4T, 7T, with washer or packing.
8.8T, 10.9T, 11T and 12.9T in general. 4. If tightens bolts on the below materials, be sure to
2. Observe standard tightening torque during bolt determine the proper torque.
tightening works and can adjust torque to be proper • Aluminum alloy: Tighten to 80 % of above torque
within 15 % if necessary. Try not to over max. table.
allowable tightening torque if not required to do so.
• Plastics: Tighten to 20 % of above torque table.

AFFECTED VIN
DI0A-34
BASIC SPECIFICATION
VEHICLE SPECIFICATIONS
Vehicle Dimension (mm)
( ) : Optional item

AFFECTED VIN
DI0A-35
SPECIFICATIONS
Systems Items Diesel (XDi) Remark
General Overall length (mm) 5,125 (5,220) ( ): optional
Overall width (mm) 1,915 (1,930) item
Overall height (mm) 1,820 (1,845)

Gross vehicle weight (kg) 2,750 (2,850)
Curb weight (kg) AT: 2,134 (2,244), MT: 2,106 (2,217)
Min. turning radius (m) 5.6
Ground clearance (mm) 200
Fuel Diesel
Fuel tank capacity 80
Engine Model D27DT
No. of cyl./Compression ratio 5/18:1
Total displacement 2,696 cc
Camshaft arrangement DOHC
Max. power 170 ps/4,000 rpm
Max. torque 34.7 kg•m/1,800 rpm
Injection timing ATDC 4° ± 1°(at idle)
Idle speed 750 ± 20 rpm
Cooling system Water-cooled/forced circulation
Coolant capacity Approx. 11.5
Lubrication Gear pump, forced circulation
Max. oil capacity 9.3
Turbo charger and cooling type Turbo charger, air-cooled
Manual Type Remote control, floor change type
transmission Gear ratio 1st 4.315
2nd 2.475
rd
3 1.536
th
4 1.000
5th 0.807
Rev. 3.591

AFFECTED VIN
DI0A-36
SPECIFICATIONS (Cont’d)
Systems Items Diesel (XDi) Remark
Automatic Model Electronic ( ): optional item
transmission Type Floor change type
st
Gear ratio 1 2.742 3.595 2.742
2nd 1.508 2.186 1.508
3rd 1.000 1.405 1.000
th
4 0.708 1.000 0.708
th
5 - 0.831 -
Rev. 1st 2.429 3.162 2.429
Rev. 2nd - 1.926 -
Transfercase Model TOD
Type Planetary gear type
Gear ratio High 1.000 : 1
Low 2.483 : 1
Clutch Type Hydraulic [A/T: Torque converter]
Disc type Dry single diaphragm type
[A/T: 3 elements 1 stage 2 phases]
Power Type Rack and pinion
steering Steering angle Inner 36° 17'
Outer 32° 40'
Front axle Drive shaft type Ball joint type
Axle housing type Build-up type
Rear axle Drive shaft type Semi-floating type
Axle housing type Build-up type
Brake Master cylinder type Tandem type
Booster type Vacuum booster
Type Inner Disc
Outer Drum (Disc)
Parking brake Cable type (internal expansion)
Suspension Front Wishbone + Coil spring
Rear 5-link + Coil spring
Air Refrigerant R134a
conditioner Compressor type Vane type
Electrical Battery type/Capacity (V-AH) MF / 12 - 90
Starter capacity (V-kW) Diesel : 12 - 2.2, Gasoline : 12 - 1.8
Alternator capacity (V-A) Diesel 12 - 140 (12 - 115)
Gasoline 12 - 115

AFFECTED VIN
DI0A-37
MAINTENANCE
Major Components and Service Interval
* Use only Ssangyong Genuine Parts.
Components Daily Weekly Service Interval Remarks
Engine Gasoline O - Initial change: 10,000 km More frequent maintenance is required if
the vehicle is operated under severe
oil and engine Replace at every 15,000 km condition.
oil filter Severe conditions?
- Frequent low-speed operation as in
stop-and-go traffic
DI diesel O - Initial change: 5,000 km - When most trips are less than 6 km (in
winter, less than 16 km)
engine Replace at every 10,000 km or 12 months - Driving in sandy, dusty, and salty road
- Driving in mountainous areas
- Extensive idling or high load operation
such as towing a trailer
Coolant O - Replace at every 60,000 km or 3 years
Brake / Clutch fluid - - Change every 2 years (Inspect frequently)
Brake pipe and hose - O Initial inspection: 1,000 km
Inspect at every 20,000 km or 1 year, replace if necessary
Brake pad, shoe and - - Inspect at every 10,000 km, adjust or replace if necessary
disc
Air Gasoline - - Clean at every 15,000 km, If vehicle is operated under dusty or sandy
cleaner engine area, frequently clean and inspect the air
Replace at every 60,000 km cleaner system. If necessary, replace the air
element cleaner element.
DI diesel - - Clean at every 10,000 km, replace if
engine necessary,
Replace at every 30,000 km
Fuel filter Gasoline - - Replace at every 60,000 km
engine
DI diesel - - Replace at every 30,000 km (Drain the water from fuel filter at every 10,000 km)
engine
Automatic transmis- - - Replace at every 60,000 km More frequent maintenance is required if the
sion oil vehicle is operated under severe condition.
- Driving in unpaved road
- Towing a trailer
Manual transmission - - Inspect at every 10,000 km,
oil Replace at every 60,000 km
Transfer case oil - - Inspect at every 10,000 km,
Replace at every 60,000 km (but, frequently check the leaks)
Axle oil - - Replace at every 30,000 km
Air conditioner air - - Replace at every 10,000 km More frequent maintenance is required if the
vehicle is operated under severe condition.
filter
- Driving in sandy, dusty, and unpaved road
- Excessive operation of air conditioner or
heater
Spark plug - - Replace at every 60,000 km
(gasoline engine)
Water separator - - Replace at 150,000 km or every 5 years. Only vehicle with water separator.
(DI diesel engine) (Drain the water at every 10,000 km)

AFFECTED VIN
DI0A-38
Lubrication Chart
Lubricant Capacity Classification
Quality API : CG grade or above,
DI Diesel class** ACEA : B2, B3 or B4
6.8 ~ 8.3 L
(DI: Direct Injection) MB sheet : 229.1/3 (preferable)
Viscosity MB sheet No. 224.1
Engine oil
Quality API : SJ grade or above,
class** ACEA : A2 or A3
Gasoline 7.0 ~ 9.0 L
MB sheet : 229.1/3 (preferable)
Viscosity MB sheet No. 224.1
MB sheet 325.0,
DI Engine 11.0 ~ 12.0 L
Engine coolant
BASF GLYSANTIN G05-11,
(Antifreeze and soft water mixed***)
Gasoline 11.3 ~ 11.5 L HOECHST GENANTIN SUPER 8023/14
Manual transmission oil 4WD: 3.6 L, 2WD: 3.4 L ATF DEXRON® II, III
Brake/Clutch fluid (Level must be
maintained between MAX & MIN Properly DOT 4
level)
Power steering fluid 1.1 L ATF DEXRON® II, III
Automatic transmission fluid 8.0 L SHELL or FUCHS ATF 3353
Transfer case fluid 1.4 L API GL-5 or SAE 80W/90 (Viscosity grade)
Front 1.3 ~ 1.4 L
Axle fluid SAE 80W/90, API GL-5
Rear 1.7 L
Wheel bearing grease Properly SHELL Retinax “A” grade
Propeller shaft grease - Front/Rear Properly ALVANIA EP#2
* Please contact Ssangyong Dealer for approved alternative fluid.

** In only case not available MB 229.1 or 229.3, API or ACEA oil may be accepted, however it would rather recommend
to shorten the change interval around 30%.
*** Mixture of antifreeze to water (demineralized)
- General region ; 50 % : 50 %
- Extremily coil region ; 60 % : 40 %

AFFECTED VIN
DI0A-39
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER (VIN)

Vehicle identification number (VIN) is is on the right front
axle upper frame.
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 0
* K P T N 0 B 1 9 S Y P 0 0 0 0 0 0 *
Digit
0 : Symbol according to no. 3. 1. 2 sentence 4 of
76/114/EEC
1 : Nation - K
2 : Maker identification - P
3 : Vehicle type
T - Passenger car
4 : Line & Models
N: STAVIC or RODIUS (LHD), V: STAVIC or RODIUS (RHD)
5 : 0: 5 Door, 1: 4 Door, 2: 3 Door
6 : A - Standard, B - Deluxe, C - Super Deluxe
7 : Restraint system 1 - 3 points Safety Belt, 2 - 2 points Safety Belt
8 : Engine type 6 - 2295cc, In-line 4 cylinders, Gasoline (E23)
F - 2696cc, In-line 5 cylinders, Diesel (D27DT)
9 : Check digit S - All area except North America
10 : Model year 4 - 2004
5 - 2005
6 - 2006
7 - 2007
8 - 2008
11 : Plant code P - Pyungtaek plant
12 ~ 17 : Production Serial Number 000001 ~ 999999
Certification Label
The certification label is affixed on the bottom of driver’s side
B-pillar.

AFFECTED VIN
DI0A-40
MANUFACTURER’S PLATE
1. Type Approval No.
2. Vehicle Identification No.
ENGINE SERIAL NUMBER

Diesel Engine (D27DT)
The engine number is stamped on the lower area of cylinder
block behind the compressor.
Gasoline Engine (3.2L DOHC)

• The engine number is stamped on the lower rear side of
the alternator.

AFFECTED VIN
DI0A-41
TRANSMISSION & TRANSFER CASE

NUMBER
Manual
The transmission label is affixed on the upper area of clutch
housing.
Automatic
The transmisson label is affixed on the right area of transmis-
sion housing.
Transfer Case
The transfer case label is affixed on the transfer case housing.

AFFECTED VIN
DI0A-42
HOW TO USE AND MAINTAIN WORKSHOP MANUAL

CONSISTS OF WORKSHOP
MANUAL Consists of Small Group
1. Group: The manual is divided in large group like 1. Contents: In small group, included subjects and
engine, transmission, axle and others and this group detailed subjects are described in.
is also divided in small group by vehicle state. 2. General: In the general, summary of the small group
2. Small group: Each small group consists of general, (assembly), function and operational principle,
vehicle service, unit repair and special tool usage. specifications, structure and components, diagnosis
and circuit diagram are described in.
MANUAL DESCRIPTION 3. Vehicle service: Service works on the vehicle like
• The contents of the manual consist of operational replacement of parts and inspection repairs are
principle of system, specifications, diagnosis, removal/ described in the order of repair works with actual
installation on vehicle, inspections, disassembly/ photos and illustrations. Also cautions in service
assembly of removed assembly, special tool usage. works, references and inspection methods after
Not providing simple removal/installation information completion of service are described in.
but focused on to describe much more functions, roles 4. Disassembly and assembly of unit assembly:
and principles of system. Detailed service works like disassembly, inspection,
• Every automotive term like part name on the manual adjustment and assembly on removed component
is the same in parts catalog, technical bulletin and (assembly) are described in with systematic contents
drawings to avoid confusion among them. and photo illustration.
Vehicle model
Abbreviation of small
group and page
Bolded: Notice, Installation Notice,

Note
Describes information on the manual Describes small group name, model

like modification, application date, and publication date
applicable V.I.N

AFFECTED VIN
DI01-1
SECTION
00 DI01
ENGINE ASSEMBLY
Table of Contents
STRUCTURE AND FUNCTION DESCRIPTIONS ........ DI01-2

D27DT engine ........................................................ DI01-2
Engine performance curve ..................................... DI01-7
General diagnosis ................................................... DI01-9
DIAGNOSTIC INFORMATION AND PROCEDURE .. DI01-14
Oil leak diagnosis .................................................. DI01-14
Compression pressure test .................................. DI01-15
Cylinder pressure leakage test ............................ DI01-17
Tightening torque .................................................. DI01-18
REMOVAL AND INSTALLATION .............................. DI01-21
Engine mounting ................................................... DI01-21
Engine assembly - removal .................................. DI01-22
DISASSEMBLY AND REASSEMBLY ........................ DI01-34
Components and special tools ............................. DI01-34
Inspection before disassembly and reassembly .. DI01-35
Engine accessories .............................................. DI01-36
Engine overhaul .................................................... DI01-50
ENGINE ASSEMBLY CHANGED BY

AFFECTED VIN
DI01-3
Engine Structure
Front View
Rear View
1. TVD (Torsional Vibration Damper) 7. Viscos clutch 13. Oil filter

2. Air conditioner compressor 8. Auto tensioner pulley 14. Vacuum pump
3. Power steering pump pulley 9. Auto tensioner 15. Crank position sensor
4. Idle pulley 10. Poly-grooved belt 16. EGR valve
5. Water pump pulley 11. Cam position sensor 17. Power steering pump
6. Alternator 12. Drive plate (M/T: DMF) 18. EGR center pipe

AFFECTED VIN
DI01-4
Top View
19. Cylinder head cover 24. Fuel pipe 29. Booster pressure sensor
20. Intake manifold 25. Injector 30. PCV valve and oil separator
21. Water outlet port 26. Fuel return line 31. Oil dipstick
22. Common rail 27. Oil filler cap 32. EGR-LH pipe
23. Fuel pressure sensor 28. Glow plug
CHANGED BY ENGINE ASSEMBLY

AFFECTED VIN
DI01-5
Left Side View
Right Side View
33. Cylinder head 38. EGR-RH pipe 42. Turbo charger booster vacuum
34. Cylinder block 39. PCV valve and oil separator modulator
35. Oil pan 40. Oil dipstick 43. EGR valve vacuum modulator
36. Drain plug 41. High pressure pump 44. EGR valve
37. Turbo charger 45. Exhaust manifold

AFFECTED VIN
DI01-6
Specifications
Description Specification
Engine Type / Number of cylinders D27DT / 5-cylinder
Cylinder Inner diameter (mm) 86.2
Stroke (mm) 92.4
Displacement (cc) 2696
Compression ratio 18:1
Maximum output (ps/rpm) 170/4,000
Maximum torque (kg.m/rpm) 34.7/1,800
Idle speed For Manual Transmission 750 ± 20 rpm

For Automatic Transmission 750 ± 20 rpm
Valve Intake Opens (BTDC) 16°
Closes (ABDC) 33°
Exhaust Opens (BBDC) 46°
Closes (ATDC) 21°
Camshaft Type DOHC

Fuel system Fuel type Low sulfur diesel
Fuel pump type Vane pump in HP pump
Fuel supply pressure HP pump inlet port: max. 400 mbar
HP pump outlet port (with IMV fully open):
over 1,050 bar
Water separation in fuel filter at every 10,000 km
Fuel tank capacity ( ) 80
Lubrication system Oil specification SAE 10W40, 5W40
(MB Sheet 229.1, 229.3 approved oil)
Lubrication type Forced delivery
Oil filter type Full flow, filter element type
Oil capacity ( ) 6.8 ~ 8.3
Cooling system Cooling type Water cooling type
Cooling fan operation type Belt operated type
Thermostat: Fully Opening
85
(Open: 100°C) temperature (°C)
Type WAX pellet type
Coolant capacity ( ) 11.5

AFFECTED VIN
DI01-7
ENGINE PERFORMANCE CURVE

Output and Torque
Output [PS]
Torque [Nm]
Speed [rpm]

AFFECTED VIN
DI01-8
Oil Temperature/Pressure and Boost Pressure

Oil pressure [bar]
Oil temperature [°C]

Boost pressure [bar]
Speed [rpm]

AFFECTED VIN
DI01-9
GENERAL DIAGNOSIS
Hard Starting Malfunction of • Faulty fuse. • Replace the fuse.
(With normal Ignition System • Faulty spark plug. • Clean, adjust the plug gap or
cranking) replace.
• Electric leakage at the high • Replace the cable.
tension cable.
• Poor connection of the high • Replace the cable or wires.
tension cable or lead wires.
• Improper ignition timing. • Adjust the ignition timing.
• Faulty ignition coil. • Replace the ignition coil.
Malfunction of • Lack of fuel in the fuel tank. • Feed the fuel.
Fuel System • Dirty or clogged fuel filter. • Replace the filter.
• Clogged fuel pipe. • Clean the fuel pipe.
• Malfunction of the fuel pump. • Replace the fuel pump.
• Malfunction of the fuel injector. • Replace the injector.
• The foreign material in the fuel • Clean the fuel tank.
tank.
Decline of • Poor tightening spark plug. • Tighten to the specified torque.
Compression Compression
Pressure • Cracked cylinder head gasket. • Replace the gasket.
• Inadequate the valve clearance. • Adjust the clearance.
• Leakage of the valve clearance. • Repair the valve.
• Interference of the valve stem. • Replace the valve or the valve
guide.
• Low elasticity or damage of the • Replace the valve spring.
valve spring.
• Abnormal interference of pistons • Replace the piston ring.
and cylinders.
• Excessive wear of pistons, rings, • Replace the ring or the piston
or cylinders. and boring or replace the
cylinder.
Others • Broken timing belt. • Replace the belt.
• Loosening, damage or leakage of • Connect the hose correctly or
the vacuum hose. replace it.
• Leakage of intake system. • Replace intake system.
Lack of Engine Decline of • Refer to above in this page. • Refer to above in this page.
Power Compression
Pressure
Ignition System • Faulty spark plug. • Adjust or replace the spark plug.
• Electric leakage or poor • Connect the cable correctly or

connection of the high tension replace it.
cable.

AFFECTED VIN
DI01-10
GENERAL DIAGNOSIS (Cont’d)

Lack of Engine Malfunction of • Clogged fuel pipe. • Clean the pipe.
Power Fuel System • Clogged or contaminated fuel • Replace the filter.
filter.
Others • Clogged exhaust system. • Check and repair the system.
• Clogged or contaminated air • Clean or replace the air cleaner
• Leak of the intake manifold • Replace the gasket.
gasket.
• Dragging brakes. • Repair or replace the brakes.
Rough Engine Decline of • Refer to “Compression Pressure • Refer to “Compression Pressure
Idling Compression Test”. Test”.
Pressure
Malfunction of • Clogged fuel pipe. • Clean the pipe.
Fuel System • Clogged or contaminated fuel • Replace the filter.
filter.
• Malfunction of the fuel pressure • Replace the regulator.
regulator.
Malfunction of • Malfunction of the spark plug. • Adjust or replace the spark plug.
Ignition System • Electric leakage or poor connec- • Connect the cable correctly or
tion of the high tension cable. replace it.
• Malfunction of the ignition coil. • Replace the ignition coil.
Others • Clogged or contaminated air • Clean or replace the air cleaner
gasket.
• Poor connection or damage or • Connect the hose correctly or
leakage of the vacuum hose. replace it.
Engine Hesitate Decline of • Refer to “Compression Pressure • Refer to “Compression Pressure
(Upon pressing Compression Test”. Test”.
accelerating Pressure
pedal, the engine Malfunction of • Poor ignition timing. • Adjust the ignition timing.
makes delayed Ignition System • Poor spark plug or Poor adjust- • Replace the plug or adjust the
response This
ment of the plug gap. gap.
situation is
remarkable when • Electric leakage or poor connec- • Connect the cable correctly or
cruising or tion of the high tension cable. replace it.
starting.) Others • Malfunction of the air cleaner • Clean or replace the air cleaner
system. system.
gasket.

AFFECTED VIN
DI01-11

Engine Surging Decline of • Refer to “Compression Pressure • Refer to “Compression Pressure
(Engine power Compression Test”. Test”.
makes Pressure
fluctuation in a Malfunction of • Clogged fuel pipe. • Clean the pipe.
fixed speed and Fuel System • Clogged or contaminated fuel • Replace the filter.
speed changes
filter.
without
operating the • Malfunction of the fuel pressure • Replace the fuel pressure
accelerating regulator. regulator.
pedal.) Malfunction of • Malfunction of the spark plug. • Adjust or replace the spark plug.
Ignition System • Electric leakage or poor • Connect the cable correctly or
cable.
Others • Leak of the intake manifold • Clean or replace the gasket.
gasket.
• Leakage of the vacuum hose. • Connect the hose correctly or
replace it.
Excessive Overheated • Refer to “Overheat” in this page. • Refer to “Overheat” in this page.
Detonation Engine
(According to Malfunction of • Abnormal spark plug. • Replace the spark plug.
the opening Fuel System • Poor ignition timing. • Adjust the ignition timing
range of Mal-
function of • Electric leakage or poor connec- • Connect the cable correctly or
metallic is made tion of the high tension cable. replace it.
with abnormal Malfunction of • Clogged or contaminated fuel • Clean or replace the fuel filter and
explosion ) Ignition System filter and fuel pipe. the fuel pipe.
Others • Leak of the intake manifold • Replace the gasket.
gasket.
• Excessive carbon deposit due to • Remove the carbon.
abnormal combustion.
Overheat Malfunction of • Lack of coolant. • Refill coolant.
Cooling System • Malfunction of the thermostat. • Replace the thermostat.
• Malfunction of the cooling fan. • Check or replace the cooling fan.
• Poor water pump performance. • Replace the pump.
• Clogged or leaky radiator. • Clean, repair or replace the
radiator.
Malfunction of • Poor engine oil. • Replace engine oil with the
Lubrication specified one.
System • Blocking oil filter or strainer. • Clean or repair the oil filter or the
strainer.
• Poor oil pump performance. • Replace or repair the pump.
Other • Leakage of oil • Repair.
• Damaged cylinder head gasket. • Replace the gasket.

AFFECTED VIN
DI01-12

Poor Fuel Decline of • Refer to “Compression Pressure • Refer to “Compression Pressure
Consumption Compression Test”. Test”.
Pressure
Malfunction of • Leakage of the fuel tank or the • Repair or replace the fuel tank or
Fuel System fuel pipe. the fuel pipe
Ignition System • Abnormal spark plug • Replace the plug.
(Excessive carbon deposit,
inadequate gap, burnt electrode).
• Electric leakage or poor • Connect the cable normally or
cable.
Malfunction of • Malfunction of the thermostat. • Repair the thermostat.
Cooling System
Others • Improperly installed valve. • Repair or replace the valve.
• Low pressure of tires. • Adjust the pressure of tires.
Excessive Leakage of • Loosened oil drain plug. • Tighten the plug.
Consumption of Engine Oil • Loosened oil pan bolt. • Tighten the bolt.
Engine Oil
• Loosened oil filter. • Tighten the filter.
• Loosened oil pressure switch. • Tighten the switch.
• Leakage of camshaft front oil seal. • Replace the seal.
• Leakage of crankshaft front oil seal. • Replace the seal.
• Leakage at the cylinder head • Replace the gasket.
cover gasket.
• Damage of the cylinder head • Replace the gasket.
gasket.
Oil Mixing in Com- • Stuck piston ring. • Remove carbon and replace the
bustion Chamber ring.
• Worn piston or cylinder. • Replace the piston or the
cylinder.
• Worn piston ring or ring groove. • Replace the piston or ring.
• Inadequate position of the piston • Adjust the position.
ring cutting part.
• Abrasion or damage of the valve • Replace the valve system.
system.
Low Oil Malfunction of Lu- • Inadequate oil viscosity. • Replace with the specified one.
Pressure brication System • Loosening of the oil pressure • Tighten the switch.
switch.
• Blocking oil strainer. • Clean the strainer.
• Lowered function of the oil pump. • Replace the pump.
• Abrasion or damage of the oil • Replace the valve.
pump relief valve.

AFFECTED VIN
DI01-13

Engine Noise Valve Noise • Inadequate valve clearance • Adjust the valve clearance.
• Abrasion of valve stem or guide. • Replace the valve stem or the
guide.
• Weak valve spring. • Replace the spring.
Piston, Ring, • Abrasion of the piston, the ring or • Boring the cylinder or replace the
Cylinder Noise the cylinder. piston, the ring or the cylinder.
Connecting Rod • Abrasion of the connecting rod • Replace the bearing.
Noise bearing.
• Loosened the connecting rod nut. • Tighten to the specified torque
Crankshaft Noise • Abrasion of the crankshaft • Replace the bearing.

bearing.
• Abrasion of the crankshaft • Grind or replace the crankshaft
journal. journal.
• Loosened bearing cap bolt. • Tighten to the specified torque.
• Excessive clearance of the • Adjust or replace.
crankshaft thrust bearing.
• Low oil pressure. • Refer to “Low Oil Pressure” in
this section.

AFFECTED VIN
DI01-14

OIL LEAK DIAGNOSIS Black Light and Dye Method
Most fluid oil leaks are easily located and repaired by vi- A dye and light kit is available for finding leaks, Refer to
sually finding the leak and replacing or repairing the nec- the manufacturer's directions when using the kit.
essary parts. On some occasions a fluid leak may be dif- 1. Pour the specified amount of dye into the engine oil
ficult to locate or repair. The following procedures may fill tube.
help you in locating and repairing most leaks.
2. Operate the vehicle normal operating conditions as
directed in the kit.
Finding the Leak 3. Direct the light toward the suspected area. The dyed
1. Identify the fluid. Determine whether it is engine oil, fluid will appear as a yellow path leading to the
automatic transmission fluid, power steering fluid, etc. source.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating Repairing the Leak
temperature, park the vehicle over a large sheet Once the origin of the leak has been pinpointed and traced
of paper. back to its source, the cause of the leak must be deter-
2.2 Wait a few minutes. mined in order for it to be repaired properly. If a gasket is
2.3 You should be able to find the approximate replaced, but the sealing flange is bent, the new gasket
location of the leak by the drippings on the will not repair the leak. The bent flange must be repaired
paper. also. Before attempting to repair a leak, check for the fol-
lowing conditions and correct them as they may cause a
3. Visually check around the suspected component.
leak.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas that
are hard to reach. Gaskets
4. If the leak still cannot be found, it may be necessary • The fluid level/pressure is too high.
to clean the suspected area with a degreaser, steam
• The crankcase ventilation system is malfunctioning.
or spray solvent.
• The fasteners are tightened improperly or the threads
4.1 Clean the area well.
are dirty or damaged.
4.2 Dry the area.
• The flanges or the sealing surface is warped.
4.3 Operate the vehicle for several miles at normal
• There are scratches, burrs or other damage to the
operating temperature and varying speeds.
sealing surface.
4.4 After operating the vehicle, visually check the
• The gasket is damaged or worn.
suspected component.
• There is cracking or porosity of the component.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method. • An improper seal was used (where applicable).
Seals
Powder Method • The fluid level/pressure is too high.
1. Clean the suspected area. • The crankcase ventilation system is malfunctioning.
2. Apply an aerosol-type powder (such as foot powder) • The seal bore is damaged (scratched, burred or nicked).
to the suspected area. • The seal is damaged or worn.
3. Operate the vehicle under normal operating • Improper installation is evident.
conditoins.
• There are cracks in the components.
4. Visually inspect the suspected component. You
• The shaft surface is scratched, nicked or damaged.
should be able to trace the leak path over the white
powder surface to the source. • A loose or worn bearing is causing excess seal wear.

AFFECTED VIN
DI01-15
COMPRESSION PRESSURE TEST

The compression pressure test is to check the conditions of internal components (piston, piston ring, intake and
exhaust vale, cylinder head gasket). This test provides current engine operating status.
Notice
• Before cranking the engine, make sure that the test wiring, tools and persons are keeping away from moving
components of engine (e.g., belt and cooling fan).
• Park the vehicle on the level ground and apply the parking brake.
• Do not allow anybody to be in front of the vehicle.
Specifications
Test temperature at normal operating temperature (80°C)
Compression pressure Normal value 32 bar
Minimum value 18 bar
Permissible pressure difference between individual cylinders Max. 3 bar

AFFECTED VIN
DI01-16
Measuring Procedure
Notice
• Disconnect the fuel rail pressure sensor connector to cut off the fuel injection.
• Discharge the combustion residues in the cylinders before testing the compression pressure.
• Apply the parking brake before cranking the engine.
1. Warm the engine up to normal operating temperature

(80°C).
2. Disconnect the fuel rail pressure sensor connector to
cut off the fuel injection.
3. Place the diagram sheet to compression pressure tester.
4. Remove the glow plugs and install the compression

pressure tester into the plug hole.
Tightening torque (Tester) 15 Nm
5. Crank the engine for approx. 10 seconds by using the

start motor.
6. Record the test result and measure the compression
pressure of other cylinders with same manner.
7. If the measured value is not within the specifications,
perform the cylinder pressure leakage test.

AFFECTED VIN
DI01-17
CYLINDER PRESSURE LEAKAGE TEST

If the measured value of the compression pressure test is not
within the specifications, perform the cylinder pressure leak-
age test.
Permissible Pressure Leakage

Test temperature at normal operating temperature (80°C)
At whole engine Max. 25 %
At valve and cylinder head gasket Max. 10 %
At piston ring Max. 20 %
Notice
• Perform the pressure in order: 1 - 2 - 3 - 4 - 5

• Do not test the cylinder pressure leakage with wet type test procedure. (do not inject the engine oil into the
combustion chamber)

AFFECTED VIN
DI01-18
TIGHTENING TORQUE
NO. Name Size Quantity Tightening Torque
1 Oil nozzle M6 x 22 5 10 ± 1
55 ± 5
2 Main bearing cap M11 x 62 12
90° ± 10°
40 ± 5
3 Connecting rod cap M9 x 52 5
90° ± 10°
4 Rear cover M6 x 20 6 10 ± 1
5 Oil pump M8 x 35SOC 3 25 ± 2.5
6 Oil baffle plate assembly M6 x 20 10 10 ± 1
M6 x 16 1 10 ± 1
M6 x 40 6 10 ± 1
7 T.G.C.C M6 x 60 3 10 ± 1
M6 x 70 2 10 ± 1
M8 x 80SOC 1 25 ± 2.5
45 ± 5
8 Flywheel M10 x 30 8
90° ± 10°
325 ± 33
9 Crankshaft hub M18 x 50 1
90° ± 10°
M6 x 20 24 10 ± 1
M6 x 35 3 10 ± 1
10 Oil pan
M6 x 38 3 10 ± 1
M6 x 40 4 25 ± 2.5
11 High pressure pump assembly M8 x 40 4 25 ± 2.5
12 High pressure pump sprocket assembly M14 x 1.5-8-1 1 65 ± 5
13 High pressure pump bracket M7 x 16 3 20 ± 2 x 90° + 10°
M8 x 25 2
25 ± 2.5
M8 x 50 2
14 Cylinder head assembly Step1: 20 Nm ± 2 Nm
M12 x 177 11
Step2: 85 Nm ± 5 Nm
M12 x 158 1 Step3: 3 x 90° + 10°
15 Camshaft cap M8 x 60 24 25 ± 2.5
16 Stud bolt M8 10 15 ± 1.5
Camshaft sprocket (Intake) 1 25 ± 2.5
17 M11 x 52
Camshaft sprocket (Exhaust) 1 90° ± 10°
18 Chain tensioner M22 1 65 ± 5
19 Coolant temperature sensor M14 1 22 ± 2.2

AFFECTED VIN
DI01-19

M8 x 45(LOWER) 1 32 ± 3
20 Auto tensioner
M12 x 90 1 82 ± 6
21 Water pump assembly M6 x 50 7 10 ± 1
22 Water pump pulley M6 x 12 4 10 ± 1
23 Hot water inlet pipe assembly M6 x 12 2 10 ± 1
24 Alternator bracket M8 x 32 4 25 ± 2.5
25 Alternator M10 x 90 2 46 ± 4.6
26 Air conditioner compressor assembly M8 x 95 4 46 ± 4.6
Air conditioner compressor bracket M8 x 25 1 25 ± 2.5
27
assembly M8 x 60 3 25 ± 2.5
Air conditioner compressor sub M6 x 14 1 10 ± 1.0
28
bracket assembly M8 x 16 1 25 ± 2.5
M8 x 45 6 25 ± 2.5
29 Intake manifold
M8 x 130 6 25 ± 2.5
30 Bracket M6 x 16 1 10 ± 1.0
31 Knock sensor M8 x 28 2 20 ± 2.6
32 Camshaft position sensor M8 x 16 1 12 ± 1.7
33 Booster pressure sensor M6 x 16 2 10 ± 1.0
34 Exhauster manifold M8 10 40 ± 4
35 Turbo charger assembly M8 4 25 ± 2.5
36 Turbo charger adaptor piece 1 32 ± 3.2
37 Nut M8 1 25 ± 2.5
38 Combination bolt M8 x 22 1 25 ± 2.5
M6 x 16 (Cylinder block side) 1 25 ± 2.5
39 T/C oil supply pipe
M16 (T/C side) 1 20 ± 2.0
M6 x 16 (T/C side) 2 10 ± 1.0
40 T/C oil return pipe
M6 x 16 (Cylinder block side) 2 10 ± 1.0
41 EGR valve assembly M8 x 22 2 25 ± 2.5
M6 x 16 2 10 ± 1.0
42 EGR-LH pipe bolt
M8 x 22 2 35 ± 2.0
M6 x 16 4 10 ± 1.0
EGR combination bolt
43 M8 x 16 4 25 ± 2.5
EGR-RH pipe nut M8 2 35 ± 2.0
44 Glow plug cable nut M5 5 15 ± 3
45 Vacuum pump M6 x 20 3 10 ± 1.0
M6 x 25 5 10 ± 1.0
46 Cooling fan bracket assembly M6 x 65 1 10 ± 1.0
M6 x 85 3 10 ± 1.0
47 Cylinder head cover M6 x 35 21 23 ± 2.3

AFFECTED VIN
DI01-20

48 Vacuum modulator M6 x 16SOC 4 10 ± 1.0
49 WDT combination bolt M6 x 16 3 10 ± 1.0
50 Oil dipstick tube M6 x 16 1 10 ± 1.0
M8 x 35SOC 1 25 ± 2.5
51 Oil filter assembly M8 x 50SOC 2 25 ± 2.5
M8 x 55SOC 1 25 ± 2.5
52 Fuel rail assembly M8 x 35SOC 3 25 ± 2.5
10 ± 1.0
53 Injector clamp washer M6 x 60 5
180 + 20°
54 Fuel pipe clip (H-C) M6 x 19 1 10 ± 1.0
55 Fuel pipe clip (C-I) M6 x 16 5 10 ± 1.0
56 Crankshaft position sensor M5 x 17 1 0.8 ± 0.4
57 Crankshaft position sensor GAP 0.7 ~ 1.5
58 Fuel pressure sensor 1
59 Wiring M6 x 16 5 10 ± 1.0
M8 x 16 2 25 ± 2.5
60 Intake manifold bracket
M8 x 40 2 25 ± 2.5
M8 x 100 2 25 ± 2.5
61 Power steering pump
NUT 2 25 ± 2.5
62 Piston protrusion 5 0.765 ~ 1.055
Clearance between connecting rod
63 5 0.05 ~ 0.31
and pin boss
64 End play of crankshaft NEW: 0.100 ~ 0.245 mm // USED: 0.300 mm

AFFECTED VIN
DI02-1
SECTION
00 DI02
ENGINE HOUSING
Table of Contents
CYLINDER HEAD/CYLINDER BLOCK ....................... DI02-2

Cylinder head .......................................................... DI02-2
Camshaft assembly .............................................. DI02-16
Timing chain assembly .......................................... DI02-24
Cylinder block ....................................................... DI02-28
CRANKSHAFT ........................................................... DI02-31
Arrangement of thrust washers and bearings ...... DI02-32
Torsional vibration damper ................................... DI02-37
Diassembly and reassembly ................................. DI02-38
FLYWHEEL ................................................................ DI02-41
Dual mass flywheel (DMF, Manual transmission
equipped vehicle) ................................................. DI02-41
PISTON AND CONNECTING ROD ............................ DI02-43
Piston ring ............................................................. DI02-44
Cylinder inner diameter and piston size ............... DI02-45
Disassembly and reassembly ............................... DI02-46
HIGH PRESSURE PUMP (HPP) ............................... DI02-50
Components locator ............................................. DI02-50
Disassembly and reassembly ............................... DI02-51
VACUUM PUMP ........................................................ DI02-56
ENGINE HOUSING CHANGED BY

AFFECTED VIN
DI02-2
CYLINDER HEAD/CYLINDER BLOCK

CYLINDER HEAD
Cylinder head bolt
Oil return check valve
System Characteristics
Intake port • 4-valve DOHC valve mechanism
• Swirl and tangential port
• 4-bolt type cylinder head bolt
• Water jacket integrated casting
• Integrated chain housing and cylinder head
Exhaust port • Oil gallery: drilled and sealing with cap and screw plug
CHANGED BY ENGINE HOUSING

AFFECTED VIN
DI02-3
Cylinder Head Pressure Leakage Test

Preceding Works:
- Removal of cylinders
- Removal of intake and exhaust manifold
- Removal of valves
Test Procedures
1. Place the pressure plate on a flat-bed work bench.
2. Install the cylinder head on the pressure plate.
3. Immerse the cylinder head with the pressure plate into

warm water (approx. 60°C) and pressurize with
compressed air to 2 bar.
Notice
Examine the cylinder head for air bubbling. If the air

bubbles are seen, replace the cylinder head.

AFFECTED VIN
DI02-4
Cylinder Head Mating Surface Check

Specifications
Height “A” (cylinder head parting surface - cylinder head cover parting surface) 142.9 ~ 143.1 mm
Minimum height after machining 142.4 mm
Flatness in longitudinal direction 0.08 mm
in transverse direction 0.0 mm
Permissible variation of parallelism of top parting surface to bottom in longitu-
within 0.1 mm
dinal direction
Peak-to-valley height 0.004 mm
Valve recess “a” Intake valve 0.1 ~ 0.7 mm
Exhaust valve 0.1 ~ 0.7 mm
Measurement
1. Measure the cylinder head height “A”.
Limit Over 142.4 mm
Notice
If the height is less than the limit, the cylinder head

must be replaced.
2. Insert the valves into the valve guides and measure the
recesses.
Valve recess “a” 0.1 ~ 0.7 mm
Notice
If the measured value is out of the specified range,

machine the valve seat as much as necessary until
the specified value is achieved.

AFFECTED VIN
DI02-5
Cylinder Head
- Disassembly and Reassembly
Disassembly
Preceding Works:
- Removal of fan belt
- Removal of fuel supply and return lines
- Removal of EGR related pipes and oil dipstick tube
- Removal of intake manifold mounting bracket
- Removal of injector fuel line and connector, and glow plug
connector
Notice
• Plug the openings of injector holes and common

rail with the protective caps.
1. Remove the cylinder head cover.
2. Remove the camshaft position sensor.
Installation Notice
• The intake manifold can be interfered by the sensor
when installing.
3. Mark on the intake camshaft sprocket and exhaust

camshaft sprocket for timing setting during installation.

AFFECTED VIN
DI02-6
5. Hold the camshafts and remove the intake camshaft

sprocket and exhaust camshaft sprocket.
6. Pull out the lock pins with a sliding hammer and remove
the upper guide rail.
Notice
Correctly align the electronic control module onto

the shift plate by using two central pins when
installing.
7. Remove the oil cooler, then remove the intake manifold.
Installation Notice
• The intake manifold can be interfered by the
cylinder head bolt (M8 x 50).

AFFECTED VIN
DI02-7
8. Remove the cylinder head bolts according to the

numerical sequence.
M8 x 25 : 2 EA
M8 x 50 : 2 EA
M12 x 177 : 11 EA
M12 x 158 : 1 EA (Vacuum pump side)
9. Measure the length of cylinder head bolts.
Installation Notice
• If the maximum length is exceeded by 2 mm,
replace the cylinder head bolt.
Length when new Maximum Limit

177 mm 179 mm
158 mm 160 mm
10. Remove the cylinder head.
Notice
• Inspect the cylinder head surface.

• Store the removed injectors and glow plugs so that
they will not be damaged.
11. Measure the piston protrusion from the mating surface.
Standard 0.765 ~ 1.055 mm

AFFECTED VIN
DI02-8
Reassembly
1. Install the cylinder head with the steel gasket.
Notice
Make sure to place the “TOP” mark upward.
2. Tighten the cylinder head bolts to specified torque and

torque angle.
Installation Notice
Step 1 20 ± 2.0 Nm
Tightening torque Step 2 85 ± 5.0 Nm
Step 3 270° (90° x 3) + 10°
• Apply the oil on the bolt thread when installing.

• Always insert new washer first.
• The bolts (12) at vacuum pump side are shorter than
others.
3. Install the HLA device and finger follower. Check the HLA
device with the diagnosis procedures before installation.
Notice
• Put the cylinder head on the locating pins.
4. Tighten the camshaft bearing cap bolts.

• Intake: #2, #4, #5
• Exhaust: #8, #10, #11

AFFECTED VIN
DI02-9
• Exhaust: #1, #3, #6

• Intake: #7, #9, #12 Intake
Installation Notice
• Check the finger follower positions and align if

needed.
Exhaust
5. Install the intake and exhaust camshaft sprockets and

the timing chain.
Installation Notice
Tightening torque 25 Nm + 90°
• If the sprocket bolt is stretched over 0.9 mm, replace

it with new one.
• Always install the intake camshaft sprocket first.
• Ensure that the markings on camshaft sprocket and
timing chain are aligned.
• Make sure that the timing chain is securely seated
on the guide rail.
6. Rotate the crankshaft pulley two revolutions and ensure

that the OT mark on the crankshaft pulley and the OT
mark on the camshaft pulley are aligned.
Notice
If the markings are not aligned, reinstall the cylinder

head.
7. Place the bearing cap with the OT marks on both

camshafts facing upward.
Notice
• Apply the sealant on the cap (#12) for the vacuum
pump when installing.
• Apply the oil on the bearing journals before
installation.

AFFECTED VIN
DI02-10
8. Fit the timing chain onto the camshaft sprockets and

install the upper guide rail.
• Install the clamping guide rail pin.
Notice
• Install the guide rail with slanted side facing

forward.
• Be careful not to change the timing of HP pump
when fitting the timing chain.
9. Tighten the intake and exhaust camshaft sprocket bolts.
Installation Notice
25 ± 2.5 Nm,
Tightening torque
90° + 10°
10. Install the camshaft position sensor.

11. Apply the Loctite to the bolt and tighten it.
Installation Notice
12. Check the intake camshaft before installing the vacuum

pump.
13. Install the intake manifold. Install the oil cooler with new
gasket.
Installation Notice
• Ensure that there is no leaks around the coolant

line for #1 cylinder

AFFECTED VIN
DI02-11
Installation Notice
Tightening torque 65 ± 5 Nm
15. Install the cylinder head cover assembly.

16. Install the rubber gasket.
17. Tighten the cylinder head cover bolts.
Installation Notice
Tightening torque 10 ± 1.0 Nm
• Apply the sealant to the bolts for the vacuum pump

and the timing chain cover.
18. Check the mating surface of the #12 bearing cap and the
cylinder head for contacting.
19. Check if the O-ring is installed in the vacuum pump.
20. Install the vacuum pump with the key groove aligned.
21. Tighten the vacuum pump mounting bolts.
Installation Notice

AFFECTED VIN
DI02-12
22. Install the PCV valve assembly on the cylinder head.
Installation Notice
23. Engage the engine oil hose and the PCV valve hose.
24. Remove the protective caps and install the new fuel supply
pipes.
Notice
• To keep the cleanness and protect the components,

the fuel pipes should be replaced with new ones.
• Be careful not to be mixed the fuel pipes because
the pipe appearance of #1 and #3 cylinders and #2
and #4 are same each other.

AFFECTED VIN
DI02-13
Intake/Exhaust - Removal/Installation
1. Remove the cylinder head assembly.
2. Install the removed cylinder head on the assembly board

(special tool) and set the supporting bar and lever (special
tool) on the cylinder head.
3. Push the valve spring seat down with the lever and remove
the valve cotter, valve seat and valve spring.
4. Remove the valves from the cylinder head.

AFFECTED VIN
DI02-14
Special Tools and Equipment

Name and Part Number Application
Compression pressure measur-

ing adapter and gauge
Y99220092B
Pressure plate
(cylinder head pressure leakage
test)
Pressure plate
(intake camshaft pressure leakage
test
Pressure plate
(exhaust camshaft pressure leak-
age test)

AFFECTED VIN
DI02-15
Cylinder head hanger
Supporting bar and lever

Y99220082B
Guide pin extractor

Y99220162B
Intake manifold guide pin

Y99220112B

AFFECTED VIN
DI02-16
CAMSHAFT ASSEMBLY
Intake camshaft and

Finger follower and HLA exhaust camshaft
Camshaft sprockets
Cylinder head
Camshaft position sensor Chain tensioner

AFFECTED VIN
DI02-17
Camshaft Position Sensor
Gap
Hall voltage
<Location of camshaft position sensor> <Operation principle of hall sensor>
The camshaft position sensor uses hall-effect to set the camshaft position and metallic-magnetic-material sensor end is
attached on the camshaft and then rotates with it. If sensor protrusion passes camshaft position sensor’s semi-conduc-
tor wafer, magnetic field changes direction of electron on the semi-conductor wafer to the current flow direction that
passes through wafer from the right angle. When operation power is supplied from camshaft position sensor, camshaft
hall sensor generates signal voltage. The signal voltage will be 0V if protrusion and camshaft position sensor are near
and 5 V if apart.
ECU can recognize that the No. 1 cylinder is under compression stroke by using this voltage signal (hall voltage).
The rotating speed of camshaft is half of the crankshaft and controls engine’s intake and exhaust valves. By installing
sensor on the camshaft, can recognize specific cylinder’s status, compression stroke or exhaust stroke, by using
camshaft position when the piston is moving toward TDC (OT). Especially when started first, it is difficult to calculate the
stroke of a specific cylinder with only crankshaft position sensor.
Accordingly, camshaft position sensor is necessary to identify the cylinders correctly during initial starting. However,
when engine is started, ECU learns every cylinder of the engine with crankshaft position sensor signals so can run the
engine even though the camshaft position sensor is defective during engine running.
Pulse generation Cam angle ± 6°

Sensor air gap 0.2 ~ 1.8 mm
Tightening torque 10 ~ 14 Nm
Operating temperature - 40 ~ 130°C
Ground
Camshaft sensor
<Circuit diagram of camshaft position sensor>

AFFECTED VIN
DI02-18
Removal
Preceding Works:
- Removal of fan belt
- Removal of fuel supply and return lines
- Removal of intake manifold mounting bracket
- Removal of EGR pipe and oil dipstick tube
1. Remove the injector fuel line and connector, and glow

plug connector
Notice
Plug the openings of injector holes and common rail
with the protective caps.
2. Remove the cylinder head cover.
3. Remove the camshaft position sensor.

AFFECTED VIN
DI02-19
4. Mark on the intake camshaft sprocket and exhaust

camshaft sprocket for timing setting during installation.
6. Hold the camshafts and remove the intake camshaft

sprocket and exhaust camshaft sprocket.
7. Remove the camshaft bearing cap bolts so that the

tightening force can be relieved evenly. Intake
• Intake: #1, #3, #6
• Exhaust: #7, #9, #12
* However, there is no specific removal sequence.
Exhaust

AFFECTED VIN
DI02-20
• Intake: #2, #4, #5

• Exhaust: #8, #10, #11
* Do not remove the bolts at a time completely. Remove
them step by step evenly.
8. Remove the intake and exhaust camshafts from the

cylinder head.
9. Remove the finger follower and the HLA device.
Notice
Avoid contact with hot metal parts when removing

the HLA device immediately after stopping the
engine.

AFFECTED VIN
DI02-21
Installation
1. Install the HLA device and finger follower. Check the HLA
device with the diagnosis procedures before installation.
Notice
• Put the cylinder head on the locating pins.
2. Place the bearing cap with the OT marks on both

camshafts facing upward.
Notice
• Apply the sealant on the cap (#12) for the vacuum

pump when installing.
• Apply the oil on the bearing journals before
installation.
3. Tighten the camshaft bearing cap bolts.

• Intake: #2, #4, #5
• Exhaust: #8, #10, #11
1 2 3 4 5 6
7 8 9 10 11 12
• Intake: #1, #3, #6

Intake
• Exhaust: #7, #9, #12
Installation Notice 1 2 3 4 5 6
• Check the finger follower positions and align if

7 8 9 10 11 12
needed.
Exhaust

AFFECTED VIN
DI02-22
4. Install the intake and exhaust camshaft sprockets and

the timing chain.
Installation Notice
Tightening torque 25 Nm + 90° + 10°
• If the sprocket bolt is stretched over 0.9 mm, replace

it with new one.
• Always install the intake camshaft sprocket first.
• Ensure that the markings on camshaft sprocket and
timing chain are aligned.
• Make sure that the timing chain is securely seated
on the guide rail.
5. Rotate the crankshaft pulley two revolutions and ensure

that the OT mark on the crankshaft pulley and the OT
mark on the camshaft pulley are aligned.
Notice
If the markings are not aligned, reinstall the cylinder

head.
Installation Notice

AFFECTED VIN
DI02-23

HLA remover
Y99220152B
Stem seal installer

Y99220142B

AFFECTED VIN
DI02-24
TIMING CHAIN ASSEMBLY

Chain Drive System
System Layout
Oil injecting direction
1. Exhaust camshaft sprocket 7. Oil pump tensioner

2. Upper guide rail 8. Oil pump sprocket
3. Intake camshaft sprocket 9. Crankshaft sprocket
4. Clamping guide rail 10. Oil nozzle
5. HP pump sprocket 11. Tensioner guide rail
6. Lower guide rail 12. Chain tensioner

AFFECTED VIN
DI02-25
Chain
• Chain type: Double Bush
• Pitch: 9.525 mm
• Load limits: 19,000 N
• No. of links: 144 EA
• Overall length: 1371.6 mm
• Replace when the chain is extended by 0.5 % from overall length (Replace if extended by over 6.858 mm)
Chain tensioner
Check valve
* Check valve opening pressure: 0.2 ~ 0.5 bar
The major function of tensioner is optimizing the movement of chain drive system by using spring constant and oil
pressure in the tensioner.
The tensioner performs function of adjusting chain tension to be always tight, not loose, while engine running. By doing
so, can reduce wears of each guide rail and sprocket.
65 ± 5.0 Nm
Tightening torque
(Installed on the cylinder head)
Guide rail
Guide rail is used to optimize the movement of chain drive system like tensioner.
Guide rail can prevent chain slap when chain is extended and reduce chain wears.
Guide rail is needed especially when the distance between the sprockets are too long.
The material is plastic.
• Location of guide rail

- Tensioner guide rail: Between crankshaft sprocket and exhaust camshaft sprocket
- Upper guide rail: Between exhaust camshaft sprocket and intake camshaft sprocket
- Clamping guide rail: Between intake camshaft sprocket and HP pump sprocket
- Lower guide rail: Between HP pump sprocket and crankshaft sprocket

AFFECTED VIN
DI02-26
Timing setting
Sprocket marking: 4 points

(Gold marking)
<Timing marking points on chain>
• Check marking links on the chain (Gold marking)

• Locate a point with two continuous marking links and align it to a marking on crankshaft sprocket ( )
• Align respective marking link to each camshaft sprocket (intake and exhaust) marking ( )
• Align another marking link to HP pump sprocket marking ( )

AFFECTED VIN
DI02-27
Removal and Installation

1. Remove the cylinder head assembly.
2. Remove the oil pan.
3. Remove the chain guide rail with a sliding hammer.
4. Remove the chain cover.
5. Remove the oil pump drive chain.

6. Remove the upper guide rail while pushing the retaining
spring with a screwdriver.
7. Remove the lower guide rail.
8. Remove the oil pump drive chain.
9. Remove the tensioner guide rail.
10. Remove the timing chain.

Notice
Thoroughly clean the removed components before
installing.

AFFECTED VIN
DI02-28
CYLINDER BLOCK
Deep head bolt thread to prevent the

deformation at cylinder bore surfaces
Internal and external ribs considered Water jacket design to increase

vibration and strength the cooling efficiency
Cambering type skirt to reduce the noise
• Rib design by considering strength against engine • Reinforcement of strength
vibrations and weight - Main bearing housing / Main bearing cap
• Cambering type skirt design on case housing wall to - Extended main bearing cap bolt
reduce the engine noise
• Water jacket design to increase the cooling efficiency
• Reducing the noise, vibration and harshness (NVH)
of cylinder bore bridge
- Minimize the vibration by adding external ribs
• Deep head bolt thread to prevent the deformation at
cylinder bore surfaces - Adding the ribs around oil pan mating surface

AFFECTED VIN
DI02-29
Knock Sensor
Two knock sensors are located on the cylinder block (intake manifold side).
To detect engine vibration under abnormal combustion, knock sensor has piezoelectric element fixed on the
vibration plate and this vibration plate is fixed on the base. If happens knocking, pistons or connecting rods
vibrate and occurs heavy sounds that hit metal. Knock sensor is used to detect those knockings caused by
abnormal combustions. It controls idling stabilities and turns on the engine warning light when detects injector
damages. And also controls pilot injection very precisely during MAP learning.
When knock sensor is defective, engine ECU corrects injection timing based on MAP values like engine speed,
intake air volume and coolant temperature.
Before checking the knock sensor unit, be sure to check the tightening torque of the sensor and connector
connecting conditions.
Insulating resistance Min. 1MΩ

Resonance frequency 25 kHz
26 ± 8 mV/g (at 5 kHz)
Output voltage 22 ~ 37 mV/g (3 ~ 10 kHz)
22 ~ 57 mV/g (10 ~ 20 kHz)
<Location of knock sensor>
1. Sensor housing 6. Upper contact plate

2. Nut 7. Piezo element
3. Disc spring 8. Lower contact plate
4. Weight 9. Body
5. Insulation disc 10. Terminal

AFFECTED VIN
DI02-30
Notice
The knock sensor should be tightened with the specified tightening torque. Otherwise, the engine output may
be decreased and the “ENGINE CHECK” warning lamp may come on. The internal resistance of the sensor is
approx. 4.7 kΩ.
Ground
Knock sensor
Signal
Signal
Knock sensor
Ground
<Circuit diagram of knock sensor>

AFFECTED VIN
DI02-31
CRANKSHAFT
Preceding Works: Removal of end cover
Removal of pistons
Removal of crankshaft sprocket
3. Crankshaft main bearing shells, upper 7. Lower thrust bearing

4. Upper thrust bearing 8. Crankshaft main bearing cap
5. Crankshaft 9. Crankshaft thrust bearing cap
6. Crankshaft main bearing shells, lower 10. 12-sided stretch bolt ....... 55 ± 5.0 Nm, 90° + 10°

AFFECTED VIN
DI02-32
ARRANGEMENT OF THRUST WASHERS AND BEARINGS
1. Crankshaft 4. Crankshaft main bearing shells, lower

2. Crankshaft main bearing shells, upper 5. Lower thrust bearing
3. Upper thrust bearing
Notice
The clearance between bearing shell and bore and between
bearing shell and journal are various. Refer to the table
on next page to select bearings when installing.

AFFECTED VIN
DI02-33
Dimensions of Crankshaft Main Bearing

(mm)
Color Crankshaft Journal Upper Main Bearing Lower Main Bearing
Blue 57.965 ~ 57.960 2.260 ~ 2.255 2.260 ~ 2.255
Yellow 57.960 ~ 57.955 2.265 ~ 2.260 2.265 ~ 2.260
Red 57.955 ~ 57.950 2.270 ~ 2.265 2.270 ~ 2.265
White 57.950 ~ 57.945 - 2.275 ~ 2.270
Violet 57.945 ~ 57.940 - 2.280 ~ 2.275
Bearing Clearance
(mm)
Description Crankshaft Bearing Thrust Bearing
When new 0.027 ~ 0.051 0.026 ~ 0.068
Radial clearance
Wear limit Max. 0.070 Max. 0.080
When new 0.100 ~ 0.254 -
Axial clearance
Wear limit Max. 0.300 -
Matching the Fit Bearing Journal Width to Thrust Washers

(mm)
Fit bearing Journal Width Thrust Washer Thickness
24.500 ~ 24.533 2.15
24.600 ~ 24.633 2.20
24.70 ~ 24.733 2.25
24.900 ~ 24.933 2.35
25.000 ~ 25.033 2.40
Notice
• Measure the crankshaft axial clearance and correct if necessary with appropriate thrust washers.
• Thrust washers of the same thickness must be installed on both sides of the fit bearing.
Matching the Crankshaft Bearing Shells to Basic Bearing Bore in Crankcase

Marking of Basic Bearing Bore in Lower Mating Surface Relevant Crankshaft Bearing Shell With Color Coding
1 punch mark or blue blue or white - blue
2 punch marks or yellow yellow or white - yellow
3 punch marks or red red or white - red
Matching Crankshaft Bearing Shells to Basic Bearing Journal of Crankshaft

Marking of Bearing journals on Crank Webs Relevant Crankshaft Bearing Shell With Color Coding
blue or white - blue blue or white - blue
yellow or white - blue yellow or white - yellow
red or white - blue red or white - red

AFFECTED VIN
DI02-34
Selection of Upper Main Bearing Shell

Punch Mark Color
• Blue
• • Yellow
• • • Red
Selection of Lower Main Bearing Shell

Mark Color
B Blue
Y Yellow
R Red
W White
V Violet

AFFECTED VIN
DI02-35
Permanent
magnet
Iron
Standard coil
position
Ring gear
<Location of crankshaft position sensor> <Structure of crankshaft position sensor>
The crankshaft position sensor is located near to flywheel on the rear of cylinder block. It generates AC voltage between
increment type driven plate that fixed on flywheel inside. The sensor consists of soft iron core that winded copper wire
on permanent magnet and generates sign wave AC voltage when magnetism on the sensor wheel passes the sensor.
When the crankshaft rotates, ‘+’ signal will be generated from near the front edge and ‘-’ signal will be generated from
near the rear edge among teeth on the driven plate near to crankshaft position. The AC voltage increases as the engine
speed increases, however, no signal occurs from the 2-missing-tooth on the increment type driven plate. By using these
teeth, ECU recognizes TDC of No. 1 and 5 cylinders.
ECU converts the alternative signals into digital signals to recognize crankshaft position, piston position and engine
speed. The piston position that coupled with crankshaft is main factor in calculating injection timing. By analyzing the
reference position and camshaft position sensor, can recognize No. 1 cylinder and calculate the crankshaft speed.
<Drive plate>
A. Distance between ‘+’ max. voltage and ‘-’ max. a. Front edge
voltage b. Rear edge
c. 2-missing-tooth

AFFECTED VIN
DI02-36
Ground
Crankshaft position Signal

Drive plate sensor
<Circuit diagram of crankshaft position sensor>
Output voltage Min. voltage: 1.0 V (40 rpm, air gap: 1.3 mm)
( 1 ~ 150 V) Max voltage: 150 V (7000 rpm, air gap: 0.3 mm)
Sensor unit coil resistance (Ω) 1,090 ± 15 %
Sensor air gap 0.3 ~ 1.5 mm

AFFECTED VIN
DI02-37
TORSIONAL VIBRATION DAMPER
Laser welding
Bearing
Pin
Cover
Hub
Bushing
Inertia ring
Pin
Silicone oil
System Description
• Components: Hub, inertia ring, cover, bearing, bushing, silicone oil
• Functions: The crankshaft pulley optimizes the drive system by reducing the amount of torsional vibration in crankshaft.
Conventional rubber damper is limited in changing materials (rubbers) to absorb vibration, but this crankshaft
pulley (viscous damper), using silicone oil, takes advantage of less changing viscosity according to the
temperature.

AFFECTED VIN
DI02-38
DIASSEMBLY AND REASSEMBLY

1. Unscrew the bolts and remove the connecting rod journal
bearing and bearing caps.
Notice
Position the #1 piston at TDC and remove the piston

connecting rod journal bearing caps.
2. Remove the bearing cap bolts.

3. Remove the bearing caps.
Notice
• The crankshaft bearing caps are marked with

stamped numbers. Start to remove from the
crankshaft pulley side.
• Do not mix up the bearing shells.
4. Remove the bearing caps and lower thrust bearing.

5. Separate the lower bearing shells from the bearing caps.
6. Remove the crankshaft.
7. Remove the upper thrust washers.

8. Remove the upper bearing shells from the crankcase.
Notice
Do not mix up the bearing shells.

AFFECTED VIN
DI02-39
Crankshaft - Reassembly
1. Thoroughly clean the oil galleries and check the journal
section and bearings. Replace if necessary.
2. Coat the upper thrust washers with oil and insert into the
crankcase so that the oil grooves are facing the crank
webs (arrow).
3. Coat the lower thrust washers with oil and insert into the
crankcase so that the oil grooves are facing the crank
webs (arrow).
Notice
The retaining lugs should be positioned in the grooves

(arrow).
Notice
If the maximum permissible length of L= 63.8 mm is
exceeded, the 12-sided stretch bolts should be
replaced.
4. Coat the new crankshaft with engine oil and place it on

the crankcase.
5. Install the crankshaft bearing caps according to the
markings and tighten the bolts.
Installation Notice
Tightening torque 55 ± 5 Nm + 90° + 10°
• Install from #1 cap.

AFFECTED VIN
DI02-40
6. Position the #1 piston at TDC and install the crankshaft.

7. Install the piston connecting rod journal to the crankshaft
journal and tighten the bolts.
8. Measure the crankshaft bearing axial clearance.
• When new: 0.100 ~ 0.245 mm
• When used: 0.300 mm
9. Rotate the crankshaft by hand and check whether it
rotates smoothly.

AFFECTED VIN
DI02-41
FLYWHEEL
DUAL MASS FLYWHEEL (DMF, MANUAL TRANSMISSION EQUIPPED VEHICLE)
Primary wheel
Ring gear
Primary wheel
Secondary
wheel
Plastic bushing
System Description
This flywheel is installed to the rear end of crankshaft and transfers the output from the engine to the power train
mechanism. When starting the engine, this drive the crank train mechanism initially by using the power from the start
motor. Also, DMF measure the crankshaft speed, sends the signals to ECU, and controls the ignition timing.
Conventional flywheel DMF

AFFECTED VIN
DI02-42
Structure
Function and characteristics
• When the output changes from the engine is high during
power stroke ( ): The damper absorbs the shocks to
reduce the changes to transmission.
• When the output changes from the engine is low during
compression stroke ( ): The damper increases the torque
changes to clutch.
<Example of DMF operation>
<Torque change curve of engine and drive shaft>

Angular acceleration amplitude [1/s 2]
Conventional system DMFW
Engine
Engine
Transmission
Transmission
Speed [rpm] Speed [rpm]
Function Advantages of DMF
• Filters irregularities of engine: The secondary flywheel • Improved torque response by using 3-stage type spring:
operates almost evenly so does not cause gear noises Strengthens the torque response in all ranges (low,
• The mass of the primary flywheel is less than medium, and high speed) by applying respective spring
conventional flywheel so the engine irregularity constant at each range.
increases more (less pulsation absorbing effect) • Stable revolution of the primary and secondary wheel
• Transmission protection function: Reduces the load to by using planetary gear: Works as auxiliary damper
powertrain (transmission) by blocking the irregularity against spring changes
of engine • Less heat generation due to no direct friction against
spring surface: Plastic material is covered on the spring
Characteristics of DMF outer surface
• Reduced vibration noise from the powertrain by blocking
• Increased durability by using plastic bushing (extends
the torsional vibrations
the lifetime of grease)
• Enhanced vehicle silence and riding comforts: reduced
engine torque changes
• Reduced shifting shocks
• Smooth acceleration and deceleration
AFFECTED VIN
DI02-43
PISTON AND CONNECTING ROD
1. No.1 compression ring 3. Oil ring

2. No.2 compression ring
Description D27 DT ENG

Cylinder bore diameter φ 86.2 (0~0.018) mm
Piston outer diameter (D1) φ 86.133 (±0.009) mm
Clearance between bore and piston 74
Piston cooling gallery Applied
Pin offset 0.15 mm (Thrust)
Length of piston pin 71.2 mm
Material of top ring / coating Steel / Gas nitride
Tightening torque of connecting rod bolt 40 ± 5.0 Nm, 90° + 10°
Permissible weight difference of connecting rod 4g
Thickness of connecting rod bearing (Red) 1.806 ~ 1.809 mm
Thickness of connecting rod bearing (Yellow) 1.809 ~ 1.812 mm
Thickness of connecting rod bearing (Blue) 1.812 ~ 1.815 mm

AFFECTED VIN
DI02-44
PISTON RING

3. Oil ring
5. Coil spring and oil control ring
6. Hook spring
Replacement of Piston Ring

• Measure piston ring end play.
- Piston ring end play (mm)
1st groove: 0.20 ~ 0.35
2nd groove: 0.20 ~ 0.35
3rd groove: 0.20 ~ 0.40
- Clearance between piston ring and piston (mm)
1st compression ring: 0.075 ~ 0.119
2nd compression ring: 0.050 ~ 0.090
3rd oil ring: 0.030 ~ 0.070
• Install the piston so that “Y” marking on piston head is

facing in the direction of travel. Arrange the piston ring
ends to be 120° apart.
• Adjust the hook spring joint in the oil ring 180 ° away from
the ring end.

AFFECTED VIN
DI02-45
CYLINDER INNER DIAMETER AND PISTON SIZE
(Unit : mm)
Engine Code Used piston Cylinder Diameter Piston Diameter
D27DT A A or X 86.200 ~ 86.206 86.124 ~ 86.130
X A, B or X 86.206 ~ 86.212 86.129 ~ 86.137
B B or X 86.212 ~ 86.218 86.136 ~ 86.142
+5 +5 86.250 ~ 86.260 86.167 ~ 86.181
+ 10 + 10 86.300 ~ 86.310 86.217 ~ 86.231

AFFECTED VIN
DI02-46
DISASSEMBLY AND REASSEMBLY

1. Install the compression ring and oil ring on the piston
with a special tool.
Arrange the piston ring ends to be 120° apart.
Notice
• Install the No.1 and No.2 pistons so that “Y” marking
on piston head is facing upward.
• No.1 piston ring is thicker than No.2 piston ring.
• Arrange the oil ring end to opposite position of
current ring end.
• Oil ring is not directional.
• Make sure that the piston ring end is not aligned to
axial direction and lateral direction.
2. Check the clearance of piston oil ring and compression

ring with a thickness gauge and adjust if necessary.
1st groove 0.20 ~ 0.35 mm

2nd groove 0.20 ~ 0.35 mm
3rd groove 0.20 ~ 0.40 mm
* Piston ring end play (mm)

1st groove: 11.0 mm
2nd groove: 10.5 mm
3rd groove: 7.0 mm
3. Check the clearance of piston rings with a thickness

gauge and adjust if necessary.
No.1 compression ring 0.075 ~ 0.119 mm

2nd compression ring 0.050 ~ 0.090 mm
3rd oil ring 0.040 ~ 0.080 mm

AFFECTED VIN
DI02-47
4. Fit the piston onto connecting rod so that the marking

on piston crown and locking slot are facing to straight
ahead direction.
Notice
Install the piston so that the piston recess (marking)
or the stamped surface of connecting rod is facing to
straight ahead direction.
5. Lubricate piston pin and push in by hand.
Notice
Do not heat up the piston.
6. Place new snap rings into the grooves.
Notice
The snap rings should be replaced with new one.
7. Lubricate the cylinder bore, connecting rod bearing

journals, connecting rod bearing shells and pistons.
8. Push piston into the cylinder with a wooden stick.
Notice
The marking on the piston crown must be facing to

straight ahead direction.
9. Insert connecting rod bearing shells.
Notice
• The upper and lower connecting rod bearings have

same appearance. Therefore, make sure to check
the part number before replacing them.
• Install bearing rod bearing cap so that so that the
retaining lugs are on the same side of the
connecting rod bearing.

AFFECTED VIN
DI02-48
10. Measure stretch shaft diameter of the connecting rod

bolts.
Limit “C” 7.1 mm
11. Lubricate the new connecting rod bolts and tighten.
Installation Notice
40 ± 5.0 Nm,
Tightening torque
90° + 10°
• End play of connecting rod cap
Specified value 0.5 ~ 1.5 mm
12. Position piston to TDC and measure the distance between

piston and mating surface of crankcase.
Permissible piston
0.765 ~ 1.055 mm
protrusion
• Measure at both ends of axial direction.

AFFECTED VIN
DI02-49

Piston protrusion measuring jig

Y99220122B
Piston insertion jig

Y99220172B

AFFECTED VIN
DI02-50
HIGH PRESSURE PUMP (HPP)
COMPONENTS LOCATOR
High pressure
line
Low pressure line Venturi return line
Fuel temperature sensor
IMV connector
Inlet Metering
Valve (IMV)
High pressure
supply line
1. Inlet Metering Valve (IMV) 7. Low pressure pump

2. Hydraulic pressure head 8. Fuel temperature sensor
3. Plunger 9. Venting
4. Drive shaft and cam ring 10. High fuel pressure supply line
5. Housing 11. Pressure regulator
6. Roller and shoe

AFFECTED VIN
DI02-51

Preceding works:
- Removal of fan belt (including cooling fan and fan clutch)
and fan shroud
- Removal of intake manifold assembly
- Removal of water pump pulley
- Removal of auto tensioner
- Removal of EGR pipe
- Removal of oil dipstic gauge
Notice
• To prevent oil leaks, store the removed auto tensioner it
upright position.
• Be careful not to damage the rubber bellows.
• Plug the oil ports for HP pump with sealing caps.
1. Set crankshaft pulley to OT point. Open the oil filler cap

and check if the cam shaft notch marking is aligned to
OT point.
2. Remove the cooling fan idle pulley with a pulley holder

(special tool).

AFFECTED VIN
DI02-52
3. Remove the cooling fan bracket assembly.
Notice
Be careful not to get the sealant or foreign materials

into the engine.
4. Place the marks on the chain and HP pump sprocket for

installation.
5. Remove the vacuum modulator bracket.

6. Remvoe the fuel pipes and wiring connectors which
connected to fuel pump.
7. Turn the crankshaft pulley to the counter clockwise

direction to ATDC 45° then remove the chain tensioner.
Installation Notice

AFFECTED VIN
DI02-53
8. While insert finger and push the chain guide backward

direction and turn the crankshaft pulley to ATDC 65° by
counter clockwise direction until feel the chain guide
inclined backward.
9. Install a special tool into the cooling fan bracket hole to

hold the sprocket.
10. Remove the sprocket bolts and center nut and after
slightly lifted up the chain, remove the pump sprocket.
Installation Notice
Tightening torque Nm
Sprocket bolt 20 Nm + 90°
Center nut 65 ± 5 Nm
11. Remove the HP pump bearing with HP pump bearing

puller (special tool).
Notice
Do not apply excessive force. The timing chain may
deviates.

AFFECTED VIN
DI02-54
12. Remove the HP pump mounting bracket.

Installation Notice
13. Unscrew the external bolts and remove the HP pump

while rocking and tapping it with a rubber hammer.
Notice
• To prevent HP pump shaft damaging, do not apply

excessive impact.
• Do not apply excessive force. The timing chain may
deviates.
14. Remove the HP pump.
15. Install the new HP pump with sealing caps.
Notice
Remove the sealing caps only when connecting the
pipes and hoses.
16. When replaced the HP pump, initialize the fuel pressure

by using SCAN-100. Refer to “Trouble Diagnosis” section
in this manual.

AFFECTED VIN
DI02-55
Notice
If the initialization of fuel pressure has not been

performed, the engine ECU controls new HP pump
with the stored offset value. This may cause the poor
engine output.
Install in the reverse order of removal and tighten the

fasteners with the specified tightening torque.
1. HP pump sprocket
2. 12-sided sprocket mounting bolt
3. HP pump bearing housing
4. HP pump (High Pressure Pump)
5. HP pump shaft
6. HP pump center nut
7. HP pump outer bolt
8. HP pump bearing shaft
9. Oil gallery
10. Bearing bushing
11. Gasket
* Tightening torque
Center nut
65 ± 5.0 Nm
(M14 x 1.5 - 1EA)
Outer bolt
24 ± 2.4 Nm
(M8 x 55 - 3EA)
Sprocket bolt
20 Nm ± 90°
(M7 x 13 - 3EA)

AFFECTED VIN
DI02-56
VACUUM PUMP
Caution
1. Removing the engine mounting insulator

To secure the enough working space for removal of the vacuum pump in the DI engine equipped vehicle, remove
the engine mounting insulator bracket before starting the operation. The distance between panels in engine
compartment is 27mm.
Working space before removing Working space after removing

the vacuum pump(27mm) the vacuum pump (41mm)
2. Tightening torque (10 ± 1.0 Nm)

The vacuum pump is installed with three bolts. And, there is no tightening point at upper area of the vacuum
pump. Therfore, the oil leak may be occurred during the engine running if the mounting bolts are not properly
tightened. The bolts should be tightened with a torque wrench and special tool (A9917 023 0B) to get the correct
tightening torque.
Special tool (Adaptor socket

Within 190mmm
for removal of vacuum pump)
A9917 023 0B
(torque: 4 ~ 12 Nm)

AFFECTED VIN
DI02-57

Preceding works:
- Disconnection of negative battery cable
- Removal of engine acoustic cover
This section also describes the removal and installation procedures for the engine mounting insulator bracket.
1. Unscrew the lower bolt (10mm) from the cooling fan shroud cover and remove the cover. Doing this eliminate the
interference between the cooling fan and shroud during lowering the engine.

AFFECTED VIN
DI02-58
2. Remove the FFH coolant inlet hose bracket nut and the engine ground. Move and attach them at front side of the
engine compartment to eliminate the interference between the engine and hoses during lifting up the engine.
3. Remove the upper engine mounting insulator nuts (19mm) at both sides.
Installation Notice
LH RH
4. Raise the main lift and unscrew the four bolts (arrows) and two fasteners (1) to remove the skid plate.

AFFECTED VIN
DI02-59
5. Place the rubber blocks under the oil pan (in front of the oil drain plug) and raise the engine with auxiliary lift.
Caution
The oil drain plug should be on the center point of the rubber block. Otherwise, the engine cannot be
raised properly due to the deviation of the center point of gravity.
Oil drain plug
6. Unscrew two engine mounting insulator bracket (RH) bolts and remove the bracket.
Installation Notice

AFFECTED VIN
DI02-60
7. Unscrew the power steering hose and pipe mounting bracket bolt from the engine mounting insulator bracket (LH)
and remove the bracket.
8. Remove two engine mounting insulator bracket bolts.
Installation Notice
Power steering hose and pipe mounting bracket bolt (12mm)
Mounting bolt Mounting bolt

(14mm) (14mm)
9. Raise the main lift and lower the engine with the auxiliary lift until the distance between the oil pan and the sub
frame No.2 crossmember is 20mm. Make sure that there is no interference between components. If the engine is
lowered beyond the specified distance, the interference between the transmission oil cooler pipe and the front axle
can be occurred.

AFFECTED VIN
DI02-61
10. Lower the main lift and remove the nut from brake booster vacuum hose.
11. Bring a torque wrench for vacuum pump and designated adaptor socket (special service tool).
Special service tool (Adaptor

socket for vacuum pump)
(Tightening torque: 4~12 Nm)
within 190 mm
12. Working position

The service personnel should work from the left side of the vehicle as shown in the figure. When removing the
vacuum pump mounting bolt (RH), move to the right side of the vehicle.

AFFECTED VIN
DI02-62
13. Install the vacuum pump with the specified tightening

torque.
Installation Notice
14. To align the camshaft and protrude section of the vacuum

pump, use the miiror as shown in the figure.
16. After installation, check the vacuum pump for leaks while
changing the engine speed for 2 minutes.

AFFECTED VIN
DI03-1
SECTION
00 DI03
INTAKE SYSTEM
Table of Contents
AIR FLOWS ................................................................. DI03-2
INTAKE SYSTEM LAYOUT ......................................... DI03-3

Components locator ............................................... DI03-3
Tightening torque of intake system ........................ DI03-4
Air cleaner ............................................................... DI03-5
Air flow sensor
(hot film air mass sensor) ....................................... DI03-8
Intercooler ............................................................. DI03-12
Intake manifold assembly ..................................... DI03-16
INTAKE SYSTEM CHANGED BY

AFFECTED VIN
DI03-2
AIR FLOWS
Intake Valve
(in combustion chamber)
Intake Manifold
Air Cleaner
Turbo
Charger Engine
HFM Sensor
Intake Air Outlet Hose Intercooler Intake Air Inlet Hose
Work Flow of Intake System

Combustion
Air HFM Turbo Intake
Intercooler Chamber in
Cleaner Sensor Charger Manifold
Engine
CHANGED BY INTAKE SYSTEM

AFFECTED VIN
DI03-3
INTAKE SYSTEM LAYOUT
COMPONENTS LOCATOR
Air cleaner Intake manifold
HFM sensor Intercooler

AFFECTED VIN
DI03-4
TIGHTENING TORQUE OF INTAKE SYSTEM
There is a possibility that the clamps of intercooler and related intake hoses are disconnected by the pressure of turbo
charger, therefore it should be tightened with proper torque using torque wrench and ratchet.

AFFECTED VIN
DI03-5
AIR CLEANER
Cover
Element
Housing
Specifications
Element Type Dry-Element Type
* Initial cleaning: 5,000 km, Clean or change every 10,000 km as required.
However, change every 30,000 km.
Service Interval
* If the vehicle is operated under severe condition (short distance driving, extensive
idling or driving in dusty condition): More frequent maintenance is required.

AFFECTED VIN
DI03-6
Air Cleaner Element - Replacement


2. Loosen the locking clamp and remove the intake duct.
3. Unscrew the screws and remove the air cleaner cover.
4. Remove the air cleaner element. Clean or replace the

element as required.

AFFECTED VIN
DI03-7
Air Cleaner Housing

- Removal and Installation
Preceding Work: Removal of air cleaner cover
1. Set aside the return hose and remove the coolant reservoir
bolts.
2. Remove the air cleaner housing bolts.

Air Cleaner Housing/Element - Check

1. Check the air cleaner body, cover and packing for
deformation, corrosion and damage.
2. Check the air duct for damage.
3. Check the air cleaner element for clogging, contamination

and damage. If the element is partially clogged, remove
the dust or foreign materials with the compressed air. If
the contamination is severe, replace it with new one. Also,
be careful not to contaminate during the replacement.
4. Check the air cleaner housing for clogging, contamination
and damage.
5. If the inside of housing is contaminated, remove the
contaminants.
Notice
When cleaning the air cleaner with compressed air,
direct the air from inside (engine) to outside (ambient
air). Otherwise, contaminants can get into the engine.
AFFECTED VIN
DI03-8
AIR FLOW SENSOR (HOT FILM AIR MASS SENSOR)
Change history
inner tube added + grid (No.3)
added + sensing chip changed +
sensing section design changed
Results
Durability has enhanced 60
times (lab test results)
<CI type HFM sensor structure>
1. Plug-in sensor 7. Hybrid

2. Cylinder housing 8. Sensor
3. Protection grid 9. Mounting plate
4. Hybrid cover 10. O-ring
5. Measuring duct cover 11. Temperature sensor
6. Housing
Air flow sensor is locating on the air intake passage between air cleaner and intake manifold and measures air volume
flows to engine combustion chamber and intake air temperature.
And intake temperature sensor built-in the sensor detects intake temperature.
Internal circuit of the air flow sensor is being used to control the voltage value to control the temperature to maintain the
heating resistance (Rh) to 160°C that is higher temperature than intake air temperature that is measured by resistance
(RI).
Temperature sensor of the heating resistance (Rh) is measured by resistance (Rs).
If temperature changes occur due to increasing/decreasing intake air volume, voltage of the heating resistance changes
to maintain the intake air temperature changes to set value (160°C).
Control unit computes intake air volume based on voltage changes of heating resistance.
Intake air temperature is measured by NTC integrated in the sensor.

AFFECTED VIN
DI03-9
Intake air temperature sensor is a part of HFM sensor and a thermister and resister and detects air temperature
changes that flow into the engine. There occurs high resistance when temperature is low and low resistance when high
(NTC type).
ECU supplies 5 V to intake air temperature sensor and then measures voltage changes to determine the intake air
temperature. When air in the intake manifold is cold, the voltage is high and air is hot, the voltage is low.
The reason for using HFM sensor is that this sensor is most proper in controlling accurate air-fuel ratio to meet the legal
emission regulations. This sensor measures actual intake air mass into engine very accurately during specific instant
acceleration and deceleration, and determines engine loads and detects intake air pulsation and air flows.
Main functions of HFM sensor are:

• Using for EGR feedback control
• Using for turbocharger booster pressure control valve control
• Using for fuel injecting compensation
CI type HFM sensor: The air flowing the sensor does not directs toward sensing section but flows along with lower wall
after passing protection grid to enhance durability of the sensor. Oil, water and dust less damage the sensor.
Air outlet Air inlet
<Structure of CI type HFM sensor>

AFFECTED VIN
DI03-10
Power supply
Intake air
flow
sensor
Ground
Ground
Signal
Intake air temperature

sensor
HFM sensor
<Circuit diagram of HFM sensor>

AFFECTED VIN
DI03-11
HFM Sensor - Removal and Installation
HFM sensor

2. Loosen the clamps on the air cleaner and the turbo
charger and remove the duct.
3. Unscrew the bolts and remove the HFM sensor assembly.
Installation Notice
4. Install the reverse order of removal.

AFFECTED VIN
DI03-12
INTERCOOLER
The turbo charger is designed to improve the engine power by introducing more air (oxygen) into the engine. However,
the intake air is heated (100 ~ 110°C) during the compression process in turbo charger compressor and the density is
lowered.
The intercooler is the device which cools (50 ~ 60°C) the air entering the engine. Colder air has more oxygen molecules
than warm air. Thus cooler air gives more power and better fuel economy.
1. Intercooler

AFFECTED VIN
DI03-13
Intercooler - Removal and Installation

1. Disconnect all wiring harnesses and related connectors from the front side of radiator assembly.
AQS sensor
Ambient temperature
sensor
Ambient temperature switch Connector
[for FFH] [for air conditioner]
Receiver drier
Electric fans

AFFECTED VIN
DI03-14
2. Remove the front end center member.
3. Remove the hood latch cable and remove the radiator support upper member.

AFFECTED VIN
DI03-15
4. Remove the intercooler inlet hose. 5. Remove the intercooler outlet hose.
Tightening torque 6 ~ 7 Nm Tightening torque 6 ~ 7 Nm
6. Unscrew the bolts and remove the intercooler assembly.

AFFECTED VIN
DI03-16
INTAKE MANIFOLD ASSEMBLY
• Shape that delivers the required capacity of compressed air from turbo charger to inlet port
• Optimized EGR gas mixture in inlet chamber
• Maximized intake efficiency with helical and tangential inlet port
- Improving the swirl ratio in low and mid operating range
- Improving the acceleration/fuel economy and reducing the maintenance in low and mid operating range
• Integrated inlet port and coolant outlet port

AFFECTED VIN
DI03-17

Intake manifold guide pin Installation of intake manifold
Y99220112B

AFFECTED VIN
DI03-18
Intake Manifold - Removal/Installation

1. Lift up the vehicle and remove the skid plate.
2. Open the coolant reservoir cap and remove loosen the

drain cock to drain the coolant.
3. Remove the air inlet hose (1) from intake manifold.

4. Loosen the clamp and remove the coolant inlet hose (2).
5. Remove the coolant inlet port housing.

6. Remove the vacuum hose from EGR valve.
7. Remove the EGR valve mounting bolts and gasket.
Remove the EGR exhaust pipe (primary) mounting bolts
and gasket.
Notice
• Replace the pipes (2, 3) at both sides of EGR cooler

(1) and gaskets with new ones.
• Make sure that the convex surface of gasket is facing
to the pressurized direction.

AFFECTED VIN
DI03-19
8. Remove the brackets and connectors from top section of

the engine.
- Vacuum hose bracket in turbo charger
- Booster pressure sensor
- Main wiring bracket
- Ground cable bracket
- Fuel pressure sensor connector
9. Unscrew the bolts and remove the vacuum modulator
bracket.
Installation Notice
Tightening torque 9.0 Nm
10. Remove the HP pump fuel supply line bolts.

11. Remove the HP pump fuel supply line mounting bracket.
12. Remove the HP pump fuel return line at fuel filter.
Notice
• Plug the openings of pipes and ports with sealing

caps to keep the cleanness of the fuel system.
• Replace the pipes with new one once removed.
13. Remove the injector return line at HP pump.
Notice
• Be careful not to damage the pipes to HP pump.

• Plug the fuel return port of the HP pump with a
sealing cap.

AFFECTED VIN
DI03-20
14. Remove the intake manifold mounting bolts.

Installation Notice
• Check the length of the bolts before installation.

M8 x 45: 6EA
M8 x 130: 6EA
15. Lift up the vehicle and remove the propeller shaft joint
bolts.
16. Unscrew the bolt in oil filter and remove the intake
manifold and gasket.
Notice
• Replace the gasket with new one.
• Make sure that the residual coolant in intake
manifold gets into the inside of inlet port.
Notice
• If replaced only gasket without any other service
operation, completely remove the coolant and other
contaminants from the engine before installation.

AFFECTED VIN
DI04-1
SECTION
00 DI04
EXHAUST SYSTEM
Table of Contents
EXHAUST SYSTEM LAYOUT ..................................... DI04-2

Components locator ............................................... DI04-2
Exhaust gas flows ................................................... DI04-3
Turbo charger assembly ......................................... DI04-5
EGR VALVE AND VACUUM MODULATOR ............... DI04-26
EGR system .......................................................... DI04-26
EGR valve and turbo charger actuator
control vacuum circuit ........................................... DI04-27
EXHAUST SYSTEM AND MUFFLER ........................ DI04-35
Muffler ................................................................... DI04-35
System overview ................................................... DI04-36
EXHAUST SYSTEM CHANGED BY

AFFECTED VIN
DI04-2
EXHAUST SYSTEM LAYOUT

COMPONENTS LOCATOR
Muffler Exhaust manifold EGR valve
Turbo charger Catalytic converter (DOC) EGR pipe Vacuum modulator
CHANGED BY EXHAUST SYSTEM

AFFECTED VIN
DI04-3
EXHAUST GAS FLOWS

Catalytic Exhaust
converter pipe Muffler
A
Atmo-
sphere
A Exhaust gas
Turbo charger
(turbine side)
EGR vacuum
modulator
To turbo
charger booster
Turbo charger
booster vacuum
modulator
Turbo charger
EGR valve
booster
Exhaust manifold
Blow-by gas
EGR pipe
Engine
Exhaust Turbo Exhaust
-Combustion Atmosphere
Manifold Charger Muffler
Chamber-
Intake
EGR Valve
Manifold

AFFECTED VIN
DI04-4
Exhaust Manifold
1. Remove the two intake hoses from the turbo charger.
2. Remove the turbo charger assembly (refer to Turbo

Charger section).
3. Remove the #3 pipe of EGR valve from the exhaust

manifold.
Installation Notice
• The #3 pipe of EGR valve is exposed to the high

temperature and pressure of exhaust gas. Replace
the gasket and pipe with new ones. Otherwise, it
may cause the leakage of exhaust gas.
4. Unscrew the nuts and remove the exhaust manifold and

gasket.
Installation Notice

AFFECTED VIN
DI04-5
TURBO CHARGER ASSEMBLY

The turbo charger is an air pump installed on the intake manifold. It enhances power and increases torque power of
engine to increase the fuel consumption rate. The engine without turbo charger cannot get as much power output as it
inducts air by the means of vacuum being generated from descending strokes of the piston. Therefore, by installing the
turbo charger on the intake manifold, it supplies great amounts of air to the cylinder increasing the volume efficiency
and, subsequently, enhances output power.
Also, as the engine’s power enhances, it increases the torque power and improves the fuel consumption rate. The
regular turbo charger operates by utilizing the pressure from the exhaust gas and the other, called Super Charger,
operates by utilizing power from the engine. When the turbo charger is installed, weight of the engine increases by 10
to 15 % whereas the output power increases by 35 to 45 %.
Operating Principle of Turbo Charger

The turbo charger has one shaft where at each ends are in-
stalled with two turbines having different angles to connect
one end of housing to the intake manifold and the other end to
Turbine
the exhaust manifold. As the turbine, at exhaust end, is ro- Impeller
tated by exhaust gas pressure the impeller, at intake end,
gets rotated to send air around center of the impeller, being Intercooler
circumferentially accelerated by the centrifugal force, into the
diffuser.
The air, which has been introduced to the diffuser having a Intake Exhaust
passage with big surface, transforms its speed energy into
the pressure energy while being supplied to the cylinder im- Intercooler
proving the volume efficiency. Also, the exhaust efficiency coolant
improves as the exhaust turbine rotates. The turbo charger is
often referred to as the exhaust turbine turbo charger.
Diffuser: With the meaning of spreading out it is a device that
transforms fluid’s speed energy into the pressure energy by
enlarging the fluid’s passage to slow down the flow.

AFFECTED VIN
DI04-6
Construction of Turbo Charger

The turbine wheel in turbo charger and compressor wheel are installed at each side of the shaft. It is comprised with the
shaft supporting center housing (supporting the compressor with two float journal bearings), the turbine side parts of
turbine wheel, shroud and turbine housing, and the compressor side parts of compressor wheel, back plate and com-
pressor housing.
• The turbine rotates turbine wheel by receiving exhaust gas energy from the engine.
• The compressor receives torque energy from the turbine and the compressor wheel inducts air to force it inside of
the cylinder.
1. Turbine housing A. Air inlet (from atmosphere)

2. Turbine wheel B. Air flow
3. Compressor housing C. Exhaust gas inlet (from cylinder)
4. Compressor wheel D. Exhaust gas outlet (to atmosphere)
5. Center housing E. Exhaust gas bypass passage
6. Turbo charger booster pressure control valve H. Oil supply opening
7. Control link J. Oil return line
8. Bypass flap

AFFECTED VIN
DI04-7
Impeller Turbine
Impeller
The impeller is wings (wheel) installed on the intake end and
performs the role of pressurizing air into the cylinder. Turbine shaft
Thrust collar Floating bearing
The radial type has the impeller plate arranged in straight line
at the center of shaft and, compared to the backward type, is Turbine
being widely used as it is simple, easy to manufacture and Impeller
appropriate for high speed rotation. As the impeller rotates in
the housing with the diffuser installed in it, the air receives
centrifugal force to be accelerated in the direction of housing’s
Exhaust gas
outer circumference and flows into the diffuser.
As surface of the passage increases, air flown into the dif-
fuser transforms its speed energy into pressure energy and
flows into the intake manifold where the pressurized air is
supplied to cylinder each time the intake valve of cylinder opens Diffuser
Oil passage
up. Therefore, the efficiency of compressor is determined by
the impeller and diffuser.
Turbine
The turbine is wings installed at the exhaust end where, by the pressure of exhaust gas, it rotates the compressor and
performs the role of transforming heat energy of exhaust gas into torque energy. The radial type is used as the turbine’s
wings. Therefore, during operation of the engine, the turbine receives temperature of exhaust gas and it rotates in high
speed, it requires to have sufficient rigidity and heat resisting property.
During operation of the engine, exhaust gas discharged through the exhaust valve of each cylinder makes turbine rotate
by coming in contact with the turbine’s wings from the outer circumference within housing of the turbine and is ex-
hausted through the exhaust manifold. At the same time, as the impeller is on the same shaft, it rotates.
Floating Bearing
Floating Bearing is a bearing, which supports the turbine shaft that rotates at about 10,000 to 15,000 rpm. It could be
rotated freely between the housing and the shaft as it gets lubricated by oil being supplied from the engine.
Notice
Stopping the engine immediately after driving at high speed stops oil from being supplied to the bearing and
may cause it to get burnt. Therefore, the engine must be stopped after cooling the turbo system by sufficiently
idling the engine.

AFFECTED VIN
DI04-8
Booster Pressure Control Valve Unit (Turbo Charger Actuator)

In order to reduce discharging of hazardous exhaust gas and to avoid the engine’s overrun the turbo charger must be
appropriately controlled. The maximum turbo charging pressure must be controlled as excessive increase in the pres-
sure and power output can cause critical damages to the engine. In order to control these, the booster pressure control
valve is installed on the turbo charger.
The difference of the booster pressure control between the existing IDI engine and DI engine is that in IDI engine, booster
pressure of the intake manifold operates the booster pressure control valve connected directly to the turbo charger
whereas in DI engine, the control is achieved by utilizing vacuum modulator (vacuum from a vacuum pump) designed to
control the booster pressure control valve. It operates booster pressure control valve by supplying electrical power to the
vacuum modulator having the amount of air being flown into the HFM sensor from the engine’s ECU as the base signal.
Refer to the EGR section in following pages for the function of turbo charger and HFM sensor in exhaust system.
Booster pressure control valve unit and vacuum modulator
Turbo charger booster Turbo charger booster

vacuum modulator

AFFECTED VIN
DI04-9
Diagnosis and Maintenance for Turbo Charger System

Cautions During Driving Inspection of Turbo Charger
The following lists cautions to take during test drive and When problem occurs with the turbo charger, it could cause
on the turbo charger vehicle, which must be considered engine power decline, excessive discharge of exhaust gas,
during the operation; outbreak of abnormal noise and excessive consumption
1. It’s important not to drastically increase the engine of oil.
rpm starting the engine. It could make rotation at 1. Inspection when installed
excessive speed even before the journal bearing is - Check the bolts and nuts for looseness or missing
lubricated and when the turbo charger rotates in poor
- Check the intake and exhaust manifold for
oil supply condition, it could cause damage of bearing
looseness or damage
seizure within few seconds.
- Check the oil supply pipe and drain pipe for
2. If the engine is running radically after replacing the
damages
engine oil or oil filter brings poor oil supply condition.
To avoid this, it’s necessary to start off after idling - Check the housing for crack and deterioration
the engine for about 1 minute allowing oil to circulate 2. Inspection of turbine in turbo charger
to the turbo charger after the replacement. Remove the exhaust pipe at the opening of the turbine
3. When the engine is stopped abruptly after driving at and check, with a lamp, the existence of interference
high speed, the turbo charger continues to rotate in of housing and wheel, oil leakage and contamination
condition where the oil pressure is at ‘0’. In such (at blade edge) of foreign materials.
condition, an oil film between the journal bearing and - Interference: In case where the oil leak sign exists,
the housing shaft journal section gets broken and even the small traces of interferences on the
this causes abrasion of the journal bearing due to the turbine wheel mean, most of times, that abrasion
contact of metal parts. The repeat of such condition has occurred on the journal bearing. Must inspect
significantly reduces life of the turbo charger. after overhauling the turbo charger.
Therefore, the engine should be stopped possibly in - Oil Leakage: Followings are the reasons for oil
the idle condition. leakage condition;
• Problems in engine: In case where the oil is
Notice
smeared on inner wall section of the exhaust
After string for long period of time during winter gas opening.
season or in the low temperature condition where • Problems in turbo charger: In case where the
the fluidity of engine oil declines, the engine, oil is smeared on only at the exhaust gas
before being started, should be cranked to outlet section.
circulate oil and must drive after checking the oil
pressure is in normal condition by idling the Notice
engine for few minutes.
Idling for long period of time can cause oil
leakage to the turbine side due to low pressure of
exhaust gas and the rotation speed of turbine
wheel. Please note this is not a turbo charger
problem.

AFFECTED VIN
DI04-10
- Oil Drain Pipe Defect

Inspection of Turbine
In case where oil flow from the turbo charger
sensor housing to the crank case is not smooth
Thoroughly check the followings.
would become the reason for leakage as oil builds
up within the center housing. Also, oil thickens Notice
(sludge) at high temperature and becomes the
indirect reason of wheel hub section. In such case, Must absolutely not operate the turbo charger with the
clogging and damage of the oil drain pipe and the compressor outlet and inlet opened as it could damage
pressure of blow-by gas within the crank case the turbo charger or be hazardous during inspection.
must be inspected.
- Interference: In case where is trace of interference or
- Damages from Foreign Materials
smallest damage on the compressor wheel means,
When the foreign materials get into the system, most of times, that abrasion has occurred on the
it could induce inner damage as rotating balance journal bearing. Must inspect after the overhaul.
of the turbo charger gets out of alignment.
- Oil Leakage: The reason for oil leakage at the
compressor section is the air cleaner, clogged by
substances such as dust, causes the compressor
inlet negative pressure;
A. Rotating in high speed at no-load for extended
period of time can cause oil leakage to the
compressor section as oil pressure within the
center housing gets higher than pressure within
the compressor housing.
B. Overuse of engine break (especially in low gear)
in down hill makes significantly low exhaust gas
energy compared to the time where great amount
of air is required during idling conditions of the
engine. Therefore, amount of air in the
compressor inlet increases but the turbo charge
pressure is not high, which makes negative
pressure at the compressor section causing the
oil leakage within the center housing.
Notice
No problem will occur with the turbo charger if

above conditions are found in early stage but oil
leaked over long period of time will solidify at
each section causing to breakout secondary
defects.
- Damages by foreign materials: In case where the
compressor wheel is damaged by foreign materials
requires having an overhaul. At this time, it’s
necessary to check whether the foreign materials have
contaminated intake/exhaust manifold or inside of
engine.

AFFECTED VIN
DI04-11
Path of Turbo Charger Defect

The following tries to understand the defects that can occur with vehicle installed with the turbo charger and to manage
the reasons of such defects.
1. In case where oil pan/oil pipe has been contaminated, oil filter is defected and where
adhesive of gaskets has been contaminated into the oil line.
Contamination of Oil
Journal Bearing Clogging of Oil

Damage or Wear Passage
Metal Contact Poor Oil Supply
Shaft Journal Bearing Wear
Rotor Wear
Interference of
Seal Wear at Seal Wear at Intake Turbine and Com-
Exhaust System System pressor Components
Oil Leakage
Abnormal Noise Lack of Power/Poor

Acceleration (Lack of
Turbo Charged Pressure)
Check Booster Pressure

Check Exhaust Gas Pipes
Control Valve

AFFECTED VIN
DI04-12
2. Oil Pump Defect: Rapid over-loaded driving after replacing oil filter and oil and clogging of oil
line.
Poor Oil Supply
Metal Contact of Shaft /Journal Bearing/

Center Housing Inner Part
Journal Bearing/Center Housing Inner Part

Wear/Seizure
Melt down of Bearing to Turbine Wheel Journal
Rotor Rotational Movement
Seal Wear at Exhaust Seal Wear at Intake Interference of Turbine and

System System Compressor Components
Oil Leakage
Lack of Power/Poor
Abnormal Noise Acceleration (Lack of
Turbo Charged Pressure)

AFFECTED VIN
DI04-13
3. Turbine Side: Inflow of foreign materials from engine

Compressor Side: such as air filter, muffler and nut
Inflow of Foreign Materials
Inflow of Foreign Materials Inflow of Foreign Materials

into Turbine into Compressor
Compressor Wheel Blade

Shaft Wheel Blade Break
Break
Unbalancing Rotor Rotation
Rotor Bearing Wear
Rotor Turning Movement
Seal Wear at Exhaust Seal Wear at Intake Interference of Turbine and

System System Compressor Components
Oil Leakage
Lack of Power/Poor Accel-

Abnormal Noise eration (Lack of Turbo
Charged Pressure)

AFFECTED VIN
DI04-14
4. Defects caused by reasons other than that of the Turbo Charger.
Oil Leakage at Turbine
<In case where the scanner <Mechanical

displays as electrical malfunction> Malfunction>
Excessive Engine Wear Excessive Inflow of Blow-By
Gas, Idling at Low Speed,
Clogging of Oil Drain Pipe
Dampness or Poor Connec-
tion of Turbo Charger Actuator
Connecting Vacuum Circuit
Oil Leakage at Turbine Oil Leakage at Seal

Housing Entrance
Detection of DTC Code

Caused By HFM Sensor or
EGR Valve Malfunction
Misunderstanding of Oil Carbonization Caused By
Leakage High Temperature
Vacuum Modulator Power

Control Error for Controlling
No Problems in Turbo Seal Wear
Actuator in Engine ECU
Charger System
Oil Leakage
Oil Leakage at Compressor
Inflow of Dust Increase of Negative Pressure

Increase at Inlet Side
Oil Leak Sign at Compres- Excessive Inflow of Blow-By

sor Inlet and Outlet Gas, No-Load High Speed
Rotation
Misunderstanding of Oil No Problems in Turbo

Leakage Charger System

AFFECTED VIN
DI04-15
How to Diagnose
The followings are cautions to take in handling defects of turbo charger, which must be fully aware of;
Cautions When Examining the Defects:

1. After stopping the engine, check whether the bolts on pipe connecting section are loose as well as the connecting
condition of vacuum port and modulator, which is connected to the actuator.
2. During idling of the engine, check for leakage in the connecting section of pipe (hoses and pipes, duct connections,
after the turbo charger) by applying soap water. The leakage condition in the engine block and turbine housing
opening can be determined by the occurrence of abnormal noise of exhaust.
3. By running the engine at idle speed, abnormal vibration and noise can be checked. Immediately stop the engine
when abnormal vibration and noise is detected and make thorough inspection whether the turbo charger shaft
wheel has any damages as well as checking the condition of connections between pipes.
4. In case where the noise of engine is louder than usual, there is possibility of dampness in the areas related with air
cleaner and engine or engine block and turbo charger. And it could affect the smooth supply of engine oil and
discharge.
5. Check for damp condition in exhaust gas when there is sign of thermal discoloration or discharge of carbon in
connecting area of the duct.
6. When the engine rotates or in case where there is change in noise level, check for clogging of air cleaner or air
cleaner duct or if there is any significant amount of dust in the compressor housing.
7. During the inspection of center housing, inspect inside of the housing by removing the oil drain pipe to check for
sludge generation and its attachment condition at shaft area or turbine side.
8. Inspect or replace the air cleaner when the compressor wheel is damaged by inflow of foreign materials.
9. Inspect both side of the turbo charger wheel after removing inlet and outlet pipe of the turbo charger.
- Is the rotation smooth when the rotor is rotated by hand?
- Is the movement of bearing normal?
- Inspect whether there has been any signs of interference between two wheels.
Notice
It’s important not to drive the engine when the intake manifold hose has been removed.

AFFECTED VIN
DI04-16
Diagnosis and Measure
Poor Engine Power or Smoke Discharge
Air Cleaner Contamination Slack between Compres-

NO NO
and Clogging of Oil Pass sor Entrance and Exhaust Leaks at Intake Manifold
Type Air Cleaner Manifold Connection
YES YES YES
Replace Air Cleaner

Element or Oil Pass Type Inspect and Repair
Reconnect Connections
Air Filter Intake Manifold
NO
Poor Rotation or Interfer-

Leaks at Exhaust Mani- NO Leaks at Turbo Charger NO
ence of Turbo Charger
fold Connecting Flange
Components
YES YES
Inspect and Repair Intake Refer to Diagnosis

Manifold Table
NO
Clogging Between Com-

Clogging Between Air NO NO
pressor Exit and Intake Clogging of Engine Muffler
Cleaner and Compressor
Manifold
YES YES YES
Clean or Replace
Clean or Replace Affected Clean or Replace Affected
Affected Compo-
Components Components
nents
NO
Weakness of Engine
Clogging of Engine Intake/ NO Function, Intake/Exhaust
Exhaust Manifold Valve Damage, Timing
Defects of Each Valve
YES YES
Inspect and Repair Inspect and Repair

Related Components Related Components

AFFECTED VIN
DI04-17
Before Diagnosis
The base of making diagnosis on the EGR related system is the inspection on the connections of the vacuum hoses in
related system as the first priority. When abnormal condition occurs with the EGR system, the basic approach is, as
described in prior sentence, making detail inspections of vacuum circuits of each system before connecting the scan
tool or vacuum tester. It is necessary to manually check on the connections if there are any slacks or loose circuits even
if the visual inspection shows vacuum hose as being connected. If there are not any problems then the next inspection
area is the connections of the system connectors. Most problems with the occurrence of system malfunction are from
conditions of vacuum line and connector connections and the causes from the malfunction of mechanical mechanism is
actually very few.
For example, when there are no problems with basic components, let’s assume that there is a vehicle having vacuum
leak from connection slack in the vacuum line between EGR vacuum modulator and EGR valve. This vehicle, due to the
driving condition or, according to the circumstances, smog or other conditions, could create customer’s complaint and
by connecting the scanning device could display as the malfunction of the EGR valve’s potentiometer.
As previously explained, this car has a separate controller to control the HUBER EGR and, in accordance with various
input element, the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through
PWM control. At this time, the controller has to receive feedback whether the EGR valve operates correctly according to
the value sent to the EGR modulator and this role is performed by the EGR potentiometer located at top section of the
EGR valve.
In other word, the controller sent correct output value to the EGR vacuum modulator but, due to the leakage of vacuum,
signal of required value can not be received from the EGR potentiometer causing to display as malfunction of related
parts.
As a reference, the EGR valve of diesel vehicle (DI Engine) controlling from the engine ECU to EGR system has different
shape than the HUBER EGR valve because the EGR valve’s operation signal in the DI engine is performed by the HFM
sensor instead of the EGR potentiometer.
This principle is that when the EGR valve opens up to flow exhaust gas into the intake unit the amount of fresh air,
comparatively, will be reduced. The DI engine ECU receives feedback signal of change in amount of air being passed
through the HFM sensor according to the opening amount of the EGR valve.
HUBER EGR System for IDI Engine EGR System for DI Engine
(Including the EGR Valve Potentiometer)

AFFECTED VIN
DI04-18
The other big difference between the HUBER EGR and EGR controller for DI engine is that from two vacuum modulator,
one is same as being the modulator for EGR valve whereas the HUBER EGR system’s the other modulator controls
ALDA of injection pump and the DI engine’s the other modulator controls waist gate of the turbo charger.
This difference is in accordance with the difference in fuel injection method where the IDI engine has mechanical
injection system and DI engine is capable of making electronically controlled fuel injection.
In other word, to reduce the amount of the fuel injection in no-load rapid acceleration mode, the IDI engine’s HUBER
EGR utilizes solenoid valve to disconnect the connection circuit between intake manifold and ALDA causing negative
pressure to occur in the vacuum modulator to reduce the amount of fuel injection. When DI engine, basing input signal
from the related sensors such as acceleration pedal sensor and engine RPM, recognizes that current mode is the no-
load rapid acceleration mode it reduces the amount of fuel injection by sending short electrical signal to the injector.
Therefore, disregarding the modulator for the EGR valve in DI engine, one must keep in mind that the other modulator is
used to control the booster pressure valve in turbo charger.

AFFECTED VIN
DI04-19
When Engine Exhaust Gas shows White Smog or

Blue Smog
Poor Connection between

NO Oil Leak Sign around NO Clogging of Engine Oil
Compressor Outlet and
Intake Manifold Element
Intake Manifold
YES YES YES
Reconnection Inspect PVC Line Replace Oil Filter
NO
Clogging or Damage Oil Leakage at Seal

NO NO Engine Malfunction (Ring,
between Air Cleaner and between Turbo Charger
Piston, Valve)
Turbo and Compressor
YES YES YES
Clean or Replace Affected Repair (overhaul)

Refer to Diagnosis Table
Components Engine
Excessive Consumption of Engine Oil
Poor Oil Seal at Turbo

Improper Inspection of Air NO Improper Viscosity of NO
Compressor Side (Oil leak
Cleaner Contamination Engine Oil Being Used sign at housing and wheel)
YES YES YES
Replace Air Cleaner Refer to Diagnosis

Replace with Specified Oil
Element Table
NO
Poor Oil Seal at Turbo Turbine Oil Leakage at Engine

NO
Side (trace of leakage in Exhaust Manifold (damages
housing and wheel) to ring, piston and valve)
YES YES
Refer to Diagnosis Table Inspect or repair Manifold

AFFECTED VIN
DI04-20
Abnormal Noise from Turbo Charger System
Leaks at Pipe and Hose Inflow of Foreign Material

Contamination or Clogging NO NO
Duct Parts between to Compressor Entrance
of Air Cleaner Manifolds of Turbo Charger or Housing
YES YES YES
Inspect and Repair Air

Clean or Replace If Inspect or Replace Cleaner Element and Turbo
required Connections Charger after Removing
Foreign Materials
NO
Poor Rotation of Rotating

Inflow of Foreign Materials NO Inflow of Foreign Materials NO
Turbo Charger Compo-
to Intake Manifold to Muffler
nents and Interference
YES YES YES
Inspect and Repair Air Repair Housing and

Repair Muffler and Turbo
Cleaner Element and Turbo Turbo Charger and
Charger After Removing
Charger after Removing Inspect Normal Opera-
Foreign Materials
Foreign Materials tion for Engine
NO
Check the Interference

between Rotating Turbo
Charger Components and
Housing
YES
Refer to Diagnosis Table

AFFECTED VIN
DI04-21
Poor Rotation of the Turbo Charger
Compressor Wheel Turbine Wheel Damages

NO NO Interference of Compres-
Damages By Inflow of By Inflow of Foreign
sor Wheel with Housing
Foreign Material Material
YES YES YES
Fatigue and Wear in

Repair or Replace Air
Repair or Replace Ex- Bearing or Shaft
Cleaner Element and
haust Manifold Journal (Refer to
Turbo Charger
Diagnosis Table)
NO
Excessive Deposit of
Clogging of Compressor NO Carbon or Combustion NO Gel Type Oil in Center
by Dust Residues Inside of Turbine Housing
Wheel by Oil Contamination
YES YES YES
Repair or Replace Air Repair or Replace Turbo Repair or Replace Engine

Cleaner Element and Charger Oil Filter and Turbo
Turbo Charger Charger
Oil Leakage at Turbine in Turbo Charger
Gel Type Oil in Center

Excessive Filling of Oil NO Clogging of Oil Drain NO
Housing or Excessively
When Installing Pipes in Turbo Charger
Contaminated Oil
YES YES YES
Oil Disappears After Clean or Replace Drain Repair or Replace

Combustion Line Engine Oil Filter and
Turbo Charger
NO
Poor Engine Function

Deterioration of Turbo NO
(Too High Blow-by gas
Charger Journal
pressure in crankcase)
YES YES
Refer to Diagnosis Table Inspect PVC Line

AFFECTED VIN
DI04-22
Oil Leakage at Compressor in Turbo Charger
Clogging or Damage of
Contamination of Air NO NO
Too High Oil Viscosity Pipe between Air Cleaner
Cleaner Element
and Turbo Charger
YES YES YES
Replace Damaged
Clean or Replace Air Replace With Specified
Components after
Cleaner Element Oil
Cleaning clogged Area
NO
Looseness in Connection
NO Oil Leakage at Intake NO Clogging of Oil Drain Pipe
between Compressor
Manifold in Turbo Charger System
Outlet and Intake Manifold
YES YES YES
Reconnect After Inspec- Inspect and Repair Intake Clean Clogged Area
tion Manifold After Inspection
NO
Clogging Between Com-

Deterioration or Damage NO NO
pressor Outlet and Intake Clogging of Engine Muffler
to Compressor Wheel
Manifold
YES YES YES
Clean, Repair or Replace

Air Cleaner Element and Refer to Diagnosis Table Inspect PCV Line
Turbo Charger

AFFECTED VIN
DI04-23
Wear in Turbo Charger Inner Diameter and

Shaft Journal
Poor Oil Filling When

NO Contamination of Oil Filter NO Lack of Oil in Turbo
Installing or Replacing
Turbo Charger or Use of Low Grade Oil Charger
YES YES YES
Clean or Replace Air

Reinstall While Using
Cleaner Element / Re- Add Oil During Idling
Specified Oil
place With Specified Oil
NO
Poor Oil Supply by Wear in Journal Section

NO Clogging of Engine Oil NO
Clogging of Oil Supply By Clogging in Center
Pipe in Turbo Charger Filter Housing
YES YES YES
Clean and Repair Dam- Repair or Replace

Replace Oil Filter
aged Components Turbo Charger
NO
Poor Function of Engine

Oil Pump
YES
Inspect and Replace If

Required
For other diagnosis, refer to Diagnosis section.

AFFECTED VIN
DI04-24
Turbo Charger Assembly

1. Remove the drain plug and drain the engine oil from the
oil pan.
Installation Notice
2. Remove the vacuum hose and inlet hose from the turbo
charger.
Installation Notice
3. Remove the bolts and nuts at the exhaust manifold in

turbo charger.
Installation Notice
4. Remove the lower and upper bolts at turbo charger oil

supply pipe.
Installation Notice

AFFECTED VIN
DI04-25
5. Remove the lower bolts at turbo charger oil return pipe.
Installation Notice
• Replace the steel gasket with new one.
6. Remove the lower bolt at turbo charger bracket.

7. Remove the turbo charger bracket bolts.
Installation Notice
• Use only 12 1/2" wrench.
8. Remove the bolts and nuts at the turbo charger and the
exhaust manifold.
Installation Notice
9. Remove the turbo charger assembly.

Notice
• Replace the steel gasket with new one.

• To prevent gas leaks, tighten the fasteners with the
specified tightening torques.

AFFECTED VIN
DI04-26
EGR VALVE AND VACUUM MODULATOR

EGR SYSTEM
General Information
EGR system controls the opening value of EGR valve by transmitting electrical signal (PWM control) from the engine
ECU to vacuum modulator. Also, the engine ECU receives the feedback signals of the amount of air flowing through the
HFM sensor.
Various sensor
Signals
1. EGR valve 4. EGR center pipe (EGR cooler)

2. Vacuum modulator 5. Intake manifold
3. Vacuum pump 6. HFM sensor

AFFECTED VIN
DI04-27
EGR VALVE AND TURBO CHARGER ACTUATOR CONTROL VACUUM

CIRCUIT
Vacuum Modulator
The biggest difference between the vacuum circuit and layout of the HUBER EGR system after K2004 has been intro-
duced is the location of the vacuum modulator for EGR valve control and the function of the other modulator. In case of
EGR equipped vehicle (IDI Engine), it performs the role of controlling the PLA of injection pump whereas, in DI engine, it
controls the turbo charger actuator.
DI engine vacuum modulator

1. EGR valve vacuum modulator
2. Turbo charger booster vacuum modulator
From vacuum pump
To EGR Valve
To turbo charger Vacuum pump

actuator
1. Vacuum modulator for EGR valve control

2. Vacuum modulator for injection pump PLA control

AFFECTED VIN
DI04-28
Vacuum Modulator and Vacuum Hose

Below figures illustrate vacuum hoses and related parts of EGR or turbo where wrong or poor connection of vacuum hose
would display condition of engine irregularity and defect diagnostic codes on the scan tool.
Related with EGR valve
From vacuum pump

EGR valve
Vacuum modulator for

EGR valve control
Related with turbo charger actuator
Turbo charger pressure valve
Vacuum modulator for turbo From vacuum pump

charger booster control

AFFECTED VIN
DI04-29
EGR System Diagram
Intercooler
Intake
manifold
Exhaust
manifold EGR
valve
Vacuum
Regulated Modulator
pump
vacuum
pressure
Duty
control
Feedback EGR Air intake signal

(Air Mass) (for EGR feed-
back control)
ECU
Improved target EGR Turbo charger
Pedal RPM
signal signal
EGR Valve
EGR valve recirculates some of exhaust gases to intake system to reduce toxic NOx from engine according to ECU
signals.
• EGR valve opening point : -270 mmHg
EGR Modulator
According to ECU signals, the vacuum modulator drives EGR valve by controlling vacuum pressure that is generated by
vacuum pump with PWM type controls.

AFFECTED VIN
DI04-30
Operation Principle of Vacuum Modulator
Vacuum pump
Output vacuum
ATM
Plunger
Connector
Vacuum control
Diaphragm
Seat assembly
Atmospheric pressure Spring
Plunger
Air flow
During duty increase (B) During duty reduction (C)
Vacuum is controlled according to relationship between chamber pressure (I) in rolling nipple cover and magnetic
force (II) in plunger.
According to ECU signals, the solenoid valve controls the vacuum pressure that is generated by vacuum pump (-900 ±
20 mbar) with PWM type control and drives the mechanical EGR valve and turbo charger.

AFFECTED VIN
DI04-31
Operating principle: Balance between original vacuum pressure and magnetic force (see above figure)
• Normal state (Fig. A): Original vacuum and seat section, 3 stoppers keep sealing
• Duty up state (Fig. B): Original vacuum pressure is connected to inside of diaphragm chamber
• Duty down state (Fig. C): Increased diaphragm chamber pressure is connected to atmosphere to compensate the
pressure.
Floating plunger Stroke

(mm)
Max. Distance 1mm
DUTY 50%
Output C/V
Operating principles when duty is applied from 0 to 50 %
Vacuum consumption: Compared to 50 % of duty, ON/OFF periods are most unstable and vacuum
consumption is most high.
Flowing
volume
Output Characteristics
Output vacuum (-mmHg)
Up
Down

AFFECTED VIN
DI04-32
Operating Conditions
• Engine is running
• Engine RPM is within a specified range. (EGR OFF under high RPM range)
• Engine torque is within a specified range. (EGR OFF under high torque range)
• Vehicle speed is within a specified range. (EGR OFF under high speed range)
• Atmospheric pressure is within a specified range. (EGR OFF under high altitude and low atmospheric pressure)
• Coolant temperature is within a specified range. (EGR OFF under high or low temperature)
• EGR OFF under extended period of idling.
Control Logic
• Main map: EGR volume is controlled based on intake air volume
• Auxiliary map
- Coolant temperature (Coolant temperature sensor)
- Engine rpm (Crankshaft position sensor)
- Engine load (TPS): Detection of sharp acceleration
- Intake air temperature (HFM): Decreases when over 60°C
- Atmospheric pressure (Barometric sensor): Compensation of altitude
• Compensation value of auxiliary map will be increased/decreased based on main map then ECU calculates EGR
volume finally to regulate the vacuum duty that applies to the vacuum modulator to control EGR valve openings.
Shut-off Conditions
• Engine rpm: over 2,950 rpm
• Vehicle speed: over 105 km/h
• Coolant temperature: over 100°C or below 10°C
• Idle period: over 50 seconds

AFFECTED VIN
DI04-33
EGR Valve and Pipe

1. Remove the vacuum hose from the EGR valve.
2. Unscrew the bolts and remove the EGR valve (2), EGR
valve #1 pipe (1) and gasket.
Installation Notice
3. Remove the EGR valve #1 pipe, #2 pipe, #3 pipe and

gaskets from the engine.
Installation Notice
Notice EGR #3 pipe (LH)

EGR #1 pipe (RH)
• Make sure to observe the specified tightening
torques. EGR center pipe
• Never reuse the EGR #1 pipe (intake) and #3 pipe
(exhaust) once removed.
• Replace the gaskets with new ones.

AFFECTED VIN
DI04-34
Vacuum Modulator
1. Remove the vacuum hose from the vacuum modulator.
2. Remove the vacuum modulator from the bracket.
Installation Notice
Notice
Make sure that the vacuum hoses are connected to

correct locations.

AFFECTED VIN
DI04-35
EXHAUST SYSTEM AND MUFFLER
Heat shield
#3 Hanger
#2 Hanger
Muffler
Heat shield
#1 Hanger
Muffler
DOC (Diesel Oxidation Catalyst)
#1 Pipe
DOC (Diesel Oxidation Catalyst) Muffler Tail pipe
MUFFLER
The muffler is located at the middle of the exhaust pipe and reduces the pulse noise and the tail pipe noise by eliminating
the flowing resistance from the exhaust gas.
The important elements of the muffler are volume, construction and location.

AFFECTED VIN
DI04-36
SYSTEM OVERVIEW
Exhaust System Muffler
Check the complete exhaust system and the nearby body Aside from the exhaust manifold connection, the exhaust
areas and trunk lid for broken, damaged, missing or system uses a flange and seal joint design rather than a
mispositioned parts, open seams, holes, loose slip joint coupling design with clamp and U-bolts. If hole,
connections, or other deterioration which could permit open seams, or any deterioration is discovered upon in-
exhaust fumes to seep into the trunk may be an indication spection of the front muffler and pipe assembly, the com-
of a problem in one of these areas. Any defects should be plete assembly should be replaced. The same procedure
corrected immediately. is applicable to the rear muffler assembly. Heat shields for
the front and rear muffler assembly and catalytic converter
Notice protect the vehicle and the environment from the high tem-
peratures that the exhaust system develops.
When you are inspecting or replacing exhaust system
components, make sure there is adequate clearance
from all points on the underbody to avoid possible
Heat Shield
overheating of the floor panel and possible damage to
the passenger compartment insulation and trim The heat shield protects the vehicle and components from
materials. the high heat generated from the exhaust system.
In this vehicle, the heat shield to block the heat from DOC
is installed to the underbody, and the heat shield to block
DOC (Diesel Oxidation Catalyst) the heat from the rear muffler is installed to the underbody
between the fuel tank and the rear muffler.
DOC (Diesel Oxidation Catalyst) is the purification device
to reduce the toxic emissions from the exhaust gas from
the engine. By using the chemical reaction, the amount of
toxic gas such as NOx can be reduced.
Hanger
The hanger is to support the components.
Notice If the ganger is not properly installed, it may cause the
vibration that is very difficult to diagnose. Therefore, install
To prevent damage of DOC, never contact the lift pad
the hanger to the correct location so that the exhaust sys-
when lifting up the vehicle.
tem cannot contact to the underbody and other
components.

AFFECTED VIN
DI04-37
DOC (Diesel Oxidation Catalyst)

System and principle Catalytic converter structure
Oxidation catalytic technology for diesel engine is basi- The Catalytic converter of monolith type consists of 2 walled
cally the same with it of gasoline engine used before de- metal bodies which is made of Cordierite.
velopment of 3 primary catalyst (2 primary catalyst), and The principal element of converter consists of the materi-
its effect and performance were already proved. als like Alumina or oxidized Serume in order to apply to
DOC (Diesel Oxidation Catalyst) reduces HO and CO con- Ceramic Monolith. Washer coat operates first, and cata-
tained exhaust gas over 80 %, and removes SOF (Soluble lytic metal elements (Pt, Pd, Ph) operates to washer coat
Organic Fraction) over 50 ~ 80 %, but because its portion next.
in total PM is low, it reduces approx, 20 ~ 40 % of TPM Monolith type is lighter than other types, easy to manu-
(Total Particulate Material). facture and quickly approaches to proper temperature.
Because of low reducing rate for PM of DOC, in order to Washer coat is used to make a contact surface with ex-
guarantee safety rate of PM regulation, this technology is haust gas bigger by adhering closely to small holes of
being used mainly. And it should keep over 80% of PM inner layer.
reducing rate, and at present it plays a role as a transition
If a lead compound or phosphorus adheres to the surface
stage.
and the temperature rises, its surface is decreased.
And also it reduces diesel odor and black smoke, plati-
The total area of general monolith converter is about
num or palladium are being used as a catalyst.
45,000 ~ 500,000 ft 3. (10 times of a football field)
On the other hand, it is a problem that it makes the reac-
Generally Alumina (AL2O3) is used as a raw material and
tion of oxidation, which SO2 produce SO3 and H2 SO4 by
its 7 phases of gamma, delta, theta have big areas and
reacting to oxygen in exhaust gas, if temperature of ex-
high stability for the temperature, and nowadays gamma
haust gas becomes over 300°C, and this produced gas is
Alumina is used usually.
very harmful to human body. To prevent is, previously it is
requested that the sulfur content rate of fuel should be
below 0.05 %, and in the future it is being expected to
keep it below 0.01 %. Cover
Insulation Upper part of
Mat converter
Plate
Lower part of Monolith catalyst

converter
Inlet gas Outlet gas

AFFECTED VIN
DI04-38
Catalytic converter and temperature

Catalytic converter has the normal function of purification at a
range of the temperature. Because it has a weak point of de-
creasing of the purification rate in the condition of continuous
high temperature, it should keep the temperature range of 400
to 500°C for normal condition. HC purification rate becomes
better according to the increase of temperature in the normal
range of temperature. CO purification rate becomes the best
near the temperature of 450°C, and NOx does so near the
temperature of 400 to 500°C.
Purification of catalytic converter

• Adhesion of soluble organic fraction (SOF) below 180°C
• Purification of soluble organic fraction (SOF) over 180°C
Chemical reaction formula
• SOF(HC) + O2 ............... O2 + H2O
• 2CO + O2 ...................... 2CO2
• 2C2H6 + 7O2 ................. 4CO2 + 6H2O
Aldehide
Aromatic HC
• Oxygen adheres to catalytic material : below 180°C
Catalytic Material
Catalytic Material

AFFECTED VIN
DI04-39
• Catalytic material supplies each CO and HC with O2 for

their oxidation : above 180°C
Catalytic Material Catalytic Material
• Catalytic material conversion process by DOC

PAH (Aromatic HC)
Catalyzer
Method for reduction of NOx

NOx is generated a great deal in case that combustion tem-
perature and excess air factor are high. EGR valve can de-
crease NOx (30 to 35 % decrease) by making temperature of
combustion chamber fall by means of exhaust gas re-
circulation.

AFFECTED VIN
DI04-40
Exhaust Pipe
1. Remove the upper bolts at turbo charger.
Notice
Use the universal type wrench.
2. Remove the lower bolts and gasket.
3. Remove the #1 hanger.

AFFECTED VIN
DI04-41

6. Remove the exhaust pipe.

AFFECTED VIN
DI05-1
SECTION
00 DI05
LUBRICATION SYSTEM
Table of Contents
LUBRICATION SYSTEM ............................................. DI05-2

Lubrication system layout ....................................... DI05-3
Lubrication diagram ................................................ DI05-4
Specifications .......................................................... DI05-5
Engine oil change ................................................... DI05-9
Oil pump ................................................................ DI05-13
Oil spray nozzle ..................................................... DI05-15
Oil pan assembly .................................................. DI05-16
TROUBLE DIAGNOSIS ............................................. DI05-24
SPECIAL TOOLS AND EQUIPMENT ........................ DI05-25
LUBRICATION SYSTEM CHANGED BY

AFFECTED VIN
DI05-2
LUBRICATION SYSTEM
Cylinder head cover Oil dipstick Oil separator Oil filter
Oil pump Oil pan Oil cooler Oil pressure switch
CHANGED BY LUBRICATION SYSTEM

AFFECTED VIN
DI05-3
LUBRICATION SYSTEM LAYOUT
Main oil gallery: φ 16

Hole to cylinder head: φ 9
Main bearing hole: φ 7
Chain and injection pump: φ 7
Cylinder head Return hole: φ 14
Chain nozzle: φ 1
HP pump bearing: φ 6
Cylinder block

AFFECTED VIN
DI05-4
LUBRICATION DIAGRAM
Chain lubrication REF-Roller Camshaft bearing Vacuum pump
Oil tensioner
check valve
Return check valve

to cylinder head Oil injection nozzle Turbo charger
Thrust bearing Connecting rod bearing Main bearing
Filter by-pass valve
Oil
filter
By-pass throttle
Contaminated oil Clean oil gallery

gallery
Oil pump Relief valve
Oil cooler
Fuel tank
1. Opening pressure of by-pass valve in oil filter: 3 ± 0.4 bar

2. To prevent instant oil shortage after stopping the engine, the return check valve is installed in oil supply line of
cylinder head.

AFFECTED VIN
DI05-5
SPECIFICATIONS
Engine oil Specification Approved by MB Sheet 229.1 or 229.3
Viscosity: See MB Sheet 224.1
Capacity 6.8 ~ 8.3 liter
Service interval Initial change: 5,000 km, Change every 10,000 km or
12 months (Frequently check the oil level and add if needed.
And, every 5,000 km or 6 months under severe conditions)
Engine oil filter Same interval with engine oil
Oil relief valve opening pressure 5.8 ± 0.3 bar
Severe condition:
- When most trips include extended idling and/or frequent low-speed operation as in stop-and-go traffic.
- When most trips are less than 6 km (Operating when outside temperatures remain below freezing and when most
trips are less than 16 km)
- When operating in dusty, sandy and salty areas
- In hilly or moutainous terrain
- When doing frequent trailer towing
Oil Pressure Switch

• Operating temperature: -40 ~ 140°C
• Operating pressure: 0.3 ~ 0.55 bar
• Permissible pressure: 10 bar

AFFECTED VIN
DI05-6
Oil Pump
Engine Oil Relief Valve Opening Pressure

MB SHEET
D27DT 229.1/3 5.8 ± 0.3 bar
SAE 10W 40, 5W 40
Differences between D27DT and old model (D29ST)

- Enlarged pump capacity: Width of tooth (pump gear): 33 mm (D29ST: 30 mm)
- Increased number of teeth (sprocket): 26 (D29ST: 24)
Oil Cooler
• Oil cooler mounting bolt: M6 x 16: 4
• Replace two oil cooler gaskets with new ones when the
oil cooler has been removed.

AFFECTED VIN
DI05-7
Blow-by Gas Reduction Device
Oil dipstick tube
PCV valve + oil

separator
to air duct
hose
Cylinder Head Cover
Blow-by gas inlet port Baffle plate
U-type oil
drain pipe
Baffle plate assembly: The baffle plates in cylinder head cover separates oil and gas from blow-by gas, and controls the
blow-by gas speed to send only gas to separator.

AFFECTED VIN
DI05-8
Oil Separator
PCV valve
Outlet port (gas only)
(connected to air duct hose)
Inlet port (oil + gas)

(connected to cylinder head cover
through blow-by hose)
Oil separator
Oil drain (oil only)

(connected to oil pan through oil dipstick tube)
The first separation will happen when blow-by gas passes through baffle plates in cylinder head cover; then oil and gas
will be separated due to cyclone effect after entering the oil separator inlet port. Separated oil returns to oil pan via oil
drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that
opens/closes due to pressure differences between the intake side and crankcase.
Engine Oil Pressure Check

Check the oil level and quality before checking the oil pressure.
1. Drain the engine oil.
2. Disconnect the oil pressure switch connector and remove the switch.
3. Install the oil pressure gauge into the switch hole. Start the engine and let it run until the coolant temperature
reaches at normal operating temperature (80 ~ 90°C).
4. Raise the engine speed by 2000 rpm and measure the engine oil pressure.
Specified oil pressure 2.5 ~ 3.0 kg/cm2(2000 RPM)
5. Install the switch and engage the connector.
Notice
• Apply the Loctite onto the thread of the switch and

check for oil leaks.
Tightening torque 120 ~ 160 kg/cm2

AFFECTED VIN
DI05-9
ENGINE OIL CHANGE

Change interval: Initial change 5,000 km, Change every 10,000 km or 12 months
Frequently check and add if needed. Shorten the change interval under severe conditions.
* Severe condition:
- When most trips include extended idling and/or frequent low-speed operation as in stop-and-go traffic.
- When most trips are less than 6 km (Operating when outside temperatures remain below freezing and
when most trips are less than 16 km)
- When operating in dusty, sandy and salty areas
- In hilly or moutainous terrain
- When doing frequent trailer towing
Notice
Water separation from the fuel filter should be performed when changing the engine oil.
Engine Oil Changing Procedures

1. Park the vehicle on the level ground and warm up the
engine until it reaches normal operating temperature.
2. Stop the engine and wait around 5 minutes. Remove the
oil filler cap, oil filter and oil drain plug to drain the oil.
Notice
After driving, the engine oil temperature may be high
enough to burn you. Wait until the oil is cooled down.
3. Install new oil filter and tighten the drain plug with specified
tighten torque.
Oil drain plug 25 ± 2.5 Nm
Notice
• Over-tightening may cause oil leaks.
• Replace the drain plug washer with new one.
4. Fill the engine oil through the oil filler opening.
Notice
The oil should not go above the upper mark on the dipstick. This would lead, for example, to increased oil
consumption, fouling of the spark plugs and excessive formation of carbon residue.
5. Close the oil filler cap and start the engine.

6. Stop the engine again and check the oil level. Add the engine oil if needed and check for the oil leaks.

AFFECTED VIN
DI05-10
Engine oil filter change

1. For changing procedures, refer to the “Lubrication System” section in this manual.
• Lubricate the engine oil gasket with engine oil before installation.
• Tighten it with the specified tightening torque.
Oil filter 25 ± 2.5 Nm

AFFECTED VIN
DI05-11
Oil Filter and Cooler

Preceding Works:
- Draining of engine oil
- Removal of EGR vacuum modulator bracket
1. Remove the oil cooler hoses (supply and return lines).
2. Disconnect the ground cable from the oil pressure switch.
3. Remove the oil cooler and filter mounting bolt.
Installation Notice
• Pay attention to the length of bolts.
4. Remove the oil cooler and filter assembly from the cylinder
block.
Notice
The oil cooler and filter assembly cannot be replaced

separately.

AFFECTED VIN
DI05-12

AFFECTED VIN
DI05-13
OIL PUMP
1. Oil pump 4. Guide pin

2. Plunger 5. Screw plug ...................................................... 50 Nm
3. Compression spring
Oil Pump - Removal and Installation

1. Remove the oil pan.
Tightening torque Nm
M6 x 20 (24 EA) 10 ± 1.0
M6 x 35 (2 EA) 10 ± 1.0
M6 x 85 (2 EA) 10 ± 1.0
M8 x 40 (4 EA) 25 ± 2.5
2. Remove the oil pump.

3. Remove the screw plugs and the relief valve.
5. Start the engine and check for oil leaks.

AFFECTED VIN
DI05-14
Oil Dipstick Guide Tube

1. Pull out the engine oil dipstick.
2. Remove the EGR valve pipe (No.3).
Installation Notice
• Replace the pipe with new one.
3. Unscrew the bolt and remove the oil dipstick guide tube.
Installation Notice
• Replace the O-ring with new one.
Notice
After installation, check for oil leaks.

AFFECTED VIN
DI05-15
OIL SPRAY NOZZLE
1. Fitting sleeve 3. Combination bolt .............................................. 10 Nm

2. Oil spray nozzle a. Oil duct
Disassembly
1. Remove the oil pan or crankshaft.
2. Unscrew the bolts and remove the nozzle.

AFFECTED VIN
DI05-16
OIL PAN ASSEMBLY
1. Oil pump 44. Bolt ................................................................... 10 Nm

9. Oil pump cover 45. Washer
10. Bolt 46. Bolt
32. Drain plug washer 49. Oil pump roller chain
33. Drain plug .............. 25 ± 2.5 Nm(replace the washer) 50. Oil pump chain lock link
35. Spring pin 51. Oil pump chain tensioner
36. Oil pump drive shaft 52. Oil pump chain spring
37. Oil pump driven shaft 53. Bush
38. Oil pump relief valve piston 56. Oil pump sprocket
39. Spring 57. Bolt
40. Oil pump relief valve pin 58. Dust cover
41. Oil pump relief valve plug 59. Cylindrical pin

AFFECTED VIN
DI05-17
BLANK

AFFECTED VIN
DI05-18
Removal and Installation of Oil Pan

Preceding works:
- Draining engine coolant
- Setting up the safety device for the sub frame and
removal of tires
- Removal of front propeller shaft
Procedures for Sub Frame Assembly

1. Placing the wheel chocks
The large portion of vehicle weight is applied to the

rear part of the vehicle when working on the 4-post
lift. Place the chocks under the rear wheels as
shown in the figure.
2. Installing the safety stands
To minimize the hazard, install two safety stands

under the sub frame before removing it. Pay particu-
lar attention that all the stands have same height.
16cm
3. Supporting points of auxiliary lift for sub frame
The auxiliary lift is used for removing and installing the sub frame. It should be located under the correct points in front
and rear sides of the sub frame. (The center point of gravity of sub frame is at the front axle mounting area.)
View from front side View from rear side

AFFECTED VIN
DI05-19
4. Installing the engine bracket
Remove the existing engine mounting brackets and install the special ser-
vice tools (temporary engine bracket) on the correct locations (dotted circles
in the figure) before removing the sub frame.
Engine mounting Special service tool

bracket for engine mounting
A9912 008 2B
View from right side View from left side

AFFECTED VIN
DI05-20
Connections on the Sub Frame
1. Remove the high and low pres- 2. Remove the front brake caliper (D) and the wheel speed sensor (D).
sure pipes (A) of the steering (Attach the removed brake caliper and wheel speed sensor to the
pump and lower arm shaft (B) vehicle after removing them.)
from the rear side of the sub
frame.
Suspension
Power steering pipe
3. Remove the high and low pressure pipes (A) of 4. Unscrew the bolts and nuts on the upper
the steering pump on the front side of sub end of the knuckle and lower end of the
frame, and loosen the pipes. shock absorber, and remove the knuckle
and shock absorber.

AFFECTED VIN
DI05-21
2. Place each auxiliary lift under the front and rear side of the sub frame while taking care of the center point
of gravity. Mark on the mounting bolts of the sub frame, and remove the bolts (19mm x 6).
Installation Notice
3. Remove the sub frame by lowering the auxiliary lifts.

AFFECTED VIN
DI05-22
4. To prevent any damage, place the rubber blocks on the sub frame contact points in the 4-post lift before the sub
frame is lowered completely.
Rubber block installation points for front side of sub frame
Rubber block installation points for rear side of sub frame

AFFECTED VIN
DI05-23
5. Install the sub frame in the reverse order of removal. Make sure that the sub frame is securely seated on the
mounting holes.
6. Unscrew the oil pan bolts (10 mm) and remove the oil pan.

AFFECTED VIN
DI05-24
TROUBLE DIAGNOSIS
Symptom Cause Action

• Loosened oil drain plug • Retighten
• Loosen oil pan bolts • Retighten
• Poor sealing at oil pan gasket • Replace
• Loosened oil filter • Retighten
• Loosened oil pressure switch • Retighten
• Poor sealing at camshaft front oil seal • Replace
• Poor sealing at crankshaft front oil seal • Replace
• Poor sealing at crankshaft rear oil seal • Replace
Excessive oil
• Poor sealing at cylinder head cover gasket • Replace
consumption
• Damaged cylinder head cover gasket • Replace
Oil intrusion into combustion chamber
• Stuck piston ring • Remove carbon or replace ring
• Worn piston or cylinder • Boring or replace
• Worn piston ring or ring groove • Replace piston and piston ring
• Improper position of ring cut-outs • Adjust
• Worn or damaged valve mechanism • Replace
• Oil leaks • Repair
• Defective turbo charger • Check
Defective lubrication system
• Improper viscosity • Replace with specified oil
• Loosened oil pressure switch • Retighten
Low engine oil • Low engine oil level • Add
pressure
• Poor oil pump • Replace
• Worn or damaged oil pump relief valve • Replace
• Clogged oil filter or oil strainer • Replace or clean
• Oil leaks • Repair

AFFECTED VIN
DI05-25
103 589 02 09 00
Engine filter cap

AFFECTED VIN
DI06-1
SECTION
00 DI06
COOLING SYSTEM
Table of Contents
COOLING SYSTEM .................................................... DI06-2
ENGINE COOLING SYSTEM ...................................... DI06-3

Specifications ........................................................ DI06-12
INSPECTION AND REPAIR ....................................... DI06-13
Inspection .............................................................. DI06-13
REMOVAL AND INSTALLATION ............................... DI06-15
PREHEATING SYSTEM ............................................ DI06-32

Overview ............................................................... DI06-33
Preheating relay ................................................... DI06-33
Preheating system diagram .................................. DI06-34
COOLING SYSTEM CHANGED BY

AFFECTED VIN
DI06-2
COOLING SYSTEM
Coolant temperature
Coolant reservoir FFH
sensor
Radiator Water pump Cooling fan
FFH (Fuel Fired Heater): refer to “FFH System” in this manual.
CHANGED BY COOLING SYSTEM

AFFECTED VIN
DI06-3
ENGINE COOLING SYSTEM
Coolant
reservoir
Engine
Cylinder head
Thermostat
Heater
Radiator
Water pump
Cylinder block
Oil cooler
(Heater line)
<PTC Engine Coolant Flows>
Coolant
reservoir
Engine
Cylinder head
Thermostat
Heater
Radiator
Water pump
Cylinder block
EGR cooler
Oil cooler
(henceforth)
<FFH Engine Coolant Flows>
• Cylinder block side

Block #5 → Oil cooler → Heater → Heater water pump inlet pipe → Water pump
• Cylinder head side
Cylinder head → Coolant outlet port (intake #1) → Radiator → Water pump

AFFECTED VIN
DI06-4
Function Description
Intake Manifold
Cylinder Head
Coolant Outlet Port
• Cylinder head coolant outlet port is integrated into intake manifold. (in front of cylinder #1)
: Improved shape and gasket material to prevent coolant from leaking
From cylinder head

From reservoir
4
5
6
From heater
1 2 3
• In OM 600 engine, coolant inflows through the heater line rear section (cylinder #4 and #5) of cylinder head. However,
in D27DT engine, coolant inflows from cylinder block through oil cooler (refer to coolant flows layout in previous
page).
: It prevents cooling efficiency from decreasing due to coolant separation between cylinder #4 and #5.
• In OM 600 engine, the cooling fan is installed with water pump, however, in case of D27DT engine, it is connected to
water pump with an additional pulley.

AFFECTED VIN
DI06-5
Radiator
This vehicle has a lightweight tube-and-fin aluminum radiator.
Be careful not to damage the radiator core when servicing.
Water pump
The belt-driven centrifugal water pump consists of an impeller,
a drive shaft, and a belt pulley. The impeller is supported by a
completely sealed bearing.
The water pump is serviced as an assembly and, therefore,
cannot be disassembled.
Coolant reservoir
Notice
Scalding hot coolant and steam could be blown out under

pressure, which could cause serious injury. Never remove
the coolant reservoir cap when the engine and radiator
are hot.
The coolant reservoir is a transparent plastic reservoir, similar

to the windshield washer reservoir. The coolant reservoir is
connected to the radiator by a hose and to the engine cooling
system by another hose. As the vehicle is driven, the engine
coolant heats and expands. The portion of the engine coolant
displaced by this expansion flows from the radiator and the
engine into the coolant reservoir. The air trapped in the radia-
tor and the engine is degassed into the coolant reservoir.
When the engine stops, the engine coolant cools and
contracts. The displaced engine coolant is then drawn back
into the radiator and the engine. This keeps the radiator filled
with the coolant to the desired level at all times and increases
the cooling efficiency. Maintain the coolant level between the
MIN and MAX marks on the coolant reservoir when the sys-
tem is cold.

AFFECTED VIN
DI06-6
Thermostat
A wax pellet-type thermostat controls the flow of the engine
coolant through the engine cooling system. The thermostat is
mounted in the water pump housing. The thermostat stops
the flow of the engine coolant from the engine to the radiator
to provide faster warm-up, and to regulate the coolant
temperature. The thermostat remains closed while the engine
coolant is cold, preventing circulation of the engine coolant
through the radiator. At this point, the engine coolant is al-
lowed to circulate only throughout the heater core to warm it
quickly and evenly. As the engine warms, the thermostat
opens. This allows the engine coolant to flow through the ra-
diator where the heat is dissipated. This opening and closing
of the thermostat permits enough engine coolant to enter the
radiator to keep the engine within proper engine temperature
operating limits. The wax pellet in the thermostat is hermeti-
cally sealed in a metal case. The wax element of the thermo-
stat expands when it is heated and contracts when it is cooled.
As the vehicle is driven and the engine warms, the engine
coolant temperature increases. When the engine coolant
reaches a specified temperature, the wax pellet element in
the thermostat expands and exerts pressure against the metal
case, forcing the valve open. This allows the engine coolant to
flow through the engine cooling system and cool the engine.
As the wax pellet cools, the contraction allows a spring to
close the valve.
The thermostat begins to open at 85°C and is fully open at
100°C. The thermostat closes at 85°C.
Operating
Thermostat Opening Value (mm)
Temperature (°C)
Begins to open 85°C 0.1 mm
Fully open 100°C 8 mm

AFFECTED VIN
DI06-7
When closed (up to 85°C) When partially opened (85°C ~ 100°C)
X. from cylinder head

Y. to crankcase
Z. from radiator
When fully opened (above 100°C)

If the cooling system is fully filled with, the coolant is auto-
matically bled through ball valve (arrow) in thermostat.

AFFECTED VIN
DI06-8
Viscous fan clutch
The cooling fans are mounted behind the radiator in the

engine compartment. The electric cooling fans increase
the flow of air across the radiator fins and across the con-
denser on air conditioner. The fan is 320 mm in diameter
with five blades to aid the airflow through the radiator and
the condenser. An electric motor attached to the radiator
support drives the fan.
1. A/C Off or Non-AC Model
• The cooling fan operates at low speed when the
1. Clutch housing 9. Pin coolant temperature reaches 95°C and at high
2. Drive disc 10. Bi-metal speed when the coolant temperature reaches
3. Flange 11. Bracket cover 100°C.
4. Seal ring 12. Separator disc • The cooling fan is turned from high speed to low
speed at 97°C and turns off at 90°C.
5. Needle bearing 13. Supply port
6. Cooling fan 14. Lever valve
2. A/C On
7. Oil scraper 15. Oil chamber
• The ECU will turn the cooling fan on at high speed
8. Spring 16. Operating chamber when the A/C system is on.
The cooling speed increases approx. 1,000 rpm with wind Engine coolant temperature sensor
noise when the engine speed is 4,000 to 4,500 rpm and
The Engine Coolant Temperature (ECT) sensor uses a tem-
the coolant temperature is 90 to 95°C.
perature to control the signal voltage to the Engine Control
Unit (ECU).
Notice
Keep hands, tools, and clothing away from the engine
cooling fans to help prevent personal injury. This fan
is electric and can turn on even when the engine is
not running.
Notice
If a fan blade is bent or damaged in any way, no attempt

should be made to repair or reuse the damaged part.
A bent or damaged fan assembly should always be
replaced with a new one to prevent possible injury.

AFFECTED VIN
DI06-9
Coolant Level Check
Notice
• Scalding hot coolant and steam could be blown out under pressure, which could cause serious injury. Never
remove the coolant reservoir cap when the engine and radiator are hot.
• Take precautions to prevent antifreeze coming in contact with the skin, eyes or vehicle body. If contact
happens, rinse affected areas immediately with plenty of water.
1. Place the vehicle on a level ground and check the coolant level through the coolant reservoir.
2. Add if needed. Change the coolant if necessary.

AFFECTED VIN
DI06-10
Coolant Temperature Sensor
Temp.
Resistance
<Coolant Temperature Sensor> <Output Characteristics of Coolant Temperature Sensor>
Coolant temperature sensor is a NTC resister that sends coolant temperature to ECU.
NTC resister has characteristics that if the engine temperature rises, the resistance lowers so the ECU detects lowering
signal voltages.
If the fuel injected into the engine through injector has more turbulence, then combusts very well. However, if engine tempera-
ture is too low, the fuel injected as foggy state forms big compounds causing incomplete combustion. So the sensor detects
coolant temperature and changes coolant temperature changes into voltage then sends to ECU to increase the fuel volume
during cold start for better starting. And detects engine overheating for fuel volume reduction to protect the engine.
ECU functions as below with coolant temperature sensor signals.
• When engine is cold, controls fuel volume to correct idle speed
• When engine is overheated, controls electrical fan and A/C compressor to protect the engine
• Sends information for emission control
Temperature NTC 1 Resistance ( Ω ) NTC 2 Resistance ( Ω )

20 2,550 6,062
50 826 1,800
80 321 638
120 123 200
Signal
Auto amp
Ground
<Coolant Temperature Sensor Circuit>

AFFECTED VIN
DI06-11
Trouble Diagnosis
Low coolant • Leaks in radiator • Replace radiator
level • Leaks in coolant reservoir • Replace coolant reservoir
• Leaks in heater core • Replace heater
• Leaks in hose connection • Reconnect hose or replace clamp
• Damaged coolant hose • Replace hose
• Leaks in water pump gasket • Replace gasket
• Leaks in water pump internal seal • Replace water pump
• Leaks in coolant inlet cap • Replace water inlet cap gasket
• Leaks in thermostat housing • Replace thermostat sealing
• Improper tightening torque of cylinder head • Retighten
• Damaged cylinder head gasket • Replace cylinder head gasket
Excessively • Coolant leaks (too low coolant level) • Add coolant
high coolant • Improper coolant mixture ratio • Check coolant concentration
temperature • Kinked coolant hose • Repair or replace hose
• Defective thermostat • Replace thermostat
• Defective water pump • Replace water pump
• Defective radiator • Replace radiator
• Defective coolant reservoir and cap • Replace coolant reservoir or cap
• Cracks on cylinder head or cylinder block • Replace cylinder head or cylinder block
• Clogged coolant passages in cylinder head or cylinder block • Clean coolant passages
• Clogged radiator core • Clean radiator core
• Improper operation of cooling fan • Replace cooling fan or repair related circuit
• Faulty temperature sensor or defective harness • Replace sensor or repair related circuit
Excessively • Stuck thermostat (with open) • Replace thermostat
low coolant • Improper operation of cooling fan • Replace cooling fan or repair related circuit
temperature
• Faulty temperature sensor or defective harness • Replace sensor or repair related circuit

AFFECTED VIN
DI06-12
SPECIFICATIONS
Description Unit Specification
Cooling system Type - Water cooling forced circulation
Coolant Capacity 11.3
Thermostat Type - Wax pellet type
Initial opening temperature DI °C 85
Fully opening temperature DI °C 100
Fully closing temperature DI °C 83
Stroke DI mm min. 8
Type - Electric
Cooling fan Blades 5
Diameter mm 320 (2)
Low speed ON temp °C 91
Low speed OFF temp °C 88
High speed ON temp °C 95
High speed OFF temp °C 92
High speed ON temp. (By A/C pressure) psi 270
Coolant reservoir pressure valve opening pressure Kg/cm2 1.2 ~ 1.5
Vacuum valve opening pressure Kg/cm2 0.1
Water pump Type - Turbo centrifugal
Impeller diameter mm 72.3
Impeller blades 10
Radiator Type - Down-flow
Core width mm 701
Core height mm 372
Core thickness mm 18
Minimum radiation capability Kcal/h 45,000
Coolant tempera- Resistance (at 20°C) KΩ 3.33 ~ 3.78
ture sensor Resistance (at 80°C) KΩ 0.32 ~ 0.35
Anti-freeze agent Type − ALUTEC-P78
Mixture ratio (water and anti-freeze) − 50 : 50

AFFECTED VIN
DI06-13
INSPECTION AND REPAIR
INSPECTION
Cooling System
1. Release the pressure from coolant reservoir by loosening
one notch of coolant reservoir cap, and then remove the
cap.
Notice
Scalding hot coolant and steam could be blown out

under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the
before the temperature goes down below 90°C.
2. Add the coolant up to upper mark (arrow) on the reservoir.
3. Install the tester to the coolant reservoir and apply the

pressure of 1.4 bar.
4. Check the coolant hoses, pipes and connections for leaks
after the pointer of the tester drops. Replace or retighten
as required.
Thermostat
Temperature gauge
Immerse the thermostat into the water. Heat the water and
check the valve opening temperature.
Valve opening temperature DI Engine: 85 ± 2°C

AFFECTED VIN
DI06-14
Coolant Temperature Gauge Unit

1. Immerse the senor unit into the water. Heat the water
and check the resistance.
2. If the measured resistance is out of specified value,

replace the gauge unit.
3. Measure the resistance between terminal A and gauge
unit housing, and terminal B and gauge unit housing.
Terminal A
Terminal B
Terminal A 0.4 Ω / 79°C
(for coolant temp.) 23.8 Ω / 115°C
Terminal B 24.8 Ω / -20°C
(for glow plug) 3.25 Ω / 20°C
Thermostat
1. Immerse the thermostat into the oil. Heat the oil until it
reaches the specified temperature and check if the
coolant temperature switch is turned “OFF”.
Coolant temperature at
113 ± 3°C
point A
Coolant temperature at
point B 116°C
Notice
Use only engine oil for this inspection. Stir the oil
during heating it. Never heat the oil over required
temperature.

AFFECTED VIN
DI06-15
REMOVAL AND INSTALLATION
Water Pump - Assembly

Preceding Works:
- Draining of coolant
- Removal of V-belt
- Removal of shroud
- Removal of cooling fan
1. Thermostat housing 4. Belt pulley

2. Gasket ........................................................... Replace 5. Bolt ................................................................... 10 Nm
3. Bolt ................................................................... 10 Nm 6. Water pump
1. Remove the V-belt while pressing down the auto tensioner

adjusting bolt.

AFFECTED VIN
DI06-16
2. Unscrew the bolts and remove the EGR pipe and bracket.
Installation Notice
3. Unscrew the bolts and remove the belt pulley while

holding the belt pulley with a special tool.
Installation Notice
4. Remove the oil dipstick tube.
Notice
• Replace the O-ring in oil dipstick with new one.

• Plug the oil dipstick hole with a cap not to get the
foreign materials into the engine.
5. Unscrew the bolts and remove the water pump assembly.

Installation Notice
Notice
Remove the gasket residues from the sealing surface

and replace the gasket with new one.

AFFECTED VIN
DI06-17
Thermostat
Preceding Works:
- Draining of coolant
- Removal of V-belt
- Removal of cooling fan
- Removal of intake duct (air cleaner to turbo charger)
1. Gasket ...................................................... Replace 5. Thermostat

2. Water pump housing 6. Seal
3. Connector 7. Coolant hose
4. Bolt ............................................................. 10 Nm

AFFECTED VIN
DI06-18
1. Unscrew the bolts and remove the thermostat housing.

Installation Notice
2. Remove the thermostat.


AFFECTED VIN
DI06-19
Water Pump Housing

Preceding Works:
- Removal of water pump assembly
- Removal of thermostat assembly
1. Remove the heater hose.
2. Unscrew the bolts and remove the alternator.

Installation Notice
3. Unscrew the bolts and remove the alternator bracket.

Installation Notice
4. Unscrew the bolts and remove the water pump housing.

Installation Notice
Notice
• Be careful not to damage the O-ring in coolant outlet

pipe (cylinder head side).
• Remove the gasket residues from the sealing
surface and replace the gasket with new one.

AFFECTED VIN
DI06-20
Radiator
Components of Radiator Module

Related Components (Assembly): Intercooler, Electric Fans, Condenser, Radiator
Preceding Work:
- Disconnection of negative battery cable
- Removal of front bumper assembly
- Discharge of refrigerant
- Draining of engine coolant
Removal Procedure
Intercooler Electric Fans
Radiator Condenser

AFFECTED VIN
DI06-21
Tightening Torques in Intake System
The clamp in the intake system related with intercooler may be moved out of its location due to the pressure from the
turbo charger when the proper tightening torque is not achieved. Always tighten the clamps to the specified value with a
torque wrench or ratchet wrench.

AFFECTED VIN
DI06-22
Intercooler Assembly
1. Disconnect all wiring harnesses and related connectors from the front side of radiator assembly.
AQS sensor
Ambient temperature
sensor
Ambient temperature switch Connector
[for FFH] [for air conditioner]
Receiver drier
Electric fans

AFFECTED VIN
DI06-23
2. Remove the front end center member.
3. Remove the hood latch cable and remove the radiator support upper member.

AFFECTED VIN
DI06-24
4. Remove the intercooler inlet hose. 5. Remove the intercooler outlet hose.
6. Unscrew the bolts and remove the intercooler assembly.

AFFECTED VIN
DI06-25
Electric Fans
1. Disconnect the electric fan connectors.
2. Unscrew the bolts at both sides and remove the electric fan assemblies.
Appearance
Front view Rear view

AFFECTED VIN
DI06-26
Condenser Assembly
1. Disconnect the receiver drier connector. 2. Remove the air conditioner inlet pipe bolt.
Appearance

AFFECTED VIN
DI06-27
Fan Shroud
1. Remove the coolant return pipe.
2. Remove the mounting bolt ( ) from the front side of the

engine.
3. Remove the bolt ( ) at bottom of the fan shroud and remove the fan shroud by pulling up the clip at the opposite
side.

AFFECTED VIN
DI06-28
Fan Clutch
• Unscrew the bolts with the fan clutch pulley locked by a special tool and remove the fan clutch.
Appearance
Front view Rear view

AFFECTED VIN
DI06-29
Fan Belt
• Remove the fan belt with the tensioning shock absorber depressed (counter-clockwise direction).
Fan Belt Arrangement
Cooling fan pulley Idle pulley
Auto temsioner pulley
Water pump pulley

Power steering pump pulley
Alternator pulley
Air conditioner
comperessor pulley
TVD (Torsional Auto tensioner

Vibration Damper)

AFFECTED VIN
DI06-30
Coolant Reservoir
2. Remove the hoses.
3. Unscrew the bolts and remove the coolant reservoir.

Installation Notice

AFFECTED VIN
DI06-31
Draining and Adding of Coolant

1. Release the pressure from coolant reservoir by loosening
one notch of coolant reservoir cap, and then remove the
cap.
Notice
Scalding hot coolant and steam could be blown out

under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the
before the temperature goes down below 90°C.
2. Loosen the drain plug in bottom of radiator and drain the

coolant.
Notice
Collect the drained coolant with a proper container.
3. Remove the drain plug and seal in the cylinder block and
drain the coolant.
4. Replace the seal with new one and install the drain plug.
Installation Notice
5. Install the drain plug in bottom of radiator.

6. Add the coolant through the coolant reservoir.
Notice
• Keep the coolant mixture ratio of 50:50 (water : anti-

freezer).
• Add the coolant until the water flows out through
the overflow hose.
7. Warm up the engine until the thermostat begins to open

and check if the coolant level is at “FULL” mark on the
reservoir. Add if necessary.

AFFECTED VIN
DI06-32
PREHEATING SYSTEM
ECU Glow indicator (meter cluster)
Glow plug Preheating relay

AFFECTED VIN
DI06-33
OVERVIEW
Glow plug is installed on the cylinder head (combustion chamber) in the D27DT preheating control unit system. Cold
starting performance has improved and exhaust gas during cold starting has reduced.
ECU receives coolant temperature and engine speed to control; after monitoring the engine preheating/after heating and
glow plug diagnosis function, the fault contents will be delivered to ECU.
• Engine preheating/after heating functions

• Preheating relay activation by ECU controls
- Senses engine temperature and controls the preheating/after heating time
- Glow indicator
• K-LINE for information exchanges between preheating unit and ECU
- Transmits preheating unit self-diagnosis results to ECU
- Transmits glow plug diagnosis results and operating status to ECU
PREHEATING RELAY
Structure
K-LINE #1 IG1
(ECU 34) Power terminal
Glow plug
control signal
(ECU 113)
Ground terminal
B+main wire
(12V)
Glow plug
terminal
Y220_06069

AFFECTED VIN
DI06-33
OVERVIEW

- Glow indicator
PREHEATING RELAY
Structure
K-LINE #1 IG1
(ECU 34) Power terminal
Glow plug
control signal
(ECU 113)
Ground terminal
B+main wire
(12V)
Glow plug
terminal
Y220_06069

AFFECTED VIN
DI06-34
PREHEATING SYSTEM DIAGRAM
Coolant
temperature
sensor
Specifications
Rated voltage DC 12 V
Operating voltage range DC 8 ~ 15 V
Operating range - 40 ~ + 100°C
Relay operating voltage Over 6.5 V
Relay releasing voltage Over 1.5 V
Relay coil resistance 11.3 Ω
Voltage drop Below 150 mV at each glow plug (at 16A of current)
Parasitic current MAX 1mA

AFFECTED VIN
DI06-35
Function
Preheating system controls and checks following functions and operating conditions.
Pre-Heating
• The power will be supplied to the glow plugs by ECU controls when the power is supplied to the IG terminal from
the battery and there are normal communications with ECU within 2 seconds. The surface of glow plug will be
heated up to 850°C very quickly to aid combustion by vaporizing air-fuel mixture during compression stroke.
• Preheating time is controlled by ECU.
After-heating
• When the engine is started, after-heating starts by ECU controls. The idle rpm will be increased to reduce toxic
smoke, pollutants and noises.
• After-heating time is controlled by ECU.
Checking glow plugs
• Check each glow plug for short in circuit
• Check each glow plug for open in circuit due to overvoltage
• Check glow plug for short to ground
Forceful relay shut-down
• When glow plug is shorted to ground
K-Line communication
• ECU sends the results to preheating time control relay through K-Line to start communication.
• Preheating time control relay sends messages including self-diagnosis data for glow plugs to ECU.
• Glow plug makes communication only as response to demand.
• When power is supplied, ECU starts self-diagnosis within 2 seconds.
• Under the following conditions, communication error occurs.
- When there is no response from glow plug module within 2 seconds
- When an error is detected in checksum
- Less byte is received
Error code of “P1720 - Pre heating control communication fail” will be reported.
Operating time
Coolant Temp. -35 °C -25 °C -20 °C -10 °C 0 °C 10 °C 20 °C

Pre- Operating Time 31 sec 22 sec 19 sec 17 sec 14 sec 0 sec 0 sec
heating Operating • IG: “ON” Release • After operating time elapsed
Conditions • B+ : below 15.2V Conditions • IG: “OFF” • When engine cranking
Coolant Temp. -30 °C -20 °C -10 °C 0 °C 10 °C 20 °C 35 °C

Operating Time 115 sec 80 sec 30 sec 19 sec 11 sec 11 sec 0 sec
After-
heating • After engine starting • After operating time elapsed
Operating Release
• Torque : 190/170 Nm
Conditions Conditions
• Speed: 2100/2050 rpm
Coolant Temp. -30 °C -25 °C -20 °C -10 °C 0 °C 10 °C 20 °C
Glow Operating Time 18 sec 16 sec 10 sec 5 sec 2 sec 0 sec 0 sec
Indicator Operating Release
• IG: “ON” • When engine cranking
Conditions Conditions

AFFECTED VIN
DI07-1
SECTION
00 DI07
FUEL SYSTEM
Table of Contents
CAUTIONS FOR DI ENGINE ....................................... DI07-2
FUEL SYSTEM ............................................................ DI07-6

Fuel injection system .............................................. DI07-6
Fuel transfer line ................................................... DI07-12
Inlet metering valve (IMV) ..................................... DI07-19
High fuel pressure line .......................................... DI07-22
Injector .................................................................. DI07-35
REMOVAL AND INSTALLATION OF FUEL TANK .... DI07-49

AFFECTED VIN
DI07-2
CAUTIONS FOR DI ENGINE

This chapter describes the cautions for DI engine equipped vehicle. This includes the water separation from engine,
warning lights, symptoms when engine malfunctioning, causes and actions.
DI Engine Water Separator Warning Light

Comparatively conventional diesel engines, DI engine con- When the water level inside water sepa-
trols the fuel injection and timing electrically, delivers high rator in fuel filter exceeds a certain level
power and reduces less emission. (approx. 39 cc), this warning light
comes on and buzzer sounds.
Also, the driving force of the vehicle
System Safety Mode decreases (torque reduction). If these
When a severe failure has been occurred in a vehicle, the conditions occur, immediately drain
system safety mode is activated to protect the system. It the water from fuel filter.
reduces the driving force, restricts the engine speed (rpm) For the draining procedures, please re-
and stops engine operation. Refer to “Diagnosis” section fer to “Draining the water from fuel fil-
in this manual. ter” in this section.

AFFECTED VIN
DI07-3
Priming Pump
The priming pump installed in fuel pump is the device to fill the fuel into the fuel filter. When the vehicle is under the
conditions as below, press the priming pump until it becomes rigid before starting the engine.
WARNING
Never reverse filter or use it in other place (clean side)
Conditions for using Priming Pump

1. After run out of fuel
2. After draining the water from fuel separator
3. After replacing filter or any intervention on system
Fuel Filter and Water Separator
1. Fuel filter 2. Water drain plug

3. Priming pump (to be drained every 15,000km max.)
4. Water separator Draining could be done at same time than oil
change
Notice
• When replaced the fuel filter or drained the water from fuel filter, press the priming pump until it becomes
rigid before starting the engine.
• The water drain from fuel filter should be performed whenever changing the engine oil.

AFFECTED VIN
DI07-4
Draining the Water From Fuel Filter

for EU Area
1. Place the water container under the fuel filter.
2. Turn the drain plug (2) to “A” direction to drain the water.
3. Press priming pump until all water is drained, then turn
the drain plug to “B” direction to tighten it.
Notice
Be careful not to be injured by surrounding
equipment during the working procedures.
4. Press the priming pump until it becomes rigid.

5. Start the engine and check the conditions.
6. Clear the fault code of ECU with scan 100.
WARNING
If the priming pump is not properly operated, air may

get into the fuel line. It may cause starting problem
or fuel system problem. Make sure to perform the
job in step 4.

AFFECTED VIN
DI07-5
Draining the Water From Fuel Filter for General Area
1. Place the water container under the fuel filter & water
separator.
2. Disconnect the connector under the drain plug of the water
separator.
3. Turn both drain plugs to “A” direction to drain the water.
4. Wait until a certain amount of fuel gets out from the port,
then turn the both drain plugs to “B” direction to tighten it.
Notice
Be careful not to be injured by surrounding

equipment during the working procedures.
4. Engage the connector under the drain plug and press 1. Fuel filter
the priming pump until it becomes rigid. 2. Priming pump
5. Start the engine and check the conditions. 3. Water separator
6. Clear the fault code of ECU with SCAN-100. 4. Drain plug
5. Connector
WARNING
If the priming pump is not properly operated, air may

get into the fuel line. It may cause starting problem
or fuel system problem. Make sure to perform the
job in step 4.

AFFECTED VIN
DI07-6
FUEL SYSTEM
FUEL INJECTION SYSTEM
Electronic Control of Fuel System
High pressure pump

Common rail
IMV valve
Low and high Injection
pressure pump pipe
Fuel temperature
sensor
Water separator
Fuel filter
Priming
pump
Water detection
sensor
Injectors
Sensors
HFM sensor
Cam position sensor
Crankshaft position sensor
Fuel tank ECU
Knock sensor, etc.
System composition
Supply line
- High pressure fuel pump - Fuel rail - Fuel pressure sensor
Return line
- Fuel injector - Electronic control unit (ECU) - Other sensors and actuators ECU connecting line
ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those
signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor deter-
mines injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal that is gener-
ated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and
sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume
changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from
coolant temperature sensor and air temperature sensor, booster pressure sensor and atmospheric pressure sensor as
compensation signal to respond to injection starting, pilot injection set values, various operations and variables.

AFFECTED VIN
DI07-7
Composition of Fuel System

Components in fuel system are designed to generate and distribute high pressure, and they are controlled electronically
by engine ECU. Accordingly, fuel system is completely different from injection pump type fuel supply system on the
conventional Diesel engine. The fuel injection system in common rail engine is composed of transfer pressure section
that transfers fuel in low pressure, high pressure section that transfers fuel in high pressure and ECU control section.
High pressure pipe
Common rail
Injector
Priming pump
Fuel pump Fuel filter

(High pressure pump, transfer pump)
<Fuel line system>
Fuel route
Transfer
Fuel tank Priming pump Fuel filter
pump
Transfer pressure line
High pressure Fuel pressure

Injector Common rail
pump regulation valve
High pressure line

AFFECTED VIN
DI07-8
Hydraulic cycle in Fuel Line (Transfer and High Pressure Line)
Transfer pres- Pressure limiter

sure regulation (High pressure)
Transfer pump High pressure pump
Return
valve
Inlet
valve
below 2 bar
below - 0.3 bar

Venturi Common rail
Up to
1050 bar
* At IMV full open
- 0.6 ~ 0.1 bar
0.05 ~ 0.1 bar Injector

Priming pump
Fuel
filter
High pressure supply line

Transfer pressure supply line
Fuel tank Return line

AFFECTED VIN
DI07-9
Components of Low Pressure Transfer Line

Low pressure stage is to supply sufficient fuel to high pressure section and components are as below.
• Fuel tank (including strainer)
• Hand priming pump
• Fuel filter
• Transfer pump
• Other low pressure fuel hoses
Fuel tank
Fuel tank is made of anti-corrosion material and its allowable
pressure is 2 times of operating pressure (more than 0.3 bar).
It has protective cap and safety valve to prevent excessive
pressure building. Also, it has structure to prevent fuel from
leaking in shocks, slopes and corners and to supply fuel
smoothly.
Priming pump
If fuel runs out during driving or air gets into fuel line after fuel
filter replacement, it may cause poor engine starting or dam-
age to each component. Therefore, the hand priming pump is
installed to bleed air from transfer line.
When the vehicle is under the conditions as below, press the
priming pump until it becomes rigid before starting the engine.
- After run out of fuel
- After draining the water from fuel filter
- After replacing the fuel filter
Press the priming pump until it becomes rigid before starting
the engine.
Fuel filter
It requires more purified fuel supply than conventional diesel
engine. If there are foreign materials in the fuel, fuel system
including pump components, delivery valve and injector nozzles
may be damaged.
Fuel filter purifies fuel before it reaches to high pressure pump
to help proper operations in high pressure pump. And more, it
separates water from fuel to prevent water from getting into
FIE system (high pressure line).

AFFECTED VIN
DI07-10
Transfer pump
The transfer pump is included in the housing of the high pres-
sure pump. The transfer pump is the volumetric blade type
pump. To deliver the continuously required fuel volume, the
pump transfers fuel from the fuel tank to high pressure pump.
Components of High Pressure Transfer Line

In the high pressure section, sufficient fuel pressure that injectors requires will be generated and stored. The compo-
nents are as below:
• High pressure pump
• Rail pressure sensor
• Pressure limit valve
• Common rail
• High pressure pipe
• Injector
• Fuel pressure regulating valve (IMV)
High pressure pump (including IMV and limit valve)

This is plunger pump that generates high pressure; and driven
by crankshaft with timing chain. The high pressure pump in-
creases system pressure of fuel to approx. 1,600 bar and this
compressed fuel is transferred to high pressure accumulator
(common rail) in tube through high pressure line.
Common rail (including pressure sensor)

It stores fuel transferred from high pressure pump and also
stores actual high pressure of fuel. Even though the injectors
inject fuel from the rail, the fuel pressure in the rail is main-
tained to a specific value. It is because the effect of accumu-
lator is increased by unique elasticity of fuel. Fuel pressure is
measured by rail pressure sensor. And the inlet metering valve
(IMV) included in high pressure pump housing keeps pres-
sure to a desired level.

AFFECTED VIN
DI07-11
High pressure pipe (fuel pipe) No.1 and 3 cylinder No. 5 cylinder
Fuel line transfers high pressure fuel. Accordingly, it is made
of steel to endure intermittent high frequency pressure changes
that occur under maximum system pressure and injection
stops. Injection lines between rail and injectors are all in the
same length; it means the lengths between the rail and each
injector are the same and the differences in length are com-
pensated by each bending.
No.2 and 4 cylinder
Injectors
The fuel injection device is composed of electrical solenoid
valve, needle and nozzle and controlled by engine ECU. The
injector nozzle opens when solenoid valve is activated to di-
rectly inject the fuel into combustion chamber in engine. When
injector nozzle is open, remaining fuel after injection returns
to fuel tank through return line.
Fuel Filter Replacement

* Fuel filter change interval: every 30,000 km
* Water separation interval: every 15,000 km max. (same
with engine oil change interval)
* Never reuse the removed fuel filter

AFFECTED VIN
DI07-12
FUEL TRANSFER LINE

Fuel Filter
Function
Foreign materials in fuel can damage the pump components, transfer valve and injectors. Therefore, the high pressure
direct injection engine must use fuel filter. Otherwise, the operation performance will drop dramatically. And, diesel fuel
may contain water due to condensation by temperature changes and this condensation water can damage the system
by corroding the injection system. Thus, the common rail engine should have function that can drain water periodically.
from HP pump to fuel tank
to HP pump
from fuel tank
Water Sensor Fuel filter

Capacity: 120 cm 3 Filter volume: 500 ± 25 cm 3
Filtering efficiency
Warning light ON level: 39 cm 3
• Particles larger than 3mm > 98 %
• Particles larger than 5mm > 99.8 %
• Particles larger than 15mm > 100 %
Drain plug

AFFECTED VIN
DI07-13
Change Interval: 30,000 km
Water separation and storage function

• Function: It separates the condensation water from diesel fuel to prevent the water from getting into FIE system, and
results in protection of FIE system. (manual drain)
• Water storage capacity: 120 cc
• Water sensor: light if over 39 cc
• Water drain interval: When changing engine oil or every 20,000 km
Water sensor
It is integrated in the filter and sends signal to ECU when water level reaches at a specified value (over 39 cc) in the filter
to let the driver drain the water.
Fuel De-Waxing – Improving starting performance in cold weather

Due to characteristics of diesel fuel, some of fuel components solidify during cold winter under below a specific tempera-
ture (-15°C). When those symptoms happen, engine may stall; however, some of the fuel (temperature rises due to high
compression) in the HP pump in D27DT engine return to the filter to warm up fuel when temperature is below 50°C by
improving cold start performance during cold winter.

AFFECTED VIN
DI07-14

1. Disconnect the fuel supply and return hoses.
Notice
• Plug the openings of hoses and fuel filter with

sealing caps.
• Ensure that the hoses are connected to correct
positions.
2. Loosen the bracket bolts and disconnect the hose from

the drain plug.
3. Remove the fuel filter.
5. Press the priming pump until it becomes rigid to deliver
the fuel to the transfer line of HP pump.

AFFECTED VIN
DI07-15
Water Separator (General Area Only)

Function
The water separator is used in the fuel supplying system in order to reduce the water content in the fuel provided to the
FIE system.
It gives additional water volume storage. A water sensor is fitted to the water separator in order to:
- Warn the driver that the water separator has to be drained
- In case of coupling the water separator to a filter, it reduces the amount of water seen by the filter.
The water sensor is connected to the ECU. The sensor is fitted on the bottom part of the water separator where water
separated from the fuel is stored.
When using the water separator coupled to fuel filter, 80 % of the volume of water separated is stopped in the water
separator.
Fuel outlet tube
Fuel inlet tube
Sedimentor cover
Cylindrical mesh
Sedimentor bowl
Schematic representation of the inner design
Water sensor
Capacity: 300 cm3
Warning light ON level: 39 cm 3

AFFECTED VIN
DI07-16
Priming Pump
If fuel runs out during driving or air gets into fuel line after fuel
filter replacement, it may cause poor engine starting or dam-
age to each component. Therefore, the hand priming pump is
installed to fill filter.
to fuel filter
When the vehicle is under the conditions as below, press the
priming pump until it becomes rigid before starting the engine.
Conditions for using Priming Pump

- After run out of fuel
from fuel tank
- After draining the water from fuel filter
- After replacing the fuel filter
Notice
When the fuel filter is replaced, the fuel in the fuel tank should be transferred to the filter by using priming
pump. So never transfer the fuel in the fuel tank to the filter by driving HP pump with cranking the engine.
Relations Between Pressure and Temperature In Fuel Transfer Line

Pump inlet pressure
Pump
High pressure common rail
Fuel transfer
line
Injector
Ventury
Pump outlet pressure Injector No.1 return pressure Injector No.5 return pressure
• The fuel transfer line is the line between fuel tank and HP pump inlet port. The pressure on this line affects the
lifetime of fuel filter.
• Temperature of fuel transfer line
- HP pump inlet temperature is less than 80°C.
- The temperature of fuel pump inlet is up to 80°C.
And, diesel fuel has lubrication effects due to its viscosity. Thus, the fuel is also used for pump lubrication.
However, this lubrication performance drops as the temperature rises. Accordingly, when the fuel temperature is
over 50°C, 100% of fuel is returned to fuel tank to cool down the temperature and then increase the lubrication
effects of fuel and prevent heat damage on each section of high fuel pressure line.

AFFECTED VIN
DI07-17
Transfer Pump
Description
The transfer pump is the device to provide sufficient fuel to high fuel pressure line and is mechanical type feed pump that
is driven by timing chain linked to crankshaft. This mechanical type feed pump is subject to air inflow, therefore, a hand
priming pump is installed to fill fuel in Low fuel pressure(LP) circuit.
The transfer pump is included in the housing of the HP pump. The transfer pump is the volumetric blade type pump and
consists of the following components:
• A rotor turned by the shaft of the HP pump. The connection is provided by splines.
• An eccentric liner fixed to the housing of the HP pump by 6 Torx bolts. The liner is positioned by two off-set pins in
order to prevent any assembly errors.
• Four blades set at 90°. Each blade is held against the liner by a coil spring.
• The inlet and outlet orifice.
Transfer pump HP pump
<Sectional view of fuel pump>
<Sectional view of transfer pump>

AFFECTED VIN
DI07-18
Principle of operation
Housing
Rotor
OUT
Blade
Chamber
Consider the chamber between the rotor, the liner and two successive blades (refer to above figure).
• When the chamber is in position 1, the volume of the chamber is minimal. The changes in volume according to the
angle of rotation of the rotor are small.
• The rotor makes a quarter turn clockwise. The previous chamber is now in position 2.
The inlet orifice is uncovered. The volume contained in the chamber quickly rises. The pressure inside the chamber
drops sharply. Fuel is drawn into the chamber.
• The rotor continues to rotate. It is now in position 3. The inlet and outlet orifices are now sealed off. The volume area
controlled by the rotor, the liner and the two blades is at the maximum. The changes in volume according to the
angle of rotation of the rotor are small.
• The rotor continues to rotate. It is finally in position 4. The outlet orifice is uncovered. The volume area controlled by
the rotor, the liner and the blades decreases quickly. The pressure inside the chamber rises sharply. The fuel is
expelled under pressure. The depression caused by the transfer pump’s rotation is sufficient to draw in diesel fuel
through the filter. The transfer pump is driven by the shaft of the HP pump, transfer pressure thus rises with engine
speed. A regulating valve allows the transfer pressure to be maintained at a practically constant level (about 6 bar)
throughout the whole range of engine operations by returning some of the fuel to the pump inlet.
Fuel
pressure
(bar)
Fuel pump speed (rpm)
Characteristics of the transfer pump
Regulating pressure 6 bar

Volume controlled 5.6 cm3/revolution
Flow 90 /h at 300 rpm pump
650 /h at 2,500 rpm pump
Intake capacity 65 mbar at 100 rpm pump

AFFECTED VIN
DI07-19
INLET METERING VALVE (IMV)
Overview
The LP actuator, also called the inlet metering valve, is used

to control the rail pressure by regulating the amount of fuel
which is sent to the pumping element of the HP pump.
This actuator has two purposes:
1. Firstly, it allows the efficiency of the injection system to IMV effect

be improved, since the HP pump only compresses the
amount of fuel necessary to maintain in the rail the level without IMV
of pressure required by the system as a function of the with IMV
engine’s operating conditions.
Torque (Nm)
Rail pressure = 80 bar
2. Secondary, it allows the temperature to be reduced in

Fuel temperature at
the fuel tank. When the excess fuel is discharged into system backleak
without IMV
the back leak circuit, the pressure reduction in the fluid with IMV
(from rail pressure down to atmospheric pressure) gives

off a large amount of heat. This leads to a temperature
Fuel Temp.(°C)
rise in the fuel entering the tank. In order to prevent too

high a temperature being reached, it is necessary to limit
the amount of heat generated by the fuel pressure
reduction, by reducing the back leak flow. To reduce the
back leak flow, it is sufficient to adapt the flow of the HP
pump to the engine’s requirements throughout its
operating range.
Torque (Nm)

AFFECTED VIN
DI07-20
Composition of IMV
The IMV is located on the hydraulic head of the pump. It is fed with fuel by the transfer pump via two radial holes. A
cylindrical filter is fitted over the feed orifices of the IMV. This makes it possible to protect not only the LP actuator, but
also all the components of the injection system located downstream of the IMV.
The IMV consists of the following components:
• A piston held in the fully open position by a spring.
• A piston filter located at inlet.
• Two O-rings ensuring pressure tightness between the hydraulic head and the body of the IMV.
• A body provided with two radial inlet holes and an axial outlet hole.
• Coil
Transfer pump Solenoid

Fuel
Filter Spring
High pressure Piston
Outlet hole O-ring

Fuel
Transfer pump

AFFECTED VIN
DI07-21
Principle of Operation
The LP actuator is used to proportion the amount of fuel sent to the pumping element of the HP pump in such a way that
the pressure measured by the HP sensor is equal to the pressure demand sent out by the ECU. At each point of
operation, it is necessary to have:
• Flow introduced into the HP pump = Injected flow + Injector backleak flow + injector control flow
The IMV is normally open when it is not being supplied with fuel. It cannot therefore be used as a safety device to shut
down the engine if required.
The IMV is controlled by current. The flow/current law is represented below.
Flow / Current Law

Flow (I/hr)
Current (mA)
Specifications
Piston stroke 1.4 mm
Diameter of holes 3.4 mm
Coil resistance 5.4 Ω (at 25°C)
Power supply Battery voltage (It is prohibited to supply the IMV directly at the battery voltage
during the diagnostic test)
Max. current 1A
Weight 260 g
Operating temperature 40°C < T < 125°C
Fluid temperature 40°C < T < 90°C
Control logic Normally open without power (The flow decreases as the current rises).
• ECU determines the value of the current to be sent to the IMV according to:
• Engine speed
E
• Flow demand • Inlet Metering
C
• Rail pressure demand Valve (IMV)
U
• Measured rail pressure

AFFECTED VIN
DI07-22
HIGH FUEL PRESSURE LINE

High Pressure Pump
Description
This pump generates high fuel pressure and is driven by timing chain (radial plunger principle). This pump pressurizes
the fuel to approx. 1600 bar and sends this high pressurized fuel to high pressure accumulator (common rail) via high
pressure line.
It is possible to extend the pumping phase in order to considerably reduce drive torque, vibration and noise since the pump no
longer determines the injection period. The differences from conventional rotary pumps lies in the fact that it is no longer the
hydraulic head rotor which turns inside the cam, but the cam which turns around the hydraulic head. Thus, any problems of
dynamic pressure tightness are eliminated because the high pressure is generated in the fixed part of the pump.
1. IMV (Inlet Metering Valve)

2. Hydraulic Head
3. Plunger
4. Drive shaft and cam ring
5. Housing
6. Roller and shoe
7. Transfer pump
8. Fuel temperature sensor
Fuel 9. High fuel pressure - OUT
discharge
10. Pressure regulator
Fuel supply
Specifications
• Maximum operating pressure: 1600 ± 150 bar
• Max. Overpressure: 2100 bar
• Maximum sealing pressure: when using a plug instead of PRV, no leaks around pump outlet port (when applying
2500 bar of constant pressure)
• Operating temperature: Continuously operating within temperature range of -30°C ~ 120°C in engine compartment
• Inflowing fuel temperature: The maximum inflowing fuel temperature is 85°C (continuously able to operate)
• Pump inlet pressure: Relative pressure Min. - 0.48 bar (to end of filter’s lifetime)
• Driving torque: 15 Nm / 1600 bar
• Gear ratio (engine: pump): 0.625
• Lubrication: - Inside lubrication (rear bearing): Fuel
- Outside lubrication (front bearing): Engine oil

AFFECTED VIN
DI07-23
Principle of operation
• During the filling phase, the rollers are kept in contact with the cam by means of coil springs mounted on either side
of each shoe. The transfer pressure is sufficient to open the inlet valve and to move the pumping plungers apart.
Thus, the dead volume between the two plungers fills with fuel.
• When the diametrically opposite rollers simultaneously encounter the leading edge of the cam, the plungers are
pushed towards each other.
• As soon as the pressure becomes higher than the transfer pressure, the inlet valve closes. When the pressure
becomes higher than the pressure inside the rail, the delivery valve opens. Consequently, the fuel is pumped under
pressure into the rail.
• During the input phase, transfer pressure pushes back the inlet valve. Fuel enters the body of the pumping element.
The valve closes as soon as the pressure in the pumping element becomes higher than the transfer pressure.
• During the input phase, the ball of the delivery valve is subject to the rail pressure on its outer face and to the transfer
pressure on its inner face. Thus the ball rests on its seat, ensuring the pressure tightness of the body of the pumping
element. When the pressure in the element becomes higher than the pressure in the rail, the ball is unbalanced and
it opens. Fuel is then pumped into the rail at high pressure.
Roller
Plunger
<Fuel input> <Pressurize>
This high pressure pump generates the driving torque with low peak torque to maintain the stress to driving components.
This torque is smaller than that of conventional injection pump, thus, only a small load will be applied to pump. The
required power to drive pump is determined by set pressure for rail and pump speed (delivery flow). Note that the fuel
leakage or defective pressure control valve may affect the engine output.

AFFECTED VIN
DI07-24
Inlet valve and delivery valve

During the input phase, transfer pressure pushes back the inlet valve. Fuel enters the body of the pumping element.
Under the effect of the transfer pressure, the two plungers are forced apart. When the rollers simultaneously encounter
the leading edge of the cam, pressure suddenly rises in the body. Of the pumping element. The valve closes as soon as
the pressure in the pumping element becomes higher than the transfer pressure. During the input phase, the ball of the
delivery valve is subject to the rail pressure on its outer face and to the transfer pressure on its inner face. Thus the ball
rests on its seat, ensuring the pressure tightness of the body of the pumping element. When the two diametrically
opposite rollers encounter the leading edges of the cam, the plungers are forced together and pressure quickly rises in
the body of the pumping element. When the pressure in the element becomes higher than the pressure in the rail, the
ball is unbalanced and it opens. The spring calibration is negligible compared with the pressure forces. Fuel is then
pumped into the rail at high pressure.
<Inlet valve> <Delivery valve>
Lubrication and cooling of the HP pump

Lubrication and cooling of the pump are provided by the fuel circulation. The minimum flow required to ensure adequate
operation of the pump is 50 /h.
Phasing of HP pump required and offer 2 advantages

Conventional fuel injection pumps ensure pressurizing and distribution of the fuel to the different injectors. It is essential
to set the pump in such a way that the injection occurs at the required place during the cycle. The HP pump of the
common rail system is no longer used for the fuel distribution, it is therefore not necessary to set the pump in relation
to the engine.
Nevertheless, the setting or phasing of the pump offers two advantages:
• It allows the torque variations of the camshaft and the pump to be synchronized in order to reduce the stresses on
the timing belt.
• It allows pressure control to be improved by synchronizing peak pressures produced by the pump with pressure-
drops caused by each injection.
This phasing allows pressure stability to be improved, which helps to reduce the difference in flow between the cylinders.

AFFECTED VIN
DI07-25
HP Pump Fuel Route

The fuel passed through the fuel filter is sent to the transfer pump via the HP inlet pump. this fuel passes through the
transfer pump by the transferring pressure and maintains the predefined value by the regulating valve in HP pump.
Also, this fuel gets into the IMV that controls only the fuel to the high pressure pump.
The below figure describes the pump operations when acceleration and deceleration.
When need high fuel pressure (acceleration)
IMV open
Venturi
to common rail
Fuel supply
to fuel tank
Backleak

AFFECTED VIN
DI07-26
When do not need high fuel pressure (deceleration)
IMV close
Venturi
to common rail
Fuel supply
to fuel tank
Backleak
The fuel is sent to the high pressure side (hydraulic head) and compressed by the plunger. And, goes into the common
rail through the high pressure pipe.
The IMV installed in the high pressure side (hydraulic head) of HP pump precisely controls the fuel amount and delivers
the rail pressure feedback same as required amount.
The IMV is controlled by ECU.
Performance curve of HP pump

The time required to obtain a sufficient pressure in the rail to enable the engine to start depends on the volume of the
system (definition of the rail, length of the pipes, etc.). The aim is to reach a pressure of 200 bars in 1.5 revolutions (3rd
compression).
• Maximum operating pressure: 1600 ± 150 bar
Rail pressure (bar)
Engine speed (rpm)
<Pressure curve of HP pump>

AFFECTED VIN
DI07-27
Sectional View of HP Pump
<Transfer Pump>
IMV valve
Drive shaft
<IMV Valve and High Pressure Pump (Drive Shaft)>

AFFECTED VIN
DI07-28
Inlet valve
Temperature sensor
Shoe and roller Delivery valve
<Inlet Valve, Delivery Valve, Shoe and Roller, Temperature Sensor>
<Hydraulic Head>

AFFECTED VIN
DI07-29
High Pressure Accumulator (Common Rail)
Description
The high pressure accumulator reserves the high pressure fuel. Simultaneously, the pressure changes due to the
delivery from HP pump and the fuel injection is diminished by rail volume. This high pressure accumulator is commonly
used in all cylinders. Even when a large amount of fuel leaks, the common rail maintains its internal pressure. This
ensures that the injection pressure can be maintained from when the injector opens.
Function
• Relieve the pressure pulsation
• Provide pressure information to ECU (fuel pressure sensor)
Specifications
• Material: Forged Steel
• Dimension: - Volume: 22 ± 1cc
- Length: Max. 397.7 mm
- Outer diameter: 25.3 mm
• Fuel pressure sensor Integrated type
- Sensor input voltage: 5 ± 0.1V
- Sensor output signal voltage: - 4.055 ± 0.125 V @ 1600 ± 15 bar
- 0.5 ± 0.04 V @ 0 bar
• Operating pressure range
- Normal condition: 0 ~ 1600 bar
- Max. Overpressure: 2100 bar
• Ambient temperature: - available within -40°C ~ 125°C
- Spontaneous max. temperature after engine stops: 140°C (acceptable against total 15 hours)
• Fluid temperature: -40 ~ 100°C under normal operating conditions
• Removal and installation: 10 times without any damage

AFFECTED VIN
DI07-30
No. 1 No. 2 No. 3 No. 4 No. 5
HP pipe
Injector
High fuel pressure pipe
Fuel rail
HP pump
<High pressure accumulator>
High Fuel Pressure Pipe

• Function: Resistant to pressure changes, tightness against surroundings, supplying fuel through pump, rail and
injector with high pressure
• Material: Steel (Zn Plated)
• Common: Cylinder 1 & 3, 2 & 4, 5
• Internal pressure
- Internal operating pressure: 0 ~ 1600 bar during its lifetime
- Spontaneous max. pressure when restoring: 2100 bar (max. total period: 20 hours)
- Bursting pressure: over 2500 bar
• To keep cleanness and tightness, the high pressure pipe assembly should be used only once.
Notice
• Make sure to replace the removed high fuel pressure pipes.

• Tighten the fasteners with the specified tightening torque.

AFFECTED VIN
DI07-31

Preceding Work: Removal of engine cover
1. Disconnect the fuel pressure sensor connector.
Notice
• Replace the fuel pipes with new ones.

• Plug the openings of hole in the common rail with
sealing caps.
• Check pressure is low before opening the circuit.
2. Unscrew the nuts and remove the fuel supply main pipe
from the fuel line.
Installation Notice
Notice

sealing caps.
3. Unscrew the high fuel pressure line nuts and remove the
fuel pipes.
Installation Notice
Notice

sealing caps.
4. Unscrew the bolts and remove the common rail

asssembly.
Installation Notice
Notice
sealing caps.

AFFECTED VIN
DI07-32
Fuel Pressure Sensor
Fuel pressure sensor on the center of common rail detects instant fuel pressure changes and then sends to ECU. When
received these signals, ECU uses them to control fuel volume and injection time.
The fuel in the rail reaches to sensor diaphragm via blind hole in the pressure sensor and the pressure signal converts to
electrical signal. The signal measured by sensor will be amplified to input to ECU.
This piezo element type sensor changes pressure into electrical signal. Accordingly, when the shape of diaphragm
changes, electrical resistance in the layers on the diaphragm changes then can measure 0.5 ~ 5 V.
• Sensor input voltage: 5 ± 0.1 V
• Output signal voltage of sensor
- 4.055 ± 0.125 V: 1600 ± 15bar
- 0.5 ± 0.04 V: 0 bar

AFFECTED VIN
DI07-33
Sensing area Amplifier

Pres- Physical
Converts to Electrically
sure changes
electric signal amplyfying
signal
<Operation principle of fuel pressure sensor>
Upper area
Output
voltage
Lower area
Pressure (P)
<Sensor voltage>
Piezo resistance
Ground
SIG
REF 5V
Pressure sensor
<Circuit diagram of fuel pressuer sensor>

AFFECTED VIN
DI07-34
Fuel Temperature Sensor
Temperature
Resistance
<Fuel temperature sensor> <Output characteristics of fuel temperature sensor>
Fuel temperature sensor is a NTC resistor that sends fuel temperature to ECU.
In case of NTC resistor, the resistance lowers if engine temperature rises so the ECU detects lowering signal voltages.
Fuel temperature sensor is installed on the fuel return line to correct pressure after measuring fuel temperature. 5V is
supplied to the sensor and voltage drop by temperature is delivered to ECU to measure the fuel temperature through
analog-digital converter (ADC).
Notice
Fuel temp sensor not to be dismounted.
Signal
Ground
<Circuit diagram of fuel temperature sensor>
HFM Sensor
- Refer to “Intake System”

- Refer to “Engine Assembly”
Knock Sensor
Camshaft Position Sensor


AFFECTED VIN
DI07-35
INJECTOR
The C2I labels including injector characteristics are attached in each injector. These C2I values should be input to ECU
by using SCAN-100 when replacing the ECU or injectors.
Special cautions:
1. Plug the openings of hoses and pipes with the sealing caps.
2. Replace the copper washer with new one plus injector holder bolt & washer.
3. Tighten the injector holder bolts with the specified tightening torque.
4. Be careful not to drop the injector.
Specifications
Length: · Injector body 181.35 mm
· Injector nozzle 22.155 mm
Nozzle basic: 5 Holes, 146°C Cone Angle,
840 mm3/min
Control: PWM type (solenoid injector)
Edge filter
Tightening: Clamping by fork
Leak off nipple Fuel return: Nipple
C2I label
Nozzle holder body
Bobbin
C2I value
Control valve
Cap nut Adaptor plate
Nozzle body
Washer
Nozzle needle

AFFECTED VIN
DI07-36
The maximum injection pressures are approximately 1,600 bar. The forces to be overcome in order to lift the needle of
the injector are therefore very large. Because of this, it is impossible to directly control the injector by using an electro-
magnetic actuator, unless very high currents are used, which would be incompatible with the reaction times required for
the multiple injections. The injector is therefore indirectly controlled by means of a valve controlling the pressurizing or
discharging of the control chamber located above the needle:
• When the needle is required to lift (at the start of injection): the valve is opened in order to discharge the control
chamber into the back leak circuit.
• When the needle has to close (at the end of injection): the valve closes again so that pressure is re-established in
the control chamber.
Valve Valve
In order to guarantee response time and minimum energy
consumption:
• The valve must be as light as possible.
Volume Contact
under making seal • The valve stroke must be as short as possible.
high
pressure • The effort needed to move the valve must be minimal, which
Depressuriza-
tion grooves means that the valve must be in hydraulic equilibrium in
Valve
Volume under the closed position.
Spill
vacuum
orifice Spring pressure ensures contact between the valve and its
seat. To lift the valve, it is therefore required to overcome the
force being applied by this spring.
Spacer Spacer
The spacer is situated underneath the valve support. It inte-
grates the control chamber and the three calibrated orifice
INO inlet SPO spill which allow operation of the injector. These orifices are:
irifice orifice
• The injector supply orifice (Nozzle Path Orifice: NPO)
• The control chamber discharge orifice (Spill Orifice: SPO)
• The control chamber filling orifice (Inlet Orifice: INO)
Control
NOP nozzle
chamber
path orifice

AFFECTED VIN
DI07-37
Principle of Operation
Ff
Ff= =pressure * space
S
(Ff rail * S)
(Ff==PPrail S)
Fo = pressure * space
Fo ==Prail * S)
(Fo
(Fo = Prail A)
Valve closed Valve opens Valve open Valve closes Valve closed
Needle closed Needle closed Needle opens Needle open Needle closed
No injection No injection Start of injection End of injection No injection
Injector at rest
The valve is closed. The control chamber is subject to the rail
pressure.
The pressure force applied by the fuel onto the needle is:
Ff = S * Prail
The needle is closed and hence there is no fluid circulation
through the NPO orifice. While static, the nozzle produces no
pressure drop. The cone of the needle is therefore subject to
the rail pressure. The force applied by the fuel to the needle is:
Fo = A * Prail
Since Ff > Fo, the needle is held in the closed position. There
is no injection.
Solenoid valve control

When the solenoid valve is energized, the valve opens. The
fuel contained in the control chamber is expelled through the * S: The area of the flat upper surface of the injector’s needle
discharge orifice known as the Spill Orifice (SPO). * A: The area of the needle surface situated above the section
of contact between the needle and its seat
As soon as Ff > Fo, the needle remains held against its seat * Ff: The force applied by the fuel onto section “S”
and there is no injection. * Fo:The force applied by the fuel onto section “A”

AFFECTED VIN
DI07-38
Start of injection
As soon as Ff < Fo, or in other words:
Pcontrol < Prail * A/S
The needle lifts and injection begins. As long as the valve is open, the injector’s needle remains lifted. When injection
begins, fuel circulation is established to feed the injector. The passage of the fuel through the inlet orifice of the injector
(similar to a nozzle) leads to a pressure drop which depends on the rail pressure.
When the rail pressure is at its highest (1600 bar), this pressure drop exceeds 100 bar. The pressure applied to the cone
of the needle (the injection pressure) is therefore lower than the rail pressure.
End of injection
As soon as the solenoid valve is de-energized, the valve closes and the control chamber is filled. Since the needle is
open, the thrust section areas situated on either side of the needle is therefore to apply different pressures to each of
these faces. The pressure in the control chamber cannot exceed the rail pressure, so it is therefore necessary to limit
the pressure applied to the needle’s cone. This pressure limitation is achieved by the NPO orifice which produces a
pressure drop when fuel is passing through it.
Prail * S (Prail - P) * S
When static, this pressure drop is zero. When the pressure in the control chamber becomes higher than the pressure
applied to the needle’s cone, the injection stops.

AFFECTED VIN
DI07-39
Injecting Process
Fuel is delivered to the injector
Delivered fuel is passed

through supply orifice (1) and
control chamber orifice (2)
The fuel is delivered to the

volume under high pressure
through the spill orifice (3)

AFFECTED VIN
DI07-40
The fuel is delivered to the

control chamber (4) in spacer
The fuel begins to get into the

nozzle needle (5)
The nozzle needle is filled with

fuel and close the valve (6) by
increased pressure

AFFECTED VIN
DI07-41
The pressure is delivered to the

spill orifice (3)
The pressure is delivered to the

control chamber (7) and the
nozzle needle (8)
The nozzle needle starts to open

and inject the fuel

AFFECTED VIN
DI07-42
The nozzle needle blocks the

control chamber (9)
The valve opens due to the

pressure decreases (10)
The pressure is delivered to

control chamber (11)

AFFECTED VIN
DI07-43
It pushes the nozzle needle and

the control chamber opens (12)
The nozzle closes (13)

AFFECTED VIN
DI07-44
Fuel pressure
Fuel pressure
• Minimum operating pressure: start injection over 100 bar
• Maximum operating pressure: 1,600 bar (max. operating pressure in normal conditions)
• Max overpressure: 2,100 bar
Maximum fuel volume at each injector cycle

• Pilot Injection 5 mm3
• Main Injection 85 mm3 (within 200 ~ 1,600 bar)
Main injection
Pilot injection
Small injection separation
• Small injection separation: min. 200

Opening delay definition (duration between the end of pilot injection and start of
main injection)
• Opening Delay
10%
signal
Injection rate
: Delayed time from applying operating voltage to start of
amplitude
Injector drive pulse injection
10%
signal • Adjustment of feedback injection volume: C2I
amplitude
Time ( )

AFFECTED VIN
DI07-45
Injector control
Current
Peak pull current
= 22.0 A
Through pull
current = 7.5 A Peak hold current
= 22.0 A
Through hold current
= 7.5 A
Time
Pull-in period Hold period
The control current of the coil takes the following form:

The low current allows the Joule effect losses in the ECU and injector to be reduced. The call current is higher than the
hold current because during the hold phase.
• The air gap between the valve and the coil is reduced and the electromagnetic force to be applied to the valve can
thus be reduced. It is no longer necessary to overcome the valve inertia.
Note
Joule Effect: The principle that the heat produced by an electric current is equal to the product of the resistance
of the conductor, the square of the current, and the time for which it flows.
I: current (A)
R: resistance (Ω)
T: time (sec)
H: calori (cal)
Heat capacity (H) = 0.24 I 2RT

AFFECTED VIN
DI07-46
Fuel Injection
Other than conventional diesel engine, common diesel engine use two steps injection as follows:
• Pilot Injection
• Main Injection
In above two step injection, the fuel injection volume and injection timing is calibrated according to fuel pressure and fuel
temperature.
Pilot injection
Before starting main injection, a small amount of fuel is injected to help proper combustion. This injection is for reducing
the engine noise and vibration.
In other words, it makes the pressure increase in combustion chamber during combustion smooth to reduce the engine
noise and vibration (suppressing the surging). Basic values for pilot injection are adjusted according to the coolant
temperature and intake air pressure.
Needle lift (k)

Cylinder pressure (p)
Needle lift (k)

Cylinder pressure (p)
Angle of crankshaft Angle of crankshaft

<Characteristic curve of discharge without pilot injection> <Characteristic curve of discharge with pilot injection>
Main injection
Actual output from engine is achieved by main injection.
The main injection determines the pilot injection has been occurred, then calculates the injection volume. Accelerator
pedal sensor, engine rpm, coolant temperature, intake air temperature and atmospheric pressure are basic date to
calculate the fuel injection volume in main injection.
Pressure
1. Pilot injection
2. Main injection
1a. Ignition pressure with pilot injection
2a. Ignition pressure without pilot injection
Angle of crankshaft
<Characteristic curve of combustion chamber pressure during pilot injection>

AFFECTED VIN
DI07-47
Preceding Work: Removal of engine cover

1. Disconnect the injector return hose.
Notice
Plug the openings with sealing caps.
2. Remove the relevant connector for the injector.
3. Unscrew the bolts and remove the fuel pipes.
Installation Notice

• Plug the openings of the common rail with sealing
caps.
4. Unscrew the injector holder bolts.
Installation Notice
9 ± 1.0 Nm
Tightening torque
180° ± 10°
• Replace the bolts and washer with new ones.
5. Disconnect the injector holder.
6. Remove the injectors with a special tool.

Notice
• Plug the openings of the injectors with sealing caps.
• Pull the dropped washer out from the engine with
a special tool.
• Clean carbon deposite in hole with specific tool.
8. Do not forget to update C2I with Scan 100 and cross old
C2I on label fitted on engine.
Notice
Replace the copper washer, holder bolts and washer
and fuel supply pipes with new ones.
AFFECTED VIN
DI07-48
ECU Wiring Diagram

AFFECTED VIN
DI07-49
REMOVAL AND INSTALLATION OF FUEL TANK

Preceding Works: Positioning the vehicle on the service lift and placing the chocks under the wheels

AFFECTED VIN
DI07-50
Components Locator
Fuel filler cap

Fuel sender cap
2-way cut valve
Fuel sender assembly
FFH supply tube

Air vent tube
Fuel filler assembly
Fuel
return line
Fuel
supply line Wiring Ventilation tube
Fuel tank module
Fuel tank strap

AFFECTED VIN
DI07-51
1. Disconnect the fuel supply hose, fuel return hose, FFH supply pipe and connector.
2. Unscrew the bolts and remove the fuel filler pipe from the fuel filler opening.
3. Install the safety jack under the fuel tank and remove the bolts (12mm x 4) from the fuel tank.

AFFECTED VIN
DI07-52
4. Carefully lower the safety jack with the fuel tank.
Caution
• Be careful not to drop the fuel tank while removing it.

AFFECTED VIN
DI07-53
5. Remove the sender gauge assembly from the removed fuel tank.
(1) Disconnect the connector from the fuel tank cap.
(2) Remove the fuel hose (FFH fuel pump, Fuel supply)
(3) Remove the fuel sender gauge cap screw.

AFFECTED VIN
DI07-54
(4) Remove the fuel sender gauge assembly from the fuel
tank.
6. Always check the gauge operating conditions when replacing the components or repairing the system.
Caution
The fuel system (fuel tank) related operation may cause a fire. Always prepare the fire-fighting equipment
before starting the fuel system related operation.

AFFECTED VIN
DI08-1
SECTION
00 DI08
ENGINE CONTROL SYSTEM
Table of Contents
SENSORS FOR DIAGNOSIS ...................................... DI08-2

Engine ECU and other components ....................... DI08-2
Top view .................................................................. DI08-3
Side view ................................................................. DI08-4
ENGINE CONTROL SYSTEM ..................................... DI08-5
ECU ......................................................................... DI08-5
Fuel pressure control ........................................... DI08-11
Fuel injecstion control ........................................... DI08-12
Fuel flow control .................................................... DI08-13
Individual injector calibration (C2I) ....................... DI08-18
Minimum drive pulse (MDP) learning .................... DI08-20
Other components ................................................ DI08-21
ENGINE CONTROL SYSTEM CHANGED BY

AFFECTED VIN
DI08-2
SENSORS FOR DIAGNOSIS
ENGINE ECU AND OTHER COMPONENTS

ECU/barometric Camshaft position Fuel filter Accelerator pedal
sensor sensor (water sensor) sensor
HFM sensor / intake air

temperature sensor Preheating relay Main relay
CHANGED BY ENGINE CONTROL SYSTEM

AFFECTED VIN
DI08-3
TOP VIEW
Booster pressure
Fuel pressure sensor sensor
Injectors (5) Glow Plugs (5)

AFFECTED VIN
DI08-4
SIDE VIEW
Coolant temperature Knock sensors (2)

sensor
Fuel pressure Crankshaft position

Fuel temperature sensor regulating valve sensor

AFFECTED VIN
DI08-5
ENGINE CONTROL SYSTEM
ECU
ECU receives signals from sensors through data line and then performs effective engine air-fuel ratio controls based on
those signals.
Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines
injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal that generated by
variable resistance changes in accelerator pedal sensor.
Air flow (hot film) sensor detects intake air volume and then transmits to ECU. Especially, the engine ECU controls the
air-fuel ratio by recognizing instant air volume changes through air flow sensor to pursue low emission gases (EGR valve
control). Furthermore, the ECU uses signals from coolant temperature and air temperature sensor, booster pressure
sensor and atmospheric pressure sensor as compensation signal to respond to injection start and pilot injection set
values and to various operations and variables.

AFFECTED VIN
DI08-6
Pin No. Description Pin No. Description

1 Engine ground 40 Fuel filter water detection sensor
2 Engine ground 41 RPM signal output
3 Main power (IG 1) 42
4 Main power (IG 1) 43
5 Main power (IG 1) 44 Knock sensor signal (#2)
6 Rail pressure sensor power supply 45 Knock sensor signal (#1)
7 46 Knock sensor ground (#1)
8 47
9 ECU power hold relay 48
10 49
11 50 Auto cruise result signal
12 ABD signal 51
13 52
14 ACC 2 sensor ground 53 ACC 1 sensor ground
15 54 CAN- H1
16 55
17 Auto cruise OFF 56
18 Auto cruise safety switch 57 ACC 2 sensor power supply
19 A/C pressure signal 58 Brake lamp switch
20 Fuel filter water detection warning lamp 59
21 Remote starter output 60 Vehicle speed indication lamp
22 Glow plug control 61 Preheater #1
23 Glow plug warning lamp 62 Preheater #2
24 63 Knock sensor ground (#2)
25 Rail pressure sensor signal 64 HFM sensor (air temperature sensor)
26 Rail pressure sensor ground 65
27 66 Engine ground
28 Engine ground 67 Auto cruise deceleration signal
29 68
30 69
31 Auto cruise acceleration signal 70
32 ACC 2 sensor signal 71 ACC 1 sensor signal
33 72 ACC 1 sensor power supply
34 K-LINE #1 73 CAN -LO
35 K-LINE #2 74
36 Vehicle speed sensor signal input 75
37 IG 1 76 A/C cycling pressure switch
38 Clutch pedal switch 77 Brake pedal switch
39 78 Trip computer

AFFECTED VIN
DI08-7

79 A/C relay 101 Coolant temperature signal
80 Cooling fan LOW 102 Coolant temperature sensor ground
81 Cooling fan HIGH 103 Camshaft position sensor signal
82 Crankshaft position sensor (-) 104 Camshaft position sensor ground
83 HFM sensor (air mass sensor) 105 Engine check warning lamp
84 HFM sensor (ground) 106
85 107 Blower switch
86 HFM sensor (power supply) 108 Booster pressure sensor power supply
87 IMV (fuel pressure regulating valve) 109 Fuel temperature sensor signal
88 Engine ground 110 Fuel temperature sensor ground
89 111 Camshaft position sensor power supply
90 Crankshaft position sensor (+) 112 Immobilizer
91 113 Engine check warning lamp
92 114 Injector #1
93 115 Injector #4
94 116 Injector #3
95 Waste gate actuator 117 Injector ground (#1, 3, 4)
96 EGR valve 118 Injector ground (#2, 5)
97 119
98 120 Injector #5
99 Booster pressure sensor signal 121 Injector #2
100 Booster pressure sensor ground

AFFECTED VIN
DI08-8
ECU Inputs·Outputs
Inputs Control Output
Booster pressure sensor

Atmospheric pressure sensor Injector
(Built-in ECU) EGR system
Air flow sensor (HFM) Fuel pressure regulating valve (IMV)
Coolant temperature sensor Electrical fan control (Low/High-speed)
Fuel temperature sensor E A/C compressor relay
Fuel pressure sensor Glow plug relay
Fuel filter water sensor Immobilizer
Knock sensor
C Warning lights
crankshaft position sensor (Water warning light, glow plug indica-
camshaft position sensor
U tor light, engine warning light)
Accelerator sensor Preheater (auxiliary heater)
Vehicle speed sensor K - line
Switch input signal CAN communication
(IG, brake, clutch, A/C signal, A/C Self-diagnosis
compressor)
Structure and Function of ECU

Function of ECU
ECU receives and analyzes signals from various sensors and then modifies those signals into permissible voltage levels
and analyzes to control respective actuators.
ECU microprocessor calculates injection period and injection timing proper for engine piston speed and crankshaft
angle based on input data and stored specific map to control the engine power and emission gas.
Output signal of the ECU microprocessor drives pressure control valve to control the rail pressure and activates
injector solenoid valve to control the fuel injection period and injection timing; so controls various actuators in
response to engine changes. Auxiliary function of ECU has adopted to reduce emission gas, improve fuel economy
and enhance safety, comforts and conveniences. For example, there are EGR, booster pressure control, autocruise
(export only) and immobilizer and adopted CAN communication to exchange data among electrical systems
(automatic T/M and brake system) in the vehicle fluently. And Scanner can be used to diagnose vehicle status and
defectives.
Operating temperature range of ECU is normally -40 ~ +85°C and protected from factors like oil, water and electromag-
netism and there should be no mechanical shocks.
To control the fuel volume precisely under repeated injections, high current should be applied instantly so there is
injector drive circuit in the ECU to generate necessary current during injector drive stages.
Current control circuit divides current applying time (injection time) into full-in-current-phase and hold-current-phase and
then the injectors should work very correctly under every working condition.

AFFECTED VIN
DI08-9
Control Function of ECU

• Controls by operating stages
: To make optimum combustion under every operating stage, ECU should calculate proper injection volume in
each stage by considering various factors.
• Starting injection volume control
: During initial starting, injecting fuel volume will be calculated by function of temperature and engine cranking
speed.
Starting injection continues from when the ignition switch is turned to ignition position to till the engine reaches
to allowable minimum speed.
• Driving mode control
: If the vehicle runs normally, fuel injection volume will be calculated by accelerator pedal travel and engine rpm
and the drive map will be used to match the drivers inputs with optimum engine power.

AFFECTED VIN
DI08-10
ECU - Removal and Installation

1. Flip up the front passenger’s seat and remove the ECU
cover nuts.
2. Remove the ECU bracket nuts.
3. Unscrew the ECU connect bolt and remove the ECU

assembly.

5. Backup the below data with SCAN-100 when replacing
the ECU.
- Current ECU data
- Vehicle Identification Number (VIN)
- Variant coding data
- Then, input the data into new ECU. For immobilizer
equipped vehicle, additional coding operation is
necessary.

AFFECTED VIN
DI08-11
FUEL PRESSURE CONTROL

Fuel Pressure Control Elements
Pressure control consists of 2 principle modules.
• Determines rail pressure according to engine operating conditions.
• Controls IMV to make the rail pressure to reach to the required value.
Pressure in the fuel rail is determined according to engine speed and load on the engine. The aim is to adapt the
injection pressure to the engine’s requirements.
• When engine speed and load are high
: The degree of turbulence is very great and the fuel can be injected at very high pressure in order to optimize
combustion.
• When engine speed and load are low
: The degree of turbulence is low. If injection pressure is too high, the nozzle’s penetration will be excessive and part
of the fuel will be sprayed directly onto the sides of the cylinder, causing incomplete combustion. So there occurs
smoke and damages engine durability.
Fuel pressure is corrected according to air temperature, coolant temperature and atmospheric pressure and to take
account of the added ignition time caused by cold running or by high altitude driving. A special pressure demand is
necessary in order to obtain the additional flow required during starts. This demand is determined according to injected
fuel and coolant temperature.
Fuel Pressure Control

Rail pressure is controlled by closed loop regulation of IMV. A mapping system – open loop – determines the current
which needs to be sent to the actuator in order to obtain the flow demanded by the ECU. The closed loop will correct the
current value depending on the difference between the pressure demand and the pressure measured.
• If the pressure is lower than the demand, current is reduced so that the fuel sent to the high pressure pump is
increased.
• If the pressure is higher than the demand, current is increased so that the fuel sent to the high pressure pump is
reduced.
Flow demand
IMV current
Open
Engine speed
IMV
Current
Rail pressure
demand
Error PIG Correction

governor
Measured rail
pressure

AFFECTED VIN
DI08-12
FUEL INJECSTION CONTROL

Fuel Injection Control
Injection control is used in order to determine the characteristics of the pulse which is sent to the injectors.
Injection control consists as below.
• Injection timing
• Injection volume
• Translating fuel injection timing and injection volume into values which can be interpreted by the injector driver.
- a reference tooth (CTP)
- the delay between this tooth and the start of the pulse (Toff)
- the pulse time (Ton)
Main injection timing control

The pulse necessary for the main injection is determined as a function of the engine speed and of the injected flow.
The elements are;
• A first correction is made according to the air and coolant temperatures.
This correction makes it possible to adapt the timing to the operating temperature of the engine. When the engine is
warm, the timing can be retarded to reduce the combustion temperature and polluting emissions (NOx). When the
engine is cold, the timing advance must be sufficient to allow the combustion to begin correctly.
• A second correction is made according to the atmospheric pressure.
This correction is used to adapt the timing advance as a function of the atmospheric pressure and therefore the altitude.
• A third correction is made according to the coolant temperature and the time which has passed since starting.
This correction allows the injection timing advance to be increased while the engine is warming up (initial 30 seconds).
The purpose of this correction is to reduce the misfiring and instabilities which are liable to occur after a cold start.
• A fourth correction is made according to the pressure error.
This correction is used to reduce the injection timing advance when the pressure in the rail is higher than the
pressure demand.
• A fifth correction is made according to the rate of EGR.
This correction is used to correct the injection timing advance as a function of the rate of exhaust gas recirculation.
When the EGR rate increases, the injection timing advance must in fact be increased in order to compensate for the
fall in termperature in the cylinder.
During starting, the injection timing must be retarded in order to position the start of combustion close to the TDC. To do
this, special mapping is used to determine the injection timing advance as a function of the engine speed and of the
water temperature. This requirement only concerns the starting phase, since once the engine has started the system
must re-use the mapping and the corrections described previously.
Pilot injection timing control

The pilot injection timing is determined as a function of the engine speed and of the total flow.
The elements are;
• A first correction is made according to the air and coolant temperatures.
This correction allows the pilot injection timing to be adapted to the operating temperature of the engine.
This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the
altitude.
During the starting phase, the pilot injection timing is determined as a function of the engine speed and of the coolant
temperature.

AFFECTED VIN
DI08-13
FUEL FLOW CONTROL

Main Flow Control
The main flow represents the amount of fuel injected into the cylinder during the main injection. The pilot flow represents
the amount of fuel injected during the pilot injection.
The total fuel injected during 1 cycle (main flow + pilot flow) is determined in the following manner.
: The driver’s demand is compared with the value of the minimum flow determined by the idle speed controller.
• When the driver depress the pedal, it is his demand which is taken into account by the system in order to
determine the fuel injected.
• When the driver release the pedal, the idle speed controller takes over to determine the minimum fuel which
must be injected into the cylinder to prevent the enigne from stalling.
It is therefore the greater of these 2 values which is retained by the system. This value is then compared with the lower
flow limit determined by the ASR trajectory control system. As soon as the injected fuel becomes lower than the flow
limit determined by the ASR trajectory control system, the antagonistic torque (engine brake) transmitted to the drive
wheels exceeds the adherence capacity of the vehicle and there is therefore a risk of the drive wheels locking. The
system thus chooses the greater of these 2 values (main flow & pilot flow) in order to prevent any loss of control of the
vehicle during a sharp deceleration.
This value is then compared with the flow limit determined by the cruise control. As soon as the injected fuel becomes
lower than the flow limit determined by the cruise control, the vehicle’s speed falls below the value required by the driver.
The system therefore chooses the greater of these 2 values in order to maintain the speed at the required level.
This valve is then compared with the flow limit determined by the flow limitation strategy. This strategy allows the flow to
be limited as a function of the operating conditions of the engine. The system therefore chooses the smaller of these 2
values in order to protect the engine. This value is then compared with the fuel limit determined by the ASR trajectory
control system.
As soon as the injected fuel becomes higher than the fuel limit determined by the ASR trajectory control system, the
engine torque transmitted to the wheels exceeds the adhesion capacity of the vehicle and there is a risk of the drive
wheels skidding. The system therefore chooses the smaller of the two values in order to avoid any loss of control of the
vehicle during accelerations.
The anti-oscillation strategy makes it possible to compensate for fluctuations in engine speed during transient conditions.
This strategy leads to a fuel correction which is added to the total fuel of each cylinder. The correction is determined
before each injection as a function of the instantaneous engine speed.
A switch makes it possible to change over from the supercharge fuel to the total fuel according to the state of the engine.
• Until the stating phase has finished, the system uses the supercharged fuel.
• Once the engine changes to normal operation, the system uses the total fuel.
The main fuel is obtained by subtracting the pilot injection fuel from the total fuel.
A mapping determines the minimum fuel which can control an injector as a function of the rail pressure. As soon as the
main fuel falls below this value, the fuel demand changes to 0 because in any case the injector is not capable of injecting
the quantity demand.

AFFECTED VIN
DI08-14
Driver’s request
Idle speed controller
ASR traction control
Cruise control
Flow limit
Speed limiter
ASR traction control

Engine status
Anti-oscillation strategy
Overflow
Programmed engine stop
Main flow < controllable min.flow
Pilot injection flow
Main flow request

0
Driver Demand
The driver demand is the translation of the pedal position into the fuel demand. It is calculated as a function of the pedal
position and of the engine speed. The driver demand is filtered in order to limit the hesitations caused by rapid changes
of the pedal position. A mapping determines the maximum fuel which can be injected as a function of the driver demand
and the rail pressure. Since the flow is proportional to the injection time and to the square root of the injection pressure,
it is necessary to limit the flow according to the pressure in order to avoid extending the injection for too long into the
engine cycle. The system compares the driver demand with this limit and chooses the smaller of the 2 values. The driver
demand is then corrected according to the coolant temperature. This correction is added to the driver demand.

AFFECTED VIN
DI08-15
Idle Speed Controller

The idle speed controller consists of 2 principal modules:
• The first module determines the required idle speed according to:
- The operating conditions of the engine (coolant temperature, gear engaged)
- Any activation of the electrical consumers (power steering, air conditioning, others)
- The battery voltage
- The presence of any faults liable to interface with the rail pressure control or the injection control. In this case,
the accelerated idle speed is activated to prevent the engine from stalling when operating in degraded mode.
- It is possible to increase or to reduce the required idle speed with the aid of the diagnostic tool.
• The second module is responsible for providing closed loop control of the engine’s idle speed by adapting the
minimum fuel according to the difference between the required idle speed and the engine speed.
Flow Limitation
The flow limitation strategy is based on the following strategies:
• The flow limitation depending on the filling of the engine with air is determined according to the engine speed and the
air flow. This limitation allows smoke emissions to be reduced during stabilized running.
• The flow limitation depending on the atmospheric pressure is determined according to the engine speed and the
atmospheric pressure. It allows smoke emissions to be reduced when driving at altitude.
• The full load flow curve is determined according to the gear engaged and the engine speed. It allows the maximum
torque delivered by the engine to be limited.
• A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are
detected by the system. In this case, and depending on the gravity of the fault, the system activates:
- Reduced fuel logic 1: Guarantees 75 % of the performance without limiting the engine speed.
- Reduced fuel logic 2: Guarantees 50 % of the performance with the engine speed limited to 3,000 rpm.
- Reduce fuel logic 3: Limits the engine speed to 2,000 rpm.
The system chooses the lowest of all these values.
A correction depending on the coolant temperature is added to the flow limitation. This correction makes it possible to
reduce the mechanical stresses while the engine is warming up. The correction is determined according to the coolant
temperature, the engine speed and the time which has passed since starting.
Superchager Flow Demand

The supercharge flow is calculated according to the engine speed and the coolant temperature. A correction depending
on the air temperature and the atmospheric pressure is made in order to increase the supercharge flow during cold
starts. It is possible to alter the supercharge flow value by adding a flow offset with the aid of the diagnostic tool.
Pilot flow control

The pilot flow represents the amount of fuel injected into the cylinder during the pilot injection. This amount is determined
according to the engine speed and the total flow.
• A first correction is made according to the air and water temperature.
This correction allows the pilot flow to be adapted to the operating temperature of the engine. When the engine is
warm, the ignition time decreases because the end-of-compression temperature is higher. The pilot flow can therefore
be reduced because there is obviously less combustion noise when the engine is warm.
This correction is used to adapt the pilot flow according to the atmospheric pressure and therefore the altitude.
During starting, the pilot flow is determined on the basis of the engine speed and the coolant temperature.

AFFECTED VIN
DI08-16
Cylinder Balancing Strategy

Balancing of the point to point flows
The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 succes-
sive injectors.
• The instantaneous speeds on two successive injections are first calculated.
• The difference between these two instantaneous speeds is then calculated.
• Finally, the time to be added to the main injection pulse for the different injectors is determined. For each injector,
this time is calculated according to the initial offset of the injector and the instantaneous speed difference.
Detection of an injector which has stuck closed

The cylinder balancing strategy also allows the detection of an injector which has stuck closed. The difference in instantaneous
speed between 2 successive injections then exceeds a predefined threshold. In this case, a fault is signaled by the system.
Accelerometer Strategy
Resetting the pilot injection
The accelerometer is used to reset the pilot injection flow in closed loop for each injector. This method allows the
correction of any injector deviations over a period of time. The principle of use of the accelerometer is based on the
detection of the combustion noises.
The sensor is positioned in such a way as to receive the maximum signal for all the cylinders. The raw signals from the
accelerometer are processed to obtain a variable which quantifies the intensity of the combustion. This variable, known
as the ratio, consists of the ratio between the intensity of the background noise and the combustion noise.
• A first window is used to establish the background noise level of the accelerometer signal for each cylinder. This
window must therefore be positioned at a moment when there cannot be any combustion.
• The second window is used to measure the intensity of the pilot combustion. Its position is such that only the
combustion noises produced by the pilot injection are measured . It is therefore placed just before the main injection.
The accelerometer does not allow any evaluation of the quantity injected. However, the pulse value will be measured
when the injector starts injection and this pulse value is called the MDP (Minimum Drive Pulse). On the basis of this
information, it is possible to efficiently correct the pilot flows. The pilot injection resetting principle therefore consists of
determining the MDP, in other words the pulse corresponding to the start of the increase in value of the ratio (increase
of vibration due to fuel combustion).
Cylinder pressure
Needle lift
Major pilot injection Ratio
Minor pilot injection
No pilot injection
No injection

AFFECTED VIN
DI08-17
This is done periodically under certain operating conditions. When the resetting is finished, the new minimum pulse
value replaces the value obtained during the previous resetting. The first MDP value is provided by the C2I. Each
resetting then allows the closed loop of the MDP to be updated according to the deviation of the injector.
Detection of leaks in the cylinders

The accelerometer is also used to detect any injector which may have stuck open. The detection principle is based on
monitoring the ratio. If there is a leak in the cylinder, the accumulated fuel self-ignites as soon as the temperature and
pressure conditions are favorable (high engine speed, high load and small leak).
This combustion is set off at about 20 degrees before TDC and before main injection.
The ratio therefore increases considerably in the detection window. It is this increase which allows the leaks to be
detected. The threshold beyond which a fault is signaled is a percentage of the maximum possible value of the ratio.
Because of the severity of the recovery process (engine shut-down), the etection must be extremely robust.
An increase in the ratio can be the consequence of various causes:
• Pilot injection too strong
• Main combustion offset
• Fuel leak in the cylinder
If the ratio becomes too high, the strategy initially restricts the pilot injection flow and retards the main injection. If the
ratio remains high despite these interventions, this shows that a real leak is present, a fault is signaled and the engine
is shut down.
Detection of an accelerometer fault

This strategy permits the detection of a fault in the sensor or in the wiring loom connecting the sensor to the ECU. It is
based on detection of the combustion. When the engine is idling, the detection window is set too low for the combustion
caused by the main injection. If the ratio increases, this shows that the accelerometer is working properly, but otherwise
a fault is signaled to indicate a sensor failure. The recovery modes associated with this fault consist of inhibition of the
pilot injection and discharge through the injectors.

AFFECTED VIN
DI08-18
INDIVIDUAL INJECTOR CALIBRATION (C2I)

Injected fuel is proportional to square root of injection time and rail pressure.
It is function between pulse and rail pressure and fuel injection curve is called injector characteristics curve having the
following shape.
Delivery (mm3/st)
Drive pulse (µsec)
Common rail injectors are very accurate components. They are able to inject fuel delivery between 0.5 to 100 mg/str
under pressure varying from 150 to 1600 bar.
This high level of accuracy requires very low machining tolerances (few ).
Nevertheless, due to the machining dispersion, the loss of charge through the functional orifices, the friction between
moving parts and electromagnetic field level are different from one injector to the other. So, the difference of fuel delivery
for the same pressure and the same pulse can reach 5 mg/str from one injector to the other. It is impossible to control
efficiently the engine with such a dispersion between the different injectors. It is necessary to add a correction that
allows injecting the demanded fuel delivery whatever the initial hydraulic characteristics of the injector is. The method
consists in correcting the pulse that is applied to the injector with an offset that depends on the initial hydraulic map of
the injector. So, the pulse should be corrected according to characteristics of each injector.

AFFECTED VIN
DI08-19
C2I is composed of models on these characteristics of injectors.

C2I consists of 16-digit; composed of numbers from 1 to 9 and alphabets from A to F. ECU remembers C2I, character-
istics of each injector, to make the most optimal fuel injection.
• When replacing the injector, C2I code on the top of new injector should be input into ECU because the ECU is
remembering the injector’s C2I value. If C2I is not input, engine power drops and occurs irregular combustion.
• When ECU is replaced, C2I code of every injector should be input. If not, cannot accelerate the vehicle even when
the accelerator pedal is depressed.
C2I Number
(16 digits)
C2I
value
For coding of C2I, refer to “Diagnosis” section

AFFECTED VIN
DI08-20
MINIMUM DRIVE PULSE (MDP) LEARNING

When the pulse value that the injector starts injection is measured, it is called mininum drive pulse (MDP). Through MDP
controls, can correct pilot injections effectively. Pilot injection volume is very small, 1 ~ 2 mm/str, so precise control of
the injector can be difficult if it gets old. So there needs MDP learning to control the very small volume precisely through
learning according to getting older injectors.
Learning Conditions
Coolant temperature > 75°C
Vehicle speed > 50 Km/h (over 5 seconds)
Intake manifold pressure > 0.7 bar
Engine speed > 2,500 rpm
Battery voltage 10 V < MDP < 16 V
Fuel temperature 0 < fuel temperature < 80°C
Initial MDP learning on each injector 5 seconds
Trouble Codes
Trouble code Description Diagnosis
P1171 Fault MDP learning on injector No. 1
P1173 Fault MDP learning on injector No. 3 • Check each injector

AFFECTED VIN
DI08-21
OTHER COMPONENTS
Accelerator Pedal Sensor
<Location of accelerator pedal sensor> <When depressing the accelerator pedal

and brake pedal simultaneously>
Accelerator pedal sensor changes accelerator pedal position into electrical signal and then sends to ECU to let know
the driver’s demand. There are 2 sensors in the accelerator pedal sensor. Accelerator pedal No.1 (ACC 1) sensor signal
determines fuel injection volume and injection timing during driving, and accelerator pedal No. 2 (ACC 2) sensor signal
compares whether the No. 1 sensor signal value is correct.
If accelerator pedal No. 1 and 2 sensors are defective, ECU remembers defect code, and acceleration responses are
getting bad and engine rpm hardly increases.
Notice
When depressing the accelerator pedal and brake pedal simultaneously while driving, the acceleration response
will be diminished abruptly and cannot drive with over 70 km/h even though depressing the accelerator pedal
to its end. At this time, the trouble code of “P-1124 Accelerator pedal sensor stuck” is stored into ECU. If
depressing the accelerator pedal over 3 times, it will be resumed to normal condition.
* For detailed information, refer to “Diagnosis” section in this manual.
Signal 1
Ground
Signal 2
Ground
<Circuit diagram of Accelerator pedal sensor>

AFFECTED VIN
DI08-22
Coolant Temperature Sensor
Temp.
Resistance
<Coolant temperature sensor> <Output characteristics of coolant temperature
sensor>
Coolant temperature sensor is a NTC resister that sends coolant temperature to ECU.
NTC resister has characteristics that if the engine temperature rises, the resistance lowers so the ECU detects lowering
signal voltages.
If the fuel injected into the engine through injector has more turbulence, then combusts very well. However, if engine
temperature is too low, the fuel injected as foggy state forms big compounds causing incomplete combustion. So the
sensor detects coolant temperature and changes coolant temperature changes into voltage then sends to ECU to
increase the fuel volume during cold start for better starting. And detects engine overheating for fuel volume reduction to
protect the engine.
ECU functions as below with coolant temperature sensor signals.
• When engine is cold, controls fuel volume to correct idle speed.
• When engine is overheated, controls electrical fan and A/C compressor to protect the engine.
• Sends information for emission control.
Temperature (°C) Ω)
NTC 1 Resistance (Ω Ω)
NTC 1 Resistance (Ω
20 2,550 6,062
50 826 1,800
80 321 638
120 123 200
Signal
Auto amp
Ground
<Circuit diagram of coolant temperature sensor>

AFFECTED VIN
DI08-23
Boost Pressure Sensor
Not using terminals
<Location of boost pressure sensor> <Boost pressure sensor>
Boost pressure sensor uses piezo element and uses only 3 terminals out of 6.
It sets fuel injection timing and corrects fuel injection volume according to atmospheric pressure.
The other function is determining EGR operation stops.
• Output voltage calculation
VO = VS x ( P x 0.004 - 0.04)
Voltage (V)
VO : Output voltage
VS : Supply voltage
P : Applying voltage
Pressure (bar)
<Output characteristics of sensor>
Performance proofing pressure range 20 ~ 250 KPa

Performance proofing temperature range - 40 ~ 110°C
Storage proofing temperature range - 40 ~ 125°C
Performance proofing supply voltage 4.85 ~ 5.35 V
Max. consuming current 10 mA (supply voltage at 5.35 V)
Responsibility TR 7ms

AFFECTED VIN
DI08-24
Ground
REF 5V
SIG
<Circuit diagram of booster pressure sensor>
Vehicle Speed Sensor

The ABS or ESP control unit sends the vehicle speed signals to ECU. ECU uses these signals to calculate the vehicle
speed and meter cluster shows signals as vehicle speed.
Function
- Limits idle control correction duty range
- Controls cooling fan ABS
or
- Cuts fuel injection if exceeds max. speed ESP control unit
- Controls vehicle shifting feeling
- Used for exhaust gas control mode CAN communication
<Circuit diagram of vehicle speed sensor>

AFFECTED VIN
DI08-25
Barometric Pressure Sensor

It is built-in the ECU and detects absolute pressure of atmosphere to correct fuel injection timing and injection volume
according to altitude.
Other switches
Brake switch
Brake switch detects brake pedal operations and then sends to engine ECU. It has dual structure with 2 combined
switches and there are brake switch 1 and 2. When these 2 signals are input, engine ECU recognizes as normal brake
signals. These switch signals are related with accelerator pedal sensor operations and used to control the fuel volume
during braking. It means there are no problems in operating accelerator pedal when the brake pedal is operated but the
fuel volume reduces if operates brake pedal while the accelerator pedal is depressed.
Brake pedal switch (NC)
Brake lamp switch (NO)
<Brake switch circuit>
Clutch pedal switch

Clutch pedal switch is installed on the upper of the clutch and sends clutch pedal operations to engine ECU. Contact
type switch allows engine ECU to recognize the shifting points to correct the fuel volume. It means it corrects fluctuation
happens during gear shifting. Another different function is canceling auto cruise function if equipped (auto cruise control
- equipped for export).
Clutch pedal switch (NO)
Engine
ground
<Clutch pedal switch circuit>

AFFECTED VIN
DI09-1
SECTION
00 DI09
ELECTRIC DEVICES
AND SENSORS
Table of Contents
ELECTRIC DEVICES AND SENSORS ........................ DI09-2

Sensors in engine compartment ............................. DI09-2
Electric devices in engine compartment ................. DI09-3
Specifications .......................................................... DI09-4
Circuit diagram of preheating system ..................... DI09-5
Circuit diagram of starting and alternator .............. DI09-6
TROUBLE DIAGNOSIS ............................................... DI09-7
General ................................................................... DI09-7
Alternator ................................................................ DI09-9
Starter ................................................................... DI09-11
Preheating system ................................................ DI09-13
Preheating time relay ............................................ DI09-15
Glow plug .............................................................. DI09-16
SPECIAL TOOLS AND EQUIPMENT ........................ DI09-18
ELECTRIC DEVICES AND SENSORS CHANGED BY

AFFECTED VIN
DI09-2
ELECTRIC DEVICES AND SENSORS
SENSORS IN ENGINE COMPARTMENT
Fuel pressure sensor Booster pressure

sensor
Camshaft position Oil pressure switch

sensor
Coolant temperature Crankshaft position

sensor sensor
Fuel temperature
sensor Knock sensor
CHANGED BY ELECTRIC DEVICES AND SENSORS

AFFECTED VIN
DI09-3
ELECTRIC DEVICES IN ENGINE COMPARTMENT
Alternator Glow plug

Capacity
PTC equipped vehicle
: 12V - 140A
FFH equipped vehicle
: 12V - 115A
Air conditioner compressor Starter

AFFECTED VIN
DI09-4
SPECIFICATIONS
Description Unit Specification
Starter Type - WP220
Output power Kw 2.2
No load test @ 12 volts A 160
Drive pinion speed at no load rpm 4500
Drive pinion speed at load rpm/A 1700/430
Brush length mm 18
Armature diameter mm 55
Armature run-out mm 0.1
Segment groove depth mm 21.7
Alternator Type - NP37
Output voltage / current V/A PTC equipped vehicle: 12V-140A
FFH equipped vehicle: 12V-115A
Regulator type - ←
Regulating voltage V 14.6
Brush Length mm 12.5
Quantity - 2
Wear limit mm 7
Battery Type - MF
Capacity AH 12V - 90AH
Rupture capatity RC 160
Glow plug Type - Seized type
Rated voltage - 11.5
Circuit connection - Parallel
Preheating time sec Max. 60 ~ 90

AFFECTED VIN
DI09-5
CIRCUIT DIAGRAM OF PREHEATING SYSTEM

AFFECTED VIN
DI09-6
CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR

AFFECTED VIN
DI09-7
TROUBLE DIAGNOSIS
GENERAL
No crank • Low battery voltage. • Charging the battery or replace
the battery.
• Battery cable is loose, • Repair or replace the battery
corroded, or damaged. cable.
• Faulty starter motor or starter • Repair or replace the starter
motor circuit is open. motor/starter motor circuit.
• Faulty ignition switch. • Replace the ignition switch.
• Ground short. • Repair the ground short.
Crank ok, but too slow • Low battery voltage. • Charging the battery or replace
the battery.
• Battery cables are loose, • Repair or replace the battery
corroded, or damaged. cable.
• Faulty starter motor. • Repair or replace the starter
motor.
Starter motor does not stop • Faulty starter motor. • Repair or replace the starter
motor.
• Faulty ignition switch. • Replace the ignition switch.
Starter motor running, but not • Broken the clutch pinion gear or • Replace the starter motor.
cranking faulty starter motor.
• Broken the flywheel ring gear. • Replace the flywheel.
• Connected circuit is open. • Repair the open circuit.
Battery discharge • Loosen the generator drive belt. • Adjust the belt tension or replace
the belt.
• The circuit is open or a short. • Repair the open or a short circuit.
• Battery run down. • Replace the battery.
• Open ground circuit. • Repair the open ground circuit.
Charging indicator lamp does not • Charging indicator lamp is blown • Repair or replace the charging
work when the ignition switch on or fuse is blown. indicator lamp/fuse.
(engine does not work) • Faulty ignition switch. • Replace the ignition switch.
• Alternator ground circuit is open • Repair the circuit.
or a short.
Charging indicator lamp does not • Battery cable is corroded or • Repair or replace the battery
put out lights after starting the damaged. cable.
engine • Loosen the generator drive belt. • Adjust the belt tension or replace
the belt.
• Faulty wiring harness. • Repair the wiring harness.
Battery over charging • Alternator voltage regulator faulty • Replace alternator
• Voltage detecfing wiring faulty • Repair wiring

AFFECTED VIN
DI09-8

Hard engine starting • Ignition coil faulty • Replace ignition coil
• Spark plug malfuntion • Replace spark plug or adjust
clearance
• Ignition timing faulty (spark plug • Resetting valve timing
light is normal)
Unstable engine idling • Spark plug malfunction • Replace spark plug or adjust
clearance
• Ignition coil faulty • Replace ignition coil
• Ignition timing faulty • Resetting valve timing
Enging acceralation malfunction • Ignition timing faulty • Resetting valve timing

AFFECTED VIN
DI09-9
ALTERNATOR
1. Viscous clutch 3. Alternator

2. Bolt ............................................................. 45 Nm 4. Plug connection

AFFECTED VIN
DI09-10

2. Remove the plug connection.
3. Unscrew the bolts and remove the alternator.

Installation Notice
Tightening torque

AFFECTED VIN
DI09-11
STARTER
1. Starter 3. Nut .................................................................... 15 Nm

2. Washer 4. Bolt ................................................................... 48 Nm

AFFECTED VIN
DI09-12

2. Disconnect the starter terminal.
3. Lift up the vehicle and remove the front propeller shaft

mounting bolts.
4. Remove the upper and lower mounting bolts.

AFFECTED VIN
DI09-13
PREHEATING SYSTEM
General
- Preheating warning light
Coolant
temperature
sensor

AFFECTED VIN
DI09-14
Function
Preheating system controls and checks following functions and operating conditions.
• Pre-heating
: The power will be supplied to the glow plugs by ECU controls when the power is supplied to the IG terminal from
the battery and there are normal communications with ECU. The surface of glow plug will be heated up to 850°C
very quickly to aid combustion by vaporizing air-fuel mixture during compression stroke.
Preheating time is controlled by ECU.
• While engine starting

: Help to warm up engine
• After-heating
: When the engine is started, after-heating starts by ECU controls. The idle rpm will be increased to reduce toxic
smoke, pollutants and noises.
After-heating time is controlled by ECU.
• Checking glow plugs

- Check each glow plug for short in circuit
- Check each glow plug for open in circuit due to overvoltage
- Check glow plug for short to ground
• Forceful relay shut-down

- When glow plug is shorted to ground
• K-Line communication
- ECU sends the results to preheating time control relay through K-Line to start communication.
- Preheating time control relay sends messages including self-diagnosis data for glow plugs to ECU.
- Glow plug makes communication only as response to demand.
- The ECU will attempt to read the diagnostic information 2 seconds after power up.
- Under the following conditions, communication error occurs.
When there is no response from glow plug module within 50 milli-second after request of ECU.
When an error is detected in checksum
Less byte is received
Error code of “Pre heating control communication fail” will be reported.

AFFECTED VIN
DI09-15
PREHEATING TIME RELAY

Structure
K-LINE #1 IG1 power

(ECU 34) terminal
Glow plug control

signal
(ECU 113)
Ground
terminal
B+ main
wire (12V)
Glow plug terminal

#1 ~ #5
Specifications
Operating range - 40 ~ + 100°C
Relay operating voltage Over 6.5 V
Relay releasing voltage Over 1.5 V
Relay coil resistance 11.3 Ω
Voltage drop Below 150 mV at each glow plug (at 16A of current)
Parasitic current Max. 1mA

AFFECTED VIN
DI09-16
GLOW PLUG
Cylinder type glow plug is inserted into the cylinder and com-
posed of heating pin and housing.
There are heating coil and control coil in the heating pin and
those coils located inside of ceramic cover turn ON or OFF
the internal switch.
Purposes of use
- Preheating before engine starting
- During engine starting
- After-heating after engine starting
Conditions for glow plugs

- Prompt heating and secured temperature stabilities (temperature changes) in low operating voltage
- Should not exceed permissible max. temperature under max. operating voltage
- Heating pin should have good heat-resisting properties against combustion gas and durability
- Material of the glow plug should meet high stressing conditions (e.g., temperature, vibration and environmental
factors)
Specifications
Rated voltage 11 ± 0.1 V
Current consumption Initial current I intial < 30.0 A
Preheating time T 850°C = 5 ± 1.5 sec.
(From ambient temperature up to 85°C)
Operating temperature 900 °C
Tightening torque 15 + 3 Nm
Trouble Code
Refer to “Diagnosis” section in this manual.

AFFECTED VIN
DI09-17

1. Turn the ignition switch to “OFF” position and disconnect
the negative battery cable.
2. Set aside the harnesses on the cylinder head.
3. Disconnect the glow plug connectors and loosen the glow

plugs.
Installation Notice
Tightening torque
4. Remove the glow plugs from the cylinder head with a

special tool. Plug the openings of the glow plugs with
sealing caps.

AFFECTED VIN
DI09-18
Glow plug remover Removal of glow plug

AFFECTED VIN
DI10-1
SECTION
00 DI10
DIAGNOSIS
Table of Contents
SCAN-100 OPERATING PROCEDURES -

D27DT ENGINE ........................................................... DI10-3
TROUBLE DIAGNOSIS TABLE ................................. DI10-25
FUEL SYSTEM DIAGNOSIS ................................... DI10-179
DIAGNOSIS CHANGED BY
AFFECTED VIN
DI10-3
SCAN-100 OPERATING PROCE-

DURES - XDi270 ENGINE
ENTERING DIAGNOSIS PROCEDURES .................... DI10-4
FUNCTION SELECTION ............................................. DI10-6

Check the trouble code .......................................... DI10-6
Sensor data check .................................................. DI10-7
Actuator check ........................................................ DI10-8
Trouble code clear ................................................ DI10-10
ECU identification .................................................. DI10-12
Injector (C2I) corrections ...................................... DI10-13
Leak detection ...................................................... DI10-15
Variant coding ....................................................... DI10-16
ECU replace .......................................................... DI10-18
Rail pressure reset ............................................... DI10-23
AFFECTED VIN
DI10-4
SCAN-100 OPERATING PROCEDURES - D27DT ENGINE

ENTERING DIAGNOSIS PROCEDURES
1. Select “1] DIAGNOSIS” and press “ ” in “MAIN MENU”
screen.
2. Select “6] STAVIC” and press “ ” in “VEHICLE

SELECTION” screen.
3. Select “1] ECU” and press “ ” in “CONTROL UNIT

CHANGED BY DIAGNOSIS
AFFECTED VIN
DI10-5
4. The “FUNCTION SELECTION” screen is displayed.
AFFECTED VIN
DI10-6
FUNCTION SELECTION
Check the Trouble Code
Preceding work: Perform the “Entering Diagnosis Pro-
cedures”
1. Select “1] TROUBLE CODE” and press “ENTER” in

“FUNCTION SELECTION” screen.
2. The “DIAGNOSTIC TROUBLE CODEs” screen is

displayed and it shows the trouble.
Note
If there is not any fault, “NO TROUBLE DETECTED”
message appears.
3. When selecting a trouble code, then

if you press “ ”: Displays the sensor data for the
detected trouble (Freeze Frame
Mode).
if you press “ ”: Displays the help tips for the
detected trouble.
AFFECTED VIN
DI10-7
Sensor Data Check

Preceding Work: Perform the “Entering Diagnosis Pro-
cedures”
1. Select “2] DATA LIST” and press “ ” in “FUNCTION

2. The screen shows approx. 58 sensor data.
3. Select the items you want to see and press “ ” key

to freeze them.
Note
You can freeze up to 5 items (*: selected items).
AFFECTED VIN
DI10-8
Actuator Check
cedures”
1. Select “3] ACTUATOR” and press “ ” in “FUNCTION

2. The screen shows 19 items. Select the item you want to

see and press “ ”.
3. For example, if you select “02] GLOW PLUG” item and

press “ ”, the screen as shown in figure is displayed.
AFFECTED VIN
DI10-9
4. If you want to operate the glow plug relay, press “ ”

key. The “OPERATING” message appears and the relay
operation alarm sounds.
5. If you want to stop the operation press “ ” key in

keyboard.
AFFECTED VIN
DI10-10
Trouble Code Clear

cedures”
1. Select “1] TROUBLE CODE” and press “ ” in

2. The “DIAGNOSTIC TROUBLE CODEs” screen is

displayed and it shows the trouble.
Note
C = Current trouble, H = History trouble
3. Fix the trouble and go back to “1] TROUBLE CODE”

screen and check if the trouble has been changed to “H
(History trouble code)” code.
AFFECTED VIN
DI10-11
4. If the trouble has been change to “H (History trouble code)”

code, press “ ” key to go back to “FUNCTION
SELECTION” screen. In this screen, select “4] TROUBLE
CODE CLEAR” and press “ ”.
5. The “TROUBLE CODE CLEAR” screen is displayed. If

you press “ ”, only the history trouble codes will be
cleared.
Note
• Current trouble codes will not be cleared.
• Check the trouble codes after clearing the trouble
codes.
AFFECTED VIN
DI10-12
ECU Identification
cedures”
1. Select “5] ECU IDENTIFICATION” and press “ ” in

2. The “ECU IDENTIFICATION” screen that shows the VIN,

ECU software number, ECU software version and
programming date is displayed.
3. If you replaced the ECU, press “ ” to input the vehicle

identification number.
AFFECTED VIN
DI10-13
Injector (C2I) Corrections

cedures”
Notice
If the injector/ECU has been replaced or the injector system

defective is suspected, go to C2I Coding item and check
the injector and coded injector C2I value.
1. Select “6] INJECTOR (C2I) CORRECTIONS” and press

“ ” in “FUNCTION SELECTION” screen.
2. The “INJECTOR (C2I) CORRECTIONS” screen that shows

current C2I coding values of #1 to #5 injector is displayed.
3. If you replaced the ECU, enter the C2I value of the relevant
injector.
Note
• The C2I value of replacing injector is recorded in
the label.
• C2I coding number: 16 digits (ex, B1 B9 D4 1B 43
C6 0E 4F)
AFFECTED VIN
DI10-14
3-1. If you enter the invalid C2I value of the relevant injector,
the message as shown in figure appears with alarm sound.
Note
If you want to go back to previous screen, press
“ ” key. You can see the previous C2I value.
3-2. If you enter the valid C2I value of the relevant injector, the
message as shown in figure appears with alarm sound.
AFFECTED VIN
DI10-15
Leak Detection
cedures”
Note
This item is for checking the high fuel pressure after the
IMV supply line of HP pump in DI engine fuel system. If
you still suspect that the fuel pressure system is defective
even after no trouble is detected, perform the fuel pressure
test again by using a fuel pressure tool kit.
1. Select “7] LEAK DETECTION” and press “ ” in

2. The “LEAK DETECTION” screen that shows the checking

conditions as shown in figure is displayed.
AFFECTED VIN
DI10-16
Variant Coding
cedures”
1. Select “8] VARIANT CODING” and press “ ” in

2. When the “VARIANT CODING” screen is displayed,

select “1] READ VARIANT VALUE” and press “ ”.
3. The “VARIANT CODING” screen that shows currently

equipped devices is displayed.
AFFECTED VIN
DI10-17
4. If you need to change the variant coding, press “ ”

key to go back to “VARIANT CODING” screen. In the
screen, select “2] WRITE VARIANT CODING” and press
“ ”.
5. When the “WRITE VARIANT CODING VALUE” screen is

displayed, change the item by using arrow keys.
6. If you press “ ”, the message as shown in figure

appears. And, then “VARIANT CODING” screen is
displayed.
7. Select “READ VARIANT VALUE” to see the coding coded

value.
AFFECTED VIN
DI10-18
ECU Replace
cedures”
1. Select “0] ECU REPLACE” and press “ ” in
2. Before starting ECU replace, check the ECU S/W version

of old ECU and new ECU.
3. When the “ECU REPLACE (STEP 2)” screen is displayed

followed by “ECU REPLACE (STEP 1) screen, turn the
ignition “OFF” and remove the currently installed ECU.
Notice
Do not turn off the Scan-100 at this time.

Record the below data:
- Vehicle identification number
- Variant coding value
- C2I coding value
- Multi calibration
4. Install the new ECU.
AFFECTED VIN
DI10-19
4. If you turn the ignition switch to “ON” position and press “ ”, the message as shown in figure 1 (system
initialization) appears, and then “MULTI CALIBRATION” screen (figure 2) is displayed.
figure 1 figure 2
5. In “MULTI CALIBRATION” screen, select the relevent

model.
6. When you press “ ”, the processing message as

shown in figure appears.
AFFECTED VIN
DI10-20
7. If the multi calibration is completed successfully, “ECU

REPLACE (STEP 5) screen is displayed.
Backup data:
- Multi calibration value
- VIN value
- Variant code value
- Injector (C2I) value
8. In immobilizer equipped vehicle, the immobilizer coding

should be done after completed the multi calibration.
9. Press “ ” and enter the user password.
10. If the password is invalid, the “access denied” screen as

shown in figure is displayed.
AFFECTED VIN
DI10-21
11. If the password is valid, an immobilizer coding is started.
12. If you want to code for additional keys, remove the first
key from key switch and insert the second key. Turn it
to “ON” position and press “ ” to proceed.
13. You can code up to five keys with same manner.
14. When the immobilizer coding is completed, press “ ”.

The completion message as shown in figure appears.
AFFECTED VIN
DI10-22
15. When you turn the ignition key to “OFF” position, the
message screen as shown in figure is displayed. Wait
for 15 seconds and turn the ignition key to “ON” position.
16. Press “ ” to return to “MAIN MENU” screen.
AFFECTED VIN
DI10-23
Rail Pressure Reset

Rail Pressure Reset Procedures
The engine ECU needs a specific amount of fuel according to the fuel supply lines and vehicle driving conditions.
However, if the fuel supply (pressure) is not achieved due to, for instance, defective fuel system, ECU designates the
offset value to the high pressure pump to compensate it.
The fuel supply pressure varies according to the offset value and the engine output could be decreased due to this
variation. When the engine output decreases, check whether all rail pressure offset values is set to 0 in the Rail
Pressure Reset screen in SCAN-100. If the setting value is not 0, measure the fuel pressure with a tester. If any
defective is found, repair the affected components and reset the rail pressure offset value to 0.
The rail pressure reset procedures should be done after replacing any high pressure pump and fuel system
related components.
1. Select the vehicle model.
2. Select [RAIL PRESSURE RESET] in [FUNCTION

SELECTION] screen.
AFFECTED VIN
DI10-24
3. Enter the current rail pressure value and press [ENTER]

to reset the offset value.
4. The screen returns back to step 3 after displaying the

[RAIL PRESSURE RESET IS SUCCESSFUL] message.
Notice
If the offset value is not set to 0, check the fuel
pressure and other DTC generations before starting
the rail pressure reset operation.
AFFECTED VIN
DI10-25
TROUBLE DIAGNOSIS TABLE
INDEX OF DTC ..................................................... 10D-26, 73

Trouble diagnosis table ......................................... 10D-29
Trouble diagnosis procedures ............................... 10D-77
AFFECTED VIN
DI10-26
INDEX OF DTC
P0102 Low HFM Sensor Signal (Circuit Open) .......... DI10-29 P1291 High Resistance for Injector #3 wiring harness .. DI10-40
P0103 High HFM Sensor Signal (Circuit Short) .......... DI10-29 P0704 Clutch switch malfunction ............................. DI10-40
P0100 Air Mass Flow (HFM) Malfunction .................. DI10-30 P1115 Coolant Temperature Sensor Malfunction ....... DI10-41
P0344 Cam Position Sensor Malfunction P0118 Coolant Temperature Sensor
(Cam Signal Missing) ..................................... DI10-30 Malfunction - Short ........................................ DI10-41
P0341 Cam Position Sensor Malfunction P0117 Coolant Temperature Sensor

(Poor Synchronization) .................................. DI10-30 Malfunction - Open ........................................ DI10-42
P0219 Too Small Clearance of Crank Angle Sensor .. DI10-30 P0115 Supply Voltage Fault to Coolant
P0336 Too Large Clearance of Crank Angle Sensor . DI10-31 Temperature Sensor ...................................... DI10-42
P0372 Crank Angle Sensor Malfunction .................... DI10-31 P0685 Main Relay Malfunction .................................. DI10-42
P1107 Barometric Sensor Circuit Short/GND Short ... DI10-31 P1405 EGR Solenoid Valve Short Malfunction - Short to ground
P1108 Barometric Sensor Circuit Short ..................... DI10-31 ...................................................................... DI10-42
P1105 Barometric Sensor Circuit Short ..................... DI10-31 P1406 EGR Solenoid Valve Malfunction - Short to +batt
P0562 Low Battery Voltage ...................................... DI10-32 ...................................................................... DI10-42
P0563 High Battery Voltage ...................................... DI10-32 P1480 Condenser Fan #1 Circuit Malfunction - Open . DI10-43
P0560 Battery Voltage Malfunction ........................... DI10-32 P1481 Condenser Fan #1 Circuit Malfunction - Short . DI10-43
P0109 Low Booster Pressure Sensor Signal ............ DI10-33 P1482 Condenser Fan #1 Circuit Malfunction -
P0106 High Booster Pressure Sensor Signal ............ DI10-33 Short to Ground ............................................. DI10-43
P0107 Booster Pressure Sensor Open/GND Short ... DI10-34 P1526 Condenser Fan #2 Circuit Malfunction - Open . DI10-43
P0108 Booster Pressure Sensor Short ..................... DI10-34 P1527 Condenser Fan #2 Circuit Malfunction - Short . DI10-43
P0105 Supply Voltage Fault to Booster P1528 Condenser Fan #2 Circuit Malfunction -
Pressure Sensor ............................................ DI10-35 Short to Ground ............................................. DI10-43
P1106 Booster Pressure Sensor Malfunction ........... DI10-35 P0325 Accelerometer #1 (Knock Sensor)
P1109 Booster Pressure Sensor Initial Check Fault . DI10-36 Malfunction .................................................... DI10-44
P0571 Brake Pedal Switch Fault ............................... DI10-36 P0330 Accelerometer #2 (Knock Sensor)
P1572 Brake Lamp Signal Fault ................................. DI10-37 Malfunction .................................................... DI10-44
P1571 Brake Lamp Signal Fault ................................. DI10-37 P1611 Injector Bank #1 Malfunction - Low Voltage ... DI10-44
P1286 Low Resistance for Injector #1 wiring harness . DI10-37 P1612 Injector Bank #1 Malfunction - High Voltage ... DI10-45
P1287 High Resistance for Injector #1 wiring harness .. DI10-38 P1618 Injector Bank #2 Malfunction - Low Voltage ... DI10-45
P1288 Low Resistance for Injector #2 wiring harness . DI10-38 P1619 Injector Bank #2 Malfunction - High Voltage .. DI10-45
P1289 High Resistance for Injector #2 wiring harness .. DI10-38 P0263 Injector #1 Balancing Fault ............................. DI10-46
P1292 Low Resistance for Injector #4 wiring harness . DI10-39 P0266 Injector #2 Balancing Fault ............................. DI10-46
P1294 Low Resistance for Injector #5 wiring harness . DI10-39 P0275 Injector #5 Balancing Fault ............................. DI10-46
P1290 Low Resistance for Injector #3 wiring harness . DI10-40 P0201 Injector #1 Circuit Open .................................. DI10-46
AFFECTED VIN
DI10-27
P0202 Injector #2 Circuit Open ................................. DI10-46 P0113 Intake Air Temperature Circuit Malfunction -
P0204 Injector #4 Circuit Open .................................. DI10-47 Short .............................................................. DI10-55
P0205 Injector #5 Circuit Open .................................. DI10-47 P0112 Intake Air Temperature Circuit Malfunction -
P0203 Injector #3 Circuit Open .................................. DI10-47 Open ............................................................. DI10-56
P1201 Injector #1 Circuit Short .................................. DI10-47 P0110 Intake Air Temperature Circuit Malfunction -
P1202 Injector #2 Circuit Short .................................. DI10-47 Source Power Problem .................................. DI10-57
P1204 Injector #4 Circuit Short .................................. DI10-47 P1171 #1 Injector MDP Malfunction ........................... DI10-57
P0182 Fuel temperature sensor - Short to Ground ... DI10-48 P1175 #5 Injector MDP Malfunction ........................... DI10-57
P0183 Fuel temperature sensor - Short to B+ ........... DI10-48 P1173 #3 Injector MDP Malfunction ........................... DI10-57
P0180 Fuel temperature sensor - Malfunction .......... DI10-49 P1252 Too High IMV Pressure ................................... DI10-58
P1678 Glow Plug Drive Malfunction - Open .............. DI10-49 P1120 Accelerator Pedal Sensor #1 Malfunction ..... DI10-58
P1679 Glow Plug Drive Malfunction - Short .............. DI10-49 P1121 Accelerator Pedal Sensor #2 Malfunction ..... DI10-58
P1680 Glow Plug Drive Malfunction - P1122 Accelerator Pedal Sensor Malfunction
Short to Ground ............................................ DI10-49 (Limp Home Mode) ......................................... DI10-58
P1530 #1 Heater operating circuit - Open ................ DI10-49 P1123 Accelerator Pedal Sensor Malfunction
P1531 #1 Heater operating circuit - Short ................ DI10-50 (Reduced Torque Mode) ................................ DI10-59
P1532 #1 Heater operating circuit - Short to Ground . DI10-50 P1124 Accelerator Pedal Sensor Malfunction - Stuck .. DI10-59
P1534 #2 Heater operating circuit - Open ................ DI10-50 P0122 Accelerator Pedal Sensor #1 Malfunction -
P1535 #2 Heater operating circuit - Short ................. DI10-50 Open .............................................................. DI10-59
P1536 #2 Heater operating circuit - Short to Ground DI10-50 P0123 Accelerator Pedal Sensor #1 Malfunction -
P1254 Maximum Rail Pressure Control Malfunction Short .............................................................. DI10-59

(IMV Fault) .................................................... DI10-51 P0120 Accelerator Pedal Sensor #1 Malfunction -
P1253 Minimum Rail Pressure Control Malfunction Supply Voltage Fault ...................................... DI10-59
(IMV Fault) .................................................... DI10-51 P0222 Accelerator Pedal Sensor #2 Malfunction -
P1256 Too Small Transfer Pressure Fuel in Open .............................................................. DI10-60
Rail Pressure System ..................................... DI10-52 P0223 Accelerator Pedal Sensor #2 Malfunction -
P1257 Too Large Transfer Pressure Fuel in Short .............................................................. DI10-60

Rail Pressure System ..................................... DI10-52 P0220 Accelerator Pedal Sensor #2 Malfunction -
P1258 Too Small High Pressure Fuel in Supply Voltage Fault ...................................... DI10-60
Rail Pressure System .................................... DI10-53 P0192 Fuel Rail Pressure Sensor Malfunction - Open .. DI10-60
P1259 Too Large High Pressure Fuel in P0193 Fuel Rail Pressure Sensor Malfunction - Short .. DI10-61
Rail Pressure System .................................... DI10-53 P0190 Supply Voltage Fault to
P1191 Pressure Build Up - Too Slow ....................... DI10-54 Fuel Rail Pressure Sensor .............................. DI10-61
P0255 IMV Driver Circuit Malfunction - Open ........... DI10-54 P0191 Fuel Rail Pressure Sensor Signal Fault .......... DI10-61
P0251 IMV Driver Circuit Malfunction - Short ........... DI10-54 P1192 Fuel Rail Pressure Sensor Initial Signal Fault -
P0253 IMV Driver Circuit Malfunction - Low ............................................................... DI10-62

Short to Ground ............................................ DI10-54
AFFECTED VIN
DI10-28
P1193 Fuel Rail Pressure Sensor Initial Signal Fault - P0671 #1 Glow Plug Fault - Open ............................. DI10-68
High ............................................................... DI10-62 P0672 #2 Glow Plug Fault - Open ............................. DI10-68
P1190 Fuel Rail Pressure Sensor Initial Signal Fault .. DI10-63 P0673 #3 Glow Plug Fault - Open ............................. DI10-68
P0215 Main Relay Fault - Stuck ................................. DI10-63 P0674 #4 Glow Plug Fault - Open ............................. DI10-69
P1500 Vehicle Speed Fault ....................................... DI10-63 P0675 #5 Glow Plug Fault - Open ............................. DI10-69
P0642 ECU Supply Voltage 1 Fault - Low (5 V) ........ DI10-63 P1671 #1 Glow Plug Fault - Short (+B) ..................... DI10-69
P0643 ECU Supply Voltage 1 Fault - High (5 V) ........ DI10-64 P1672 #2 Glow Plug Fault - Short (B+) ..................... DI10-69
P0641 ECU Supply Voltage 1 Fault (5 V) ................... DI10-64 P1673 #3 Glow Plug Fault - Short (B+) ..................... DI10-69
P0652 ECU Supply Voltage 2 Fault - Low (5 V) ........ DI10-64 P1674 #4 Glow Plug Fault - Short (B+) ..................... DI10-69
P0653 ECU Supply Voltage 2 Fault - High (5 V) ........ DI10-64 P1675 #5 Glow Plug Fault - Short (B+) ..................... DI10-70
P0651 ECU Supply Voltage 2 Fault (5 V) ................... DI10-64 P0700 TCU Signal Fault ............................................. DI10-70
P0698 ECU Supply Voltage Fault - Low (2.5 V) ........ DI10-65 P1540 Air Conditioner Operating Circuit Fault - Open . DI10-70
P0699 ECU Supply Voltage Fault - High (2.5 V) ........ DI10-65 P1541 Air Conditioner Operating Circuit Fault - Short . DI10-70
P0697 ECU Supply Voltage Fault (2.5 V) ................... DI10-65 P1542 Air Conditioner Operating Circuit Fault -
P0245 Turbo Charger Actuator Circuit Fault - Short .. DI10-65 Short to Ground ............................................. DI10-70
P0246 Turbo Charger Actuator Circuit Fault - P1149 Too High Water Level in Fuel Filter ................. DI10-70
Short to B+ ..................................................... DI10-65 P1634 Immobilizer Fault (refer to immobilizer section) .. DI10-70
P0606 ECU Watchdog Fault ...................................... DI10-65 P1635 No response from Immobilizer
P1607 ECU Injector Cut Fault ..................................... DI10-65 (refer to immobilizer section) ......................... DI10-70
P1600 ECU Shut Down Fault ..................................... DI10-66 P1630 Wrong response from Immobilizer
P1601 ECU Fault ....................................................... DI10-66 (refer to immobilizer section) ......................... DI10-71
P1602 ECU Fault ....................................................... DI10-66 P1631 Immobilizer Fault (refer to immobilizer section) . DI10-71
P1614 ECU C2I/MDP Fault ......................................... DI10-66 P1632 Immobilizer Fault (refer to immobilizer section) . DI10-71
P1620 ECU Fault ....................................................... DI10-66
P1621 ECU Fault ....................................................... DI10-66
P1622 ECU Fault ....................................................... DI10-66
P1603 ECU Fault ....................................................... DI10-67
P1604 ECU Fault ....................................................... DI10-67
P1605 ECU Fault ....................................................... DI10-67
P1148 Accelerometer (Knock Sensor) Learning Fault . DI10-67
P0400 EGR Control Valve Fault ................................. DI10-67
P1235 VGT Operation Fault ...................................... DI10-67
P1608 ECU Fault ....................................................... DI10-67
P0335 No Crank Signals ............................................ DI10-67
P1170 Torque Trim Fault - High ................................. DI10-67
P1676 Glow Plug Communication Fault ..................... DI10-68
P1677 Glow Plug Controller Fault .............................. DI10-68
AFFECTED VIN
DI10-29
TROUBLE DIAGNOSIS TABLE

Torque Torque Delayed Immediately Limp
DTC Trouble Help Reduction Reduction Engine Engine Home
(max.50%) (max.20%) Stop Stop Mode
P0102 Low HFM Sensor Signal - HFM sensing values are lower than
(Circuit Open) minimum sensing values.
- Check the resistance in HFM sensor.
- Check the ECU wiring harness (open
and poor contact).
• Check the ECU pin #83 and #84 for
open circuit.
- Actual air mass flow vs. Output
voltages.
• -20 Kg/h: 0.47 V
• 0 Kg/h: 0.99 V
• 10 Kg/h: 1.2226 ~ 1.2398 V
• 15 Kg/h: 1.3552 ~ 1.3778 V
• 30 Kg/h: 1.6783 ~ 1.7146 V
• 60 Kg/h: 2.1619 ~ 2.2057 V
• 120 Kg/h: 2.7215 ~ 2.7762 V
• 250 Kg/h: 3.4388 ~ 3.5037 V
• 370 Kg/h: 3.8796 ~ 3.9511 V
• 480 Kg/h: 4.1945 ~ 4.2683 V
• 640 Kg/h: 4.5667 ~ 4.6469 V
- Replace the ECU if required.
P0103 High HFM Sensor Signal - HFM sensing values are higher than
(Circuit Short) maximum sensing values.
- Check the resistance in HFM sensor.
- Check the ECU wiring harness (open
and poor contact).
open circuit.
voltages.
• -20 Kg/h: 0.47 V
• 0 Kg/h: 0.99 V
• 10 Kg/h: 1.2226 ~ 1.2398 V
• 15 Kg/h: 1.3552 ~ 1.3778 V
• 30 Kg/h: 1.6783 ~ 1.7146 V
• 60 Kg/h: 2.1619 ~ 2.2057 V
• 120 Kg/h: 2.7215 ~ 2.7762 V
• 250 Kg/h: 3.4388 ~ 3.5037 V
• 370 Kg/h: 3.8796 ~ 3.9511 V
• 480 Kg/h: 4.1945 ~ 4.2683 V
• 640 Kg/h: 4.5667 ~ 4.6469 V
AFFECTED VIN
DI10-30

P0100 Air Mass Flow (HFM) Mal- - The external power supply is faulty.
function • Check the external power supply.
• Check the sensor wiring harness
(open, short, poor contact).
voltages.
• -20 Kg/h: 0.47 V
• 0 Kg/h: 0.99 V
• 10 Kg/h: 1.2226 ~ 1.2398 V
• 15 Kg/h: 1.3552 ~ 1.3778 V
• 30 Kg/h: 1.6783 ~ 1.7146 V
• 60 Kg/h: 2.1619 ~ 2.2057 V
• 120 Kg/h: 2.7215 ~ 2.7762 V
• 250 Kg/h: 3.4388 ~ 3.5037 V
• 370 Kg/h: 3.8796 ~ 3.9511 V
• 480 Kg/h: 4.1945 ~ 4.2683 V
• 640 Kg/h: 4.5667 ~ 4.6469 V
P0344 Cam Position Sensor Mal- - No cam recognition signal (missing
function (Cam Signal Missing) events).
- Check the source voltage of cam posi-
tion sensor (ECU pin #111) (specified
value: 4.5 ~ 12 V).
- Check the sensor wiring harness for
ECU pin #103 and #104 (open, short,
poor contact).
- Check the cam position sensor.
- Measure the air gap: 0.2 ~ 1.8 mm
P0341 Cam Position Sensor Malfunc- - Not synchronized with Crank angle
tion (Poor Synchronization) signal.
- Check the source voltage of cam posi-
tion sensor (specified value: 4.5 ~ 12 V).
ECU pin #103 and #104 (open, short,
poor contact).
- Check the cam position sensor.
P0219 Too Small Clearance of - Crank angle signal faults or clearance
Crank Angle Sensor too close.
ECU pin #90 and #82 (open, short, poor
contact).
- Check the resistance of crank angle
sensor: 1090 Ω ± 15 %.
• 1.3 mm of air gap: outputs 1.0 V at
40 rpm
• 0.3 mm of air gap: outputs 150 V at
7000 rpm
- Check the teeth condition.
• Drive plate (A/T), DMF (M/T)
AFFECTED VIN
DI10-31

P0336 Too Large Clearance of - Air gap of crank angle sensor is
Crank Angle Sensor abnormal.
contact).
sensor: 1090 Ω ± 15 %.
40 rpm
7000 rpm
P0372 Crank Angle Sensor Mal- - Even though cam position recognition
function is normal, no crank angle signal recog-
nition (missing tooth).
contact).
sensor: 1090 Ω ± 15 %.
40 rpm
7000 rpm
P1107 Barometric Sensor Circuit - Out of range about barometric sensor
Short/GND Short (short to ground).
- Actual barometric pressure vs. Output
voltages.
• 15 Kpa: 0 V 35 Kpa: 1.0 V
• 55 Kpa: 2.0 V 80 Kpa: 3.0 V
• 100 Kpa: 4.0 V 110 Kpa: 4.5 V
- Replace the ECU.
Short (short to B+).
voltages.
• 15 Kpa: 0 V 35 Kpa: 1.0 V
• 55 Kpa: 2.0 V 80 Kpa: 3.0 V
• 100 Kpa: 4.0 V 110 Kpa: 4.5 V
- Replace the ECU.
Short (over voltage).
voltages.
• 15 Kpa: 0 V 35 Kpa: 1.0 V
• 55 Kpa: 2.0 V 80 Kpa: 3.0 V
• 100 Kpa: 4.0 V 110 Kpa: 4.5 V
- Replace the ECU.
AFFECTED VIN
DI10-32

P0562 Low Battery Voltage - Malfunction in recognition of system O
source voltage (Lower than threshold).
• Less than minimum 8 Volts in 2000
rpm below
• Less than 10 Volts in 2000 rpm above.
- Check the battery wiring harness for
ECU pin #3, #4 and #5 (open, short,
poor contact).
- Check the battery main relay and fuse.
- Check the body ground.
- Measure the resistance between body
ground and ECU ground.
• Repair the ECU ground if the resis-
tance is high.
P0563 High Battery Voltage - Malfunction in recognition of system O
source voltage (Higher than threshold).
• More than minimum 16 Volts in 2000
rpm below
poor contact).
- Check the alternator.
tance is high.
P0560 Battery Voltage Malfunc- - Malfunction in recognition of system O
tion source voltage (A/D converter faults).
• Less than minimum 8 Volts in 2000
rpm below
• Less than 10 Volts in 2000 rpm above.
poor contact).
- Check the battery main relay and fuse.
tance is high.
AFFECTED VIN
DI10-33

P0109 Low Booster Pressure - Out of signal range about boost pres-
Sensor Signal sure sensor at Ignition key-On and En-
gine Stop (Lower than specified values).
- Check the supply voltage to sensor.
- Actual boost pressure vs. Output
voltages.
• Raw Signal Range: 0.545 ~ 2.490 bar
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
- Check the sensor wiring harness for ECU
pin #99 and #100 (open, poor contact).
- Visually check sensor and replace if
required.
- Check whether existing or not about
turbo boosting control malfunction
(P1235) simultaneously.
- If there is turbo boost control fault,
Should be checked followings also;
• Leakage before turbo system
• Vacuum pump malfunction
• Waste gate’ solenoid valve
• Turbo charger system defect or mal-
function itself
• Air inlet restriction
• Exhaust system restriction
P0106 High Booster Pressure - Out of signal range about boost pres-
Sensor Signal sure sensor at Ignition key-On and En-
gine Stop (Higher than specified
values).
- Actual boost pressure vs. Output
voltages.
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
ECU pin #99 and #100 (open, poor
contact).
required.
• Turbo charger system defect or
malfunction itself
AFFECTED VIN
DI10-34

P0107 Booster Pressure Sensor - Out of signal range about boost pres-
Open/GND Short sure sensor at Engine running condi-
tion (Lower than specified values).
- Actual boost pressure vs. Output volt-
ages
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
contact).
required.
function itself
P0108 Booster Pressure Sensor - Out of signal range about boost pres-
Short sure sensor at Engine running condi-
tion (Higher than specified values).
ages
• Raw Signal Range: 0.545~2.490 bar
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
contact).
required.
malfunction itself
AFFECTED VIN
DI10-35

P0105 Supply Voltage Fault to - Out of range of supply voltages about
Booster Pressure Sensor boost pressure sensor at Ignition key-
On and Engine Stop (Higher than speci-
fied values).
- Actual boost pressure vs. Output voltages
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
contact).
required.
function itself
P1106 Booster Pressure Sensor - Out of range of supply voltages about
Malfunction boost pressure sensor at Ignition key-
On and Engine Stop (Higher than speci-
fied values).
- Actual boost pressure vs. Output voltages.
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
contact).
required.
malfunction itself
AFFECTED VIN
DI10-36

P1109 Booster Pressure Sensor - Implausible signal values or range about
Initial Check Fault boost pressure sensor at Engine run-
ning condition (Higher than specified
values).
ages
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
contact).
required.
function itself
P0571 Brake Pedal Switch Fault - The brake pedal switch or light switch
is faulty.
• Brake pedal switch: Normal Close
(NC)
• Light switch: Normal Open (NO)
• When operating the brake switch,
one signal (NO) is sent to auto
cruise and the other (NC) is sent to
brake lamp.
- Check the brake and light switch wir-
ing harness.
- Check the supply voltage to brake and
light switch (12 V).
- Check the brake and light switch for
contact.
- Check the ECU wiring harness for ECU
pin #77 and #58 (short, poor contact).
AFFECTED VIN
DI10-37

P1572 Brake Lamp Signal Fault - The brake pedal switch or light switch
is faulty.
(NC)
• When operating the brake pedal
switch, one signal (NO) is sent to
auto cruise and the other (NC) is
sent to brake lamp.
- Check the brake pedal and light switch
wiring harness.
- Check the supply voltage to brake pedal
and light switch (12 V).
- Check the brake pedal and light switch
for contact.
pin #58 (open, short, poor contact).
P1571 Brake Lamp Signal Fault - The brake pedal switch is faulty.
(NC)
• When operating the brake pedal
switch, one signal (NO) is sent to
auto cruise and the other (NC) is
sent to brake lamp.
- Check the brake pedal switch wiring
harness.
- Check the supply voltage to brake pedal
switch (12 V).
- Check the brake pedal switch for
contact.
pin #77 (open, short, poor contact).
P1286 Low Resistance for Injec- - Out of range about wiring harness re-
tor #1 wiring harness sistance for Injector #1.
• Low: Less than 0.115 Ω (injector
circuit open)
- Check the injector #1 wiring harness
and electric isolation.
for open circuit.
• If the pin in injector #1 is defective,
replace injector #1 and perform C2I
coding, then check again.
• If the pin in injector #1 is not
defective, check the ECU wiring
harness.
AFFECTED VIN
DI10-38

P1287 High Resistance for Injec- - Out of range about wiring harness re-
• High: More than 0.728 Ω (injector
circuit short)
for short circuit.
• If the trouble still exists after remov-
ing the injector connector, replace
injector #1 and perform C2I coding,
then check again.
• If the trouble is fixed after removing
the injector connector, check the
wiring harness between ECU and
injector.
circuit open)
for open circuit.
harness.
circuit short)
for short circuit.
then check again.
injector.
AFFECTED VIN
DI10-39

circuit open)
for open circuit.
harness.
circuit short)
for short circuit.
then check again.
injector.
circuit open)
for open circuit.
harness.
AFFECTED VIN
DI10-40

circuit short)
for short circuit.
then check again.
injector.
circuit open)
for open circuit.
harness.
circuit short)
for short circuit.
then check again.
injector.
P0704 Clutch switch malfunction - The clutch switch is faulty (Manual
Transmission Only).
- Check the switch wiring harness.
• Check the ECU pin #38 for open,
short and poor contact.
- Check the switch supply voltage and
operations.
AFFECTED VIN
DI10-41

P1115 Coolant Temperature Sen- - Implausible values of coolant tempera-
sor Malfunction ture (If the temperature is below the
limits values after warm up).
- If Fuel temperature is invalid, the previ-
ous coolant temperature is retained.
- Actual coolant temp. vs. Resistance
• 20°C: 2449 Ω
• 50°C: 826.3 Ω
• 80°C: 321.4 Ω
• 100°C: 112.9 Ω
- Check the wiring harness (open, short
and poor contact).
• ECU pin #101 and #102
- Visually check the sensor and replace
if required.
- Check the thermostat, water pump ra-
diator related coolant route (thermostat
stuck).
P0118 Coolant Temperature Sen- - Malfunction in recognition of coolant
sor Malfunction - Short temperature
• More than maximum values (Circuit
Short)
• External power supply malfunction
• 20°C: 2449 Ω
• 50°C: 826.3 Ω
• 80°C: 321.4 Ω
• 100°C: 112.9 Ω
- Check the wiring harness (short and
poor contact).
• ECU pin #101 and #102
if required.
AFFECTED VIN
DI10-42

P0117 Coolant Temperature Sen- - Malfunction in recognition of coolant
sor Malfunction - Open temperature
• Less than minimum values (Circuit
Open)
• External power supply malfunction
• 20°C: 2449 Ω
• 50°C: 826.3 Ω
• 80°C: 321.4 Ω
• 100°C: 112.9 Ω
- Check the wiring harness (open and
poor contact).
• ECU pin #101 and #102
if required.
P0115 Supply Voltage Fault to - Check if the supply voltage of approx.
Coolant Temperature Sen- 12 V is applied.
sor
P0685 Main Relay Malfunction - The the main relay is unexpectedly
high/low state (ECU is supplied after 3
seconds).
- Relay resistance: 92 ± 9 Ω (at 20°C)
- Check the relay wiring harness (open,
short and poor contact).
• Check for open and short: ECU pin #9.
- If the forced operation is not available,
replace the ECU.
P1405 EGR Solenoid Valve - Out of range about EGR gas: High.
Malfunction - Short to • EGR controller circuit: Open or short
ground to ground
- Check the EGR actuator wiring harness.
- Check the supply voltage to EGR sole-
noid valve.
- Check the EGR solenoid valve.
- Check the EGR valve for stick.
- Check the resistance of EGR actuator:
15.4 Ω.
- Check the ECU wiring harness for open
and short.
• ECU pin #96
P1406 EGR Solenoid Valve - Out of range about EGR gas: Low.
Malfunction - Short to • EGR controller circuit: Short to battery
+Batt
noid valve.
- Check the EGR solenoid valve.
- Check the EGR valve for stick.
- Check the resistance of EGR actuator:
15.4 Ω
and short.
• ECU pin #96
AFFECTED VIN
DI10-43

P1480 Condenser Fan #1 Circuit - Condenser fan #1: Open
Malfunction - Open - Check the relay and relay wiring
harness.
and short.
• ECU pin #80
- If the forced operation is not available
after replacing the relay, replace the
ECU.
P1481 Condenser Fan #1 Circuit - Condenser fan #1: Short
Malfunction - Short - Check the relay and relay wiring
harness.
and short.
• ECU pin #80
ECU.
P1482 Condenser Fan #1 Circuit - Condenser fan #1: Short to ground.
Malfunction - Short to Ground - Check the relay and relay wiring
harness.
and short.
• ECU pin #80
ECU.
P1526 Condenser Fan #2 Circuit - Condenser fan #2: Open
Malfunction - Open - Check the relay and relay wiring
harness.
and short.
• ECU pin #81
ECU.
P1527 Condenser Fan #2 Circuit - Condenser fan #2: Short
Malfunction - Short - Check the relay and relay wiring
harness.
and short.
• ECU pin #81
ECU.
P1528 Condenser Fan #2 Circuit - Condenser fan #2: Short to ground
Malfunction - Short to Ground - Check the relay and relay wiring
harness.
and short.
• ECU pin #81
ECU.
AFFECTED VIN
DI10-44

P0325 Accelerometer #1 (Knock - The signal / noise ratio is too low about
Sensor) Malfunction accelerometer # 1.
- Check the accelerometer wiring har-
ness and tightening torque.
• Tightening torque: 20 ± 5 Nm
and short.
• ECU pin #45 and #46
- If the trouble still exists even after re-
placing the accelerometer, replace the
ECU.
P0330 Accelerometer #2 (Knock - The signal / noise ratio is too low about
Sensor) Malfunction accelerometer # 1.
- Check the accelerometer wiring har-
ness and tightening torque.
• Tightening torque: 20 ± 5 Nm
and short.
• ECU pin #44 and #63
- If the trouble still exists even after re-
placing the accelerometer, replace the
ECU.
P1611 Injector Bank #1 Malfunc- - Malfunction of injector (#1, #4, #3) cir-
tion - Low Voltage cuit (Low): Short to Ground or to
Battery.
- Operating voltage: 6 ~ 18 V
- Check the injector bank #1: Open and
poor contact
- Check if the trouble recurs with the
injectors removed and the ignition key
“OFF”.
• If recurred, check the injector and
ECU wiring harness.
- Check if the trouble recurs while in-
stalling the injectors one by one with
the ignition key “ON”.
• If recurred, replace the injector (perform
C2I coding after replacement).
• Check the other injectors with same
manner.
- Check the ECU wiring harness.
AFFECTED VIN
DI10-45

P1612 Injector Bank #1 Malfunc- - Malfunction of injector (#1, #4, #3) cir-
tion - High Voltage cuit (High): Short to Ground or to Battery.
- Check the injector bank #1: Short and
poor contact
- Check if the trouble recurs with the injec-
tors removed and the ignition key “OFF”.
ECU wiring harness.
manner.
P1618 Injector Bank #2 Malfunc- - Malfunction of injector (#2, #5) circuit
tion - Low Voltage (Low): Short to Ground or to Battery.
- Check the injector bank #2: Open and
poor contact
ECU wiring harness.
manner.
P1619 Injector Bank #2 Malfunc- - Malfunction of injector (#2, #5) circuit
tion - High Voltage (High): Short to Ground or to Battery.
- Check the injector bank #2: Short and
poor contact
ECU wiring harness.
manner.
AFFECTED VIN
DI10-46

P0263 Injector #1 Balancing Fault - Injector #1 cylinder balancing faults
(Injector stuck closed).
- Check the injector circuit for open.
- Check the glow plug.
- Check the inlet tube for clogging.
- Check the EGR.
- Replace the ECU if required (perform
- Check the EGR.
- Check the EGR.
- Check the EGR.
- Check the EGR.
P0201 Injector #1 Circuit Open - Injector #1 circuit malfunction: Open.
• If the injector pin is defective, per-
form C2I coding and check again.
• If the injector pin is normal, check
the ECU wiring harness (ECU pin:
#117, #114).
#118, #121).
AFFECTED VIN
DI10-47

#117, #115).
#118, #120).
#117, #116).
P1201 Injector #1 Circuit Short - Injector #1 circuit malfunction: Short.
• If the trouble recurs with the injec-
tor removed, replace the injector.
Perform C2I coding and check
again.
• If the trouble does not recur, check
the wiring harness between the in-
jector and ECU (ECU pin: #117, #114).
again.
again.
again.
AFFECTED VIN
DI10-48

again.
P0182 Fuel temperature sensor - - The sensing values are higher than
Short to Ground specified values for fuel temperature
sensor. (More than maximum sensing
values 140°C - Circuit Short)
- Actual fuel temp. vs. Resistance
• -40°C: 75.780 Ω -20°C: 21.873 Ω
• -10°C: 12.462 Ω 0°C: 7.355 Ω
• 10°C: 4.481 Ω 20°C: 2.812 Ω
• 25°C: 2.252 Ω 30°C: 1.814 Ω
• 40°C: 1.199 Ω 50°C: 0.811 Ω
• 70°C: 0.394 Ω 90°C: 0.206 Ω
• 120°C: 0.087 Ω
- Recovery values when fuel tempera-
ture sensor failure: 95°C
- Check the wiring harness for open,
• ECU pin: #109, #110
- Check the ECU wiring and replace the
ECU if required.
P0183 Fuel temperature sensor - - The sensing values are lower than
Short to B+ specified values for fuel temperature
sensor. (Less than maximum sensing
values - 40°C - Circuit Open)
• -40°C: 75.780 Ω -20°C: 21.873 Ω
• -10°C: 12.462 Ω 0°C: 7.355 Ω
• 10°C: 4.481 Ω 20°C: 2.812 Ω
• 25°C: 2.252 Ω 30°C: 1.814 Ω
• 40°C: 1.199 Ω 50°C: 0.811 Ω
• 70°C: 0.394 Ω 90°C: 0.206 Ω
• 120°C: 0.087 Ω
• ECU pin: #109, #110
ECU if required.
AFFECTED VIN
DI10-49

P0180 Fuel temperature sensor - - The power source circuit is faulty for
Malfunction fuel temperature sensor. (Fuel tem-
perature sensor is mounted in high
pressure pump)
• -40°C: 75.780 Ω -20°C: 21.873 Ω
• -10°C: 12.462 Ω 0°C: 7.355 Ω
• 10°C: 4.481 Ω 20°C: 2.812 Ω
• 25°C: 2.252 Ω 30°C: 1.814 Ω
• 40°C: 1.199 Ω 50°C: 0.811 Ω
• 70°C: 0.394 Ω 90°C: 0.206 Ω
• 120°C: 0.087 Ω
• ECU pin: #109, #110
ECU if required.
P1678 Glow Plug Drive Malfunc- - Glow plug circuit malfunction: Open.
tion - Open - Check the glow plug wiring harness
for open.
• ECU pin #113
- Check the glow plug relay operations.
- Check the glow plug power supply.
ECU if required.
P1679 Glow Plug Drive Malfunc- - Glow plug circuit malfunction: Short.
tion - Short - Check the glow plug wiring harness
for open.
• ECU pin #113
ECU if required.
P1680 Glow Plug Drive Malfunc- - Glow plug circuit malfunction: Short to
tion - Short to Ground ground.
- Check the glow plug wiring harness
for open.
• ECU pin #113
ECU if required.
P1530 #1 Heater operating circuit - #1 heater circuit malfunction: Open.
- Open - Check the wiring harness for open.
• ECU pin #61
- Check the heater relay operations.
replace the ECU.
ECU if required.
AFFECTED VIN
DI10-50

P1531 #1 Heater operating circuit - #1 heater circuit malfunction: Short.
- Short - Check the wiring harness for short.
• ECU pin #61
replace the ECU.
ECU if required.
P1532 #1 Heater operating circuit - #1 heater circuit malfunction: Short to
- Short to Ground ground.
- Check the wiring harness for short.
• ECU pin #61
replace the ECU.
ECU if required.
P1534 #2 Heater operating circuit - #2 heater circuit malfunction: Open.
- Open - Check the wiring harness for open.
• ECU pin #62
replace the ECU.
ECU if required.
P1535 #2 Heater operating circuit - #2 heater circuit malfunction: Short.
- Short - Check the wiring harness for short.
• ECU pin #62
replace the ECU.
ECU if required.
P1536 #2 Heater operating circuit - #2 heater circuit malfunction: Short to
- Short to Ground ground.
- Check the wiring harness for short.
• ECU pin #62
replace the ECU.
ECU if required.
AFFECTED VIN
DI10-51

P1254 Maximum Rail Pressure - Rail pressure faults: Too high
Control Malfunction (IMV - Check the IMV wiring harness.
Fault)
• Check the ECU pin #87 for open and
short.
- Check the high pressure fuel lines, fuel
rails and high pressure pipes for leaks.
- Check the rail pressure sensor.
• Supply voltage: 5 ± 0.1 V
• Output voltage at 1600 bar: 4.055 ±
0.125 V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the transfer pressure fuel pres-
sure lines.
• Check the fuel level in fuel tank.
Check the fuel system for air influx.
• Check the fuel filter specification.
- Check the IMV resistance: 5.44 Ω
• When out of specified value: replace
high pressure pump and IMV
P1253 Minimum Rail Pressure - Rail pressure faults: Too low
Control Malfunction (IMV - Check the IMV wiring harness.
Fault)
short.
- Check the high pressure fuel lines, fuel
rails and high pressure pipes for leaks.
0.125 V
sure lines.
AFFECTED VIN
DI10-52

P1256 Too Small Transfer Pres- - Rail pressure fault: IMV current trim too
sure Fuel in Rail Pressure high, drift.
System - Check the IMV wiring harness.
short.
0.125 V
sure lines.
- Check the high pressure fuel system.
• Check the fuel rails and high pres-
sure pipes for leaks.
P1257 Too Large Transfer Pres- - Rail pressure fault: IMV current trim too
sure Fuel in Rail Pressure high, drift.
System - Check the IMV wiring harness.
short.
0.125 V
sure lines.
AFFECTED VIN
DI10-53

P1258 Too Small High Pressure - Rail pressure fault: IMV current trim too
Fuel in Rail Pressure Sys- high, drift.
tem - Check the IMV wiring harness.
short.
0.125V
- Check the transfer pressure fuel lines.
P1259 Too Large High Pressure - Rail pressure fault: IMV current trim too
Fuel in Rail Pressure Sys- high, drift.
tem - Check the IMV wiring harness.
short.
0.125 V
AFFECTED VIN
DI10-54

P1191 Pressure Build Up - Too - The pressure build up during cranking
Slow is too slow.
- Check the IMV wiring harness.
short.
0.125 V
P0255 IMV Driver Circuit Malfunc- - IMV driver circuit malfunction: Open O O
tion - Open - Check the IMV wiring harness.
• Check the ECU pin #87 for open.
- Check the IMV resistance.
P0251 IMV Driver Circuit Malfunc- - IMV driver circuit malfunction: Short O O
tion - Short - Check the IMV wiring harness.
• Check the ECU pin #87 for short.
P0253 IMV Driver Circuit Malfunc- - IMV driver circuit malfunction: Short to O O
tion - Short to Ground ground
• Check the ECU pin #87 for short to
ground.
AFFECTED VIN
DI10-55

P0113 Intake Air Temperature Cir- - The intake air temperature sensing
cuit Malfunction - Short value is lower than maximum value of
150°C: Open
• Actual air temperature vs. Voltages
• 20°C: 2.65 Ω
• 30°C: 2.18 Ω
• 50°C: 1.40 Ω
• Recovery values when intake air
temperature sensor failure: 50°C
- Check the sensor wiring harness.
• Check the source power circuit for
short to ground.
- Check the sensor resistance.
• Actual air temperature vs. Resis-
tance
• -40°C: 39.260 Ω
• -20°C: 13.850 Ω
• 0°C: 5.499 Ω
• 20°C: 2.420 Ω
• 40°C: 1.166 Ω
• 60°C: 0.609 Ω
• 80°C: 0.340 Ω
• 100°C: 0.202 Ω
• 120°C: 0.127 Ω
open.
AFFECTED VIN
DI10-56

cuit Malfunction - Open value is lower than maximum value of
150°C: Open
• 20°C: 2.65 Ω
• 30°C: 2.18 Ω
• 50°C: 1.40 Ω
short to ground.
tance
• -40°C: 39.260 Ω
• -20°C: 13.850 Ω
• 0°C: 5.499 Ω
• 20°C: 2.420 Ω
• 40°C: 1.166 Ω
• 60°C: 0.609 Ω
• 80°C: 0.340 Ω
• 100°C: 0.202 Ω
• 120°C: 0.127 Ω
open.
AFFECTED VIN
DI10-57

cuit Malfunction - Source value is lower than minimum value or
Power Problem higher than maximum value, or the ex-
ternal power to HFM sensor is faulty.
• 20°C: 2.65 Ω
• 30°C: 2.18 Ω
• 50°C: 1.40 Ω
short to ground.
tance
• -40°C: 39.260 Ω
• -20°C: 13.850 Ω
• 0°C: 5.499 Ω
• 20°C: 2.420 Ω
• 40°C: 1.166 Ω
• 60°C: 0.609 Ω
• 80°C: 0.340 Ω
• 100°C: 0.202 Ω
• 120°C: 0.127 Ω
open and short.
P1171 #1 Injector MDP Malfunction - The #1 injector MDP is faulty.
- C2I coding check
- Check fault code
- No fault condition, vehicle speed 70 KPH
- Coolant temp. 75°C above condition try
again
- Replace the injector and perform C2I
coding again.
- C2I coding check
- Check fault code
again
coding again.
AFFECTED VIN
DI10-58

- C2I coding check
- Check fault code
again
coding again.
- C2I coding check
- Check fault code
again
coding again.
- C2I coding check
- Check fault code
again
coding again.
P1252 Too High IMV Pressure - The rail pressure is excessively high.
short.
0.125 V
P1120 Accelerator Pedal Sensor - The potentiometer 1 is not plausible O
#1 Malfunction with potentiometer 2.
- Check the wiring harness.
• Check the ECU pin #71, 53 and #32,
14 for open and short.
- Check the accelerator pedal module.
AFFECTED VIN
DI10-59

P1121 Accelerator Pedal Sensor - The potentiometer 1 is not plausible O
#2 Malfunction with potentiometer 2.
• Check the ECU pin #71, 53 and #32,
14 for open and short.
P1122 Accelerator Pedal Sensor - When triggering limp home mode.
Malfunction (Limp Home - Check the supply voltage to sensor.
Mode)
• Check the ECU pin #72, 71, 53 and
#57, 32, 14 for open and short.
P1123 Accelerator Pedal Sensor - When triggering reduced torque mode. O
Malfunction (Reducde Torque - Check the supply voltage to sensor.
Mode)
• Check the ECU pin #72, 71, 53 and
#57, 32, 14 for open and short.
- Replace the ECU if required
P1124 Accelerator Pedal Sensor - The accelerator pedal sensor is stuck. O
Malfunction - Stuck - Check the brake switch wiring harness
and operations.
- Check the accelerator pedal operations.
P0122 Accelerator Pedal Sensor - Out of range about potentiometer 1 of O
#1 Malfunction - Open pedal sensor: lower than specified
values
• Check the circuit for open and short.
• Check the ECU pin #71, #53 for open
and poor contact.
- Check the accelerator pedal.
#1 Malfunction - Short pedal sensor: higher than specified
values
• Check the ECU pin #71, #53 for short
and poor contact.
AFFECTED VIN
DI10-60

P0120 Accelerator Pedal Sensor - The 5 V supply voltage is faulty. O
#1 Malfunction - Supply - Check the supply voltage to sensor.
Voltage Fault
and short.
#2 Malfunction - Open pedal sensor: lower than specified val-
ues
and poor contact.
#2 Malfunction - Short pedal sensor: higher than specified val-
ues
and poor contact.
P0220 Accelerator Pedal Sensor - The 2.5 V supply voltage is faulty. O
#2 Malfunction - Supply - Check the supply voltage to sensor.
Voltage Fault
and short.
AFFECTED VIN
DI10-61

P0192 Fuel Rail Pressure Sensor - The fuel rail pressure sensing values O
Malfunction - Open are lower than specified values.
• Minimum sensing values: - 112 bar
(Open)
0.125 V
- Check the sensor and ECU wiring
harness.
and poor contact.
- Check the fuel rail pressure sensor.
P0193 Fuel Rail Pressure Sensor - The fuel rail pressure sensing values O
Malfunction - Short are higher than specified values.
• Maximum sensing values: 1,600 bar
(Short)
• Output voltage at 1600 bar: 4.055±
0.125V
pressure: 0.5±0.04V
harness.
and poor contact.
P0190 Supply Voltage Fault to Fuel - The supply voltage to fuel rail pres- O
Rail Pressure Sensor sure sensor is faulty.
• Output voltage at 1600 bar: 4.055±
0.125V
pressure: 0.5±0.04V
harness.
and short.
AFFECTED VIN
DI10-62

P0191 Fuel Rail Pressure Sensor - The rail pressure drop is too high. O
Signal Fault - Check the supply voltage to sensor.
0.125 V
harness.
and short.
P1192 Fuel Rail Pressure Sensor - The rail pressure sensor initial values O
Initial Signal Fault - Low are lower than specified values with
the ignition “ON”.
(Open)
0.125 V
harness.
and poor contact.
Initial Signal Fault - High are higher than specified values with
the ignition “ON”.
• Maximum sensing values: 90 bar
(Short)
0.125 V
harness.
and poor contact.
AFFECTED VIN
DI10-63

Initial Signal Fault are higher or lower than specified val-
ues with the ignition “ON”.
• Maximum sensing values: 90 bar
(Short)
(Open)
0.125 V
harness.
and short.
P0215 Main Relay Fault - Stuck - The main relay is stuck ; Shut down.
- Resistance of main relay: 92 Ω ± 9 Ω
(at 20°C)
- Check the main relay wiring harness.
• Check the ECU pin #3, 4, 5 for open
and short.
replace the ECU.
- Check the fuse for main relay
P1500 Vehicle Speed Fault - The vehicle speed signal through CAN
communication is faulty.
- Check the CAN communication line for
open and short.
- Check the ABS/ESP and TCU commu-
nication lines.
P0642 ECU Supply Voltage 1 Fault - Malfunction reference supply voltage
- Low (5 V) from ECU
• Supply voltage: 5 V
- Check the supply voltage to each sen-
sor
• Supply voltage (5 V): accelerator
pedal sensor 1, HFM sensor, rail
pressure sensor, booster pressure
sensor, cam sensor
- Check the wiring harnesses.
AFFECTED VIN
DI10-64

- High (5 V) from ECU
sor
sensor, cam sensor
(5 V) from ECU
sor
sensor, cam sensor
P0652 ECU Supply Voltage 2 Fault - Malfunction reference supply voltage O O
- Low (5 V) from ECU
sor
sensor, cam sensor
- High (5 V) from ECU
sor
sensor, cam sensor
(5 V) from ECU
sor
sensor, cam sensor
AFFECTED VIN
DI10-65

P0698 ECU Supply Voltage Fault - - Malfunction reference supply voltage
Low (2.5 V) from ECU
• Supply voltage: 2.5 V
sor
• Supply voltage (2.5 V): accelerator
pedal sensor 2
P0699 ECU Supply Voltage Fault - - Malfunction reference supply voltage
High (2.5 V) from ECU
sor
• Supply voltage (2.55 V): accelera-
tor pedal sensor 2
P0697 ECU Supply Voltage Fault - Malfunction reference supply voltage
(2.5 V) from ECU
sor
• Supply voltage (2.55 V): accelera-
tor pedal sensor 2
P0245 Turbo Charger Actuator - The waste gate driver circuit is short O
Circuit Fault - Short to ground or open
- Check the actuator wiring harness.
- Check the solenoid valve.
short.
P0246 Turbo Charger Actuator - The turbo charger actuator power O
Circuit Fault - Short to B+ source circuit is short.
- Check the actuator wiring harness.
- Check the solenoid valve.
- Check the ECU wiring harness for short
and poor contact.
P0606 ECU Watchdog Fault - The ECU is defective.
- Check the chassis ground wiring
harness.
- Check the ECU.
P1607 ECU Injector Cut Fault - The ECU is defective.
harness.
- Check the ECU.
AFFECTED VIN
DI10-66

P1600 ECU Shut Down Fault - The ECU is defective.
harness.
- Check the ECU.
P1601 ECU Fault - The ECU is defective.
harness.
- Check the ECU.
harness.
- Check the ECU.
P1614 ECU C2I/MDP Fault - The ECU is defective. O
harness.
- Check C2I code
- Check the ECU.
P1615 ECU Fault - The ECU is defective. O
harness.
- Check the ECU.
harness.
- Check the ECU.
harness.
- Check the ECU.
harness.
- Check the ECU.
harness.
- Check the ECU.
harness.
- Check the ECU.
AFFECTED VIN
DI10-67

harness.
- Check the ECU.
harness.
- Check the ECU.
harness.
- Check the ECU.
P1148 Accelerometer (Knock - Check if the MDP is successful. O
Sensor) Learning Fault - Check the accelerometer (knock
sensor) sensor and wiring harness.
P0400 EGR Control Valve Fault - When the EGR emission is more than
specified value.
• The EGR controller circuit is open
or short to ground.
• The EGR controller is short to
battery.
noid valve.
- Check if the EGR valve is stuck.
- Check the resistance of EGR valve: 15.
4 Ω.
short.
P1235 VGT Operation Fault - The boost pressure control is faulty. O
- Check the air intake system.
- Check the wiring harness and the ECU
wiring harness.
harness.
- Check the ECU.
P0335 No Crank Signals - Refer to P0372.
P1170 Torque Trim Fault - High - Refer to P0372.
AFFECTED VIN
DI10-68

P1676 Glow Plug Communication - The communication between ECU and
Fault glow plug is faulty.
- Check the communication line between
ECU and glow plug.
- Check the glow plug wiring harness.
- Check the resistance of glow plug:
below 1 Ω.
- Check the glow plug relay.
ground.
P1677 Glow Plug Controller Fault - The communication between ECU and
glow plug is faulty.
ECU and glow plug.
- Check the glow plug wiring harness.
- Check the resistance of glow plug:
below 1Ω.
- Check the glow plug relay.
ground.
P0671 #1 Glow Plug Fault - Open - The glow plug circuit is open.
ECU and each glow plug.
- Check each glow plug wiring harness.
- Check the resistance of each glow
plug: below 1 Ω.
- Check each glow plug relay.
plug: below 1 Ω.
plug: below 1 Ω.
AFFECTED VIN
DI10-69

plug: below 1Ω.
plug: below 1 Ω.
P1671 #1 Glow Plug Fault - Short - The glow plug circuit is short.
(B+) - Check the communication line between
plug: below 1 Ω.
plug: below 1 Ω
plug: below 1 Ω
plug: below 1 Ω
AFFECTED VIN
DI10-70

plug: below 1Ω
P0700 TCU Signal Fault - The communication between ECU and
TCU is faulty.
ECU and TCU.
- Check the ECU pin #54, 73 for open
and short.
P1540 Air Conditioner Operating - Check the air conditioner sensors and
Circuit Fault - Open wiring harnesses.
- Check the ECU if required.
Circuit Fault - Short wiring harnesses.
Circuit Fault - Short to wiring harnesses.
Ground - Check the ECU wiring harness.
P1149 Too High Water Level in - Drain the water from fuel filter.
Fuel Filter
P1634 Immobilizer Fault (refer to - No response from immobilizer.
immobilizer section) - Perform the immobilizer coding again.
short.
- Check the immobilizer unit for open and
short or check the supply voltage.
- Check the immobilizer antenna.
P1635 No response from Immobi- - No response from immobilizer.
lizer (refer to immobilizer - Perform the immobilizer coding again.
section)
short.
- Check the immobilizer antenna.
AFFECTED VIN
DI10-71

P1630 Wrong response from Im- - The invalid key is inserted or no communi-
mobilizer (refer to immobi- cation between transponder and immobi-
lizer section) lizer (no response from transponder).
- Perform the immobilizer coding again.
short.
- Check the immobilizer antenna and
transponder for damage.
P1631 Immobilizer Fault (refer to - The immobilizer is not operating.
short.
P1632 Immobilizer Fault (refer to - No response from immobilizer.
short.
P1633 Immobilizer Fault (refer to - No key coding.
short.
P0633 Immobilizer Fault (refer to - Key memory is not available (permissible
immobilizer section) - 5).
- Perform the immobilizer coding again.
short.
AFFECTED VIN
DI10-72

P1636 Immobilizer Fault (refer to - Severe trouble is not defined.
short.
AFFECTED VIN
DI10-73
INDEX OF DTC
HMF sensor Signal Fault (Electric Failure) .......... DI10-77 Brake Lamp Signal Fault ..................................... DI10-93
P0102 ............................................................ DI10-77 P1572 ............................................................ DI10-93
P0103 ............................................................ DI10-77 P1571 ............................................................ DI10-93
P0100 ............................................................ DI10-77
High Wiring Resistance (Injector #1) ................... DI10-94
Cam Position Sensor (missing event) .................. DI10-78 P1286 ............................................................ DI10-94
P0344 ............................................................ DI10-78 P1287 ............................................................ DI10-94
Cam Position Sensor Malfunction High Wiring Resistance (Injector #2) ................... DI10-95
(Poor Synchronization of Crank and Cam) ........... DI10-79 P1288 ............................................................ DI10-95
P0341 ............................................................ DI10-79 P1289 ............................................................ DI10-95
Too Small Clearance of Crank Angle Sensor ........ DI10-80 High Wiring Resistance (Injector #3) ................... DI10-96
P0219 ............................................................ DI10-80 P1292 ............................................................ DI10-96
P1293 ............................................................ DI10-96
Too Large Clearance of Crank Angle Sensor ........ DI10-81
P0336 ............................................................ DI10-81 High Wiring Resistance (Injector #4) ................... DI10-97
P1294 ............................................................ DI10-97
Crank Angle Sensor Malfunction .......................... DI10-82
P1295 ............................................................ DI10-97
P0372 ............................................................ DI10-82
High Wiring Resistance (Injector #5) ................... DI10-98
Barometric Sensor Malfunction (Out of range, using
P1290 ............................................................ DI10-98
strategy of restoring by MAP sensor) .................. DI10-83
P1291 ............................................................ DI10-98
P1107 ............................................................ DI10-83
P1108 ............................................................ DI10-83 Clutch Switch Malfunction ................................... DI10-99
P1105 ............................................................ DI10-83 P0704 ............................................................ DI10-99
Battery Voltage Monitoring Signal Malfunction ..... DI10-84 Coolant Temperature Sensor Malfunction
P0562 ............................................................ DI10-84 (Implausible Signal) ........................................... DI10-100
P0563 ............................................................ DI10-84 P1115 ........................................................... DI10-100
P0560 ............................................................ DI10-84
Coolant Temperature Sensor Malfunction
Booster Pressure Sensor Malfunction (Electric Fault) .................................................. DI10-101
(Out of range with Key ON) ................................. DI10-86 P0117 .......................................................... DI10-101
P0109 ............................................................ DI10-86 P0118 .......................................................... DI10-101
P0106 ............................................................ DI10-86 P0115 .......................................................... DI10-101
Booster Pressure Sensor Malfunction Too Fast or Low Main Relay Operation .............. DI10-102
(Out of range with Key ON) ................................. DI10-88 P0685 .......................................................... DI10-102
P0107 ............................................................ DI10-88
EGR Actuator Malfunction ................................. DI10-103
P0108 ............................................................ DI10-88
P1405 .......................................................... DI10-103
P0105 ............................................................ DI10-88
P1406 .......................................................... DI10-103
P1106 ............................................................ DI10-88
Condenser Fan Driving Signal Fault (Type 1) ..... DI10-104
Booster Pressure Malfunction
P1480 .......................................................... DI10-104
(Implausible Signal) ............................................. DI10-90
P1481 .......................................................... DI10-104
P1109 ............................................................ DI10-90
P1482 .......................................................... DI10-104
Brake Pedal Switch Malfunction .......................... DI10-92
P0571 ............................................................ DI10-92
AFFECTED VIN
DI10-74
Condenser Fan Driving Signal Fault (Type 2) ..... DI10-105 Open Circuit (Injector #3) ................................... DI10-121
P1526 .......................................................... DI10-105 P0203 .......................................................... DI10-121
P1527 .......................................................... DI10-105
HSD Circuit Short to LSE (Injector #1) .............. DI10-122
P1528 .......................................................... DI10-105
P1201 .......................................................... DI10-122
#1 Accelerometer Malfunction
(Idling Signal/Too Small Noise Ratio) ................. DI10-106
P1202 .......................................................... DI10-123
P0325 .......................................................... DI10-106
P1204 .......................................................... DI10-124
(Idling Signal/Too Small Noise Ratio) ................. DI10-107
P0330 .......................................................... DI10-107 HSD Circuit Short to LSE (Injector #5) .............. DI10-125
P1205 .......................................................... DI10-125
Injector Bank 1 Malfunction
(Short to Ground or B+) ..................................... DI10-108 HSD Circuit Short to LSE (Injector #3) .............. DI10-126
P1611 .......................................................... DI10-108 P1203 .......................................................... DI10-126
P1612 .......................................................... DI10-108 Fuel Temperature Sensor Malfunction ................ DI10-127
Injector Bank 2 Malfunction P0182 .......................................................... DI10-127
(Short to Ground or B+) ..................................... DI10-110 P0183 .......................................................... DI10-127
P1618 .......................................................... DI10-110 P0180 .......................................................... DI10-127
P1619 .......................................................... DI10-110 Glow Plug Malfunction (Driving Signal) .............. DI10-128
Cylinder Balancing Fault (Injector #1) = P1678 .......................................................... DI10-128
Clogged Air Intake System ................................ DI10-112 P1679 .......................................................... DI10-128
P0263 .......................................................... DI10-112 Heater 1 Malfunction (Driving Signal) ................. DI10-129
Cylinder Balancing Fault (Injector #2) = P1530 .......................................................... DI10-129
P0266 .......................................................... DI10-113 P1532 .......................................................... DI10-129
Cylinder Balancing Fault (Injector #4) = Heater 2 Malfunction (Driving Signal) ................. DI10-130
P0272 .......................................................... DI10-114 P1535 .......................................................... DI10-130
P1536 .......................................................... DI10-130
Cylinder Balancing Fault (Injector #5) =
Clogged Air Intake System ................................ DI10-115 Rail Pressure Control Fault
P0275 .......................................................... DI10-115 (Too High Pressure) ........................................... DI10-131
P1254 .......................................................... DI10-131
P1253 .......................................................... DI10-131
Clogged Air Intake System ................................ DI10-116
P0269 .......................................................... DI10-116 Rail Pressure Control Fault
(Too High IMV Current Trim, drift) ....................... DI10-133
Open Circuit (Injector #1) ................................... DI10-117
P1256 .......................................................... DI10-133
P0201 .......................................................... DI10-117
P1257 .......................................................... DI10-133
Open Circuit (Injector #2) ................................... DI10-118 P1258 .......................................................... DI10-133
P0202 .......................................................... DI10-118 P1259 .......................................................... DI10-133
Open Circuit (Injector #4) ................................... DI10-119 Rail Pressure Control Fault
P0204 .......................................................... DI10-119 (Too Slow Pressure Build Up while Cranking) .... DI10-135
P1191 .......................................................... DI10-135
Open Circuit (Injector #5) ................................... DI10-120
P0205 .......................................................... DI10-120
AFFECTED VIN
DI10-75
IMV Operation Fault (Electrical Fault) ................ DI10-137 Accelerator Pedal Sensor Malfunction
P0255 .......................................................... DI10-137 (Electrical Fault, Track 2) .................................. DI10-149
P0251 .......................................................... DI10-137 P0222 .......................................................... DI10-149
P0253 .......................................................... DI10-137 P0223 .......................................................... DI10-149
P0220 .......................................................... DI10-149
Intake Air Temperature Sensor Fault
(Electric Fault) .................................................. DI10-138 Fuel Rail Pressure Sensor Malfunction
P0112 .......................................................... DI10-138 (Out of Range, ADC or Vref) .............................. DI10-150
P0113 .......................................................... DI10-138 P0192 .......................................................... DI10-150
P0110 .......................................................... DI10-138 P0193 .......................................................... DI10-150
P0190 .......................................................... DI10-150
MDP Fault (Injector #1) ..................................... DI10-139
P0191 .......................................................... DI10-150
P1171 .......................................................... DI10-139
Fuel Rail Pressure Sensor Malfunction
MDP Fault (Injector #2) ..................................... DI10-139
(Out of Range when Key ON) ............................ DI10-152
P1172 .......................................................... DI10-139
P1192 .......................................................... DI10-152
MDP Fault (Injector #4) ..................................... DI10-140 P1193 .......................................................... DI10-152
P1174 .......................................................... DI10-140 P1190 .......................................................... DI10-152
MDP Fault (Injector #5) ..................................... DI10-140 Main Relay Malfunction - Stuck ......................... DI10-154
P1175 .......................................................... DI10-140 P0215 .......................................................... DI10-154
MDP Fault (Injector #3) ..................................... DI10-141 Vehicle Speed Fault .......................................... DI10-155
P1173 .......................................................... DI10-141 P1500 .......................................................... DI10-155
Rail Pressure Fault (Too High) ........................... DI10-142 5V Supply Voltage 1 Fault ................................. DI10-156
P1252 .......................................................... DI10-142 P0642 .......................................................... DI10-156
Accelerator Pedal Sensor Malfunction P0643 .......................................................... DI10-156
(Relationship between Track 1 and Track 2) ...... DI10-144 P0641 .......................................................... DI10-156
P1120 .......................................................... DI10-144 5V Supply Voltage 2 Fault ................................. DI10-157
P1121 .......................................................... DI10-144 P0652 .......................................................... DI10-157
(Limp Home Mode Operation) ........................... DI10-145 P0651 .......................................................... DI10-157
P1122 .......................................................... DI10-145 2.5V Supply Voltage Fault ................................. DI10-158
(Torque Reduction Mode Operation) .................. DI10-146 P0699 .......................................................... DI10-158
P1123 .......................................................... DI10-146 P0697 .......................................................... DI10-158
Accelerator Pedal Sensor Malfunction Turbo Charger Actuator Operation Fault (signal) DI10-159
(Electrical Fault, Pedal Stuck) ......................... DI10-147 P0245 .......................................................... DI10-159
P1124 .......................................................... DI10-147 P0246 .......................................................... DI10-159
Accelerator Pedal Sensor Malfunction ECU Watchdog Fault ........................................ DI10-160

(Electrical Fault, Track 1) .................................. DI10-148 P0606 .......................................................... DI10-160
P0122 .......................................................... DI10-148 ECU Watchdog Fault (Injector Cut-off) ............... DI10-151
P0123 .......................................................... DI10-148 P1607 .......................................................... DI10-151
P0120 .......................................................... DI10-148
ECU Watchdog Fault (Watchdog Trip) .............. DI10-162
P1600 .......................................................... DI10-162
P1601 .......................................................... DI10-162
P1602 .......................................................... DI10-162
AFFECTED VIN
DI10-76
ECU Non-Volatile Memory Fault ........................ DI10-163 Glow Plug Module Circuit Malfunction - Open .... DI10-173
P1614 .......................................................... DI10-163 P0674 .......................................................... DI10-173
P1615 .......................................................... DI10-163 P0675 .......................................................... DI10-173
P1616 .......................................................... DI10-163 P0671 .......................................................... DI10-173
P1606 .......................................................... DI10-163 P0672 .......................................................... DI10-173
P1620 .......................................................... DI10-163 P0673 .......................................................... DI10-173
P1621 .......................................................... DI10-163
Glow Plug Module Circuit Malfunction - Short .... DI10-174
P1622 .......................................................... DI10-163
P1674 .......................................................... DI10-174
ECU Memory Integration Fault .......................... DI10-164 P1675 .......................................................... DI10-174
P1603 .......................................................... DI10-164 P1671 .......................................................... DI10-174
P1604 .......................................................... DI10-164 P1672 .......................................................... DI10-174
P1605 .......................................................... DI10-164 P1673 .......................................................... DI10-174
Accelerometer Learning Fault ............................ DI10-165 TCU Signal Fault ............................................... DI10-175
P1148 .......................................................... DI10-165 P0700 .......................................................... DI10-175
EGR Valve Control Fault .................................... DI10-166 Air Conditioner Operating Circuit Fault .............. DI10-176
P0400 .......................................................... DI10-166 P1540 .......................................................... DI10-176
P1541 .......................................................... DI10-176
VGT Operation Fault ......................................... DI10-167
P1542 .......................................................... DI10-176
P1235 .......................................................... DI10-167
Excessive Water in Fuel Filter ........................... DI10-177
TBD .................................................................. DI10-169
P1149 .......................................................... DI10-177
P1608 .......................................................... DI10-169
Immobilizer Malfunction ..................................... DI10-178
No Crank Signal ................................................ DI10-170
P1634 .......................................................... DI10-178
P0335 .......................................................... DI10-170
P4335 .......................................................... DI10-178
High Torque Trim ............................................... DI10-171 P1630 .......................................................... DI10-178
P1170 .......................................................... DI10-171
P1631 .......................................................... DI10-178
Glow Plug Module Communication Fault ........... DI10-172 P1632 .......................................................... DI10-178
P1676 .......................................................... DI10-172 P1633 .......................................................... DI10-178
P1677 .......................................................... DI10-172 P0633 .......................................................... DI10-178
P1636 .......................................................... DI10-178
AFFECTED VIN
DI10-77
TROUBLE DIAGNOSIS PROCEDURES
HMF sensor Signal Fault (Electric Failure)
Trouble Code and Symptom
Trouble Code Symptom
P0102 Low Signal MIL ON
P0103 High Signal Not available EGR control(Air flow)
P0100 Supply Voltage
Diagnosis Procedures
Read DTC
YES
Fault in sensor supply voltage? Sensor problem caused by supply voltage.
Locate the problem while disconnecting the
sensor connector one by one. If not a sen-
sor problem, check the sensor supply volt-
age circuit for open and short.
NO
Check sensor wiring and

connector NO
YES
Wiring Problem? Repair or Check wiring and insulation
replace
NO YES
Wiring Problem? Repair wiring
Check sensor resistance

NO
YES
Resistance Problem? Replace Replace ECU
sensor
Check ECU wiring
YES
Wiring Problem? Repair or
replace
NO
AFFECTED VIN
DI10-78
Cam Position Sensor (missing event)
P0344 Cam Position Sensor Malfunction
Check sensor wiring and

connector
NO
YES
replace
Check wiring insulation
NO
YES
Check sensor
NO
YES
Sensor Problem? Replace
sensor
Check cam installation
NO
YES
Cam Wheel Problem? Replace cam
Check ECU wiring wheel
NO
YES
replace
Replace ECU
NO
Check if the cam and

flywheel signals are normal
with an oscilloscope
YES
Anmormal Signal? Repair or
replace
AFFECTED VIN
DI10-79
Cam Position Sensor Malfunction

(Poor Synchronization of Crank and Cam)
P0341 Cam Position Sensor Malfunction - Poor Synchro- MIL ON

nization
Check sensor wiring
YES NO
replace
NO
YES
Check sensor Wiring Problem? Repair wiring
YES NO
sensor
Check cam installation
NO
YES
Check ECU wiring Cam Wheel Problem? Replace cam
wheel
YES NO
replace
Replace ECU
NO
Check if the cam and

flywheel signals are normal
with an oscilloscope
YES
Anmormal Signal? Repair wiring
AFFECTED VIN
DI10-80
Too Small Clearance of Crank Angle

Sensor
P0219 Too Small Clearance of Crank Angle Sensor
Check sensor wiring
YES
replace
YES
Trouble Continues? Replace APS
NO wheel
NO
Check ECU wiring
Replace wheel
YES
replace
YES
Trouble Continues? Replace ECU
NO
NO
Check insulation and open
circuit
Repair completed
YES
NO
YES
Trouble Continues? Replace VR
sensor
NO
New sensor installed
AFFECTED VIN
DI10-81
Too Large Clearance of Crank Angle

Sensor
P0336 Too Large Clearance of Crank Angle Sensor MIL ON
Check sensor wiring
YES
replace
YES
NO wheel
NO
Check ECU wiring
Replace wheel
YES
replace
YES
NO
NO
circuit
Repair completed
YES
NO
YES
sensor
NO
AFFECTED VIN
DI10-82
Crank Angle Sensor Malfunction
P0372 Crank Angle Sensor Malfunction 3 MIL ON
Check sensor wiring
YES
replace
YES
NO wheel
NO
Check ECU wiring
Replace wheel
YES
replace
YES
NO
NO
circuit
Repair completed
YES
NO
YES
sensor
NO
AFFECTED VIN
DI10-83
Barometric Sensor Malfunction

(Out of range, using strategy of
restoring by MAP sensor)
P1107 Low Signal
P1108 High Signal
Replace ECU
AFFECTED VIN
DI10-84
Battery Voltage Monitoring Signal

Malfunction
P0562 Low Signal Not operatable.
P0563 High Signal Injector #1 resistance fault. Use estimate resis-

tance level.
P0560 Supply Voltage Injector #2 resistance fault. Use estimate resis-

tance level.
Injector #4 resistance fault. Use estimate resis-

tance level.

tance level.

tance level.
Unable EGR control (Air Flow)
Unable RPC trim problem detection
Unable HP leak detection
Unable accelerometer learing strategy
MIL ON
Operating limited rail pressure mode
TBD
AFFECTED VIN
DI10-85
Key ON and check battery

voltage
YES
Battery Problem? Charge
battery
Charge battery, check wiring
NO
YES
Charge battery, wiring problem Repair or
Check battery wiring replace
NO
YES
Battery Wiring Problem? Repair or
replace
Replace ECU
NO
Check ECU wiring
YES
replace
NO
Check resistance of body

ground and ECU ground
YES
High Resistance Repair ECU
ground
AFFECTED VIN
DI10-86
Booster Pressure Sensor Malfunction

(Out of range with Key ON)
P0109 Low
P0106 High Location demand=change the boost control to

O.L. mode at f (boost demand, engine cycling speed)
1. Diagnosis Procedures (Boost Pressure)
Read DTC
YES
Booster Pressure Problem? Refer to Diagnosis Tree “Check sensor(1)”
NO
Check air line malfunction:

* VGT/Turbo. * Air filter.
* Vacuum line. * Vacuum pump.
* Solenoid valve open.
* Vane condition.
* Air inlet valve function
Repiar Completed
AFFECTED VIN
DI10-87
2. Diagnosis Procedure (Check sensor (1))
Read DTC
YES
NO
Check sensor wiring

NO
YES
replace Check wiring and insulation
NO
YES
Visually check sensor
NO
YES
sensor Replace sensor
NO
YES
Check ECU wiring
NO
YES
replace Repiar Completed
NO
AFFECTED VIN
DI10-88
Booster Pressure Sensor Malfunction

(Out of range with Key ON)
P0107 Low
P0108 High Location demand=change the boost control to

P1106 GRAD
Read DTC
YES
Booster Pressure Problem? Refer to Diagnosis Tree “Check sensor(1)”
NO

* Vane condition.
Repiar Completed
AFFECTED VIN
DI10-89
2. Diagnosis Procedures (check sensor (1))
Read DTC
YES
NO
Check sensor wiring

NO
YES
NO
YES
NO
YES
NO
YES
Check ECU wiring
NO
YES
NO
AFFECTED VIN
DI10-90
Booster Pressure Malfunction

(Implausible Signal)
P1109 Booster Pressure Sensor Malfunction
Location demand=change the boost control to

Read DTC
YES
Booster Pressure Sensor Refer to Diagnosis Tree “Check sensor(1)”
Problem?
NO

* Vane condition.
Repiar Completed
AFFECTED VIN
DI10-91
2. Diagnosis Procedures (check sensor (1))
Read DTC
YES
NO
Check sensor wiring

NO
YES
NO
YES
NO
YES
NO
YES
Check ECU wiring
NO
YES
NO
AFFECTED VIN
DI10-92
Brake Pedal Switch Malfunction
P0571 Brake Pedal Switch Malfunction MIL ON
Unable Cruise Control
Check switch wiring
YES NO
replace
Check ECU wiring
NO
YES
Check 12V switch supply Wiring Problem? Repair or
voltage replace
NO
YES
Source Power Problem? Check wiring
and fuse
Check wiring and insulation
NO
YES
Check switch operation
NO
YES
Switch Problem? Replace
switch
Replace ECU
AFFECTED VIN
DI10-93
Brake Lamp Signal Fault
P1572 Brake Lamp Signal Fault MIL ON
P1571 Brake Lamp Signal Fault MIL ON
Check switch wiring
YES NO
replace
Check ECU wiring
NO
YES
voltage replace
NO
YES
and fuse
NO
YES
NO
YES
Switch Problem? Replace
switch
Replace ECU
AFFECTED VIN
DI10-94
High Wiring Resistance (Injector #1)
P1286 Low Resistance of injector #1 fault. Use estimate re-

sistance level.
P1287 High MIL ON
Unable Dynamic Leak of Injector #1
Unable Accelerometer Learning Strategy
Read DTC
YES
“Low” Fault? Refer to
injector circuit
malfunction
NO (open) tree
Read DTC
YES
“High” Fault? Refer to
injector circuit
malfunction
NO (short) tree
No any other possibility
AFFECTED VIN
DI10-95

sistance level.
P1289 High MIL ON
Read DTC
YES
injector circuit
malfunction
NO (open) tree
Read DTC
YES
“High”s Fault? Refer to
injector circuit
malfunction
NO (short) tree
AFFECTED VIN
DI10-96

sistance level.
P1293 High MIL ON
Read DTC
YES
injector circuit
malfunction
NO (open) tree
Read DTC
YES
injector circuit
malfunction
NO (short) tree
AFFECTED VIN
DI10-97

sistance level.
P1295 High MIL ON
Read DTC
YES
injector circuit
malfunction
NO (open) tree
Read DTC
YES
injector circuit
malfunction
NO (short) tree
AFFECTED VIN
DI10-98

sistance level.
P1291 High MIL ON
Read DTC
YES
injector circuit
malfunction
NO (open) tree
Read DTC
YES
injector circuit
malfunction
NO (short) tree
AFFECTED VIN
DI10-99
Clutch Switch Malfunction
P0704 Clutch Switch Malfunction
Check switch wiring
YES NO
replace
Check ECU wiring
NO
YES
voltage replace
NO
YES
and fuse
NO
YES
NO
YES
Switch Contact Problem? Replace switch
Replace ECU
AFFECTED VIN
DI10-100

(Implausible Signal)
P1115 Coolant Temperature Sensor Malfunction Unable Air Conditioner Operation
Below Limited Temperature of Engine Overheat

Detection
Read DTC
YES
NO
Check sensor wiring

NO
YES
NO
YES
NO
YES
Resistance Problem? Replace
sensor Replace ECU
NO
Check ECU wiring
YES
replace
NO
AFFECTED VIN
DI10-101

(Electric Fault)
P0117 Low Unable Air Conditioner Operation
P0118 High Below Limited Temperature of Engine Overheat

Detection
Read DTC
YES
NO
Check sensor wiring

NO
YES
NO
YES
NO
YES
sensor Replace ECU
NO
Check ECU wiring
YES
replace
AFFECTED VIN
DI10-102
Too Fast or Low Main Relay Operation
P0685 Main Relay Malfunction
Check relay wiring
YES NO
replace
Perform forced operation
NO and replace relay
Check ECU wiring YES

Not available forced operation? Replace ECU
YES
Wiring Problem? Repair or NO
replace
NO
Repiar Completed
YES
AFFECTED VIN
DI10-103
EGR Actuator Malfunction
P1405 EGR Vacuum Modulator - Short to GND MIL ON
P1406 EGR Vacuum Modulator - Short to +Batt Unable EGR Control (Air Flow)
Check actuator wiring
NO
YES
replace Replace actuator
NO
YES
Check resistance of actuator
NO
YES
actuator
Repiar Completed
NO
Check ECU wiring
YES
replace
NO
YES
NO
AFFECTED VIN
DI10-104
Condenser Fan Driving Signal Fault

(Type 1)
P1480 Open Circuit Unable Air Conditioner Operation
P1481 Short Circuit MIL ON
P1482 Short to Ground Below Limited Temperature of Engine Overheat

Detection
Check relay wiring
NO
YES
replace
Repiar Completed
NO
Check ECU wiring
YES
replace
NO
YES
NO

and replace relay
YES
NO
AFFECTED VIN
DI10-105
Condenser Fan Driving Signal Fault

(Type 2)
P1526 Open Circuit Unable Air Conditioner Operation
P1527 Short Circuit MIL ON
P1528 Short to Ground Below Limited Temperature of Engine Overheat

Detection
Check relay wiring
NO
YES
replace
Repiar Completed
NO
Check ECU wiring
YES
replace
NO
YES
NO
Perform forced drive and

replace relay
YES
NO
AFFECTED VIN
DI10-106
(Idling Signal/Too Small Noise Ratio)
P0325 #1 Accelerometer (Knock Sensor) Malfunction MIL ON
“Caution: Check the sensing

value of coolant temp., intake
air temp., fuel temp. baromet-
ric pressure. Incorrect default
values of theses sensors may
cause wrong diagnosis.”
Check accelerometer wiring

and tightening torque, espe-
cially shield ground.
NO
YES
replace Replace accelerometer
(knock sensor)
NO
YES
Check ECU wiring Trouble Continues? Replace ECU
NO
YES
replace
Repiar Completed
NO
YES
NO
AFFECTED VIN
DI10-107
(Idling Signal/Too Small Noise Ratio)
P0330 #2 Accelerometer (Knock Sensor) Malfunction MIL ON
“Caution: Check the sensing

value of coolant temp., intake
air temp., fuel temp. baromet-
ric pressure. Incorrect default
values of theses sensors
may cause wrong diagnosis.”
Check accelerometer wiring

and tightening torque,
especially shield ground.
NO
YES
replace Replace accelerometer
(knock sensor)
NO
YES
Check ECU wiring Trouble Continues? Replace ECU
NO
YES
replace
Repiar Completed
NO
YES
NO
AFFECTED VIN
DI10-108

(Short to Ground or B+)
P1611 Low Injector Bank 1 Voltage Resistance of injector #1 fault. Use estimate re-
sistance level.
P1612 High Injector Bank 1 Voltage Resistance of injector #4 fault. Use estimate re-
sistance level.
Resistance of injector #3 fault. Use estimate re-

sistance level.
MIL ON
Unable Cylinder Balancing
Unable Injector #1 Operation
Unable High Pressure Leak Detection
AFFECTED VIN
DI10-109
1. Fuel Injection Bank 1/2 2. Check Injector Wiring
Injector - short (SC+ or SC-) Check ECU wiring
Key OFF and check injector

wiring
YES
replace
YES
Injector Wiring Problem? Repair or NO
replace
NO
Disconnect injector connec- YES

tor and key ON Wiring Problem? Repair wiring
YES NO
Trouble Continues? Refer to check
injector wiring
NO Replace ECU
Delete default and key OFF.

Key ON while connecting
injector connectors one by one.
YES
Trouble Recurred? Replace the
injector - Enter
new injector
NO C2I into ECU
Repeat same procedures for

all injectors
AFFECTED VIN
DI10-110

(Short to Ground or B+)
P1618 Low Injector Bank 2 Voltage Resistance of injector #2 fault. Use estimate re-
sistance level.
P1619 High Injector Bank 2 Voltage Resistance of injector #5 fault. Use estimate re-
sistance level.
MIL ON
Unable High Pressure Leak Detection
AFFECTED VIN
DI10-111
1. Fuel Injection Bank 1/2 2. Check Injector Wiring
Injector - short Check ECU wiring

wiring
YES
replace
YES
Injector Wiring Problem? Repair or NO
replace
NO
Disconnect injector connec- YES

tor and key ON Wiring Problem? Repair wiring
YES NO
Trouble Continues? Refer to check
injector wiring
NO Replace ECU
Delete default and key OFF.

Key ON while connecting
injector connectors one by one.
YES
Trouble Recurred? Replace the
injector - Enter
new injector
NO C2I into ECU
Repeat same procedures for

all injectors
AFFECTED VIN
DI10-112

Clogged Air Intake System
P0263 #1 Cylinder Balancing Fault MIL ON
Read DTC
NO
YES
Injector Circuit Open? Circuit Open:
Wiring problem Check air intake system
NO
YES
Air Intake System Clogged? Repair air
intake system
Check engine hardware
and check
NO EGR
YES
Engine Hardware Problem? Repair or
replace
Replace injector and enter new
injector C2I value into ECU
NO
Check glow plug
YES
Glow Plug Problem? Repair or
replace
NO
Perform forced valve opera-

tion and check it
YES
Valve Problem? Repair or
replace valve
NO
AFFECTED VIN
DI10-113

Read DTC
NO
YES
NO
YES
intake system
and check
NO EGR
YES
replace
Replace injector and enter
new injector C2I into ECU
NO
Check glow plug
YES
replace
NO

tion and check it
YES
replace valve
NO
AFFECTED VIN
DI10-114

Read DTC
NO
YES
NO
YES
intake system
and check
NO EGR
YES
replace
NO
Check glow plug
YES
replace
NO

tion and check it
YES
replace valve
NO
AFFECTED VIN
DI10-115

Read DTC
NO
YES
NO
YES
intake system
and check
NO EGR
YES
replace
NO
Check glow plug
YES
replace
NO

tion and check it
YES
replace valve
NO
AFFECTED VIN
DI10-116

Read DTC
NO
YES
NO
YES
intake system
and check
NO EGR
YES
replace
NO
Check glow plug
YES
replace
NO

tion and check it
YES
replace valve
NO
AFFECTED VIN
DI10-117
Open Circuit (Injector #1)
P0201 #1 Injector Circuit - Open Unable RPC Trim Fault Detection
Unable H/P Leak Detection

wiring
NO
YES
Wiring Problem? Repair or Check ECU wiring
replace
NO YES
replace
NO
YES
Wiring Problem? Repair or Replace ECU
replace
NO
“If the wiring is normal,

disconnect the injector
connectors and check the
resistance (difficult to check
injector resistance)”
YES
Injector Wiring Problem? Replace
injector
and enter new
NO injector C2I
value into ECU
AFFECTED VIN
DI10-118

wiring
NO
YES
replace
NO YES
replace
NO
YES
replace
NO

YES
injector
and enter new
NO injector C2I
value into ECU
AFFECTED VIN
DI10-119

wiring
NO
YES
replace
NO YES
replace
NO
YES
replace
NO

YES
injector
and enter new
NO injector C2I
value into ECU
AFFECTED VIN
DI10-120

wiring
NO
YES
replace
NO YES
replace
NO
YES
replace
NO

YES
injector
and enter new
NO injector C2I
value into ECU
AFFECTED VIN
DI10-121

wiring
NO
YES
replace
NO YES
replace
NO
YES
replace
NO

YES
injector
and enter new
NO injector C2I
value into ECU
AFFECTED VIN
DI10-122
HSD Circuit Short to LSE (Injector #1)
P1201 #1 Injector Circuit - Short Unable RPC Trim Fault Detection

wiring
NO
YES
Wiring Problem? Repair or Check wiring insulation
replace
NO YES
Disconnect injector connector

NO
YES
Same Trouble Continues? Replace Replace ECU
injector
and enter new
NO injector C2I
value into ECU
Shorted injector circuit.

Check wiring from injector tip
to ECU.
YES
replace
NO
AFFECTED VIN
DI10-123

wiring
NO
YES
replace
NO YES

NO
YES
injector
and enter new
NO injector C2I
value into ECU

to ECU.
YES
replace
NO
AFFECTED VIN
DI10-124

wiring
NO
YES
replace
NO YES

NO
YES
injector
and enter new
NO injector C2I
value into ECU

to ECU.
YES
replace
NO
AFFECTED VIN
DI10-125

wiring
NO
YES
replace
NO YES

NO
YES
injector
and enter new
NO injector C2I
value into ECU

to ECU.
YES
replace
NO
AFFECTED VIN
DI10-126

wiring
NO
YES
replace
NO YES

NO
YES
injector
and enter new
NO injector C2I
value into ECU

to ECU.
YES
replace
NO
AFFECTED VIN
DI10-127
Fuel Temperature Sensor Malfunction
P0182 Low
P0183 High
Read DTC
YES
Fault in sensor supply voltage? Sensor problem caused by supply voltage
to sensor. Locate the problem while dis-
connecting the sensor connectors one by
one. If not sensor problem, check sensor
supply voltage circuit for open and short.
NO
Check sensor wiring

NO
YES
NO
YES
NO
YES
sensor Replace ECU
NO
Check ECU wiring
YES
replace
NO
AFFECTED VIN
DI10-128
Glow Plug Malfunction (Driving Signal)
P1678 Open Circuit MIL ON
P1679 Short Circuit Glow Plug Indicator ON
P1680 Short to Ground
Check glow plug box wiring
NO
YES
replace
Repiar Completed
NO
Check ECU wiring
YES
replace
NO
YES
NO
Replace glow plug box
YES
NO
AFFECTED VIN
DI10-129
Heater 1 Malfunction (Driving Signal)
P1530 Open Circuit Unable Heater Operation
P1531 Short to +Batt
Check relay wiring
NO
YES
replace
Repiar Completed
NO
Check ECU wiring
YES
replace
NO
YES
NO

and replace relay
YES
NO
AFFECTED VIN
DI10-130
Heater 2 Malfunction (Driving Signal)
P1534 Open Circuit Unable Heater Operation
P1535 Short to +Batt
Check relay wiring
NO
YES
replace
Repiar Completed
NO
Check ECU wiring
YES
replace
NO
YES
NO

and replace relay
YES
NO
AFFECTED VIN
DI10-131
Rail Pressure Control Fault

(Too High Pressure)
P1254 Maximum Value Unable Accelerometer Decoding
P1253 Minimum Value MIL ON
1. Rail Pressure Control
Read DTC
YES
YES Transfer Fuel System Repair or
Rail preaaure sensor or IMV Refer to IMV
Problem? replace
Related DTC? diagnosis
NO
NO
YES Check high pressure fuel

Rail Pressure Sensor Repair or
system
Problem? replace
NO YES
H/P Fuel System Problem? Repair or
replace
Check transfer fuel system
NO
Replace ECU
AFFECTED VIN
DI10-132
2. Transfer Fuel System 3. High Pressyre Fuel System
Check fuel level Check high pressure fuel

system
YES
Fuel Exhausted? Add fuel YES
Cause Found? Add fuel
NO
NO
“Visually check transfer fuel

system (fuel leaks, installation)”
HP fuel system is normal
YES
Transfer Fuel System Repair or
Problem? replace
NO
Check if the air in transfer

fuel system is too much
YES
Excessive Air in Transfer Install a
Fuel System? container to
H/P pump
venturi.
Remove
venturi return
NO lines. Fill fuel
with hand
pump.
Check fuel filter specification
YES
Different Specification? Replace filter
with new one
NO
Transfer fuel system is normal
AFFECTED VIN
DI10-133
Rail Pressure Control Fault

(Too High IMV Current Trim, drift)
P1256 Small Delivery of Transfer Fuel Unable Accelerometer Decoding
P1257 Large Delivery of Transfer Fuel MIL ON
P1258 Small Delivery of High Pressure Fuel Unable Dynamic Leak of Injector #1
P1259 Large Delivery of High Pressure Fuel Unable Dynamic Leak of Injector #2
1. Diagnosis Procedures (Rail Pressure Control)
Read DTC
YES
Problem? replace
NO
NO

system
Problem? replace
NO YES
replace
NO
Replace ECU
AFFECTED VIN
DI10-134
2. Diagnosis Procedures (Transfer Fuel System)
Check fuel level
NO
YES
Fuel Exhausted? Add fuel
NO
YES
with new one
NO
YES
Transfer Fuel System Repair or Repiar Completed
Problem? replace
NO

fuel system is too much
YES
H/P pump
venturi.
Remove
venturi return
NO
lines. Fill fuel
with hand
pump.
3. Diagnosis Procedures (High Pressure Fuel System)
YES
Cause Found? Repair or
replace
NO
H/P Fuel System - Normal
AFFECTED VIN
DI10-135
Rail Pressure Control Fault (Too Slow

Pressure Build Up while Cranking)
P1191 Rail Pressure Build Up - Too Slow Unable Accelerometer Decoding
Limited Rail Pressure Mode Operation
Read DTC
YES
Problem? replace
NO
NO

system
Problem? replace
NO YES
replace
NO
Replace ECU
AFFECTED VIN
DI10-136
Check fuel level
NO
YES
NO
YES
with new one
NO
YES
Transfer Fuel System Repair or Transfer fuel system is normal
Problem? replace
NO

fuel system is too much (with
a low pressure tester)
YES
H/P pump
venturi.
Remove
venturi return
NO
lines. Fill fuel
with hand
pump.
3. Diagnosis Procedures (High Pressyre Fuel System)
YES
replace
NO
AFFECTED VIN
DI10-137
IMV Operation Fault (Electrical Fault)
P0255 Open Circuit Unable Accelerometer Decoding
P0251 Short Circuit Delayed Engine Stop
P0253 Short to Ground Unable Dynamic Leak of Injector #1
Check IMV wiring

NO
YES Check resistance of IMV

replace
NO YES
Resistance Problem? Replace H/P
pump and IMV
Check ECU wiring
NO
YES Replace ECU

replace
NO
YES
AFFECTED VIN
DI10-138
Intake Air Temperature Sensor Fault

(Electric Fault)
P0112 High MIL ON
P0113 Low
Read DTC
YES
NO
Check sensor wiring

NO
YES
NO
YES
NO
YES
sensor Replace ECU
NO
Check ECU wiring
YES
replace
NO
AFFECTED VIN
DI10-139
MDP Fault (Injector #1)
P1171 #1 Injector MDP Fault Unable Accelerometer Decoding
MIL ON
Unable Pilot and Post Injection
Torque Limit For Injector Drift
Enter the injector data into

ECU after replacing injector
MIL ON

AFFECTED VIN
DI10-140
MIL ON

MIL ON

AFFECTED VIN
DI10-141
MIL ON

AFFECTED VIN
DI10-142
Rail Pressure Fault (Too High)
P1252 Too High IMV Pressure
Read DTC
NO
Check high pressure fuel

YES system
Rail preaaure sensor or IMV Refer to
Related DTC? IMV diagnosis
YES
NO H/P Fuel System Problem? Repair or
replace
YES NO
Problem? replace
Replace ECU
NO
YES
Transfer Fuel System Repair or
Problem? replace
AFFECTED VIN
DI10-143
Check fuel level
NO
YES
NO
YES
with new one
NO
YES
Transfer Fuel System Repair or Repiar Completed
Problem? replace
NO

fuel system is too much (with
a low pressure tester)
YES
H/P pump
venturi.
Remove
venturi return
lines. Fill fuel
with hand
pump.
3. Diagnosis Procedures (High Pressyre Fuel System)
YES
replace
NO
AFFECTED VIN
DI10-144
Accelerator Pedal Sensor Malfunction

(Relationship between Track 1 and Track 2)
P1120 Accelerator Pedal Sensor 1 Malfunction Unable Cruise Control
P1121 Accelerator Pedal Sensor 2 Malfunction
Torque Reduction Mode Operation
Read DTC
YES
NO
YES
Sensor Wiring Problem? Replace
sensor NO
YES
NO
YES
NO
YES
NO
YES
Check ECU wiring
NO
YES
NO
AFFECTED VIN
DI10-145

(Limp Home Mode Operation)
P1122 Accelerator Pedal Sensor Malfunction (Limp MIL ON

Home Mode)
Limp Home Mode Operation
Read DTC
YES
NO
YES
Check sensor wiring Replace
sensor NO
YES
NO
YES
NO
YES
NO
YES
Check ECU wiring
NO
YES
NO
AFFECTED VIN
DI10-146

(Torque Reduction Mode Operation)
P1123 Accelerator Pedal Sensor Malfunction (Torque MIL ON

Mode)
Read DTC
YES
NO
YES
Check sensor wiring Replace
sensor NO
YES
NO
YES
NO
YES
NO
YES
Check ECU wiring
NO
YES
NO
AFFECTED VIN
DI10-147

(Electrical Fault, Pedal Stuck)
P1124 Accelerator Pedal Sensor Malfunction - Stuck Unable Cruise Control
Limp Home Mode Operation
Read DTC
NO
YES
Brake switch malfunction Repair or Check ECU wiring
replace brake
switch.
NO
YES
replace
Check if accelerator pedal is
normal NO
YES Check wiring insulation

Accelerator Pedal Stuck? Replace
accelerator
pedal YES
NO Wiring Problem? Repair wiring
Check if accelerator pedal NO

signal is correct with scan tool
Replace brake switch

YES
Signal Problem? Repair or
replace YES
NO
Check brake wiring connection NO
YES Repiar Completed

replace
AFFECTED VIN
DI10-148

(Electrical Fault, Track 1)
P0122 Low MIL ON
P0123 High Unable Cruise Control
P0120 Supply Voltage Limp Home Mode Operation
Read DTC
YES
NO
Check sensor wiring

NO
YES
NO
YES
NO
YES
NO
YES
Check ECU wiring
NO
YES
NO
AFFECTED VIN
DI10-149

(Electrical Fault, Track 2)
P0222 Low MIL ON
P0223 High Unable Cruise Control
P0220 Supply Voltage Torque Reduction Mode Operation
Read DTC
YES
NO
Check sensor wiring

NO
YES
NO
YES
NO
YES
NO
YES
Check ECU wiring
NO
YES
NO
AFFECTED VIN
DI10-150

(Out of Range, ADC or Vref)
P0192 Low Unable Pilot and Post Injection
P0193 High Unable Dynamic Leak of Injector #1
P0190 Supply Voltage Unable Dynamic Leak of Injector #2
P0191 Excessive Pressure Drop Unable Dynamic Leak of Injector #4
Unable RPC Trim Fault Detection
Fully Forced Open IMV
Unable High Rail Pressure Detection
AFFECTED VIN
DI10-151
Read DTC
YES
Sensor Voltage Fault? Sensor problem caused by supply voltage
NO
Check sensor wiring

(Check sensor output) NO
YES
Wiring Problem? Repair or Replace rail and sensor
replace
NO YES
Check ECU wiring

NO
YES
Wiring Problem? Repair or Check fuel system
replace
NO
YES
AFFECTED VIN
DI10-152

(Out of Range when Key ON)
P1192 Low Unable Pilot and Post Injection
P1193 High Unable Dynamic Leak of Injector #1
P1190 Supply Voltage Unable Dynamic Leak of Injector #2
Unable RPC Trim Fault Detection
Fully Forced Open IMV
Unable High Rail Pressure Detection
AFFECTED VIN
DI10-153
Check sensor wiring

NO
YES
Wiring Problem? Repair or Reinstall connect and wiring
replace
NO
YES
Trouble Continues? Replace rail
and sensor
Check ECU wiring
NO
YES
Wiring Problem? Repair or Repair completed
replace
NO
Check resistance of wiring
YES
AFFECTED VIN
DI10-154
Main Relay Malfunction - Stuck
P0215 Main Relay Malfunction- Stuck MIL ON
Check relay wiring
NO
YES
replace Perform forced operation
and replace relay
NO
YES
Check ECU wiring Not available forced Replace ECU
operation?
YES
Wiring Problem? Repair or NO
replace
NO Repair completed
YES
AFFECTED VIN
DI10-155
Vehicle Speed Fault
P1500 Vehicle Speed Fault Unable Cruise Control
Check vehicle conditions
NO
YES
Automatic Transmission Recognize
Equipped? vehicle speed Check gear box target
through CAN.
Check CAN
NO and
YES
transmission. Gear Box Target Problem? Replace gear
box target
Check sensor and wiring NO
YES Install new target

replace
NO YES
Check ECU wiring

NO
YES
replace
NO
YES
replace
AFFECTED VIN
DI10-156
5V Supply Voltage 1 Fault
P0642 Low Unable Cruise Control
P0643 High
Supply Voltage 1 (5V):

Accelerator Pedal Sensor 1
“Supply Voltage 2 (5V): HFM
sensor, Rail pressure
sensor, Boost pressure
sensor and Cam sensor”
Supply Voltage (2.5 V): Accelera-
tor Pedal Sensor 2
Read DTC
YES
All DTCs for sensors Sensor problem caused by supply voltage to
connected to sensor supply sensor. Locate the problem while discon-
voltage? necting the sensor one by one. If not sensor
problem, check wiring.
NO
Check wiring
YES
NO
Repair completed
AFFECTED VIN
DI10-157
5V Supply Voltage 2 Fault
P0652 Low
P0653 High
Supply Voltage 1 (5 V):

“Supply Voltage 2 (5 V): HFM
Supply Voltage (2.5 V): Accelera-
tor Pedal Sensor 2
Read DTC
YES
All DTCs for sensors Sensor problem caused by supply voltage
connected to sensor supply to sensor. Locate the problem while dis-
voltage? connecting the sensor one by one. If not
sensor problem, check wiring.
NO
Check wiring
YES
NO
Repair completed
AFFECTED VIN
DI10-158
2.5V Supply Voltage Fault
P0698 Low Unable Cruise Control
P0699 High
Supply Voltage 1 (5 V):

“Supply Voltage 2 (5 V): HFM
Supply Voltage (2.5 V):
Read DTC
YES
All DTCs for sensors Sensor problem caused by supply voltage
connected to sensor supply to sensor. Locate the problem while dis-
voltage? connecting the sensor one by one. If not
sensor problem, check wiring.
NO
Check wiring
YES
NO
Repair completed
AFFECTED VIN
DI10-159
Turbo Charger Actuator Operation Fault

(signal)
P0245 Short to GND Unable Cruise Control
P0246 Short Circuit to B+ Unable VGT Operation
Check actuator wiring
NO
YES
replace Replace actuator
NO
YES
Check resistance of actuator
NO
YES
Resistance Problem? Replace Repair completed
actuator
NO
Check EUC wiring
YES
replace
NO
YES
NO
AFFECTED VIN
DI10-160
ECU Watchdog Fault
P0606 ECU Watchdog Fault
Read DTC
YES
ECU Related DTC? Check body
ground wiring
NO
Check wiring
YES
NO
Repair completed
AFFECTED VIN
DI10-161
ECU Watchdog Fault (Injector Cut-off)
P1607 ECU Injector Cut-off
Read DTC
YES
ground wiring
NO
Check wiring
YES
NO
Repair completed
AFFECTED VIN
DI10-162
ECU Watchdog Fault (Watchdog Trip)
P1600 Trip TPU Write Fault
P1601 Trip Shut Dowm Write Fault
P1602 Trip Noise Write Fault
Read DTC
YES
ground wiring
NO
Check wiring
YES
NO
Repair completed
AFFECTED VIN
DI10-163
ECU Non-Volatile Memory Fault
P1614 MDP MIL ON/Limp Home Mode Operation
P1615 Tele-Coding MIL ON/Limp Home Mode Operation
P1616 Watchdog MIL ON/Limp Home Mode Operation
P1606 CAN MIL ON/Limp Home Mode Operation
P1620 ECU Malfunction MIL ON/Limp Home Mode Operation
P1621 ECU Malfunction MIL ON/Limp Home Mode Operation
P1622 ECU Malfunction MIL ON
Read DTC
YES
ground wiring
NO
Check wiring
YES
NO
Repair completed
AFFECTED VIN
DI10-164
ECU Memory Integration Fault
P1603 Code Integrity Immediately Engine Stop
Read DTC
YES
ground wiring
NO
Check wiring
YES
NO
Repair completed
AFFECTED VIN
DI10-165
Accelerometer Learning Fault
P1148 Accelerometer (Knock Sensor) Learning Fault Torque Reduction Operation
Unable Cruise Control
Read DTC
YES
Knock Sensor Related DTC? Refer to
“Accelerom-
eter (Knock
NO Sensor)
Diagnosis”
Vehicl driving conditions are

not satisfy with MDP learning
requirements
AFFECTED VIN
DI10-166
EGR Valve Control Fault
P0400 EGR Valve Control Fault Unable Cruise Control
Read DTC
YES
EGR valve and HFM sensor Check
related DTC? sensors and
EGR system
NO
Check vacuum modulator/

turbo charger boost modula-
tor and vacuum lines for leak
and installation
Repair completed
AFFECTED VIN
DI10-167
VGT Operation Fault
P1235 VGT Operation Fault Unable Cruise Control
Location demand=change the boost control to O.L.

mode at f (boost demand, engine cycling speed)
1. Diagnosis Procedures(Boost Pressure)
Read DTC
YES
Boost Pressure Problem? Refer to
Diagnosis
Tree “Check
NO sensor(1)”

* Vane condition.
Repair completed
AFFECTED VIN
DI10-168
2. Diagnosis Procedures(Check sensor (1))
Read DTC
YES
Sensor Supply Voltage Sensor problem caused by supply voltage
Problem? to sensor. Locate the problem while dis-
NO
Check sensor wiring

NO
YES
NO
YES
Visually check sensor replace
NO
YES
NO
YES
Check ECU wiring
NO
YES
replace Check fuel system
AFFECTED VIN
DI10-169
TBD
P1608 ECU Malfunction
Read DTC
YES
ground wiring
NO
Check wiring
YES
NO
Repair completed
AFFECTED VIN
DI10-170
No Crank Signal
P0335 No Crank Signal MIL ON
Check sensor wiring
YES
YES
replace Trouble Continues? Replace APS
wheel
NO
NO
Check ECU wiring

Install new wheel
YES
YES
replace Trouble Continues? Replace ECU
NO
NO
Check wiring for open and

short
Repair completed
YES
NO
YES
sensor
NO
Install new sensor
AFFECTED VIN
DI10-171
High Torque Trim
P1170 High Torque Trim MIL ON
Read DTC
YES
IMV Related DTC? Refer to IMV
diagnosis
NO
Read DTC
NO
YES
Rail Pressure Sensor Repair or Check high pressure fuel
Problem? replace system
NO
YES
High pressure fuel system Repair or
Problem? replace
Check transfer pressure fuel
system
NO
YES
Transfer pressure fuel Repair or Replace ECU
system Problem? replace
* Refer to “Check High and Transfer pressure system”.
AFFECTED VIN
DI10-172
Glow Plug Module Communication Fault
P1676 Communication
P1677 Controller
Read DTC
NO
YES
Poor Glow Plug Communica-
Communication? tion problem Check wiring and insulation
between ECU
and glow plug
NO box. Check
YES
related wirings. Wiring Problem? Repair wiring
NO
YES
Wiring Problem? Repair or Replace glow plug box
replace
NO
YES
Check glow plug and wiring
(Resistance: below 1 Ω) NO
YES Repair completed

Problems? Repair or
replace glow
plug
NO
Check ECU wiring
YES
replace
AFFECTED VIN
DI10-173
Glow Plug Module Circuit Malfunction -

Open
P0671 Glow Plug #1
P0672 Glow Plug #2
P0673 Glow Plug #3
P0674 Glow Plug #4
P0675 Glow Plug #5
Read DTC
NO
YES
between ECU
and glow plug
NO
box. Check YES
NO
YES Replace glow plug box

replace
NO YES

Repair completed
YES
Problems? Repair or
replace glow
NO
plug
Check ECU wiring
YES
replace
AFFECTED VIN
DI10-174
Glow Plug Module Circuit Malfunction -

Short (B+)
P1671 Glow Plug #1
P1672 Glow Plug #2
P1673 Glow Plug #3
P1674 Glow Plug #4
P1675 Glow Plug #5
Read DTC
NO
YES
between ECU
and glow plug
NO
box. Check YES
NO
YES Replace glow plug box

replace
NO YES

Repair completed
YES
Problems? Repair or
replace glow
NO
plug
Check ECU wiring
YES
replace
AFFECTED VIN
DI10-175
TCU Signal Fault
P0700 TCU Signal Fault
Check ECU wiring
YES
replace
NO
YES
NO
Check CAN communication

(between High and Low: 120 Ω)
YES
Communication problem Repair or
continues replace
(Replace TCU)
NO
Repair completed
AFFECTED VIN
DI10-176
Air Conditioner Operating Circuit Fault
P1540 Open Circuit Unable A/C Operation
P1541 Short to +Batt Unable A/C Operation
P1542 Short to Ground Unable A/C Operation
Check vehicle condition

(above fault is related to A/C
system) NO
YES Check wiring and insulation

Switch without sensor? N/A
NO YES
Check sensor connection NO
YES Check A/C circuit and

Wiring Problem? Repair or compressor
replace
NO
YES
A/C Problem? Repair or
replace
Check sensor
NO
YES
Sensor Problem? Replace Replace sensor
sensor
NO
YES
Check ECU wiring
NO
YES
replace
AFFECTED VIN
DI10-177
Excessive Water in Fuel Filter
P1149 Excessive Water in Fuel Filter Water Separator Warning Light ON

Remove fuel filter
NO
YES
Water in fuel filter? Repair
completed Check ECU wiring
NO
YES
Check water detection sensor
replace
NO
YES
NO
YES
Check water detection
sensor wiring
NO
YES
replace
NO
Check resistance of water

detection sensor
YES
coolant
temperature
sensor
AFFECTED VIN
DI10-178
Immobilizer Malfunction
P1634 Immobilizer Malfunction MIL ON
P4335 Immobilizer Warning Light ON
P1630
P1631
P1632
P1633
P0633
P1636
Check immobilizer unit

and ECU wiring
YES
replace
NO
YES
Perform immobilizer coding Repair
again completed
NO
Repair or replace immobi-

lizer unit and related devices
AFFECTED VIN
DI10-179
FUEL SYSTEM DIAGNOSIS
FUEL SYSTEM DIAGNOSIS ................................... DI10-180

Overview ............................................................. DI10-180
Fuel pressure system ......................................... DI10-181
Fuel system pressure test .................................. DI10-184
Fuel system check process ................................ DI10-186
PRESSURE LEAKAGE TEST WITH SCAN-100 ...... DI10-195
AFFECTED VIN
DI10-180
FUEL SYSTEM DIAGNOSIS

OVERVIEW
When the Diagnostic Trouble Code (DTC) is detected through scan tool, it’s necessary to check the transfer and high
pressure fuel lines in fuel system before replacing the components.
If the trouble continues even after the trouble has been fixed with scan tool, must perform the fuel pressure test.
Below schematic diagram shows the specifications of pressure, flow mass and temperature in fuel system.
Transfer fuel Pressure limit valve

pressure regulator (High pressure line)
IMV
High pressure
Transfer pump pump
Supply
valve
Suction
valve
Below 2 bar
Below -0.3 bar

Venturi Common rail
Up to
1050 bar
-0.6 ~ 0.1 bar
-0.6 ~ 0.1 bar
Injectors
0.05 ~ 0.1 bar
Priming pump
Fuel filter
High pressure fuel

supply line
Transfer fuel supply line
Fuel tank Return line
AFFECTED VIN
DI10-181
FUEL PRESSURE SYSTEM
Pressure/Volume Consumption in System Pressure/Volume Displacement from Pump
Conservation of fuel pressure/

volume (rail) for proper system
operation
Pump capacity for

supplying the required
target pressure/volume
Injector back
leak volume
Fuel injection
volume
AFFECTED VIN
DI10-182
Example of Too Much Injector Back leak
Increased injector back leak volume
Pressure/volume loss
Injector back Pump capacity

leak volume
Fuel injection
volume
Pressure/volume Pressure/volume
consumption build up
Too Much Injector Back leak

When the injector cannot be sealed due to entering the foreign materials
Example:
• Foreign materials in fuel
• Burnt out or worn high pressure pump
• Mechanical damage in inside of injector
AFFECTED VIN
DI10-183
Example of Pressure/Volume Loss in Pump
Decreased pressure/volume from

pump
Pressure/volume loss
Injector back
leak volume
Pump capacity
Fuel injection
volume
Pressure/volume Pressure/volume
consumption build up
Pressure/Volume Loss in High Pressure Pump

When the required target pressure/volume cannot be delivered due to fuel supply line or pump damage
Example:
• Air in fuel supply line
• Excessive vacuum pressure in fuel supply line (-300 mbar)
• Burnt out or mechanically damaged pump
• Supply fuel with increased temperature ( > 65°C)
AFFECTED VIN
DI10-184
FUEL SYSTEM PRESSURE TEST

Test Tool Kit
For High Pressure Line
For Transfer Line
AFFECTED VIN
DI10-185
Prerequisite
1. Check the connections in fuel supply lines.
2. Check the fuel level in fuel tank.
3. Check if the air exists in fuel supply lines (air bubbles in fuel supply lines or fuel with air bubbles).
4. Check the fuel supply lines for leaks (transfer and high pressure).
5. Check if the specified fuel is used.
6. Check the fuel filter for contamination and abnormality.
Fuel System Test Process
Determine DTC
No Yes
DTC Detected?
No High pressure fuel Fuel system

related problem related DTC:
P1252, P1253,
P1254...P0251
no
Check and repair Diagnose and repair
transfer and H/P fuel Check fuel filter and H/P according to the de-
system fuel system tected DTC
Notice
If more than one DTC have been detected, check the wiring
harness for open or short first.
Check the transfer fuel system and fuel filter before
proceeding the high pressure fuel system check in next page.
AFFECTED VIN
DI10-186
FUEL SYSTEM CHECK PROCESS

Initial Check
• Transfer fuel system (air in system), specified fuel used
• Fuel leaks, fuel filter
• Diagnostic Trouble Code
• Wiring harness
• Abnormal noise from injector
No
No Abnormality Check and repair
in Initial Check?
Yes
Check fuel rail pressure (refer to 4-1)

When cranking engine for 5 seconds
after disconnecting IMV connector, is
the rail pressure over 1,050 bar?
Check transfer fuel system (refer to 4-2)

Yes Install the transparent tube between fuel
filter and priming pump. Check the trans-
fer fuel system for clogged or air bubbles.
Check if the vacuum pressure is proper.
No
* Thoroughly clean the components
before installation
Check the injector
back leak volume
Method 1 Method 2
Static Test for Injector Back leak Volume Dynamic Test for Injector Back leak Volume (refer to 4-4)
(refer to 4-3)
(with engine running)
(with engine cranking but not running)
1. Warm up engine (coolant temp.: over 60°C), place an
Place an empty plastic container under the return of empty plastic container under the return of injector, and
injector: start engine.
Remove IMV and injector connectors, crank for 5 2. Run the engine for 30 seconds at idle speed, perform :
seconds, and check the injector back leak volume. fuel system pressure leakage test” with Scan-i, and
The fuel length in tube should be over 20 cm. check the fuel level in container. It should be over 38 ml.
High Pressure Pump Test (refer to 4-5)

No Install the closed rail into high pressure No
pump at outlet port. Remove IMV connector
and crank engine for 5 seconds. Is the pres-
Yes Yes
sure over 1,050 bar?
Replace the injector Replace the injector

Enter new injector C2I data into ECU Enter new injector C2I data into ECU
after replacing the injector after replacing the injector
Perform the initial check again. Yes
No
Replace high pressure pump
AFFECTED VIN
DI10-187
4-1. High Pressure System Pressure Test
Fuel Rail Pressure Test

1. Disconnect the fuel rail pressure sensor connector and
IMV connector.
2. Install the pressure tester in tool kit to the fuel rail

pressure sensor connector.
3. Crank the engine for 5 seconds (twice).

- Read the maximum pressure displayed on the tester.
- If the maximum pressure is below 1,050 bar, refer to
“Fuel System Check Process” section.
AFFECTED VIN
DI10-188
How To Use Pressure Tester

1. Check if the “TEST?” is displayed on the display when
pressing the “ ” button.
2. The maximum pressure will be displayed when pressing

the button while cranking the engine (around 4 seconds
elapsed from 5 seconds).
Note
The fuel rail pressure can be measured through the scan
tool.
AFFECTED VIN
DI10-189
4-2. Transfer Fuel System Test
Test Procedures
1. All wiring harnesses, connectors and fuel lines should
be installed properly and the engine should be ready to
start.
2. Prepare the special tools for transfer fuel system test
and thoroughly clean the system.
3. Disconnect the key connector for connecting the priming pump to fuel filter and install both connectors of the
special tool to the fuel pump and the priming pump hoses.
4. Start the engine and visually check the transfer line for clogged and air bubbles while running the engine at idle
speed.
5. If the fuel flows are not smooth or air bubbles are found in fuel lines, locate the leaking area and correct it.
AFFECTED VIN
DI10-190
4-3. Static Test for Injector Back leak Volume

1. Remove the injector return hose and seal the openings with screw type caps (included in tool kit).
2. Install the hoses from back leak test containers to return

nipples of injector.
3. Disconnect the IMV connector in H/P pump and the fuel

pressure sensor connector.
AFFECTED VIN
DI10-191
4. Crank the engine twice with 5 seconds of interval.

5. Check if the back leak volume meets the specification.
Specified value Below 20 cm
Note
If the measured value is out of specified value, replace
the injector.
AFFECTED VIN
DI10-192
4-4. Dynamic Test for Injector Back leak Volume

1. Start the engine and warm up until the coolant temperature reaches to 60°C.
2. Remove the injector return hose and seal the openings with screw type caps (included in tool kit).
3. Install the hoses from back leak test containers to return

nipples of injector.
4. Start the engine and let it run for 30 seconds at idle
speed.
5. Launon injector leak detection cycles with SCAN-100.
6. Check if the back leak volume meets the specification.
Specified value Below 38 ml
AFFECTED VIN
DI10-193
4-5 High Pressure Pump Test

1. Prepare the special tools for high pressure pump test
and thoroughly clean the system.
2. Remove the high pressure fuel supply pipe and install

the closed rail delivered with tool kit.
Specified value 40 Nm
* The figure is to show the test method. However, the

actual test operation should be done while the high
pressure pump is installed in vehicle.
3. Install the opposite end of the closed rail into the fuel rail
for test.
Specified value 40 Nm
4. Remove the high pressure fuel return hose and install

the transparent tube between the high pressure pump
and the return port of fuel rail for test.
AFFECTED VIN
DI10-194
5. Connect the digital tester connector into the sensor

connector of fuel rail for test.
6. Disconnect the IMV connector and the fuel rail pressure
sensor connector.
7. Check if the measured value on the digital tester meets
the specified value.
Specified value Over 1,050 bar
AFFECTED VIN
DI10-195
PRESSURE LEAKAGE TEST WITH SCAN-100

1. When performing the static test for injector back leak Volume, the fuel pressure leakage test with SCAN-100
should be done simultaneously. And, the fuel pressure leakage test with SCAN-100 can be done separately.
2. Test Conditions:
• No defective or faulty sensors and components in fuel system: checked by Scan-i
• Coolant temperature: over 60°C
3. The diagnosis procedures with SCAN-100 are as below:
1) Install the SCAN-100 to the diagnostic connector. Select

“DIAGNOSTICS” and press “ENTER” in “MAIN MENU”
screen. Select “STAVIC” and press “ENTER” in “VEHICLE
2) Select “ECU” and press “ENTER” in “CONTROL UNIT

3) Select “LEAK DETECTION” and press “ENTER” in

AFFECTED VIN
DI10-196
4) If there are not any troubled conditions in “TEST

CONDITION” screen, press “ENTER”.
AFFECTED VIN
2 2A
ELECTRIC SYSTEM LAYOUT

1. LOCATIONS OF UNITS AND SENSORS IN PASSENGER COMPARTMENT
TV antenna Windshield
amplifier heated glass unit Sensor cluster (ESP) Air bag unit (SDM)
STICS
ICM
module
Sun sensor
Amplifier/Tuner/Navigation unit and PAS unit
PAS unit
DSP integrated amplifier
Tuner
Navigation unit
CHANGED BY ELECTRICAL SYSTEM

EFFECTIVE DATE STAVIC - 2004.09
AFFECTED VIN
2A 3
TV antenna Steering wheel angular

AM/FM radio amplifier amplifier sensor Rain sensing unit and ECM
Sun roof unit and motor
Interior temperature and

humidity sensor
Auto light sensor
Engine ECU
TCU and TCCU
TCU
TCCU
ELECTRICAL SYSTEM CHANGED BY

STAVIC - 2004.09 EFFECTIVE DATE
AFFECTED VIN
4 2A
2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT

(EXCEPT ENGINE RELATED SENSORS AND UNITS)
FFH (Fuel Fired Heater)
Horn
Ambient temperature sensor (FFH)
AQS/Ambient temperature sensor

(Integrated type) – Air conditioner Receiver drier
AQS sensor
Ambient tempera-
ture sensor

AFFECTED VIN
2A 5
Fuse and relay box in engine

Brake pressure sensor
compartment
ABS (ESP) HECU (under the battery)
PTC power supply relay (PTC system

equipped vehicle)
beside battery positive

(+) terminal
Theft deterrent horn (under the

Sub condenser washer fluid reservoir)

AFFECTED VIN
6 2A
3. SWITCHES IN PASSENGER COMPARTMENT
Audio remote control switch on the steering wheel
Power button
Mute button
Mode button
Volume button – Up
SEEK button – Up
Volume button – Down

SEEK button – Down
4WD switch and rear washer/

wiper switch
Outside rearview mirror

adjusting and folding
switch
Window switches

AFFECTED VIN
2A 7
Room lamp and sun roof switch

(multi meter integrated type) Driver seat warmer Front defogger switch Front fog lamp
switch
Sun roof switch
Room lamp switch

(coupled operation Hazard switch
with door)
Multi meter
Outside rearview mirror and ESPOFF
rear glass heated switch
Front room lamp switch
Passenger seat
warmer switch
Multifunction switch and

steering wheel angular sensor
Passenger’s window
switch

AFFECTED VIN
8 2A
4. SYSTEM LAYOUT (BASED ON DVD SYSTEM EQUIPPED VEHICLE)
Tweeter speaker
Tweeter speaker
Center speaker
Center speaker
AV head unit
Audio remote
control switches
Front speaker (RH)

Sub woofer (amplifier
integrated type)
Front tweeter GPS antenna
speaker (RH)
Center speaker
(RH)
AV head unit
Center
DVD changer s p e a k e r
Center speaker
(LH)
Front tweeter
speaker (LH)
Front speaker (LH)
Amplifier integrated sub woofer

AFFECTED VIN
2A 9
DVD changer
Rear tweeter speaker (RH)

TV antenna amplifier (RH)
Rear speaker (RH)

Radio antenna
amplifier
Rearview camera
Rear monitor
Tuner/Amplifier/Navigation unit
Rear speaker (LH)
TV antenna amplifier (LH)

Rear tweeter speaker (LH) Tuner
DSP integrated
amplifier
Navigation unit

AFFECTED VIN
10 2A
ELECTRIC COMPONENTS AND LAYOUT

1. WIRING HARNESS ARRANGEMENT

AFFECTED VIN
2A 11
2. COMPONENTS LOCATOR

AFFECTED VIN
12 2A
FUSES AND RELAYS

Fuse and relay box is located in the engine compartment, and the interior fuse box is located under the driver side
instrument panel. Especially, ICM box, an integrated circuit of relays, is mounted along with STICS behind the driver
side instrument panel.
1. ENGINE COMPARTMENT FUSE AND RELAY BOX
Connector arrangement
Back of the fuse and relay box (after removal)
Fuses and relays

AFFECTED VIN
2A 13
Arrangement of Fuses and Relays
Descriptions of Fuses and Relays

Fuse NO. Capacity Usage Fuse NO. Capacity Usage
SB1 120A/140A Generator (FFH, PTC) Ef9 20A AV System
SB2 60A ABS, ABS/ESP Ef10 30A Glass HTD
SB3 30A IGN KEY “2”, Start RLY Ef11 15A
SB4 30A Condenser Fan (High) Ef12 15A Seat Warmer
SB5 30A Condenser Fan (Low),
Condenser Fan Ef13 20A Sun Roof
SB6 50A ENG MAIN RLY
SB7 30A Fuse Box “BATT-2”
Ef14 20A 4WD (TOD)
SB8 30A Blower (FRT)
SB9 30A PWR Window (FRT) Ef15 20A Driver PWR Seat
SB10 30A PWR Window (RR) Ef16 10A Tail Lamp (LH)
SB11 30A Fuse Box “BATT-1” Ef17 10A Tail Lamp (RH)
Ef1 10A A/C Compressor, A/C RLY Ef18 7.5A Illumination
Ef2 15A Fog Lamp (FRT) Ef19 15A ENG ECU
Ef3 15A DRL Ef20 15A Fuel Pump (GSL)
Ef4 10A Horn Ef21 15A Head Lamp (High)
Ef5 15A ENG SNR 1 Ef22 15A RR Blower
Ef6 20A FFH, Window Shield Glass Ef23 20A PWR Outlet (RR)
Ef7 30A ABS, ABS/ESP Ef24 20A AV Head Unit, Tuner Unit
Ef25 15A Buzzer
Ef8 15A Head Lamp (Low)
Ef26 15A Out Side Mirror

AFFECTED VIN
14 2A
2. INTERIOR FUSE AND ICM BOX

Interior Fuse Box
• The interior fuse box is located in the lower area of driver side instrument panel.
• To check the fuses, open the driver side door and remove the fuse box cover.

AFFECTED VIN
2A 15
ICM(Integrated Control Module) Box

The ICM box is installed along with RK STICS on the bracket behind the Instrument panel undercover.
It contains an integrated module with around 14 relays according to the vehicle model. Relays in the module are installed
on the integrated circuit with a safety circuit. This system operates with small current (by using transistor) and mini-
mizes the sparks that occur during operations (connection/disconnection) of relays; therefore its durability and wear
resistance has been greatly increased compared to the conventional relays.
Relays in the ICM box cannot be replaced respectively; so when the internal components (including relay) are defective,
ICM box should be replaced as an assembly.
RK STICS
ICM box

AFFECTED VIN
16 2A
Printed Circuit Board Arrangement of ICM Box

The figure shows the internal arrangement of ICM box when the cover is removed and then disassembled.
The relays cannot be disassembled and replaced respectively; so the ICM box should be replaced as an
assembly when any internal components are defective.
Front view
Relay 15
(rear fog lamp)
Relay 3
Relay 1 (spare 2) (seat warmer, LH)
Relay 4
Relay 2 (seat warmer, RH)
(O 2 sensor: gasoline)
Relay 9
Relay 5 (horn relay)
(wiper INT-LOW)
Relay 6 Relay 8
(wiper HIGH) (door lock relay)
Relay 7 Relay 14
(power socket) (flasher unit)
Relay 10
(front cigarette lighter
and power socket)
Relay 13
(theft deterrent relay) Relay 11
(door unlock)
Relay 12
(driver’s door unlock)
Buzzer 1
(Back sonar)
Chime bell circuit
Buzzer 2

AFFECTED VIN
2A 17
Rear view
Relay 3
Relay 4 Relay 1
(spare 2)
Relay 2
Relay 9
Relay 5
Relay 8
Relay 15
Relay 6
Relay 7
Relay 12
Relay 11 Relay 13
Buzzer 2 Relay 10 Relay 14 Buzzer 1

AFFECTED VIN
18 2A
ICM Connector Arrangement (Based on Wiring Connectors)

Never apply battery power from the rear of ICM printed circuit board directly to inspect internal circuit of the ICM box.
Otherwise, the precise internal circuits and safety circuit can be destroyed. When inspecting the power supply and
others, the connectors should be removed before starting the inspection.
The pin arrangements shown in the figure are also based on the connectors.
! " # $ % & '

! " # $ % & '
! " # $ % &
' ! ! ! !! !" !# !$ !% !& !' "

AFFECTED VIN
2A 19
ICM Box Power Supply Circuit
The figure shows ICM box power supply circuit. For details, refer to the appropriate wiring diagrams.
1) Door lock relay / Cigarette lighter relay / Power outlet relay
This circuit is supplied the power through the relevant fuse and STICS. The supplied power magnetize the switch to
supply the power to the appropriate system.
To inspect this circuit, turn the switch on and check if the voltage from ICM box is within specified range. After then,
check the output through the ICM box.
Checking the condition of the relevant component in the system should be done before doing this inspection.

AFFECTED VIN
20 2A
2) Wiper HI and LO relay / Horn relay
The rain sensing system in this vehicle has a different control logic compared to conventional rain sensing system. In the
conventional rain sensing system, the rain sensor unit controls the wipers directly. However, in this vehicle, the rain
sensor communicates the data with STICS, and the STICS controls the wiper motor.
Signals from STICS to rain sensor unit contain the information that there is no rain under the current mode based on
following conditions;
- Washer switch is operating,
- Operating under MIST mode, or
- The multifunction wiper switch is in AUTO mode.
For more details, refer to the “Rain Sensing Wiper” section in this manual.

AFFECTED VIN
2A 21
3) Flasher unit relay / Burglar relay / Chime bell
The relay and unit that controls the hazard warning flasher and turn
signal lamp is also installed in the ICM box as illustrated. Also, the
theft deterrent relay that operates the hazard warning flasher and the
theft deterrent horn is installed.
This vehicle has two separate horns in the engine compartment; a

horn (see figure) located in front of the battery is used for theft deter-
rent warning and beep sound during the operation of doors by remote
control key.

AFFECTED VIN
22 2A
4) Seat warmer relay (front seats) / Back sonar

Each seat warmer installed in the front seats has its own relay in ICM box.
When pressing the seat warmer switch prepared for each front seat, the seat cushion and seatback get warm. The
thermistor in the seat maintains the warming temperature at around 45¡ÆC by cutting off or connecting the power to the
heated wire.
The heated glass (defogger) system contains the windshield heated glass, outside rearview mirror heated glass, and
tailgate heated glass.
When the seat warmer switch is operated, the seat warmer relay in engine compartment fuse box supplies the power to
tailgate glass and outside rearview mirrors. This is controlled by STICS. However, the windshield heated glass (deicer)
is controlled by the separate control unit installed behind the driver side instrument panel undercover.
The fuse (30A) for tailgate heated glass and outside rearview mirror heated glass and the fuse (15A) for windshield
heated glass are in the engine compartment fuse box.

AFFECTED VIN
2A 23
Tailgate Heated Glass, Outside Rearview Mirror Heated Glass (controlled by STICS)
1. The outside rearview mirror heated glass operates for 12 minutes when turning on the defogger switch while the
engine is running.
2. If the defogger switch is pressed again during the operation, the operation stops.
3. If the defogger switch is pressed again within 10 minutes after completion of the first operation, the defogger
system operates for 6 minutes just for once.
4. The defogger is not available when the ignition switch is in “OFF” position or the alternator is not running.
Windshield Heated Glass (controlled by separate unit)

The windshield heated glass control unit is installed behind the driver side Instrument panel undercover. Whenever
pressing the switch, the windshield heated glass operates for 12 minutes and turns off if pressed again during its
operation. If the switch is pressed again, it operates another 12-minute operation.
Windshield heated glass unit
Defogger switch
Parking Aid Sensors on Rear Bumper

In the parking aid system equipped vehicle, its control unit is installed inside of the rear quarter trim behind the driver’s
seat. The buzzer for the back sonar is installed in ICM box. For more details, refer to “Parking Aid System” section in
this manual.
Back sonar
buzzer

AFFECTED VIN
24 2A
Removal and Installation of ICM Box

2. Unscrew the screws from driver side instrument panel
undercover and remove the undercover.
3. Unscrew the nuts and remove the ICM box.
4. Unscrew the connector mounting nuts from the back of the ICM box and disconnect the connector A and B.

AFFECTED VIN
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Wiring Harness, Connector & Ground Location

1) W/H Engine room

AFFECTED VIN
26 2A
2) W/H Main

AFFECTED VIN
2A 27
3) W/H Floor (LH)

AFFECTED VIN
28 2A
4) W/H Floor (RH)

AFFECTED VIN
2A 29
5) W/H Air-con
Front air-con

AFFECTED VIN
30 2A
Rear air-con

AFFECTED VIN
2A 31
6) W/H Door
Front door
Rear door Tailgate door

AFFECTED VIN
32 2A
7) W/H Roof

AFFECTED VIN
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8) W/H Seat
Driver’s
Passenger’s

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MEMO
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2A 1
2A - Electrical System (2005 ~)
Table of Contents
ELECTRIC SYSTEM LAYOUT .......................... 2A-2
1. Locations of units and sensors in passenger compartment
....................................................................................... 2A-2
2. Switches, units and sensors in engine compartment
(except engine related sensors and units) ................... 2A-4
3. Switches in passenger compartment ........................... 2A-6
4. System layout (based on DVD system equipped vehicle)
....................................................................................... 2A-8
ELECTRIC COMPONENTS AND LAYOUT .... 2A-10

1. Wiring harness arrangement ..................................... 2A-10
2. Components locator ................................................... 2A-11
FUSES AND RELAYS ..................................... 2A-12

1. Engine cmpartment fuse and relay box ..................... 2A-12
2. Interior fuse and ICM box .......................................... 2A-14

RODIUS /STAVIC - 2005.07 EFFECTIVE DATE
AFFECTED VIN
2 2A
ELECTRIC SYSTEM LAYOUT

1. LOCATIONS OF UNITS AND SENSORS IN PASSENGER COMPARTMENT
TV antenna Windshield
amplifier heated glass unit Sensor cluster (ESP) Air bag unit (SDM)
STICS
ICM
module
Sun sensor
Amplifier/Tuner/Navigation unit and PAS unit
PAS unit
DSP integrated amplifier
Tuner
Navigation unit

EFFECTIVE DATE RODIUS /STAVIC- 2005.07
AFFECTED VIN
2A 3
TV antenna Steering wheel angular

AM/FM radio amplifier amplifier sensor Rain sensing unit and ECM
Sun roof unit and motor
Interior temperature and

humidity sensor
Auto light sensor
Engine ECU
TCU and TCCU
TCU
TCCU

AFFECTED VIN
4 2A
2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT

(EXCEPT ENGINE RELATED SENSORS AND UNITS)
FFH (Fuel Fired Heater)
Horn
Ambient temperature sensor (FFH)
AQS/Ambient temperature sensor

(Integrated type) – Air conditioner Receiver drier
AQS sensor
Ambient tempera-
ture sensor

AFFECTED VIN
2A 5
Fuse and relay box in engine

Brake pressure sensor
compartment
ABS (ESP) HECU (under the battery)
PTC power supply relay (PTC system

equipped vehicle)
beside battery positive

(+) terminal
Theft deterrent horn (under the

Sub condenser washer fluid reservoir)

AFFECTED VIN
6 2A
3. SWITCHES IN PASSENGER COMPARTMENT
Audio remote control switch on the steering wheel
Power button
Mute button
Mode button
Volume button – Up
SEEK button – Up
Volume button – Down

SEEK button – Down
4WD switch and rear washer/

wiper switch
Outside rearview mirror

adjusting and folding
switch
Window switches

AFFECTED VIN
2A 7

(multi meter integrated type) Driver seat warmer switch Rear fog lamp Front fog lamp
Sun roof switch
Room lamp switch

(coupled operation Hazard switch
with door)
Multi meter
Refogger switch ESPOFF

Passenger seat
warmer switch
Multifunction switch and

steering wheel angular sensor
Passenger’s window
switch

AFFECTED VIN
8 2A
4. SYSTEM LAYOUT (BASED ON DVD SYSTEM EQUIPPED VEHICLE)
Tweeter speaker
Tweeter speaker
Center speaker
Center speaker
AV head unit
Audio remote
control switches
Front speaker (RH)

Sub woofer (amplifier
integrated type)
speaker (RH)
Center speaker
(RH)
AV head unit
Center
DVD changer s p e a k e r
Center speaker
(LH)
Front tweeter
speaker (LH)
Front speaker (LH)
Amplifier integrated sub woofer

AFFECTED VIN
2A 9
DVD changer

Rear speaker (RH)

Radio antenna
amplifier
Rearview camera
Rear monitor
Tuner/Amplifier/Navigation unit
Rear speaker (LH)
TV antenna amplifier (LH)

Rear tweeter speaker (LH) Tuner
DSP integrated
amplifier
Navigation unit

AFFECTED VIN
10 2A
ELECTRIC COMPONENTS AND LAYOUT

1. WIRING HARNESS ARRANGEMENT

AFFECTED VIN
2A 11

AFFECTED VIN
12 2A
FUSES AND RELAYS

Fuse and relay box is located in the engine compartment, and the interior fuse box is located under the driver side
instrument panel. Especially, ICM box, an integrated circuit of relays, is mounted along with STICS behind the driver
side instrument panel.
1. ENGINE COMPARTMENT FUSE AND RELAY BOX
Connector arrangement
Back of the fuse and relay box (after removal)
Fuses and relays

AFFECTED VIN
2A 13
Arrangement of Fuses and Relays
Descriptions of Fuses and Relays

Fuse NO. Capacity Usage Fuse NO. Capacity Usage
SB1 120A/140A Generator (FFH, PTC) Ef9 20A AV System
SB2 60A ABS, ABS/ESP Ef10 30A Glass HTD
SB3 30A IGN KEY “2”, Start RLY Ef11 15A
SB4 30A Condenser Fan (High) Ef12 15A Seat Warmer
SB5 30A Condenser Fan (Low),
Condenser Fan Ef13 20A Sun Roof
SB6 50A ENG MAIN RLY
SB7 30A Fuse Box “BATT-2”
Ef14 20A 4WD (TOD)
SB8 30A Blower (FRT)
SB9 30A PWR Window (FRT) Ef15 20A Driver PWR Seat
SB10 30A PWR Window (RR) Ef16 10A Tail Lamp (LH)
SB11 30A Fuse Box “BATT-1” Ef17 10A Tail Lamp (RH)
Ef1 10A A/C Compressor, A/C RLY Ef18 7.5A Illumination
Ef2 15A Fog Lamp (FRT) Ef19 15A ENG ECU
Ef3 15A DRL Ef20 15A Fuel Pump (GSL)
Ef4 10A Horn Ef21 15A Head Lamp (High)
Ef5 15A ENG SNR 1 Ef22 15A RR Blower
Ef6 20A FFH, Window Shield Glass Ef23 20A PWR Outlet (RR)
Ef7 30A ABS, ABS/ESP Ef24 20A AV Head Unit, Tuner Unit
Ef25 15A Buzzer
Ef8 15A Head Lamp (Low)
Ef26 15A Out Side Mirror

AFFECTED VIN
14 2A
2. INTERIOR FUSE AND ICM BOX

Interior Fuse Box
• The interior fuse box is located in the lower area of driver side instrument panel.
• To check the fuses, open the driver side door and remove the fuse box cover.

AFFECTED VIN
2A 15
ICM (Integrated Control Module) Box

The ICM box is installed along with RK STICS on the bracket behind the Instrument panel undercover.
It contains an integrated module with around 14 relays according to the vehicle model. Relays in the module are installed
on the integrated circuit with a safety circuit. This system operates with small current (by using transistor) and mini-
mizes the sparks that occur during operations (connection/disconnection) of relays; therefore its durability and wear
resistance has been greatly increased compared to the conventional relays.
Relays in the ICM box cannot be replaced respectively; so when the internal components (including relay) are defective,
ICM box should be replaced as an assembly.
RK STICS
ICM box

AFFECTED VIN
16 2A
Printed Circuit Board Arrangement of ICM Box

The figure shows the internal arrangement of ICM box when the cover is removed and then disassembled.
The relays cannot be disassembled and replaced respectively; so the ICM box should be replaced as an
assembly when any internal components are defective.
Front view
Relay 15
(rear fog lamp)
Relay 3
Relay 1 (spare 2) (seat warmer, LH)
Relay 4
Relay 2 (seat warmer, RH)
(O 2 sensor: gasoline)
Relay 9
Relay 5 (horn relay)
(wiper INT-LOW)
Relay 6 Relay 8
(wiper HIGH) (door lock relay)
Relay 7 Relay 14
(power socket) (flasher unit)
Relay 10
(front cigarette lighter
and power socket)
Relay 13
(theft deterrent relay) Relay 11
(door unlock)
Relay 12
(driver’s door unlock)
Buzzer 1
(Back sonar)
Chime bell circuit
Buzzer 2

AFFECTED VIN
2A 17
Rear view
Relay 3
Relay 4 Relay 1
(spare 2)
Relay 2
Relay 9
Relay 5
Relay 8
Relay 15
Relay 6
Relay 7
Relay 12
Relay 11 Relay 13
Buzzer 2 Relay 10 Relay 14 Buzzer 1

AFFECTED VIN
18 2A
ICM Connector Arrangement (Based on Wiring Connectors)

Never apply battery power from the rear of ICM printed circuit board directly to inspect internal circuit of the ICM box.
Otherwise, the precise internal circuits and safety circuit can be destroyed. When inspecting the power supply and
others, the connectors should be removed before starting the inspection.
The pin arrangements shown in the figure are also based on the connectors.
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

AFFECTED VIN
2A 19
ICM Box Power Supply Circuit
The figure shows ICM box power supply circuit. For details, refer to the appropriate wiring diagrams.
1) Door lock relay / Cigarette lighter relay / Power outlet relay
This circuit is supplied the power through the relevant fuse and STICS. The supplied power magnetize the switch to
supply the power to the appropriate system.
To inspect this circuit, turn the switch on and check if the voltage from ICM box is within specified range. After then,
check the output through the ICM box.
Checking the condition of the relevant component in the system should be done before doing this inspection.

AFFECTED VIN
20 2A
2) Wiper HI and LO relay / Horn relay
The rain sensing system in this vehicle has a different control logic compared to conventional rain sensing system. In the
conventional rain sensing system, the rain sensor unit controls the wipers directly. However, in this vehicle, the rain
sensor communicates the data with STICS, and the STICS controls the wiper motor.
Signals from STICS to rain sensor unit contain the information that there is no rain under the current mode based on
following conditions;
- Washer switch is operating,
- Operating under MIST mode, or
- The multifunction wiper switch is in AUTO mode.
For more details, refer to the “Rain Sensing Wiper” section in this manual.

AFFECTED VIN
2A 21
3) Flasher unit relay / Burglar relay / Chime bell
The relay and unit that controls the hazard warning flasher and turn
signal lamp is also installed in the ICM box as illustrated. Also, the
theft deterrent relay that operates the hazard warning flasher and the
theft deterrent horn is installed.
This vehicle has two separate horns in the engine compartment; a

horn (see figure) located in front of the battery is used for theft deter-
rent warning and beep sound during the operation of doors by remote
control key.

AFFECTED VIN
22 2A
4) Seat warmer relay (front seats) / Back sonar

Each seat warmer installed in the front seats has its own relay in ICM box.
When pressing the seat warmer switch prepared for each front seat, the seat cushion and seatback get warm. The
thermistor in the seat maintains the warming temperature at around 45°C by cutting off or connecting the power to
the heated wire.
Parking Aid Sensors on Rear Bumper

In the parking aid system equipped vehicle, its control unit is installed inside of the rear quarter trim behind the driver’s
seat. The buzzer for the back sonar is installed in ICM box. For more details, refer to “Parking Aid System” section in
this manual.
Back sonar
buzzer

AFFECTED VIN
2A 23
Removal and Installation of ICM Box

2. Unscrew the screws from driver side instrument panel
undercover and remove the undercover.
3. Unscrew the nuts and remove the ICM box.
4. Unscrew the connector mounting nuts from the back of the ICM box and disconnect the connector A and B.

AFFECTED VIN
24 2A
Wiring Harness, Connector & Ground Location

1) W/H Engine room

AFFECTED VIN
2A 25
2) W/H Main

AFFECTED VIN
26 2A
3) W/H Floor (LH)

AFFECTED VIN
2A 27
4) W/H Floor (RH)

AFFECTED VIN
28 2A
5) W/H Air-con
Front air-con

AFFECTED VIN
2A 29
Rear air-con

AFFECTED VIN
30 2A
6) W/H Door
Front door
Rear door Tailgate door

AFFECTED VIN
2A 31
7) W/H Roof

AFFECTED VIN
32 2A
8) W/H Seat
Driver’s
Passenger’s

AFFECTED VIN
2B 3
METER CLUSTER / INDICATOR DISPLAY
1. APPEARANCE
The instrument panel in this vehicle is different from conventional type of instrument panel. The meter cluster and
indicator display are separated. The meter cluster is located at the center of the dash panel, and the indicator display is
located in front of driver’s seat.
Meter cluster
Coolant Fuel level

RPM gage
temperature Speedometer gauge
gauge
Warning lamps and indicators
CLUSTER / WARNING & INDICATOR PANEL CHANGED BY

AFFECTED VIN
4 2B
2. CONNECTORS AND CIRCUIT DIAGRAM
Gauge Panel
A B
Indicator Display D C
CHANGED BY CLUSTER / WARNING & INDICATOR PANEL

AFFECTED VIN
2B 5
Circuit Diagram of Indicator Display

AFFECTED VIN
6 2B
3. DESCRIPTIONS OF INDICATOR DISPLAY
Illumination lamp (bulb)
Connector B Connector A
1. Immobilizer indicator 12. Seat belt reminder

2. Glow indicator 13. Low fuel level warning light
3. Winter mode indicator 14. Defogger indicator
4. Left turn signal indicator and hazard flasher 15. Door open warning light
5. Auto shift indicator (for automatic transmission) 16. High beam indicator
6. Right turn signal indicator and hazard flasher 17. Engine oil pressure warning light
7. 4WD CHECK warning light 18. Air bag warning light
8. 4WD LOW indicator 19. Water separator warning light
9. Engine check warning light 20. ABS warning light
10. Brake warning light 21. EBD warning light
11. Battery charge warning light 22. ESP warning light

AFFECTED VIN
2B 7
4. FUNCTION DESCRIPTION AND INSPECTION OF METER CLUSTER

Meter Cluster
Tachometer – Engine RPM Display
Danger range (red zone)
The tachometer indicates engine speed in revolutions per minute. Multiply 1,000 to the current number, then it will be the
current number of engine revolutions.
Under the normal engine operating temperature, the proper idling speed is 700~800 rpm. The red zone (danger rpm
range) starts from 4,500 rpm.
1. Connect the tachometer for tune-up test and start the engine.
2. Eliminate the hysteresis by tapping the tachometer.
3. Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive.
Description Specification (VIN=13 ± 0.1V, Temperature: 25°C)

Engine speed (rpm) 700 1000 2000 3000 4000 5000 6000
Tolerance (rpm) +50 +100 +125 +150 +150 - -
-100 -100 -125 -150 -150
If the tachometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in
tachometer. If there is a difference between actual engine speed (rpm) and reading from tachometer, connect a scanner
and then compare the value on tachometer with the reading from scanner.

AFFECTED VIN
8 2B
Speedometer
The speedometer indicates the vehicle speed by calculating the signals from the rear right wheel speed sensor through
ABS or ESP unit.
If the speedometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in
speedometer. However, these symptoms also could be appeared when the tire has uneven wear, different tire inflation
pressures or different tire specifications.
Perform the speedometer test regarding the tolerance as described. However, it is not similar simple work in field due to
lack of measuring conditions such as test equipment and preciseness.
1. Check the allowable tolerance of the speedometer and operations of the trip odometer by using a tester.
2. Check if the speedometer pointer is shaking and the abnormal noise sounds.
3. Eliminate the hysteresis by tapping the speedometer.
[Notice]
The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range.
(VIN=13 ± 0.1V, Temperature: 25°C)

Standard speed (Km/h) 20 40 (60) 80 100 120 140 (160) (180)
Tolerance (Km/h) +4 +5.5 +7 +9 +10.5 +12.5 +14.5 +16 +18
0 +2 +2.5 +3.5 +4 +6 +7.5 +8.5 +10

AFFECTED VIN
2B 9
Fuel Level Gauge
The fuel level gauge displays the resistance value of the float on the fuel sender in the fuel tank through a pointer. Note
that this vehicle doesn’t have a service hole for checking the fuel sender connector in the fuel tank.
The fuel sender and its connector can be checked and replaced only when the fuel tank is removed. The power supply
and resistance value should be measured at the connector in front of the fuel sender (refer to wiring diagram).
When the power supply and output resistance are normal, the float operation by fuel level may be defective; if so, replace
the fuel sender.
Tolerance and resistance value by indicating angle

Scale Full (3/4) 1/2 (1/4) Full (LFW)
Indicating angle (°) 40 20 0 - 20 - 40
Tolerance (°) +4~0 ± 2.5 ±3 ± 2.5 + 1.5
Resistance(Ω) 38 ± 1 67 ± 1 99.5 ± 1 247 ± 1 260 ± 1
This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, the differ-
ences that can be occurred by the road conditions and fuel fluctuations are ignored.

AFFECTED VIN
10 2B
Coolant Temperature Gauge
40o
0o
-40o
The coolant temperature gauge displays the coolant temperature with a pointer. The angle of pointer that changes by
coolant temperature is as shown below.

Indicating angle - 40 (H) 0°C (1/2) +40(°C)
Tolerance ± 2.5 +0°C +5°C
- 5°C +1°C
Coolant temperature 40°C 70°C ~ 110°C Over 125°C
Measurement of coolant temperature sensor resistance

Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is out
of specified range.
Resistance value by coolant temperature: 20°C : 2449 Ω ±5 %

50°C : 826 Ω ±5 %
80°C : 321 Ω ±5 %
100°C : 112 Ω ±5 %
When the resistance value by coolant temperature is within the specified range, check thermostat, water pump, radiator
related coolant circuit for normal operation. Also, check the wiring harnesses and connectors for proper connection.

AFFECTED VIN
2B 11
TRIP ODOmeter (TRIP A, TRIP B) and ODOmeter
Reset button
* Press and hold (over 1 sec.)
Trip odometer “TRIP A” and “TRIP B” will be reset to 0. (However, only the corresponding driving
range will be set to 0.)
* Press shortly (between 0.1 ~ 1 sec.)

The mode changes in order as shown in the figure.
ODO TRIP A TRIP B

Displaying range: 0 ~ 999999 km Displaying range: 0.0 ~ 999.9 km Displaying range: 0.0 ~ 999.9 km
(The odometer stops at 999999 km.) Increment: 0.1 km Increment: 0.1 km
Increment: 1 km

AFFECTED VIN
12 2B
5. WARNING & INDICATOR PANEL
This indicator comes on when the ignition

switch is turned on and stays on for a short
time or may go off right away. When the glow Parking Reverse Neutral Driving Driving gears
plugs are sufficiently heated for cold starting,
the light will go out. Then, start the engine. This indicator shows the automatic
The indicator comes on when the Win- transmission selector lever position.
In the vehicle equipped with direct injection
type engine, this indicator may come on very ter mode (W) switch near the gear se- When the selector lever is at "D" posi-
shortly or may not come on. lector lever is pressed. Use this mode tion while driving, "D" indicator and cur-
to drive off smoothly under icy and slip- rently selected gear indicator are com-
pery road. In this mode, the vehicle ing on. If you move the selector lever to
Glow Indicator (For Diesel Engine)
drives off with second gear in forward left or right direction, only the selected
and reverse driving. gear indicator comes on.
This indicator indicates the operating condi- Winter Mode Indicator Auto Shift Indicator
tions of immobilizer system. This indicator
(For Automatic Transmission) (for automatic transmission)
comes on when the ignition key is communi-
cating with the engine control unit (during
engine starting) and goes out after starting
the engine. If this indicator blinks, it may indi-
cate that there is something wrong in the im-
mobilizer system.
Immobilizer Indicator
4WD CHECK Warning Light /

4WD LOW indicator
4WD CHECK Warning Light
This warning light comes on when the igni-
tion switch is turned to “ON” and should go
out if the system is normal. If “4WD CHECK”
warning light stays on or “4WD LOW” indica-
tor blinks continuously, it may indicate that
there is something wrong in the immobilizer
system.
Engine Check Warning Light Battery Charge Warning Light
4WD LOW indicator*
This warning light comes on when the
When shifting the driving mode between “4WD
ignition switch is turned to ON and goes This warning light comes on when the
LOW” and “4WD HIGH”, this indicator blinks
out if the engine is in normal condition. If ignition switch is turned on and go off
until the shifting operation is completed. After
the light stays on or comes on while when the engine is started. If this light
completion of mode change, the indicator goes
driving, some of engine control compo- doesn’t go off after engine starting or
out.
nents including sensors and devices are comes on while driving, it means there
defective. When this warning light comes is a malfunction in the system. The bat-
on, the vehicle operates in safety mode tery voltage is also displayed on the multi
to maintain minimum driving conditions meter.
and to prevent the system from being
Brake Warning Light damaged. In this mode, the engine driv-
Seat Belt Reminder
ing force may be decreased or the en-
When the ignition is switched on, this warn-
gine may stall. For more details, refer to The seat belt warning light comes on
ing light comes on and should go out. This
“Engine” section in this manual. and the seat belt warning chime sound
warning light comes on when the parking
brake is applied and/or the brake fluid level is for 6 seconds when the ignition switch
lower than specified level. If the vehicle is is turned to “ON” position unless the
driven for over 2 seconds (over 10 km/h) while driver’s seat belt is securely fastened.
the parking brake is applied, the parking brake This reminding operation stops when
warning light comes on and warning buzzer the driver fastens the seat belt even
sounds. during its operation period.

AFFECTED VIN
2B 13
Windshield Heated Glass (controlled by separate unit)

The windshield heated glass control unit is installed on the
bottom of driver side Instrument panel. Whenever pressing the
switch, the windshield heated glass operates for 12 minutes
and turns off if pressed again during its operation. If the switch
is pressed again, it operates another 12-minute operation.
When the water level inside water separator
Tailgate Heated Glass, Outside Rearview Mirror in fuel filter exceeds a certain level, this warn-
Heated Glass (controlled by STICS) ing light comes on and buzzer sounds. Also,
The outside rearview mirror heated glass operates for 12 min- the driving force of the vehicle decreases. If
utes when turning on the seat warmer switch while the engine these conditions occur, immediately drain the
is running. If the seat warmer switch is pressed again within water from fuel filter and water separator.
10 minutes after completion of the first operation, the seat For the draining procedures, refer to “Engine”
warmer operates for 6 minutes just for once. section in this manual.
Defogger Indicator Water separator warning light
ABS / EBD ESP Warning Light

ESP Warning Light
This warning light comes on when pressing
the “ESP OFF” switch or the ESP system is
defective. If the ESP function operates while
Engine Oil Pressure Warning driving, this warning light flickers and the
alarm sounds.
Light
EBD Warning Light
This warning light comes on when the This warning light comes on when the igni-
ignition is switched on and should go tion switch is turned to ON and should go out
Door Open Warning Light out when the engine is started. If the if the system is normal. If the EBD system is
light comes on while driving, it indicates abnormal, both EBD warning light and ABS
This light comes on when a door or tail- that the oil pressure is dangerously low. warning light come on simultaneously.
gate is either opened or not closed Check the oil lines and lubricating sys-
ABS Warning Light
completely. If you drive over 10 km/h of tem for leak.
vehicle speed without closing the door, This warning light comes on when the igni-
the warning light blinks. tion switch is turned to ON and should go out
if the system is normal.
Air Bag Warning Light [NOTE]
When the ignition is switched on, this The vehicle equipped with ABS
Low Fuel Level Warning Light warning light illuminates and then performs self-diagnosis on the system
should go out, to confirm that the air when the engine is started and drives
This warning light indicates that the fuel bag is operational. If it does not come off. During the diagnosis, brake pedal
will soon be exhausted. The time it takes on, or if it does not go out, or if it flashes vibration and noise may be apparent
to turn on, however, varies according to or illuminates continuously while when the driving motors discharges
the vehicle operating conditions or gradi- driving, it means that there is malfunc-
ent of the road.
the hydraulic pressure from the
tion in the system.
internal hydraulic device. This means
the ABS is properly functioning.

AFFECTED VIN
14 2B
6.REMOVAL AND INSTALLATION OF METER CLUSTER AND INDICATOR

DISPLAY
Meter Cluster
1. Remove the screws from the front cup holder.
2. Pull out the front cup holder, disconnect the cigarette connector and the power socket connector, and remove the
front cup holder.
3. Carefully pry off the chrome coated cover from the selector lever cover, unscrew the screws and remove the
selector lever cover.

AFFECTED VIN
2B 15
4. Carefully pull out the center speakers and disconnect the connectors.
5. Remove the screws and take out the front cover from the instrument panel.
6. Disconnect all switch connectors including TRIP switch connector (2) during removal of the front cover.

AFFECTED VIN
16 2B
7. Unscrew four screws and pull out the meter cluster housing.
8. Disconnect the connector and remove the meter cluster housing.

AFFECTED VIN
2B 17
Indicator Display
1. Remove the indicator display cover.
2. Unscrew the screws and pull out the indicator display

housing.
3. Disconnect the connector and remove the indicator

display housing.

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2B 1
2B - Cluster / Warning
& Indicator Panel (2005 ~)
Table of Contents
METER CLUSTER / INDICATOR DISPLAY ...... 2B-3
1. Appearance ................................................................. 2B-3
2. Connectors and circuit diagram ................................... 2B-4
3. Descriptions of indicator display .................................. 2B-6
4. Function description and inspection of meter cluster ... 2B-7
5. Warning & indicator panel ......................................... 2B-12
6. Removal and installation of meter cluster and indicator
display ...................................................................... 2B-14

RODIUS/STAVIC - 2005.07 EFFECTIVE DATE
AFFECTED VIN
2B 3
METER CLUSTER / INDICATOR DISPLAY
1. APPEARANCE
The instrument panel in this vehicle is different from conventional type of instrument panel. The meter cluster and
indicator display are separated. The meter cluster is located at the center of the dash panel, and the indicator display is
located in front of driver’s seat.
Meter cluster
Coolant
temperature RPM gage Fuel level
Speedometer gauge
gauge
Warning lamps and indicators

AFFECTED VIN
4 2B
2. CONNECTORS AND CIRCUIT DIAGRAM
Meter Cluster
A B
Warning Lamps and Indicators D C

EFFECTIVE DATE RODIUS/STAVIC - 2005.07
AFFECTED VIN
2B 5
Circuit Diagram of Indicator Display

AFFECTED VIN
2B 7
4. FUNCTION DESCRIPTION AND INSPECTION OF METER CLUSTER

Meter Cluster
Tachometer – Engine RPM Display
Danger range (red zone)
The tachometer indicates engine speed in revolutions per minute. Multiply 1,000 to the current number, then it will be the
current number of engine revolutions.
Under the normal engine operating temperature, the proper idling speed is 700~800 rpm. The red zone (danger rpm
range) starts from 4,500 rpm.
1. Connect the tachometer for tune-up test and start the engine.
2. Eliminate the hysteresis by tapping the tachometer.
3. Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive.
Description Specification (VIN=13 ± 0.1V, Temperature: 25°C)

Engine speed (rpm) 700 1000 2000 3000 4000 5000 6000
Tolerance (rpm) +50 +100 +125 +150 +150 - -
-100 -100 -125 -150 -150
If the tachometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in
tachometer. If there is a difference between actual engine speed (rpm) and reading from tachometer, connect a scanner
and then compare the value on tachometer with the reading from scanner.

AFFECTED VIN
8 2B
Speedometer
The speedometer indicates the vehicle speed by calculating the signals from the rear right wheel speed sensor through
ABS or ESP unit.
If the speedometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in
speedometer. However, these symptoms also could be appeared when the tire has uneven wear, different tire inflation
pressures or different tire specifications.
Perform the speedometer test regarding the tolerance as described. However, it is not similar simple work in field due to
lack of measuring conditions such as test equipment and preciseness.
1. Check the allowable tolerance of the speedometer and operations of the trip odometer by using a tester.
2. Check if the speedometer pointer is shaking and the abnormal noise sounds.
3. Eliminate the hysteresis by tapping the speedometer.
[Notice]
The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range.
(VIN=13 ± 0.1V, Temperature: 25°C)

Standard speed (Km/h) 20 40 (60) 80 100 120 140 (160) (180)
Tolerance (Km/h) +4 +5.5 +7 +9 +10.5 +12.5 +14.5 +16 +18
0 +2 +2.5 +3.5 +4 +6 +7.5 +8.5 +10

AFFECTED VIN
2B 9
Fuel Level Gauge
The fuel level gauge displays the resistance value of the float on the fuel sender in the fuel tank through a pointer. Note
that this vehicle doesn’t have a service hole for checking the fuel sender connector in the fuel tank.
The fuel sender and its connector can be checked and replaced only when the fuel tank is removed. The power supply
and resistance value should be measured at the connector in front of the fuel sender (refer to wiring diagram).
When the power supply and output resistance are normal, the float operation by fuel level may be defective; if so, replace
the fuel sender.

Scale Full (3/4) 1/2 (1/4) Full (LFW)
Indicating angle (°) 40 20 0 - 20 - 40
Tolerance (°) +4~0 ± 2.5 ±3 ± 2.5 + 1.5
Resistance(Ω) 38 ± 1 67 ± 1 99.5 ± 1 247 ± 1 260 ± 1
This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, the differ-
ences that can be occurred by the road conditions and fuel fluctuations are ignored.

AFFECTED VIN
10 2B
Coolant Temperature Gauge
40o
0o
-40o
The coolant temperature gauge displays the coolant temperature with a pointer. The angle of pointer that changes by
coolant temperature is as shown below.

Indicating angle - 40 (H) 0°C (1/2) +40(°C)
Tolerance ± 2.5 +0°C +5°C
- 5°C +1°C
Coolant temperature 40°C 70°C ~ 110°C Over 125°C
Measurement of coolant temperature sensor resistance

Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is out
of specified range.
Resistance value by coolant temperature: 20°C : 2449 Ω ±5 %

50°C : 826 Ω ±5 %
80°C : 321 Ω ±5 %
100°C : 112 Ω ±5 %
When the resistance value by coolant temperature is within the specified range, check thermostat, water pump, radiator
related coolant circuit for normal operation. Also, check the wiring harnesses and connectors for proper connection.

AFFECTED VIN
2B 11
TRIP ODOmeter (TRIP A, TRIP B) and ODOmeter
Reset button
* Press and hold (over 1 sec.)
Trip odometer “TRIP A” and “TRIP B” will be reset to 0. (However, only the corresponding driving
range will be set to 0.)
* Press shortly (between 0.1 ~ 1 sec.)

The mode changes in order as shown in the figure.
ODO TRIP A TRIP B

Displaying range: 0 ~ 999999 km Displaying range: 0.0 ~ 999.9 km Displaying range: 0.0 ~ 999.9 km
(The odometer stops at 999999 km.) Increment: 0.1 km Increment: 0.1 km
Increment: 1 km

AFFECTED VIN
12 2B
5. WARNING & INDICATOR PANEL
This indicator comes on when the ignition P R N D 1 2 3 4 5

switch is turned on and stays on for a short
time or may go off right away. When the glow Parking Reverse Neutral Driving Driving gears
plugs are sufficiently heated for cold starting,
the light will go out. Then, start the engine. This indicator shows the automatic
The indicator comes on when the Win- transmission selector lever position.
In the vehicle equipped with direct injection
type engine, this indicator may come on very ter mode (W) switch near the gear se- When the selector lever is at "D" posi-
shortly or may not come on. lector lever is pressed. Use this mode tion while driving, "D" indicator and cur-
to drive off smoothly under icy and slip- rently selected gear indicator are com-
pery road. In this mode, the vehicle ing on. If you move the selector lever to
Glow Indicator (For Diesel Engine)
drives off with second gear in forward left or right direction, only the selected
and reverse driving. gear indicator comes on.
This indicator indicates the operating condi- Winter Mode Indicator Auto Shift Indicator
tions of immobilizer system. This indicator
(For Automatic Transmission) (for automatic transmission)
comes on when the ignition key is communi-
cating with the engine control unit (during
engine starting) and goes out after starting
the engine. If this indicator blinks, it may indi-
cate that there is something wrong in the im-
mobilizer system.
Immobilizer Indicator
4WD CHECK Warning Light /

4WD LOW indicator
tion switch is turned to “ON” and should go
out if the system is normal. If “4WD CHECK”
warning light stays on or “4WD LOW” indica-
tor blinks continuously, it may indicate that
there is something wrong in the immobilizer
system. Seat Belt Reminder
The seat belt warning light comes on
4WD LOW indicator* and the seat belt warning chime sound
When shifting the driving mode between “4WD for 6 seconds when the ignition switch
LOW” and “4WD HIGH”, this indicator blinks is turned to “ON” position unless the
until the shifting operation is completed. After driver’s seat belt is securely fastened.
completion of mode change, the indicator goes This reminding operation stops when
out. the driver fastens the seat belt even
during its operation period.
Brake Warning Light Battery Charge Warning Light Low Fuel Level Warning Light
When the ignition is switched on, this warn- This warning light indicates that the fuel
This warning light comes on when the will soon be exhausted. The time it takes
ing light comes on and should go out. This
ignition switch is turned on and go off to turn on, however, varies according to
warning light comes on when the parking
when the engine is started. If this light the vehicle operating conditions or gradi-
brake is applied and/or the brake fluid level is
doesn’t go off after engine starting or ent of the road.
lower than specified level. If the vehicle is
comes on while driving, it means there
driven for over 2 seconds (over 10 km/h) while
is a malfunction in the system. The bat-
the parking brake is applied, the parking brake
tery voltage is also displayed on the multi
warning light comes on and warning buzzer
meter.
sounds.

AFFECTED VIN
2B 13
Windshield Heated Glass Tailgate

Heated Glass, Outside Rearview Mir-
ror Heated Glass (controlled by STICS) When the water level inside water separator This warning light comes on when the ig-
The outside rearview mirror heated glass op- in fuel filter exceeds a certain level, this warn- nition switch is turned to ON and goes out
erates for 12 minutes when turning on the seat ing light comes on and buzzer sounds. Also, if the engine is in normal condition. If the
warmer switch while the engine is running. If the driving force of the vehicle decreases. If light stays on or comes on while driving,
the seat warmer switch is pressed again these conditions occur, immediately drain the some of engine control components includ-
within 10 minutes after completion of the first water from fuel filter and water separator. ing sensors and devices are defective.
operation, the seat warmer operates for 6 min- For the draining procedures, refer to “Engine” When this warning light comes on, the
utes just for once. section in this manual. vehicle operates in safety mode to main-
tain minimum driving conditions and to pre-
vent the system from being damaged. In
Defogger Indicator Water separator warning light this mode, the engine driving force may
be decreased or the engine may stall. For
more details, refer to “Engine” section in
this manual.
Engine Check Warning Light
ABS / EBD ESP Warning Light

ESP Warning Light
This warning light comes on when pressing
the “ESP OFF” switch or the ESP system is
defective. If the ESP function operates while
Engine Oil Pressure Warning driving, this warning light flickers and the
alarm sounds.
Light
EBD Warning Light
This warning light comes on when the This warning light comes on when the igni-
ignition is switched on and should go tion switch is turned to ON and should go out
out when the engine is started. If the if the system is normal. If the EBD system is
light comes on while driving, it indicates abnormal, both EBD warning light and ABS
that the oil pressure is dangerously low. warning light come on simultaneously.
Check the oil lines and lubricating sys-
ABS Warning Light
tem for leak.
tion switch is turned to ON and should go out
if the system is normal.
Door Open Warning Light Air Bag Warning Light [NOTE]
This light comes on when a door or tail- When the ignition is switched on, this The vehicle equipped with ABS
gate is either opened or not closed warning light illuminates and then performs self-diagnosis on the system
completely. If you drive over 10 km/h of should go out, to confirm that the air when the engine is started and drives
vehicle speed without closing the door, bag is operational. If it does not come off. During the diagnosis, brake pedal
the warning light blinks. on, or if it does not go out, or if it flashes vibration and noise may be apparent
or illuminates continuously while when the driving motors discharges
driving, it means that there is malfunc- the hydraulic pressure from the
tion in the system.
internal hydraulic device. This means
the ABS is properly functioning.

AFFECTED VIN
14 2B
6.REMOVAL AND INSTALLATION OF METER CLUSTER AND INDICATOR

DISPLAY
Meter Cluster
front cup holder.

AFFECTED VIN
2B 15
6. Disconnect all switch connectors including TRIP switch connector (2) during removal of the front cover.

AFFECTED VIN
16 2B
7. Unscrew four screws and pull out the meter cluster housing.
8. Disconnect the connector and remove the meter cluster housing.

AFFECTED VIN
2B 17
Indicator Display
1. Remove the indicator display cover.
2. Unscrew the screws and pull out the indicator display

housing.
3. Disconnect the connector and remove the indicator

display housing.

AFFECTED VIN
2C 3
REKES + STICS (RK STICS)

The STICS in this vehicle has similar functions with the one used in other vehicle models. Additional function of diagnos-
ing through SCAN-I has been added into new STICS.
The major difference in hardware-wise is that receives automatic door unlock signal from airbag module through G-
sensor in RK STICS unit when the vehicle has collided over 15 km/h of vehicle speed.
Air bag ECU
Sends the vehicle collision signals

to STICS.
Theft deterrent horn
STICS / ICM module
RK STICS
Installed under the battery. This
horn works only for the theft deter-
rent function, panic function, and
remote starting.
ICM module Diagnosis connector
REKES
This module contains

This diagnosis connector is used for
various relays, chime and Added the escort and
STICS key coding and trouble
buzzer controlled by STICS panic function
diagnosis.
RK STICS CHANGED BY
AFFECTED VIN
4 2C
2. TRANSMITTER CODING
Coding process:
1. Remove the ignition key from key hole.

2. Connect the No. 3 terminal (REKES coding) and No. 16 terminal (battery+) on the diagnosis connector with a
jumper cable.
3. Press any button on the remote control key shortly. (approx. 0.5 sec.)
4. When the coding is successful, turn signal lamps blink once and warning horn sounds once.
5. If the coding has failed, repeat 1 to 4 steps.
Connector pin descriptions
1 - 2 IG1
3 REKES (for coding) 4 Ground
5 Signal ground 6 CAN_High
7 ECU 8 ABS
9 Air bag 10 TGS
11 TCU 12 FFH (for diagnosis)
13 TCCU 14 CAN_Low
15 REKES (for diagnosis) 16 Battery+
CHANGED BY RK STICS
AFFECTED VIN
2C 5
3. DESCRIPTIONS
Below table shows the major differences compared to the previous vehicle model before year 2004. For whole functions
and details, refer to corresponding section.
Item RK STICS
Door lock The door unlock output is sent to all doors once for 0.5 seconds when the “LOCK”
signal is inputted into unit within 0.5 seconds after closing the driver’s or
passenger’s door. This is regardless of key in or key out. It is to prevent the
doors from locking due to impact when the door is closed.
Auto door unlock Previously, G-sensor in STICS outputs auto door unlock signal if the vehicle
collides over 15 km/h of vehicle speed. However, the air bag system is installed
in this vehicle as a basic equipment. When a collision, the “Auto Door Unlock”
function is activated by using a collision signal from the air bag module.
Front room lamp 1. When receiving the unlock signal from remote control key with the door
closed, the front room lamp comes on for 30 seconds.
2. When receiving the unlock signal again during the time lagging operation,
another 30 seconds will be extended from unlock point.
Time lag power window control The power window can be operated for 30 seconds after removing the ignition
key from key switch. This lagging operation stops when closing the door.
Parking brake warning When the vehicle speed signal is inputted with the parking brake applied, the
warning light blinks and the chime buzzer in ICM box continuously sounds for 0.
6 seconds with 0.3 seconds of pausing time (when driving over 10 km/h of vehicle
speed for more than 2 seconds).
Tail lamp auto cut (battery saver) 1. Turns on or off the tail lamp relay according to the tail lamp switch
operations.
2. The tail lamp relay is turned off (auto-cut) when removing the ignition key
and opening and closing the door while the tail lamp switch is turned on.
Theft deterrent alarm The hazard warning relay in ICM box outputs when the remote control key is
operated or the theft deterrent alarm is activated. At this time, separate warning
horn sounds.
Panic alarm operating only 1. The theft deterrent horn sounds for 27 seconds when receiving the panic
(ON: IGN S/W in) signal from the remote control key.
2. The panic alarm is turned off when receiving any signal from the remote
control key during the panic alarm operation.
3. This function works under armed mode.
Headlamp control (escort) 1. The headlamp control supplies the power to headlamp relay for 20 seconds and
turns off when receiving the escort signal from the remote control key with the
ignition key off (if the escort signal is inputted again, it will be extended once for
20 seconds). However, the power supply and output is activated only when the
vehicle is in armed mode activated by remote control key.
2. The headlamp relay output is turned off immediately after receiving the
remote control lock signal during its operation (however, signals other than
lock signal from remote control key will be ignored).
3. The headlamp relay output is immediately turned off when the key is turned
to “ON” position during its operation (this function is also activated under
remote starting).
RK STICS CHANGED BY
AFFECTED VIN
6 2C
4. CONNECTOR ARRANGEMENT (UNIT)
NO. Description Status NO. Description Status

1 Wiper relay (HI) Output 38 Hood switch Input
2 Tailgate heated glass/outside rearview mirror relay Output 39 Rear LH/RH door switch Input
3 Driver’s door unlock Output 40 Seat belt warning light Output
4 Coding 41 Wiper motor relay (parking) Input
5 Door lock Output 42 Vehicle speed signal Input
6 ALT_D Input 43 Tailgate switch Input
7 Power window relay Output 44 Tail lamp switch Input
8 Ground 45 Passenger’s door lock switch Input
9 Headlamp relay Output 46 Passenger’s door unlock switch Input
10 Door unlock Output 47 Diagnosis (KWP 2000) Input/Output
11 Passenger’s door lock switch Input 48 Rear door lock switch Input
12 Chime buzzer (in ICM box) Output 49 Washer switch Input
13 Front room lamp Output 50 Intermittent auto switch Input
14 Wiper relay (LO) Output 51 Door opening indication Output
15 Tail lamp relay Output 52 Intermittent volume Input
16 V+ 53 Key hole illumination Output
17 Engine start relay Output 54 Headlamp relay Output
18 Ground 55
19 Theft deterrent horn Output 56
20 Rear room lamp Output 57
21 IGN 2 Input 58
22 IGN 1 Input 59
23 Parking brake warning light Output 60
24 Tailgate glass and outside rearview mirror heated glass Input 61
25 Seat belt switch Input 62
26 Rain sensor input Input 63
27 Key reminder switch Input 64
28 Tailgate lock switch Input 65
29 Driver’s door lock switch Input 66
30 Input/Output 67
31 Hazard flasher relay (in ICM box) Output 68
32 Input 69
33 Theft deterrent alarm selection switch Input 70
34 Rain sensor output Output 71
35 Parking brake switch Input 72
36 Driver’s door switch Input 73
37 Passenger’s door switch Input 74
CHANGED BY RK STICS
AFFECTED VIN
2C 7
5. SPECIFICATIONS
1) Electrical Performance
Item Requirement Remark
Operating voltage DC 9~16 V Should operate normally within this range.
Operating temperature -30°C ~ +80°C
Reserved temperature -40°C ~ +85°C
Max. operating humidity 95%
Resistible voltage 24 V
Insulating resistance No heat and fire due to the Confined with PCB, waterproof and coating that requires
current leaks. the insulation.
Parasitic current below 4.0 mA IGN = OFF, Full output load = OFF, 90 seconds (after
(below 6.0 mA) received the signals), No input changes for 2 seconds
Voltage drop below 1.2 V Pin no. 8 and 2, 3, 5, 7, 10, 12, 13, 15, 19, 20, 23, 40, 47,
below 2.0 V 51, 53, 54
Pin no. 8 and 9, 13, 15, 23, 40, 51, 53
2) Chattering of Input Signals

1. Vehicle speed input:
The vehicle speed calculating time is 1.0 seconds. The elapsed time of 1.5 seconds after IGN 1 switch :ON” is not
included.
2. 20 ms target input:
Wiper motor A/S (parking) terminal
3. 100 ms target input switch

All switches except wiper motor A/S (parking) terminal
3) Time Tolerance
1. If not indicated, time tolerance will be ± 10%.
However, if less than 500 ms, time tolerance will be ± 50 ms.
2. The time indicated in each function does not include chattering processing time from switch input changing point.
RK STICS CHANGED BY
AFFECTED VIN
8 2C
RK Stics
1 IGN 1 ON = BAT (IGN “ON” or “START”) BAT = Battery

2 IGN 2 ON = BAT (IGN “ON”)
3 ALT_D ON = BAT equivalent (engine running)
4 Key reminder (door ajar warning switch) IGN = BAT (Key in)
5 Driver’s door switch OPEN = GND
6 Passenger’s door switch OPEN = GND
7 Rear door switch OPEN (one of rear seat) = GND
CLOSE (one of rear seat) = OPEN
8 Tailgate switch OPEN = GND
9 Central door lock switch ON = GND
10 Central door unlock switch ON = GND
11 Driver’s door lock/unlock switch LOCK = OPEN, UNLOCK = GND
Passenger’s door lock/unlock switch LOCK = OPEN, UNLOCK = GND
12 Rear door lock/unlock switch UNLOCK (one of rear seat) = GND
LOCK (one of rear seat) = OPEN
13 Tailgate lock/unlock switch LOCK = OPEN, UNLOCK = GND
- - -
- - -
16 Hood switch OPEN = GND
17 Tailgate switch ON = GND
18 Defogger switch ON = GND
19 Seat belt switch Fastened = OPEN, Unfastened = GND
20 Parking brake switch ON = GND (applied)
21 Washer switch ON = GND
22 Intermittent switch ON = GND
23 Intermittent volume 0 Ω ~ 50 kΩ (for intermittent wiper)
24 Wiper motor (parking) ON = GND
25 Rain sensor unit input ON = GND (during sending from rain sensor)
26 Rain sensor unit output ON = GND (during sending from RK STICS)
27 Hazard warning flasher selection switch ON = GND
28 Collision sensor ON = 200 ms output (LOW)
29 Speed sensor Vehicle speed signal (OPEN COLLECTOR)
30 Coding ON = BAT
31 Diagnosis (K-Line) ON = BAT (during Installation or
communication)
CHANGED BY RK STICS
AFFECTED VIN
2C 9
6. FUNCTIONS OF RK STICS
1) Wiper Control
Wiper MIST and Washer Coupled Wiper
1. The wiper relay is turned on 0.3 seconds (T1) after turning “ON” the washer switch for 0.2 ~ 0.59 seconds (T2) with
the ignition key “ON”, and it is turned off when the parking terminal is turned off.
2. The wiper relay is turned on 0.3 seconds (T1) after turning “ON” the washer switch over 0.6 seconds (T2) with the
ignition key “ON”, and it is turned on three times immediately after turning off the washer switch.
T1: within 0.5s T2: over 0.6s T3: one wipter cycle
RK STICS CHANGED BY
AFFECTED VIN
10 2C
3. If the washer operating signal is inputted while the wipers are operating in intermittent or AUTO mode, the system
stores the previous intermittent interval and operates the washer coupled wiper. After then, the wiper operation
returns back to intermittent or AUTO mode with the stored operating interval.
T1: within 0.3s T2: 0.2 ~ 0.59s T3: over 0.6s T4: 3 cycles T5: operationg interval
CHANGED BY RK STICS
AFFECTED VIN
2C 11
Rain Sensor Coupled Wiper
If equipped with RE-STICS rain sensor, has following operation system.
1. System layout
This vehicle has a different wiper control logic compared to other models. As shown in the system diagram, the rain
sensor unit does not control wiper directly. The rain sensor unit sends infrared rays signal through LED and then
receives it with photo diode and then sends the returned signal to STICS and the STICS controls the wipers directly.
For more details, refer to rain sensing wiper section in this manual.
Multi-function (wiper)
switch
Rain
RESTICS sensor
Wiper LO
Wiper HI
Wiper motor
RK STICS CHANGED BY
AFFECTED VIN
12 2C
2. Rain sensing operation point

1) The wiper relay is turned on and the wiper motor runs one cycle when the ignition key is turned to “ON” position
(while the wiper switch is in “AUTO” position).
2) The wiper relay (LO) is turned on and the wiper motor runs one cycle when changing the wiper switch to “AUTO”
position from any other positions (while the ignition key is in “ON” position). When the wiper switch is turned to
“AUTO” position again from other positions, the system drives the wiper relay (LO) to run the wiper motor one cycle
only when the rain sensor detects the “Rain Detected” signal.
T1: 1 cycle
3. Rain sensing sensitivity control

The wiper relay is turned on and the wiper motor runs one cycle when the volume sensitivity is increased (ex: from 0 to
1) (while the ignition key is in “ON” position, the wiper switch is in “AUTO” position, and the wiper motor is in “Parked”
position). However, the wiper motor can be operated only when the rain sensor detects the “Rain Detected” signal.
* If the volume sensitivity is changed more than 2 stages within 2 seconds, the wiper motor runs only one cycle.
SENSITIVITY
RAIN SENSOR Rain Detected

OFF
WIPER RELAY ON
LO OFF
T1: 1 cycle
CHANGED BY RK STICS
AFFECTED VIN
2C 13
4. Wiper operation when the wiper parking terminal is grounded

1) The wiper system continuously outputs the parking signal of current sensitivity when the parking terminal is
grounded (while the ignition key is in “ON” position and the wiper switch is in “AUTO” position).
* The wiper motor runs only when the rain sensor requires.
IGN (Operation)
GND (Stop)
2) When the parking terminal is fixed to IGN (HIGH), the wiper system outputs the operating signal of current sensitivity
for 2 seconds, then continuously outputs the parking signal of current sensitivity
* The wiper motor runs only when the rain sensor requires.
IGN (Operation)
GND (Stop)
RK STICS CHANGED BY
AFFECTED VIN
14 2C
5. Defective rain sensor

1) The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from
3 during receiving the malfunction signal (1) from the rain sensor (while the ignition key is in “ON” position and the
wiper switch is in “AUTO” position).
SENSITIVITY
RAIN SENSOR
Malfunction signal (1): Yes

Malfunction signal (1): No
WIPER RELAY ON
LO OFF
T1: 1 cycle
wiper switch is in “AUTO” position).
SENSITIVITY
RAIN SENSOR

WIPER RELAY ON
LO OFF
T1: 1 cycle
CHANGED BY RK STICS
AFFECTED VIN
2C 15
wiper switch is in “AUTO” position). Also, the wiper relay (LO) is turned on and the wiper motor runs one cycle when
the wiper sensitivity is changed to 2 from 1 during receiving the ground fixed or IGN fixed signal from the rain
sensor.
SENSITIVITY
RAIN SENSOR

WIPER RELAY ON
LO OFF
T1: 1 cycle
Speed Sensitive INT (Intermittent) Wiper

For STICS without rain sensor, perform the following operation:
1. Controls the wiper intermittent operation by the values from vehicle speed and volume.
- Calculates and converts the Intermittent interval automatically by using the vehicle speed and INT VOLUME
when the ignition switch is in “ON” position and the INT switch is in “ON” position (the engine is running).
- The wipers are operated in vehicle speed sensitive mode when turning the INT switch to “ON” position with the
engine running or starting the engine with the INT switch positioned “ON”.
- Intermittent interval (at 0 km/h): 3 ± 0.5 ~ 19 ± 2 seconds
2. Vehicle speed calculation
[Input the vehicle speed]
It is calculated by the numbers of input pulses for one second.
1 [pulses/sec] = 60 [km/h] x 60 [sec] / 637 pulses = 1.41 [km/h]
3. VOLUME calculation
- Calculates the INT VOLUME with 5 grades as shown in the table in next page.
4. Pause time calculation
- Pause time: the duration that wipers are stopped at parking position
- Elapsed time: the duration after the wiper motor started to operate from parking position
- The pause time is calculated by the vehicle speed and VOLUME value as shown in the table in next page.
* If the pause time is below 1.0 second, the wipers operate without pause.
* If the pause time is over 1.5 seconds, the wipers operate intermittently.
RK STICS CHANGED BY
AFFECTED VIN
16 2C
Pause time against vehicle speed
Pause time
(sec.)
Vehicle speed (km/h)
[Notice]
(1) Wiper MIST and washer coupled wiper
1) When turning on the washer switch while the wiper relay is operating.
- If the wiper relay “ON” request time is shorter than the remained “ON” time, it is disregarded.
(2) Speed sensitive INT (intermittent) wiper
1) The wiper relay continues to output for remaining “ON” time even when the INT switch is turned off.
2) IGN 2 switch “ON”, INT switch “OFF”: resume the intermittent time when turning “ON”
3) IGN 2 switch “OFF”, INT switch “ON”: resume the intermittent time when turning “ON”
(3) Controls when the wiper motor parking is defective
- The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiper relay is
“ON” (INT switch = ON or Washer switch = ON) (The output stops immediately after turning off the switch)
CHANGED BY RK STICS
AFFECTED VIN
2C 17
2) Ignition Key Reminder
Key Reminder Warning

1. The chime buzzer output in the ICM box continues when opening the driver’s door while the ignition key is inserted
into ignition switch.
2. When removing the ignition key or closing the driver’s door during chime buzzer output, the output turns off.
3. This function is not available when the ignition switch is “ON”.
CHIME BUZZER
Key Reminder
1. This function does not work if the vehicle speed is over 3 km/h.
2. The system outputs “UNLOCK” for 5 seconds (T2) from 0.5 seconds after the driver’s door is opened and the door
lock switch is changed to “LOCK” (while the ignition key is in ignition switch).
3. The system outputs “UNLOCK” for 5 seconds (T2) when the door lock switch is changed to “LOCK” from “UNLOCK”
and the driver’s door is closed within 0.5 seconds (T1) (while the ignition key is in ignition switch).
T1: 0.5s T2: 5s T3: within 0.5s
[Note]
Operating conditions for (*1) and (*2)
(*1): Driver’s door is opened and driver’s door lock switch is turned to LOCK
(*2): Passenger’s door is opened and passenger’s door lock switch is turned to LOCK
RK STICS CHANGED BY
AFFECTED VIN
18 2C
All Door Lock Prevention Function when a Door is Opened

1. When a door is opened, all doors should be unlocked for 5 seconds if inputs LOCK signal.
- The LOCK signal means the central door locking (REKES, central door lock switch, knob switch) except LOCK
input by rear door knob.
- After unlocking and opening only the driver’s door with remote control key under armed mode (driver’s door is
unlocked but passenger’s and rear doors are locked), only the driver’s door generates unlock signal when trying to
lock the driver’s door with the driver’s door opened.
- Above operations is regardless of key positions and have priority over the ignition key reminder function.
2. When the door is closed during unlock output for 5 seconds under item 1 condition, the unlock output stops.
- All doors except tailgate and hood output “UNLOCK” for 5 seconds (T1) when the “LOCK” signal is inputted (while
the ignition key is removed and a of door is opened).
- When the door is closed during unlock output for 5 seconds, the unlock output stops.
CHANGED BY RK STICS
AFFECTED VIN
2C 19
3) Mark Lamp Left on Warning

1. The chime buzzer in the ICM box sounds with the interval of 0.8 second when opening the driver’s door while the tail
lamp is turned on and the ignition key is removed.
2. The buzzer output stops when turning off the tail lamp and closing the driver’s door.
3. The system outputs “UNLOCK” for 5 seconds when the driver’s and passenger’s door lock switch is locked (while
the tail lamp is turned on and the driver’s door is opened).
4. This function is not available when the ignition key is in “ON” position.
RK STICS CHANGED BY
AFFECTED VIN
20 2C
4) Door Ajar Warning

1. The warning light in indicator display comes on when opening any of driver’s door, passenger’s door, rear door or
tailgate while the vehicle speed is below 6 km/h (V1).
2. The warning light goes off when closing the door under step 1.
3. The warning light blinks when the vehicle speed is over 10 km/h (V1) for more than 2 seconds while the warning
light is turned on.
4. The warning light blinks when a door is opened while the vehicle speed is over 10 km/h (V1) (while the warning light
is turned off).
5. The warning light goes off when closing the door under step 3.
6. The warning light comes on when the vehicle speed is below 3 km/h (V2) under step 3.
VEHICLE SPEED OVER V1

BELOW V1
CHANGED BY RK STICS
AFFECTED VIN
2C 21
5) Seat Belt Warning

1. The seat belt warning light comes on and the chime buzzer in the ICM box sounds for 6 seconds when turning the
ignition key to “ON” from “OFF”. If the seat belt is fastened before turning the ignition key to “ON” position, the
warning light in the indicator display blinks for 6 seconds, however, the chime buzzer does not sound.
2. The seat belt warning light goes off and the chime buzzer in the ICM box stops when turning the ignition switch to
“OFF” position.
3. The chime buzzer stops and the seat belt warning light stays on for the specified duration (6 seconds) when
fastening the seat belt during the warning operation.
4. The seat belt warning light comes on and the chime buzzer sounds for 6 seconds again when unfastening the seat
belt during fastening operation.
FASTEN
UNFASTEN
RK STICS CHANGED BY
AFFECTED VIN
22 2C
6) Parking Brake Warning

1. The parking brake warning light comes on for approx. 4 seconds (T4) when turning the ignition key from “OFF” to
“ON” position regardless of the vehicle speed and parking brake switch position.
2. The warning light comes on when the parking brake switch is turned on while the vehicle speed is below 10 km/h
(V1).
3. The warning light goes off when turning off the parking brake switch under step 2.
4. The warning light blinks and the chime buzzer in the ICM box sounds for 2.85 seconds and stops for 1.5 seconds
when the vehicle speed is over 10 km/h (V1) for more than 2 seconds while the parking brake switch is turned on.
5. The warning light goes off and the chime buzzer stops when turning off the parking brake switch under step 4.
6. The warning light comes on and the chime buzzer stops when the vehicle speed goes down below 7 km/h (V2)
under step 4.
7. This function is not available when the ignition key is turned to “OFF” position.
VEHICLE SPEED OVER V1

BELOW V2
CHANGED BY RK STICS
AFFECTED VIN
2C 23
7) Room Lamp Control
Front Room Lamp

1. The front room lamp comes on when opening the driver’s door or passenger’s
door while the front room lamp switch is at door coupled position and the
key reminder switch is turned off.
2. The room lamp stays on for 2 seconds (T1) and then decays through 3
seconds (T2) when closing the driver’s door or passenger’s door.
3. The room lamp output should stop immediately after turning on the ignition Door coupled front
key during decaying operation. room lamp switch
4. The front room lamp comes on for 30 seconds (T3) when receiving the
unlock signal from the remote control key while the door is closed.
5. The front room lamp output period is extended by 30 seconds (T3) when receiving the unlock signal from the remote
control key again during output.
6. When a door is opened during its extended period, the lamp stays on. If closed, operates as in step 2.
7. The room lamp output stops immediately after receiving the lock signal from driver’s door and passenger’s door
lock switch while the driver’s door and passenger’s door are closed.
RECEIVE
NO SIGNAL
OUTPUT
RK STICS CHANGED BY
AFFECTED VIN
24 2C
Rear Room Lamp

1. The rear room lamp comes on when opening the rear door while the door
coupled rear room lamp switch is pressed (except for luggage room lamp).
2. The rear room lamp extends its lighting period by 5 seconds when closing
the rear door.
3. The room lamp output stops immediately after turning the ignition key to
“ON” position during the extended period. Door coupled rear
4. The room lamp output stops immediately after receiving the lock signal room lamp switch
from the rear door lock switch or the remote control key while the rear door
is closed.
CHANGED BY RK STICS
AFFECTED VIN
2C 25
8) Ignition Key Hole Illumination (Except For Immobilizer)

1. The ignition key hole illumination comes on when opening the driver’s door or passenger’s door while the ignition
key is removed.
2. The ignition key hole illumination stays on for 10 seconds when closing the door after step 1.
3. The output stops when the ignition key is turned to “ON” position.
4. The output stops when receiving the lock signal from the remote control key (under armed mode).
RK STICS CHANGED BY
AFFECTED VIN
26 2C
9) Battery Saver (Tail Lamp Auto Cut)

1. The tail lamp is turn on or off according to the operations of the multifunction tail lamp switch.
2. The tail lamp relay is turned off (auto cut) when opening and closing the driver’s door after removing the ignition key
without turning off the tail lamp.
3. Tail lamp relay is turned on when inserting the ignition key into ignition switch again after step 2 operation.
4. The tail lamp relay is turned off (auto cut) when opening and closing the driver’s door while the ignition key is
removed and the tail lamp is turned on.
AUTO CUT
AUTO CUT
CHANGED BY RK STICS
AFFECTED VIN
2C 27
10) Defogger Timer

1. The system outputs the tailgate, windshield and outside rearview mirror heated glass “ON” signal when turning on
the defogger switch (while the engine is running).
2. The output stops when turning on the defogger switch again during its operation.
3. The output is “ON” only for 6 minutes (T3) when turning “ON” the rear defogger switch within 10 minutes (T2) after
completion of output.
When turning on the defogger switch again within 10 minutes (T2) after completion of initial 12 minutes (T1) of
output, the output comes on for 6 minutes (T3) again once only.
4. The output stops when the IGN 2 switch is turned to “OFF” position or the ALT is “OFF”.
OVER 9V
BELOW 9V
REAR DEFOGGER
SWITCH
REAR DEFOGGER
RELAY
T1: 12 min. T2: 10 min. T3: 6 min.
This vehicle has the windshield heated glass and the tailgate and outside rearview mirror heated glass. The heater relay
in the ICM box controls the tailgate and outside rearview mirror heated glass and its fuse (15A) is located in the engine
compartment fuse box.
Defogger switch
RK STICS CHANGED BY
AFFECTED VIN
28 2C
11) Door LOCK/UNLOCK Control
Door Lock/Unlock by Door Lock Switch

1. The door lock system outputs “LOCK” for 0.5 seconds (T1) when positioning the driver’s or passenger’s door lock
switch to lock position (while the driver’s and passenger’s door lock switch is in “UNLOCK” position).
2. The door lock system outputs “UNLOCK” for 0.5 seconds (T2) when positioning the driver’s or passenger’s door
lock switch to unlock position.
3. “LOCK” or “UNLOCK” by the door lock switch is ignored when outputting the “LOCK” or “UNLOCK” by other
functions.
4. The door lock/unlock system is not working regardless of the door lock switch positions when connecting the
battery.
5. All door lock signals are “UNLOCK” for 0.5 seconds (T4) just for once when receiving the “LOCK” signal within 0.5
seconds (T3) after closing the driver’s or passenger’s door. However, this operation is regardless of the ignition key
positions.
[Notice]
This function prevents the door from locking by shock when slamming a door while the ignition key is inserted into the key
switch hole.
T3: within 0.5s
CHANGED BY RK STICS
AFFECTED VIN
2C 29
Door Lock/Unlock by Central Door Lock Switch

1. The door lock system outputs “LOCK” for 0.5 seconds (T1) when pressing “LOCK” button on the central door lock
switch.
2. The door lock system outputs “UNLOCK” for 0.5 seconds (T2) when pressing “UNLOCK” button on the central door
lock switch.
3. The “LOCK” or “UNLOCK” inputs from the central door lock switch in armed mode are ignored.
RK STICS CHANGED BY
AFFECTED VIN
30 2C
Door LOCK/UNLOCK by Remote Control Key

1. The door lock system outputs “LOCK” for 0.5 seconds (T2) when receiving “LOCK” signal from the remote control
key.
2. The door lock system outputs “UNLOCK” signal for driver’s door for 0.5 seconds (T3) when receiving “UNLOCK”
signal from the remote control key.
3. The door lock system outputs “UNLOCK” signal for all doors for 0.5 seconds (T3) when receiving “UNLOCK” signal
again within 30 seconds (T1) after receiving the first “UNLOCK” signal (second unlock step).
4. The “second unlock step” is canceled when receiving “LOCK” signal within 30 seconds (T1) after receiving the first
“UNLOCK” signal.
NO SIGNAL
T1: within 30s
CHANGED BY RK STICS
AFFECTED VIN
2C 31
Auto Door Lock

1. The door lock system outputs “LOCK” when the vehicle speed stays over 50 km/h. However, it doesn’t output
“LOCK” when all doors are locked or failed.
2. If any of doors is unlocked after outputting “LOCK” in step 1, outputs “LOCK” up to 5 times (except step 1) with
interval of one second.
3. If any of doors is unlocked after 5 times of “LOCK” outputs, the door is regarded as “FAIL”.
4. If the door that was regarded as fail changes (UNLOCKàLOCK) to unlock, only one “LOCK” output will be done.
5. If the door that was “LOCK” is changed to “UNLOCK”, only one “LOCK” output will be done.
However, if it maintains unlock after lock output, the corresponding door will not be regarded as fail.
6. The door lock system outputs “UNLOCK” automatically if the “LOCK” output conditions are established by this
function or the key is cycled (IGN1=ONàOFF) (even when there is no “Lock” output while the vehicle speed stays
over 50 km/h under lock condition).
However, when the ignition key is turned to “OFF” position, the lock output conditions will be cancelled.
7. The “FAIL” condition of the door will be erased when the ignition key is turned to “OFF” position.
VEHICLE OVER 50 KM/H

SPEED BELOW 50 KM/H
LOCK OUTPUT
5 times
RK STICS CHANGED BY
AFFECTED VIN
32 2C
Auto Door Unlock (Crash Unlock)

For conventional vehicles, G-sensor in RK STICS generates “UNLOCK” signal when collided over 15 km/h over vehicle
speed. In this vehicle, the factory installed air bag module transmits the collision signal to STICS to unlock the door.
1. The air bag collision signal cannot be accepted within 7 seconds after turning the ignition key to “ON” position.
2. After this period, the door lock system outputs “UNLOCK” for all doors for 5 seconds (T2) from 0.4 seconds (T2)
after receiving the air bag collision signal.
3. Even though the key is turned to “OFF” position during the output of “UNLOCK”, the output continues on for
remaining period.
4. After input of the air bag collision signal, the door lock system doesn’t output “UNLOCK” even when turning the
ignition key to “ON” position.
ING SW(*1) ON
OFF
AIR BAG SIG ON

OFF
UNLOCK ON
RELAY OFF
[Notice]
(1) The “Unlock” control by air bag signal prevails over any “LOCK” or “UNLOCK” control by other functions.
(2) The “LOCK/UNLOCK” request by other functions will be ignored after/during the output of “UNLOCK” by the air bag.
However, the door lock is controlled by other functions when IGN1 SW is “OFF” and IGN2 SW is “OFF”.
(3) If the door lock system outputs “LOCK” and “UNLOCK” simultaneously, only the “LOCK” output can be activated.
(4) Even though the “LOCK/UNLOCK” output is requested, the door lock system cannot output “LOCK/UNLOCK” when all
door lock switches are locked/unlocked.
Also, even though the “UNLOCK” output for the driver’s door is requested, the door lock system cannot output “UNLOCK”
when the driver’s door is unlocked.
CHANGED BY RK STICS
AFFECTED VIN
2C 33
12) Time Lag Power Window Control

1. The power window is turned off when turning the ignition key to “ON” position.
2. The power window relay is turned “ON” for 90 seconds (T1) when turning the ignition key to “OFF” position.
However, the power window relay stays on for 90 seconds (T2) when the ignition key is turned to “OFF” position
while the door is opened.
3. The power window relay is turned “ON” again for 90 seconds (T2) just for once when opening the door during its
extended operation period of 90 seconds (T1).
4. The power window relay is turned “OFF” when closing the door during its extended operation period of 90 seconds
(T2).
RK STICS CHANGED BY
AFFECTED VIN
34 2C
13) REKES (Remote Keyless Entry System)
Transmitter
PANIC function is added on the previous version of REKES.
Door lock button

1. Door locking and theft deterrent armed mode
2. Press door lock button to release.
Door unlock (2-step operation)

Step 1: Unlocking driver’s door
Step 2: Unlocking all doors and tailgate Panic button: Operates under the theft deterrent
armed mode
Theft deterrent horn: Sounds approx. 27 seconds
Specification: CR 2032
Quantity: 1 ea
CHANGED BY RK STICS
AFFECTED VIN
2C 35
Receiver
1. Operating requirements
- IGN key = OUT (removed)
2. Code registration requirement
- After connecting the B+ to external coding terminal (applying battery voltage)
Transmitter Code Registration

- Only one transmitter code can be registered.
- The received code cannot be output during the registration.
1. Coding terminal: OFF à ON (applying battery voltage)

2. Press LOCK, UNLOCK or PANIC switch on the transmitter.
3. Outputs hazard warning flasher for 0.5 seconds (once) and horn for 0.04 seconds (once) during registration.
4. Code output requirements
- The system outputs the function code when the CUSTOM and ID code are correct and the Rolling code is within
operating range while the ignition key is removed and the coding terminal is turned off (grounded).
- Available function code: LOCK / UNLOCK / PANIC
RK STICS CHANGED BY
AFFECTED VIN
36 2C
14) Theft Deterrent
Description of Burglar Alarm Function

1) Armed mode activation requirements
1. The “LOCK” output is “ON” when receiving the “LOCK” signal from transmitter while the ignition key is removed and
all doors are closed. The armed mode is activated when the door lock switch is locked (theft deterrent horn output:
once, hazard relay output: twice).
2. The theft deterrent horn and hazard relay outputs are “ON” when receiving the “LOCK” signal from the remote
control key again in armed mode (theft deterrent horn output: once, hazard relay output: twice).
3. When receiving “LOCK” signal from the remote control key while any of doors is not closed, only the “LOCK” output
can be done and then activates the armed ready mode (without theft deterrent horn and hazard warning flasher). At
this moment, if the ignition key is in the ignition switch, the door unlock switch is turned “ON” or the door lock
switch is unlocked (after 0.6 seconds), cancels the armed mode and activates the normal mode. However, in these
cases, if closing the door and locking the door lock switch, the theft deterrent horn outputs once and the hazard
warning flasher outputs twice and then activates armed mode.
4. When the door is not opened or the ignition key is not inserted into ignition switch for 30 seconds after receiving
“UNLOCK” signal, outputs “LOCK” and then activates armed mode (RELOCK operation). Also, at this moment, the
system outputs the theft deterrent horn and hazard warning flasher.
5. The armed mode will not be activated except above conditions.
Ex) The armed mode will not be activated when the door is locked by the ignition key.
Tx SIGNAL
NO SIGNAL
ENTRANCE
DOOR SW
ENTRANCE
DOOR
LOCK SW
OPERATION ARMED MODE

OTHERS
CHANGED BY RK STICS
AFFECTED VIN
2C 37
2) Armed mode cancellation requirements

1. Unlocking by remote control key or engine starting.
3) Warning operation requirements

1. When opening the door in armed mode
2. When unlocking the door lock switch in armed mode
3. When closing and then opening the door after completion of warning (27 seconds)
4) Warning operation
1. The theft deterrent horn and hazard warning flasher output is “ON” for T3 (27 seconds) with the interval of T2 (1
second).
5) Warning cancellation requirements

1. Cancels warning by using any signal from the remote control key (LOCK, UNLOCK, START, STOP, PANIC,
CHECK) during warning operation.
2. Cancels warning after 27 seconds (remaining period) while the ignition key is turned to “ON” position.
6) Operation when warning is cancelled

1. The theft deterrent horn and hazard warning flasher outputs are “OFF”.
WARNING ESTABLISHED
REQUIREMENTS NO ESTABLISHED
WARNING ESTABLISHED
CANCELLATION NO ESTABLISHED
THEFT WARNING
DETERRENT ARMED
STATE NORMAL
RK STICS CHANGED BY
AFFECTED VIN
38 2C
15) PANIC Warning

1. The PANIC warning output is “ON” (theft deterrent horn) when receiving the PANIC signal from the remote control
key (pressing PANIC button for less than 0.5 ~ 1.0 second).
2. The PANIC warning output is “OFF” when receiving any signal from the remote control key during PANIC warning.
3. Followings are theft deterrent warnings:

1) The theft deterrent warning is canceled when receiving PANIC signal from the remote control key during theft
deterrent.
2) The theft deterrent warning output is “ON” when the theft deterrent conditions are established during PANIC
warning (PANIC output is “OFF”).
3) The PANIC warning output is “ON” when receiving the PANIC signal from the remote control key in Armed Ready
/ Armed / Warning Completion / Relock Ready mode (maintaining the theft deterrent mode).
4. This function operates only in armed mode.

5. The system sends the current vehicle conditions (LOCK, engine running) when the PANIC warning is turned off by
the remote control key.
REMOTE
CONTROL KEY
PANIC SIGNAL
THEFT WARNING
DETERRENT OTHERS
MODE
HORN
CHANGED BY RK STICS
AFFECTED VIN
2C 39
16) Auto Light Function

1. The lights automatically come on and off according to the ambient brightness when the multifunction light switch is
in “AUTO” position while the ignition key is in “ON” position.
RK STICS CHANGED BY
AFFECTED VIN
40 2C
7. DIAGNOSIS TROUBLE CODE AND HELP TIPS

The RK STICS and related devices in this vehicle can be diagnosed by SCAN-100.
Diagnostic Procedures
1. Select the vehicle model.
2. Select RK STICS. 3. Select the DTC code.
Check the part number and version for Sensor data check screen
installed units
CHANGED BY RK STICS
AFFECTED VIN
2C 41
Code Descriptions Help

01 Defective auto door lock opera- This DTC is set when the unit didn’t receive the contact signal of door
tion lock actuator after the unit has sent the “LOCK” signal to the door lock
relay (while the auto door lock is activated and the vehicle speed is
over 50 km/h).
02 Defective door lock relay This DTC is set when the unit didn’t receive the contact signal of door
lock actuator after the unit has sent the “LOCK” signal to the door lock
relay by the remote control key or knob.
03 Defective door unlock relay This DTC is set when the unit didn’t receive the contact signal of door
unlock actuator after the unit has sent the “LOCK” signal to the door
unlock relay by the remote control key or knob.
04 Defective driver’s door unlock This DTC is set when the unit didn’t receive the contact signal of door
relay unlock actuator after the unit has sent the “LOCK” signal to the door
unlock relay by the remote control key. (When the function that opens
driver’s door only is not operating)
05 Defective wiper relay This DTC is set when the wiper stop signal cannot be detected during
the wiper relay operation.
06 Defective INT operation This DTC is set if the “OPEN” signal (4 V) is detected when changing
the INT VOLUME value (0 V: FAST, 4 V: SLOW) in vehicle speed
sensitive INT wiper equipped vehicle.
07 Abnormal speed signal This DTC is set when more than 3 km/h of vehicle speed is detected
from the vehicle speed signal input area while the ignition key is in
“ON” position and ALT D is “LOW”.
08 Abnormal air bag collision signal The air bag unit receives the collision signal.
This DTC is set when the door lock actuator is locked in unlock condi-
tions after the collision signal is entered into collision sensor input end
in air bag unit.
09 Abnormal door ajar warning light This DTC is set when the door ajar warning light comes on while the
signal vehicle speed is over 3 km/h.
10 Abnormal air bag collision This DTC is set whenever the collision signal is entered into the colli-
sensor’s input signal sion sensor while the ignition key is in “OFF” position
11 Abnormal air bag collision signal This DTC is set when the STICS sends the door unlock signal and its
feedback value is normal.
12 Abnormal speed signal This DTC is set when more than 200 km/h of vehicle speed is detected.
13 Defective parking brake warning This DTC is set when the brake warning light comes on while the
light vehicle speed is over 3 km/h.
14 Numbers of auto door lock fault Maximum numbers: 20 times
The number increases by 1 up to 20 when the fault is detected during
every IGN ON. It is reset to 0 when the DTC code is erased.
15 Numbers of door lock relay fault Maximum numbers: 20 times
The number increases by 1 up to 20 when the fault is detected during
16 Numbers of door unlock relay Maximum numbers: 20 times
fault The number increases by 1 up to 20 when the fault is detected during
17 Numbers of driver’s door unlock Maximum numbers: 20 times
relay fault The number increases by 1 up to 20 when the fault is detected during
RK STICS CHANGED BY
AFFECTED VIN
42 2C
Removal and Installation of STICS

Preceding Work: Removal of driver side instrument panel undercover
1. Unscrew four bolts and remove the STICS unit.
CHANGED BY RK STICS
AFFECTED VIN
2D 3
RAIN SENSING WIPER

The rain sensing wiper unit in this vehicle doesn’t control the wiper directly. The rain sensing unit detects the amount of
rain drops and sends the operating signal to STICS, and STICS drives the wiper directly.
1. COMPONENTS
Multifunction wiper switch:
Rain sensing unit AUTO and sensitivity control
AUTO
A sensor that emits infrared rays through LED : Wiper operates automatically by rain sensor
and then detects the amount of rain drops by
FAST <-------> SLOW
receiving reflected rays against sensing section
(rain sensor mounting section on the windshield) : Auto delay/Auto speed control. A position that
with photodiode. can control sensitivity against rains on the
windshield and transmits wiping demand
signal accordingly.
STICS The rain sensing unit detects the amount of

rain drops and sends the operating signal to
STICS, and STICS drives the wiper directly.
At this moment, STICS determines the wiper ICM box
operation mode (washer, MIST, AUTO), then The wiper related relays are
sends the information to the rain sensor. installed in ICM box.
RAIN SENSING WIPER CHANGED BY

AFFECTED VIN
4 2D
2. RAIN SENSOR OPERATION

The rain sensor is installed on the specific heat treated windshield that has minimum 13% of transmittance rate with
specified intensity of radiation. It is installed on the glass with a adhesive of Sorepa. It communicates with STICS and
makes the wipers to operate automatically under the rain sensing mode (multifunction switch wiper: AUTO mode). The
emitting section of the rain sensor unit emits infrared rays against the windshield and then detects the amount of rain
drops by receiving reflected rays with photodiode.
The sensing section on the windshield is located just above the center point between LED and photodiode.
Components and functions of the rain sensor unit
Rain sensor unit (including cover)
Rear Front
PCB assembly and

emitter lens
Unit latch
Emitter lens
Rain sensor The LED emits the infrared
unit rays is located at bottom and
the lens guides the infrared
rays to target point.
Housing and
receiver lens
Receiver lens
The receiver lens guides the
reflected infrared rays from
windshield to photodiode.
Housing and PCB
CHANGED BY RAIN SENSING WIPER

AFFECTED VIN
2D 5
3. RAIN SENSOR RELATED CIRCUIT

The rain sensor has one connector with 4 pins and each pin has following function as shown in the circuit diagram.
However, in this vehicle, the terminal No. 1 and No. 2 are for communications between STICS and the rain sensor; the
No. 1 terminal sends the detected value from the rain sensor to STICS then the STICS drives wiper motor.
No.2 terminal sends the wiper and washer operation information such as
- washer operation mode,
- MIST mode, or
- AUTO wiper position
to the rain sensor to recognize whether it is actual rain or it is in rain sensing wiper operation mode.
Multifunction switch Rain sensor unit
Wiper
relay (LO)
STICS
Wiper
motor
Wiper relay
(HI)
Washer motor

AFFECTED VIN
6 2D
4. OPERATION MODE OF RAIN SENSING WIPER SYSTEM

Switch positions Operation mode
MIST (Transmits the manual operation As long as the switch is in MIST position, the wiper motor operates in
mode signal to sensor) low speed. The wiper blade returns to parking position if the switch
returns to the original position. The rain sensor ignores inputs during
parking signal periods.
OFF (Transmits the manual operation The wiper motor rotates in low speed until it returns to parking position.
mode signal to sensor) When the system is in manual mode, the sensitivity of sensor will be
set to 2 (AUTO 2) internally. By doing so, immediate wiping with proper
intervals is possible when a driver sets the system from OFF to AUTO.
AUTO 1 SLOW Auto delay/auto speed control. Low sensitivity against rains on
(Low sensitivity) windshield. When the switch is in AUTO position, the sensor trans-
mits the wiping request signal to STICS.
AUTO 2 Auto delay/auto speed control.
(Low/medium sensitivity) Low/medium sensitivity against rains on windshield.
(Medium sensitivity) Medium sensitivity against rains on windshield.
(Medium/High sensitivity) Medium/high sensitivity against rains on windshield.
FAST
(High sensitivity) High sensitivity against rains on windshield.
LOW SPEED (transmits the manual The wiper motor rotates continuously in low speed of approx. 45 rev./
operation mode signal to sensor) minute at B+=13.5V. The rain sensor operations are same as in MIST.
HI SPEED (transmits the manual operation The wiper motor rotates continuously in high speed of approx. 70 rev./
mode signal to sensor) minute at B+=13.5V. The rain sensor operations are same as in MIST.
Washer switch The washer can be operated as long as the washer switch is pressed.
And, the wiper operates several times as specified. When releasing
the washer switch, the wiper returns back to the parking position. The
STICS transmits the washer signal during its whole washing period
(including dry wiping operation). The rain sensor ignores the rain de-
tection during the washing period.

AFFECTED VIN
2D 9
6. DIAGNOSIS PROCEDURES
1. Check the glass and coupler for proper installation.
2. Check the power up function.
3. Check the instant wipe function.
4. Check the washer coupled wiper function.
5. Check the high speed.
6. Find the causes for irregular operations (abrupt operations).
7. Check the system with self-diagnosis function.

AFFECTED VIN
10 2D
7. TROUBLESHOOTING
1. The wiper should not operate one cycle when turning the wiper switch to “AUTO” from “OFF” position
or Ig S/W (Ig2) while the wiper switch is in “AUTO” position.
1) When Ig2 with the wiper switch “AUTO” position, the wiper operates one cycle to remind a driver that the wiper
switch is in “AUTO” position.
2) When the wiper switch is turned to “AUTO” from OFF, the wiper operates one cycle. It always operates one cycle
for the initial operation, however, the wiper does not operate afterwards to prevent the wiper blade wear if not raining
when turning the wiper switch to “AUTO” from “OFF”. However, the wiper operates up to 5 minutes after rain stops.
If this function does not occur, check No. 1 pin. If the pin is normal, check the wiper relay related terminals in ICM
box.
2. It rains but the system does not work in “AUTO” position.
1) Check whether the wiper switch is in “AUTO” position.

2) Check the power to sensor. Check the conditions of pin 3 (Ground) and pin 4 (IGN).
3) Check the wiper relay for defective.
3. The wiper operates 3 or 4 times with high speed abruptly.
Check whether the variable resistance knob on the wiper switch is set in “FAST”. The “FAST” is the highest stage
of sensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to low sensitivity.
4. The wiper operates continuously even on the dry glass.
1) Check the wiper blade for wear. If the wiper blade cannot wipe the glass uniformly and clearly, this problem could
be occurred. In this case, replace the wiper blade with new one.
2) Check whether the variable resistance knob on the wiper switch is set in “FAST”. The “FAST” is the highest stage
of sensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to low sensitivity.

AFFECTED VIN
2D 11
5. The wiper responses are too fast or slow.
Check whether the variable resistance knob on the wiper switch is set in “FAST” or “SLOW”.
Notify that the customer can select the sensitivity by selecting the variable resistance value. And, select a proper
stage.

AFFECTED VIN
12 2D
8. REMOVAL AND INSTALLATION OF RAIN SENSOR

1. Pry off the rain sensor cover by inserting a small flat-blade screwdriver into service holes at both sides.
[Notice]
Otherwise, the cover or rain sensor components could be damaged.
Service hole
2. Pull of the rain sensor unit from the windshield glass and disconnect the rain sensor connector.

AFFECTED VIN
2 2E
INTERIOR SWITCHES
Audio remote control switch
Audio power button
Mute button
Mode button
Volume button - Up
SEEK button – Up
Volume button - Down

SEEK button - Down
4WD switch and rear

washer/wiper switch
Outside rearview mirror control

and folding switch
Window switch
CHANGED BY SWITCH
AFFECTED VIN
2E 3

(multi-meter integrated type)
Driver’s seat warmer switch Rear fog lamp switch Front fog lamp switch
Hazard warning flasher switch

Sun roof switch
Multi-meter
Defogger switch ESP OFF switch Passenger’s seat
Front room lamp Front room lamp warmer switch
operation operation
Multifunction switch
Window switch
SWITCH CHANGED BY
AFFECTED VIN
4 2E
SWITCHES
1. CENTER SWITCH
Seat Warmer Switch
The seat warmer relay is installed in ICM box and the seat heated wire is installed in the driver’s and passenger’s seat.
When the seat warmer switch is operated, the seat cushion and seatback gets warm. If the temperature of seat surface
gets 40 ± 5°C, the thermistor cuts or connects the power to heated wire to maintain the temperature to the specified
level.
The is no control switch and unit to control the temperature of the seat surface temperature.
Driver’s seat warmer Passenger’s seat

switch warmer switch
Seat heated wire (driver’s and Seat heated wire (driver’s and passenger’s seat)
passenger’s seat) – in ICM box
Seat heated wire relay - LH
Seat heated wire relay - RH
CHANGED BY SWITCH
AFFECTED VIN
2E 5
Connector Terminals and Circuit

- Internal circuit diagram of seat warmer switch
Rated capacity: DC 12V, 1A
Seat warmer relay

(in ICM box)
[Notice]
The temperature of seat surface should be increased over 20°C within 3 minutes after turning on the switch while a person
(height: 175 ± 5 cm, weight: 75 ± 5 kg).
[Notice]
- Do not place anything sharp on the seat.

- When cleaning the seats, do not use organic solvents such as benzene or thinner.
- Do not use this function when the engine is not running. The battery could be discharged.
SWITCH CHANGED BY
AFFECTED VIN
6 2E
Fog Lamp Switch
Fog lamp
Fog lamp relay

Fog lamp switch Fog lamp connector
• The fog lamp with indicator comes on when pressing the fog lamp switch while the light switch is “ON”. It goes off
when pressing the switch again.
Fog lamp relay

Engine compartment
fuse and relay box
CHANGED BY SWITCH
AFFECTED VIN
2E 7
Hazard Warning Flasher Switch

The hazard warning flasher switch is connected to the turn signal lamp circuit. The hazard warning flasher unit is
integrated into the ICM box. If the flasher unit is defective, should replace the ICM box assembly.
Indicator lamp
Flasher unit (in ICM box)
• The hazard warning indicators on the indicator display, both turn signal lamps, and both side repeaters blink when
pressing the hazard warning flasher switch.
ICM box
Flasher unit Turn signal lamp

switch
Left side Right side

lamps lamps
SWITCH CHANGED BY
AFFECTED VIN
8 2E
Defogger Switch
The windshield, tailgate glass, and outside rearview mirrors have heated wire. STICS controls the defogger relay in the
engine room fuse and relay box.
Defogger indicator STICS Defogger relay and fuses
Comes on during operation Controls the heated glass In the engine compartment
CHANGED BY SWITCH
AFFECTED VIN
2E 9
Circuit Diagram
The defogger switch is connected to STICS. The STICS controls the tailgate windshield and outside rearview mirror
heated glass according to the switch operations while the engine is running.
SWITCH CHANGED BY
AFFECTED VIN
10 2E
Tailgate Heated Glass, Windshield Galss and Outside Rearview Mirror Heated Glass (controlled
by STICS)
1. The outside rearview mirror heated glass operates for 12 minutes when turning on the defogger switch while the
engine is running.
3. If the defogger switch is pressed again within T2 (10 minutes) after completion of the first operation (T1), the
defogger system operates for 6 minutes just for once.
OVER 9 V
BELOW 9 V
T1: 12 min. T2: within 10 min. T3: 6 min.
CHANGED BY SWITCH
AFFECTED VIN
2E 11
ESPOFF Switch
If the driving wheels are slipping on the snowy or icy road, the engine rpm may not be increased even when depressing
the accelerator pedal, and accordingly, the vehicle may not be started off. In this case, stop the ESP function by
pressing the ESPOFF switch. When the ESPOFF switch is pressed, the ESP function stops and the vehicle is driven
independently from the sensor outputs. However, the ABS function is still activated.
ESP OFF switch ESPOFF switch and connector
ESP indicator and warning light ICM box
ESP operation alarm buzzer
• When the ESP warning light comes on

The lamp comes on when the vehicle posture control function is cancelled by pressing ESPOFF switch or ESP
related system is defective.
• When the ESP warning light blinks and the alarm sounds
It means the ESP function is operating while the vehicle is driving under extremely unstable conditions.
SWITCH CHANGED BY
AFFECTED VIN
12 2E
Resuming the ESP function by using ESPOFF switch
The ESP function will be resumed if pressing the ESPOFF switch on the center switch panel again shortly when the ESP
function is cancelled (when the ESP warning light comes on). At this moment, the ESP warning light in the indicator
display goes off and the ESP function is resumed.
[Notice]
- The ESP system deactivates when stopping the engine. It will be resumed when the engine is started again.
- If the vehicle is controlled by ESP during driving, the ESPOFF switch will not work.
- If the ESP warning light comes on, the ESP related system is defective. At this moment, the ABS works in a basic way.
- If the ESP warning light and the ABS warning light come on simultaneously, both ESP and ABS system are not working.
- If the ESP warning light blinks and the alarm sounds, it means that the vehicle stability is controlled by the ESP function
when the vehicle stability is extremely unstable.
- If the ESP function operates while driving, the indicator lamp blinks and the alarm sounds with the interval of 0.1
second.
Rated capacity: DC 12 V, 1 A
CHANGED BY SWITCH
AFFECTED VIN
2E 13
Removal and Installation of Center

Switches
front cup holder.
SWITCH CHANGED BY
AFFECTED VIN
14 2E
6. Disconnect all switch connectors including TRIP switch connector during removal of the front cover.
CHANGED BY SWITCH
AFFECTED VIN
2E 15
• Disconnect the air conditioner connector.
7. Remove the center switch cover and pull out the switches from it.
SWITCH CHANGED BY
AFFECTED VIN
16 2E
4WD SWITCH, REAR WIPER/WASHER SWITCH

1. 4WD (4H ↔ 4L) SWITCH: TOD (FULL TIME 4 WHEEL DRIVE)
Driving Mode Change

Driving mode 4H ↔ 4L This warning light comes on when the
Changing requirement Vehicle is stationary. 4WD system is defective.
Selected gear Neutral
4WD LOW indicator

“4H” (4-Wheel Drive, High) : for driving on normal road
This indicator blinks during mode changes
“4L” (4-Wheel Drive, Low) : for maximum traction needed
(4H ↔ 4 L), then goes off after completion.
in slippery roads, steep hills
and rough roads.
CHANGED BY SWITCH
AFFECTED VIN
2E 17
Rear Wiper/Washer Switch
The rear wiper operates with a specific speed when The washer fluid is sprayed when pressing the switch.
pressing this switch. It stops when pressing the switch And, the wiper operates when pressing the switch
again. over 0.6 seconds.
Rated capacity : wiper - DC 12V, 3.0A

washer - DC 12V, 3.8A
SWITCH CHANGED BY
AFFECTED VIN
18 2E

1. Remove the driver side lower switch panel and remove
the switch bezels.
[Notice]
Be careful not to damage the surroundings during its removal

procedures.
2. Disconnect the connectors and remove the switches.
CHANGED BY SWITCH
AFFECTED VIN
2E 19
SWITCHES ON STEERING WHEEL

1. AUDIO REMOTE CONTROL SWITCH
POWER
Turns on and off the audio system.
MODE
Changes the audio mode in order as below:
MUTE
SEEK Stops audio output from audio system.
SEEK To resume the audio output, press the
button again.
• In radio mode
VOLUME
- Press briefly: Manual searching for a station.
VOLUME
- Press and hold: Automatic searching for a station.
• In CD (DVD) player/Cassette tape mode Increases or decreases the volume.
- Press briefly: Replay next/previous track.

- Press and hold: Move forward/backward in current tract.
SWITCH CHANGED BY
AFFECTED VIN
20 2E
2. CIRCUIT DIAGRAM OF AUDIO REMOTE CONTROL SWITCH
Audio
switches
Tail
lamp
relay
Pin number Descriptions

31 Audio signal
32 Audio ground
33 Tail lamp relay
CHANGED BY SWITCH
AFFECTED VIN
2E 21
Remote control switch on steering

wheel
1. Remove the screws at both sides.
2. Remove the air bag module (horn) from the steering
wheel.
3. Unscrew the bolts and disconnect the remote control switch connector.
4. Remove the remote control switch from the steering wheel.
SWITCH CHANGED BY
AFFECTED VIN
22 2E
3. HORN AND THEFT DETERRENT HORN

Horn
Theft Deterrent Horn
CHANGED BY SWITCH
AFFECTED VIN
2E 23
4. SWITCHES ON DOOR TRIM

System Components
Outside rearview mirror switch
Outside rearview mirror folding switch

The mirrors are folded/unfolded when pressing the
switch more than 1 second.
Mirror selection switch
[Note]
The mirrors can be folded/unfolded for 30 seconds
after turning the ignition key to “OFF” position.
Manual folding or unfolding the outside rearview
mirrors may cause a malfunction of the mirror
folding system.
Driver’s door trim panel
Outside rearview mirror folding unit
Switches on driver’s door trim

Driver’s door window switch
• When the front of the switch is lightly pressed (stage 1), the
window will be lowered while the switch is pressed. When
pressed to its end (stage 2), the window will open automati-
Window lock cally until it is fully opened. The window stops during its
switch operation when pressing the switch (stage 1) again or pulling
If this switch is pressed, up the switch.
all door windows are • The other window can be operated only while the appropriate
operated only by driver’s switch is activated.
door window switches.
Time lag of window operation

The operation of power window can be continued for
90 seconds after turning the ignition switch to “OFF”
position.
Central door locking switch
SWITCH CHANGED BY
AFFECTED VIN
24 2E
2) Switches on Driver’s Door
Door lock switch Window lock switch
Window lock switch
* Abbreviations
FLU: Front Left Up FLD: Front Left Down
FRU: Front Right Up FRD: Front Right Down
RLU: Rear Left Up RLD: Rear Left Down
RRU: Rear Right Up RRD: Rear Right Down
CHANGED BY SWITCH
AFFECTED VIN
2E 25
2) Circuit Diagram of Switches on Driver’s Door
Front Left Front Left Down (FLD) 4

Front Left Up (FLU) 2
Front Right Front Right Down (FRD) 5
Front Right Up (FRU) 7
Rear Left Rear Left Down (RLD) 8
Rear Left Up (RLU) 11
Rear Right Rear Right Down (RRD) 12
Rear Right Up (RRU) 14
Door Lock LOCK 10
UNLOCK 6
Illumination ILL 1
Power B+ 3
B+ (S) 13
E(-) 9
SWITCH CHANGED BY
AFFECTED VIN
26 2E
Removal of Outside Rearview Mirror Switch

1. Remove the screws (arrows) from the door trim.

2. Remove the door armrest grip cover and unscrew the screw.
3. Pry off the door lever cover and remove the mounting screws.
4. Remove the door trim.
CHANGED BY SWITCH
AFFECTED VIN
2E 27
5. Unscrew the bolts and remove the door grip from the removed door trim.
6. Unscrew the bolts and remove the outside rearview mirror switch from the door grip.
SWITCH CHANGED BY
AFFECTED VIN
28 2E
Removal and Installation of Window Switch

Preceding works: Disconnection of negative battery cable, Removal of door trim
Unscrew the screws and remove the window switch from the removed door trim.
Driver side
Passenger side
CHANGED BY SWITCH
AFFECTED VIN
2E 29
MULTIFUNCTION SWITCH
1. MULTIFUNCTION SWITCH
Steering wheel
Steering wheel
angular sensor
Light switch Wiper/washer
switch
Specifications
Descriptions Specifications
Multifunction Rated voltage DC 12V
switch Operating temperature range -30°C ~ +80°C
Rated load Light switch Turn on: 1 A (relay load)
Dimmer and passing switch Hi/Low/Passing: 0.3 A (relay load)
Turn signal switch 6.6 ± 0.5 A (lamp load)
Wiper switch Low: 5 A, Hi: 7 A (motor load)
AUTO: 0.22 ± 0.05 A (relay load)
Fixed: max. 28 A (motor load)
Washer switch 4 A (motor load)
Intermittent wiper switch Max. 25 mmA
MIST switch 5 A (motor load)
SWITCH CHANGED BY
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30 2E
Multifunction Switch Operating Range
CHANGED BY SWITCH
AFFECTED VIN
2E 31
Connector Pins and Designations of Multifunction Switch
Connector A Connector B
1. Connector A Pin number Descriptions

1 EB: Dimmer and passing ground
2 HL: Headlamp low beam
4 3 11 9 10 3 HU: Headlamp high beam

4 HS(2): Passing switch
5 TS: Tail lamp switch
2 1 56 7 8
6 HS(1): Headlamp switch
7 F/AUTO: Rear fog lamp
8 DEL: Light switch ground
9 TB: Flasher unit power
10 TL: Turn signal (LH) lamp switch
11 TR: Turn signal (RH) lamp switch

14 LO: Low wiper speed
15 HI: High wiper speed
16 S: Wiper stop
15 14 16 22 21 17 20
17 AUTO(W): Intermittent wiper
18 INT(T): Intermittent WIPER
18 19 19 BWT: Intermittent power
20 W: Front washer switch
21 BW: Wiper and washer switch
22 MS: Low wiper speed (MIST switch)
SWITCH CHANGED BY
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32 2E
Multifunction switch connector
1) Light switch and auto light switch
2) Dimmer and passing switch
3) Turn signal lamp switch
4) Wiper and intermittent switch
CHANGED BY SWITCH
AFFECTED VIN
2E 33
Removal and Installation of Multifunction Switch Assembly

Preceding work: Disconnection of negative battery cable
Cautions
1. Be careful not to drop or shock the air bag module

during removal procedures.
A
2. Lift up the hook when disconnecting the air bag
contact coil connector.
1. Place the steering wheel to the straight forward direction.

Unscrew the screws at both sides and remove the horn
pad (air bag module).
2. Put an installation mark on the steering wheel and nut and remove the steering wheel.
SWITCH CHANGED BY
AFFECTED VIN
34 2E
3. Remove the driver side instrument lower panel .
4. Unscrew the screws from the steering column cover and

remove the upper and lower covers.
5. Disconnect the multifunction switch connector. Unscrew the screws from the air bag contact coil, and remove the
air bag contact coil assembly.
* For installation, align the steering wheel to the

installation mark and tighten the nut to the
specified tightening torque.
CHANGED BY SWITCH
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2E 35
6. Disconnect the steering wheel angular sensor connector. Unscrew the screws and remove the multifunction switch
assembly.
SWITCH CHANGED BY
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36 2E
2. AUTO LIGHT SENSOR

Overview
The auto light control is a system that turns on/off the tail
lamps and headlamps automatically. The auto light sensor is
installed on the instrument panel (passenger side). This sen-
sor detects the ambient brightness and automatically turns
on and off the tail lamps and headlamps while the light switch
is in AUTO position without light switch operations. The sys-
Auto light sensor
tem turns on and off the lamps when passing through the
tunnel during day driving and getting dark due to fog, rain or
snow.
Specifications
Description Specifications
Auto light sensor unit Operating voltage 9 ~ 16V
Load Max. 200 mA (relay load)
Operating temperature -30°C ~ +85°C
Storage temperature -40°C ~ +120°C
Location on instrument panel (passenger side)
Input / Output Circuit Diagram
Headlamp
relay
Tail lamp
relay
Ignition switch
Battery 12V Control

circuit
Auto light switch
Tail lamp
Headlamp switch
switch
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2E 37
Auto Light Sensor Unit Terminals
1. System power supply

2. Tail lamp relay
3. Headlamp relay
4. Brightness detecting sensor
5. Auto light switch
6. System ground
Auto light operating conditions

Switch functions
1. Turn the ignition switch to “ON” position and turn the multifunction switch in order of OFF → tail lamp → headlamp
→ AUTO.
2. Turn on and off the light switch.
3. Turn the light switch to “AUTO” position. At this moment, the tail lamps and headlamps come on and off automatically
when the brightness of light that reflected on the photodiode in the auto light sensor is the same as voltage that is
set by software in CPU.
4. When operating the tail lamp and headlamp switch manually again, the lamps comes on and off according to the
switch operations not by brightness of light that detected by sensor.
5. When the ignition key is removed, tail lamps and headlamps go off.
Turning on conditions
Lamp
Tail lamp ON condition Headlamp ON condition Operation delay time
Brightness
ON 30.5 ± 5(LUX) 8.9 ± 3(LUX) 0.5 ± 0.1 second
OFF 60.5 ± 5(LUX) 17.2 ± 3(LUX) 3 ± 1 second
SWITCH CHANGED BY
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38 2E
Operational Characteristics
IGN SW
Within OFF range Within ON range
AUTO light SW
Tail lamp
Headlamp
However, the tail lamp and headlamp should be within ON and OFF ranges.
T1: 3 ± 1.0 sec T2: 500 ± 100 msec
Inspection
Position the multifunction switch to “AUTO” position and cover
the auto light sensor on the instrument panel (passenger side)
with a cloth to block the light coming from outside and then
check the auto light functions.
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2E 39
WIPER AND WASHER ASSEMBLY

1. GENERAL
System Layout of Wiper and Washer
Front wiper and washer assembly
Wiper blade
assembly
Washer nozzle and

washer hose
Wiper motor and

linkage assembly Washer motor and
washer fluid reservoir
Rear wiper and washer assembly
Washer nozzle and

washer hose
Wiper blade
assembly Wiper motor and
linkage assembly
Washer motor and

SWITCH CHANGED BY
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40 2E
Specifications
Motor Rated voltage DC 12 V ± 0.3 V
Test voltage DC 13.5 V ± 0.3 V
Minimum operating voltage Below DC 8 V
Insulating voltage Over 1 mΩ
Restraint test Torque Over 1.1 Km
Voltage Below 14 A
Surrounding voltage range -40°C ~ +80°C
Control Rated voltage DC 12 V
Operating temperature range -30°C ~ +80°C
Reserving temperature range -40°C ~ +90°C
Insulating voltage Over 1 mΩ
Voltage drop Below 0.5 V
(terminals between 5-7, 6-8, 5-8, 6-7 @ 5 A)
Test voltage 14.0 ± 0.5 A
Acceptable load current Maximum 10 A
Circuit Diagram
Relay 1
Voltage
controller
Relay 2
Wiper motor
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2E 41
2. REMOVAL AND INSTALLATION OF WIPER ASSEMBLY

1. Front Wiper Assembly
Components Locator
Wiper blade
Wiper linkage
Wiper motor
SWITCH CHANGED BY
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42 2E
1. Detach the washer hose , unscrew the nut and remove the wiper blade assembly, and remove the hood cowl
grille.
A. Wiper blade assembly
B. Cowl grill
2. Unscrew the bolts and remove the wiper linkage assembly.
CHANGED BY SWITCH
AFFECTED VIN
2E 43
3. Disconnect B motor connector . Unscrew two mounting bolts and two nuts and remove the wiper motor.
SWITCH CHANGED BY
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44 2E
2. Rear Wiper Assembly

Preceding work: Disconnection of negative battery cable, removal of tailgate trim
Components Locator
Wiper blade assembly
Rear wiper motor
Rear wiper assembly
CHANGED BY SWITCH
AFFECTED VIN
2E 45
1. Release the wiper arm cap , remove the wiper nut and wiper blade , and unscrew the motor lock nut .
2. Disconnect the wiper motor connector , unscrew the bolts , and remove the wiper motor assembly from
tailgate.
1. Motor connector
2. Motor mounting bolts
SWITCH CHANGED BY
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MEMO
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2E 1
2E - Switch (2005 ~)
Table of Contents
INTERIOR SWITCHES ...................................... 2E-2
SWITCHES ........................................................ 2E-4
1. Center switch .............................................................. 2E-4

......................................................................... 2E-16
1. 4WD switch .............................................................. 2E-16
2. Rear wiper / washer switch ...................................... 2E-17
SWITCHES ON STEERING WHEEL ............... 2E-19

1. Audio remote control switch ..................................... 2E-19
2. Circuit diagram of audio remote control switch ........ 2E-20
3. Horn and theft deterrent horn .................................. 2E-22
4. Switches on door trim ............................................... 2E-23
MULTIFUNCTION SWITCH .............................. 2E-29

1. Multifunction switch .................................................. 2E-29
2. Auto light system ...................................................... 2E-36
WIPER AND WASHER ASSEMBLY ................. 2E-39

1. General .................................................................... 2E-39
2. Removal and Installation of wiper assembly ............ 2E-41
SWITCH CHANGED BY
AFFECTED VIN
2 2E
INTERIOR SWITCHES
Audio remote control switch
Audio power button
Mute button
Mode button
Volume button - Up
SEEK button – Up
Volume button - Down

SEEK button - Down
4WD switch and rear

washer/wiper switch
Outside rearview mirror control

and folding switch
Window switch
CHANGED BY SWITCH
AFFECTED VIN
2E 3

(multi-meter integrated type)
Driver’s seat warmer switch Rear fog lamp switch Front fog lamp switch
Hazard warning flasher switch

Sun roof switch
Multi-meter
Defogger switch ESP OFF switch Passenger’s seat
Front room lamp Front room lamp warmer switch
operation operation
Multifunction switch
Window switch
SWITCH CHANGED BY
AFFECTED VIN
4 2E
SWITCHES
1. CENTER SWITCH
Seat Warmer Switch
The seat warmer relay is installed in ICM box and the seat heated wire is installed in the driver’s and passenger’s seat.
When the seat warmer switch is operated, the seat cushion and seatback gets warm. If the temperature of seat surface
gets 40 ± 5°C, the thermistor cuts or connects the power to heated wire to maintain the temperature to the specified
level.
The is no control switch and unit to control the temperature of the seat surface temperature.
Driver’s seat warmer Passenger’s seat

switch warmer switch
Seat heated wire (driver’s and Seat heated wire (driver’s and passenger’s seat)
passenger’s seat) – in ICM box
Seat heated wire relay - LH
Seat heated wire relay - RH
CHANGED BY SWITCH
AFFECTED VIN
2E 5

- Internal circuit diagram of seat warmer switch
Seat warmer relay

(in ICM box)
[Notice]
The temperature of seat surface should be increased over 20°C within 3 minutes after turning on the switch while a person
(height: 175 ± 5 cm, weight: 75 ± 5 kg).
[Notice]
- Do not place anything sharp on the seat.

- When cleaning the seats, do not use organic solvents such as benzene or thinner.
- Do not use this function when the engine is not running. The battery could be discharged.
SWITCH CHANGED BY
AFFECTED VIN
6 2E
Fog Lamp Switch
Fog lamp
Fog lamp relay

Fog lamp switch Fog lamp connector
• The fog lamp with indicator comes on when pressing the fog lamp switch while the light switch is “ON”. It goes off
when pressing the switch again.
Fog lamp relay

Engine compartment
fuse and relay box
CHANGED BY SWITCH
AFFECTED VIN
2E 7
Hazard Warning Flasher Switch

The hazard warning flasher switch is connected to the turn signal lamp circuit. The hazard warning flasher unit is
integrated into the ICM box. If the flasher unit is defective, should replace the ICM box assembly.
Indicator lamp
Flasher unit (in ICM box)
• The hazard warning indicators on the indicator display, both turn signal lamps, and both side repeaters blink when
pressing the hazard warning flasher switch.
ICM box
Flasher unit Turn signal lamp

switch
Left side Right side

lamps lamps
SWITCH CHANGED BY
AFFECTED VIN
8 2E
Defogger Switch
The windshield, tailgate glass, and outside rearview mirrors have heated wire. STICS controls the defogger relay in the
engine room fuse and relay box.
Defogger indicator STICS Defogger relay and fuses
Comes on during operation Controls the heated glass In the engine compartment
CHANGED BY SWITCH
AFFECTED VIN
2E 9
Circuit Diagram
The defogger switch is connected to STICS. The STICS controls the tailgate heated glass windshield glass and
outside rearview mirror heated glass according to the switch operations while the engine is running.
SWITCH CHANGED BY
AFFECTED VIN
10 2E
Tailgate Heated Glass, Windshield Glass and Outside Rearview Mirror Heated Glass (controlled by
STICS)
1. Defogger relay operates for 12 minutes when turning on the defogger switch while the engine is running.
3. If the defogger switch is pressed again within T2 (10 minutes) after completion of the first operation (T1), the
defogger system operates for 6 minutes just for once.
OVER 9 V
BELOW 9 V
DEFOG SW
DEFOG
RELAY
T1: 12 min. T2: within 10 min. T3: 6 min.
CHANGED BY SWITCH
AFFECTED VIN
2E 11
ESPOFF Switch
If the driving wheels are slipping on the snowy or icy road, the engine rpm may not be increased even when depressing
the accelerator pedal, and accordingly, the vehicle may not be started off. In this case, stop the ESP function by
pressing the ESPOFF switch. When the ESPOFF switch is pressed, the ESP function stops and the vehicle is driven
independently from the sensor outputs. However, the ABS function is still activated.
ESP OFF switch ESPOFF switch and connector
ESP indicator and warning light ICM box
ESP operation alarm buzzer
• When the ESP warning light comes on

The lamp comes on when the vehicle posture control function is cancelled by pressing ESPOFF switch or ESP
related system is defective.
• When the ESP warning light blinks and the alarm sounds
It means the ESP function is operating while the vehicle is driving under extremely unstable conditions.
SWITCH CHANGED BY
AFFECTED VIN
12 2E
Resuming the ESP function by using ESPOFF switch
The ESP function will be resumed if pressing the ESPOFF switch on the center switch panel again shortly when the ESP
function is cancelled (when the ESP warning light comes on). At this moment, the ESP warning light in the indicator
display goes off and the ESP function is resumed.
[Notice]
- The ESP system deactivates when stopping the engine. It will be resumed when the engine is started again.
- If the vehicle is controlled by ESP during driving, the ESPOFF switch will not work.
- If the ESP warning light comes on, the ESP related system is defective. At this moment, the ABS works in a basic way.
- If the ESP warning light and the ABS warning light come on simultaneously, both ESP and ABS system are not working.
- If the ESP warning light blinks and the alarm sounds, it means that the vehicle stability is controlled by the ESP function
when the vehicle stability is extremely unstable.
- If the ESP function operates while driving, the indicator lamp blinks and the alarm sounds with the interval of 0.1
second.
Rated capacity: DC 12 V, 1 A
CHANGED BY SWITCH
AFFECTED VIN
2E 13
Removal and Installation of Center

Switches
front cup holder.
SWITCH CHANGED BY
AFFECTED VIN
14 2E
6. Disconnect all switch connectors including TRIP switch connector during removal of the front cover.
CHANGED BY SWITCH
AFFECTED VIN
2E 15
• Disconnect the air conditioner connector.
7. Remove the center switch cover and pull out the switches from it.
SWITCH CHANGED BY
AFFECTED VIN
16 2E

1. 4WD SWITCH
TOD
P/Time
TOD P/Time
Driving Mode Change

Type Part time TOD This warning light comes on when the
Driving mode 4H ↔ 2H ↔ 4L 4H ↔ 4L 4WD system is defective.
Requirement Gear Neutral (A/T), Clutch signal (M/T)

Vehicle 4WD LOW indicator
Stationary
speed This indicator blinks during mode changes
4WD HIGH indicator

4WD
HIGH This indicator blinks during mode changes
CHANGED BY SWITCH
AFFECTED VIN
2E 17
2. REAR WIPER/WASHER SWITCH
The rear wiper operates with a specific speed when The washer fluid is sprayed when pressing the switch.
pressing this switch. It stops when pressing the switch And, the wiper operates when pressing the switch
again. over 0.6 seconds.
Rated capacity : wiper - DC 12V, 3.0A

washer - DC 12V, 3.8A
SWITCH CHANGED BY
AFFECTED VIN
18 2E

1. Remove the driver side lower switch panel and remove
the switch bezels.
[Notice]
Be careful not to damage the surroundings during its removal

procedures.
2. Disconnect the connectors and remove the switches.
CHANGED BY SWITCH
AFFECTED VIN
2E 19
SWITCHES ON STEERING WHEEL

1. AUDIO REMOTE CONTROL SWITCH
POWER
Turns on and off the audio system.
MODE
Changes the audio mode in order as below:
MUTE
SEEK Stops audio output from audio system.
SEEK To resume the audio output, press the
button again.
• In radio mode
VOLUME
- Press briefly: Manual searching for a station.
VOLUME
- Press and hold: Automatic searching for a station.
• In CD (DVD) player/Cassette tape mode Increases or decreases the volume.
- Press briefly: Replay next/previous track.

- Press and hold: Move forward/backward in current tract.
SWITCH CHANGED BY
AFFECTED VIN
20 2E
2. CIRCUIT DIAGRAM OF AUDIO REMOTE CONTROL SWITCH
POWER ON/OFF
Audio
switches
Tail
lamp
relay
Pin number Descriptions

31 Audio signal
32 Audio ground
33 Tail lamp relay
CHANGED BY SWITCH
AFFECTED VIN
2E 21
Remote control switch on steering

wheel
1. Remove the screws at both sides.
2. Remove the air bag module (horn) from the steering
wheel.
3. Unscrew the bolts and disconnect the remote control switch connector.
4. Remove the remote control switch from the steering wheel.
SWITCH CHANGED BY
AFFECTED VIN
22 2E
3. HORN AND THEFT DETERRENT HORN

Horn
Theft Deterrent Horn
CHANGED BY SWITCH
AFFECTED VIN
2E 23
4. SWITCHES ON DOOR TRIM

System Components
Outside rearview mirror switch
Outside rearview mirror folding switch

The mirrors are folded/unfolded when pressing the
switch more than 1 second.
Mirror selection switch
[Note]
The mirrors can be folded/unfolded for 30 seconds
after turning the ignition key to “OFF” position.
Manual folding or unfolding the outside rearview
mirrors may cause a malfunction of the mirror
folding system.
Driver’s door trim panel
Outside rearview mirror folding unit
Switches on driver’s door trim

• When the front of the switch is lightly pressed (stage 1), the
window will be lowered while the switch is pressed. When
pressed to its end (stage 2), the window will open automati-
Window lock cally until it is fully opened. The window stops during its
switch operation when pressing the switch (stage 1) again or pulling
If this switch is pressed, up the switch.
all door windows are • The other window can be operated only while the appropriate
operated only by driver’s switch is activated.
door window switches.
Time lag of window operation

The operation of power window can be continued for
30 seconds after turning the ignition switch to “OFF”
position.
Central door locking switch
SWITCH CHANGED BY
AFFECTED VIN
24 2E
1) Switches on Driver’s Door
Door lock switch Window lock switch
Window lock switch
* Abbreviations
FLU: Front Left Up FLD: Front Left Down
FRU: Front Right Up FRD: Front Right Down
RLU: Rear Left Up RLD: Rear Left Down
RRU: Rear Right Up RRD: Rear Right Down
CHANGED BY SWITCH
AFFECTED VIN
2E 25
2) Circuit Diagram of Switches on Driver’s Door
Front Left Front Left Down (FLD) 4

Front Left Up (FLU) 2
Front Right Front Right Down (FRD) 5
Front Right Up (FRU) 7
Rear Left Rear Left Down (RLD) 8
Rear Left Up (RLU) 11
Rear Right Rear Right Down (RRD) 12
Rear Right Up (RRU) 14
Door Lock LOCK 10
UNLOCK 6
Illumination ILL 1
Power B+ 3
B+ (S) 13
E(-) 9
SWITCH CHANGED BY
AFFECTED VIN
26 2E
Removal of Outside Rearview Mirror Switch

1. Remove the screws (arrows) from the door trim.

2. Remove the door armrest grip cover and unscrew the screw.
3. Pry off the door lever cover and remove the mounting screws.
4. Remove the door trim.
CHANGED BY SWITCH
AFFECTED VIN
2E 27
5. Unscrew the bolts and remove the door grip from the removed door trim.
6. Unscrew the bolts and remove the outside rearview mirror switch from the door grip.
SWITCH CHANGED BY
AFFECTED VIN
28 2E
Removal and Installation of Window Switch

Preceding works: Disconnection of negative battery cable, Removal of door trim
Unscrew the screws and remove the window switch from the removed door trim.
Driver side
Switch
Passenger side
Switch
CHANGED BY SWITCH
AFFECTED VIN
2E 29
MULTIFUNCTION SWITCH
1. MULTIFUNCTION SWITCH
Steering wheel
Steering wheel
angular sensor
Light switch Wiper/washer
switch
Specifications
Multifunction Rated voltage DC 12V
switch Operating temperature range -30°C ~ +80°C
Rated load Light switch Turn on: 1 A (relay load)
Dimmer and passing switch Hi/Low/Passing: 0.3 A (relay load)
Turn signal switch 6.6 ± 0.5 A (lamp load)
Wiper switch Low: 5 A, Hi: 7 A (motor load)
AUTO: 0.22 ± 0.05 A (relay load)
Fixed: max. 28 A (motor load)
Washer switch 4 A (motor load)
Intermittent wiper switch Max. 25 mmA
MIST switch 5 A (motor load)
SWITCH CHANGED BY
AFFECTED VIN
30 2E
Multifunction Switch Operating Range
CHANGED BY SWITCH
AFFECTED VIN
2E 31
Connector Pins and Designations of Multifunction Switch

1 EB: Dimmer and passing ground
2 HL: Headlamp low beam
4 3 11 9 10 3 HU: Headlamp high beam

4 HS(2): Passing switch
5 TS: Tail lamp switch
2 1 56 7 8
6 HS(1): Headlamp switch
7 F/AUTO: Rear fog lamp
8 DEL: Light switch ground
9 TB: Flasher unit power
10 TL: Turn signal (LH) lamp switch
11 TR: Turn signal (RH) lamp switch

14 LO: Low wiper speed
15 HI: High wiper speed
16 S: Wiper stop
15 14 16 22 21 17 20
17 AUTO(W): Intermittent wiper
18 INT(T): Intermittent WIPER
18 19 19 BWT: Intermittent power
20 W: Front washer switch
21 BW: Wiper and washer switch
22 MS: Low wiper speed (MIST switch)
SWITCH CHANGED BY
AFFECTED VIN
2E 39
WIPER AND WASHER ASSEMBLY

1. GENERAL
System Layout of Wiper and Washer
Front wiper and washer assembly
Wiper blade
assembly
Washer nozzle and

washer hose
Wiper motor and

linkage assembly Washer motor and
Rear wiper and washer assembly
Washer nozzle and

washer hose
Wiper blade
assembly Wiper motor and
linkage assembly
Washer motor and

SWITCH CHANGED BY
AFFECTED VIN
40 2E
Specifications
Motor Rated voltage DC 12 V ± 0.3 V
Test voltage DC 13.5 V ± 0.3 V
Minimum operating voltage Below DC 8 V
Insulating voltage Over 1 mΩ
Restraint test Torque Over 1.1 Km
Voltage Below 14 A
Surrounding voltage range -40°C ~ +80°C
Control Rated voltage DC 12 V
Operating temperature range -30°C ~ +80°C
Reserving temperature range -40°C ~ +90°C
Insulating voltage Over 1 mΩ
Voltage drop Below 0.5 V
(terminals between 5-7, 6-8, 5-8, 6-7 @ 5 A)
Test voltage 14.0 ± 0.5 A
Acceptable load current Maximum 10 A
Circuit Diagram
Relay 1
Voltage
controller
Relay 2
Wiper motor
CHANGED BY SWITCH
AFFECTED VIN
2E 41
2. REMOVAL AND INSTALLATION OF WIPER ASSEMBLY

1. Front Wiper Assembly
Components Locator
Wiper blade
Wiper linkage
Wiper motor
SWITCH CHANGED BY
AFFECTED VIN
42 2E
1. Detach the washer hose , unscrew the nut and remove the wiper blade assembly, and remove the hood cowl
grille.
A. Wiper blade assembly
B. Cowl grill
2. Unscrew the bolts and remove the wiper linkage assembly.
CHANGED BY SWITCH
AFFECTED VIN
2E 43
3. Disconnect B motor connector . Unscrew two mounting bolts and two nuts and remove the wiper motor.
SWITCH CHANGED BY
AFFECTED VIN
44 2E
2. Rear Wiper Assembly

Preceding work: Disconnection of negative battery cable, removal of tailgate trim
Components Locator
Wiper blade assembly
Rear wiper motor
Rear wiper assembly
CHANGED BY SWITCH
AFFECTED VIN
2E 45
1. Release the wiper arm cap , remove the wiper nut and wiper blade , and unscrew the motor lock nut .
2. Disconnect the wiper motor connector , unscrew the bolts , and remove the wiper motor assembly from
tailgate.
1. Motor connector
2. Motor mounting bolts
SWITCH CHANGED BY
AFFECTED VIN
2F 3
MULTI-METER
1. LOCATION
1. MODE button - Mode change and reset

Selects a mode (altitude, direction, time, calendar, average speed, driving time, battery)
2. UP button - coupled operation with MODE button

Increases the value (altitude, direction, date, atmospheric pressure) in each mode.
3. DOWN button - coupled operation with MODE button

Decreases the value (altitude, direction, date, atmospheric pressure) in each mode.
4. Display
Displays a selected mode screen, parking aid signal, and battery voltage message.
MULTIMETER CHANGED BY
AFFECTED VIN
4 2F
2. CIRCUIT DIAGRAM
CHANGED BY MULTIMETER
AFFECTED VIN
2F 5
3. DISPLAY MODE
Mode changing sequence:
[Time and Calendar] [Altitude, Direction] [Driving time]
[Note]
The previously selected

mode screen appears
when starting the engine.
[Battery voltage] [Average speed]
AFFECTED VIN
6 2F
4. FUNCTIONS IN EACH MODE

1) Time and Date
Displays and adjusts time, date, and day of the week.
Adjusting the Time and Date

1. Press and hold the MODE button for more than 1 second to start time and date mode. Move and select the
information to be adjusted while briefly pressing the MODE button (0.5 seconds). The selected information
is blinking.
Changing sequence:
AM (PM) Hour Minute Day Month Year
3. Adjust the information by using UP or DOWN button.

4. Press and hold the MODE button for more than 1 second to set the time and date.
[Note]
- A day of the week is automatically changed according to the adjusted date, month, and year.
- An intercalary is automatically calculated.
AFFECTED VIN
2F 7
2) Direction, Atmospheric Pressure, Altitude Mode
Electronic Compass
It indicates 8-direction by interval of 45° according to the vehicle’s driving direction.
1. Screen display for direction
Display Direction
N 0°
NE 45°
E 90°
SE 135°
S 180°
SW 225°
W 270°
NW 315°
[Note]
This function is available only when the vehicle speed is over 2.8 km/h.
2. Turning Calibration
This operation is needed to calibrate the indication tolerance between the actual direction and the indicated direction
at current vehicle location.
Turning calibration conditions

- when the multi-meter is installed in the vehicle.
- when the battery is replaced.
Turning calibration procedure

1. When pressing the MODE and UP button simultaneously for more than 1 second, the current direction flashes.
2. Turn the vehicle over 1 complete circle within 128 seconds slowly, then the calibration will be accomplished.
3. When the calibration is finished, the vehicle’s new direction will be indicated.
[Note]
The turning calibration process is automatically canceled if the vehicle is not turned within 120 seconds after calibration
mode started.
AFFECTED VIN
8 2F
Altimeter
1. Absolute Altimeter
0 m above the sea level is equivalent to 1013.25 hpa and the altimeter convert the difference between this pressure and
atmospheric pressure to absolute altitude. Its Indication range is -200 m to 2,800 m.
Current atmospheric pressure
Current altitude
How to calibrate the absolute altitude

1) UP button
Press briefly (below 0.5 seconds): increases by 20 m
Press and hold (over 0.5 seconds): continues to increase by 20 m with the interval of 0.2 seconds
2) DOWN button
Press briefly (below 0.5 seconds): decreases by 20 m
Press and hold (over 0.5 seconds): continues to decrease by 20 m with the interval of 0.2 seconds
How to erase the calibrated altitude value

Press the UP and DOWN buttons simultaneously for more than 1 second to cancel the altitude calibration.
Altitude calibration range

It can be calibrated by 300 m within the range of 0 to 2,800 m.
AFFECTED VIN
2F 9
2. Relative Altimeter
It indicates the specific area’s relative altitude based on the current altitude of the vehicle (current altitude is indicated
to 0 m).
Indication of relative altimeter
Indication of base altitude
Changing to relative altimeter mode

The mode is switched between the relative altimeter mode and absolute altimeter mode when pressing the MODE
button over 1 second in direction/atmospheric pressure/altitude mode.
Barometer
It indicates the current atmospheric pressure in range from 720 hpa to 1045 hpa by 1 hpa.
AFFECTED VIN
10 2F
3) Speed Sensing Indicator

The flashing interval of the road signs changes gradually ac-
cording to the vehicle speed.
Flashing interval according to the vehicle speed
Vehicle speed Flashing interval

below 1.8 km/h stays ON
below 40 km/h 1 second
below 60 km/h 0.8 seconds
over 100 km/h 0.2 seconds
4) Driving Time
- It indicates the driving time from start up to now.
- It can be reset to 0 when turning the ignition key to “OFF”
position or pressing UP or DOWN button for a specific
period of time.
- Indication range: 0:00 ~ 23:59
5) Average Speed
- It indicates the average vehicle speed from start up to
now.
- It can be reset to 0 km/h when turning the ignition key to
“OFF” position or pressing UP or DOWN button for a
specific period of time.
- Indication range: 0 ~ 120 km/h
AFFECTED VIN
2F 11
6) Parking Aid Signal Mode

The rearview display appears when placing the gear selector lever to “R” position.
This message appears when the

parking aid sensor is defective.
[Note]
The display returns back to previous mode screen when
placing the selector lever to other positions.
Display changes according to the distance between rear bumper and rear obstacle
Rear left sensor Rear center Rear right

sensor sensor
Detecting obstacle at rear Detecting obstacle at rear Detecting obstacle at rear Detecting obstacle at rear right
left of the vehicle center of the vehicle right of the vehicle and rear center of the vehicle
All displaying bars are displayed when the distance between rear bumper and obstacle is over 120 cm.
The number of displaying bars is decreased and the alarm interval becomes faster as the obstacle approaches.
Step Distance Alarm interval (msec) Display
Step 1 80 ~ 120 cm
Step 2 50 ~ 80 cm
Step 3 below 50 cm
AFFECTED VIN
12 2F
7) Battery Mode
- The screen shows fully charged battery when the battery voltage is over 12 V.
- It indicates the current battery voltage by 0.1 V.
- When the battery voltage goes below 9 V, current display is changed to battery voltage mode and “LOW VOLTAGE”
message flashes.
Charging level Battery voltabe
Charging Level
Battery voltage Indication
Over 12.0 V
(fully charged)
11.9 ~ 11.0 V
10.9 ~ 10.0 V
9.9 ~ 9.0 V
AFFECTED VIN
2F 13
1. Open the sunglasses box, remove two screws from the

box, and pry off the overhead console with a flat blade
screwdriver.
2. Disconnect the multi-meter connector and the room lamp

connector and remove the overhead console.
3. Unscrew three screws from the back of the overhead console and remove the multi-meter.
AFFECTED VIN
2G 3
AV SYSTEM
1-DIN head unit equipped with cassette deck and radio is installed as a factory installed item and 2-DIN head unit
equipped with extra CD player (with MP3) and equalizer is installed as an optional item. There are 6 speakers in basic
and it can be 12 including tweeter if equipped with DVD system.
6-CD changer and 8-DVD changer can be installed as an extra item. DVD changer is available for the vehicle equipped
with DVD head unit and can play audio CD, video CD, MP3 CD and DVD CD.
Followings are AV systems and will be described based on the vehicle equipped with DVD system.
1. AV SYSTEM BY VEHICLE MODEL

1-DIN head unit and 2-DIN head unit equipped with CD player
Front door speaker Rear speaker
Tweeter CD changer
Head unit
Audio remote control

switch on steering wheel
DVD head unit + Navigation + DVD changer
Subwoofer with built-in amplifier

Tweeter
Front door speaker
Rear speaker
DVD changer
TV antenna module
Radio antenna module
GPS antenna
Rearview camera
AV head unit Rear monitor

(DVD)
Front center speaker Rear center Amplifier/tuner/navigation unit

Audio remote control switch speaker with built-in DSP function
on steering wheel Rear center
tweeter
AV SYSTEM CHANGED BY
AFFECTED VIN
4 2G
2. SYSTEM LAYOUT (BASED ON DVD EQUIPPED SYSTEM)
Tweeter speaker
Tweeter speaker
Center speaker
Center speaker
AV head unit
Audio remote
control switch
Front speaker (RH)
Subwoofer with
built-in amplifier
speaker (RH)
Center speaker
(RH)
AV head unit
Center speake
DVD changer
Center speaker
(LH)
Front tweeter
speaker (LH)
Front speaker (LH)
CHANGED BY AV SYSTEM
AFFECTED VIN
2G 5
DVD changer

Rear speaker (RH)
Radio antenna amplifier
Rearview camera
er
Rear monitor
Tuner/amplifier/navigation unit
Rear speaker (LH)
TV antenna amplifier (LH) Tuner

Rear tweeter speaker (LH)
Amplifier with built-in

DSP function
Navigation unit
AFFECTED VIN
6 2G
3. DVD SYSTEM SIGNALS AND DATA PROCESSING
DVD changer Rearview camera

It is installed in the center console. Audio signal of Even though the AV head unit is turned off, the rear-
DVD changer outputs to corresponding speakers view display always appears when placing the gear
through optical fiber cable. Video signal is transmit- selector lever to “R” position. The reverse driving
ted to the monitor of AV head unit and rear monitor. signal is prior to all other video signals.
Send Optical fiber cable
Receive
Tuner
TV sound (TV antenna, LH)
TV sound (TV antenna, RH)

Send
TV video data
Sound communication line

(Bus line)
AV head unit
(with built-in EGA 6.5” monitor)
AM/FM radio antenna AMP

The heated wire and radio antenna is integrated
in the tailgate glass. The antenna transmits AM/
FM audio signals to tuner.
TV antenna AMP (LH and RH)

The glass antennas at both rear quarter glasses
are to receive TV and AM radio (quarter RH
glass) signals and transmits each 2-channel
video and audio signals to tuner. Each AMP
amplifies receives TV signals and then trans-
mits to tuner.
AFFECTED VIN
2G 7
Navigation (DVD data)

Displays current vehicle position on the built-in map
after receiving vehicle position signal through GPS
antenna and then transmits to monitor. By using DVD-
ROM, it supports enormous convenience data and
3D view.
GPS satellite
GPS antenna (installed behind passen-

ger side instrument panel )
A device that receives and transmits current vehicle
position from and to GPS satellite to display the ve-
hicle position on the map as dot.
Audio signal
Front speaker (LH)
Video signal
Tweeter speaker (LH)
Front speaker (RH)
Tweeter speaker (RH)
Rear speaker (LH)

Optical fiber cable
Tweeter speaker (LH)
Receive
Rear speaker (RH)
Tweeter speaker (RH)

AMP (with built-in DSP)
Power AMP in the DVD system has built-in
DSP function that digitalizes sound to divide Center speaker (LH)
and control. It amplifies sound goes to each
speaker and has function of allowing dynamic
and vivid sound.
Center speaker (RH)
Center speaker
(back of center console)
Rear monitor
Video signal
Subwoofer (with built-in AMP)

Woofer with built-in amplifier is installed at
the bottom of passenger’s seat. It enforces
mid-low sounds and the amplifier built-in the
woofer amplifies sound signal received from
The rear monitor (7”) can be folded down approx. 25¡Æ
power AMP directly.
when the open button is pressed to display. When opened,
the angle can be adjusted up to 100¡Æ manually.
AFFECTED VIN
8 2G
4. SYSTEM LAYOUT (BASED ON DVD SYSTEM)

1) Front Head Unit
Functions
The AV head unit equipped with DVD system has two optical output terminals; one is to receive the sound signal from 8-
DVD changer and the other is to send the sound signal to amplifier with built-in DSP. The tuner unit transmits the TV and
video signals to the head unit through cable. However, the head unit receives the video signal or color and video signal
directly from the rearview camera and navigation without tuner.
If equipped with roof monitor, the AV head unit transmits the video signal to roof monitor through cable.
[Notice]
The DVD system drives the amplifier, tuner, head unit and 12 speakers and operates two monitors. Therefore, the battery
can be discharged easily if operate DVD system without engine running.
Rearview camera DVD NAVI
Audio signal
(Video signal)
AVC-LAN
AV head unit
(EGA/6.5”)
DVD changer Roof monitor (7”)
OPTIC
TX
Optical fiber cable
(Video signal)
OPTIC OPTIC
RX TX
Optical fiber cable
Tuner unit 5.1 channel

power amplifier
OPTIC
RX
AFFECTED VIN
2G 9
Appearance
Front view of head unit

Touch-screen panel
When cleaning the touch screen, turn off the system and clean
the surface with a dry and soft cloth. Never use any coarse
cloth, hard cloth, chemical agent, volatile cleaning solvent
(alcohol, benzene, thinner) for cleaning the touch screen.
[Notice]
Do not apply excessive force to adjust, open, and close the monitor. Do not impede the automatic
movement of the unit.
When removing LCD monitor
DVD deck
Tape deck Reset button
Forceful operation or impeding the

movement of AV system may
cause unstable operations. When
the system operation is unstable,
push the reset button with a sharp
object like a ball-point pen to initial-
ize the system.
Rear view of head unit
AFFECTED VIN
10 2G
Usable Discs (DVD Head Unit)

Following disc types can be used on the system.
Disc type and logo Disc size Play time

approx. 133 minutes (SS/SL)
approx. 242 minutes (SS/DL)
DVD video approx. 266 minutes (SD/SL)
approx. 484 minutes (DS/DL)
SS = Single side
SL = Single layer DL = Double layer
Video CD 5” (12 cm) approx. 74 minutes
Audio CD 5” (12 cm) approx. 74 minutes
CD-ROM 5” (12 cm) MP3 audio file
DVD head unit and DVD changer cannot play following discs.
• DVD-R
• DVD-RAM
• DVD-ROM
• DVD-Audio
• CD-G
• Mixed CD (Date)
• Active Audio (Date)
• VSD
• Multi-section disc
• DVD with region code other than (3) or (ALL)
Bulk CD-R or CD-RW that their quality cannot be secured may not be recognized.
Region code (3)

• DVD player and DVD videodisc has designated region code. If region code is different, the disc cannot be played.
This system cannot play the disc if the region code is other than (3) or (ALL).
PBC (Play back control) – compatible video CD

• This system can play PBC–compatible video CD.
• Typical audio and video CDs can be played and PBC-compatible video CD uses recorded PBC menu on the disc to
play the CD interactively.
Double layer DVD video disc

• When playing the double layer disc, there occurs time lag between at the end of first layer and start of second layer
causing broken display and sound for seconds. It normal for double layer disc so it is not malfunction of the system.
AFFECTED VIN
2G 11
Head Unit Operation Buttons
POWER
Turns ON/OFF AV system. NAVI (CURRENT LOCATION)
Available while the ignition key is in “ACC” or
“ON” position. This button is used for changing Mode in AV
mode. In NAVI screen, this button is used for
displaying the current location.
MODE
Changes AV mode and turns on/off the Mode
display with Power ON. The display returns back
to previous screen when pressing Mode button
over 2 seconds in NAVI mode. DESTINATION
This button is used for setting

VOL Destination in NAVI mode.
Volume Up/Down
MENU OPEN / CLOSE
AV MODE: Controls the display, tone and Moves the monitor to fully open or close position.
menu with Power ON. When pressing this button, the monitor moves to
fully open position if it is not in fully open position,
NAVI MODE: Displays menus in NAVI and moves to previously stored tilting position if it
mode. is in fully open position.
To control the display, volume and others,

TILT
press and hold the button for over 2
seconds. Moves the monitor to desired tilting position while
pushing this button.
UP button is not available when the fully close
position.
The down tilting angle can be precisely adjusted by
using Down button within a specified range. If it
reaches to its end, no more movement can be done.
AFFECTED VIN
12 2G
Descriptions of Terminals
Connector A (26-pin) Connector B (20-pin) Connector C (16-pin)
1. BUS 1 output 1. - 1. R–VSYNC

2. BUS 1 input 2. - 2. R–SYNC
3. BUS 1 ground 3. M. Ground 3. V–ground
4. TV LH- 4. Rearview camera battery output 4. R-G
5. TV RH- 5. Rearview camera V–ground 5. RGB ground
6. Remote control ground 6. Rearview camera video 6. R-Mode 1
7. S-Remote control 7. Navigation voice 7. Ground
8. V-ground 8. Navigation V–ground 8. Mute
9. TV-Video 9. Navigation CSYNC 9. Video
10. Illumination- 10. Navigation Gi 10. Power ON
11. Reverse signal 11. Remote control optic sensor ground 11. N.C.
12. ACC+ 12. Remote control optic sensor signal 12. R-SSW
13. Battery+ 13. Amp mute 13. R-B
14. BUS 2 output 14. Amp ON 14. R-R
15. BUS 2 input 15. Amp voice ON 15. R-Mode 2
16. BUS 2 ground 16. Amp ground 16. -
17. TV LH+ 17. Navigation voice output
18. TV RH+ 18. Navigation voice ON
19. Ground 19. Navigation voice BI
20. R-Remote control 20. Navigation GI
21. Remote control ground
22. VSYNC
23. Illumination +
24. Parking signal
25. Ground
26. Speed pulse
AFFECTED VIN
2G 13
Specifications
System Function
Radio/TV - Manual preset: FM1 (6), FM2 (6), AM (6), TV1 (6), TV2 (6)
- Manual channel up/down
- Seek up/down
- BSM (AM/FM), auto memory (TV)
- Local/DX (use with BSM: -20db)
Tape - Program/Play
- FF (fast forwarding)/REW (rewinding)
- DOLBY B-NR
- AUTO METAL
- Repeat
- Back-up eject function
- Auto power when tape is inserted
DVD player - Chapter, file, track up/down, direct
- FF (fast forwarding), FB (fast back), up/down
- Repeat
- PBC
- SCAN
- Compatible conversion between audio and caption
- MP3 file information display
- CD-DA, video CD, DVD audio, DVD video, MP3
Key input - Touch screen: touch panel
* Displays keys by each mode
- Front key: Potential difference type
* POWER, MODE, MENU
* Eject, slide up/down
* NAVI, Destination
* Volume up/down
- NAVI mode: NAVI graphic video switch shift
NAVI display - Touch screen key: full touch
Display OFF - If the display disturbs the driving conditions at night, possible to turn off just display.
- Cancellation of display OFF
* Screen touching
* Power key input
* NAVI key input
* MODE and MENU key input
Audio OFF - Operates only in NAVI mode
* Performs mute under AM, FM, TV, TAPE, DVD, DVDC mode
* Under TAPE mode, deck operation stops
* Under DVD changer and DVD player mode, it stops
Sliding memory - Sliding memory setting
* Set the desired position with slide up/down key
- Returning to slide position
* Open key input under full-open state
* When changing ACC OFF to ON, moves to the latest stored position
AFFECTED VIN
14 2G
Function Settings on Touch Panel (Example)

DSP control
* STADIUM: Turns off EQ mode and changes to STADIUM
* HALL: Turns off EQ mode and changes to HALL
* CHURCH: Turns off EQ mode and changes to CHURCH
* CLUB: Turns off EQ mode and changes to CLUB
* OFF: Turns off DSP mode and changes to EQ mode
* Finish: Changes to start page of each mode.
* Previous: Changes to basic control display
EQ control
* DEFEAT: Changes to DEFEAT in EQ mode
* CLASSIC: Changes to CLASSIC in EQ mode
* JAZZ: Changes to JAZZ in EQ mode
* ROCK: Changes to ROCK in EQ mode
* , : Up/down in selected band
* Finish: Changes to start page of each mode
FADER, BALANCE control
* , , , : Up/down in FADER/BALANCE
* Available in DSP OFF
* Finish: Changes to start page of each mode
POSITION control
* POS: Changes in order of ALL → F/R → F/L → REAR → ALL →

* Finish: Changes to start page of each mode.
* Can control if in DSP ON
DVDC DISC input
DVDC DISC input display

* 1~8: DISC selection
* Finish: Moves to normal video display
* Previous: Changes to basic 1 display of DVDC DVD OSD
AFFECTED VIN
2G 15
Terms on DVD System

5.1 channel
As the technology that can digitalize audio and video data and analog audio source, it became possible to separate
audio source into various speakers to realize vivid and dynamic sound.
In general, 5 from 5.1 channel means the function that can divide audio source into 2 front speakers, 1 center speaker
and 2 rear speakers. 0.1 means woofer speaker. Above explanation is based on home theater and has no relation with
the number of speakers. It can be said 5.1, 6.1 and 7.1 channel by the digital audio source dividing function and effect
comes out through speakers.
5.1 channel on the STAVIC has 2 front speakers, 3 center speakers and 2 rear speakers to realize 5 channels and
subwoofer with built-in AMP is in charge of 0.1 channel.
According to vehicle shapes and structures and how to deliver the sound, there can be 1 or 2 center speakers and 3
speakers like in STAVIC that carries a lot of people.
Dolby digital (AC-3)

It encodes/decodes by each 6 channels respectively. It has been developed from the technology called Dolby surround
(Dolby Pro Logic) that can divide current 2 channels into 4 channels.
DTS (Digital theater systems)

A system that developed by Digital Theater Systems, California, USA, and designed to play digitalized film audio tracks.
It is a sound track for DVD titles in NTSC.
DSP (Digital Signal Processor)

Audio source is digitalized and can set the atmosphere proper for the place. AV system on STAVIC has 4 fields -
STADIUM, HALL, CHURCH and CLUB.
DTS-DVD
Recently, it is using as music format for DVD titles. Dolby Digital or PCM type is poplar for DVD-VIDEO, but DTS
function is increasing for high-end AMP or players. In case of DTS, level of sound division and every details are recorded
(DVD title) and has 1/3 of compression ratio compared with Dolby Digital 5.1. So a title, having large capacity, that
formatted by DTS function cannot record other supplement and subtitles.
However, it is very sensitive to sound so people accustomed to 5.1 channel prefer DTS titles.
AFFECTED VIN
16 2G
2) Tuner / 5.1 Channel AMP with Built-in DSP / DVD Navigation

(DVD System Basic)
Tuner, AMP and navigation units are installed together at bot-
tom of driver side rear quarter door panel. Remove the lower
quarter trim panel to replace the units.
Tuner
A tuner filters and cuts unnecessary signals among
received signals and then precisely adjusts input
signals. Installed tuner has following functions.
Connecting terminal of the tuner receives amplified
signals from each TV antenna module locating rear
quarter glass that receives TV signals from glass
antenna and then inputs to left and right channel.
AM/FM radio module on the roof panel rear end re-
ceives amplified signals from glass antenna and then
transmits to tuner input (1 channel).
TV antenna module RH 2 channels
2 channels
TV antenna module LH
Radio antenna module
DVD Navigation
Navigation unit in this vehicle transmits huge amount of data on the
DVD CD directly to AV head unit, without via tuner and AMP. It has
3D view function for roads and buildings and supporting data. GPS
antenna to receive/send vehicle position from/to satellite is located
behind the Instrument panel.
AFFECTED VIN
2G 17
5.1 channel power amplifier with built-in DSP

DVD system displays high quality pictures and separates digital audio sources to give digital effects according to speaker
arrangement. A chipset that can treat digital audio source signal is installed on the exterior AMP and has following function.
1. DSP (Digital Signal Processor) function

* AC-3, DTS 5.1 channel decoder (Decoder: separates and analyzes
audio source)
* Dolby Pro Logic, Dolby Pro Logic II function
* Sound filed setting (HALL/CHURCH/STADIUM/CLUB)
* Equalizer mode (Classic/Jazz/Pop/Rock)
* Speaker output control (All/driver’s side/passenger’s side/rear seats)
Appearance 2. Speaker control (Basic function)

Terminals on the below connector control speaker output. Terminals de-
code according to speakers like front, rear, center and tweeter and out-
put separated sound. Decoded signal goes to subwoofer that has built-in
AMP and the AMP in the woofer outputs sound directly.
Optical fiber cable

(AV head unit)
Connector
AFFECTED VIN
18 2G
3) Rear Monitor (Roof Monitor)
Location
The size of rear monitor is 7 inch. When pressing the OPEN button, the power is supplied and the rear monitor slide
down by approx. 25°. After then, manually adjust the monitor to desired angle. Its angle can be adjusted by 100°.
Rear monitor
Front monitor
Monitor Control
Rear monitor Brightness / Tint / Color control dial OPEN switch
When pressing the OPEN button, the power is sup-
plied and the rear monitor slide down by approx. 25°.
OPEN switch (Power supply button)
AFFECTED VIN
2G 19
Location
Opening angle
When pressing the OPEN button, the power is supplied and the rear monitor slide down by approx. 25°. After then,
manually adjust the monitor to desired angle. Its angle can be adjusted by 100°.
Press OPEN (approx. 25°) Maximum opening angle (approx. 100 ° )
Remote controller for rear monitor

Remote controller for rear monitor is available. Point the remote controller’s LED toward rear monitor to operate the AV
system. Remote controller works normally when the monitor is closed. Therefore, the system can be operated without
opening the monitor in some modes (radio / tape / audio CD and MP3) that do not need to see display.
Receiver window
Remote controller’s LED
Rearview camera equipped vehicle

When moving the gear selector lever into R (Reverse) position while watching DVD or VCD, the rearview appears on the
front monitor but the rear monitor continues to show the current screen.
AFFECTED VIN
20 2G
5. REMOVAL AND INSTALLATION

Head Unit (Based on DVD System)
Preceding work: Removal of center panel assembly
1. Remove four screws from the AV head unit.

2. Disconnect the connectors and optical fiber cables from the back of the head unit.
[Note]
The unit with DVD changer has two optical fiber cables and the unit without it has one optical fiber cable.
3. Remove the AV head unit assembly.
AFFECTED VIN
2G 21
Tuner
1. Disconnect four TV antenna terminals, main connector
and radio antenna connector.
Main connector
TV antenna
Radio antenna
2. Unscrew eight bolts and remove the deck.

3. Unscrew bolts and remove the tuner unit.
[Tuner unit]
AFFECTED VIN
22 2G
Amplifier with Built-in DSP

Preceding work: Removal of Tuner/Amplifier deck
Main connector
Optical fiber cable
1. Disconnect the amplifier connector.

2. Unscrew bolts (3 x 2) at front and rear sides and remove the amplifier.
DVD Navigation
Preceding work: Removal of Tuner/Amplifier deck
• Unscrew the bracket bolts (2 x 2), disconnect the rear amplifier connector, and remove the navigation unit.
[Notice]
Make sure to remove the tuner/amplifier deck before

disconnecting the connector.
AFFECTED VIN
2G 23
Rear Monitor
1. Unscrew four fixing bolts (10 mm) with the rear monitor
lowered.
2. Disconnect the connector and remove the rear monitor assembly.
AFFECTED VIN
24 2G
Subwoofer Speaker
Preceding work: Removal of passenger’s seat
• Remove four bracket bolts and disconnect the connector and terminals.
Front Door Speaker
• Refer to “Body” section.
AFFECTED VIN
2G 25
Rear Door Tweeter Speaker
1. Remove the rear door trim.
2. Disconnect the connector from the door trim.
3. Unscrew the bolts from the removed door trim and remove the tweeter speaker.
AFFECTED VIN
26 2G
Rear Quarter Speaker

Preceding work: Removal of passenger’s seat
1. Remove the rear lower quarter panel. 2. Disconnect the connector A from the rear quarter
speaker.
3. Unscrew the screws and remove the rear quarter speaker.
AFFECTED VIN
2G 27
Front Center Speaker
1. Separate the front center speaker as shown in

below figure.
2. Disconnect the connector from the front center

speaker assembly.
3. Unscrew the screws from the removed front center speaker assembly and remove the front center
speaker.
AFFECTED VIN
28 2G
Front Tweeter Speaker
1. Remove the instrument panel.
2. Disconnect the tweeter speaker connector from the removed instrument panel, unscrew the screws and
remove the tweeter speaker.
AFFECTED VIN
2G 29
TV Antenna Module (LH/RH) Radio Antenna Module

Preceding work: Removal of rear quarter upper Preceding works:
panel Removal of luggage room lamp,Removal of third
and fourth row seats, Removal of rear quarter upper
and lower trims, Removal of rear headlining
TV antenna connections Radio antenna connection
AFFECTED VIN
MEMO
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2H 3
COMPONENTS OF PARKING AID SYSTEM

(PARKING AID SYSTEM + REARVIEW CAMERA)
1. REARVIEW CAMERA EQUIPPED VEHICLE

When moving the gear selector lever into R (Reverse) position while watching DVD or VCD, the rearview appears on the
front monitor but the rear monitor continuously shows current screen.
Multi-meter Front monitor ICM box
Even in other modes, it is changed to the parking When moving the gear selector lever into When moving the gear selector lever into “R”
aid screen when moving the gear selector lever into “R” position while watching DVD or VCD, position, the alarm buzzer in ICM box sounds
“R” position. the rearview appears on the front monitor. (installed at bottom of STICS).
Rearview camera
When selecting R position while A/V system is in use:
• The video mode in front A/V system is changed to rear-
view monitoring mode. However, the audio mode stays on.
• The video mode in front A/V system resumes when
shifting out from “R” position.
• The audio and video mode in rear A/V system are not
changed.
When selecting R position while A/V system is not in use:
• Both monitors are automatically turned on to display rearview.
• Both monitors are automatically turned off when shifting
out from “R” position.
Gear selector lever

(R position)
Applies power to parking aid system.
Parking aid sensor Rearview camera PAS unit

(Rear bumper)
The three parking aid sensors send the distance The rearview camera sends the rear- It is a control unit for the parking aid system (PAS)
data between rear bumper and obstacle to PAS view to the monitor by using wide angle and transmits the signals from sensors to multi-
unit. lens. meter and buzzer.
(installed in tuner/amplifier bracket)
PARKING ASSISTANCE SYSTEM CHANGED BY

AFFECTED VIN
4 2H
2. SYSTEM CONTROL
Parking Aid Unit
Send
Generates sensor
12 V
driving signals
Back Regulator
GND
sonar
Signal transmitter
AMP Receive
& BPF
Parking Aid Sensor
Back sonar
sensor
Reverse driving
(supplies power) (LH)
Back sonar
sensor
Buzzer (Center)
(ICM box)
Back sonar
sensor
(RH)
CHANGED BY PARKING ASSISTANCE SYSTEM

AFFECTED VIN
2H 5
3. PARKING AID SYSTEM (PAS)

1) System Configuration
Multi-meter Rear center obstacles Rear right obstacles Rear left obstacles
Rear left sensor Rear center sensor Rear right sensor
Parking aid
buzzer
PAS unit
Right sensor Left sensor
Center sensor
This unit controls the parking aid system. One of 3

Tuner
LEDs comes on when the corresponding parking
Amplifier with
aid sensor is defective and shows below mes-
built-in DSP
sage on multi-meter.
Navigation unit

AFFECTED VIN
6 2H
4. COMPONENT SPECIFICATIONS
The parking aid system emits the supersonic wave signals from the sensors on the rear bumper with a specific interval
and detects the reflected signals from obstacles while the gear selector lever is in “R” position.
The number of displaying bars is decreased and the alarm interval becomes faster as the obstacle approaches. This
supplementary system is to secure the safety distance for parking.
Descriptions Value Descriptions Value

Rated voltage DC 12 V Operating temperature -30°C ~ +80°C
Operating voltage DC 9 V ~ 16 V Storage temperature -40°C ~ +85°C
Current Unit Below 100 mA Relative humidity 95%RH max
consumption
Sensor Below 20 mA (each) Weight Unit 160g ± 10g max
Sensor insulating resistance Over 5 MΩ Sensor 70g ± 10g max
1) Parking aid unit

Detecting type: Super sonic wave
Detecting distance: 25 ~ 120 cm (distance between sensor
and obstacle)
2) Parking aid sensor

- Type: Piezo ceramic element
- Frequency: 40 KHz ± 2 KHz
- Detecting range (13.5 V)
* Horizontal: Min. 20° at 110 ± 5 cm Min. 100° at 50 ± 5 cm
* Vertical: Min. 20° at 110 ± 5 cm Min. 60° at 50 ± 5 cm

AFFECTED VIN
2H 7
3) Alarm interval
Alarm interval and display changes according to the distance as below:
While reversing, if obstacles are within stage 1, the warning beep sounds with long intervals. If within stage 2, the
warning beep sounds with short intervals and if within stage 3, the warning beep sounds continuously.
Stage L, C, R sensor Interval (msec) Remark

65
65
1 81 ~ 120 cm “Beep ”
195
195
65
65 65
65 “Beep ,
2 51 ~ 80 cm Beep ,
Beep ”
3 25 ~ 50 cm “Beep ”
Troubleshooting of Sensor
When the power is applied (gear selector lever is in “R” position), the sensor will be diagnosed once. If found any failure
due to open circuit to sensor or communication error, warning buzzer sounds for 3 seconds and the data on failed
sensor transmits to the instrument panel to light up the corresponding LED. If normal, the warning buzzer sounds only
for 65 ms.
1) Whenever the power is applied, the diagnosis mode is initiated.

2) Sensor failure conditions (conditions for warning beep due to failure)
(a) Sensor failure conditions (conditions for warning beep due to failure)
(b) Open in sending circuit
(c) Open in receiving circuit
(d) Open in power circuit (+, -)
Back sonar (RH) Back sonar (LH)
* Warning beeps Back sonar (center)
300ms
300ms
When failed
65ms
65ms
When normal

AFFECTED VIN
8 2H
4) Cautions on parking aid system
* Note that the display does not show everything in the rear area.
Always check nobody, especially animals and children, is behind the vehicle.
* Normal precautions when reversing should be maintained.
1. The parking aid system is just a supplemental device to help your parking operation.
2. Always keep the safety precautions.
3. Do not press or shock the sensors by hitting or high-pressure water gun while washing, or the sensors will be
damaged.
4. If the system is in normal operating conditions, a short beep sounds when the gear selector lever is moved into “R”
position with the ignition key “ON”.
5. If the system is in abnormal operating conditions, a beep sounds for 3 seconds when the gear selector lever is
moved into “R” position with the ignition key “ON” or engine running. However, it is also occurred when the obstacle
is within 50 cm from the rear bumper.
The parking aid system will not work or improperly work under following cases:
1) Certain obstacles that sensors can not detect

- Wires, ropes, chains.
- Cotton, sponge, clothes, snow that absorb ultrasonic waves.
- Obstacles lower than the bumper.
2) Not defective but improperly working

- When the sensing portion is frozen.
- When the sensing portion is covered by rain, water drops, snow or mud.
- When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles).
- When a high-power radio is turned on.
3) Narrowed sensing area

- When the sensing portion is partially covered by snow or mud.
- Surrounding temperature of sensor is too high (approx. over 80°C) or too low (approx. below -30°C)
4) Not defective but may occur improper working

- When driving on the rough roads, gravel road, hill and grass.
- When the bumper height is changed due to the heavy load.
- When the sensing portion is frozen.
- When the sensing portion is covered by rain, water drops, snow or mud.
- When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles).
- When a high-power radio is turned on.
- When some accessories are attached in detecting ranges

AFFECTED VIN
2H 9
5) Circuit Diagram

AFFECTED VIN
10 2H

Parking Aid Sensor
Preceding work: Removal of rear bumper
1. Remove the guide piece from the rear bumper and remove the bumper guide and energy shock absorber.
2. Remove the sensor cover and sensor while pushing and turning the sensor cover.

AFFECTED VIN
2H 11
Parking Aid Unit

Preceding work: Removal of rear lower quarter trim cover
Disconnect the unit connector and remove the parking aid unit.
- In AV system non-equipped vehicle
- In AV system equipped vehicle
PAS unit

AFFECTED VIN
12 2H
REARVIEW CAMERA
This is a supplementary parking aid system to display the rearview when the gear selector lever is moved into “R”
position.
“R” position Rearview camera
Power supply
Operates only when the gear selector lever is The rearview camera displays the rearview
in “R” position
Front monitor Rear monitor
The rear monitor displays the rearview only

when the A/V system is not in use.
The audio and video mode in rear A/V system are not changed when selecting R position while A/V system is in use.
[Notice]
• The real distance is different from what you see in monitor because the camera uses wide-angle lens.
• Note that the display does not show everything in the rear area.
• Keep the camera lens clean with a lens cleaner.

AFFECTED VIN
2H 13
1. OPERATIONAL PRINCIPLE OF REARVIEW CAMERA

In the rearview camera equipped vehicle, the monitors display when selecting “R” position for safe parking. The operating
conditions are as below:
General
When selecting R position while A/V system is in use:
• The video mode in front A/V system is changed to rearview monitoring mode. However, the audio mode stays on.
• The video mode in front A/V system resumes when shifting out from “R” position.
• The audio and video mode in rear A/V system are not changed.
When selecting R position while A/V system is not in use:
• Both monitors are automatically turned off when shifting out from “R” position.
Operating Conditions and Modes of Rearview Camera

The rearview camera cannot operate alone. If the gear selector lever stays in “R” position more than 3 seconds with
the ignition key “ON” or engine running, the rearview appears on the monitors automatically regardless of displays
by head unit.
[Notice]
When the rearview mode is activated, the AV system doesn’t work even though the buttons on the AV unit are pressed.
However, the monitor angle can be adjusted when the AV system is changed to the rearview mode with the head unit turned
off. And, the monitor angle and volume can be adjusted when the AV system is changed to the rearview mode with the head
unit turned on.
Auto mode
* Automatic operating mode
When selecting R position while A/V system is not in use (Ignition switch “ON”, engine running):
• Both monitors are automatically turned off when shifting out from “R” position.
When selecting R position while A/V system is in use (Ignition switch “ON”, engine running):
• The video mode in front A/V system is changed to rearview monitoring mode. However, the audio mode stays on.
• The video mode in front A/V system resumes when shifting out from “R” position.
• The audio and video mode in rear A/V system are not changed.
[Notice]
• The real distance is different from what you see in monitor because the camera uses wide-angle lens.
• Note that the display does not show everything in the rear area.
• Keep the camera lens clean with a lens cleaner.

AFFECTED VIN
14 2H
2. REARVIEW CAMERA OPERATION

The reverse signal works as an operation signal for rearview camera. If it receives reverse signal, the rearview camera is
turned on even though the AV unit is turned off.
The rearview camera consists of AV unit (including monitor), reverse signal, battery voltage and rearview camera.
The AV unit receives the power from battery and if it receives the reverse signal, supplies the power to rearview camera.
When the rearview camera operates, it transmits color video signal to the A/V unit then the rearview is displayed on the
monitor.
3. REARVIEW CAMERA INSTALLATION

The rearview camera is securely installed on the rear spoiler with high torque and strong adhesive. Do not apply exces-
sive force to remove it. Otherwise, it could be damaged.

AFFECTED VIN
2 2I
EXTERIOR LAMPS
1. LOCATIONS OF EXTERIOR LAMPS
Front Lamps
Side turn signal lamp:

one at each side (12V - 5W)
Headlamp Headlamp
: one at each side (12V - 5W)
Fog lamp (LH) Fog lamp (RH)
Tail lamp:
Low beam:
Turn signal lamp:

High beam:
Tail lamp
Connector
3 2
4 Tail lamp/Turn signal lamp

connector
5
Headlamp Headlamp Turn signal lamp

(High beam) (Low beam)
CHANGED BY LAMP
AFFECTED VIN
2I 3
Rear Lamps
High mounted stop lamp
: center – 1 (12V – 5W)
Tail lamp assembly

License plate lamp
: center – 2 (12V – 5W)
Rear lamp
Rear fog lamp
Stop lamp: one at each side (12V - 8W)
Rear turn signal lamp: one at each side (12V - 27W)
Tail lamp: one at each side (12V - 8W)
Stop lamp
Tail lamp assembly

Rear turn signal lamp/Rear fog lamp
connector
Tail lamp
LAMP CHANGED BY
AFFECTED VIN
4 2I
2. AIMING AND ADJUSTMENT OF FRONT LAMP

Headlamp Aiming
An approved beam setting device should be used for a Headlamp aiming requirements:
correct headlamp aiming. - parking on a flat surface
Make sure to follow the operating instructions provided by - specified tire pressure
the manufacturer.
- one passenger (driver, 65 kg),
If not available to use the beam setting device, adjust the
- spare tire and OVM tools loaded (unlade all other loads)
headlamp aiming with a screen.
Adjustment of low beam

No.1 adjustment hole: Up and Down
No.2 adjustment hole: Left and Right
Adjustment of high beam

No.3 adjustment hole: Up and Down
No.4 adjustment hole: Left and Right
No.1 adjustment: No.2 adjustment: No.3 adjustment: No.4 adjustment:

Direction A - Up Direction C - Left Direction E - Up Direction G - Left
Direction B - Down Direction D - Right Direction F - Down Direction H - Right
CHANGED BY LAMP
AFFECTED VIN
2I 5
Cautions During the Aiming

Procedures
The headlamp angle should be within the adjustment range
as shown in the figure.
Adjust the headlamp aiming by rotating the direction control

levers (Up, Down, Left, Right) in turn with a screwdriver.
When using a beam setting device

1. Align the vehicle and beam setting device according to the operating instructions provided by the manufacturer.
2. Adjust the headlamp aiming by rotating the direction control levers (Up, Down, Left, Right) in turn with a screwdriver.
LAMP CHANGED BY
AFFECTED VIN
6 2I
When Using a Screen

1. Install a screen (2m X 1.5m) in front of the headlamps in vertical by 3m away and align the center lines of the vehicle
and the screen.
(Unit: mm)
Center line of
vehicle
Vertical line of headlamp bulb
Horizontal line of
headlamp bulb
Horizontal line of headlamp

focus
2. Run the engine with approx. 2,000 rpm and turn on the
(Unit: mm)
headlamp. At this moment, the focus of the headlamp
should aim the “A” point.
Allowable focusing Allowable focusing

area area
3. If the focus deviates the “A” point, adjust the headlamp

aiming by rotating control levers (Up, Down, Left, Right)
in turn with a screwdriver.
CHANGED BY LAMP
AFFECTED VIN
2I 7
Fog Lamp Aiming Adjustment
1. Down
The lamp aiming moves down
when the knob is turned to direc-
tion 1 (clockwise).
2 1
2. Up
The lamp aiming moves up when
the knob is turned to direction 2
(counterclockwise).
Knob
To adjust the fog lamp downwards
Fog lamp
1 - Clockwise
Down
Knob
To adjust the fog lamp upwards
Fog lamp
2 - Counterclockwise
Up
Knob
LAMP CHANGED BY
AFFECTED VIN
8 2I
3. REMOVAL AND INSTALLATION OF EXTERIOR LAMPS

Locations of Exterior Lamps
3. Side turn signal lamp
Connector
Bulb
Lamp cover
2. Fog lamp assembly

Lamp cover Lamp cover
1. Headlamp assembly
Bulb
4. High mounted stop lamp
7. Rear tail lamp assembly 5. License plate lamp 6. Tail lamp (back-up lamp)
CHANGED BY LAMP
AFFECTED VIN
2I 9
1) Headlamp Assembly
• The headlamp assembly consists of position lamp, headlamp low beam, headlamp high beam, and front turn signal lamp.
1. Remove two bolts on the lamp housing.
2. Remove one bolt in engine compartment, disconnect two connectors, and remove the lamp assembly.
3. Carefully remove the headlamp.

Cover rubber ring
[Notice]
If the cover rubber ring is worn, replace it with new one.
LAMP CHANGED BY
AFFECTED VIN
10 2I
Replacement of Headlamp Bulb

1. Remove the headlamp dust cover.
High beam cover
Low beam cover
2. Disconnect the headlamp bulb connector.
3. Push up the bulb clamp to remove it.
Push
Remove
CHANGED BY LAMP
AFFECTED VIN
2I 11
4. Remove the bulb and install new bulb with same

specifications.
Replacement of Tail Lamp/Turn

Signal Lamp
1. Disconnect the tail lamp/turn signal lamp connector from
the headlamp assembly.
2. Remove the tail lamp/turn signal lamp bulbs from the headlamp assembly and install new bulb with same
specifications.
Tail lamp bulb assembly
Turn signal lamp bulb assembly
Headlamp (low beam) bulb assembly
Headlamp (high beam) bulb assembly
LAMP CHANGED BY
AFFECTED VIN
12 2I
2) Fog Lamp Assembly
Removal and Installation of Fog Lamp Assembly

1. Disconnect the fog lamp connector.
2. Remove the mounting screws (when removing the 3. Remove the fog lamp bulb (when only removing
assembly). the bulb).
4. Remove the fog lamp assembly.
Lamp Lamp cover
Bulb connector
Mounting screws
Bulb
CHANGED BY LAMP
AFFECTED VIN
2I 13
3) Side Turn Signal Lamp Assembly
Removal and Installation of Side Turn Signal Lamp

1. Push the turn signal lamp forward and pull in the rear
side of the lamp to separate.
2. Disconnect the connector and remove the lamp.
Bulb connector
Lamp assembly
Bulb assembly
Bulb cover rubber ring:

If the cover rubber ring is defective,
replace it with new one.
LAMP CHANGED BY
AFFECTED VIN
14 2I
4) High Mounted Stop Lamp Assembly
Removal and Installation of High Mounted Stop Lamp

1. Remove the high mounted stop lamp cover from the tailgate spoiler.
[Notice]
Be careful not to damage the installation surface when removing the tailgate spoiler.
Adhesive area
Adhesive area
High mounted spoiler Adhesive area
Lamp
Mounting screw
Mounting screw
Lamp cover
2. Unscrew the screws from the high mounted stop lamp, disconnect the lamp connector, and remove the lamp assembly.
Tailgate spoilera
Rearview camera
High mounted stop lamp bulb
Rearview camera cover
High mounted stop lamp
High mounted stop lamp cover
CHANGED BY LAMP
AFFECTED VIN
2I 15
5) License Plate Lamp Assembly

1. Remove the license plate lamp assembly from the tailgate rear garnish.
2. Remove the bulb connector from the removed lamp assembly and pull out the bulb from the bulb connector.
3. Replace the bulb with new one and install the assembled lamp assembly into the mounting hole.
Bulb connector
Bulb
Lamp
License plate
lamp assembly
6) Tail Lamp (Back-up) Lamp Assembly (Rear Fog Lamp)

1. Remove the tailgate inner trim. 2. Disconnect the back-up lamp connector (1) and remove
the nuts (2) from the tail lamp (back-up lamp) assembly.
Fog lamp /
Back-up lamp
3. Remove the tail lamp (back-up lamp) assembly and pull out the bulb from the removed tail lamp assembly.
Bulb connector
Bulb connector
Tail lamp
(back-up lamp)
/ Fog lamp
LAMP CHANGED BY
AFFECTED VIN
16 2I
7) Tail Lamp Assembly

1. Open the tailgate and remove two screws from the tail lamp assembly.
Tail lamp assembly (RH)
Tail lamp assembly (LH)
2. Disconnect the connector and remove the tail lamp assembly.
CHANGED BY LAMP
AFFECTED VIN
2I 17
3. Remove the bulb connector by rotating it counterclockwise from the removed tailgate lamp assembly. Pull out the
bulb from the bulb connector and install the new bulb with same specifications.
Tail (stop) lamp
Rear fog lamp

/ Rear turn signal lamp
Bulb connector
Tail (position) lamp
LAMP CHANGED BY
AFFECTED VIN
18 2I
INTERIOR LAMPS
1. LOCATIONS OF INTERIOR LAMPS
1. Front room lamp
: one at both sides (12V – 5W)
Front room lamp switch Side (third row set) room lamp
(coupled operation with door)
Rear room lamp switch
(coupled operation with door)
Side (second row set) room lamp
The front room lamps (1, 2) are turned on when pushing the lamp
body regardless of the positions of front room lamp coupled switch.
Press the lamp body again to turn off.
Front room lamps (driver’s and passenger’s) are turned on when
opening one of front doors with this switch (A) pressed in.
2. Rear room lamp (in second and third row seats)

: one at both sides (12V – 5W)
3. Center console lamp

: one at back of center console (12V – 5W)
Rear room lamps are turned on and off when the switch (1) is
pressed in and out.
Four rear room lamps are turned on when opening a rear door
with this switch pressed in. The rear room lamps are turned off
when closing the door.
Center console lamp is turned on when opening

a door.
CHANGED BY LAMP
AFFECTED VIN
2I 19
4. Luggage room lamp

: one at center (12V – 5W)
Rear (third row set) room lamp
Rear (second row set) room lamp
Front room lamp
Luggage room lamp is turned on and off when the

switch (1) is pressed in and out.
Luggage lamp is turned on and off when opening
and closing one of rear doors with the front room
Glove box lamp lamp switch pressed in.
Center console lamp

5. Glove box lamp
: one at center (12V – 5W)
6. Door courtesy lamp

: one at each door (12V – 5W)
Door courtesy lamp is turned on when opening a door while

the ignition switch is in “ON” position.
LAMP CHANGED BY
AFFECTED VIN
20 2I
2. DOOR COUPLED ROOM LAMP SWITCH OPERATION

Front/Rear Door Coupled Operation
Door coupled room

lamp switch
1. Front door coupled

room lamp switch
Front room lamps (C) are turned on when open-
ing one of front doors with this switch (1)
pressed in. The front room lamps are dimmed out
after closing the door.
2. Rear door coupled room

lamp switch
1. Rear room lamps (A) and luggage room lamp (B) are turned on when
opening a rear door with this switch (2) pressed in. The lamps are
dimmed out after closing the door.
2. Rear and luggage room lamps are turned on only when the side room
lamp coupled switch is pressed in.
CHANGED BY LAMP
AFFECTED VIN
2I 21
3. REMOVAL AND INSTALLATION OF INTERIOR LAMPS

Locations of Interior Lamps
1. Door courtesy lamp 2. Luggage room lamp 3. Glove box lamp assembly
4. Interior room lamp assembly 5. Front room lamp assembly 6. Center console lamp assembly
LAMP CHANGED BY
AFFECTED VIN
22 2I
1) Door Courtesy Lamp Assembly

1. Remove the door courtesy lamp cover (1) from the door panel and pull out the bulb (2) with new one with same
specifications.
2) Glove Box Lamp Assembly

1. Open the glove box cover and push down the front portion of the lamp. Disconnect the connect and remove the
lamp assembly.
2. Disconnect the lamp connector and remove the lamp. However, it is not necessary to disconnect the connector
when removing only the bulb.
3. Install in the reverse order of removal. Replace the bulb with new one with same specifications.
CHANGED BY LAMP
AFFECTED VIN
2I 23
3. Luggage Room Lamp Assembly

1. Open the tailgate and remove the luggage room lamp cover with a flat blade screwdriver. At this time, be careful not
to damage the surroundings.
2. Remove the bulb from the luggage room lamp with new one with same specifications.
Bulb
LAMP CHANGED BY
AFFECTED VIN
24 2I
4) Side Room Lamp Assembly

1. Unscrew the screws and remove the side room lamp

assembly.
[Notice]
1. Be careful not to damage the lamp cover when removing it.

2. Replace the bulb with new one with same specifications.
2. Disconnect the lamp connector (1), unscrew the screws from the removed room lamp assembly, and remove the
lamp.
* when removing the bulb

Remove the lamp cover (1) and pull out the bulb (2). Be careful not to damage the lamp cover when removing it.
CHANGED BY LAMP
AFFECTED VIN
2I 25
5. Front Room Lamp Assembly

Removal and Installation of Front

Room Lamp
1. Open the sunglasses box and remove two screws.
2. Remove the front room lamp assembly.
3. Disconnect the multi-meter connector (1) and bulb

connector (2).
4. Remove the bulb from the removed front room lamp. Install in the reverse order of removal.
LAMP CHANGED BY
AFFECTED VIN
26 2I
* when replacing the bulb
Remove the lamp cover (1) and pull out the bulb (2).
[Notice]
1. Be careful not to damage the lamp cover when removing it.

2. Replace the bulb with new one with same specifications.
CHANGED BY LAMP
AFFECTED VIN
2 3A
AIR CONDITIONING SYSTEM

1. SYSTEM LAYOUT AND COMPONENTS
Sun load sensor - instrument
Type Air conditioner controller panel upper left
FATC
Manual air
conditioner
It changes sun load coming through front
windshield into current to input to FATC
controller.
AQS/Air source selection

Compressor – engine right
switch
A function that turns on/off the air Driven by engine and transmits refriger-
source selection and air quality system. ant from condenser to inside of vehicle.
Front air conditioner module assembly – inside instrument panel
Air mix door Air source door

actuator actuator
PTC (If equipped)
Air conditioner filter
Duct temperature
sensor
Blower motor
Blower high
speed relay
Mode door
actuator
Thermo AMP
Air conditioner
Power transistor
wiring
CHANGED BY AIR CONDITIONING SYSTEM

AFFECTED VIN
3A 3
Receiver drier Sub-condenser –

Condenser
– Condenser right right wheel front
Absorbs moisture in the refrigerant and Installed in front of vehicle and condenses Condenses high temperature and high
reserves refrigerant to supply smoothly. vapor refrigerant into low temperature and pressure vapor refrigerant into low-tem-
high pressure liquid refrigerant. perature-high-pressure liquid refrigerant.
Engine ECU – passenger’s Coolant temperature sensor

footstep – on engine
Detects A/C AUTO switch position, cool- A sensor that detects coolant temperature
ant temperature, engine condition and driv- and transmits to engine ECU.
ing condition to control the air conditioner.
Rear air conditioner module assembly – bottom of rear left
Front
Blower motor
Air conditioner high

pressure/low pressure pipe Power transistor
Rear
Rear fan speed dial Air mix door
actuator
A switch that controls the rear air con-

ditioner module.
AIR CONDITIONING SYSTEM CHANGED BY

AFFECTED VIN
4 3A
2. VENTILATION SYSTEM
1) Locations of Vents
Front Ventilation
Rear ventilation
Air conditioned air flows
Heated air flows

Heater vent

AFFECTED VIN
3A 5
2) Ventilation Modes
* Vent mode * Bi-level mode
* Floor mode * Defrost and floor mode
* Defrost mode * Rear air conditioning mode

AFFECTED VIN
6 3A
3. AIR CONDITIONER MODULE WIRING AND LAYOUT

1) Front Air Conditioner Module
Wiring layout
C211A A/C
Mode motor
wiring
C211A A/C wiring (FATC)
(manual)
Duct sensor
Air source
selection motor
High speed relay
Blower motor
(FATC, manual)
Interior temperature
sensor (interior
humidity sensor)
C211B A/C wiring Air mix FATC: power transistor
motor Manual: blower resistance
C211 A/C wiring A/C control Thermo amp

A/C control (FATC, manual)
panel (FATC)
panel (manual)
Components
Air conditioner filter Evaporator
Air source selection

door actuator
Blower
motor
Blower high
speed relay
Heater core

AFFECTED VIN
3A 7
2) Rear Air Conditioner Module

Wiring layout
Rear blower motor
Rear blower relay (Hi)
Rear power transistor
Air mix motor C305 A/C

wiring
(RR)
Components
Roof air conditioner duct
Blower motor
Air mixer door actuator
Rear floor heater duct
Evaporator Mixer door
Heater & air conditioner

pipes
Heater core

AFFECTED VIN
8 3A
4. AIR CONDITIONER CONTROLLER (UNIT)

Full Automatic Air Conditioner Controller
Fan speed control switch and
AMP switch Display window (VFD)
- Each switch mode appears as a symbol on the fluorescent

display and malfunction of each sensor in air conditioner
control system is also displayed.
- When controlling the fan speed by rotating

this switch in AUTO mode, the mode is
Temperature control switch and
changed from AUTO to manual and the fan
AUTO button
speed can be changed in 6 stages.
- When pressing the air conditioner AUTO mode
- When pressing this switch, the outside tem- and temperature control dial switch, the system
perature measured by ambient temperature operates in AUTO mode and can set the desired
temperature (18 ~ 32°C) by rotating.
sensor comes on for 5 seconds and then
To get the desired temperature, the air conditioner
returns back to preset temperature. controls compressor, door mode, air source door,
air mix door and blower motor automatically.
Rear fan speed control switch

The positions that can control in
3 stages in front seat.
(cannot control the rear fan speed in rear seats)
Rear blower OFF
Rear air conditioner switch: ON (can control

the rear fan speed in rear seats)
Front/rear independent cooling/heating
1. Front: Air conditioner operation 2. Front: No air conditioner operation 3. Rear: Heater operation and control
Rear: Heater operation Rear: Heater operation
Front air conditioner: ON Front air conditioner: OFF Rear air conditioner switch: R position
Rear fan control switch: 1, 2, or 3 position Rear fan control switch: 1, 2, or 3 position Rear heater switch: ON
Rear heater switch: ON Rear heater switch: ON Fan control switch in rear seats: can con-
trol the rear fan speed

AFFECTED VIN
3A 9
Air conditioner OFF switch A/C switch: When pressing this switch, the air conditioner oper-
ates in manual mode and A/C ON indicator comes
on.
AQS system
- Air Quality System (AQS) changes the air source selection to
recirculation mode when polluted air is detected through AQS
sensor. The air source selection returns back to fresh air intake
mode after a specified period or the polluted air is disappeared
(refer to AQS and ambient temperature sensor).
Defroster switch
When pressing this switch, the airflow direction will be changed

to windshield and door glasses, the air conditioner operates auto-
matically and outside air comes in. At this moment, the defroster
indicator, air conditioner indicator and fresh air mode indicator
come on. When pressing the switch again, the air conditioner re-
turns back to normal operations.
When pressing the AUTO switch, the defroster mode appears

on the VFD until the coolant temperature reaches at a certain
level.
MODE switch
- By depressing this switch, the airflow mode is changed.

AFFECTED VIN
10 3A
Manual Air Conditioner Controller

Manual air conditioner controller controls the fan speed, air distribution direction, air source selection and temperature
control with motor actuators according to soft button and dial switch operations.
Fan switch
Temperature control switch
- Controls the airflow temperature. : Turns off the blower motor and compressor.
1~4: Controls the fan speed 1 to 4 stage.
32 °
18 °

The positions that can control in
3 stages in front seat.
(cannot control the rear fan speed in rear seats)
Rear blower OFF
Rear air conditioner switch: ON

(can control the rear fan speed
in rear seats)
Front/rear independent cooling/heating
1. Front: Air conditioner operation 2. Front: No air conditioner operation 3. Rear: Heater operation and control
Rear: Heater operation Rear: Heater operation
Front air conditioner: ON Front air conditioner: OFF Rear air conditioner switch: R position
Rear fan control switch: 1, 2, or 3 position Rear fan control switch: 1, 2, or 3 position Rear heater switch: ON
Rear heater switch: ON Rear heater switch: ON Fan control switch in rear seats: can
control the rear fan speed

AFFECTED VIN
3A 11
Defroster switch
A/C switch When pressing this switch, the airflow direction will be
Operates air conditioner by turning on blower mo- changed to windshield and door glasses, the air condi-
tor and compressor. tioner operates automatically and outside air comes in. At
this moment, the air source selection indicator goes off.
Mode switch
Vent mode
The air flows towards face and
the indicator comes on.
Defroster and floor mode

The air flows towards front windshield
and floor and the indicator comes on.
Floor mode
The air flows towards floor and
the indicator comes on.
Bi-level mode
The air flows towards face and
floor and the indicator comes on.
Air source selection switch

Rear heater switch
When pressing this switch, the air recirculates in the vehicle in-
side and indicator comes on. When pressing it again, the indicator When pressing this switch, the rear heater op-
goes off and the fresh air comes in. erates and the indicator comes on.
(However, under defroster mode or defroster/floor mode, it stays

in the fresh air mode.)

AFFECTED VIN
12 3A
5. SELF DIAGNOSIS (ONLY FOR FATC AIR CONDITIONER)

Self Diagnosis Code
The FATC controller has self diagnosis function that can diagnose the system by itself. Before checking each component,
be sure to check the default code by using self diagnosis function.
Code Malfunction Remark Code Malfunction Remark

0 Normal 1 8 - -
1 Defective interior temperature sensor 25 9 Defective AQS -
2 Defective ambient temperature sensor 25 10 Defective humidity sensor -
3 Defective duct sensor - 11 - -
4 Defective air mix door motor - 12 Defective intake door -
5 Defective sun sensor - 13 - -
6 Defective power transistor - 14 - -
7 Defective blower high relay - 15 - -
Self Diagnosis
1. Set the temperature to 26°C with the temperature control switch (AUTO), and press the OFF switch 3 times within
3 seconds after temperature setting while the AUTO switch is pressed.
AUTO switch Self diagnosis display
Press OFF switch 3 times.

AFFECTED VIN
3A 13
2. At this moment, the air conditioner controller performs the self diagnosis procedures.
3. The Micro computer integrated in controller displays the defect codes in turns on the VFD after performing self
diagnosis. Below figure shows the defect code caused by disconnecting the interior temperature sensor/humidity
temperature sensor connector.
Defect code ON
Defect code ON
4. After displaying defect code, operates again in AUTO mode.
[Note]
For sun sensor, the diagnosis for short circuit is only available. When the switch circuit is opened, the system recognize it
as a night.

AFFECTED VIN
14 3A
Phenomenon when Air Conditioner System is Defective

(Initial Automatic Diagnosis)
- If any sensor in the air conditioner system is defective, the temperature display blinks about 3 times during initial
operation of air conditioner controller.
Current setting
temperature blinks
- If the setting temperature starts to blink, the self diagnosis starts to check the conditions of defective sensor.

AFFECTED VIN
3A 15
6. SYSTEM DIAGRAM
User Setting Power

Control temperature
transistor Fan speed control
(Blower motor
Blower high control)
speed relay
Ambient
temperature
Duct
temperature
Air mix motor Temperature control

Environ- Interior
ments temperature Air
condi-
tioner
Sun loads Mode motor Air flow control
control-
ler
Air source Air source selection
AQS sensor selection motor control
Vehicle
Vehicle speed
informa-
tion Wiper
operation Engine ECM Compressor control
Air Conditioner Compressor Control by Engine ECU

In case of current vehicle models, the system turns ON/OFF the compressor switch according to refrigerant pressure,
ambient temperature and condenser temperature to protect air conditioner circuits. However, for the vehicle equipped
with DI engine, the engine ECU turns off air conditioner compressor as below in addition to above conditions.
1. Coolant temperature: below -20°C

2. Coolant temperature: over 115°C
3. For approx. 4 seconds after starting the engine
4. When engine speed is below 650 rpm
5. When engine speed is over 4,500 rpm
6. During abrupt acceleration for the vehicle equipped with manual transmission

AFFECTED VIN
16 3A
7. CIRCUIT DIAGRAMS IN AIR CONDITIONER SYSTEM

FATC (Full Auto Temperature Control)
1) Condenser fan, air mix motor, sun load, coolant temperature sensor

AFFECTED VIN
3A 17
2) Front blower, motor (mode/air source selection), inside air/humidity, outside air/AQS sensor

AFFECTED VIN
18 3A
3) Rear air conditioner (blower, mode actuator)

AFFECTED VIN
3A 19
Manual Air Conditioner

1) Power, air conditioner compressor, motors (mode, inside air/outside air, air mix)

AFFECTED VIN
20 3A
2) Blower motor (front, rear)

AFFECTED VIN
3A 23
Inspection
If the active incar sensor defect code (DTC 1) and the humidity sensor defect code (DTC 10) are set, check as below:
Air conditioner controller
Air conditioner controller connector AIH sensor (based on sensor)

(based on wiring)
[Active incar sensor] [Humidity sensor]
1. Remove the integrated AIH sensor and measure the 1. Apply 5 V to terminal No. 1 and 3 on the humidity
resistance between terminal No. 5 and 6 on the sensor connector.
sensor connector.
2. Connect the positive (+) probe of a tester on No. 2
(standard: approx. 25°C, 2.2 kΩ)
terminal and the negative (-) probe on No. 3 terminal,
2. If the measured value is out of the specified range, and measure the output voltage while the voltage is
replace the AIH sensor. If the measured values are applied.
within the specified range, check as below. (output voltage: approx. 0.8 ~ 3.4 V)
3. Turn the ignition switch to ON position and measure 3. Check whether the output voltage is changed when
the voltage to active incar sensor from the FATC blowing into the inlet of the sensor. If there is a voltage
controller connector. change, the sensor is in normal condition. However,
(standard: approx. 2 V at 25°C) if the voltage is not changed, replace the humidity
sensor.
4. If the voltage value cannot be measured, check the
circuit for open. If the measured value is within the 4. In addition, if the output voltage is extremely high or
specified range, replace the FATC controller. low even in the specified range, replace the humidity
sensor.

AFFECTED VIN
24 3A
9. AIR QUALITY SYSTEM (AQS)

1) Components of AQS
Air Quality System (AQS) changes the air source selection to recirculation mode when polluted air is detected through
AQS sensor. The air source selection returns back to fresh air intake mode after a specified period or the polluted air is
disappeared.
AQS sensor and ambient tempera-

ture sensor
AQS sensor
Ambient temperature sensor
Connector
AQS and air source selection switch

The AQS switch is integrated with the air source selection switch.
AUTO Mode
The air source is not changed when pressing the AQS and air source
selection switch in “AUTO” mode. However, the indicator on the
switch turned ON/OFF. In other words, the air source cannot be
changed to recirculation mode in AUTO mode by just pressing the
switch.
To change the air source to recirculation mode in AUTO mode, get
into Manual mode first, then press the air source selection switch.
Manual Mode
To change the AQS mode to Manual mode from AUTO mode, use
the MODE switch or the fan speed control dial. In Manual mode, the
“AUTO” symbol on the display is disappeared. When pressing the
AQS and air source selection switch, the mode is changed in order
of AQS LED ON, AQS LED OFF (fresh air), and air source LED ON
(recirculation).
The figure shows that the mode has been changed to the recircula-
tion mode from fresh air mode under AQS mode (AQS LED ON)
after detecting the polluted outside air.

AFFECTED VIN
3A 25
2) AQS Operation
The AQS operates under air conditioner AUTO mode or when the AQS switch is pressed under manual mode. It requires
preheating time (for seconds) for operation and the module and sensor are integrated.
(However, it operates only when the DEF (defroster) switch on the air conditioner switch panel is not pressed in.)
1. Self diagnosis and preheating process during initial operation of A/C controller (AUTO mode)
1. When the air conditioner controller is operated in AUTO
mode during its initial operation, the air source is changed
to the recirculation mode and AQS LED comes on.
(This is the self diagnosis and preheating process for
AQS.)
2. After completing the above process, the AQS LED is

turned off and the air source is automatically changed to
the fresh air mode.
[Note]
If the AQS switch is pressed in, the AQS function works
regardless of air conditioner controller operation.
2. AQS operation (AQS switch is pressed in): detecting the polluted outside air
1. When pressing the AQS switch, the LED on the AQS
switch is turned on and the AQS function is activated.
2. When the polluted outside air is detected, the AQS
operates and converts the air source to recirculation mode
automatically. At this moment, the recirculation mode
indicator comes on in the display.
3. When driving out of polluted area

1. If the polluted air is disappeared, the air source is
automatically changed to the fresh air mode and AQS
LED stays on.
2. The air source is not changed when pressing the AQS
and air source selection switch in “AUTO” mode. To
change the air source to recirculation mode in AUTO
mode, get into Manual mode first, then press the air
source selection switch.

AFFECTED VIN
26 3A
3) AQS Operation Circuit
5. IGN2
3. AQS signal (Output)

1. Ambient temperature switch
2. Sensor ground
4. Ground
2. Sensor ground
3. AQS signal (Output)
4. Ground
5. IGN 2
[AQS sensor] [Ambient temperature sensor]

1. Measure the voltage value of AQS. 1. Remove the sensor and measure the resistance
(between connector terminal No. 3 and 4.) between terminal No. 5 and 6 on the sensor
connector.
2. If the measured voltage is out of 0.1 to 4.8 V, replace (standard: approx. 25°C, 2.2 kΩ)
the AQS.
In addition, if the resistance is extremely high or low,
replace the sensor.
3. If the measured voltage is out of the specified range,
replace the AQS. If it is within the specified range,
2. If the measured value is out of the specified range,
check as below.
replace the ambient temperature sensor. If the
measured value is within the specified range, check
4. Turn the ignition key to “ON” position.
as below.
5. Measure the voltage between terminal B9 and B15
3. Turn the ignition switch to ON position and measure
on the air conditioner controller.
the voltage to ambient temperature sensor from the
6. If the voltage value cannot be measured, check the FATC controller connector.
circuit for open. If the measured value is within the (standard: approx. 2 V at 25°C)
specified range, replace the FATC controller.
4. If the voltage value cannot be measured, check the
circuit for open. If the measured value is within the
specified range, replace the FATC controller.

AFFECTED VIN
3A 27
4) Removal and Installation

1. Disconnect the negative battery cable and remove the front bumper assembly.
2. Disconnect the AQS sensor connector, unscrew two bolts (10 mm) and remove the AQS sensor assembly.
(Install in the reverse order of removal.)
AQS sensor
Ambient temperature
sensor
Connector

AFFECTED VIN
28 3A
10. AIR CONDITIONER MODULE SENSORS AND ACTUATORS

1) Duct Temperature Sensor
The duct temperature sensor is installed on the top of heater unit. It detects the inside temperature of duct and transmits
the voltage value that is changed according to resistance value (NTC) to FATC controller.
Inspection
If the duct temperature sensor defect code (DTC 3) is set, check as below.
1. Remove the duct temperature sensor and measure the resistance between terminals on the sensor connector.
(standard: approx. 25°C, 2.2 kΩ)
In addition, if the resistance is extremely high or, replace the sensor.
2. If the measured value is out of the specified range, replace the duct temperature sensor. If the measured value is
within the specified range, check as below.
3. Turn the ignition switch to ON position and measure the voltage to duct temperature sensor from the FATC controller
connector.
(standard: approx. 2 V at 25°C)
4. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified
range, replace the FATC controller.

AFFECTED VIN
3A 29
2) Power Transistor
The power transistor controls the fan speed. It controls the blower motor operating speed without stages by changing
the current value to the base of power transistor when receiving the fan control signal from FATC.
Front air conditioner power transistor
Rear air conditioner power transistor

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Inspection
If the power transistor defect code (DTC 6) is appeared, check as below.
1. Turn the ignition switch to ON position.

2. Measure the voltage between terminals while changing the fan speed from stage 1 to stage 6.
3. The specified voltage value in each stage:
Stage Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6

Blower (V) 4.5 6.0 7.5 9.0 11 Max. HI
4. If the voltage is out of specified value, check the circuit for open. If the circuit is in normal condition, replace the
power transistor.

AFFECTED VIN
30 3A
3) Mode Door Actuator

The mode door actuator is an actuator that closes, opens and adjusts the mode door for VENT, FLOOR and DEF mode
to change the air flow directions according to FATC controller. Under the FATC controller AUTO mode, it stays on DEF
mode until the engine coolant temperature reaches at normal operating level and the mode is changed as below when
the MODE switch is pressed.

AFFECTED VIN
3A 31
Inspection
Terminal arrangement
Circuit diagram
If the intake door mode on FATC is different from the actual intake door mode, check as below.

2. Measure the voltage between each terminal (P1 through P5)and positive (+) terminal in respective mode.
(If the voltage is changed from 0 V to 12 V after selecting the mode, it is normal.)
3. If the voltage value is out of the specified value, check the related circuits for open.
4. If the circuits are in normal condition, replace the FATC.
5. If the voltage is within the specified value, replace the mode door actuator assembly.
6. Connect the positive (+) and negative (-) cables of temporary power supply to the door mode actuator. And, connect
the negative cable to each terminal (P1 through P5) to check its operation.
(If it operates as shown in above figure, it is normal.)

AFFECTED VIN
32 3A
4) Air Door Actuator

The air door actuator sets the intake door mode according to the control signals from FATC.

AFFECTED VIN
3A 33
Inspection
Circuit diagram
If the intake door mode on FATC is different from the actual intake door mode, check as below.

2. Measure the voltage between terminal P1 and P2 (approx. 12 V) and terminal a and b (approx. 5V).
4. If the circuits are in normal condition, replace the air door actuator assembly.
5. If the voltage is within the specified value, replace the mode door actuator assembly.
6. Connect the positive (+) and negative (-) cables of temporary power supply to the air door actuator. And, connect
the cable to each terminal (P1 and P2) in turn to check the motor operation and terminal output.
Air source Mode Bc resistance

Fresh air P1 (-), P2 (+) below 300 Ω
Recirculation P1 (+), P2 (-) over 2.4 kΩ

AFFECTED VIN
34 3A
5) Air Mix Door Actuator

The air mix door actuator controls the discharging air temperature properly by closing/opening the damper according to
the control signals from FATC.

AFFECTED VIN
3A 35
Inspection
Circuit diagram
If the air mix door defect error is indicated, check as below.

2. Measure the voltage between terminal P1 and P2 (approx. 12 V) and terminal a and b (approx. 5V).
4. If the circuits are in normal condition, replace the air mix door actuator assembly.
5. Connect the positive (+) and negative (-) cables of temporary power supply to the air mix door actuator. And,
connect the cable to each terminal (P1 and P2) in turn to check the motor operation and terminal output.
AMD Mode Bc resistance

Cool P1 (-), P2 (+) below 300 Ω
Hot P1 (+), P2 (-) over 2.4 kΩ

AFFECTED VIN
36 3A
6) Thermo AMP
The thermo AMP outputs the compressor ON or OFF signal to ECU to prevent evaporator from freezing. The sensing part
of the thermistor is the evaporator fin contact type.
If the air conditioner does not turn on, check as below.

1. Remove the thermo AMP and measure the voltage between terminal No. 1 and 2 on the connector.
2. Check whether the output voltages (ON: approx. 12 V, off: 0 V).
3. If the voltage value is out of the specified value, replace the thermo AMP. If the circuit is in normal condition, check
as below.
4. Turn the ignition switch to ON position and turn on the air conditioner by pressing the A/C button. And measure the
voltage between terminal A12 and A11 on the FATC controller connector. (standard: approx. 12 V)
5. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified
range, replace the FATC controller.

AFFECTED VIN
3A 37
11. AIR CONDITIONER AND HEATER PIPE LAYOUT

AFFECTED VIN
38 3A
Removal and Installation of Sensors and Actuators

Preceding work: Disconnection of negative battery cable and removal of instrument panel
Air mix door actuator * Removal and installation

All removal and installation operations for sensors and actuators
have similar procedures.
1. Disconnect the corresponding connector (1).

2. Remove the mounting bolts for each mode actuator.
However, the thermo AMP and blower high speed relay can be
removed only after removing the air conditioner module.
Duct temperature sensor
Mode door actuator
Mode door actuator:

Disconnect the door link (A) and then disconnect the
connector and remove the bolts.

AFFECTED VIN
3A 39
Thermo AMP
The thermo AMP is installed on the
heater core inside of air conditioner
module.
Air door actuator
Make sure that the parts (2) of air door actuator is securely
seated when installing it.
Power transistor

AFFECTED VIN
40 3A
12. REMOVAL AND INSTALLATION OF THE RELATED COMPONENTS

1) Control Switch Assembly
* Preceding works: Disconnection of negative battery cable
Removal of cup holder assembly and gear selector lever cover
1. Remove the center instrument panel.
2. Unscrew the screws and remove the air conditioner switch assembly .

AFFECTED VIN
3A 41
2) Air Duct Assembly

1. Instrument panel assembly
1) Remove the instrument panel.
2) Unscrew the screws and remove the air duct assembly.
2. Lower air duct assembly

1) Unscrew the screws and remove the lower air duct.
2) Unscrew the screws and remove the air duct assembly.

AFFECTED VIN
42 3A
3. Rear air duct assembly

1) Remove the rear quarter panel.
2) Unscrew the mounting screw from the rear cooler duct and heater duct and remove the air duct assemblies.
Rear air conditioner duct
Rear heater duct

AFFECTED VIN
3A 43
3) Air Conditioner Module Assembly

Front air conditioner module
* Preceding works: 1. Disconnection of negative battery cable and removal of instrument panel
2. Collection of air conditioner refrigerant (dispose the wasted refrigerant to designated place)
1. Disconnect the heater hose and remove the high and low pressure pipes from the air conditioner. (in case of FFH
equipped vehicle, remove the FFH assembly.)
Tightening torque: 10 ~ 15 Nm
2. Disconnect the air conditioner module connector , unscrew the mounting screws and remove the blower unit
assembly.
A B

AFFECTED VIN
44 3A
3. Disconnect the ground cable , unscrew the mounting screws and remove the heater unit assembly.
Heater pipe mounting nut
Ground cable (A) and mounting nut

Heater module mounting nuts (side) (bottom)

AFFECTED VIN
3A 45
Rear Air Conditioner Module

Preceding works: 1. Disconnection of negative battery cable and removal of rear quarter panel
1. Remove the rear cooler duct and heater duct .

AFFECTED VIN
46 3A
2. Remove the rear air conditioner module assembly with the sequence as below:
1) Remove the heater hose/pipe .
2) Remove the air conditioner high and low pressure pipes .
3) Disconnect the connector .
4) Remove the rear air conditioner module mounting screws .
5) Unscrew the lower mounting screw and remove the rear air conditioner module assembly.
Heater/air conditioner pipe
Lower mounting screw

AFFECTED VIN
3A 47
3. Remove the rear air conditioner module assembly.
4. Install in the reverse order of removal. Make sure that no air leaks on the connections of heater and cooler duct.
Top of A/C duct
Top of heater duct
Bottom of A/C duct

AFFECTED VIN
48 3A
4) Receiver Drier and Condenser

Preceding works: 1. Collection of air conditioner refrigerant (dispose the wasted refrigerant to designated place)
2. Removal of front bumper assembly
1. Remove the turbo charger cooler assembly.

- Tightening torque for hose: 6 ~ 7 Nm
2. Disconnect the cooling fan (condenser) connector , unscrew the mounting bolts and remove the condenser
cooling fan.

AFFECTED VIN
3A 49
3. Disconnect the receiver drier connector and remove the condenser mounting bolts. Remove the condenser
assembly.
Detailed of “A”
4. Unscrew the receiver drier mounting bolt from the removed

condenser.

AFFECTED VIN
50 3A
5. Unscrew the lower mounting bolt and remove the receiver drier. The O-rings on the pipes should be replaced with
new ones. (Tightening torque: 20 ~ 30 Nm)

AFFECTED VIN
3A 51
5) Compressor Assembly
Preceding works: 1. Disconnection of negative battery cable and removal of fan belt
1. Remove the two air conditioner pipe flange bolts at compressor side and disconnect the connector .
(At this moment, the sealing washer on the pipe flange bolt should be removed. And, it should be replaced with new
one during installation)
B. Connector
A. High/Low pressure pipe flange bolt C. Compressor mounting bolt (20 ~ 30 Nm)
(10 ~ 15 Nm)
2. Unscrew the compressor mounting bolt remove the compressor from the engine.

AFFECTED VIN
52 3A
6) Sub condenser
Preceding works: 1. Disconnection of negative battery cable and removal of fan belt
1. Remove the wheel cover, disconnect the sub condenser connector and remove the air conditioner pipe .
2. Unscrew four mounting bolts and remove the sub condenser.
Install in the reverse order of removal. Tightening torque of A/C pipe mounting bolt: 10 ~ 15 Nm

AFFECTED VIN
3A 53
Composition of sub condenser
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Sub condenser
Fan cover bracket
Fan
Protective mesh
Fan motor

AFFECTED VIN
3B 3
FFH (FUEL FIRED HEATER) SYSTEM

1. GENERAL INFORMATION
The system is to increase the coolant temperature quickly by firing diesel fuel in the burner that is installed in engine
cooling system when in winter time the ambient temperature and engine coolant temperature is low. (Option)
FFH System consists of independent fuel lines, fuel pump, coolant circuit, coolant ciculation pump, electrical glow plug
and exhaust system by driver’s intention because FFH system is automatically.
Operated according to the coolant temperature and the ambient temperature.
FFH system operates up to more than 2 minutes to burn the residual fuel inside the system when driver stop the engine
during its operation. Therefore, a certain period of FFH operation after stopping the engine is not a malfunction.
Diagnostic connector Ambient temperature switch
Fuel tank and fuel pump for FFH FFH assembly
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FFH & PTC CHANGED BY

AFFECTED VIN
4 3B
2. COMPONENTS AND LOCATIONS
Ambient temperature switch
FFH coolant pump

FFH assembly
Heater / A/con module (front)
PTC (If applied)

Front duct
Air conditioner control panel
Rear floor duct
FFH fuel pump
Roof duct (A/con)
Rear duct (heater)

Fuel tank
Heater / A/con module (rear)
CHANGED BY FFH & PTC

AFFECTED VIN
3B 5
3. SYSTEM LAYOUT
FFH Overview
1. FFH assembly 8. Ambient temperature switch

2. Water pump & bracket 9. Suction hose
3. FFH NO.1 bracket assembly 10. Fuel pipe NO.1
4. FFH NO.2 bracket assembly 11. Fuel pipe NO.2
5. Silencer & pipe assembly 12. Pump outlet hose assembly
6. Fuel pump assembly 13. FFH inlet hose assembly
7. Fuel pump bracket assembly A. FFH assembly

AFFECTED VIN
6 3B
FFH Heater Disassembly

AFFECTED VIN
3B 7
1. Jacket 18. Surface sensor with cable

2. Jacket cover 19. Controller connector -14-pin connector (waterproof)
3. Combustion air fan 20. Pressure spring for surface sensor
4. Combustion chamber 21. Pressure spring for control and overheating sensor
5. Combustion chamber with flame tube 22. O-ring
6. Heat exchanger 23. Coolant hose (inlet)
7. Controller 24. Coolant hose (outlet)
8. Seal (between combustion chamber and 25. Tooth ring (2x)
combustion air fan) 26. Cable harness cover
9. O-ring 27. Rubber seal
10. Glow plug with cable 28. O-ring
11. Seal (between combustion chamber and heat 29. Screw (M4 x 55 TORX/2x)
exchanger) 30. Screw (M4 x 16 TORX/2x)
12. Upper bush for fuel pipe 31. Screw (M4 x 12 TORX/2x)
13. Lower bush for fuel pipe 32. Screw (M4 x 16 TORX/4x)
14. Flame sensor 33. Screw (M4 x 44 TORX/4x)
15. Bush for flame sensor (graphite) 34. Controller cable harness
16. Control and overheating sensor with cable 35. Insulation washer
17. O-ring

AFFECTED VIN
8 3B
4. FFH SPECIFICATION
Heater D 5 S-H
Heating medium Coolant
Control of the heat flow Large (full load) Small (small load)
Heat flow 5000 W 2300 W
Fuel consumption per hour 0.63 0.28
Mean electric power consumption in operation 35 W 11 W
at start 100 W
after-running 12 W
Rated voltage 12 V
Operating range
• Lower voltage limit: An undervoltage protection
10 V
device in the controller switches the heaters off at
approx. 10 volt.
• Upper voltage limit: An overvoltage protection device
in the controller switches the heaters off at approx. 15 V
15 volt.
Tolerable operating pressure up to 2.5 bar overpressure
Minimum water flow through the heater 300 L/H
Fuel In the main fuel tank
Tolerable ambient temperature operation -40°C ~ 80°C
storage -40°C ~ 125°C (2h for 125°C)
Weight
approx. 2.7 kg
(with controller, water pump and fuel pump)

AFFECTED VIN
3B 9
5. FFH OPERATING PROCESS

Operating Condition
FFH is operated according to the ambient temperature and coolant tempreature.
Initial and repeat operating conditions of FFH

Initial Operating Conditions of FFH:
Ambient temperature: below 5°C
Coolant temperature: below 75°C
Repeat Operating Conditions of FFH:
Coolant temperature: below 75°C
When the difference between the ambient temperature at initial operation and current ambient temperature is
over 3°C (to reduce the hysteresis with the temperature difference when operating FFH), FFH is operated
again. For example, if the initial operating temperature was 4°C, the ambient temperature at repeat operation
should be below 1°C and the coolant temperature should be below 75°C.
FFH operations according to the changes of coolant temperature
Above graph shows the FFH control process while the FFH is operating.
The control element is coolant as shown in the graph.
The FFH is operated in HI mode (high output: approx. 5000 W) until the coolant temperature reaches at 80°C and starts
to be operated in LO mode (low output: approx. 2300 W) from 81°C.
When the coolant temperature reaches at approx. 85°C, FFH stops its operation until the operating conditions will be
met again.

AFFECTED VIN
10 3B
Coolant Circulating Route
Rear
Water pump
Engine
Fan
Heater module
Front
Heater
Blower fan
Heater module
Heating system
Connecting the Coolant Circuit

The heater is connected to the coolant circuit in the coolant feed pipe from the vehicle engine to the heat exchanger.
[Notice]
• Parts conveying coolant must be routed and fastened in such a way that they pose no temperature risk to person or
material sensitive to temperature from radiation and direct contact.
• Before working on the coolant circuit, disconnect the negative battery cable and wait until all components have cooled
down completely.
• When installing the heater and the water pump, note the direction of flow of the coolant circuit.
• Fill the heater and water hoses with coolant before connecting to the coolant circuit.
• When routing the coolant pipes, observe a sufficient clearance to hot vehicle parts.
• Protect all coolant hoses/coolant pipes from chafing and from extreme temperatures.
• Secure all hose connections with hose clips.

AFFECTED VIN
3B 11
Circuit Diagram
The FFH has various sensors in FFH unit, and the FFH unit is connected to the water pump, the fuel circulation pump
and the ambient temperature sensor (switch) that provides important signals for the initial and repeat operations.
For diagnosis, remove the FFH system connector and install the scan tool. Currently, the K-Line that is connected to
the diagnostic connector is not available.

AFFECTED VIN
12 3B
Control and Safety Mode

Heater operations and safety mode
* If the fuel pump 5. The fuel pump does not start when the glow plug is
1. If the fuel pump fails to ignite within 90 seconds after defect or electrical lead to the dosing pump is
fuel pumping starts, the start procedure is repeated interrupted.
as described. If after a further 90 seconds fuel pumping 6. The fan motor speed is monitored continuously.
the fuel pump still fails to ignite, the heater is switched If the fan motor does not start up, is blocked or if the
off in fault mode. speed falls below 40% of the nominal speed, the
The controller is locked after a certain number of failed heater is switched off in fault mode after 60 seconds.
starts. 7. It is possible to diagnose the system by connecting
2. If the flame does out by itself during operation, firstly the diagnostic device to controller. For details, refer
a new start is activated. If the fuel pump fails to ignite to the “Diagnosis Procedures” section.
within 90 seconds after fuel pumping has started
again, the heater is switched off. [Emergency shutdown]
3. If the heater is overheated (lack of water, poorly vented If an emergency shutdown -EMERGENCY OFF- is
cooling circuit), the overheating sensor triggers, the necessary during operation, proceed as follows;
fuel supply is interrupted and the heater is switched
• Pull the fuse (Ef6: 20A) out.
off.
• Disconnect the heater from the battery.
4. The heater is switched off if the lower or upper voltage
limit is reached.
Specification - Water Pump

Rated voltage 12 V
Operating voltage 9 V ~ 15 V
Power consumption 16 W
Pumping capacity (0.1 bar) 800 l/h
Operating temperature -40°C ~ 135°C
Weight 0.28 kg
Characteristic Curve of Water Pump (12 V)

AFFECTED VIN
3B 13
Function Diagram
Control stage
Control stage large small
Sectional Drawing According to the Temperatures

AFFECTED VIN
14 3B
6. FFH ASSEMBLY
[Notice]
There is no need to disassemble the FFH unit for repair. This section is to show the internal components of the FFH unit.
Jacket cover
- The O-rings are installed between jacket cover and two
coolant hoses.
- The coolant hoses should be connected to right side.
1. Jacket
2. Jacket cover
3. Cable harness cover
Control and overheating sensor

The Control and overheating sensor and cable harness make
up one component.
1. Control and overheating sensor

2. Mounting spring
Check control and overheating sensor

Check the control and overheating sensor with a digital
multimeter. If the resistance according to the changes of flame
Resistance (Ohm)
sensor temperature is out of specified values, the flame sen-

sor is defective.
Temperature (°C)
Specified value
Temperature [°C] 0 10 20 30 40 50 60 70 80 90 100 110 120
Resistance [Ω] 32.54 19.87 12.48 8.06 5.33 3.60 2.48 1.75 1.25 0.91 0.67 0.50 0.38

AFFECTED VIN
3B 15
Surface sensor
The surface sensor and cable harness make up one
component.
1. Surface sensor
2. Mounting spring
Check surface sensor

Check the surface sensor with a digital multimeter.
If the resistance of flame sensor is out of specified
Resistance (Ohm)
values, the flame sensor is defective.
Temperature (°C)
Specified value
Temperature [°C] 0 10 20 30 40 50 60 70 80 90 100 110 120
Resistance [Ω] 30.00 19.53 13.03 8.90 6.20 4.41 3.19 2.34 1.75 1.32 1.02 0.79 0.62
Controller
The surface heater and cable harness make up one
component.
3. Combustion chamber housing

4. Surface sensor assembly

AFFECTED VIN
16 3B
Glow plug
1. Glow plug
2. Combustion chamber with flame pipe
Combustion chamber housing

1. Jacket
2. Combustion chamber
3. Combustion chamber housing
4. Insulation washer
5. Seal - combustion chamber / combustion air fan
6. Seal - combustion chamber / heat exchanger
Flame sensor
1. Flame sensor
2. Graphite bush
3. Bush

AFFECTED VIN
3B 17
Check flame sensor

Check the surface sensor with a digital multimeter. If the re-
sistance of flame sensor is out of specified values, the flame
Resistance (Ohm)
sensor is defective.
Temperature (°C)
Specified value
Temperature [°C] -50 0 10 20 30 50 80 90 100 130 150 200 250 300 350 400
Resistance [Ω] 803 1000 1022 1062 1097 1194 1309 1347 1385 1498 1573 1758 1941 2120 2297 2470
Combustion air fan

2. O-ring
3. Rubber seal
4. Combustion air fan
5. Screw

AFFECTED VIN
18 3B
Combustion chamber
2. Heat exchanger
3. Jacket
4. O-ring
Heat exchanger
1. Jacket
2. Heat exchanger
3. Combustion chamber with flame tube
5. O-ring (for heat exchanger)
Heat exchanger
1. Heat exchanger
2. Jacket
3. Stopper
4. Groove (bottom of heat exchanger)

AFFECTED VIN
3B 19

[Notice]
• This supplementary heater is a fuel burning type and improves the heating effect by increasing the engine coolant
temperature.
• This device is automatically operated by conditions of the coolant temperature and the ambient temperature.
• In initial operating stage, the fuel pump generates the operating sound and the FFH heater produces white smoke. These
are normal states to fill the fuel into the FFH fuel line.
Fuel Pump
1. Fuel pump connector
2. Fuel supply hose (FFH)
4. Fuel pump
3. Fuel supply hose
Removal and Iinsallation of Fuel Pump

1. Disconnect Fuel Pump Connector as the vehicle lifted.
2. Disconnect both left (2) and right (3) fuel supply hose
in above picture. Fuel Tank
3. Unscrew fuel pump mounting bolt (10M-1EA) and
disassemble fuel pump.
FFH
[Notice]
Cap the fuel supply hose to prevent oil leakage

AFFECTED VIN
20 3B
Ambient Temperature Switch

Preceding Work: Disassemble the front bumper assy
3. Connector pin
4. Connector
2. Holder
1. Disassemble the ambient temperature sensor (1) from

holder (2).
2. Disconnect connector (4) as push the connector pin (3).

AFFECTED VIN
3B 21
FFH Assembly
Preceding Work: Disconnect the battery terminal (-)
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AFFECTED VIN
22 3B
1. Disconnect FFH coolant circulation pump connector.

2. Disconnect FFH connector (2).
3. Disassemble the fuel pump hose and pipe.
[Notice]
Use cap to prevent fuel leakage and be careful in handling
the hose & pipe.
4. Unscrew the bracket nut (1) & clamp and disassemble

the inlet (3) & outlet (2) hose in coolant circulation pump.
5. Disconnect the coolant outlet hose (1).

AFFECTED VIN
3B 23
6. Disconnect the FFH assembly. (Install in the reverse order of removal)

( Fuel feeding process should be done)
: Silence braket bolt
: Left/ Right (10mm - 2EA)
1. FFH Mounting
bolt (10mm - 6EA)

AFFECTED VIN
24 3B
Fuel Feeding Process

Fuel Feeding job should be followed after changing FFH assy or after fuel line job.
[Notice]
Picture B
Without feeding job, FFH system could make white
smoke with abnormal noise.
1. Disconnect the ambient temperature switch as

shown in picture (A).
2. Check if the fuel comes out after engine starting
as the FFH fuel supply hose is disconnected.
(Picture B)
Picture A 3. If the fuel is sprayed out, connect the fuel pipe to

FFH assembly and keep the engine running for
1 minute.
4. Connect the ambient temperature connector.

AFFECTED VIN
3B 25
8. TROUBLE DIAGNOSIS
1. FFH Heater Trouble Diagnosis Precedure
When Faults Occur, First Check…

• Faulty wiring?
(short circuits, interruptions)
• Visual check for
- corroded contacts
- defect fuses
- damaged electrical leads, links and connections
- damaged exhaust and combustion air guidance
• Check battery voltage
Battery voltage < 10 volt: the undervoltage protection has triggered
• Check fuel supply
Check Voltage Supply Ubatt (terminal 30)

Disconnect the 10-pin connector and measure the voltage present in connector between chamber 1 and chamber 2.
For deviations in the battery voltage, check the fuses, supply lines, ground connection and plus point on battery for loss
of voltage (corrosion / interruption).
Check Key-ON signal (D+)

Disconnect the 10-pin connector and measure the voltage present in connector 1 between chamber 6 and chamber 2.
[Notice]
Heater operating conditions
• Ambient temperature: below 5°C
• Engine coolant temperature: below 75°C
Controller Lock
• The controller is locked when the following faults occur:
Overheating
• If FFH overheats 10 times in succession, error code 015 appears and the controller is locked.
Too many start attempts

If FFH performs 10 start attempts in vain, error code 050 appears and the controller is locked.

AFFECTED VIN
26 3B
SCAN100 Diagnosis
1. Vehicle 2. Choose No.11 item FFH
3. Choose trouble code checking.

AFFECTED VIN
3B 27
DTC (Diagnosis Trouble Code)

Trouble
Trouble Description Remedies
Code
0 No faults • Measure battery voltage (must be < 15.9V)
10 Shutdown for overvoltage • Check alternator
• Check alternator over voltage
11 Shutdown for undervoltage • Measure battery voltage (must be > 10.2V under load)
• Check alternator
• Check lead
12 Overheating (software threshold) Temperature at overheating sensor >125°C
• Check cooling system:
• Check the temperature sensor and overheating sensor, replace
if necessary
14 Overheating (difference evaluation) Difference in temperature values between surface sensor and con-
trol overheating sensor is too large. (Prerequisite for this trouble
code display is that the heater is in operation and the water tem-
perature at the overheating sensor has reached min. 80°C)
• Check cooling system
if necessary
15 Overheating (operating block) The controller is locked.
• Delete the fault memory to release the controller
if necessary
16 Difference evaluation 2 If the surface sensor has a far higher temperature value than the con-
trol overheating sensor, then the system proceeds with a fault shutdown.
17 Overheating (hardware, device) Temperature at control overheating sensor > 125°C
• Check the temperature sensor and overheating sensor,replace
if necessary
20 Glow plug interruption • Check cable harness for this component for damage and
through current and replace component if necessary
• Check plug-in connection, replace component if necessary
21 Overload, short-circuit or ground • Check cable harness for this component for damage, replace
contact, glow plug output component if necessary
22 Glow plug output defect • Check cable harness for this component for damage, replace
component if necessary
25 Comunication line short • Check the line

AFFECTED VIN
28 3B
Trouble
Code
30 Speed of combustion fan motor out- Fan wheel or combustion air fan motor blocked (frozen,
side tolerable range contaminated, stiff, cable harness scrapes on shaft end, …)
• Eliminate blockage
• Measure speed of combustion air fan motor:
- dismantle combustion air fan
- check with 8.2 V + 0.2 V, to do so, unclip the cable 0.752
black from chamber 13 of the 14-pin connector and the
cable 0.752 brown from chamber 14. Apply marking (white
paint) to the fan wheel and measure speed with contactless
speed meter.
If the measured speed is outside a range of 8,800 rpm to
10,400 rpm, then replace the combustion fan. If the mea-
sured speed is within a range of 8800 rpm to 10400 rpm,
then replace the controller.
31 Burner motor interruption • Check cable harness for this component for damage and
through current
• Check plug-in connection, replace component if necessary
32 Overload, short-circuit or ground • Fan wheel or combustion air fan motor blocked
contact, burner motor (contaminated, stiff)
• Check cable harness of this component for damage, if neces-
sary replace component
34 Burner motor output defect • Check whether the lead to this component has a short-circuit
to GND, if not, check component for ground contact, if neces-
sary replace controller
47 Overload, short-circuit or ground • Check cable harness to the external component for damage
contact, fuel pump and through current and replace external component if neces-
sary
48 Fuel pump interruption • Check cable harness to the external component for damage
and through current
• Check plug-in connection, replace external component if
necessary
49 Fuel pump output defect • Check whether lead to this component has short-circuit to
+Ub, if not, check component for ground contact, replace
controller if necessary
50 Operating block because too many Too many start attempts, the controller is locked
start attempts in vain (10 start • Delete the fault memory to release the controller
attempts, also one start repeat for
• Check fuel quantity and fuel supply
every start attempt)
51 Time exceeded for cold blowing • During start (no flame formed yet), the flame sensor reports
temperature value too high for too long
• Check exhaust and combustion air
• Check flame sensor

AFFECTED VIN
3B 29
Trouble
Code
52 Safety time exceeded • Check exhaust and combustion air system
• Clean or replace sieve used in fitting of fuel pump
53 Flame aborted from “power” stage
Warning
54 Flame aborted from “large” stage In the case of flame aborted in “power”, “large” and “small”
56 Flame aborted from “small” stage stage and with still tolerable start attempts, the heater proceeds
with a new start or with subsequent start repeat. If the new
start or start repeat is successful, the trouble code display goes
off.
Fault(because no more start attempt allowed )

• Check exhaust and combustion air system
• Check flame sensor - see trouble code 64 and 65
60 Control overheating sensor interrup- • Check cable harness to this component for damage and through
tion current
• Check plug-in connection
• Check sensor resistance value, replace component if necessary
61 Short circuit or ground contact con- • Check cable harness to this component for damage
trol overheating sensor • Check sensor resistance value, replace external component if
necessary
64 Flame sensor interruption • Check cable harness to this component for damage and
through current
65 Short circuit flame sensor • Check cable harness to this component for damage
• Check sensor resistance value, replace external component if
necessary
71 Surface sensor interruption • Check cable harness to this component for damage and through
current
72 Short circuit surface sensor • Check cable harness to this component for damage
• Check sensor resistance value, replace external component if
necessary
74 Overheating hardware defect, operating • Replace controller
block
87 Internal temperature sensor short-circuit • Replace controller
88 Internal temperature sensor interruption • Replace controller
89 CAN error • Check CAN interface
90 Watch dog reset • Replace controller

AFFECTED VIN
30 3B
Trouble
Code
91 Too many resets • Replace controller
92 ROM error • Replace controller
93 RAM error • Replace controller
94 Transistor fault occurs too frequently • Remedy short-circuit of the component to +Ub to GND, replace
- operation block controller if necessary
95 Software stack overflow • Replace controller
96 No valid process, operation lock • Replace controller
97 Resonator/quartz faulty, • Replace controller
wrong processor cycle
98 Main relay faulty • Replace controller
99 EEPROM error • Replace controller

AFFECTED VIN
3B 31
General Trouble Causes and Remedies

Condition Causes Remedies
Coolant leakage Change the radiatior
Leakage in coolant auxiliary tank Change the coolant auxiliary tank
Leakage in heater core Change heater core
Leakage in joint junction of coolant hose Check the condition of hose and changing clamp
Leakage in defective coolant hose Change the hose
Low coolant
level Leakage in water pump gasket Change the gasket
Leakage in water pump sealing Change the water pump
Leakage in water inlet cap Change the water inlet cap gasket
Leakagein thermostat housing Change the thermostat sealing
Insufficient tightening torque of cylinder head bolt Fasten the bolt to specified torque
Damaged cylinder head gasket Change the head gasket
The coolant leakage (Check the coolant level) Add coolant
excessive anti-freezer Check the density coolant (Anti-freezer)
Bad coolant hose condition Check the bent area of hose or change if needed
Defective themostat Change thermostat
Defective water pump Change water pump
Abnormally
Defective radiator Change radiator
high coolant
temperature Defective coolant auxiliary tank or tank cap Change coolant auxiliary tank or tank cap
Crack in cylinder head or in cylinder block Change cylinder head or cylinder block
Clogged water flow in cylinder head or block Clean the coolant flow line
Clogged water flow in radiator core Clean the radiator core
Defective cooling fan Change or check the cooling fan
Defective temp.sensor, wiring, and lamp cluster Chaange the sensor and related area
Abnormally Defective thermostat Change the thermostat

loow coolant Defective cooling fan Change or check the cooling fan
temperature Defective tem.sensor, wiring, and lamp cluster Change the sensor and related area

AFFECTED VIN
32 3B
PTC (POSITIVE TEMPERATURE COEFFICIENT) SYSTEM

The supplementary electrical heater is installed in D27DT engine equipped vehicle as a basic equipment. The PTC
system is operated according to two temperature values measured at the coolant temperature sensor and HFM sensor.
This device is mounted in the heater air outlet and increase the temperature of air to the passenger room.
Because PTC system is heated by electrical power, high capacity alternator is required. (Alternator of 12V 75A/90A has
changed to 12V 140A)
Non-opeational Condition
- During engine cranking
- When too low battery voltage (Below 11V)
- During preheating process of glow plugs
PTC Assembly Engine ECU

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PTC Relay
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AFFECTED VIN
3B 33
2. PTC COMPONENTS
Radiator Element Frame
Connector Spring clip
PTC-Ceramic
Characteristics of PTC
P.T.C Heater
Heating type Air heating type
Heating efficiency Excellent
Element Ceramic PTC (BaTio3)
Weight approx. 500g
Durability Excellent
Safety Excellent
Advantages - Stable output regardless of voltage changes
- Block the overcurrent with switch effect of PTC element
- High heating capacity in a moment
- Excellent durability of heating element against high current

AFFECTED VIN
34 3B
3. PTC OPERATING PROCESS

PTC Operating (ON) Condition
The operating condition of PTC is controlled by two step.
Generally, ECU control the power relay for PTC depending on the coolant temperature and ambient temperature sensor.
1st step (Initial PTC operating condition)

When coolant temperature < 15°C, PTC is operating (ON).
When coolant temperature ≥ 15°C, tow conditions decribed below must be satisfied.
2nd step (Coolant temperature: 15°C)

When coolant temperature 65°C ≤ and ambient temperature ≤ 10°C PTC operates (ON)
When coolant temperature 65 ~ 60°C and ambient temperature -10°C ~ 0°C PTC operates (ON)
When coolant temperature ≤ 60°C and ambient temperature ≤ 0°C ~ 5°C, PTC operates (ON)
PTC “OFF” Condition

Airconditioner blower switch OFF
Ambient temperature sensor error (wiring short or open)
When engine craking
Battery voltage is lower than 11V
When preheating the engine (Glow indicator “ON”)

AFFECTED VIN
3B 35
Circit Diagram

AFFECTED VIN
36 3B

Preceding work: - Disconnect battery terminal (-)
- Remove I/P panel
1. Unscrew cable mounting bolt (1) 2. Disconnect PTC connector
3. Unscrew PTC mounting bolt and disassemble the PTC assembly.

AFFECTED VIN
4A 3
GENERAL INFORMATION
OVERVIEW
2WD 4WD
34: D27DT (2WD)

1.
7202700600 DC Part Number Without Torque Converter 722 600 0 61: D27DT (4WD)
Blank 62: E3.2 Engine (4WD)
722 600 0 DC Variant Number
Engine Code Number
377900 Serial Number
Transmission Type
2. Bar Code: Automatic Transmission for
Passenger Car
3. Marked Number: 107 : 34 (D27DT, 2WD)
A/T Part Number A/T Serial # A/T Variant 105 : 61 (D27DT, 4WD)
with Torque Converter 100 : 62 (E3.2 GS1, 4WD)
DC 5-Speed Automatic Transmission

DCAG 5-speed automatic transmission is an electronically controlled 5-speed transmission with a lockup clutch in the
torque converter.
The ratios for the gears are realized by three planetary gear sets. The 5th gear is designed with a step-up ratio of 0.83
as an overdrive. The selector lever is controlled by electronically and mechanically. The gears are shifted by the corre-
sponding combination of three hydraulically actuated multiple-disc brakes, three hydraulically actuated multiple-disc
clutches and two mechanical one-way clutches.
This electronically controlled automatic transmission adjusts the operating pressure to provide proper shifting in relation
to engine power. This function improves shifting quality significantly. And, the driver can select “S” (Standard) mode or
“W” (Winter) mode according to the driving conditions.
This automatic transmission provides two gears even during reverse driving. The internal sensors and controls are
connected to TCU by cylindrical 13-pin connector.
* DCAG 5-speed automatic transmission offers the following advantages:

1. Improved shifting quality
2. More gears
3. Extended working life and reliability
4. Reduced fuel consumption
DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY

AFFECTED VIN
4 4A
STRUCTURE
Basic structure of DC 5-speed automatic transmission
1. Torque converter 7. Disc brake B3 13. Freewheel F2

2. Oil pump 8. Disc clutch C3 14. Center planetary gear set
3. Input shaft 9. Disc brake B2 15. Electric control unit (valve body)
4. Disc brake B1 10. Output shaft 16. Freewheel F1
5. Disc clutch C1 11. Parking lock gear 17. Stator shaft
6. Disc clutch C2 12. Intermediate shaft 18. Converter lockup clutch
CHANGED BY DC 5-SPEED AUTOMATIC TRANSMISSION

AFFECTED VIN
4A 5
PERFORMANCE CURVE AND GENERAL CHARACTERISTICS
Standard mode Lockup mode (open/sleeping)
Vehicle speed (kph)

Pedal value (%)
4-LOW mode
Vehicle speed (kph)
Vehicle speed (kph)
Pedal value (%)
Pedal value (%)

Note
1. Based on DI Engine + A/T equipped vehicle 4. FAST OFF
specifications • When abruptly releasing the accelerator pedal, the
• Gear ratio transmission remains at 4th gear other than 4 → 4
1st gear: 3.595 shift (when slowly releasing the accelerator pedal, the
Rev. 1st gear: 3.167 transmission is shifted to 5th gear).
2nd gear: 2.185
Rev. 2nd gear: 1.926
3rd gear: 1.405
4th gear: 1.000 Axle ratio: 3.31
5. Dynamic shift range
5th gear: 0.831 • When operating the accelerator pedal, the 4 → 3 shift
2. WINTER Mode: Standard Mode is completed by kick-down signal after completion of
4 → 4 shift.
3. Allowable shifting point:
• When promptly operating the accelerator pedal, the 4
Upshift
→ 3 shift is done in shaded arae.
Downshift
Lockup (sleeping)
Unlock (open)
FAST OFF
Dynamic shift range

AFFECTED VIN
6 4A
SPECIFICATIONS
Item W5A330 (300) W5A580 (400)
Input torque 330 Nm 580 Nm
Weight (including ATF) 78 kg 78 kg
Diameter (Torque converter) 270 mm 270 mm
Lockup function Yes Yes
Gear ratios 1st 3.951 3.595
2nd 2.423 2.186
3rd 1.486 1.405
4th 1.000 1.000
5th 0.833 0.831
Reverse: S mode / W mode 3.147/1.93 3.167/1.926
Driving type 2WD (4WD)
Fluid specification Fuchs ATF 3353
or Shell ATF 3353
Fluid capacity approx. 8
Selector lever position P.R.N.D Mechanical
D+/D- Electrical
Parking lock system Brake switch (signa) → TGS lever
Reverse lock system CAN → TGS lever
Selected lever indication P.R.N.D Lever position
4, 3, 2, 1 CAN
Oil temperature sensor Resistance: R, D 0.5 ~ 2.5 kΩ
Resistance: P, N 20 kΩ
TCU EGS 52
Shift solenoid valve Resistance 3.8 ± 0.2 Ω
(25°C) Operating distance 0.2 mm
Operating current 1.5 ~ 2 A
M/P, S/P solenoid valve Resistance 5.0 ± 0.2 Ω
Operating current 0~1A
Lockup solenoid valve Resistance 2.5 ± 0.2 Ω
Operating current 1.5 ~ 2.0 A
Operating range 3rd to 5th gears
RPM sensor Resistance HALL type
Operating voltage 6V
Start lockout switch Switch contact ON (D, R position )
Switch contact OFF (P, N position)

AFFECTED VIN
4A 7
Item W5A330 (300) W5A580 (400)

Mode switch W (Winter)
S (Standard)
One-way clutch F1, F2
Planetary gear set Plain planetary gear: 3 (number of pinion) 3, 4, 3 4, 4, 4
Friction plates C1, B1, B3 Single side friction plate
C2, C3, B2 Double side friction plate

AFFECTED VIN
8 4A
POWER FLOW
Sectional View
Shifting elements
Gear C1 C2 C3 B1 B2 B3 F1 F2
1 z 3)
z 3)
z z z
2 z z 3)
z z
3 z z z
4 z z z
5 z z z 3)
z
P/N 1)
z z
P/N 2)
z z
R 1) z z 3)
z z
R 2)
z z z
1) Selector program switch: “S” mode

2) Selector program switch: “W” mode
3) Overrun
AFFECTED VIN
4A 9
Torque
converter
lockup Flywheel
clutch
Torque Automatic Final drive Output

Engine torque
converter transmission gear torque
Multiple disc Multiple disc

clutch brake

AFFECTED VIN
10 4A
1st Gear (3.932)
Input Output
16. Torque converter lockup clutch E. 3rd gear ratio M. Center planetary gear set
A. Engine speed F. Mounting elements P. Impeller
B. Transmission, input shaft H. Rear planetary gear set T. Turbine wheel
C. 1st gear ratio L. Stator V. Front planetary gear set
D. 2nd gear ratio
* Input shaft: Clockwise rotation

* Front sun gear: Locked by F1 and B1, Planetary gear carrier: Rotation with reduced speed
* Rear ring gear: Counterclockwise rotation
* Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Clockwise rotation with reduced speed
* Center ring gear: Clockwise rotation
* Center sun gear: Locked by B2, Rotation with reduced speed
* Output shaft: Clockwise rotation
Gear C1 C2 C3 B1 B2 B3 F1 F2 Lockup clutch

1 z 3)
z 3)
z z z
3) Overrun

AFFECTED VIN
4A 11
2nd Gear (2.408)
Output
16. Torque converter lockup clutch D. 2nd gear ratio M. Center planetary gear set
A. Engine speed E. Mounting elements P. Impeller

* Sun gear and planetary gear carrier: Clockwise rotation by C1 activation
* Rear ring gear: Clockwise rotation
* Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Rotation with reduced speed
* Center ring gear: Clockwise rotation
* Sun gear: Locked by B2, Planetary gear carrier: Rotation with reduced speed
2 z z 3)
z z
3) Overrun

AFFECTED VIN
12 4A
3rd Gear (1.486)
Input Output
16. Torque converter lockup clutch D. Mounting elements P. Impeller

A. Engine speed H. Rear planetary gear set T. Turbine wheel
B. Transmission, input shaft L. Stator V. Front planetary gear set
C. 1st gear ratio M. Center planetary gear set

* Front ring gear: Clockwise rotation
* Center ring gear: Clockwise rotation by clutch 2 activation (direct connection)
* Center sun gear: Locked by B2, Planetary gear carrier: Clockwise rotation with reduced speed
3 z z z

AFFECTED VIN
4A 13
4th Gear (1.000)
Output
16. Torque converter lockup clutch L. Stator T. Turbine wheel

A. Engine speed M. Center planetary gear set V. Front planetary gear set
B. Planetary gear set P. Impeller

* Center ring gear and rear planetary gear carrier: Clockwise rotation
* Front sun gear and planetary gear carrier: Clockwise rotation (direct connection)
* Rear sun gear: Rotation by ring gear and planetary gear carrier (direct connection)
* Center ring gear: Clockwise rotation by C3 activation
* Planetary gear carrier: Clockwise rotation by center sun gear and ring gear (direct connection)
4 z z z

AFFECTED VIN
14 4A
5th Gear (0.830)
Output
16. Torque converter lockup clutch E. 3rd gear ratio M. Center planetary gear set
D. 2nd gear ratio

* Front sun gear: Locked, Planetary gear carrier: Rotation with reduced speed
* Rear planetary gear carrier: Clockwise rotation with reduced speed
* Center ring gear and rear planetary gear carrier: Clockwise rotation by clutch C2 activation
* Rear sun gear: Clockwise rotation because rear planetary gear carrier rotates faster than rear ring gear (increased
speed)
* Center sun gear: Clockwise rotation with increased speed by C3 activation
* Center planetary gear carrier: Clockwise rotation (increased speed)
* Output shaft: Clockwise rotation (increased speed)
5 z z z 3)
z
3) Overrun

AFFECTED VIN
4A 15
Reverse 1st Gear (3.160, “S” Mode)
Input Output
16. Torque converter lockup clutch E. Mounting elements M. Center planetary gear set
D. 2nd gear ratio

* Front sun gear: Locked by one-way clutch F1
* Front planetary gear carrier: Clockwise rotation (reduced speed)
* Rear planetary gear ring gear: Clockwise rotation
* Rear planetary gear carrier: Locked by B3
* Rear sun gear and center sun gear: Counterclockwise rotation (increased speed)
* Center ring gear: Locked by B3
* Center planetary gear carrier: Counterclockwise rotation (reduced speed)
* Output shaft: Counterclockwise rotation
R (S) z z 3)
z z
3) Overrun
AFFECTED VIN
16 4A
Reverse 2nd Gear (1.930, “W” Mode)
Input Output
16. Torque converter lockup clutch D. 2nd gear ratio M. Center planetary gear set
A. Engine speed E. Mounting elements P. Impeller

* Front planetary gear carrier: Clockwise rotation by clutch C1 activation (direct connection)
* Rear planetary gear carrier and center ring gear: Locked by brake B3
* Rear sun gear and center sun gear: Counterclockwise rotation (increased speed)
* Center planetary gear carrier: Counterclockwise rotation (reduced speed)
* Output shaft: Counterclockwise rotation
R (W) z z z

AFFECTED VIN
4A 17
FUNCTION AND DESCRIPTION

SELECTOR LEVER
P: Parking and starting position
This position is used when the vehicle is parking, starting the engine or stationing the vehicle. In this position, the driving
wheels are locked by parking pawl. To shift into any other positions, must depress the brake pedal (parking lock system).
R: Reverse driving
Conversion between Standard and Winter switch changes the reverse gear ratio but must be operated before the
selector lever is moved. Pressing on the Winter switch allows to have effective driving when driving on the slippery road
surface and, also, possible to have smooth driving in reverse as it starts in 2nd gear.
N: Neutral, starting and towing position
The engine can be started in this position. And, this position is used in temporary stop. If it is necessary to tow a vehicle,
use a professional tow truck service. If not available, use emergency towing by towing vehicle and lope. In this case, the
towing distance should be limited by 50 km with 50 km/h of towing speed.
D: All forward gears (1st ~ 5th)

This position is for all normal forward
driving in 1st to 5th gear. At 5th gear, the
gear ratio is 0.83:1. When driving for-
ward at the speed of over 10 km/h, the
selector lever cannot be changed to “P”
or “R” position by parking reverse block
function.
4: Up shifting only up to 4th gear
In general, up to 4th gear is automati-
cally shifted at the normal road driving
position. In “D” position, while driving,
pushing the lever in the left (–) direction
once makes down shift to 4th gear,
which is the same function as the O/D
OFF (Over Drive OFF) of normal vehicle.
3: Up shifting only up to 3rd gear
Automatically shifts up to only 3rd gear
and able to achieve engine brake effect
on long slope/down hill and, in “D”
position, pushing the lever in the left (–)
direction twice makes down shift from
5th gear to 3rd gear.
1←2←3←4←D -D+ 1→2→3→4→D

2: Up shifting only up to 2nd gear
Automatically shifts up to only 2nd gear and used in
mountain road, unpaved road and while being towed
by trailer. It can achieve engine brake effect and, in D
position, pushing the lever in the left (–) direction 3
times makes down shift from 5th gear to 2nd gear.
1: Driving in 1st gear only

Drives only in 1st gear, and used in long mountainous
terrain, steep heel and unpaved road. It is used when
engine brake effect for driving down hill is required.
To shift gear lever from “P” position to other positions,
depress the location shown above picture

AFFECTED VIN
18 4A
TORQUE CONVERTER
Function (4WD)
Torque converter is installed between engine and automatic transmission. It consists of pump impeller, turbine and
stator. The pump impeller is welded at converter housing and the converter housing is bolted at the drive plate.
The torque converter converts the mechanical energy from engine to hydraulic energy, and the turbine connected to
transmission input shaft converts this hydraulic energy to mechanical energy again. The stator between pump and
turbine increases the output torque from turbine by converting the flowing direction.
The stator has a torque converter area that changes the flowing direction and a fluid coupling area where the stator
rotates. And, the lockup clutch integrated in torque converter prevents the power from losing and reduces fuel consumption.

AFFECTED VIN
4A 19
Installation and Inspection

• Place the automatic transmission upright as shown in
figure and install the torque converter by rotating the torque
converter. When installing from sideway, the torque
converter sealing ring may be damaged by driving flange
which could cause oil leaks.
• Use special tools when removing and installing torque

converter.
[Notice]
Place the automatic transmission upright when removing

and installing torque converter.
If not, the oil seal may be damaged when servicing the torque
converter.
• The distance between the upper end of torque converter

and the mating surface of automatic transmission housing
should be within specified value as follows:
Specified installation height (A) below 6.5 mm
* Torque converter
P/NO Diameter Clutch disk Engine
A210 250 05 02 270 mm 2 EA E23/E28/E32/D27DT

AFFECTED VIN
20 4A
LOCKUP CLUTCH
1. Impeller wheel 10. Multiple disc clutch pack

2. Turbine wheel 11. Piston
3. Stator wheel
4. Stator shaft A : Closed (lockup clutch activates)
5. Multiple disc clutch drum B : Slipping
6. Multiple disc clutch hub C : Open (lockup clutch deactivates)
7. Converter cover n : Transmission output speed
8. One-way clutch d : Accelerator pedal position
9. Input shaft
Lockup clutch consists of multiple disc clutches as shown The characteristic curves shown in the diagram illustrate
in the figure and is activated in 3th, 4th and 5th gears. The the different operating states of the torque converter lockup
aim of using torque converter lockup clutch is to reduce clutch in relation to the accelerator pedal position and the
the fuel consumption and exhaust gas emissions of the transmission output speed, plotted for one transmission
vehicle by reducing torque converter slip. This stands in gear.
contradiction to the ride comfort demands made on the
drive train with regard to its vibration behaviors. The task of • Variables influencing the states of the torque converter
the electronic transmission control is therefore to close lockup clutch:
the clutch in all driving situations relevant to fuel
1. Accelerator pedal movement
consumption, if possible, and ensure that the engine vi-
2. Uphill and downhill gradients
brations are isolated from the drive train.
3. Transmission shift functions
4. Transmission oil temperature
5. Load conditions
6. Engine control influences

AFFECTED VIN
4A 21
Lockup Clutch Regulating Valve
Torque converter Torque converter Transmission

Lockup clutch output input lubrication points
Torque converter lockup

solenoid valve
Oil sump
drain
Oil cooler
Working
pressure
Oil sump drain
Lubrication pressure
Shift valve
pressure
Oil sump drain
Lockup clutch regulating valve controls the lockup clutch in torque converter and distributes the lubricating oil to the
friction parts. TCU generates the lockup clutch control pressure by duty controlling the lockup solenoid valve, and this
pressure is applied to the lockup clutch regulating valve to engage, disengage and slip the lockup clutch. When the
lockup clutch control pressure is increased, the lockup clutch regulating valve moves up and the working pressure is
applied to lockup clutch. In its regulating position (slipping, torque converter lockup clutch pressurized), a reduced
volume of lubricating oil flows through the annular passage bypassing the torque converter and passing direct through
the oil cooler into the transmission. The rest of the lubricating oil is directed via the throttle “a” into the torque converter
in order to cool the torque converter lockup clutch.

AFFECTED VIN
22 4A
PLANETARY GEAR SET
Ring gear
Pinion gear
Sun gear
Planetary gear carrier
Output Locked Input

Input
Locked Output Output
Relatively high Relatively low Direction reversal and

step-down ratio step-down ratio step-down ratio
Relatively high step-down ratio

Ring gear locked
Sun gear driving (clockwise)
Planet gears driven (rotating counterclockwise)
Planet carrier driven (revolving clockwise)
Relatively low step-down ratio

Sun gear locked
Ring gear driving (clockwise)
Planet gears driven (rotating clockwise)
Planet carrier driven (revolving clockwise)
Direction reversal and step-down ratio

Planet carrier locked
Sun gear driving (clockwise)
Planet gears driven (counterclockwise)
Ring gear driven (counterclockwise)
Gear ratio: teeth of sun gear / teeth of ring gear

AFFECTED VIN
4A 23
MULTIPLE-DISC CLUTCH
1. Input shaft C1c. Internally toothed disc carrier C1 M1. Middle sun gear
9. Externally toothed disc C2a. Piston C2 M3. Middle planet carrier
10. Internally toothed disc C2b. Externally toothed disc carrier C2 M4. Middle ring gear
H1. Rear sun gear C3a. Piston C3 V1. Front sun gear
C1a. Piston C1 C3b. Externally toothed disc carrier C3 V3. Front planet carrier
C1b. Externally toothed disc carrier C1 C3c. Internally toothed disc carrier C3 V4. Front ring gear
Location
Three multiple-disc clutches, the front, middle and rear multiple-disc clutches K1, K2 and K3, are located in the plan-
etary gear sets in the transmission housing.
Funtion and description

A multiple-disc clutch consists of a number of internally toothed discs (10) on an internally toothed disc carrier and
externally toothed discs (9) on an externally toothed disc carrier.
If the piston (C1a) on multiple-disc clutch K1 is subjected to oil pressure, it presses the internal and external discs of the
disc set together. The sun gear (V1) is locked with the planet carrier (V3) via the externally toothed disc carrier (C1b) and
the internally toothed disc carrier (C1c). The front planetary gear set is thus locked and turns as a closed unit. If the
multiple-disc clutch C2 is actuated via the piston (C2a), the piston compresses the disc set. The ring gear (V4) of the
front planetary gear set is locked with the ring gear (M4) of the middle planetary gear set via the externally toothed disc
carrier (K2b) and the middle planet carrier (M3) on which the internally toothed discs are seated. Ring gear (V4) and ring
gear (M4) turn at the same speed as the input shaft (1). If the multiple-disc clutch C3 is actuated via the piston (C3a), the
piston compresses the disc set. The sun gear (M1) of the middle planetary gear set is locked with the sun gear (H1) of
the rear planetary gear set via the externally toothed disc carrier (C3b) and the internally toothed disc carrier (C3c). Sun
gear (M1) and sun gear (H1) turn at the same speed.
AFFECTED VIN
24 4A
FREEWHEEL
1. Outer race A. Rotation direction “A”

2. Inner race B. Rotation direction “B”
3. Locking elements V1/H1. Front or rear sun gear
4. Locking element cage
Location
Freewheels are installed in the front planetary gear set between the sun gear and the stator shaft, and in the rear
planetary gear set between the sun gear and the intermediate shaft.
Function and description

The freewheel consists of an outer race (1), an inner race (2), a number of locking elements (3) and a cage (4) for these
locking elements.
If the inner race (2) of the freewheel is locked and the outer race (1) turns in direction “A”, the locking elements (3) adopt
a diagonal position on account of their special contours, allowing the freewheel function.
The outer race (1) slides over the locking elements (3) with negligible friction. If the rotation of the outer race (1) changes
to direction “B”, the locking elements (3) stand up and lock the outer and inner races (1, 2) together.

AFFECTED VIN
4A 25
SENSORS AND CONTROLS

Components
Valve body assembly
1. Cap 5. Lockup PWM solenoid valve 9. 1-2/4-5 shift solenoid valve

2. Socket bolt (M6 x 32) 6. 2-3 shift solenoid valve 10. 3-4 shift solenoid valve
3. Socket bolt (M6 x 30) 7. Shift pressure (SP) solenoid valve 11. Electronic control module
4. Leaf spring 8. Modulating pressure (MP) solenoid valve 12. Lockup clutch control solenoid valve

AFFECTED VIN
26 4A
Shift Pressure Control Solenoid Valve
1. Leaf spring 7. Solenoid valve

2. Contact spring A. 1-2, 4-5 shift solenoid valve
3. Conductor track B. 3-4 shift solenoid valve
4. O-ring 8. Solenoid valve
5. O-ring C. Shift pressure control solenoid valve
6. Shift plate D. Modulating pressure control solenoid valve
9. Solenoid valve
E. Lockup PWM solenoid valve
F. 2-3 shift solenoid valve
Function
The plastic Electric Hydraulic Control Unit (EHU) is installed on the top of valve body. RPM sensor, start lock-out switch
and oil temperature sensors are integrated in EHU.
The 13-pin connector is connected to automatic transmission via PCB.
Three up/downshift solenoid valves are installed on the top of hydraulic control unit.
The solenoid valves are sealed with two O-rings against the valve body. The solenoid valves are pressed against the valve
body by the leaf springs.
AFFECTED VIN
4A 27
Characteristics of up/downshift solenoid valve

The solenoid valve remains energized and therefore open until
I (Current)
the shift process is completed according to the engine and
transmission conditions. If a solenoid valve is energized, it
opens and transmits shift valve pressure to the corresponding
command valve. 2.5A
Working Current 1.5 ~ 2.0 A

Operating distance 0.2 mm
Resistance 3.8 ± 0.2 Ω (25°C) 1.5A
60mA T (Time)
Circuit diagram
3-4 shift S/V 2-3 shift S/V 1-2, 4-5 shift S/V

AFFECTED VIN
28 4A
Modulating Pressure (MP) and Shift Pressure (SP) Control Solenoid Valve
Solenoid valve
1. Leaf spring 4. MP control solenoid valve

2. Shift plate 5. SP control solenoid valve
3. Strainer
Function
These valves control the modulating pressure and the shift Working Current 0 ~ 1.0 A
pressure by applying appropriate electric current to sole-
noid valves according to driving condition of engine and Operating distance 0.6 mm
transmission. Resistance 5 ± 0.2 Ω (25°C)
When the electric current from TCU is high/low, the regu-
lated pressure decreases/increases.
Regulated
pressure
Regulated pressure
Drain line
Drain line Line pressure

AFFECTED VIN
4A 29
Circuit diagram

AFFECTED VIN
30 4A
Lockup Solenoid Valve
1. Leaf spring 3. Shift plate

2. O-ring
Function
This valve activates and releases the lockup clutch by
Working Current 1.5 ~ 2.0 A
adjusting the current to solenoid valve according to engine
throttle opening value and output shaft speed. The lockup Operating distance 0.2 mm
clutch operates in 3rd, 4th and 5th gear with steps to re- Resistance 2.5 ± 0.2 Ω (25°C)
duce shift shocks.
Operating range 3, 4, 5 shift
Circuit diagram
Lockup S/V

AFFECTED VIN
4A 31
Speed Sensor
Speed Speed
sensor (n3) sensor (n2)
1. Leaf spring 3. Pulse ring

2. Valve body
Function
The speed sensors are fixed to the shell of the hydraulic control unit via the contact tabs. A leaf spring, which rests
against the valve body, presses the speed sensors against the transmission housing. This ensures a precise distance
between speed sensors and impulse rings. speed sensor (n3) detects the speed of the front sun gear and speed sensor
(n2) detects the speed of the front planetary carrier. If the speed sensor is defective, the transmission is operated in
emergency driving mode. Below table shows the detection of speed sensor.
Gear N2 N3
1 • -
2 • •
3 • •
4 • •
5 • -
R (S mode) • -
R (W mode) • •

AFFECTED VIN
32 4A
Circuit diagram
Speed Speed
sensor sensor
n3 n2

AFFECTED VIN
4A 33
Oil Temperature Sensor
Oil temperature sensor
Function
The oil temperature sensor is installed in hydraulic control unit and is connected in series with the starter lock-out
contact.
This means that the temperature signal is transferred to TCU when the starter lock-out contact is closed.
The oil temperature has a considerable effect on the shifting time and therefore the shift quality. By measuring the oil
temperature, shift operations can be optimized in all temperature ranges.
Circuit diagram
Starter lock-out contact

AD converter

AFFECTED VIN
34 4A
Starter Lock-out Contact Switch
1. Plunger 3. Reed contact

2. Permanent magnet
Function
The starter lock-out contact is installed beside oil temperature sensor and is actuated by a cam rail, which is located on
the latching plate.
In the selector lever positions “P” and “N”, the permanent magnet is moved away from the reed contact. This opens the
reed contact and the transmission control module receives an electrical signal. The transmission control module acti-
vates the starter lock-out relay module. This closes the electrical circuit to the starter in selector lever positions “P” and
“N” via the starter lock-out relay module. In other words, when the selector lever is in driving positions, the contact is
closed and the starter cannot be operated.
Circuit diagram
Ignition switch 50
Start lock-out contact
AD converter
Starter

AFFECTED VIN
4A 35
Kick-down Control
Function
When the throttle valve is partially opened, the shifting point gets faster. When the throttle valve is widely opened,
shifting point is delayed because the system needs low speed gear with bigger driving force.
Kick-down control is a system that enables to get bigger driving force as the down shift occurs by suddenly increasing
the throttle openings during constant driving. It has no separate kick-down switch where the down shift operates when
a certain point (about 1 second) lapses after opening of full throttle. The signal recognition allows to send control signal
to TCU from engine ECU via CAN communication.
Circuit diagram
Accelerator pedal module

( ) : For gasoline engine

AFFECTED VIN
36 4A
Mode Switch
Function
The mode switch is installed beside the selector lever and it has two modes of “S” mode (Standard
Mode) and “W” mode (Winter Mode).
- “S” mode is used in normal driving (starts off with 1st gear). TCU (Transmission Control Unit)
provides pleasant driving by changing the shifting pattern according to the driving habits
(downhill gripping: approx. 11 ~ 13.5 %)
- When “W” mode is selected, the Winter mode indicator in meter cluster comes on, and the
vehicle starts off with 2nd gear to achieve smooth starting on the icy or slippery road.
In winter mode, the up shift becomes faster and the down shift becomes slower for improving fuel consumption. The “W”
mode is automatically changed to “S” mode in full throttle or kick-down operation. The vehicle can starts off with 2nd
reverse gear (gear ratio: 1.92 ~ 1.93) when the “W” mode is selected. It is very useful on icy and slippery road. However,
in this case, the “W” switch should be selected before placing the selector lever to “R” position.
Even though “W” mode is selected, the vehicle starts off with 1st gear in following:
When the system recognizes the mode switch operation, the selector lever control unit sends the control signal TCU via
CAN communication.
1. When the selector lever is in “1” position.
2. When fully depressing the accelerator pedal or when starting off with kick-down condition.
Circuit diagram
Instrument panel
Selector lever control unit

AFFECTED VIN
4A 37
Reverse/Parking (R/P) Lock System
12
1. Selector lever 7. Locking lever

2. Shift pattern display 8. Shift detene spring
3. Parking lock release flap 9. Potentiometer for detecting selector lever position
4. Selector lever control unit 10. Base body
5. Mode switch 11. Spring of shift detent mechanism
6. Locking disc 12. Solenoid valve
Function
Reverse (R) lock system is a safety system that prevents the selector lever from shifting to “P” or “R” position by
activating the solenoid valve when the selector lever unit determines that the vehicle speed exceeds 10 km/h by check-
ing the speed signal from wheel speed sensor via CAN communication.
Parking (P) lock system uses the signals from brake switch other than conventional cable system to shift to other
positions. The wiring harness for detecting brake switch operation is connected to selector lever control unit.

AFFECTED VIN
38 4A
Circuit diagram
Brake switch
Selector lever control unit
Function of reverse (R) lock

Above a speed of approx. 10 km/h, the R/P locking solenoid
is actuated by the selector lever control unit. The R/P lock
lever (8) is turned to the lock position. The tab on lock lever
(10) locks the locking disc (1). The selector lever (1) cannot
be shifted into selector position “R”.
1. Locking disc 7. R/P locking solenoid

2. Cam (P lock) 8. Locking lever
3. Cam (R lock) 9. Tab on lock lever (P lock)
4. Selector lever 10. Tab on lock lever (R lock)
5. Base body 11. Potentiometer for detecting
6. Mode switch selector lever position
12. Intermediate lever

AFFECTED VIN
4A 39
Function of parking (P) lock

The selector lever position “P” is locked whenever the R/P
locking solenoid is not actuated by selector lever control unit.
The prerequisites for this are as follows:
* No voltage supply to the selector lever control unit (Ignition
switch is not positioned to “ON”)
* Brake pedal not depressed
Under these conditions, the locking lever (8) is in the locking

position. The tab on lock lever (9) locks the locking disc (1). It
is not possible to shift the selector lever out of selector lever
position “P”.
1. Locking disc 7. R/P locking solenoid

2. Cam (P lock) 8. Locking lever
3. Cam (R lock) 9. Tab on lock lever (P lock)
4. Selector lever 10. Tab on lock lever (R lock)
5. Base body 11. Potentiometer for detecting
6. Mode switch selector lever position
12. Intermediate lever
Parking Lock Mechanism

Location and function
The parking lock gear (6) is located on the output shaft in the
rear section of the transmission housing. In selector lever po-
sition “P”, the cone (3) slides between the parking lock pawl
(4) and the guide sleeve (5). The parking lock pawl (4) is there-
fore pushed against the parking lock gear (6). If the tooth of
the parking lock pawl (4) does not engage in a tooth space
when the vehicle is stationary, but rather touches a tooth of
the parking lock gear (6), the cone (3) is pre-tensioned by the
spring (2) and positioned ready for operation. If the parking
lock gear (6) continues to turn, the parking lock pawl (4) en-
gages in the next tooth space. To prevent damage due to
misuse, the widths of the tooth spaces are designed such
1. Detent plate 4. Parking lock pawl
that the parking lock pawl (4) can only engage when the ve-
2. Spring 5. Guide sleeve
hicle is stationary or moving very slowly. If the vehicle rolls
faster, the shape of the teeth prevents the parking lock pawl 3. Cone 6. Parking lock gear
(4) from engaging.

AFFECTED VIN
40 4A
Selector Lever Control Unit

Function
Selector lever control unit functions as follows:
A. Informing the selector lever’s position to other units via CAN.
B. Turning on the selector lever indicator while tail lamp is turning on.
C. Turning on the back-up lamp during reverse driving.
D. Operating the parking/reverse lock system.
Terminals
Pin No. Use For Remark

8 Selector lever unit power
6 CAN HI Connected to HECU, ECU, TCU,
7 CAN LO instrument panel etc.
5 Brake switch signal Parking lock operation

3 Self diagnosis
2 Tail lamp Turning on position indicator
9 Back-up lamp power
10 Back-up lamp
4 Ground

AFFECTED VIN
4A 41
Circuit diagram
Ignition switch Ignition switch

Tail lamp relay
Self diagnostic 10
Brake switch
Selector lever
control unit
Backup lamp
Instrument panel,
HECU, ECU

AFFECTED VIN
42 4A
CAN (Controller Area Network )

Function
CAN input signal CAN output signal
Accelerator pedal position Selected gear

Wheel speed (all wheels) Shifted status
Engine rpm, Engine torque Lock-up clutch status
Coolant temperature Automatic transmission
Downshift Kick-down status
Speed control (constant) TCU Driving conditions
Meshed gear Engine torque control
2nd gear start up control Dangerous status (changes to
emergency mode when
Selected gear in transfer case overloading, dangerous conditions,
Selector lever position and internal fault exists)
Odometer (I/P) ATF Temperature
Circuit diagram
Self diagnostic 11
Instrument panel Selector lever unit

AFFECTED VIN
4A 43
TCU (Transmission Control Unit)
TCU
TCCU
Function
TCU controls the gear groups according to the driving conditions. It receives the driving data from many sensors and
switches as input signals. It is also connected with ECU, HECU, instrument panel and selector lever control unit.
1. Shifting Method
Basic shift operation includes up-shift and down-shift for all gear groups. Shift control unit determines driving
resistance, accelerator pedal position, vehicle speed and some parameters (road surface condition, up hill and
down hill gradients, trailer driving conditions, catalytic converter conditions, driving habits and automatic transmission
oil temperature) to select a shift gear.
2. Down Shift
When engine speed increases excessively, the down shift does not occur.
3. Engine RPM Adjustment
During shifting, the engine torque is reduced to optimize the shift operation by delaying the ignition time.
4. Lock-Up Clutch Control
The lockup clutch in torque converter is activated in 3rd, 4th and 5th gear and operates in sequence via PWM
solenoid valve.
5. Others
The transmission is automatically controlled to compensate durability and wear.
The shift control values such as shifting point, shifting time, pressure during shifting, and lockup clutch control are
permanently saved and the diagnosis is partially available.

AFFECTED VIN
44 4A
TCU block diagram
Engine torque M/P S/V

36
Max. Engine torque S/P S/V
37
Engine power loss
Engine rpm Power supply (valves)

38
Engine Sol.
control ACC pedal position 1-2/4-5 gears S/V valve
14
Shift pattern changes 3-4 gears S/V
D 15
Engine control status 2-3 gears S/V
16
Engine torque
reduction I Lockup clutch S/V
17
T G
Wheel speed (FR, FL)
Sensor power supply
Wheel speed (RR, RL) I 13
Sensor
Sensor fround
HECU C 33
Shift pattern changes
T
Driving force control
A
Start signal Starter
Posi. Identifi. signal WO A C 7 relay
L
Posi. Identifi. signal W1
Selector Posi. Identifi. signal W2

angle N N2 speed
Posi. Identifi. signal W3 12
N3 speed
W/S mode signal input 35 T/M
Shift pattern changes
U Driving force controls
W/S mode indication
Selector lever indication Diagnosis Diag.

I/P 1
Conn.
Mileage
TCU (EGS) power

29
Part- P/N starting recognition IGN1
25, 27
time
TOD Selected T/C gear
TCCU TCU (EGS) ground Power

30
ground

AFFECTED VIN
4A 45
Characteristics of TCU and Automatic Transmission (LHM: Limp-Home

Mode)
The emergency driving mode is to minimize vehicle’s operation when is a mode for maintaining minimum driving condi-
tion when the automatic transmission is defective. In emergency driving mode, excessively long driving and unreason-
able driving should be avoided to prevent bigger fault occurring in advance. Emergency driving mode can largely be
divided in electrical defective and hydraulic pressure/mechanical defective.
Electrical defect
• If an electrical defective occurs in transmission during driving, current shift gear position is held.
A. Shut off of various solenoid valves
B. Internal pressure in transmission increases (shift shock gets bigger when changing selector lever due to
maximized MP and SP)
C. Lockup clutch is released
• If the shift operation cannot be activated, the driver must reset the system as follows:
A. Stop the vehicle and place the selector lever to “P” position.
B. Wait for 10 seconds after stopping the engine (release hydraulic pressure)
C. Start the engine.
D. Place the selector lever to “D” or “R” position.
Mechanical/hydraulic pressure defect

• Characteristics that appears in the vehicle are as below:
A. Holds at 3rd gear (It can be held at proper gear if the fault occurs at 3rd gear)
B. Electrical devices operate normally and the shift shock is acceptable during shift operation.
• If the shift operation cannot be activated, the driver must reset the system as follows:
A. Stop the vehicle.
B. Put the selector lever in “P” or “N” position.
C. Stop the engine.
D. In most cases, it is reset when the engine is started and the vehicle operate normally.
If, however, hydraulic or mechanical problem is not cleared, shifting is hold in 3rd or most stable gear range.

AFFECTED VIN
46 4A
Connector arrangement and pin functions
○
○
○
○
○
○
○
○
○
○
Connector A
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○ Connector B
○
○
Pin No. Description Connected to

1 Diagnostic Diagnostic connector pin No.11
7 Initiating the starter relay Starter relay
12 RPM sensor N2 13-pin plug No.3
13 RPM sensor voltage supply 13-pin plug No.7
14 1-2, 4-5 solenoid valve 13-pin plug No.13
15 3-4 solenoid valve 13-pin plug No.9
16 2-3 solenoid valve 13-pin plug No.11
17 Lockup clutch solenoid valve 13-pin plug No.11
29 TCU voltage supply -
30 Ground -
33 RPM sensor ground 13-pin plug No.12
34 ATF temperature, Starter lock-out contact 13-pin plug No.4
35 RPM sensor N3 13-pin plug No.1
36 Modulating pressure solenoid valve 13-pin plug No.2
37 Shift pressure solenoid valve 13-pin plug No.10
38 Each solenoid valve voltage 13-pin plug No.6
L CAN Low ECM, HECU, selector lever unit, instrument panel
H CAN High ECM, HECU, selector lever unit, instrument panel

AFFECTED VIN
4A 47
OTHER FUNCTIONS
OIL LEVEL CONTROL
Function
This is the function that closes the opening between oil chamber and planetary gear set chamber, so that the gear set
does not splash in oil if the oil level rises.
The lubricating oil flowing continuously out of the gear sets returns through the opening (2) into the oil chamber. If the oil
level rises, the oil forces the float (1) against the housing.
The float separates the oil chamber from the gear set chamber. The lubricating oil which escapes further from the gear
sets is thrown against the housing wall by the rotating parts and flows now through the upper opening (arrow) back into
the oil chamber.
Reduction of power losses and prevention of fluid loss from the transmission at high fluid level.
1. Float A. Oil chamber

2. Opening B. Planetary gear set chamber

AFFECTED VIN
48 4A
Oil Check and Specification
Lock pin
Lock pin
Cap
Checking and adding Tip Automatic transmission fluid capacity and

A. Place the vehicle on level ground. Pull out the lock specification
pin and remove the cap (add 4 to 5 liter if oil has
Fluid capacity Approx. 8
been completely drained out).
Specification Fuchs ATF 3353 or Shell ATF 3353
B. Place the selector lever to “P” position. Start the
engine and leave it idling (add 2.5 liter if oil has been
completely drained out).
C. Warm the engine up while moving the selector lever
to all positions. Check if the oil temperature is approx.
80°C with a scanner (apply the parking brake).
: Selector lever position - R or D
D. Check the oil level with oil dipstick while engine is
running in “P” position.
E. Check several times with attention, and add or drain
the oil as required.
[Notice]
1) Use only specified ATF oil.

2) Measure the ATF oil temperature as the shift lever is in
“R” or “P”.

AFFECTED VIN
4A 49
SHIFT ROD ADJUSTMENT

Adjustment
1. Range lever D. “D” range

2. Shift rod P. “P” range
3. Selector lever
A. Disengage the shift rod from range lever and place the range lever at “D” position.
B. Place the selector lever at “D” position.
C. Insert the shift rod into range lever and tighten nut.
[Notice]
Lock the selector lever so that it will not move.
D. Check if the indication lamp in meter cluster indicates correct gear position while moving the selector lever to “P”,
“R”, “N”, and “D” position.
E. Check if the engine can be started at selector lever “P” or “N” position.

AFFECTED VIN
50 4A
CIRCUIT DIAGRAM
Starter, Selector Lever, CAN Communication

AFFECTED VIN
4A 51
Solenoid, Oil Temperature Sensor, RPM Sensor (N2, N3)

AFFECTED VIN
52 4A
TROUBLE CODE AND DIAGNOSIS

TROUBLE DIAGNOSIS WITH SCANNER
Scanner Diagnosis Procedure

1. Connect the scanner connector to the diagnostic socket.
3. Select [DIAGNOSTICS] in [MAIN MENU] screen and press [ENTER].
4. Select [STAVIC] in [VEHICLE SELECTION] screen and press and press [ENTER].
5. Select [TCU] in [CONTROL UNIT SELECTION] screen and press [ENTER].
6. Select [TROUBLE CODE] in [FUNCTION SELECTION] screen and press [ENTER].
7. Determine the DTC and locate the trouble cause.
[Reference]
Choose “data list” item to check sensors and other
informative data.

AFFECTED VIN
4A 53
TCU Coding for DC 5-Speed Automatic Transmission
If the TCU or automatic transmission has been replaced, the TCU should be coded with SCAN 100.
Entering the diagnosis procedures
1. Select “1] DIAGNSTICS” and press in MAIN

MENU.
2. Select “6] STAVIC” and press in VEHICLE

SELECTION screen.
3. Select “2] TCU” and press in CONTROL UNIT

SELECTION screen.

AFFECTED VIN
54 4A
4. Select “5] TCU CODING” and press in FUNCTION

SELECTION screen.
5. If the message as shown in the figure appears, select

the drive type .
6. Select “YES” to start TCU coding.
7. If the message as shown in the figure appears, turn the

ignition key to “OFF” position and then turn it “ON” again.

AFFECTED VIN
4A 55
TCU SCN Coding

To satisfy the vehicle diagnosis regulation(OBD II & EOBD), TCU SCN coding is supplemented to the conventional TCU
Item list on the SCAN100 SCN Coding is to clarify the identity of vehicle software and to check if any software coding is
performed
SCN(Software Calibration Number)

SCN are composed of 16Byte ASCII code to identify the software version.
TCU part number is included.
CVN(Calibration Verification Number)

CVN is made by TCU inner coding algorithm to check any software change of TCU
Procedure
1. Vehicle selection 2. Control unit selection
3. Select “TCU SCN” 4. Select the vehicle

AFFECTED VIN
56 4A
5. Select “Yes” 6. Ignition key off and on and then, wait 50 seconds
Going in to TCU original number mode.
7. Check the TCU SCN and CVN number

(CVN specified number will be distrubuted to you soon)
[Notice]
• CVN number which is shown right after SCN coing is

not available.
• Check only the CVN number which is taken after waiting
50seconds, after ingintion Key is turned to “On” from
“Off”.

AFFECTED VIN
4A 57
DTC (Diagnosis Trouble Code) of DC5AT

Trouble
Defectives Action
Code
P2000 Faulty TCU internal watchdog test - Self-diagnosis with IGN ON.
- Cycle the IGN switch from OFF to ON. Check and replace TCU if the
trouble still exists.
P2001 Faulty TCU internal watchdog - Self-diagnosis.
function - Cycle the IGN switch from OFF to ON. Check and replace TCU if the
P2002 Faulty TCU external watchdog test - Self-diagnosis with IGN ON.
P2003 Faulty TCU external watchdog - Self-diagnosis.
function - Cycle the IGN switch from OFF to ON. Check and replace TCU if the
P2004 Faulty TCU Clock - Self-diagnosis.
P2005 Faulty TCU RAM - Self-diagnosis with IGN ON.
P2006 Faulty TCU RAM CAN-Controller 1 - Self-diagnosis with IGN ON.
P2007 Faulty TCU RAM CAN-Controller 2 - Self-diagnosis with IGN ON.
P2008 Faulty TCU ROM - Self-diagnosis with IGN ON.
- When the TCU internal checksum is different from scanner checksum.
P200A Faulty TCU EEPROM - Self-diagnosis with IGN ON.
P200B Faulty TCU CPU (internal) - Self-diagnosis.
- Check harness contact.
P200C Faulty TCU program control - Self-diagnosis.
- Check harness contact.
P2010 No TCU variant coding - Self-diagnosis with IGN ON.
- When the TCU coding is not exist.
- Check again after TCU coding.
P2011 Faulty TCU variant coding - Self-diagnosis with IGN ON.
- When the TCU coding is faulty.
- Check again after TCU coding.
P2012 Faulty TCU checksum - Self-diagnosis with IGN ON.
P2013 Faulty TCU (internally) - Self-diagnosis with IGN ON.

AFFECTED VIN
58 4A
Trouble
Defectives Action
Code
P2100 Defective 1-2, 4-5 shift solenoid valve - When 1-2 or 4-5 shift solenoid valve is defective.
- Measure the resistance of 1-2 or 4-5 shift solenoid valve (turn the IGN
OFF, then and disconnect TCU connector).
• TCU connector terminals: B12, B3
• Specified value: 3.8 ± 0.2 Ω
- Triggered emergency mode when the defective is detected.
• Fixed at 2nd gear in “D” range.
- Check the related harness for open, short and contact.
P2101 1-2, 4-5 shift solenoid valve - short - When 1-2 or 4-5 shift solenoid valve is defective.
- Measure the resistance of 1-2 or 4-5 shift solenoid valve (turn the IGN
OFF, then disconnect TCU connector).
P2102 Defective 2-3 shift solenoid valve - When 2-3 shift solenoid valve is defective.
- Measure the resistance of 2-3 shift solenoid valve (turn the IGN OFF,
then disconnect TCU connector).
P2103 2-3 shift solenoid valve - short - When 2-3 shift solenoid valve is defective.
- Triggered mechanical emergency mode when the defective is detected.
P2104 Defective 3-4 shift solenoid valve - When 3-4 shift solenoid valve is defective.
P2105 3-4 shift solenoid valve - short - When 3-4 shift solenoid valve is defective.

AFFECTED VIN
4A 59
Trouble
Defectives Action
Code
P2106 Defective lockup clutch solenoid valve - Measure the resistance of lockup clutch solenoid valve (turn the IGN
OFF, then disconnect TCU connector).
P2107 Defective modulator pressure sole- - Measure the resistance of modulator pressure solenoid valve (turn the
noid valve IGN OFF, then disconnect TCU connector).
P2108 Defective shift pressure solenoid - Measure the resistance of shift pressure solenoid valve (turn the IGN
valve OFF, then disconnect TCU connector).
• Electrical error: Fixed at 2nd gear in “D” range.
P2200 Faulty rpm sensor N2 signal - When the rpm sensor N2 detects 0 rpm of front sun gear speed.
• TCU connector terminal B6: rectangular wave signal
B8: signal ground
B13: 6V
P2203 Faulty rpm sensor N3 signal - When the rpm sensor N3 detects 0 rpm of planetary gear carrier speed.
• TCU connector terminal B6: rectangular wave signal
B8: signal ground
B13: 6V
P220A Abnormal rpm sensor output signal - When the rpm difference between rpm sensor N2 and N3 is over
(N2, N3) 150 rpm.
P2220 Oil temperature sensor - short - Turn the IGN OFF, then disconnect TCU connector.
- Selector lever position: R or D
- Measure the resistance of oil temperature sensor.
P2221 Abnormal oil temperature sensor - Turn the IGN OFF, then disconnect TCU connector.
signal - Selector lever position: R or D

AFFECTED VIN
60 4A
Trouble
Defectives Action
Code
P2222 Abnormal oil temperature sensor signal - Turn the IGN OFF, then disconnect TCU connector.
- Selector lever position: R or D
P2300 Faulty CAN communication - Turn the IGN OFF, then disconnect TCU connector.
- Check the communication line for open, short and contact.
- Measure the resistance of CAN line: B1, B2
• Specified value: approx. 60 Ω
P2301 Faulty CAN communication - Turn the IGN OFF, then disconnect TCU connector.
- Check the communication line for open, short and contact.
- Measure the resistance of CAN line: B1, B2
• Specified value: approx. 60 Ω
P2310 CAN: Faulty brake system communi- - Check CAN communication line H and L.
cation - Check ABS/ESP unit.
P2311 CAN: Faulty ECU communication - Check CAN communication line H and L.
- Check engine ECU.
P2312 CAN: Faulty ECU communication - Check CAN communication line H and L.
- Check engine ECU.
P2313 CAN: Faulty selector lever control - Check CAN communication line H and L.
communication - Check selector lever.
P2315 CAN: Faulty instrument panel commu- - Check CAN communication line H and L.
nication - Check instrument cluster.
P2317 CAN: Faulty communication between - Check CAN communication line H and L.
TCCU/TOD and CAN - Check TCCU/TOD unit.
P2330 CAN: Faulty brake system signal - Check CAN communication line H and L.
- Check ABS/ESP unit.
P2331 CAN: Faulty ECU message - Check CAN communication line H and L.
- Check engine ECU.
P2332 CAN: Faulty ECU message - Check CAN communication line H and L.
- Check engine ECU.
P2333 CAN: Faulty selector lever signal - Check CAN communication line H and L.
- Check selector lever.
P2335 CAN: Faulty instrument cluster signal - Check CAN communication line H and L.
- Check instrument cluster.

AFFECTED VIN
4A 61
Trouble
Defectives Action
Code
P2337 CAN: Faulty TCCU/TOD - Check CAN communication line H and L.
- Check TCCU/TOD unit.
P2400 CAN: Faulty rear RH wheel speed - Check CAN communication line H and L.
sensor signal - Check ABS/ESP unit.
• Check wheel speed sensor connector.
• Check the air gap between tooth wheel and wheel speed sensor.
Check tooth wheel installation. (specified air gap: 0.309~0.958 mm).
• Check the numbers of tooth wheel: 48
P2401 CAN: Faulty rear LH wheel speed - Check the related harness for open, short and contact.
sensor signal - Check CAN communication line H and L.
Check tooth wheel installation. (specified air gap: 0.309~0.958 mm).
P2402 CAN: Faulty front RH wheel speed - Check CAN communication line H and L.
Check tooth wheel installation. (specified air gap: 0.335~0.945 mm)
P2403 CAN: Faulty front LH wheel speed - Check CAN communication line H and L.
Check tooth wheel installation. (specified air gap: 0.335~0.945 mm)
P2404 CAN: No brake signal - Check CAN communication line H and L.
P2405 CAN: No accelerator pedal signal - Check CAN communication line H and L.
- Check engine ECU.
P2406 CAN: No engine torque signal - Check CAN communication line H and L.
- Check engine ECU.
P2407 CAN: No ESP signal - Check CAN communication line H and L.
- Check engine ECU.
P2408 CAN: No minimum engine torque signal - Check CAN communication line H and L.
- Check engine ECU.
P2409 CAN: No maxmum engine torque signal - Check CAN communication line H and L.
- Check engine ECU.

AFFECTED VIN
62 4A
Trouble
Defectives Action
Code
P240A CAN: No engine rpm signal - Check CAN communication line H and L.
- Check engine ECU.
P240B CAN: No engine coolant temperature - Check CAN communication line H and L.
signal - Check engine ECU.
P240C CAN: No selector lever position signal - Check CAN communication line H and L.
- Check selector lever.
P240D CAN: No transfer case position signal - Check CAN communication line H and L.
- Check TCCU/TOD unit.
P2500 Invalid transmission gear ratio - Cycle the IGN switch from OFF to ON. Check A/T system again after a
certain period of driving.
- If the trouble still exists, replace A/T assembly.
- To protect transmission, any shift is not available.
P2501 Excessive engine rpm - Check CAN communication line H and L.
- Check engine ECU.
P2503 Current selected gear - Check selector lever.
P220B Excessive N2, N3 rpm - Check rpm sensor N2 and N3.
P2510 Torque converter lockup clutch stuck - Check the hydraulic lines for leaks (valve No.22 in valve body).
- Check the resistanve of lockup clutch solenoid valve (Turn the
IGN OFF, then disconnect TCU connector).
P2511 Faulty torque converter lockup heat - Check the hydraulic lines for leaks.
control
P2520 Faulty recognition of torque reduction - Check ECU.
P2502 Poor gear mesh, transmission slip - Check the hydraulic lines for leaks.
- Check oil filter.
P2600 Too low TCU supplying voltage - Check TCU supplying voltage.
P2601 Too high TCU supplying voltage - Check TCU supplying voltage.
P2602 Abnormal solenoid valve supplying - Check solenoid supplying voltage.
voltage
P2603 Abnormal speed sensor supplying - Check speed sensor supplying voltage.
voltage • TCU connector terminals B13: 6V

AFFECTED VIN
4A 63
HYDRAULIC SYSTEM
STRUCTURE OF VALVE BODY
Torque converter
Oil pump
Input shaft Output shaft

B1 C1 C2 B3 C3 B2
Parking lock gear

Intermediate shaft
F2
F1 Center planetary gear
Valve body
Stator shaft
Lockup clutch
1. Shift housing 8. Shift valve pressure control valve

2. 1-2/4-5 command valve 9. Torque converter lockup clutch control valve
3. 1-2/4-5 holding pressure shift valve 10. 2-3 shift pressure shift valve
4. 1-2/4-5 shift pressure shift valve 11. 2-3 command valve
5. 1-2/4-5 overlap control valve 12. 2-3 holding pressure shift valve
6. Shift pressure control valve 13. Shift valve B2
7. Regulating pressure control valve

AFFECTED VIN
64 4A
HYDRAULIC CIRCUIT
M/P S/V S/P S/V 1-2/4-5 shift 3-4

S/V shift
S/V
Lockup S/V 2-3 shift S/V

AFFECTED VIN
4A 65
1. Selector valve 21. Shift valve pressure control valve

2. 2-3 overlap control valve 22. Lock-up clutch control valve
3. Lubricating pressure control valve 24. 2-3 shift valve
4. Operating pressure control valve 25. 2-3 command valve
5. Holding pressure shift valve 26. 2-3 holding pressure shift valve
6. Command valve 27. B 2 shift valve
7. 3-4 shift valve 28. Modulating pressure solenoid valve
8. 3-4 overlap control valve 29. Shift pressure solenoid valve
9. One-way throttle valve 30. 1-2/4-5 shift solenoid valve
10. Ball change over valve 31. 3-4 shift solenoid valve
11. Ball change over valve 32. Lock-up solenoid valve
12. Filter screen 33. 2-3 shift solenoid valve
13. Ball change over valve 50. Oil pump
14. 1-2/4-5 command valve 51. Oil cooler
15. 1-2/4-5 holding pressure shift valve 52. Oil pan
16. 1-2/4-5 shift valve 53. Oil filter
18. 1-2/4-5 overlap control valve 54. Oil sump
19. Shift pressure control valve
p-A. Operating pressure

p-Sm. Lubricating pressure
p-KUB. Lock-up clutch operating pressure
p-RV. Control valve pressure
p-Mod. Modulating pressure

p-S/RMV. Solenoid valve shift pressure
p-S. Shift pressure
p-SV. Shift valve pressure

p-S/KUB. Lock-up clutch control pressure
Huile. Reserved oil

AFFECTED VIN
66 4A
Oil Pressure
Modulating pressure Shift pressure control

control solenoid valve solenoid valve
1. Lubricating pressure control valve 6. Shift pressure control valve

2. Operating pressure control valve 7. Oil pump
3. One-way throttle valve 8. Drain
4. Shift valve pressure pressure control valve p-A. Operating pressure
5. Control valve pressure control valve
Operating Pressure (p-A)

The inscribed gear type oil pump is installed into torque converter housing and is driven via the drive flange of the torque
converter.
The operating pressure produced from oil pump supplies oil pressure to mail line in hydraulic system to operate the
actuator. The operating pressure is the highest pressure in the hydraulic system. All other pressures are derived from it.
The operating pressure is regulated at the operating pressure control valve depending on load (modulating pressure) and
driving range (C1, C2 pressure). The spring in the operating pressure control valve adjusts a minimum pressure level
(base pressure).

AFFECTED VIN
4A 67
Lubricating Pressure (p-SM)

This pressure limits the pressure in torque converter and lubricates and cools the mechanical transmission parts.
At the operating pressure control valve, excess fluid is diverted to the lubricating pressure control valve (1) and, from
there, regulated for transmission lubrication use (including torque converter).
Control Valve Pressure (p-RV)

The control valve pressure is set at the control pressure regulating valve (5) in relation to the operating pressure up to 8
bar.
This pressure supplies oil to modulating pressure (MP) solenoid valve, shift pressure (SP) solenoid valve, shift valve
pressure control valve (6).
Modulating Pressure (p-M)

The modulating pressure is adjusted at the modulating pressure control solenoid valve. The height of modulating pres-
sure is dependent on engine load by TCU. It acts on the operating pressure control valve and the pressure overlap control
valve. It increases the operating pressure (line pressure) when the load is heavy.
Shift Pressure (p-S)

The shift pressure is adjusted at the shift pressure control solenoid valve and shift pressure control valve (4). Additional
pressure from clutch C2 acts on the shift pressure control valve. As a result, the shift pressure in 2nd gear is reduced.
Shift Valve Pressure (p-SV)

The shift valve pressure converts the control valve pressure (p-RV) to shift valve pressure. Then it supplies oil to com-
mand valve, lockup solenoid valve, and shift pressure control solenoid valves.

AFFECTED VIN
68 4A
Shift Groups
The hydraulic control range (including shift elements), which is responsible for the pressure distribution before, during
and after a gear change, is designated a shift group.
The hydraulic system consists of 3 shift groups.
A shift group can be in two phases.
• Shift phase
• Stationary phase
In the shift phase, a change takes place in one shift group of the engaged clutch/brake. The other two shift groups are
then in the stationary phase.
Shift group C1/B1 (gear change 1-2/4-5) is responsible for the up/down shifts 1-2/2-1 and 4-5/5-4.
It includes:
• Clutch C1
• Brake B1
• Command valve
• Holding pressure shift valve
• 1-2/4-5 shift solenoid valve
• Pressure overlap control valve
• 1-2/4-5 shift solenoid valve
Shift group C2/C3 (gear change 2-3) is responsible for the up/down shifts 2-3/3-2.
It includes:
• Clutch C2
• Clutch C3
• Command valve
• 2-3 shift solenoid valve
• Pressure overlap control valve
Shift group C3/B2 (gear change 3-4) is responsible for the up/down shifts 3-4/4-3 and the engagement process.
It includes:
• Clutch C3, 3-4 pressure overlap control valve
• Brake B2, 3-4 shift solenoid valve
• Brake B3
• Command valve

AFFECTED VIN
4A 75
STRUCTURE OF ELECTRO-HYDRAULIC CONTROL MODULE (SHIFT PLATE)
A. Adjusting valve: Operating pressure, Lubricating C. 3-4 shift group

pressure, 2-3 group overlap D. 2-3 shift group, Clutch lockup control valve, shift
B. 1-2/4-5 shift group, control valve: Control valve valve B2
pressure, Shift valve pressure
Rear Section
1. Dowel pin 3. Valve ball (steel) 5. Plastic valve

2. Valve ball (plastic) 4. Filter

AFFECTED VIN
76 4A
Left Section
1. Shift housing 8. Shift valve pressure control valve

2. 1-2/4-5 command valve 9. Torque converter lockup clutch control valve
3. 1-2/4-5 holding pressure shift valve 10. 2-3 shift pressure shift valve
4. 1-2/4-5 shift pressure shift valve 11. 2-3 command valve
5. 1-2/4-5 overlap control valve 12. 2-3 holding pressure shift valve
6. Shift pressure control valve 13. Shift valve B2
Right Section
1. Valve housing 4. Lubricating pressure control valve 7. 3-4 command valve

2. Selector valve 5. Operating pressure control valve 8. 3-4 shift pressure shift valve
3. 2-3 overlap control valve 6. 3-4 holding pressure shift valve 9. 3-4 overlap control valve

AFFECTED VIN
4A 77
Disassembly and Reassembly

1. Remove the leaf spring (5).
2. Remove the bolt (1).
Installation Notice
3. Remove the shift housing (4) from valve housing (2).
[Notice]
Before installation, make sure to insert the dowel pin into

correct position.
4. Remove the sealing plate (3).
[Notice]
Be careful not to lose 4 plastic balls and 8 steel balls in shift

housing.
5. Unscrew the bolts from shift housing and valve housing

and remove the side cover. 1. Bolts (29) 4. Shift housing
Installation Notice 2. Valve housing 5. Leaf spring
3. Sealing plate
[Notice]
Check the valves for damage, and replace if necessary.

AFFECTED VIN
78 4A
REMOVAL AND INSTALLATION (DC 5-SPEED A/T)

COMPONENTS
4WD 2WD
4WD 2WD
1. Torque converter housing 1. Oil filler pipe
2. Plug connector 2. Drain plug
3. Oil line 3. Union bolt
4. Shield 4. Shield
5. Bolts 5. Plug connector
6. Transfer case adapter housing 6. Torque converter bolts
7. Union plugs 7. Transmission assembly
8. Drain plug 8. Shift rod
9. Torque converter bolts 9. Oil line
10. Oil line

AFFECTED VIN
4A 79

Transmission Assembly
Preceding Work: 1) Disconnect battery negative cable
2) Make sure the vehicle stand stable with safty wedge under tires
3) Put the shifting lever in “N”
4) Remove skid plate
* Check point
Make sure that the oil cooler pipe hose is not twisted, oil cooler pipe (radiator side) is not clogged. If it is contami-
nated with foreign materials, thoroughly clean before replacing transmission assembly (This work is necessary
when removing and installing the radiator).

AFFECTED VIN
80 4A
1. Remove the front and rear propeller shaft from the transfer Bolt No Tightening torque
case.
M17 4 81 ~ 89 Nm
M14 4 70 ~ 80 Nm
Front
Rear
Oil draining
If necessary, drain the oil. However, when removing or install-
ing the transmission without any other processes, just add oil
excluding drainage.
Installation Notice

AFFECTED VIN
4A 81
2. Disconnect T/C motor connector, T/M plug connector, T/M shift lever, air bleeder hose and other attachments.
1. T/C motor connector (1) & plug connector (2). 2. Air bleeder hose (3).
3. T/M shift lever.

* Locate the shift lever in “N”.
“P”
“N”

AFFECTED VIN
82 4A
3. Remove T/M oil return pipe (A), supply pipe (B), oil filler pipe (C) from T/M.
A. Oil return pipe B. Oil supply pipe C. Oil filler pipe
* Transmission Assembly
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[Notice]
1. Collect the dropping oil from removed pipes in the oil collecter and seal the pipes with caps.
2. Be careful not to contaminate the body and work space.

AFFECTED VIN
4A 83
4. For easier removal, unscrew the stabilizer mounting bolts (B) and put it down to the sub frame.
5. Support the transmission with hydraulic jack.
A. Stabilizer bar link

AFFECTED VIN
84 4A
6. Unscrew the center cross member mounting bolts.
A.Center bolts-center cross frame (14 mm - 2 EA) B.Side bolts-center cross frame (14 mm - 8 EA)

AFFECTED VIN
4A 85
7. Unscrew the T/M insulator bracket bolts and remove the bracket.
8. Unscrew the transfer case mounting bolts (12 mm - 11 EA) and remove the T/C from the T/M.

AFFECTED VIN
86 4A
9. Remove the torque converter hole cover and unscrew torque converter bolts one by one as rotating the engine crank
shaft clockwise. (14 mm - 6 EA)
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AFFECTED VIN
4A 87
10. Unscrew the mission housing bolts and drop the transmission slowly with hydraulic jack (17 mm - 8EA, Tightening
torque: 50 - 60 Nm)
[Notice]
Be careful not to drop the torque converter
11. Remove the torque converter with special tool.
[Notice]
When install the torque converter on the mission, apply

small amount of ATF oil to the input shaft & frange.
[Notice]
• Add the ATF oil and check the oil lever.

• Before reinstallation, clean the T/M and related
components.

AFFECTED VIN
88 4A
Selector Lever Assembly

1. Separate the selector. [Notice]
Place the selector lever at “P” position when removing

installing selector lever and wire cable.
A. Shift rod
: Remove the shift rod pin (1) and separate the shift
rod from selector lever
2. Remove the selector lever cover (1) and the center

console (2).
3. Remove the selector lever lower duct (1) and connector

(2).
4. Unscrew the selector lever assembly mounting bolts.

AFFECTED VIN
4A 89
DISASSEMBLY AND REASSEMBLY (DC 5-SPEED A/T)

COMPONENTS
Torque converter
Oil pump
C3 assembly
Input shaft
Output shaft
B1 C1 C2 B3 C3 B2
C2 assembly
Parking lock gear
F2 Intermediate shaft
Center planetary gear
F1
Valve body
Stator shaft
B3 assembly Lockup clutch
Housing assembly
C1 assembly
B2 assembly
B1 assembly
Output flange Oil pump
Adaptor plug
Valve body and oil pan (transmission wiring connection) Torque converter

AFFECTED VIN
90 4A
Friction Disc
Transmission Friction Disc C1 C2 C3 B1 B2 B3 Remark
Numbers 4 4 4 3 5 4
W5A300
Single Dual Single Single Dual Dual
(G32D: 4WD) Type
face face face face face face
Numbers 5 5 4 4 5 5
W5A400
Single Dual Single Single Dual Dual
(D27DT: 4WD) Type
face face face face face face
Tightening Torque
Tightening
No. Description Remark
Torque (Nm)
1 Oil drain plug (oil pan) 14 Heaxgon, 5 mm
2 Oil filler pipe (upper) 12 ~ 14 -
3 Oil filler pipe (lower) 7~8 -
4 Oil cooler pipe 30 ~ 38 -
5 Oil pan 8 T 30
6 Torque converter housing/oil pump 20 -
7 Transmission rear mounting bracket (both sides) 36 ~ 44 -
8 Transmission rear mounting bracket (center) 20 -
9 Torque converter bolt 42 -
10 Converter housing/engine 50 ~ 60 -
11 Converter housing/transmission housing 20 T 45
12 Valve body 8 T 30
13 Valve body side cover 4 T 30
14 Solenoid valve 8 -
15 12-Angle collar nut 200 12-Angle, each 30 mm
16 B2 housing bolt 16 T 45
17 Selector lever unit bolt 6 -

AFFECTED VIN
4A 91

Valve Body Assembly
5. Valve body
1. Guide bush 5-3. Pin 5-9. Solenoid valve

2. Drain plug 5-4. Plate leaf spring 5-10. Plate spring
3. Bolts 5-5. Bolts 5-11. Screw
4. Oil filter 5-6. Electric kit 5-12. Screw
5. Valve body 5-7. Solenoid valve 5-13. Bolts
5-1. Valve body assembly 5-8. Lifting solenoid valve 6. Oil pan
5-2. Body assembly

AFFECTED VIN
92 4A
Preceding work:
Install the transmission on the fixture stand.
[Note]
• To eliminate unnecessary working time and process,

prepare general tools, special tools, and gaskets before
starting work.
• The automatic transmission is very precise equipment.
Keep the transmission clean and tighten the bolts with
specified tightening torque.
1. Unscrew the bolt and remove the guide bush (1).

(7 mm - 1EA)
2. Unscrew the oil pan bolts and remove the oil pan (6).
Installation Notice
3. Remove the oil filter.

AFFECTED VIN
4A 93
4. Unscrew the bolts and remove the valve body from

transmission housing.
Installation Notice
5. Disassembly and reassemblt the valve body assembly.

5-1. Remove the solenoid valve cap.
5-2. Unscrew the bolts on solenoid valve and remove the leaf
springs.
Installation Notice
[Notice]
The socket bolts do not have same length. Be careful not to

mix up.
5-3. Remove the solenoid valves from valve body.

AFFECTED VIN
94 4A
[Notice]
1. Make sure to install the solenoid valves at correct

locations.
2. Check the O-rings, and replace if necessary.
5-4. Remove the electronic control module (Y3/6) from shift

plate.
[Notice]
Correctly align the electronic control module onto the shift

plate by using two central pins when installing.

AFFECTED VIN
4A 95
Converter Housing and Transmission Housing
Transmission housing
Converter housing assembly
1. Install the transmission assembly on the fixture stand.
Fixture stand 116 589 06 59 00
2. Remove the rear extension housing from transmission

housing.
Installation Notice

AFFECTED VIN
96 4A
3. Stretch out the bent point in 12-sided collar nut on output

shaft.
4. Unscrew the collar nut with special tool and remove

output shaft flange.
Installation Notice
* Bend the collar nut to lock it during installation.
5. Remove the rear oil seal ring.
6. Remove the snap ring with snap ring pliers and remove
the washer.

AFFECTED VIN
4A 97
7. Remove the ball bearing from transmission housing.

• Install the flare clamping pliers.
• Install the puller onto inner bearing race.
• Rotate the clamping pliers counterclockwise (arrow
direction) to tighten.
Puller 001 589 50 33 00

Collet chuck 140 589 06 34 00
• Remove the ball bearing from transmission housing

with spanner.
8. Unscrew the socket bolts fastening converter housing

and transmission housing and remove the transmission
housing from converter housing.
Installation Notice
[Note]
Slightly turn the transmission housing to left and right

direction to make the removal process easier.
[Notice]
• Apply loctite to the bolts from T/C housing to T/M. (15EA)

• No loctite to the bolts from T/M to T/C housing. (2EA)

AFFECTED VIN
98 4A
Converter Housing Assembly
Clutch C3
Clutch C2
Clutch C1
Brake B1
Oil pump

AFFECTED VIN
4A 99
1. Remove the clutch C3 from converter housing assembly.
4. Remove the brake B1.

4-1. Remove the bolts on brake B1.
Installation Notice

AFFECTED VIN
100 4A
4-2. Remove the bolts in converter housing.

Installation Notice
4-3. Remove the brake B1 from converter housing.
4-4. Separate the plate from valve body.
[Notice]
• Install two bolts on the opposite side of disc brake B1 and

tap the surface of disc brake B1 with plastic hammer to
remove it ftom converter housing.
• Align the dowel pin (arrow) on disc brake B1 and groove
in converter housing when installation.
• Apply the sealant on the socket bolts and tighten them.
5. Unscrew the bolts and remove the oil pump.

Installation Notice
[Notice]
Install two bolts on the opposite side of oil pump housing

and tap the surface of oil pump with plastic hammer to
remove it from converter housing.

AFFECTED VIN
4A 101
5-1. Remove the pump gears (1, 2) from pump housing.
5-2. Check the radial seal ring (3), and replace if necessary.
5-3. Replace the O-ring (4) with new one.
[Notice]
• Lubricate the pump gears (1, 2) before installation.

• Place the pump gear (2) into pump housing and install the
pump gear (1) onto the pump housing chamber.

AFFECTED VIN
102 4A
Transmission Housing Assembly
Parking lock gear
Brake B2 Brake B3
Snap ring
Components of selector lever

AFFECTED VIN
4A 103
1. Install the transmission assembly on fixture stand.
Fixture stand 116 589 06 59 00
2. Remove the snap ring from transmission housing.
3. Remove the spring washer and disc pack B3 from

[Notice]
• To make the removal easier, remove the disc pack B3 while

compressing it.
• Check each disc for wear and burnt out.
4. Remove the fixing bolts for brake B2 from transmission

housing.
Installation Notice

AFFECTED VIN
104 4A
5. Remove the disc brake B2 from transmission housing.
6. Remove the parking lock gear.
7. Remove the fixing bolts for range selector lever.

Installation Notice
[Notice]
Check the sealing ring for damage.
8. Remove the range selector lever, rod and detent plate.

AFFECTED VIN
4A 105
9. Remove the snap rings from parking lock pawl.
10. Remove the pin from transmission housing.
11. Remove the parking lock pawl from transmission housing.

AFFECTED VIN
106 4A
COMPONENTS OF EACH ASSEMBLY
Clutch C1
Clutch C2
Clutch C3

AFFECTED VIN
4A 107
Clutch C1 Clutch C2 Clutch C3

1. Sealing ring in disc carrier 11. Front planetary gear set 24. Clutch C3
2. Piston 12. Gear wheel 25. Sealing ring
3. Sealing ring in piston 13. Snap ring 26. Piston
4. Return spring 14. Thrust bearing 27. Disc spring
5. Spring plate 15. Clutch C2 and input shaft 28. Snap ring
6. Snap ring 16. Piston 29. Disc pack
7. Disc and steel plate 17. Inner sealing ring in piston 30. Snap ring
8. Snap ring 18. Outer sealing in piston
9. Snap ring 19. Return spring
10. One-way clutch F1 20. Spring plate
A. Oil gallery in clutch C1 21. Snap ring
22. Disc and steel plate
23. Snap ring

AFFECTED VIN
108 4A
Multi-disc brake B1
Multi-disc brake B2
Multi-disc brake B1 Multi-disc brake B2

1. Disc brake B1 8. Disc carrier B2 15. Spring plate
2. Piston 9. Sealing ring 16. Snap ring
3. Return spring 10. Sealing ring 17. Piston guides in B2 and B3
4. Snap ring 11. Piston in B2 18. O-ring
5. Cushion spring 12. Sealing ring in piston guide ring 19. Disc and steel plate
6. Disc and steel plate 13. Sealing ring in piston guide ring 20. Snap ring
7. Snap ring 14. Return spring 21. Cushion plate

AFFECTED VIN
4A 109
Rear gear set and center output shaft
Rear freewheel and rear hollow shaft
Rear gear set and center output shaft Rear freewheel and rear hollow shaft
1. Output shaft in center gear set 12. Hollow shaft
2. Needle bearing 13. O-ring
3. Teflon ring 14. Snap ring
4. Thrust washer 15. Freewheel
5. Thrust needle bearing 16. Inner disc carrier and rear sun gear/clutch C3
6. Shim 17. Thrust needle bearing
7. Snap ring 18. Shim
8. Rear gear set 19. Snap ring
9. Thrust washer
10. Clutch C3
11. Rear hollow shaft
C. Oil outlet port in clutch C3
D. Oil inlet port in clutch C3

AFFECTED VIN
110 4A
MEASUREMENT AND ADJUSTMENT

Shaft Axial Clearance Adjust
1. Measure the clearance between the ball bearing and the
parking lock gear.
• Place the measuring bridge on top of transmission
housing and measure the distance from the parking
lock gear (a) to the measuring bridge.
• Measure the distance from measuring bridge to the
ball bearing groove on mating surface with gauge (b).
• Adjust the axial play “E” with adjusting shim.
ex) Distance “a” 49.90 mm

Distance “b” 49.00 mm
Difference 0.90 mm
Axial play “E” 0.40 mm
Shim size 0.50 mm
Axial play (specified value) 0.3 ~ 0.5 mm
[Notice]
Select a proper thickness of shim:

0.2, 0.3, 0.4, 0.5 mm
2. Install a shim.
Measuring bridge 126 589 04 31 00
3. Insert the ball bearing into rear part of transmission

housing.
[Notice]
Measure the clearance between ball bearing (2) and snap

ring. Install the appropriate size of snap ring.
(2.0, 2.1, 2.2 mm)

AFFECTED VIN
4A 111
4. Install the radial sealing with a tool.
Arbor 140 589 12 15 00

AFFECTED VIN
112 4A
Measurement of Disc Brake B1 (Figure 1)
(1) Sectional drawing of brake B1

6b External disc carrier
6c Piston
6f Disc spring
6h Snap ring
69 Friction disc
70a External disc (1.8 mm)
70b External disc (2.8 mm)
70c External disc (4.0 mm)
L Clearance
(2) Procedure (Figure 2)

1. Soak new discs into ATF for one hour before installation.
2. Install the brake B1 discs with the order as shown in
(Figure 1).
3. Install the compressor (078) on external discs (70c) and
apply the 1200N of force to the disc pack. This force is
applied on the marking ring point (small arrow in figure
2). Do not apply excessive force.
4. Determine the clearance (L) at three points between
external disc (70c) and snap ring (6h) with feeler gauge.
• The snap ring (6h) should be contacted to top of the
external disc carrier (6b) during installation.
5 adjust the clearance with proper snap rings if needed.
Specified clearance (L): No. of single face friction disc No. of dual face friction disc
- 2 : 2.2 ~ 2.6 mm - 2.3 ~ 2.7 mm
- 3 : 2.4 ~ 2.8 mm - 2.7 ~ 3.1 mm
- 4 : 2.6 ~ 3.0 mm - 3.0 ~ 3.4 mm
Thickness of B1 snap ring: 2.6, 2.9, 3.2, 3.5, 3.8, 4.1 mm

AFFECTED VIN
4A 113

14a External disc carrier
27 Piston
134d Friction disc
134e Disc spring
144a Snap ring
L Clearance

(Figure 1).
3. Install the compressor (078) on external discs (134a) and
external disc (134a) and snap ring (144a) with feeler gauge.
• The snap ring (144a) should be contacted to top of the
external disc carrier (14a) during installation.
5. adjust the clearance with proper snap rings if needed.
Specified clearance (L): No. of friction disc

- 3 : 1.9 ~ 2.3 mm
- 4 : 2.0 ~ 2.5 mm
- 5 : 2.0 ~ 2.4 mm
Thickness of B2 snap ring: 2.9, 3.2, 3.5, 3.8 mm

AFFECTED VIN
114 4A

2 Automatic transmission housing
(External disc carrier)
14a Piston
133d Disc spring
133e Friction disc
133f Snap ring
L Clearance
(Figure 1).
external disc (133c) and snap ring (133a) with feeler gauge.
• The snap ring (133a) should be contacted to top of the
external disc carrier (133c) during installation.
4. Adjust the clearance with proper snap rings if needed.
Specified clearance (L): 1.0 ~ 1.4 mm

Thickness of B3 snap ring: 3.2, 3.5, 3.8, 4.1, 4.4, 4.7 mm

AFFECTED VIN
4A 115
Measurement of Disc Clutch C1 (Figure 1)
(1) Sectional drawing of clutch C1

86 Piston
86b Disc spring
89d Friction disc
90 Snap ring
L Clearance

2. Install the brake C1 discs with the order as shown in
(Figure 1).
external disc (89c) and snap ring (90) with feeler gauge.
• The snap ring (90) should be contacted to top of the
5. Adjust the clearance with proper snap rings if needed.
- 3 : 2.4 ~ 2.8 mm - 2.7 ~ 3.1 mm
- 4 : 2.6 ~ 3.0 mm - 3.0 ~ 3.4 mm
- 5 : 2.8 ~ 3.2 mm - 3.3 ~ 3.7 mm
- 6 : 2.9 ~ 3.3 mm - 3.6 ~ 4.0 mm
Thickness of C1 snap ring : 2.6, 2.9, 3.2, 3.5, 3.8, 4.1 mm

AFFECTED VIN
116 4A

101 Piston
105d Friction disc
106 Snap ring
107 Disc spring
L Clearance

(Figure 1).
external disc (105c) and snap ring (106) with feeler gauge.
• The snap ring (106) should be contacted to top of the
Specified clearance (L): No. of dual face friction disc

- 3 : 2.3 ~ 2.7 mm
- 4 : 2.4 ~ 2.8 mm
- 5 : 2.5 ~ 2.9 mm
- 6 : 2.7 ~ 3.1 mm
Thickness of C2 snap ring: 2.3, 2.6, 2.9, 3.2, 3.5, 3.8 mm

AFFECTED VIN
4A 117

37 Friction disc (2.1mm)
41a External disc (4.0mm)
44c Piston
44g Snap ring
44h Disc spring
L Clearance

(Figure 1).
3. Install the compressor (078) on external discs (41a) and
external disc (41a) and snap ring (44g) with feeler gauge.
• The snap ring (44g) should be contacted to top of the
- 3 : 2.3 ~ 2.7 mm - 2.3 ~ 2.7 mm
- 4 : 2.4 ~ 2.8 mm - 2.4 ~ 2.8 mm
- 5 : 2.5 ~ 2.9 mm - 2.5 ~ 2.9 mm
Thickness of C3 snap ring: 2.0, 2.3, 2.6, 2.9, 3.2, 3.5 mm

AFFECTED VIN
118 4A
[Notice]
* Free play of each disc - This value is measured by special

tool(208 589 00 21 00)
- Exept “B3”
Component Number of friction plate Single side disk No single side disk
3 2.4 - 2.8 mm 2.7 - 3.1 mm
4 2.6 - 3.0 mm 3.0 - 3.4 mm
C1
5 2.8 - 3.2 mm 3.3 - 3.7 mm
6 2.9 - 3.3 mm 3.6 - 4.0 mm
3 2.3 - 2.7 mm
4 2.4 - 2.8 mm
C2
5 2.5 - 2.9 mm
6 2.7 - 3.1 mm
3 2.3 - 2.7 mm 2.3 - 2.7 mm
C3 4 2.4 - 2.8 mm 2.4 - 2.8 mm
5 2.5 - 2.9 mm 2.5 - 2.9 mm
2 2.2 - 2.6 mm 2.3 - 2.7 mm
B1 3 2.4 - 2.8 mm 2.7 - 3.1 mm
4 2.6 - 3.0 mm 3.0 - 3.4 mm
3 1.9 - 2.3 mm
B2 4 2.0 - 2.5 mm
5 2.0 - 2.4 mm
3 1.0 - 1.4 mm
B3 4 1.0 - 1.4 mm
5 1.0 - 1.4 mm
[Notice]
1) Approximately 1,200 Nm must be applied to keep the piston

down (B1, B2, C1, C2, C3)
2) 10 Nm is to be applied for “B3”

AFFECTED VIN
4A 119
722.6 Circlip thickness Circlip part number Clearance spec.

Shift member in mm in mm
# frictions/spec
C1 2.6 140 994 87 40 (3) 0.5 - 1.8
2.9 140 994 88 40 (4) 0.5 - 1.8
3.2 140 994 89 40 (5) 0.5 - 1.9
3.5 140 994 29 35 (6) 0.5 - 2.0
3.8 140 994 30 35
C2 2.3 140 994 92 40 (3) 0.7 - 1.7
2.6 140 994 93 40 (4) 0.7 - 1.7
2.9 140 994 94 40 (5) 0.7 - 1.8
3.2 140 994 32 35
3.5 140 994 33 35
C3 2.0 140 994 99 40 (3) 0.7 - 1.9
2.3 140 994 10 35 (4) 0.7 - 1.9
2.6 140 994 11 35 (5) 0.7 - 2.0
2.9 140 994 35 35
3.2 140 994 36 35
B1 2.6 140 994 87 40 (2) 0.5 - 1.7
2.9 140 994 88 40 (3) 0.5 - 1.7
3.2 140 994 89 40 (4) 0.5 - 1.8
3.5 140 994 29 35
3.8 140 994 30 35
B2 2.9 140 994 63 35 (4) 0.2 - 1.3
3.2 140 994 62 35 (5) 0.2 - 1.4
3.5 140 994 61 35
3.8 140 994 60 35
4.1 140 994 59 35
B3 3.2 140 994 15 35 (ALL) 1.0 - 1.4
3.5 140 994 16 35
3.8 140 994 17 35
4.1 140 994 41 35
4.4 140 994 42 35
4.7 140 994 43 35

AFFECTED VIN
120 4A

Special Tool
W 126 589 01 62 00 Removal and installation of torque converter

Handle
W 116 589 06 59 00 Fixing automatic transmission

Assembly stand
W 140 589 12 15 00 Installation of sealing ring

Arbor
W 001 589 50 33 00 Removal and installation of

Puller transmission housing ball housing

AFFECTED VIN
4A 121
W 140 589 34 63 00 Fixing automatic transmission

Fixing plate
W 140 589 06 34 00 Removal and installation of transmission housing ball bearing

Collet chuck
W 140 589 13 43 00 Removal and installation of B1, B2, B3 piston

Piston puller
W 126 589 02 09 00 Removal and installation of

Socket collar nut for output shaft

AFFECTED VIN
122 4A
128 589 04 31 00 Measuring the clearance between ball

bearing and parking lock gear
Measuring bridge
W 208 589 00 21 00 Compressing clutch and disc brake

Compressor
W 140 589 15 21 00 Measuring the oil level

Pipstick guage

AFFECTED VIN
4A 123
Fixing Plate Assembly Stand W 140 589 34 63 00

AFFECTED VIN
MEMO
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4B 3
GENERAL INFORMATION
1. OVERVIEW
4WD 2WD
1. TSM54/52 transmission is designed to link the gear ratio, installation dimensions and shapes with current T5
transmission and BTRA automatic transmission. It provides maximum drivability by the optimized engine torque
and gear ratio.
2. TSM54/52 transmission uses linkage type shift elements directly connected to the transmission. It prevent the
transmission from shifting to the reverse gear from 5th gear when shifting to reverse gear. It also prevents the break
and wear.
TSM54/52 MANUAL TRANSMISSION CHANGED BY

AFFECTED VIN
4 4B
Features
3. All gears use the helical type and high strength
materials.
[Notice]
The helical type gear provides less noise.
4. The synchronizing devices are installed in 1/2,

3/4, 5/R gears. To prevent the double engagement,
the independent interlock devices are installed.
[Notice]
TSM54/52 transmission uses the inertia lock type key to
make smooth gear engagement and to provide silent gear
engagement.
5. The clutch release system is available to use CSC

(Concentric Slave Cylinder) or Fork type according
to the vehicle model. New Rexton uses the fork type
clutch release system.
6. The semi-remote control type gear shift mechanism
is used to prevent incorrect shifting.
CHANGED BY TSM54/52 MANUAL TRANSMISSION

AFFECTED VIN
4B 5
2. SPECIFICATIONS
General Specifications
Description DI ENGINE
Length (mm) 4WD: 628.3, 2WD: 672
Distance between shafts (mm) 81
Input torque (kgxm) 34.7 (340 Nm)
Transmission control type Semi-remote
Weight (kg) - not including transmission fluid (kgxm) 4WD: 44, 2WD: 45
Gear ratio/Gear teeth 1st gear 4.315
(input gear: main gear) 2nd gear 2.475
3rd gear 1.536
4th gear 1.000
5th gear 0.807
Reverse gear 3.591
Transmission fluid Specification ATF DEXRON II or III
Capacity ( ) 4WD: 3.6, 2WD: 3.4
Change interval Inspect at every 10,000 km, replace at every
60,000 km (add or replace if necessary)
Tightening Torque
Description Tightening Torque
Oil drain plug 4 ~ 5 kgfxm 39.22 ~ 49.03 Nm
Backup lamp switch (24mm) 3 ~ 4 kgfxm 29.42 ~ 39.22 Nm
Extension housing bolt (14mm) 4.2 ~ 5.7 kgfxm 41.18 ~ 55.89 Nm
Shift top cover bolt (12mm) 1.7 ~ 2.6 kgfxm 16.67 ~ 25.48 Nm
Extension housing spring plug (19mm) 7 ~ 10 kgfxm 68.6 ~ 98 Nm
Offset plate countersunk screw 0.4 ~ 0.6 kgfxm 3.92 ~ 5.88 Nm

AFFECTED VIN
6 4B
3. SYSTEM COMPONENTS
Gear Combinations
5/R shift fork 1/2 shift fork 3/4 shift fork

1st gear 2nd gear
Input gear
Output shaft Input shaft
5th gear Counter shaft 3rd gear 4th gear
Shift Fork and Rail Combinations
Speedometer gear (2WD) Transmission adaptor Interlock plate
Reverse lock plate

AFFECTED VIN
4B 7
Sectional View
4WD

AFFECTED VIN
8 4B
1. Transmission front housing 38. Reverse idler gear

2. Input shaft oil seal 39. Reverse idler spacer
3. Front cover 40. Reverse idler bracket
4. Hexagon flange bolt (17 ~ 26 Nm) 41. Retainer ring
5. Oil drain plug 42. Reverse lock nut
6. Sealing 43. Transmission adaptor
7. Pin 44. Input shaft spacer
8. Input shaft 45. Counter spacer
9. Clutch 4th gear 46. Reverse needle bearing
10. Taper roller bearing (main) 47. Reverse gear
11. Taper roller bearing 48. Reverse clutch gear
12. Counter shaft 49. Reverse counter gear
13. Taper roller bearing (counter) 50. Synchro hub
14. Output shaft 51. Counter 5th gear
15. Inner race (reverse) 52. 5th needle bearing
16. Inner race (1st) 53. 5th gear
17. Needle bearing 54. 5th clutch gear
18. 1st gear 55. Thrust washer
19. 1st clutch gear 56. Spring pin
20. Synchro outer ring 57. 5th outside retainer ring
21. Synchro - middle cone 58. 5th retainer ring
22. Synchro inner ring 59. Counter shaft bushing
23. Synchro spring 60. Counter roller bearing assembly
24. Synchro key 61. Retainer ring
25. Synchro hub 62. Extension housing
26. Double synchro sleeve 63. Output shaft oil seal
27. 2nd gear 64. Offset plate
28. 3rd gear 65. Counter screw
29. 3rd clutch gear 66. Top cover
30. Synchro hub (3 & 4th) 67. Counter oil seal
31. Synchro ring (4/5/R) 68. Shift shaft
32. Single synchro sleeve 69. Shift lever
33. Retainer ring 70. Detent pin
34. Adaptor dowel pin 71. Joint pin
35. Reverse idler shaft 72. Retainer ring
36. Dowel pin 73. Semi remote lever assembly
37. Needle bearing

AFFECTED VIN
4B 9
2WD

AFFECTED VIN
10 4B
1. Transmission front housing 39. Reverse idler spacer

2. Input shaft oil seal 40. Reverse idler bracket
3. Front cover 41. Retainer ring
4. Hexagon flange bolt (17 ~ 26 Nm) 42. Reverse lock nut
5. Oil drain plug 43. Transmission adaptor
6. Sealing 44. Input shaft spacer
7. Pin 45. Counter spacer
8. Input shaft 46. Reverse needle bearing
9. Clutch 4th gear 47. Reverse gear
10. Taper roller bearing (main) 48. Reverse clutch gear
11. Taper roller bearing 49. Reverse counter gear
12. Counter shaft 50. Synchro hub
13. Taper roller bearing (counter) 51. Counter 5th gear
14. Output shaft 52. 5th needle bearing
15. Inner race (reverse) 53. 5th gear
16. Inner race (1st) 54. 5th clutch gear
17. Needle bearing 55. Thrust washer
18. 1st gear 56. Spring pin
19. 1st clutch gear 57. 5th outside retainer ring
20. Synchro outer ring 58. 5th retainer ring
21. Synchro - middle cone 59. Counter shaft bushing
22. Synchro inner ring 60. Counter roller bearing assembly
23. Synchro spring 61. Retainer ring
24. Synchro key 62. Extension housing
25. Synchro hub 63. Output shaft oil seal
26. Double synchro sleeve 64. Offset plate
27. 2nd gear 65. Counter screw
28. 3rd gear 66. Top cover
29. 3rd clutch gear 67. Counter oil seal
30. Synchro hub (3 & 4th) 68. Shift shaft
31. Synchro ring (4/5/R) 69. Shift lever
32. Single synchro sleeve 70. Detent pin
33. Retainer ring 71. Joint pin
34. Adaptor dowel pin 72. Retainer ring
35. Reverse idler shaft 73. Semi remote lever assembly
36. Dowel pin 74. Rear flange
37. Bearing 75. Ball bearing
38. Reverse idler gear 76. Lock nut

AFFECTED VIN
4B 11
Front View and Rear View
Front view
Rear view
1. Oil filler plug 8. Interlock bolt 16. Reverse idler assembly

(tightening torque: 40 ~ 50 Nm) (tightening torque: 40 ~ 50 Nm) 17. Spring pin (6 x 25)
2. Shift rug (3 & 4th) 9. Shift lever 18. Spring pin (6 x 25)
3. Spring pin (6 x 25) 10. Interlock plate 19. Backup lamp switch
4. Shift rug (5 & reverse) 11. Shift rail (1 & 2nd) 20. Concentric slave cylinder adaptor
5. Shift rail (5 & reverse) 12. Shift rug (1& 2nd)
6. Backup lamp switch 13. Shift fork (3 & 4th) (8) Apply Loctite 243
(tightening torque: 30 ~ 40 Nm) 14. Input shaft (6) Apply Loctite DRI LOC 200
7. Shift rail (3 & 4th) 15. Counter shaft

AFFECTED VIN
12 4B
Cross Sectional Diagram of Major Components
Shift rail and 5/R gear
1/2 shift rail
5/R shift rail
3/4 shift rail
Offset lever
5. Apply Loctite DRI LOC 200

10. Apply Loctite 5900
A. Apply Long-term grease MoS2
1. Reverse lock spring 7. TGS bushing 13. Rolling plunger

2. Reverse lock plate 8. Outer spring pin 14. Return spring
3. Reverse lock bolt 9. TGS pin 15. Spring plug
4. Stopper plate 10. Lock bolt (tightening torque: 30 ~ 35 Nm)
5. Air vent (tightening torque: 17 ~ 26 Nm)
(tightening torque: 30 ~ 40 Nm) 11. Offset lever A. Apply Long-term grease MoS2
6. Lock washer 12. Offset lever bushing when installing the offset lever.

AFFECTED VIN
4B 13
Power Flows
1st gear
Counter shaft
4th 3rd 2nd 1st Reverse 5th

gear gear gear gear gear gear
2nd gear


AFFECTED VIN
14 4B
Power Flows (Cont’d)
3rd gear

4th gear


AFFECTED VIN
4B 15
Power Flows (Cont’d)
5th gear

Reverse gear
Reverse
gear

gear gear gear gear idler gear
gear

AFFECTED VIN
16 4B
4. SHIFTING MECHANISM
Interlock System
Interlock system prevents the gears from meshing over two sets.
Interlock bolt
Interlock plate Inner shift lever
1/2 3/4 5/R

(3/4 & 5/R lock) (1/2 & 5/R lock) (1/2 & 3/4 lock)
Reverse Interlock System

Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward.
Neutral 5/R select 5/R shift 5th gear disengaged

AFFECTED VIN
4B 17
Offset Lever and Rolling Plunger

To make the next shift easier, the offset lever applies a reaction force to shift lever toward center position of gear
selection gate after a gear has been selected.
1. Offset lever 3. Shift shaft

2. Shift lever 4. Rolling plunger (rolling plunger return spring and ball)

AFFECTED VIN
18 4B
1. Shift check device

It determines the shift fork position (N or each gear) and Detent pin
gives a detent movement to notice a shift lever seating
when operating the shift lever.
Adaptor - T/M
Also, it prevent the selected gear from getting out of its
meshed position.
3 & 4 Rall Set ball
2. Gear jump out locking device

It prevents the shift lever is beyond the correct shift Hub spline Sleeve spline
position while shifting.
Clutch gear spline
3. Guiding a control direction and preventing an over stroke.
Offset lever Offset plate
Backup Lamp Switch

It is normal open type switch. Its circuit is formed when the
reverse gear is selected.
[Notice]
Installation Notice
• Sealant: Loctite DRI LOC 200
• Tightening torque: 3 kg•m ~ 4 kg•m

AFFECTED VIN
4B 19
Synchronizer
Composition
It consists of synchronizer hub, sleeve, ring, key and spring (1/2, 5/R, and 3/4 synchronizer are different from each
other).
- 3/4 and 5/R shift: Single cone type
- 1/2 shift: Double cone type - Improving the capacity to bigger engine torque of 1/2 shift (added synchronizer inner
cone and middle cone)
Single cone type Double cone type
1/2 shift 3/4 shift 5/R shift

1/2 shift 3/4 shift 5/R shift
1. Synchronizer sleeve 5. Synchronizer key locking ring

2. Synchronizer hub 6. Synchronizer inner cone
3. Synchronizer ring 7. Synchronizer middle cone
4. Synchronizer key
[Notice]
Be careful not to mix up the 1/2 shift synchronizer sleeve with 3/4 or 5/R shift synchronizer sleeve.
The 3/4 synchronizer hub also different from 1/2 and 5/R synchronizer hub (different oil gallery).

AFFECTED VIN
20 4B
Synchronizer element
A cone or sleeve that slides to and fro on the transmission main shaft and makes the gears rotate at the same speed to
prevent clash when the gears are about to mesh. Whenever a vehicle is rolling, the transmission main shaft is turning
and the clutch gear is spinning. Even though the clutch is disengaged, the clutch gear continues to spin until friction
slows it down or stops it. Thus when the driver shifts into another gear he is trying to mesh gears that may be moving at
different speeds. By using synchronizers, the possibility of broken or damaged teeth is reduced and shifting effort is
lowered.
[1st step]
Sleeve Synchronizer ring

Gear spline area
Projected area
Synchronizer key
Spline area of sleeve

Spline area of synchronizer ring

[2nd step]
Gear spline area
Synchronizer key
Spline area of sleeve Spline area of synchronizer ring

[3rd step]
Gear spline area
Synchronizer key
Spline area of sleeve
Spline area of synchronizer ring

AFFECTED VIN
4B 21
Bearing
The needle bearings are introduced to each gear and the taper roller bearings are used for input and counter shaft in
Taper roller bearing Needle bearing
1. Taper roller bearing 3. Needle bearing for reverse gear

(input shaft, counter shaft and output shaft) (with cut out area)
2. Needle bearings for 1/2 and 3/4 shift 4. Needle bearing for 5th gear
End Play of Taper Roller Bearing
1. Taper roller bearing for input shaft A. End play A: 0.85 ~ 2.28 mm
2. Taper roller bearing for counter shaft B. End play B: 1.17 ~ 1.97 mm
[Notice]
Use the following spacers to adjust the end play (A or B) between input shaft and counter shaft.
(Specified range of end play: 0.05 ~ 0.1 mm)
• For input shaft: 0.75 ~ 1.45 mm (15 spacers with increment of 50 µm)
• For output shaft: 0.4 ~ 1.45 mm (10 spacers with increment of 50 µm)

AFFECTED VIN
22 4B
Thrust Ring (Washer)

When the driving force from engine is transmitted to the output shaft of transmission, each shaft and gear assembly
receives the axial force and this force acts as a resistance to rotating gears.
Input shaft Thrust ring 1 3/4 1/2 5/R Thrust washer Output shaft
synchronizer synchronizer synchronizer
Thrust washer
Counter gear assembly
Head set 3rd 2nd 1st Reverse 5th

Lubrication
Transmission oil: ATF DEXRON II or III
Initial installation for taper roller bearing and needle roller bearing, lubrication for shift rail: MoS2 Grease
Oil level
Oil drain screw
Installation Notice
Sealant on oil drain screw during installation: Loctite DRI LOC 200

AFFECTED VIN
4B 23
4WD 2WD
1. Oil filler plug

2. Air vent
[Notice]
Sealant on oil drain screw during installation: Loctite DRI LOC 200

AFFECTED VIN
24 4B
5. DIAGNOSTIC INFORMATION AND PROCEDURES

Trouble Diagnosis
Will not shift Control lever assembly broken or damaged. Replace control lever and housing assembly.
(control lever moves) Damaged offset lever, shift fork, selector Remove extension, adapter or case cover.
place or selector arm. Check or replace damaged parts.
Hard shift or control lever Clutch not releasing. Adjust or replace clutch.
will not move into gear Improper or low transmission oil. Add or replace with specified oil.
Shift or shift rail binding. Remove extension, adapter or case cover.
Check or replace damaged parts.
Binding of sliding synchronizers or gears. Remove extension, adapter or case cover.
Check synchronizers and gears and replace
damaged parts.
If reverse only, faulty backup switch. Check or replace backup switch.
Worn or damaged flywheel pilot bushing. Replace pilot bushing.
Gears crash when shift- Engine idle speed too high. Adjust idle speed to specified speed.
ing Damaged or faulty clutch. Adjust or replace clutch.
Pilot bearing between input shaft and output Replace or check roller bearings.
shaft binding.
Damaged synchronizer. Check or replace synchronizer parts.
Bell housing misaligned. Align bell housing and bore.
Damaged gear(s). Check or replace gear(s).
Worn or damaged flywheel pilot bushing. Replace pilot bushing.
Transmission jumps out Loosened transmission or flywheel housing Tighten bolts to specified value. Realign if
bolts, improper alignment. necessary.
Synchronizer damaged or excessively worn. Check or replace synchronizer parts.
Blocking ring damaged, worn index slots or Check or replace blocking ring.
friction surfaces worn or damaged.
Excessive countershaft end play. Check worn or damaged parts. Adjust shim
thickness using roller bearings if necessary.
Worn or damaged fork due to loosened shaft, Check for wear or damaged. Replace worn
rail or shifting fork. or damaged parts.
Transmission locked in Fork or offset lever loose on shaft or rail. Replace extension, adapter or case cover.
one gear Check or replace loose parts on shaft or rail.
Replace roll pin(s).
Worn or damaged forks, offset lever, shaft Remove extension, adapter or case cover.
or rail. Check for wear or damaged. Replace dam-
aged parts.

AFFECTED VIN
4B 25

Transmission locked in Worn or damaged synchronizer. Check worn or damaged synchronizer parts
one gear and replace if necessary.
Worn or damaged gears. Check worn or damaged gears and replace
if necessary.
Transmission noise Improper or low transmission oil. Add or drain and replace with proper oil.
Loose bolts or other attaching parts. Tighten as specified.
Improper flywheel housing to engine crank- Realign correctly.
shaft alignment.
Noisy transmission bearing. Check bearings, bearing rollers and parts for
wear or damage. Replace if necessary.
Noisy gears. Check for worn or damaged gears(including
speedometer gear). Replace if necessary.
Transmission leakage Leakage from transmission. Clean all exposed surfaces, then check for
leaks.
Vent or breather clogged. Clean or replace vent or breather.
Too much oil. Check oil level.
Loose bolts at sealing faces. Tighten as specified.
Improperly applied sealant. Clean leaking surfaces. Reapply sealant.
Worn or damaged oil seal. Replace oil seal.

AFFECTED VIN
26 4B
Diagnosis Table
Applicatio
1 Shift Hop-out
2 Shift Gear Crash
3 Shift Block-out
4 Hard Shift
5 Noise in Reverse Gear
6 Noise in 5th Gear
7 Noise in 4th Gear
8 Noise in 3rd Gear
9 Noise in 2nd Gear
10 Noise in 1st Gear
11 Noise in All Speeds
12 Leak at Transmission Rear Part
13 Leak at Transmission Center Part
14 Leak at Transmission Front
Possible Faulty Part
Transmission Case
Extension Housing
Shift Cover / Shift Shaft
Shift Control Lever
Input Bearing Retainer
Input Gear Set
3rd Speed Gear Set
2nd Speed Gear Set
Reverse Speed Gear Set
1st Speed Gear Set
5th Speed Gear Set
Clutch Housing and Release Derive
Crankshaft Pilot Bushing and Release Bearing
Input Bearing
Main Shaft Input Bearing
Main Shaft Thrust Bearing
3rd Speed Gear Bearing
2nd Speed Gear Bearing
1st Speed Gear Bearing
Reverse Idler Gear Bushing
Counter Shaft Front Bearing
Counter Shaft Rear Bearing
Counter Shaft Thrust Bearing
5th Speed Drive Gear Bearing
Slip Yoke Bushing
Slip Yoke Seal
Speedometer Drive / Driven Gears
Speedometer Driven Gear Housing
Input Shaft Seal
1 - 2 Synchronizer Assembly
3 - 4 Synchronizer Assembly
5th Synchronizer Assembly
AFFECTED VIN
4B 27
6. CIRCUIT DIAGRAM (BACKUP LAMP)

AFFECTED VIN
28 4B
ON-VEHICLE SERVICE
1. OIL CHECK/CHANGE
[Notice]
Do not check or change the oil Immediately after driving off.

It may cause serious hurt.
Place the vehicle on the flat and even ground and stop the
engine. After 5 minutes, check the oil level.
1. Remove the oil level plug (1) and check the oil level.
[Notice]
If the oil level is up to the bottom line of plug hole, it is OK.
1. Oil level check plug

2. If needed, add the oil through the oil level plug hole (1). 2. Oil drain plug
3. Fully tighten the plug and check the oil leaks.
4. If the oil level is up to the bottom line of plug hole, it is
OK.
[Notice]
• The oil in manual transmission is major element for mechanical durability of transmission. Check the oil level with a
specific interval and add if needed.
• The oil replacement should be done at the qualified and authorized service station.

AFFECTED VIN
4B 29

4WD
Propeller shaft - Rear
Transfer case
Mounting insulator
Propeller shaft - Front
Cross member -Center

T/M assembly
2WD
Propeller shaft - Rear
Mounting insulator
Cross member -Center

T/M assembly

AFFECTED VIN
30 4B

Preceding work: Disconnect the battery negative cable.
1. Remove the center cup holder assembly (1), shifting lever nob (2) and center console cover (3).
2. Unscrew the shifting lever mounting nut (A) and the shifting lever cover mounting nut (12 mm - 2 EA) (B).
[Notice]
IIf the oil should be changed, remove the oil drain plug in
transmission housing and fully drain the oil. And, retighten
the plug.
Installation Notice
3. Unscrew extension bar - sem remote mounting nut (1) and remove a pin (A) which connects the shifting lever and
extension rod.

AFFECTED VIN
4B 31
4. Unscrew 6 bolts at T/M output shaft flange, and fix the

propeller shaft on the body.
5. Disconnect the back up lamp switch connector and air bleeder hose from the T/M assembly.

AFFECTED VIN
32 4B
6. Disconnect the clutch oil hose (Fix the hose with a tool to prevent oil leakage) at “A” marked position.
7. For easier work, unscrew three T/M housing bolts (1) and disconnect stabilizer bar from link (A) to have the
stabilizer bar down to sub frame.

AFFECTED VIN
4B 33
8. Securely support the T/M with a hydraulic jack and then, remove center cross member.
- Center cross member mounting

bolts (A) (14 mm - 8EA)
- T/M mounting insulator bracket
bolts (B) (14 mm - 4EA)
9. Unscrew the T/M housing bolts.

AFFECTED VIN
34 4B
10. Drop the hydraulic jack with T/M slowly.


AFFECTED VIN
4B 35
T/M ASSEMBLY
1. ASSEMBLY OVERVIEW
Top Cover Assembly
1. Top cover assembly - semi remote 7. Pin 13. Stud bolt

2. Nut 8. Joint housing 14. Bolt
3. Remote shift lever 9. Offset lever 15. Shift top cover
4. Shift boot - inner 10. Control housing arm insulator 16. Offset control lever
5. Snap ring 11. Semi remote kit assembly 17. Control shift spring
6. Lining shift socket 12. Shift rail

AFFECTED VIN
36 4B
T/M Housing & Adaptor, Extension Housing
1. Front cover 10. Bolt 18. Shift lever rail-inner 26. 3rd/4th shift rail
2. Spacer 11. Extension housing 19. 1st/2nd shift fork 27. Reverse lock nut
3. T/M housing 12. Oil seal 20. 3rd/4th shift fork 28. 5th/R shift rail
4. Filler plug 13. Rear cover 21. Inner lock plate 29. Spacer
5. Back up lamp S/W 14. Lock nut 22. Shift lug 30. Roller bearing
6. Drain plug 15. Rear flange 23. T/M adaptor 31. Reverse idler shaft
7. Adaptor 16. Bearing 24. 5th/R shift fork 32. Reverse idler gear
8. Clutch cylinder 17. Shift lug 25. 1st/2nd shift rail 33. Reverse idler bracket
9. Pipe

AFFECTED VIN
4B 37
Gear Assembly
1. Input shaft assembly 8. Synchronizer assembly (1st/2nd) 15. Taper bearing

2. 4th shift gear 9. Reverse shift gear 16. Counter gear assembly
3. Synchronizer assembly (3rd/4th) 10. Synchronizer assembly (5th/Reverse) 17. Retainer ring-counter
4. 3rd shift gear 11. 5th shift gear gear
5. 2nd shift gear 12. Ball bearing 18. Taper bearing
6. Main shaft 13. Counter gear-5th 19. counter reverse spacer
7. 1st shift gear 14. Counter gear-Reverse

AFFECTED VIN
38 4B
2. DISASSEMBLY
Preceding work: 1. Drain the T/M oil.
2. Remove the T/M from vehicle.
1. Remove the T/M top cover assembly.
[ 2WD Manual Transmission ]

1) Unscrew the rear flange lock nut (1) and bolts (2) to
remove rear flange.
2) Remove the T/M rear cover (A).
2. Remove the spring pin (6 x 25), as the offset lever pulled

side and remove the offset lever.

AFFECTED VIN
4B 39
3. Remove the bolts from the extension housing.
4. Remove the extension housing with a special tool.
[Notice]
Remove the offset lever and rolling plunger with the extension
housing. Be careful not to drop them.
5. Remove the rear ball bearing with a puller and remove

the speedometer driven gear.
6. Remove the 5/R shift fork spring pin (6 x 28).

AFFECTED VIN
40 4B
7. Pull the counter gear (5th gear) retainer ring out from the
ring groove with a ring pliers.
[Notice]
Be careful not to stiffen the retainer ring.
8. Spread the retainer ring and remove the counter 5th gear
with a puller.
9. Remove the counter reverse spacer.

AFFECTED VIN
4B 41
10. Remove the 5th gear retainer ring with a ring pliers.
11. Remove the thrust washer from the shaft.
12. Remove the 5th gear and pull out the spring pin.
[Notice]
Be careful not to lose or mix the spring pins.
13. Remove the 5th gear needle bearings (2).
[Notice]
Be careful not to lose or mix the needle bearings.

AFFECTED VIN
42 4B
14. Remove the 5th gear synchronizer ring.
[Notice]
Store at a safe place not to be mixed with other synchronizer

rings.
15. Remove 5/R gear retainer ring from the shaft with a ring
pliers.
[Notice]
Store the ring with the relevant gear to prevent incorrect

installation.
16. Remove the 5/R synchronizer hub assembly, the reverse

gear and the shift fork at a time.
17. Remove the counter reverse gear.

AFFECTED VIN
4B 43
18. Remove the counter reverse gear needle bearing.
[Notice]
Store the needle bearing with the relevant gear.
19. Remove the interlock bolt.
20. Remove the transmission adaptor from the transmission

housing.
[Notice]
Be careful not to damage the adaptor mating surface.
21. Remove the gear assembly from the housing.
[Notice]
Do not forcefully remove the gear assembly. It may damage

the level grooves resulting in incorrect installation. Carefully
remove the gear assembly.

AFFECTED VIN
44 4B
22. Remove the main and counter gear assembly.

• Pull out the pins from 5/R and 1/2 shift rails and
remove the shift rails through rear section of adaptor.
• Pull out the locking pins from shift forks.
23. Remove the shift rail and shift fork. Place the output shaft
and counter gear on the special tool.
24. Place the output shaft assembly with the 1st gear facing
down and remove the intermediate taper roller bearing
with a special tool.
[Notice]
• To prevent the bearing damage, securely seat the special

tool before removing the intermediate taper roller bearing
that is pressed in.
• Do not use general bearing puller.
25. Remove the 3/4 gear retainer ring.
[Notice]
Be careful not to lose or mix the retainer ring.

AFFECTED VIN
4B 45
26. Remove the 3/4 gear synchronizer hub and single

synchronizer sleeve and 3rd gear with a special tool.
Pull out the needle bearing.
27. Loose the 1/2 gear and hub and double synchronizer
sleeve with a press.
28. Remove the reverse gear inner race.
29. Remove the main taper roller bearing.

AFFECTED VIN
46 4B
30. Remove the inner race and 1st gear from 1st gear, and
remove the needle bearing from the shaft.
[Notice]
Store the disassembled gears by relevant components.
31. Remove the synchronizer inner intermediate cone and

outer ring in 1st gear side.
Synchronizer Synchronizer Synchronizer

under ring intermediate outer ring
cone
32. Remove the 1/2 gear synchronizer hub along with double
synchronizer sleeve.
33. Remove the synchronizer inner intermediate cone and

outer ring in 2nd gear side.
Synchronizer Synchronizer Synchronizer

outer ring intermediate under ring
cone

AFFECTED VIN
4B 47
34. Remove the 2nd gear and needle bearing.
35. Remove the oil seal from the extension housing.

AFFECTED VIN
48 4B
3. INSPECTION BEFORE REASSEMBLY

1. Clean all the disassembled components with solvent and
dry them with compressed air.
Check the components for crack, wear and damage.
• Case, extension housing, shift lever
• Input bearing retainer
• Counter shaft rear bearing retainer
2. Check the bearing and shaft supporting area for wear
and replace if needed.
3. Check the surface conditions on:

• Input shaft
• Main shaft and gears
• Counter shaft and 5th drive gear
4. Reverse idler shaft and gears
[Notice]
Replace the excessively worn components. Do not grind the

precisely machined components.
5. Check the following components for wear:

• Selector arm
• Interlock plate
• 1/2 and 3/4 shift fork
• Shift shaft
• Detent/guide plate and offset lever
• Each shift lever shift fork

AFFECTED VIN
4B 49
• Hub and sleeve

• 1/2 shift fork, pads, synchronizer sleeve
• 3/4 shift fork, pads, synchronizer sleeve

• 5th gear shift rail/fork, pads, synchronizer sleeve
• Reverse fork and reverse idler gear sleeve
6. Check the following components for excessive wear:

• Crankshaft bushing in front of input shaft
• Clutch release bearing
• Main shaft pilot bearing roller
• Main shaft thrust bearing mating surface
• Main shaft speed gear roller bearing
• Main shaft rear bearing
• Counter shaft front and rear bearing
7. Check the gear sets for wear in teeth surface.

8. Check the gear sets for excessive wear, crack and break
and replace if needed.

AFFECTED VIN
50 4B
9. Check the conditions of each synchronizer sleeve and

hub.
• Engagement of hub and sleeve
• Wear on cone clutch surface in blocking ring (brass)
engaging the gears
10. Measure the clearance between blocking ring and speed

gear.
• New 1/2 gear blocking ring: 1.1 ~ 1.5 mm
• New 3/4 gear blocking ring: 1.1 ~ 1.5 mm
[Notice]
If the clearance is excessive, replace it with new one. Otherwise,

it may cause the missing or breakage of the gears.
11. Check the speed gear clutch and synchronizer sleeve

for damage in teeth surface.
12. Check the engagement of synchronizer sleeve and speed
gear clutch.

AFFECTED VIN
4B 51
4. REASSEMBLY
1. Install the 2nd gear needle bearing.
[Notice]
The 1st/2nd/3rd gear needle bearings have one bearing row

and the sizes of them are same. The reverse needle bearing
has two bearing rows. The 5th needle bearing is smaller than
others and consists of two bearings.
2. Install the 2nd gear and synchronizer outer ring,

intermediate cone and inner ring in regular sequence.
3. Insert three keys into 1/2 synchronizer hub and double

synchronizer sleeve. Install the synchronizer spring in
offset so that it should not be missed out.
[Notice] Groove
1/2 gear double synchronizer sleeve doesn’t have a step at

edge, however, 3/4 and 5/R gears have it.
No step

AFFECTED VIN
52 4B
4. Install the 1/2 synchronizer hub and double synchronizer

sleeve into the output shaft by using a press.
[Notice]
Make sure that the hub groove faces to 2nd gear. Align the
synchronizer key and the synchronizer ring groove in 2nd
gear.
5. Install the synchronizer outer ring, intermediate cone and

inner ring in regular sequence.
6. Install the 1st gear.
7. Install the 1st gear needle bearing.

AFFECTED VIN
4B 53
8. Install the 1st gear inner race by using a press.
[Notice]
The 1st inner race doesn’t have a step at edge.
9. Install the main taper roller bearing by using a press.
10. Install the reverse fear inner race by using a press.
[Notice]
The reverse gear inner race has a step at edge.
11. Place the output shaft assembly with the 1st gear facing
downward and install the 3rd gear.

AFFECTED VIN
54 4B
12. Install the 3rd gear.
13. Install the synchronizer ring on the 3rd gear.
14. Insert three keys into 3/4 synchronizer hub and

[Notice]
3/4 gear synchronizer sleeve have a step at edge. Place the

groove in hub to face the 3rd gear and align the synchronizer
key and the synchronizer ring groove in 3rd gear.

AFFECTED VIN
4B 55
15. Install the 3/4 gear retainer ring.
[Notice]
Adjust the end play between retainer ring and hub to a range
of 0.05 to 0.1 mm by using a thickness gauge.
16. Install the intermediate taper roller bearing by using a

press.
[Notice]
Apply the force on the inner race other than other points.
17. Install the input shaft along with the 4th synchronizer
ring. Place the input shaft to face downward on the work
bench.

AFFECTED VIN
56 4B
18. To relieve the load to the shaft bearing, insert a special

tool.
19. Place the counter gear on the work bench with the same
manner.
20. Install the transmission adaptor on the input shaft and

the counter gear.
21. Install the reverse gear needle bearing.
[Notice]
The reverse gear needle bearing has two bearing rows and
the others consist of two bearings.

AFFECTED VIN
4B 57
22. Install the reverse gear in the shaft.
23. Install the synchronizer ring on the reverse gear.
24. Insert three keys into 5/R synchronizer hub and

[Notice]
Place the groove in hub to face the 5th gear and align the
synchronizer key and the synchronizer ring groove in reverse
gear.
25. Install the 5/R gear retainer ring.
Notice
[Notice]

AFFECTED VIN
58 4B
26. Install the counter reverse gear by using a press.
[Notice]
Place the counter reverse gear with a longer protrusion facing

to the adaptor.
27. Install the counter reverse spacer.
28. Install the 5th synchronizer ring.
29. Install two 5th gear needle bearings in line.

AFFECTED VIN
4B 59
30. Install the 5th gear.
31. Install the counter 5th gear by using a press. At this

time, place it with a longer protrusion facing to the adaptor.
32. Install the counter 5th gear retainer ring.
33. Install the locking ball.

AFFECTED VIN
60 4B
34. Install the thrust washer (t= 5.0) while aligning the key
grooves.
35. Install the retainer ring.
[Notice]
36. Install the inner race of counter roller bearing by using a

press.
[Notice]
Place it with a protrusion facing to the adaptor
37. Place the gear assembly on a work bench in parallel.

AFFECTED VIN
4B 61
38. Install the inner shift lever and interlock plate in the 3/4
gear shift rail. Interlock plate Inner shift lever
[Notice]
The spring pin for locking the inner shift lever is small (6 x
22) and its slot should face to the shaft.
39. Install the 3/4 hear shift rail in the transmission adaptor.
40. Install the 3/4 gear shift fork.
[Notice]
The 1/2 and 5/R shift fork are compatible, but 3/4 shift fork
isn’t. Also, the 3/4 shift fork is chamfered, but 1/2 and 5/R
aren’t.
41. Install the 3/4 shift fork and shift rail while aligning the
grooves.

AFFECTED VIN
62 4B
42. Install the 1/2 gear shift rail in the transmission adaptor.
43. Partially engage the 1/2 shift fork to the shift rail.
44. Install the shift lug on the 1/2 shift rail. Install the reverse
lock spring, reverse lock plate and reverse lock bolts.
[Notice]
Align the 1/2 gear shift lug and interlock plate mating surface.
45. Partially engage the 5/R gear shift fork to the shift rail.

AFFECTED VIN
4B 63
46. Install the 5/R shift lug and 5/R shift fork on the shift rail.
[Notice]
Align the 5/R shift lug and the interlock plate surface.
47. Install the spring pin into the 1/2 shift lug. (intermediate
size: t= 6 x 25)
[Notice]
Place the spring pin with the pin slot facing to the shaft.
48. Install the spring pin into the 5/R shift lug. (intermediate
size: t= 6 x 25)
[Notice]
49. Install the spring pin into the 1/2 shift fork. (longer size:
t= 6 x 28)
[Notice]

AFFECTED VIN
64 4B
50. Install the spring pin into the 5/R shift fork. (longer size:
t= 6 x 28)
[Notice]
51. Install the reverse lock plate and reverse lock spring on
the 1/2 shift rail.
52. Install the stopper plate on the 3/4 shift rail and insert the
spring pin. (intermediate size: t= 6 x 25)
[Notice]

AFFECTED VIN
4B 65
53. Apply the sealant to the transmission housing.
[Notice]
Sealant: LOCTITE 5900
54. Install the gear assembly and the adaptor to the

55. Install the speedometer driven gear on the output shaft
and install the ball bearing by using a press.
56. Apply the sealant to the extension housing. Press down

the extension housing against the adaptor.
[Notice]
Sealant: LOCTITE 5900

AFFECTED VIN
66 4B
57. Tighten the extension housing bolts.
58. Insert the offset lever into the 3/4 rail and install the spring
pin. (intermediate size: t= 6 x 25)
59. Apply the grease into the offset lever bushing.
60. Apply the grease to the interlock bolt and insert it into
the interlock plate hole and bolt hole.
[Notice]
Make sure that the gear is at neutral position. If not, the

interlock bolt cannot be inserted into the interlock plate
hole.
Sealant LOCTITE 243


AFFECTED VIN
4B 67
Transmission Adaptor
1. Remove the reverse idler retainer ring.
2. Remove the components as follows and install in the

reverse order of removal.
• Unscrew the reverse lock nut and idler bracket bolts
and remove the bracket and spacer.
• Remove the reverse idler gear and the needle bearing.
• Pull out the dowel pin and remove the reverse idler
shaft.
Installation Notice
Reverse idler bracket bolt 17 ~ 26 Nm

Reverse lock nut 70 ~ 100 Nm
Backup Lamp Switch

Remove the backup lamp switch with 24 mm wrench. Apply
the sealant when installing.
Installation Notice
Sealant LOCTITE DRI LOC 200


AFFECTED VIN
68 4B
INSPECTION/MAINTENANCE
SHIM ADJUSTMENT
1. Unscrew the bolts and remove the front fork cover.
[Notice]
The shim adjustment is necessary when replacing the

housings, counter gear, input shaft and output shaft.
2. Separate the front fork cover from the housing.
3. Remove the input spacer.

AFFECTED VIN
4B 69
4. Remove the counter spacer.
5. Prepare the special tools and dial gauge.
6. Place the transmission with the output shaft facing

downward and set the special tool on the counter gear
and input shaft. Apply a proper force to the counter gear
and input shaft so that the end plays for bearings are
maximized.
7. Tighten the adjusting bolt on the special toll to hold the

bearings.

AFFECTED VIN
70 4B
8. Set up the dial gauge on the transmission housing surface

and put the gauge needle to “0” point.
9. Put the probe end of the gauge on the taper roller bearing
outer race in counter gear and measure the end play.
* If the measured value is out of the specified range,
adjust it by using spacers.
End play 0 ~ 0.05 mm
10. Put the probe end of the gauge on the main taper roller
bearing outer race and measure the end play.
* If the measured value is out of the specified range,
adjust it by using spacers
End play 0 ~ 0.05 mm
11. Apply the sealant to the front fork cover and tighten the
bolts. Measure the starting torque after installation.
Starting torque 20 ~ 25 Nm
Sealant LOCTITE 5900

AFFECTED VIN
4B 71
661 589 04 62 00 (W 99 31 007 0B) Removal/installation of transmission

Transmission fixture
W 99 31 001 1B Removal of pressed in taper roller bearing

Bearing puller
W 99 31 002 1B Pressing of the bearing and gear

Pressure pipe
W 99 31 003 1B Providing a space to input shaft

Insert key bearing

AFFECTED VIN
72 4B
W 99 31 004 1B Assembly of gears and bearings on

Die the shafts
W 99 31 005 2B Measurement of taper roller

Holder bearing end play
W 99 31 006 1B Measurement of taper roller

Dial gauge holder bearing end play
W 99 31 007 1B Removal of 5/R synchronizer hub

Drift assembly, reverse gear and shift fork

AFFECTED VIN
4C 3
GENERAL INFORMATION
1. OVERVIEW
Driving Elements Operating Elements
The driving elements consist of two flat surfaces machined The clutch control system consists of the clutch pedal,
to a smooth finish. clutch master cylinder, concentric slave cylinder.
One of these is the rear face of the engine flywheel and This system directly releases the clutch by using hydrau-
the other is the clutch cover pressure plate. The clutch lic pressure while the conventional clutch system releases
pressure plate is fitted into a clutch steel cover, which is the clutch by using release lever and release fork.
bolted to the flywheel. This system provides higher efficiency than conventional
clutch system, and its durability is superior.
Driven Elements
The driven element is the clutch disc with a splined hub Adaptor (mounted on transmission case)
which is free to slide lengthwise along the splines of the Concentric slave cylinder pipe (mounted inside of
input shaft. transmission)
The driving and driven elements are held in contact by Concentric slave cylinder (mounted inside of transmission)
spring pressure. This pressure is exerted by a diaphragm
spring in the clutch cover pressure plate assembly.
B. Concentric slave cylinder pipe
A. Adaptor
D. Clutch assembly C. Concentric slave cylinder
CLUTCH ASSEMBLY CHANGED BY

AFFECTED VIN
4 4C
SAT (Self Adjusting Technology)

: SAT is new clutch which adjusts the clutch free play according to the wearness of clutch disc.
Operation description
Diaphram spring rotates the adjusting equipment as clutch disc is wearing and so, pressure plate is pushed to clutch
disc side at the amount of wearness.
* Disc wear (Free play) → Diaphram spring (1) → Adjusting equipment (2, 3) → Pressure plate (4)
Clutch assembly Adjusting equipment
Clutch replacement
1) Replacement of cluch disc → Replace the clutch cover assembly together.
2) Reinstallation of clutch disc & cover → Apply the zig set (SST) on the clutch cover set.
(Engine removal and reinstallation, Flywheel related job, Checking the clutch assy)
[Notice]
When reinstall the clutch assembly without the special zig, Disc can be slip and worn easily.
Installation of special zig

1) Identify the SAT clutch with adjusting equipment around the clutch cover.
2) Adapt the zig set(4 pieces) between the clutch cover and diaphram spring around (Refer to the picture).
Diaphram
Adjusting
equipment
Cover
Zig for clutch removal

and installation
CHANGED BY CLUTCH ASSEMBLY

AFFECTED VIN
4C 5
2. COMPONENTS
1. Concentric slave cylinder cover 7. Hose 12. Clutch housing

2. Concentric slave cylinder 8. Pipe 13. Switch
3. Clutch cover 9. Clutch fluid chamber 14. Bracket
4. Clutch disk 10. Clutch hydraulic line 15. Clutch pedal
5. Adaptor 11. Clutch pin (B) 16. Clutch pedal pad
6. Clutch master cylinder

AFFECTED VIN
6 4C
Clutch Fluid Reservoir Tank

(Common Usage with Brake Oil Reservoir Tanks)
Clutch / Brake fluid

reservoir tank
• Operation
Concentric
Clutch master
Clutch pedal Pusha rod (piston) slave Clutch cover Clutch disk
cylinder
cylinder

AFFECTED VIN
4C 7
Clutch Release Chamber

• Clutch release chamber keeps the oil pressure stable in the clutch hose & pipe and also helps the oil pressure
transfer quickly by keeping some oil pressure every moments.
Clutch Pedal
Clutch pedal
• Pendant type clutch pedal (leverage effect is applied to reduce the effort to the feet).
• Clutch pedal has freeplay to prevent the clutch disk heated and damaged.
If this freeplay is too wide, engine power disconnection is difficult and arise the gear damage with abnormal noise.

AFFECTED VIN
8 4C
Clutch Assembly
• Clutch assembly is composed of clutch cover (diaphram spring, pressure plate), clutch disk.
[Notice]
Because self adjust clutch includes compensation function

to make up for the wearness of clutch disk, this clutch
assembly applied to the vehicle can be oprated with constant
force in the clutch pedal.
• Clutch disk connect the power from engine flywheel to the

transmission input shaft by the diaphram spring
compressing the clutch disk which has spline in the middle
frinction disk.

AFFECTED VIN
4C 9
Cross Sectional View of Clutch Assembly
1. Transmission housing 4. Bolt

2. Clutch disc assembly 5. Washer
3. Clutch disc cover assembly 6. Bolt

AFFECTED VIN
10 4C
Specifications
Operating type Hydraulic
Clutch pedal Type Suspended
Maximum pedal stroke Diesel engine equipped vehicle: 140 mm
Gasoline engine equipped vehicle: 150 mm
Pedal free play 5 ~ 10 mm
Clutch disc Type Single dry diaphragm
Dimension of facing 240 X 155 X 4.0 mm
Facing size/quantity 263 cm2/2
Thickness of disc Free: 9.4 ~ 10.0 mm
When loaded: 9.0 ± 0.3 mm
Clutch cover assembly setting force Min. 720kgf
Clutch master cylinder Stroke 28.4 mm
Inner diameter φ 17.46 mm
Concentric slave cylinder Stroke 7.0 mm
Sectional area 706.2 mm2
Clutch fluid DOT 4
Tightening Torque
Description Tightening Torque
Clutch housing bolt (8 locations) 5.0 ~ 6.0 kgf•m 50 ~ 60 Nm
Clutch cover (pressure plate) bolt 2.1 ~ 2.7 kgf•m 21 ~ 27 Nm
Concentric slave cylinder bolt (3 locations) 1.7 ~ 2.6 kgf•m 17 ~ 26 Nm
Concentric slave cylinder flare nut 2.0 ~ 2.5 kgf m
• 20 ~ 25 Nm
Adaptor flare nut 1.0 ~ 1.6 kgf•m 10 ~ 16 Nm
Clutch oil pipe flange nut 1.52 ~ 1.83 kgf•m 15 ~ 18 Nm
Master cylinder bolt 3.05 ~ 4.07 kgf•m 30 ~ 40 Nm
Fulcrum (clutch pedal bushing) bolt/nut 1.63 ~ 2.24 kgf m• 16 ~ 22 Nm
Clutch pedal bracket mounting bolt 0.81 ~ 1.83 kgf•m 8 ~ 18 Nm
Stopper bolt 1.63 ~ 2.24 kgf•m 16 ~ 22 Nm

AFFECTED VIN
4C 11
3. AIR BLEEDING
[Notice]
• Keep the fluid level over MAX in reservoir during bleeding

operation.
• Do not let the fluid contact a painted surface.
Specified oil DOT 4

Capacity Between Max and ADD
Procedure
1. Remove the air bleed bolt cap on the release cylinder. [Notice]
2. Put the other side of the tube into a empty container.
• This work has to be done by two service persons.
3. Slowly pump the clutch pedal several times.
• After bleeding, check the clutch system for operation
4. With clutch pedal fully depressed, open the air bleed and noise.
bolt and bleed the air and fluid from the fluid line.
• Use only Ssangyong genuine clutch fluid, and check
5. Repeat step 3 through 4 until no more air bubbles are the clutch fluid level in reservoir.
in the escaping fluid.

AFFECTED VIN
12 4C
MAINTENANCE
Clutch Assembly
Preceding Work: Remove the transmission assembly.
1. Insert the centering pin (special tool) into center spline. Loosen the clutch cover bolts 1/2 turns in cross sequence
until the spring tension is released.
Tightening torque 2.4 ± 0.3 kgfxm
[Notice]
1) Do not remove the bolts at a time, or clutch cover may be damaged or deformed.
2) If the clutch disk is to be reused, insert a mounting plate between the dia phram spring and cover plate when uninstall.
2. Unscrew the bolts and remove the clutch cover, pressure

plate and clutch disc.
[Notice]
1) Be careful not to drop the pressure plate and clutch disc.

2) Replace the clutch cover and disk at every disassembly.
Tightening torque 21 ~ 27 Nxm

AFFECTED VIN
4C 13
Concentric Slave Cylinder

Preceding Work: Remove the transmission assembly.
1. Unscrew the oil pipe nut(1), adaptor mounting bolt(3) and oil pipe nut(2) which connected to concentric slave(A)
from the inside of clutch housing.
2. Remove the oil pipe from the clutch housing.
3. Unscrew the concentric slave cylinder mounting bolts (3EA) and remove the concentric slave cylinder
assembly in the clutch housing.

AFFECTED VIN
14 4C
Clutch Master Cylinder

1. Drain the clutch fluid.
2. Pull out the snap pin and clevis pin from the clutch pedal
connection.
3. Remove the clutch tube.
Installation Notice
[Notice]
Be careful not to contact the fluid into a painted surface.
4. Remove the master cylinder mounting nuts and pull off

the master cylinder.
Installation Notice

6. Check the clutch pedal operation.
7. Perform the air bleeding job.

AFFECTED VIN
4C 15
Clutch Fluid Pipe

1. Draw out the fluid.
2. Unscrew the bolt and remove the supply pipe from clutch
master cylinder.
3. Unscrew the supply pipe bolt and remove primary oil pipe
from clutch fluid chamber.
4. Unscrew the bolt and remove the secondary clutch fluid

pipe from clutch release chamber.
5. Install the pipes. Be careful not to mix the pipes.
[Notice]
• Make sure to bleed the air from the system after

installation.
• Check each pipe bolt for oil leaks.
• Clutch pipes are reusable. However, must check the pipes
for damages and cracks.

AFFECTED VIN
16 4C
Clutch Pedal
1. Remove the snap pin from master cylinder push rod and
remove the clevis pin from pedal.
2. Remove the turnover spring.
3. Unscrew the fulcrum bolt and remove the clutch pedal

from bracket
4. Unscrew the bolts and remove the master cylinder.

AFFECTED VIN
4C 17
5. Unscrew the mounting bolts and remove the clutch pedal

bracket.
Installation notice
1. Install in the reverse order of removal. Adjust pedal stroke Description Tightening Torque
after installation.
Fulcrum bolt/nut 16 ~ 22 Nm
[Notice] Bracket mounting bolt 8 ~ 18 Nm

Stopper bolt 16 ~ 22 Nm
1. Apply long-life grease (T/M DBL 6611.00) to the connections.
2. Remove foreign materials.
3. Keep the tightening torque.
4. Replace the bushings with new ones.
Inspection and adjustment

1. Pedal Stroke (A)
Maximum pedal stroke 158 mm
2. Pedal Height (B)
Height (from carpet) 192 ± 5 mm
[Notice]
To adjust the pedal stroke, loosen the lock nut (C) of the
stopper bolt (D) and turn the stopper bolt until the stroke is
correct. After adjustment, tighten the lock nut.
3. Pedal Free Play (E).

Free play 5 ~ 10 mm
[Notice]
To adjust the pedal free play, loosen the lock nut (F) of the
master cylinder and turn the push rod until the free play is
correct.
4. Check the fulcrum bolt and the bushing for wear, the
pedal for bending and the spring for damage.

AFFECTED VIN
18 4C
2. INSPECTION
• Check any heat damage, abnormal noise, poor rotation
and wear of the concentric slave cylinder bearing.
Clutch Cover Assembly

• Check the diaphragm spring tip for wear and height
unevenness.
Unevenness limit 0.8 mm
• Check the pressure plate surface for wear, crack and

discoloration.
• Check the strap plate rivet for looseness and replace if
necessary.
Clutch Disc
• Check the facing for rivet looseness, sticks, oil and grease.
• Measure the rivet head depth. If out of limit, replace the
disc.
Wear limit 0.3 mm

AFFECTED VIN
18 4C
2. INSPECTION
• Check any heat damage, abnormal noise, poor rotation
and wear of the concentric slave cylinder bearing.
Clutch Cover Assembly

• Check the diaphragm spring tip for wear and height
unevenness.
Unevenness limit 0.8 mm
• Check the pressure plate surface for wear, crack and

discoloration.
• Check the strap plate rivet for looseness and replace if
necessary.
Clutch Disc
• Check the facing for rivet looseness, sticks, oil and grease.
• Measure the rivet head depth. If out of limit, replace the
disc.
Wear limit 0.3 mm

AFFECTED VIN
4C 19
Clutch Disc Run-Out

• Measure the clutch disc run-out and replace if necessary.
Run-out limit 0.7 mm
Pressure Plate
1) Check the pressure spring for wear.
[Notice]
The excessively worn components should be replaced.
2) Check the alignment conditions of clutch housing as

follows:
• Install the magnetic holder on pressure spring.
• Alignment check for housing bore
A. Install a dial gauge in the housing bore.
B. Measure and record the pointer value while
rotating the crankshaft.
• Alignment check for clutch housing surface

A. Install a dial gauge on the clutch housing surface.
B. Measure and record the pointer value while
rotating the crankshaft.
[Notice]
If the pointer indicates beyond 0.010 inch, align the clutch

housing by inserting shims between the housing and clutch.

AFFECTED VIN
20 4C
3. SPECIAL TOOLS AND EQUIPMENT

661 589 00 15 00 (L 99 30 001 0B) Centering the clutch disc

Centering pin
601 589 02 40 00 (A 99 10 014 0B) Locking the crankshaft

Engine lock

AFFECTED VIN
4C 21
TROUBLE DIAGNOSIS
1. DIAGNOSTIC INFORMATION AND PROCEDURES
Check Possible Cause Action
Clutch slips Excessive wear of facing Replace
Hard or oily facing Repair or replace
Damaged pressure plate or flywheel Replace
Damaged or burnt diaphragm spring Replace
Clutch pedal free play insufficient Adjust
Faulty operation of clutch pedal Repair or replace
Worn or damaged clutch disc Replace
Poor disengagement Vibration or excessive run-out of disc Replace
Rust or wear of disc spline Repair or replace
Oily facing Repair or replace
Damaged diaphragm spring Replace
Excessive clutch pedal free play Adjust
Hard to shift or will not shift Excessive clutch pedal free play Adjust pedal freeplay
Faulty clutch release cylinder Repair release cylinder
Worn disc, excessive run-out, damaged lining Repair or replace
Dirty or burred splines on input shaft or clutch disc Repair as necessary
Damaged clutch pressure plate Replace
Clutch chatters when starting Oily facing Repair or replace
Hard or faulty facing Replace
Burnt torsion spring Replace
Faulty pressure plate Replace
Bent clutch diaphragm spring Replace
Hard or bent flywheel Repair or replace
Engine mounts loose or burnt lever Tighten or replace
Difficult pedal operation Poor lubrication on clutch cable Lubricate or replace
Poor lubrication on pedal shaft Lubricate or replace
Poor lubrication on clutch pedal Repair
Not using the clutch Insufficient clutch pedal free play Adjust
Excessive wear of facing Replace
Clutch noisy
After disengagement Worn or damaged release bearing Replace

When disengaging Poor lubrication contact surface of bearing Replace
Faulty installation of clutch assembly or bearing Repair
Clutch pedal is partially Damaged pilot bushing Replace
depressed and vehicle
speed is reduced
[Notice]
Clutch cover and disk should be replaced altogether.

AFFECTED VIN
MEMO
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4D 3
GENERAL INFORMATION
1. LAYOUT
Sub frame
T/M
Front propeller shaft
Exaust pipe
Transfer case (TOD)
Rear propeller shaft
TOD CHANGED BY
AFFECTED VIN
4 4D
2. GENERAL DESCRIPTION
TOD system means the full time 4WD system and the Distribution of Driving Force
registered trade mark of Borg Warner. TOD is an abbre-
viation of Torque On Demand.
According to Road Surface
TOD (Torque On Demand) system, which is superior than 1. On normal road surface
existing Full Time 4WD, checks the road surface and ve- In vehicle with existing part time transfer case, when
hicle conditions via various sensors and, subsequently, a driver turns the steering wheel to park in the 4WD
according to the situations and conditions, distributes the mode, the vehicle may halt sensation of tight corner
most optimal driving force to front wheels and rear wheels braking phenomena. However, in vehicle with TOD
by activating the electro-magnetic clutch located inside of system, this phenomena does not occur and the
TOD Transfer Case. driving force is properly and automatically distributed.
TOD receives the speed signals from speed sensors in- 2. On paved road with high speed
stalled in front axle and rear axle, the TPS signals from Driving at high speed on roads such as highway
engine, and the operating signals from ABS control unit mainly uses rear wheels as driving wheel. At this
via CAN. Based on these data, TOD control unit controls moment, some of torques is also distributed to front
the electro-magnetic clutch to distribute the 3:97 ~ 44:56 wheels so that the vehicle could maintain safe ground
of driving force to front wheels and rear wheels. grab capacity against side winds and rain. Distribution
The conventional system uses “FR driving” (theoretically, ratio: 15 % for front wheels and 85% for rear wheels.
the 100 % of driving force is transferred to rear wheels) on 3. When turning on the road with low friction rate
normal paved road. When the system detects a slip in the During cornering on roads such as unpaved, snowy,
rear wheels, a proper percentage of driving force is trans- icy and muddy, ground grab capacity is increased
ferred to front wheels. by distributing required torque and, at the same time,
TOD control unit receives the wheel speed signals from comfortable steering operation is maintained by
the speed sensors in propeller shaft of transfer case and controlling the ground grab capacity at high level.
engine output information from the engine control unit. TOD Distribution ratio: 30 % for front wheels and 70 % for
control unit changes the pressure force of the electro- rear wheels.
magnetic clutch based on the analyzed data. 4. When climbing or starting off on the road with low
friction rate
In order to secure the maximum ground grab capacity
and driving force during climbing or starting off on the
roads such as unpaved, snowy and icy road, the
system controls the driving force to distribute properly
in full 4WD mode. Distribution ratio: 44 % for front
wheels and 56 % for rear wheels.
CHANGED BY TOD
AFFECTED VIN
4D 5
Transfer Case
Planetary gear set
Planetary Gear set consists of sun gear, ring gear and carrier. It is engaged with the gear in “HIGH-LOW” collar to
increase the driving force by reducing vehicle speed.
Sun gear is connected to input shaft and ring gear is fixed into the transfer case.
Splined rear output shaft is able to slide on the “HIGH - LOW” collar.
The inside and outside ends of “HIGH - LOW” collar have machined gear. The input shaft transmits the power to driving
wheels by engaging with sun gear and carrier gear.
If the 4WD switch is at “4WD HIGH”, the TOD control unit operates the shift motor to engage “HIGH - LOW” collar
directly with input shaft for transmitting the driving force to front and rear propeller shafts.
When a driver selects “4WD LOW”, the TOD control unit controls the electro-magnetic clutch and operates the shift
motor to engage “HIGH - LOW” collar with carrier. The power from transmission is increased up to 2.48:1 by reduction
ratio from planetary gear, and then is sent to front and rear propeller shafts.
Ball type slant cam and clutch disc pack

If the speed sensors installed on front and rear propeller shafts
detect the slips at front and rear wheels, and these slips ex-
ceed the specified range, TOD control unit controls electro-
magnetic clutch to transmit driving force to front wheels. At
this time, ball slant cam is moved to compress multi-disc
located in clutch disc to transmit driving force to front wheels.
TOD CHANGED BY
AFFECTED VIN
6 4D
Electro Magnetic Clutch (EMC)

EMC consists of coil and housing. TOD control unit controls EMC by controlling duty cycle according to the road and
driving conditions. These controls use the continuity time and amount of electric current to determine the torque to be
transmitted to front wheels.
Measuring the rotating speed

of front propeller shaft
Measuring the rotating

speed of rear propeller shaft
NO
Is the wheel slip exceeded
allowable limits?
YES
Decreases clutch engagement
Increases clutch engagement
Basic controls in EMC
CHANGED BY TOD
AFFECTED VIN
4D 7
Signal Flow
Instrument Panel
4WD Switch
Output
TOD Control
Unit
Input
Rear Speed
Manetic Clutch
Motor
Front Output Front Speed
TOD CHANGED BY
AFFECTED VIN
8 4D
Power Flow
4H Mode (4WD Drive - High Speed)
Transmission Rear Axle

(Rear Wheel)
Front Axle
(Front Wheel)
Front Speed
Sensor
Rear Speed Transmission

TOD Control Unit
Sensor Input Shaft
Throttle Open
Rate
(TPS Value)
Magnetic Clutch Output Shaft
Force Distribution Unit

BALL RAMP
Driving Sprocket Multi-Plate Clutch
Chain
Front Propeller Rear Propeller

Shaft Shaft
CHANGED BY TOD
AFFECTED VIN
4D 9
4H Mode (4WD Drive - Low Speed)
Transmission Rear Axle

(Rear Wheel)
Front Axle
(Front Wheel)
Front Speed Transmission

Sensor Input Shaft
Rear Speed TOD Control Unit

Sensor
Throttle Open
Rate
(TPS Value)
Magnetic Clutch Planetary Gear
MAX DUTY (2.483)
Force Distribution Unit

BALL RAMP
Driving Sprocket Multi-Plate Clutch Output Shaft
Chain
Front Propeller Rear Propeller

Shaft Shaft
TOD CHANGED BY
AFFECTED VIN
10 4D
Specifications
TOD Model TOD transfer case
Overall length 343.0 mm
Weight (including oil) 37.9 kg
Shifting mode 4H and 4L
Gear ratio High 1:1
Low 2.48:1
Oil specification Specification Ssangyong genuine oil
(ATF S-3, S-4 or Dexron II/III)
Capacity 1.4
Change interval Check at every 15,000 km,
replace at every 60,000 km
TOD Maximum torque (front) Approx. 76 kg•m

control Voltage Normal operating
unit 9 ~ 16 V
range
CAN communication 6 ~ 16 V
Current (below maximum IG switch OFF 2 mA
operating voltage) IG switch ON 1A
Maximum operating Motor OFF 7A
current Motor ON 20 A
CHANGED BY TOD
AFFECTED VIN
4D 11
3. CIRCUIT DIAGRAM
TOD CHANGED BY
AFFECTED VIN
12 4D
4. OPERATION
System Layout
Combi meter
4WD switch
TOD control unit
Output
Input
Rear speed
Magnetic clutch
Motor
Front output shaft Front speed
CHANGED BY TOD
AFFECTED VIN
4D 13
4WD Operation Overview

Application Mode Position Operation Condition
Driving type 4H 4WD Drive Normal Driving on the normal road or highway, or high speed driving.
(High Speed) Slipped road such as snow, rainy, sand, mud etc.
4L 4WD Drive Max driving force requiring condition such as towing, rough road.
(Low Speed) Same function as part time transfer case 4L.
Transferring 4H ↔ 4L 4WD Drive A vehicle should stop for transfer.
High Speed ↔ Manual Transmission
Low Speed
• Transfer starts after the vehicle stops and the clutch is applied
Automatic Transmission
• Transfer starts after the vehicle stops and the shift lever is shifted
[N] position.
[Notice]
To make the mode shift easier, stop the vehicle, depress the brake pedal, select the mode switch, and move the selector
lever with the sequence of [N-P-N].
Mode Switch
Selection Mode 4L Mode
The TOD system has 2 selectable mode, 4H and 4L. When selecting 4L mode, EMC is locked to apply maximum
4H is the normal operating mode when drive of which torque into front and rear propeller shafts (when the wheel
gear ratio is 1:1 and 4L mode distributes power to front speed is more than 87Hz). Shift motor rotates also 4L posi-
and rear wheels 50:50 of which gear ratio is 2.48:1. tion by rotation of cam thus propeller shaft torque changes
from 1:1 to 2.48:1 by planetary gear set.
Releasing the 4L Mode

When selecting 4H mode, 4L drive mode is released and 4H
mode is resumed.
• “4H” switch: Self-return type
• “4L” switch: Push lock type
TOD CHANGED BY
AFFECTED VIN
14 4D
COMPONENTS
1. TOD ASSEMBLY
Front case
Rear cover
T/M RR. Propeller shaft
Frt. Propeller shaft
Front & rear Shift motor/Electronic

speed sensor magnetic clutch
Input shaft Rear cover
Companion flange
Air bleeder cap
Shift motor
Rear speed sensor

Front companion flange
CHANGED BY TOD
AFFECTED VIN
4D 15
2. TCCU (TRANSFERCASE CONTROL UNIT)

Location Under Driver’s Seat
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
Item TCCU
Vehicle speed signal CAN
Cluster lamp CAN
Clutch signal (M/T) CAN
Neutral signal (A/T) CAN
TOD CHANGED BY
AFFECTED VIN
16 4D
TCCU
Description New TCCU

Connector type Two separated connectors
Number of pins 30
Weight 0.22 kg
CAN-BUS O
Vehicle speed signal CAN communication
Lamp CAN communication
Clutch signal (M/T) CAN communication
Neutral signal (A/T) CAN communication
Appearance and Function

1 Motor HI - LO 16 Speed sensor voltage supply
2 Motor LO - HI 17 Ground
3 EMC 18 Ground
4 Battery 19 Battery
5 Ignition 20 K-Line
6 Position ground 21 N/A
7 N/A 22 CAN H
8 N/A 23 CAN L
9 4H-4L switch 24 N/A
10 Position 2 25 ABS operation
11 Front speed sensor 26 N/A
12 N/A 27 Position 1
13 Ground – speed sensor 28 Position 3
14 Motor HI-LO 29 Rear speed sensor
15 Motor LO-HI 30 Position 4
CHANGED BY TOD
AFFECTED VIN
4D 17
Transfer Case Block Diagram
4 2 Shift motor output

Battery voltage
19 15 (Motor LO-HI)
T
Ignition switch ON/
5 O 1 Shift motor output
OFF
14 (Motor HI-LO)
Position 1 27
Position 2 10 3 EMC
C
Position 3 28
Position 4 30 O
Position encoder
N 6 ground
(Return position)
4H/4L switch signal 9

T
O
Front speed Speed sensor ground
11 13
sensor signal (Return position)
L
Front/rear speed
Rear speed 29 16 Sensor 5V power
sensor signal U supply
CAN HIGH 22 I 20 Self diagnosis
CAN LOW 23 17
18
TOD CHANGED BY
AFFECTED VIN
18 4D
Section Pin No. Name Description

Power 17, 18 Ground TOD control unit ground
supply 4, 19 B+ TOD control unit battery voltage input
Input side 5 Ignition switch Ignition switch power
: ON - over 4 V, OFF - below 0.9 V
27 Position 1 Position encoder – shift motor position recognition
HIGH - over 4 V, LOW - below 0. 9 V
10 Position 2 Same as above
9 4H and 4L switch Mode input according to 4H and 4L selection
: HIGH - over 4 V, LOW - below 0.9 V
11 Front speed sensor Front speed sensor (hall effect) signal input
29 Rear speed sensor Rear speed sensor (hall effect) signal input
25 ABS operation ABS operating signal input (ABS ON/OFF)
Operation - over 4 V, Not operation - below 0.9 V
(NON CAN ABS model)
Both sides 22 CAN HIGH CAN bus HIGH line
23 CAN LOW CAN bus LOW line
20 K - LINE Connected to trouble diagnosis connector
Output side 16 Speed sensor voltage Supplying 5V to front/rear speed sensors
1, 14 Motor HI-LO Motor output port
- Connected to battery when shifting to LO from HI
- Connected to ground when shifting to HI from LO or
braking the motor
2, 15 Motor LO-HI Motor output port
- Connected to battery when shifting to HI from LO
- Connected to ground when shifting to LO from HI or
braking the motor
3 EMC Supplying the voltage to clutch coil
- Frequency: 50 Hz, - Duty ratio: 6 ~ 88 %
6 Speed return Providing the ground to position encoder
13 Speed return Providing the ground to speed sensor
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SYSTEM OPERATION
TCCU Initialization
• TCCU sends relevant data to meter cluster via CAN to diagnose and check the indicators when the ignition switch is
turned to ON. At this time, the 4WD indicators (4WD LOW, 4WD HIGH, 4WD CHECK) comes on for 0.6 seconds.
• If the selector switch position and the shift motor position code does not match when the IG power is turned ON, the
shift is controlled to move in the direction of the selector switch position
Interpretation of Position Sensor

- When the 4H/4L switch is operated and the position sensor recognizes the shift motor position while the system is
energized, the system operates as follows:
4H/4L Switch Input Motor Position Operation

4H Left stop Does not operate, 4L lamp off
4H Left top Does not operate, 4L lamp off
4H Top Does not operate, 4L lamp off
4H Right top - 4L lamp flickers
- Tries shifting to 4H if shifting conditions are satisfied.
- After shifting to 4H the flickering of 4L lamp stops.
4H Zone 1 Same as above
4H Neutral Same as above
4H Zone 2 Same as above
4H Bottom Same as above
4H Right stop Same as above
4L Left stop - 4L lamp flicker
- Tries shifting to 4L if shifting conditions are satisfied.
- After shifting to 4L the 4L lamp lights on.
4L Left top Same as above
4L Top Same as above
4L Right top Same as above
4L Zone 1 Same as above
4L Neutral Same as above
4L Zone 2 Same as above
4L Bottom Does not operate, 4L lamp lights on
4L Right stop Does not operate, 4L lamp lights on
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If 4H/4L switch position is not matched with shift motor position code with the ignition switch “ON”, the shift require-
ments operate to the direction of 4H/4L switch. However, the shifting requirements should be met to shift.
• Shifting requirements:
- The transmission is in neutral for 2 seconds after the shift is requested.
- Both propeller shaft speeds are below 43 Hz.
A command to shift will only be acted upon if the TOD is reading a valid code at the time the command to shift is made.
After a shift has started, the TOD will power the shift motor until the code for the requested position is read. If an invalid
code is read, the TOD will go into a default mode.
During a shift attempt, the shift motor will be energized for a maximum of 5 seconds.
In case of manual transmission, the clutch pedal should be depressed.
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ELECTRIC SHIFT SYSTEM OPERATION
The electric shift system is responsible for changing the transfer case gear ratio by controlling the electric shift motor.
The TOD monitors the 4H/4L switch, neutral switch, speed sensors, position encoder, and ignition switch.
A range change is initiated when:
1. The 4H/4L switch is changed from 4H to 4L or from 4L to 4H.
2. The motor position (as indicated by the position encoder) does not match the 4H/4L switch immediately after the
ignition is turned on.
Shift Requirements
When a range change is initiated a diagnostic test will be completed on the motor, speed sensors, and position
encoder. If the diagnostic test fails, the shift will not be attempted. If all components are operating properly, the TOD will
attempt a range change after the following shift requirements are met:
1. The transmission is in neutral for 2 seconds after the shift is requested.
In case of manual transmission, the clutch pedal should be depressed.
2. Both propeller shaft speeds are below 43 Hz.
If the transmission is taken out of neutral before 2 seconds has elapsed, or either propeller shaft speed increases above
the limit, the shift will be suspended and the 4L indicator will continue to flicker until the requirements are met again or
the 4H/4L switch is returned to the original position. However, if the initial switch position is “4L”, “4L” indicator remains
on. If the shift requirements are met, the shift motor attempt to shift again.
Range Change
When the shift requirements are met, the motor rotates to the appropriate direction (as determined by the selector
switch) until one of the following occurs:
1. The motor reaches its destination.
2. The motor is on for 5 seconds without reaching its destination. The shift has failed and the TOD will respond as
default mode.
3. A fault occurs with either the motor or position encoder. Refer to the diagnosis requirement.
When the motor is energized, the Ignition, 4H/4L switch, propeller shaft speeds, and transmission neutral inputs are
ignored.
Shift operation is only allowed when some conditions are satisfied. These shift conditions should be satisfied for 2
seconds before starting motor. The motor has three seconds of delay at its initial operation to do trouble diagnosis.
Once the motor starts, the shift conditions are no longer checked.
Shift conditions are as follows:
- Normal battery voltage and shift motor for all gears
- Shift operation between 2H/4H and 4L is only available when the vehicle speed is below 43 Hz.
- No defective speed sensor
- The selector lever should be in “N” position (in case of manual transmission, the clutch pedal should be depressed).
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Shift Conditions
Shift is allowed only when certain conditions for the vehicle are satisfied. This means that the shift conditions must
satisfy the operating conditions for 2 seconds before motor starts and 2 seconds of delay at initial stage is to diagnose
the system.
The shift requirements are as follows:

- There should be no fault with battery voltage and shift motor for all shifts.
- Shift between 4H and 4L is operated only under the vehicle speed of below 43 Hz.
- There should be no fault with speed sensors.
- Transmission must be in neutral position (In case of manual transmission, the clutch pedal should be depressed).
Motor Controls
• The shift steps have the sequence of 4H → 4L and 4L → 4H → 2H. TCCU operates the shift motor until it reads
required position code. If it detects the faulty code, the system is operated with the compensation mode.
• Once the shift operation is started, it is completed regardless of ignition power. If there are not operating signals from
position sensor, the shifting failure due to timeout occurs. This failure appears when the shifting time between 2H
and 4H and between 4H and 4L is delayed over 5 seconds compared to normal shift. Once the shifting time exceeds
the specified time, TCCU cannot properly supply the voltage to shift motor and is operated in compensation mode.
• Even though the system recognize a fault before motor starts, it is considered as fault.
• Motor stops operation when it reaches at target range.
Compensation Mode
The motor stops when the encoder related troubles are detected during shift operation. It moves toward LOW-HIGH
direction for 5 seconds so that the motor is not left in unidentified position.
Indicator Function on Shifting

Once a range change has been initiated the 4L Indicator will
0.3 seconds
begin to blink at a rate of 0.3 seconds on, 0.3 seconds off until
the shift is completed or canceled. Shift completed
4L Indicator illuminates as below figure.
Electric Shift Default Mode

If the motor fails to reach its destination, the TOD will attempt 0.3 seconds
the following (in order):
1. The TOD will wait 3 seconds then attempt the shift again. (4H → 4L)
2. If the second attempt to reach the destination fails the

TOD will wait 3 seconds then attempt to rotate the motor
back to the original position. If successful, all future shifts
will be inhibited until the Ignition is cycled. 0.3 seconds
3. If the attempt to return to the original position fails, the Shift completed
TOD will wait 3 seconds then attempt to rotate the motor
to the original position again. If the second attempt to
return to the original position is successful, the “4WD
CHECK” indicator will be illuminated, and all future shifts
will be inhibited until the Ignition is cycled. 0.3 seconds
4. If the second attempt to return to the original position

fails the motor will be turned off, the “4WD CHECK” (4L → 4H)
indicator will be illuminated, and all future shifts will be
inhibited until the Ignition is cycled.
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Etc
The TOD system is responsible for distributing torque between the front and rear axles. The TOD monitors the propeller
shaft speeds, operating range (High/Low), and ABS activity and then applies a calculated amount of torque to the front
axle by Pulse Width Modulating the current applied to the EMC.
Touch-off torque
The minimum EMC Duty Cycle is based on the vehicle speed and throttle position.
The TOD receives the TPS signal from the following sources:
On vehicles equipped with CAN, the TOD receives the TPS signal from the CAN bus.
When slip detection

The TOD continuously monitors the front and rear propeller shaft speeds to detect wheel slip.
Wheel slip control

When wheel slip is detected the TOD controls the EMC duty cycle as necessary until the wheel slip is reduced below
the allowable limit. The EMC Duty Cycle will then be reduced to the Touch-Off value.
Brake/ABS strategy
When the ABS System is active, the EMC Duty Cycle is set to a fixed duty cycle (30 %) to aid in braking without
counteracting the ABS System.
4L strategy
When the system is operating in 4L, the TOD continues TOD (operation provided that the propeller shaft speed is below
87 Hz). When the speed increases above 10 Hz, the EMC Duty Cycle is set to the maximum value (88 %) which applies
the maximum available torque to the front axle.
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Shifting Sequence
Flow chart
Start No
Shift Yes Check shift Satisfied shift

requirements conditions conditions for 2
seconds
Yes
Analyzing position
No encoder
Canceling general encoder

Is the position No DTC Shift is not available
code valid? during ignition cycle
Yes
Move further to
requested direction
Does the motor Yes

Motor stops Shift
operate for
time out DTC
maximum limit?
No
Is the position Moto stops

No
code valid and General
sequential? encoder DTC
Yes
No
Motor ON to L-H
Reached at
during maximum limit
target location?
Shift is not available

during ignition cycle
Yes
Shift motor OFF
Completed
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Shift Requirements
• If 4H/4L switch position is not matched with shift motor position code with the ignition switch “ON”, the shift requirements
operate to the direction of 4H/4L conversion switch.
• The next shift requirements are identified only when those are different from current operation.
Shift Conditions
Shift is allowed only when certain conditions for the vehicle are satisfied. This means that the shift conditions must
satisfy the operating conditions for 2 seconds before motor starts and 2 seconds of delay at initial stage is to diagnose
the system.
The shift requirements are as follows:

- There should be no fault with battery voltage and shift motor for all shifts.
- Shift between 4H and 4L is operated only under the vehicle speed of below 43 Hz.
- There should be no fault with speed sensors.
- Transmission must be in neutral position (In case of manual transmission, the clutch pedal should be depressed).
Reading position encoder

The position encoder is the code that TCCU can determine the shift motor position.
Position
Motor Position Remark
1 2 3 4
1 1 1 0 Left Stop
1 0 1 0 Left top
0 0 1 0 Top
0 0 0 0 Right top
Input voltage
1 0 0 0 Zone 1
1 : above 4.5V (HIGH)
1 0 0 1 Neutral
0 : below 0.5V (LOW)
0 0 0 1 Zone 2
0 1 0 1 Bottom
0 1 0 0 Right stop
1 1 1 1 Off State
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3. SPEED SENSOR AND CLUTCH COIL

The front and rear speed sensor utilizes the hall effect. These sensors generate 0V and 5V of square type digital
wave according to the rotation of the wheel with teeth of transfer case front and rear output shaft. The speed
signal from front and rear propeller shaft is entered into TOD control unit.
Pin Function
4 Clutch coil
6, 7 Sensor power supply (5V)
1, 2, 5 Sensor signal 1(G) 2(G)
3 Sensor ground 3(B) 5(Sb)
6(Gr/R)
7(Gr/R)
4(Br)
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4. SHIFT MOTOR CONNECTOR

When selecting a position in 4WD switch (4H/4L), TOD control unit exactly changes the motor position to 4H and 4L by
detecting the electric signals from position encoder that monitors motor position.
Pin Function
1 Position A
2 Position B
3 Position C 1(Br/W) 2(P/W)
4 Position D
3(W) 5(Y/W)
5 Position ground
6(Y) 7(P)
6 Control (4L - 4H)
7 Control (4H - 4H)
4(V)
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1. TCCU
1. Move the driver’s seat to for front and open the seat cover.
2. Unscrew TCCU mounting nuts (M5-2EA)
3. Disconnect the TCCU connector and seperate the unit.
[Notice]
Be careful not to apply any impact to TCCU body.
Installation Notice
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2. SHIFT MOTOR
2. Disconnect the shift motor/electronic magnetic clutch connector (black, 7-pin) and front and rear speed sensor
connector (white, 4-pin) at the rear top section of the transfer case.
3. Disconnect the front and rear speed sensor connector (white, 7-pin) from bracket.
4. Remove shift motor mounting bolts.

5. Remove bracket mounting bolt.
[Notice]
Remove two bolts for fixing the motor and bracket before
removing the shift motor and bracket.
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6. Pull the shift motor assembly out while keeping the level.
7. Clean the mating surface of the transfer case and shift

motor.
[Notice]
Do not disassemble the shift motor since it is replaced as an
assembled unit.
8. Apply sealant on the mating surface if new shift motor

assembly.
9. Install in the reverse order of removal. Make sure that
the mode switch selection is matched with the motor’s
driving position before installation.
[Notice]
To do that, install a new shift motor on the same location
that the used shift motor was on.
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3. SPEED SENSOR
Rear speed sensor
Front speed sensor
Rear speed sensor connector

2. Remove the shift motor assembly.
3. Disconnect the front and rear speed sensor connector (white, 7-pin) at the rear top section of the transfer case.
4. Disconnect the speed sensor connector from the locking sleeve.
5. Remove the wire fixing retainer at the rear side of disconnected connector.
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6. Remove the rear speed sensor bolts on the rear case flange.
7. Remove the rear speed sensor with a suitable tool.
[Notice]
Do not apply excessive force to protect mounting area and sensor.
8. Remove the tapings in both sides of protective tube.

9. Remove the tube.
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10. Hold the “L” pin in speed sensor connector with long nose pliers and push it rearward to disconnect from the
connector.
11. Disconnect the “M” and “N” pin and wire from the
connector with same manner.
[Notice]
EMC wire cannot be disconnected from outside, therefore do
not try to disconnect it.
12. Get a new speed sensor.

13. Insert three pins and wires into each location from rear
side of the connector.
14. Hold each pin with long nose pliers and pull it to securely
install in the connector.
15. Insert each rubber cap into the connector to prevent the
pins from disconnecting.
16. Insert the protective tube for connector into the harness.
17. Bind both ends of the protective tube with tape.
18. Install the rear speed sensor into the mounting hall and
press both ends of it to be securely seated.
19. Tighten the bolts.
Installation Notice
20. Install the speed sensor connector. Insert the connector

into the locking sleeve.
[Notice]
Remove the shift motor first before removing the front
propeller shaft speed sensor. When replacing the sensor
assembly after removing the shift motor, use the same manner
for removal of rear speed sensor.
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4. TOD ASSEMBLY
2. Lift up the vehicle and fix it safely.
3. Place the empty container to collect the draining oil.
4. Remove the drain plug and drain the oil. Reinstall the
drain plug.
[Notice]
Oil drain should be along with whole transfer case
disassembly and assembly.
5. Disconnect transmission extension wiring connector from

rear side of transfer case.
[Notice]
When disconnect connector, make sure on direction of
locking tab towards inside.
6. Disconnect the shift motor/clutch coil connector (black,

7-pin) and front and rear speed sensor connector (white,
7-pin) at the rear top section of the transfer case.
7. Remove the breather hose.

8. Support the transfer case with jack and remove the front
propeller shafts bolts (4ea).
Installation Notice
9. Remove the rear propeller shaft mounting bolts (4).
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10. Unscrew the bolts and remove the crossmember from

the transmission.
L/R Mounting Bolt 21 ~ 35 Nm

Center Mounting Bolt 62 ~ 93 Nm
11. Remove the insulator mounting bolts.

Installation Notice
12. Unscrew the bolts and remove the transfer case.

Installation Notice
[Notice]
Apply long-life grease to the inner spline of transfer case
input shaft.
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TOD ASSEMBLY
1. CROSSE SECTIONAL DIAGRAM
4H-4L planetary gear set Chain Clutch pack EMC
Ball lamp
Input shaft
Oil pump
4H-4L shift motor
Front wheel
output shaft
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Exploded View
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1. Snap ring 35. Breather

2. Snap ring 37. Output shaft
3. Snap ring 38. Dust shield
4. Bearing 39. Magnet
5. Hub 40. Snap ring
6. Input shaft assembly 41. Lower sprocket
7. Thrust plate 42. Tone wheel (lower)
8. Sun gear 43. Chain
9. Snap ring 44. Thrust bearing assembly
10. Carrier assembly 45. Retaining ring
11. Reduction hub 46. Bearing
12. Main shaft assembly 47. Bearing
13. Geroter pump assembly 48. Cover
14. Thrust washer 49. Clip
15. Hose clamp 50. Bolt
16. Hop 51. Oil seal
17. Filter 52. Washer
18. Electric coil assembly 53. Nut
19. Cam/coil housing assembly 54. Companion flange
20. Ball 55. Oil seal
21. Cam 56. Spacer
22. Spring 57. Tone wheel (upper)
23. Armature 58. Nut
24. Insulator washer 59. “J” clip
25. Retaining ring 60. Hexagon bolt
26. Clutch pack assembly 61. Clip
27*. Sprocket assembly 62. Connector
28. Shift rail 63. Connector lock
29. Shift fork assembly 64. Hexagon cap screw
30. Electric shift cam 65. Speed sensor (upper)
31. Torsion spring 66. Electric motor assembly
32. Shift shaft 67. Oil seal
33. Retaining ring 68. Pipe plug
34*. Transfer case assembly 69. Speed sensor (lower)
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2. DISASSEMBLY PROCEDURE
1. Disconnect transfer case from vehicle
2. Using a 30 mm thin-wall socket, first remove the rear
output nut, output shaft yoke washer, oil seal then the
case flange.
3. Disconnect shift motor/clutch coil connector and speed
sensor connector from upper bracket of transfer case.
[Notice]
When disconnect connector, pull forwards grasping
connector housing.
4. Remove outer tube on speed sensor connector.

5. Remove wire supporting cape back side of speed sensor
connector.
6. Disconnect pin of clutch coil wire (yellow) from speed

sensor connector (7 pin) using long-nose plier.
03E-019
7. Remove shift motor.
[Notice]
When remove shift motor, pay attention to the location of
triangular slot and shaft in transfer case inside motor.
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8. Disconnect front and rear speed sensor as needed.

9. Remove the 17 bolts that retain the front case to the rear
case.
10. Make sure that the front case is facing downward so

that the rear cover is facing upwards.
11. Remove the rear front case from the rear case.
12. Remove all traces of gasket sealant from the mating
surfaces of the front case and rear case.
13. If the speedometer drive gear is to be replaced, first
remove the flange seal by prying and pulling the curved-
up lip of the flange seal.
[Notice]
Be careful not to damage the bearing, bearing cage or case.
Remove and discard the flange seal.
14. Remove the speedometer drive gear and upper tone wheel.
15. If the rear output shaft bearing requires replacing, remove
the internal snap ring that retains the bearing in the bore.
16. From the outside of the case, drive out the bearing using
the driver.
17. Remove the three nuts and washers retaining the clutch
coil assembly to the rear case.
18. Pull the assembly, along with the O-ring and wire, from
the case.
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19. Remove bearing assembly from output shaft.

20. Remove the clutch housing from the output shaft.
21. Remove the balls and apply cam and wave washer from
the output shaft.
22. Remove snap ring from output shaft.
23. Remove clutch pack assembly from output shaft.
24. Remove the chain, driven sprocket and drive sprocket as

an assembly.
25. Remove thrust washer from output shaft.
26. Remove the magnet from the slot in the front of the case
bottom.
27. Remove the output shaft and oil pump as an assembly.
28. If required, to remove the pump from the output shaft,
rotate the pump to align.
29. Pull out the shift rail.
30. Remove the helical cam from the front case.
31. If required, remove the helical cam, torsion spring and
sleeve from the shaft.
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32. Remove the high-low range shift fork and collar as an

assembly.
33. Expand the tangs of the large snap ring in the case.
34. With the input shaft against a bench, push the case down
and slide the main drive gear bearing retainer off the
bearing.
35. Lift the input shaft and front planet from the case.
36. If required, remove the oil seal from the case by prying
and pulling on the curved-up lip of the oil seal.
[Notice]
37. Remove the internal snap ring from the planetary carrier.
38. Separate the front planet from the input shaft.
39. Remove the external snap ring from the input shaft.
40. Place the input shaft in a vise and remove the bearing.
41. Remove the thrust washer, thrust plate and the sun gear
off the input shaft.
42. Inspect the bushing and needle bearing in the end of the
input shaft for wear or damage.
[Notice]
Under normal use, the needle bearing and bushing should
not require replacement. If replacement is required, the
bushing and needle bearing must be replaced as a set.
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43. If replacement of the needle bearing and bushing is

required, press the bearing and bushing is required, press
the bearing and bushing out as follows:
• Position the input shaft on Axle Bearing/Seal plate,
and using Pinion Bearing Cone Replacer as a spacer.
• Insert Input Shaft Bearing Remover into the input shaft
so it is resting on top of the bearing cage.
• Tighten the actuator pin until it stops, then press the
bearing and bushing out together.
44. If required, remove the front yoke to flange seal by prying

and pulling on the curved-up lip of the yoke to flange
seal.
[Notice]
45. If required, remove the internal snap ring retaining the

front output shaft ball bearing and remove the bearing.
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3. ASSEMBLY PROCEDURE
1. Before assembly, lubricate all parts with Automatic
Transmission Fluid or equivalent.
2. If removed, drive the bearing into the front output case
bore.
[Notice]
Drive the bearing in straight, making sure it is not cocked in
the bore.
3. Install the internal snap ring that retains the bearing to

the front case.
4. If removed, install the front yoke to flange seal in the
front case bore.
5. If removed, install the yoke to flange seal into the mounting
adapter bore.
6. If the input shaft needle bearing and bushing were

removed, install a new bearing and bushing as detailed
in the following steps:
Press a new needle bearing, then a new bushing in the
input shaft as follows:
• Position the input shaft on Axle Bearing/Seal Plate
or equivalent, and Pinion Bearing Cone Replacer as
a spacer.
• Press a new needle bearing into the end of the input
shaft until it seats in the input shaft.
• Press in a new bushing.
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7. The recessed face of the sun gear and the snap ring
groove on the bearing outer race should be toward the
rear of the transfer case.
8. The stepped face of the thrust washer should face toward
the bearing.
9. Slide the sun gear, thrust plate and thrust washer into
position on the input shaft.
10. Press the bearing over the input shaft.
11. Install the external snap ring to the input shaft.
12. Install the front planet to the sun gear and input shaft.
13. Install the internal snap ring to the planetary carrier.
14. Place the tangled snap ring in the case. Expand snap
ring with snap ring pliers and install planetary carrier
assembly. Check installation by holding the case and
carefully tapping the face of the input shaft against a
wooden block to make sure the snap ring is installed.
15. Remove all traces of gasket sealant from the front case
and mounting adapter mating surfaces. Install a bead of
gasket sealant on the surface of the front case.
16. Install the high-low shift fork and high-low collar as an

assembly into the front planet.
17. If new pump is used, align the flat of the output shaft and
the flat of the pump. Slide the pump onto the output shaft.
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18. Inspect the outside surfaces and bore of the oil pump.
19. Install the output shaft and oil pump in the input shaft.
Make sure that the internal splines of the ouput shaft
engage the internal splines of the high-low shift collar.
Make sure that the oil pump retainer arm and oil filter leg
are in the groove and slot of the front case.
20. Install the magnet in the slot in the front case just above
the oil filter leg.
21. Install the front output shaft in the front case.
22. Install the thrust washer on the rear output shaft.
23. Install the chain, drive sprocket and driven sprocket as

an assembly over the output shaft.
[Notice]
The driven sprocket (on the front output shaft) must be
installed with the marking REAR facing toward the rear case,
if so marked.
Drive sprocket has a bushing pressed into it.
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24. Install tone wheel onto the front output shaft. Make sure
the spline on the tone wheel engages the spline on the
front output shaft.
25. Install clutch pack assembly onto the rear output shaft.
Make sure the spline of the clutch pack engages to the
spline of the sprocket.
26. Install snap ring onto the rear output shaft. Start the snap
ring over the spline and use the wave spring to seat the
snap ring in the snap ring groove.
If the snap ring will not install, the thrust washer inside
the clutch pack may not be seated properly.
27. Install wave spring, insulator washer and armature. (Three
offset slots must align with housing to be installed)
[Notice]
Three slots on the thrust washer must be aligned with the
three tabs on the clutch pack housing.
28. Install apply cam onto the rear output shaft,

29. Install three balls into the apply cam.
30. Install cam and coil housing assembly onto rear output
shaft.
31. Install thrust bearing assembly onto output shaft.
32. If removed, drive the front output shaft ball bearing into
the rear cover bore with Front Shaft Needle Bearing
Replacer and Driver Handle.
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33. If removed, install the rear output bearing in the rear case
bore. Drive the bearing into the rear case bore with Output
Shaft Bearing Replacer and Driver Handle. Make sure
that the bearing is not cocked in the bore.
34. Install the internal snap ring that retains the bearing to
the rear case.
35. Install the clutch coil from inside the rear case until the
wire and studs extend through the cover.
[Notice]
Do not kink or trap the wire while seating the clutch coil to
the case.
36. Install the washers and nuts and tighten.

Installation Notice
8 - 11 Nm
Tightening torque
(71 - 97 lb-in)
37. Slide the spring spacer on the camshaft and position it

beneath the drive tang.
38. Place the torsion spring on the camshaft. Position the
first spring tang to the left of the camshaft drive tang.
39. Rotate the second spring tang clockwise past the drive
tang.
43a
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AFFECTED VIN
50 4D
40. Push the torsion spring and sleeve in as far as it will go.
41. Install the helical cam and slide the drive tang between
the torsion spring tangs as far as it will go.
42. Install the pin on the tang end of the helical cam into the
hole in the front case. Position the torsion spring tangs
so that they are pointing toward the top side of the
transfer case and just touching the high-low shift fork.
[Notice]
Do not bend the helical cam during installation to the front
case because of possible damage to the pin at the tang end of
the motor shaft.
43. Install the shift rail through the high-low shift fork and
make sure that the reverse gear shift rail is seated in the
front case bore.
44. Install upper and lower speed sensors into the cover.
Feed the coil wire through the upper speed sensor wire
shield.
45. Install upper tone wheel, speedometer gear and rear

output seal. Use Output Shaft Seal Replacer and Driver
or equivalent to install seal.
CHANGED BY TOD
AFFECTED VIN
4D 51
46. Coat the mating surface of the front case with a bead of
Black Non-Acid Cure Silicone Rubber or equivalent.
47. The following procedure must be followed prior to installing
the rear case onto the front case half:
• Align the output shaft with the rear case output shaft
bore.
• Align the helical cam with the rear case motor bore.
• If difficulty is encountered with seating the rear case,
tap the rear output shaft with a sharp blow using a
rubber mallet in a direction away from the triangular
shaft while pushing down on the rear case.
48. Install the bolts retaining the case halves and tighten.
Installation Notice
25 - 37 Nm
Tightening torque
(8 - 27 lb-in)
49. Install shift shaft oil seal if it is not installed.
50. Using pliers equipped with soft jaws, rotate the triangular
shaft so it is aligned with the triangular slot in the transfer
case shift motor.
[Notice]
If triangular shaft will not rotate, rotate the rear output shaft.
TOD CHANGED BY
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52 4D
51. Tighten manually the two nuts that attach the slotted
support bracket to the end of the motor house.
52. Apply Black Non-Acid Cure Silicone Rubber or equivalent
to motor housing base and install on transfer case.
53. Install the transfer case shift motor and three bolts along
with speed sensor wire harness bracket and tighten.
Installation Notice
8 - 11 Nm
Tightening torque
(71 - 97 lb-in)
54. Holding the slotted support bracket tight against the motor
housing end, secure the bracket to the transfer case,
tightening the bolt with lock washer.
Installation Notice
8 - 11 Nm
Tightening torque
(71 - 97 lb-in)
55. Retighten the two nuts that attach the slotted support
bracket to the end of the motor.
Installation Notice
3 - 6 Nm
Tightening torque
(27 - 53 lb-in)
56. Install the clutch coil wire terminal(brown) and other shift
motor wires to the 7-pin connector(black).
57. Install the connector retainer at the connector end.
58. Connect the front and rear speed sensors wiring to the
7-pin connector(white).
59. Install the rear case flange on the output shaft.
60. Install the rubber seal, output shaft yoke washer and nut.
Tighten the nut.
Installation Notice
Tightening torque 137 - 196 Nm
61. Install the drain plug and tighten.
19 - 30 Nm
Tightening torque
(14 - 22 lb-in)
62. Fill the transfer case with 1.4 liters of Automatic

Transmission Fluid or equivalent.
63. Install the fill plug and tighten.
Installation Notice
19 - 30 Nm
Tightening torque
(14 - 22 lb-in)
64. Install the transfer case as outlined in removal and

Installation.
CHANGED BY TOD
AFFECTED VIN
4D 53
661 589 01 37 00 (W 99 31 001 1B) Removal/installation of carrier

Pliers assembly in transfer case
DW 220 - 080 (W 99 31 005 0B) Installation of oil seal to

Oil seal installer transmission case
TOD CHANGED BY
AFFECTED VIN
54 4D
TROUBLE DIAGNOSIS
TCCU periodically monitors the input and output while the system is in operation. When a fault is detected, the trouble
code is stored into TCCU memory.
If the ignition switch is turned to “OFF”, TCCU stops monitoring for input and output, however, when the ignition switch
is turned to “OFF” before shifting completes, TCCU continues monitoring for input and output required for the shifting.
1. SELF DIAGNOSIS TEST

Shift Motor Test
When TOD control unit detects a fault in shift motor or position encoder for over 1 second, “4WD CHECK” warning lamp
comes on and the trouble code is stored into memory.
• Shift motor fault occurs when the motor is in “OFF” state:
- short to ground in motor HI-LO circuit
- short to ground in motor LO-HI circuit
- open in motor circuit
• Shift motor fault occurs when the motor is in normal operation state:
- short to ground in motor HI-LO circuit
- short to ground in motor LO-HI circuit
- short between motor LO-HI and motor HI-LO circuit
- open in motor circuit
• Position encoder fault occur when
- Detected unmatched code with 9 valid position codes
- An encoder circuit is short to ground
• When the fault occurs before the shift operation is started, the TOD control unit does not respond to any shift
command.
• When, after receiving shift command, the fault occurs without any operation, the TOD control unit cancels the
command and does not respond to any following shift command.
• If TOD control unit, even while shift command is in progress, detects an invalid position code, it stops the operation
and turns motor to “HIGH” position. After then, TOD control unit does not respond to any shift command.
• When the shift motor and position encoder assembly fault (fault other than motor fault that is caused when normal
power supply is applied) is restored continuously for 1 second, the TOD control unit function becomes normal. At
this time, “4WD CHECK” warning lamp comes on but the trouble code is stored into memory.
• The trouble code being detected in shift motor during its operation is defined as timeout.
• The trouble code for shift motor can be erased by using scanner.
Position Encoder Test

• When the system detects a fault in shift motor for over 1 second, “4WD CHECK” warning lamp comes on and the
trouble code is stored into memory.
• Position encoder fault can be divided into general encoder fault and short to ground of position encoder circuit.
- General encoder fault: Invalid position code input
- Short to ground of position encoder circuit: Ground for encoder circuit
CHANGED BY TOD
AFFECTED VIN
4D 55
Front Sensor Speed Test

When the system detects a fault from front speed sensor for over 0.5 second, “4WD CHECK” warning lamp comes on.
At this time, the responds from TOD control unit are as follows:
• If the system is in “4H” state, the TOD control unit uses rear speed sensor value to determine the amount of EMC
touch off and the wheel slip control stops.
• If the system is in “4L” state, the EMC duty cycle is set at maximum value (according to the vehicle speed) until
system stops “4L” operation.
• All electrical shift operations are stopped until ignition switch is cycled from “OFF” to “ON” position. Any shift
operation in progress completes the process. When the front speed sensor is restored continuously for 0.5 seconds,
the TOD control unit becomes normal status. At this time, “4WD CHECK” warning lamp comes on but the trouble
code still remains in the memory.
Rear Speed Sensor Test

When the system detects a fault from rear speed sensor for over 0.5 second, “4WD CHECK” warning lamp comes on.
At this time, the responds from TOD control unit are as follows:
• If the system is in “4H” state, the TOD control unit uses front speed sensor value to determine the amount of EMC
touch off and the wheel slip control stops.
operation in progress completes the process. When the rear speed sensor is restored continuously for 0.5 seconds,
All Troubles from Speed Sensor

When the system detects a fault from front and rear speed sensors for 0.5 seconds, “4WD CHECK” warning lamp
comes on. At this time, the responds from TOD control unit are as follows:
• If the system is in “4H” state, the TOD control unit is set up based on EMC touch off amount and the wheel slip
control stops.
operation in progress completes the process. When the rear speed sensor is restored continuously for 0.5 seconds,
EMC Test
The EMC tests whether the circuit is short or open to ground. When the system detects a fault for 0.8 seconds, “4WD
CHECK” warning lamp comes on and TOD stops its operation. When the EMC is restored continuously for 0.8 seconds,
the TOD control unit functions normally. At this time, “4WD CHECK” warning lamp comes on but the trouble code still
remains in the memory.
TOD CHANGED BY
AFFECTED VIN
56 4D
CAN TPS Test

• When TCCU receives CAN message including TPS value of over 100 % continuously for 1 second, TCCU determines
it as signal error and “4WD CHECK” warning lamp comes on.
When the system is in TOD mode, the TOD control unit considers that the throttle is in idle.
• When the TPS value is restored continuously for 1 second, the TCCU functions normally and “4WD CHECK” warning
lamp comes on but the trouble code still remains in the memory.
• TCCU receives CAN TPS messages periodically. If TCCU cannot receive the messages for 4 periods, TCCU determines
it as signal loss. If it happens continuously for 1 second, TCCU considers it as the invalid signal and “4WD CHECK”
warning lamp comes on.
• When the CAN message including ABS value is restored continuously for 1 second, TCCU functions normally and
“4WD CHECK” warning lamp comes on but the trouble code still remains in the memory.
Transmission Neutral Test

• If TCCU cannot receive the messages for 4 periods, TCCU determines it as signal loss. If it happens continuously for
1 second, TCCU considers it as the invalid signal and “4WD CHECK” warning lamp comes on. And TCCU determines
that the transmission is not in neutral position.
• When CAN message including indication of transmission in neutral is restored continuously for 1 second, TCCU
functions normally and “4WD CHECK” warning lamp comes on but the trouble code still remains in the memory.
Stuck in Low Test

• Stuck in low DTC is set when the shift conditions are satisfied, no encoder trouble exists and the TCCU is not
formed outside of shift range. Stuck in low trouble completing time is 1 second longer than the maximum shift. If the
trouble is detected, “4WD CHECK” warning lamp comes on and shifting is not possible.
• If stuck in low fault is not valid, it is erased at the next ignition cycle and the “4WD CHECK” lamp lights out but fault
code remains in the memory.
CAN Bus Off Test

• CAN bus off trouble is set when the transferring trouble exceeds 255 times and CAN bus in TCCU goes to off
condition. When the trouble counter exceeds 255 times, the signal is recognized as invalid and the “4WD CHECK”
warning lamp comes on.
• If CAN bus in TCCU goes to reset condition while in Bus off condition, the transferring and receiving signals are
interrupted and the synchronization for bus disappears. Once it is reset, TCCU tries to resynchronize with CAN bus.
When the resynchronization stops, the communication is resumed. At this time, the trouble is erased and “4WD
CHECK” warning lamp comes on but the trouble code still remains in the memory.
CHANGED BY TOD
AFFECTED VIN
4D 57
2. CODING ON TOD CONTROL UNIT

What’s Coding?
An input activity of data for the proper performance by match-
ing specification, devices and system with control unit.
Coding required
1. Replacement of TOD control unit.
2. Adjustment by input error.
Coding method
1. Check and record engine type, axle ratio and tire size.
3. Connect the scanner with diagnosis connector.
5. Select “TOD” from “CONTROL UNIT SELECTION” screen
and press “ENTER”.
6. Read the current memorized specification in TOD control
unit.
7. Compare memorized specification with the checked
record. If not matched, perform a coding.
8. Read again memorized coding specification in TOD
control unit for confirmation of coding.
10. After 5 seconds, turn the ignition switch to “ON” position.
11. Check coding specification whether it matches with
vehicle or not. If not, perform a coding again.
TOD CHANGED BY
AFFECTED VIN
58 4D
3. DIAGNOSTIC TROUBLE CODE

Code Description Action
P1806 CAN Bus OFF - Check communication line.
- Check the relevant connectors for contact.
- Replace TOD unit if necessary.
P1816 CAN: abnormal TPS signal - Check communication line.
- Check engine ECU.
P1814 CAN: no TPS signal - Check communication line.
- Check engine ECU.
P1815 CAN: no neutral signal - Check communication line.
- Check TCU.
P1817 CAN: no ABS signal - Check communication line.
P1821 Open or short to battery in magnetic clutch - Check communication line.
coil circuit - Replace TOD unit if necessary.
P1822 Short to ground in magnetic clutch coil cir- - Voltage at TCCU pin No.11: 11 ~ 15 V
cuit - EMC resistance: 2.5 Ω
P1830 Abnormal rear speed sensor signals - The indicator is flickering even after IG switch ON.
- The indicator is flickering over 0.5 seconds.
- Check the relevant harnesses.
- Replace sensors if necessary.
P1831 Too low front speed sensor voltage - Too low front speed sensor voltage
P1832 Too high front speed sensor voltage - Too high front speed sensor voltage
P1833 Too low rear speed sensor voltage - Pin voltage: below 0.9 V
- Check the rear speed sensor harness for contact.
- Replace TCCU if necessary.
P1834 Too high rear speed sensor voltage - Pin voltage: 4.75 ~ 5.25 V
CHANGED BY TOD
AFFECTED VIN
4D 59
Code Description Action

P1835 Too low speed sensor reference voltage - Reference voltage: below 4 V
P1836 Too high speed sensor reference voltage - Reference voltage: over 8 V
P1841 Open to ground in shift motor circuit - When TCCU detects the motor failure for 1 second
(Action: IG switch ON)
- Check the relevant harnesses for contact.
- Replace shift motor if necessary.
P1842 Short to ground in shift motor output circuit - When TCCU detects the motor failure for 1 second
(Action: IG switch ON)
P1843 Shift system timeout - 2H-4H: after 1.5 seconds
- 4H-4L: after 3 seconds
P1844 Too low position encoder voltage (Stuck in - When no signals from the position encoder
Low) - Check the relevant harnesses for contact.
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2 4E
GENERAL INFORMATION
1. SYSTEM OVERVIEW
4WD
Power steering pipe
Sub frame
assembly
Brake assembly Brake assembly
Front axle
assembly
Power steering assembly
Rear propeller shaft
C.G.P
(Center Gravity Point)
CHANGED BY FRONT SUSP & AXLE

AFFECTED VIN
4E 3
When the sub frame needs to be removed
* 4WD * 2WD
1. Engine oilpan replacement. 1. Engine oilpan replacement.

2. Front axle replacement.
3. Power steering assembly replacement.
2WD
Power steering pipe
Sub frame
assembly
Brake assembly
Brake assembly
Stabilizer bar Power steering assembly
FRONT SUSP & AXLE CHANGED BY

AFFECTED VIN
4 4E
2. SPECIFICATION
Suspension type Double wishbone
Spring type Coil spring : K = 8.8 (kgf/mm)
Shock absorber type Gas type
Stabilizer type Torsion bar : ∅ 30
Camber : 0° ± 30′
Wheel alignment Caster : 4.5° ± 30′
Toe-in : 0 ~ 4 (mm)
Axle size 214 (mm)
Axle ratio 3.7 3.9 4.1 4.3 4.6 4.9 5.4 5.9
Pinion 11 11 9 11 9 9 8 7
Number of tooth
Gear 41 43 37 47 41 44 43 41
Weight 34 (kg)
Length 250.43 (mm)
Oil capacity 1.4 ( )
Specified oil SAE 90

AFFECTED VIN
4E 5
Dimension (Sub Frame)

(Unit : mm)

AFFECTED VIN
6 4E
3. FRONT AXLE ASSEMBLY

Front axle assembly located between left and right wheel transfer the power from the transmission to both wheel when
4-wheel drive mode is chosen.
At the end of axle sides, axle shafts are connected by constant velocity joint and differential carrier is located in the axle
housing.
Mounting Point Mounting Point
Left drive shaft Right drive shaft
Mounting Point
Front propeller shaft
Drive Shaft Assembly

Left and right axle have same over length and removal and Location Grease capacity
maintenance are easily performed.
In boot 140 ~ 160g
Out boot 200 ~ 220g
Wheel side
Diffential carrier side
Out boot In boot

AFFECTED VIN
4E 7
4. FRONT SUSPENSION
Coil spring
Upper arm
Knuckle
Stabilizer bar Lower arm
* Characteristics of front suspension

1. Upper arm mounted relatively high.
2. Coil spring and shock absorber mounted.
3. Maximzed torsion bar effciency.
4. Big rubber bush for better comfort.
5. Minimized king pin offset to decrease vehicle movement.
6. Increased effective wheel base.
7. Diversfied type (2WD, 4WD)

AFFECTED VIN
8 4E
1) Knuckle (4WD)
1. There are two types of knuckle (4WD, 2WD)
2) Upper arm
1. Minimized gap between coil spring and tire (15mm).

2. Optinized ball joint angle against fluctuating.
3) Lower arm assembly

1. Shock absorber mounted on the bush is
connected to the sub frame with upper arm and
lower arm. It suports the load, at the same time,
it absorbs shock and vibration transferred to the
vehicle.
2. Front mount bush is set on the sub frame and
camber bolt for camber/caster adjustment is
assembled to the lower arm
Cam bolt

AFFECTED VIN
4E 9
5) Shock absorber and coil spring

Shock absorber and coil spring is a device for damping
sudden and rapid motion, as the recoil of a spring-
mounted object from shock.
4) Stabilizer bar assembly
Stabilizer bar
Mounting bracket Mounting bracket
Stabilizer link Stabilizer link
Stabilizer bars are part of a car’s suspension system.

They are sometimes also called anti-sway bars or anti-roll bars.
Their purpose in life is to try to keep the car’s body from “rolling” in a sharp
turn.

AFFECTED VIN
10 4E
Structure of Shock Absorber and Coil Spring
1. Coil spring
Specification
4WD 2WD
Spring constant (kg/mm) 8.8 ± 5 % 8.8 ± 5 %
Coil diameter (mm) 16.7 16.6
Coil inner diameter (mm) D1 75.0 75.0
D2 105.0 105.0
Pitch (mm) 85.0 85.0
Number of winding 9.36 9.36
Number of active winding 7.86 7.86
C.V.W Height (mm) 256.0 256.0
(Curved vehicle weight) Weight (kg) 1047 ± 5 % 905 ± 5 %
Strength (kg/mm) 65.8 68.2
Winding direction Rightward Leftward

AFFECTED VIN
4E 11
2. Shock Absorber Assembly

Specification
Max. working distance 540 (mm)

Min. working distance 452 (mm)
Working distance 88 (mm)

AFFECTED VIN
12 4E

1. COMPONENTS
Front Syspension Assembly
1. Coil spring
16. Upper arm bush
3. Upper bracket
5. Lower bush
15. Upper arm
6. Spring-upper rubber sheet
14. Upper arm ball joint
2. Shock absorber
7. Dust cover
13. Knuckle
9. Stopper-bumper
8. Cam bolt
11. Lower arm 12. Lower arm ball joint
4. bush
10. Lower arm rubber bush
4WD 2WD
23. Hub assembly
13. Knuckle
18. Brake dust shield

22. Brake disk
19. Lock nut
19. Lock nut 13. Knuckle 22. Brake disk

17. Axle shaft
18. Brake dust shield
20. Hub assembly 21. Washer

21. Washer

AFFECTED VIN
4E 13
Front Axle Assembly
Air bleeder
Carrier cover
Ring gear
Axle mounting bracket
Ball bearing
Shim
Pinion gear
Oil seal Ball bearing

Pinion drive seal
Axle mounting bracket
Axle housing
Snap ring Shim

Flage
Ball bearing
Lock nut
Inner shaft
Axle shaft assembly

AFFECTED VIN
14 4E
2. PRECEDING WORK FOR SUB FRAME REMOVAL
1. Install the safety wedge under both rear wheels

(Put the shifting lever in “P” position and apply the parking brake)
2. Additional safety jack

Because the weight balance move to rear when the sub
frame is removed, safe working condition must be
prepaired.
For this reason, Installing the safety jack to both under
body is important to avoid unexpectable accident.
(The height of safty jack to both side must be same)
16.5 cm
3. The mounting location of suplement lift

The supplement lift is used when you remove or install the sub frame
(Keep in mind the center of gravity of sub frame locate near front axle mounting point)
Front Rear

AFFECTED VIN
4E 15
4. Remove the engine lnsulating brackets from the front sub frame as the
engine hung by an additional lift (crane)
5. Install the engine mounting bracket
Before removal of sub frame, install the special tool (Engine mounting
brackets) on the body frame
RH LH RH LH
Engine insulating Engine mounting

brackets on the sub frame brackets on the body
Part number : A9912 008 2B
RH LH

AFFECTED VIN
16 4E
3. REMOVAL OF SUB FRAME

Preceding Work: 1. Secure the frame and remove the tires
2. Remove the front propeller shaft.
Sub Frame Connected Area

1. Remove the power steering pipes 2. Remove the front calier (C) and wheel speed sensor (D)
(A: High, Low pressure) and lower arm (Fix the caliper and speed sensor on the body. Disconnect the brake
shaft (B) at the rear side of syb frame. hose clip)
Wheel
Power steering
pipes (Front)
3. Unscrew the power steering pipe (A) mounting bracket 4. Unscrew the knuckle upper bolt (E) and
(1, 2) and release them shock absorber lower bolt/nut (F) and then,
remove the shock absorber from knuckle.

AFFECTED VIN
4E 17
5. Leave mark with a marking painter on the sub frame mounting bolts (19mm - 4EA).
(Tightening torque: 95 ~ 142 Nm)
6. Locate two sypplement lifts under sub frame (Front/Rear) and unscrew the sub frame mounting bolts (19mm -
6EA). And then, drop the lifts slowly.
[Notice]
Apply rubber blocks under sub frame to prevent the frame and other components from damage.

AFFECTED VIN
18 4E
Rubber block at the front side
Rubber blocks at the rear side

AFFECTED VIN
4E 19
7. Installation is in the reverse order of removal (Keep the exact mount holes and tightening torque)

AFFECTED VIN
20 4E
Removal of Sub Frame with Two Colume Lift

1. Since two column type lift does not have supplementary lift, special tool to support the sub frame is required. When
install, apply the special tool with guide pin on the sub frame 3rd cross member and fix the guide bar of special tool
on the 2nd cross member.
2nd cross member
Guide bar Guide bar
3rd cross member
Guide pin

AFFECTED VIN
4E 21
2. Do the same preceding work to remove the sub frame (page 624 ~ 626).
3. Remove the sub frame mounting bolts (19mm - 6EA)
4. Drop the special tool with sub frame slowly.

AFFECTED VIN
22 4E
4. FRONT AXLE ASSEMBLY

Preceding Work: 1. Remove the tires.
2. Remove the brake calipers and wheel speed sensors (Fix to the body).
Axle Shaft (Drive Shaft)
Coil spring & shock absorber assembly
Upper arm
Knuckle
Brake caliper
Stablilizer
Power steering assembly
Brake disk
1. Unscrew axle shaft lock nut (30 mm - 1EA) and remove

washer.
[Notice]
• Axle shaft lock nut can not be reused. Replace it with new
one when reinstall.
• Keep the tightening torque and cock the nut.

AFFECTED VIN
4E 23
2. Unscrew the knuckle upper bolt & nut (19mm - 1EA).
3. Remove the knuckle from axle shaft and lay outward.
4. Pull out the axle shaft.

AFFECTED VIN
24 4E
Axle Housing Oil Seal

Preceding Work: Remove the axle shaft.
1. Unscrew the axle mounting bracket bolts and nut, and remove the axle mounting bracket.
Tightening torque
Mounting bolts (4EA) 10 ± 1.0 Nm

Mounting bolt / nut (1EA) 95 ~ 142 Nm

AFFECTED VIN
4E 25
Axle Housing Assembly

Preceding Work: Remove the sub frame assembly and disassemble the axle shaft from axle assembly.
Axle assembly
Removal of axle shaft
Diffential carrier &

Housing assembly
Bolt
Bolt
Bush
Bush
Washer
Bush
Washer Nut
Bush
Nut
Washer
Nut

AFFECTED VIN
26 4E
1. Unscrew the axle housing mounting bolt on the sub frame and disassemble the axle.
A. Axle mounting bolt/nut

* Keep the right direction of busing when install
Upper bush
Spacer
Color coke
Lower bush coated
Lower bush
Bracket on the sub frame
B. Axle housing mounting nut - Left C. Axle housing mounting nut - Right
(Tightening torque : 95 ~ 142 Nm) (Tightening torque : 95 ~ 142 Nm)

AFFECTED VIN
4E 27
5. FRONT SUSPENSION ASSEMBLY

Preceding Work: 1. Remove the tires.
2. Remove the brake calipers and wheel speed sensors (Fix to the body).
Upper Arm Assembly
Upper arm assembly
Upper arm assembly
Upper arm bush

AFFECTED VIN
28 4E
1. Remove wheel speed sensor and cable. (10 mm - 1EA, Tightening torque : 6 ~ 8 Nm)
Cable
Speed sensor mounting bolt
2. Unscrew knuckle upper mounting bolt/nut (19 mm - 1EA) and upper arm mounting bracket bolts (14 mm - 4EA) to
remove upper arm assembly.
Knuckle upper bolt (Upper arm ball joint) Upper arm mounting bracket bolts
Tightening torque : 140 ~ 160 Nm Tightening torque : 140 ~ 160 Nm

AFFECTED VIN
4E 29
Lower Arm Assembly

Check point before removal
When you need to remove lower arm assembly, leave a mark on the lower arm mounting bolts (Front /
Rear) for wheel alignment job.
Front
Rear
Lower arm assembly
Lower arm
Ball jont
Ball joint
mounting bolt Cam bolt
Washer / Bolt Cam bolt

AFFECTED VIN
30 4E
1. Unscrew the shock absorber lower mounting bolt/nut (1) and stabilizer link low nut (2).
Shock absorber lower bolt/nut : 110 ~ 130 Nm

Tightening torque
Stabilizer link lower nut : 110 ~ 120 Nm
2. Unscrew lower arm ball joint bolt/nut (Knuckle).
3. Unscrew lower arm bolt/nut (Frame).
4. Remove lower arm assembly from the sub frame.

AFFECTED VIN
4E 31
Coil Spring & Shock Absorber Assembly

Preceding Work: Remove the tire and wheel speed sensor.
Coil spring & shock absorber
1. Use a special tool to remove the coil spring

from shock absorber assembly.
2. Keep the specified end gap between shock

absorber and adjust bolt (10 mm).

AFFECTED VIN
32 4E
1. Unscrew knuckle upper bolt and then, lay the knuckle

outward.
2. Unscrew the coil spring upper seat mounting nuts (1) at

the top of the shock absorber (10 mm x 3EA).
[Reference]
RH Under FFH
LH Under brake oil reservoir tank
3. Unscrew the shock absorber lower bolt and pull upward as putting down the assembly.

AFFECTED VIN
4E 33
Stabilizer Bar Assembly
Stabilizer bar assembly
Stabilizer bar assembly
Mounting bracket
Mounting bracket
Stabilizer bar link

Stabilizer bar link

AFFECTED VIN
34 4E
Stabilizer bar link Stabilizer bar link
Mounting bracket
Mounting bracket
2. Unscrew the stabilizer bar cap bolts (3) and 1. Unscrew the stabilizer bar link upper nut (1) and
remove the stabilizer bar. lower bolt (2) to remove the link.
Tightening torque 110 ~ 120 Nm Upper bolt : 60 ~ 80 Nm

Tightening torque
Lower bolt : 110 ~ 130 Nm

AFFECTED VIN
4E 35
Knuckle Assembly
Preceding Work: 1. Removal of tires.
2. Removal of brake caliper and wheel speed sensor (Fix the sensor to the body).
Knuckle assembly

AFFECTED VIN
36 4E
1. Unscrew the lock nut (1) and brake disk mounting bolts Tightening torque 8 ~ 12 Nm
(2: 5 mm - 2EA) and then, remove the disk from knuckle
assembly.
2. Unscrew the brake dust shield mounting bolts (3EA).
3. Remove the knuckle mounting bolts in the following order

A. Tie rod end nut (19mm - 1EA)
: Remove the pin first (A)
[Notice]
Keep the tightening torque and if the position of pin hole is

improper, rotate the nut to the tightening direction.
B. Lower arm bolt nut (19mm - 1EA)

: Release the bolt first. Remove after upper arm bolt
(C) is removed.
C. Upper arm bolt/nut (19mm -1EA)

AFFECTED VIN
4E 37
4. Remove the front wheel nuckle from the drive shaft.

(Replace the brake disk lock nut with new one for every disassembly and do the cocking job for the nut)

AFFECTED VIN
38 4E
TROUBLE DIAGNOSIS
Vehicle rolling Broken stabilizer bar Replace
Faulty shock absorber Replace
Abnormal noises Loosening mountings Re-tighten
Damaged or worn wheel bearing Replace
Damaged shock absorber Replace
Damaged tire Replace
Poor riding Over inflated tire Pressure adjust
Faulty shock absorber Replace
Loosened wheel bolt Tighten as specified torque
Bent or broken coil spring Replace
Damaged tire Replace
Worn bushing Replace
Vehicle pulls to right or left Deformed arm assembly Replace
Worn bushing Replace
Bent or broken coil spring Replace
Hard steering Incorrect front wheel alignment Repair
Excessive resistance of lower arm ball joint Replace
Insufficient tire pressure Adjust
Faulty power steering Repair or replace
Steering instability Incorrect front wheel alignment Repair
Worn or loosened lower arm bushing Re-tighten or replace
Vehicle bottoming Worn or broken coil spring Replace

AFFECTED VIN
2 4F
REAR AXLE CARRIER (MODULE)

1. SYSTEM OVERVIEW
Shock absorber
Camber link
Coil spring Axle shaft
Wheel carrier
Tension link
Track rod
Thrust link
Stabilizer
Axle mounting
Front View
CHANGED BY REAR SUSP & AXLE

AFFECTED VIN
4F 3
Rear View
Axle mounting
Rear brake cable
Rear Axle & Axle Shaft
Rear axle Axle shaft
Spring link
REAR SUSP & AXLE CHANGED BY

AFFECTED VIN
4 4F
2. SPECIFICATION
Suspension type Multi-link
Spring type Coil spring K=120 kgf/mn
Shock absorber type Gas
Stabilizer type Torsion bar Ø14
Toe-in 0.04° ± 0.08°
Wheel alignment
Camber -1.0° ± 0.5°
Diameter (Axle) (mm) Ø 230
Gear ration 37 3.9 4.1 4.3 4.6 4.9 5.4 5.9
Pinion 11 11 9 11 9 9 8 7
Number of tooth
Gear 41 43 37 47 41 44 43 41
Weight (kg) 40
Length (mn) 250.43
Oil capacity ( ) 1.7
Specified oil TOTAL-ISU EP- B85W-90

AFFECTED VIN
4F 5

1. Move the 2nd raw seat to te front end and unscrew the 2. Remove the rear shock absorber upper nut (2),
rear shock absorber upper cover mounting screw (1). washer and bush.
Keep the specified end gap between shock absorber.

(A: 7 ~ 12 mm)

AFFECTED VIN
6 4F
3. Remove the rear propeller shaft. 4. Disconnect the parking brake cable.
5. unscrew the frame mounting bolt on the rear axle 6. Remove the wheel speed sensor (LH/RH).
carrier module front side.

AFFECTED VIN
4F 7
7. Unscrew the stabilizer mounting bolt (A) and remove it from the vehicle.
8. Remove rear frome mounting bolt (B) at the rear axle carrier module.

AFFECTED VIN
8 4F
9. Remove the rear axle carrier module from the vehicle.
Front
Rear

AFFECTED VIN
4F 9
REAR SUSPENSION SYSTEM

1. SYSTEM OVERVIEW
Camber link
Tension link
Track rod
Thrust link
Stabilizer bar

AFFECTED VIN
10 4F
Spring link
Wheel carrier
Stabilizer link
Coil spring
Shock absorber

AFFECTED VIN
4F 11
2. COMPONENTS
1) Rear Shock Absorber
• Keep the suitable distance when compressed and
expanded.
• Minimum length is 10 mm longer than the minimum length
under compression.
Specification
Max. length Min. length Working distance
487 mm 326.6 mm 160.4 mm
Marking Point
X : Part No.
Y : Lot Number
Ex : 3 C 12
12 ......... Day
3 ........... Month
2003 ...... Year

AFFECTED VIN
12 4F

1. Move the 2nd raw seat to the front end and unscrew 2. Remove the rear shock absorber upper nut (2), washer
the rear shock absorber upper cover mounting bolt (1). and bush.
3. Unscrew the lower mounting nut on the spring link (17 mm).

AFFECTED VIN
4F 13
4. Remove the shock absorber as pushing upward.
Shock absorber assembly

AFFECTED VIN
14 4F
2) Coil Spring
• Steel for high tensional spring is adapted.
• Maintain more than 20 mm of freeplay when compressed.
• Spring seat applied.
Specification
4WD
Part Number 45110-21000
Spring constant (kg/mm) 12.0 ± 5%
Coil diameter (mm) 15.9
Coil inner diameter (mm) 69.1
Pitch (mm) 85.0
Number of winding 9.55
Number of active winding 8.35
C.V.W Height (mm) 250
Weight (kg) 880.0
Strength (kg/mm/mm) 62.1
Winding direction Right
Spring length (mm) 323.3

AFFECTED VIN
4F 15

Compress the coil spring with special tool and then, disas-
semble the spring.
[Notice]
For easier removal, remove the spring seat first.
[Notice]
Pay attention to use special tool and coil spring.
Sudden release of coil spring could cause a serious accident.

AFFECTED VIN
16 4F
3) Thrust Link / Tension Link
Thrust Link
Tension Link

AFFECTED VIN
4F 17
Thrust Link
1. Unscrew the thrust link mounting bolts (19 mm-2EA) and remore the link.
2. When install, apply two washers to the thrust link mounting bolt/nut (A. Wheel carrier)
Tightening torque (A, B) 70 ± 8 Nm
A. Wheel carrier B. Body
[Reference]
1. Keep the right position when reinstall (faced outward).
2. Apply the longer bolt to the thrust link wheel carrier side.

AFFECTED VIN
18 4F
Tension Link
1. Unscrew the tension link mounting bolt (B. Body-19 mm).

2. Unscrew the tension link mounting bolt (A. Wheel carrier-19 mm).
Body: 70 ± 8
Tightening torque
Wheel carrier: 70 ± 8
[Reference]
1. Keep the right position when reinstall.
2. Apply the longer bolt to the tension link wheel carrier side.

AFFECTED VIN
4F 19
4) Track Rod
1. Unscrew the track rod mounting bolt (A. Body-19 mm)
Tightening torque 70 ± 8
2. Unscrew the track rod mounting bolt (B. Wheel carrier-17 mm)
A. Body B. Wheel carrier

AFFECTED VIN
20 4F
5) Camber Link
1. Unscrew the camber link mounting bolt (B. Body-19 mm)
2. Unscrew the camber link mounting bolt (A. Wheel carrier-19 mm)
[Notice]
1. When install, apply two washer to the camber link mounting
bolt/nut (A. Wheel carrier).
2. Keep the right position when reinstall.

AFFECTED VIN
4F 21
6) Stabilizer Bar / Stabilizer Link
Stabilizer Link
Stabilizer bar
Stabilizer link
1. Unscrew the stabilizer link upper mounting bolt (17 mm) and lower mounting bolt (13 mm).
A B

AFFECTED VIN
22 4F
Stabilizer Bar
Preceding work: Removal of stabilizer link
- Remove stabilizer bar mounting bracket to seperate the stabilizer bar from the vehicle.

AFFECTED VIN
4F 23
7) Spring Link
1. Compress the spring with special tool for easier removal and installation.
2. Unscrew the wheel carrier mounting bolt (A), stabilizer link mounting nut (B) and shock absorber mounting nut (C).
Wheel carrier: 20 Nm
Tightening torque Stabilizer link: 120 Nm
Shock absorber: 55 Nm

AFFECTED VIN
24 4F
3. Unscrew the spring link mounting bolt on the rear axle

carrier and remove the spring link.
Spring Link
Wheel carrier
Shock absorber
Stabilizer link
Body

AFFECTED VIN
4F 25
8) Wheel Carrier Assembly

1. Remove the wheel speed sensor.
2. Remove the brake caliper.
3. Unscrew the brake disk mounting unt (2 EA) and remove the disk.

AFFECTED VIN
26 4F
4. Remove the lock nut (30 mm).
[Notice]
Lock nut can not be reused. Replace by every disassembly.
5. Remove the parking brake shoe (Refer to the wheel &

tire).
6. Remove the parking brake cable from the wheel carrier.
7. Unscrew the wheel carrier mounting nut and remove it

from the spring link.
8. unscrew the tension link, track rod, thrust link mounting
nuts on wheel carrier.

AFFECTED VIN
4F 27
9. Remove the wheel carrier from drive shaft.
A. Front view B. Rear view

AFFECTED VIN
28 4F
REAR AXLE HOUSING & AXLE SHAFT

1. SYSTEM OVERVIEW
Front mounting point Drive shaft
Rear mounting point Axle housing
Specification
Axle size Ø 214
Gear ratio 3.3 3.9 4.1 4.3 4.6 4.9 5.4 5.9
Pinion 13 11 9 11 9 9 8 7
Number of tooth
Gear 43 43 37 47 41 44 43 41

AFFECTED VIN
4F 29
2. REAR AXLE DIFFERENTIAL ASSEMBLY

Sectional Diagram

AFFECTED VIN
30 4F
1. Rear axle housing 19. Spring pin

2. Gear set (HAG 230, i = 3.31) 20. Bearing cover
3. Gear set (HAG 230, i = 3.54) 21. Bearing cover shim
4. Gear set (HAG 230, i = 3.73) 22. Differential side seal
5. Gear set (HAG 230, i = 3.91) 23. Bearing cover O-ring
6. Gear set (HAG 230, i = 4.11) 24. SOC/HD bolt
7. Gear set (HAG 230, i = 4.27) 25. Drive pinion shim
8. Gear set (HAG 230, i = 4.56) 26. Rear drive pinion bearing assembly
9. Gear set (HAG 230, i = 4.89) 27. Drive pinion tube spacer
10. Differential spider gear 28. Drive pinion support disk
11. Differential side gear 29. Drive pinion front bearing assembly
12. Spiral washer 30. Drive pinion seal
13. Differential spider shaft 31. Drive pinion flange assembly
14. Differential case - i = 3.31 - 3.73 32. Two-welled side lock nut
15. Differential case - i = 3.91 - 4.89 33. Inner flange assembly
16. Differential thrust washer 34. Inner axle shaft shim
17. Differential side bearing assembly 35. Differential assembly snap ring & shaft
18. Ring gear safety bolt 36. Rear axle housing cover

AFFECTED VIN
4F 31

Rear Axle Shaft
Preceding work: Removal of wheel and tire
1. Unscrew rear axle shaft mounting bolts from axle housing
(6 EA).
Initial: 70 ~ 80 Nm [Notice]
Tightening torque
Secondary: 90 ± 5° Replace the bolts by every removal
2. Unscrew lock nut (30 mm) from wheel disk side and
remove the axle shaft.
[Notice]
Replace the lock nut to new one by every disassembly.

AFFECTED VIN
32 4F
Rear Axle Housing

Preceding work: Removal of rear axle shaft
1. Support the axle housing with mounting jack.

2. Unscrew one front mounting bolt and two rear mounting bolts to remove the axle housing from the rear sub frame.

AFFECTED VIN
4F 33
Replacement of Radial Sealing and

O-ring
Preceding work: Removal of rear axle housing
1. Drain oil in the axle housing.
2. Remove the axle mounting damper
[Notice]
Damper bolt should be replaced by ecery removal.
3. Remove the axle housing cover and damper bracket.
4. Remove the connecting flange snap ring with special tool.

AFFECTED VIN
34 4F
5. Pull out the inner flange.
6. Remove the radial sealing with a tool.
7. To replace the O-ring, unscrew the side bearing cover

mounting bolts.
8. Remove shim and replace the O-ring.
Inner flange
Radial sealing
Shim
O-ring
Snap ring
Back lash adjust shim

AFFECTED VIN
4F 35
Replacement of Radial Sealing and

O-ring on Propeller Shaft Flange
1. Unscrew the lock nut with socket wrench (30 mm).
[Notice]
Replace the lock nut to new one by every disassembly.
2. Remove the radial sealing with a tool.
Lock nut
Inner flange
Radial sealing

AFFECTED VIN
MEMO
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4G 3
GENERAL INFORMATION
1. OVERVIEW
The power steering system consists of pump, oil reservoir, rack and pinion gear. The power steering pump is a vane type
and delivers hydraulic pressure to operate the power steering system. The pressure relief valve in pump controls the
discharging pressure.
The rotary valve in rack and pinion gear directs the oil from the power steering pump to one side of rack piston.
The integrated rack piston converts the hydraulic pressure to linear movement.
The operating force of rack moves the wheels through tie rod, tie rod end and steering knuckle.
Even though the hydraulic pressure cannot be generated, a driver can steer the vehicle without power assist but it needs
very high steering force.
In this case, the operating force of steering wheel is conveyed to pinion, and the movement of pinion moves the rack
through pinion gear combined to rack gear.
2. SPECIFICATION
Item Specification
Steering wheel Number of spoke 4 spokes
Outer diameter 390 mm
Rotation 3.6 rotations
Gear box Type Rack & Pinion
Gear ratio ∞
Steering Inner 37° 42′
angle Outer 32° 56′
Tilting angle ±2
Minimum turning radius 5.882 m
Oil pump Type Clustered in reservoir tank
Displacement 11.3 cc/rev
Max. pressure 90 bar
Oil Specified oil ATF Dexron II, III
Capacity Approx. 1 liter
POWER STEERING CHANGED BY

AFFECTED VIN
4G 3
GENERAL INFORMATION
1. OVERVIEW
The power steering system consists of pump, oil reservoir, rack and pinion gear. The power steering pump is a vane type
and delivers hydraulic pressure to operate the power steering system. The pressure relief valve in pump controls the
discharging pressure.
The rotary valve in rack and pinion gear directs the oil from the power steering pump to one side of rack piston.
The integrated rack piston converts the hydraulic pressure to linear movement.
The operating force of rack moves the wheels through tie rod, tie rod end and steering knuckle.
Even though the hydraulic pressure cannot be generated, a driver can steer the vehicle without power assist but it needs
very high steering force.
In this case, the operating force of steering wheel is conveyed to pinion, and the movement of pinion moves the rack
through pinion gear combined to rack gear.
2. SPECIFICATION
Item Specification
Steering wheel Number of spoke 4 spokes
Outer diameter 390 mm
Rotation 3.6 rotations
Gear box Type Rack & Pinion
Gear ratio ∞
Steering Inner 37° 42′
angle Outer 32° 56′
Tilting angle ±2
Minimum turning radius 5.882 m
Oil pump Type Clustered in reservoir tank
Displacement 11.3 cc/rev
Max. pressure 90 bar
Oil Specified oil ATF Dexron II, III
Capacity Approx. 1 liter

AFFECTED VIN
4 4G
3. COMPONENTS
Steering wheel
Power steering Column shaft

pump assembly
Power steering
oil pipe & hose
Lower shaft
Tie rod end
assembly
Tie rod end

assembly
Steering gear
box assembly
CHANGED BY POWER STEERING

AFFECTED VIN
4G 5
Power Steering Gear Box Assembly
Gear box assembly
Clamp mounting
Tie rod end
Tie rod end
Tie rod
Tie rod
Boot Bush mounting Boot
The power steering gear consists of power cylinder and Additionally, the safety check valve is installed so that the
control valve. system can be operated manually when the system is
The power cylinder has cylinder, piston and piston rod. defective.
The control valve directs the oil to one end face of the pis-
ton to enhance the steering force. Sub frame mounting Clamp mounting (2EA)
The control valve controls the directions and operations of (4 points) Bush mounting (2EA)
power cylinder.
Power Steering Pump

The vane type pump that is connected to engine by belt is
used for the power steering system. This pump generates
and controls a proper hydraulic pressure and flows by us-
ing the flow control valve and pressure relief valve.
The flow control valve regulates the excessive amount of
discharging oil. When the steering wheel is stationary or
the oil circuit is blocked, the pressure relief valve returns
the over pressurized oil to the oil reservoir.
Oil Reservoir
The oil reservoir sends the oil to the power steering pump
and receives the oil from the power steering gear.
The oil level in the reservoir depends on the steering wheel Steering pump Reservoir tank
positions. therefore, measure the oil level when the steer-
ing wheel is positioned at straight ahead direction (neutral).

AFFECTED VIN
6 4G
GENERAL INSPECTION
1. STEERING WHEEL
Power Steering Wheel Free Play
Check
1. Start the engine and place the wheels at straight ahead
direction.
2. Turn the steering wheel until the tires starts to move and
measure the distance on the circumference of the
steering wheel.
Specified value 30 mm
[Notice]
If the free play is out of the specified value, check the

clearance in steering column shaft connection and steering
linkage. Replace or repair if necessary.
Steering Effort Check

1. Park the vehicle on a paved and flat ground and place
the front wheels at straight ahead direction.
2. Start the engine and let it run around 1,000 rpm.
3. Install the spring scale on the circumference of the
steering wheel and measure the steering effort in both
directions.
Tightening torque Below 3.0 kg
[Notice]
The difference between both sides should be within 0.6 kg.
Steering Angle Check

1. Place the front wheel on a turning radius measuring tool.
2. Turn the steering wheel to the its both ends and measure
the maximum steering angle.
Inner 37° 42′

Specified value
Outer 32° 56′
[Notice]
If the free play is out of the specified value, check and adjust
the toe-in.

AFFECTED VIN
4G 7
Power Steering Gear Preload

Adjustment
1. Place the steering wheel at straight ahead direction.
2. Lift up the vehicle very carefully.
3. Remove the adjusting plug lock nut.
4. Measure the torque of adjusting plug.
5. If the measured torque is out of range, adjust it to the

specified value.
• Place the rack gear in center position.
• Tighten the adjusting plug by 100 kg.cm
• Turn the pinion gear to move the rack gear between
both ends by 5 times.
• Remove the adjusting plug.
• Tighten the adjusting plug by 45 ~ 55 kg.cm
• Release the adjusting plug by 67.5°.
6. Tighten the adjusting plug lock nut.

AFFECTED VIN
8 4G
2. OIL PUMP PRESSURE

Check the oil pump pressure to locate any defect in oil pump.
[Notice]
Before checking the pressure, check the oil level and belt
tension. Prepare the empty container to collect the spilled
oil during the service.
1. Unscrew the pressure line fitting in power steering pump.

2. Install the pressure gauge between the power steering
pump and the power steering oil pressure line.
3. Place the shift lever to neutral position.
4. Apply the parking brake.
5. Open the valve in pressure gauge.
6. Start the engine and let it run at idle speed.
7. Turn the steering wheel several times so that the oil
temperature reaches to normal operating level. (50 ~ 80°C)
8. Fully close the valve in pressure gauge and measure the
oil pressure.
[Notice]
To prevent internal damage, do not close the gauge valve

over 10 seconds.
Pump relief valve pressure 89 ~ 97 kg/cm2
9. Measure the oil pressure with the gauge valve fully closed.
Pump pressure at no load 3 ~ 5 kg/cm2
10. If the pump pressure is in specified range, the pump is

normal. If not, replace the power steering pump.
3. OIL LEVEL CHECK

The power steering oil level have to be checked by two
Displacement of oil level
conditions; one is checked at normal operating temperature,
and the other one is checked when it is cooled. If the differ-
ence between two measurements is below 5 mm and the level
is between HOT and ADD level, it’s normal. If it is over 5 mm,
HOT
bleed air from the system.
HOT
1. Place the vehicle on a flat ground and start the engine
and let it run at idle speed. ADD
ADD
2. Turn the steering wheel several times so that the oil
temperature reaches to normal operating level.
3. Place the steering wheel at straight ahead direction. Engine off Engine on
4. Measure the oil level in the power steering oil reservoir.
5. Adjust the oil level between HOT and ADD.
AFFECTED VIN
4G 9
4. OIL CHANGE
1. Lift up the vehicle carefully.
2. Disconnect the oil supply hose from the power steering
pump.
3. Drain the oil from the power steering oil reservoir.
4. Connect the oil supply hose to the power steering pump.
5. Disconnect the oil return line from the power steering oil
reservoir.
6. Periodically crank the starting motor and turn the steering
wheel to its both ends to drain the oil in the reservoir
through the return line.
7. Connect the return line to the steering oil reservoir.
8. Fill the oil into the steering oil reservoir to the specified
level. H. MAX - when the oil is hot
9. Bleed the air from the system. C. Leverage value - when the oil is cooled
ADD. MIN
[Notice]
Always keep the oil level over the ADD line.
5. BELT TENSION CHECK AND

ADJUSTMENT
1. Check the belt for wear, crack and damage. Replace it if
needed.
2. Press the center of belt with around 10 kg of force and
check the deflection.
[Notice]
If the deflection is too large:

• Replace the auto tensioning assembly.
• Check the belt and replace.

AFFECTED VIN
10 4G
6. AIR BLEEDING
After the power steering repairing, do the air bleeding job.
Checking bubble is foune
1. Lift up the vehicle ( A load to the steering wheel) .

2. Add the specified oil in the reservoir tank up to max level.
3. Turn the steering wheel to its both ends several times.
4. Check if bubble is found and do the previous job several times.
5. If bubble can not be found, add the specified oil in the reservoir tank to the specified level.
6. Start the engine and operate the second and third job to air bleed clearly.
[Notice]
If the air bleeding is not properly performed, the life span of

the power steering pump may be shortened.

AFFECTED VIN
4G 11

1. COMPONENTS
Airbag
Lock nut
Bolt
Steering wheel
Washer
Wheel damper
Cover
Bolt
Column shaft Power steering high pressure hose
Lower shaft
Power steering return pipe
Bolt
Cot pin
Nut
Bolt
Nut
Tie rod
Tie rod end
Power steering gear assembly
Bolt

AFFECTED VIN
12 4G
Tightening Torque
Item Kgfxxm Nxx m
Power steering column Steering column mounting bolt 2.0 ~ 2.5 20 ~ 25
shaft
Steering wheel and column shaft lock nut 4.0 ~ 6.1 40 ~ 60
Airbag module mounting bolt 0.7 ~ 1.1 7.0 ~ 11
Steering column and lower shaft mounting bolt 1.8 ~ 2.5 18 ~ 25
Power steering gear Steering gear box and sub frame mounting bolt 7.0 ~ 9.0 70 ~ 90
box
Steering box and lower shaft mounting bolt 1.8 ~ 2.5 18 ~ 25
Tie rod end nuckle 3.5 ~ 4.5 35 ~ 45
Tie rod end lock nut 6.5 ~ 8.0 65 ~ 80
Steering gear box and high pressure pipe 1.2 ~ 1.8 12 ~ 18
Steering gear box and return(Low pressure) line 1.2 ~ 1.8 12 ~ 18
Power steering pump Power pump bracket and timing gear case cover 2.0 ~ 2.3 20 ~ 23
mounting bolt
Power pump and high pressure pipe 4.0 ~ 5.0 40 ~ 50
Power steering oil pipe Return line and mounting bolt 1.2 ~ 1.8 12 ~ 18

AFFECTED VIN
4G 13
2. COLUMN SHAFT AND LOWER SHAFT

1. Disconnect the battery negative cable and place the tires to straight ahead direction.
2. Unscrew the screws at both sides of steering wheel and remove the horn pad (air bag module). Disconnect the
airbag module connector.
3. Unscrew the steering wheel lock nut and remove the wheel with special tool.
[Notice]
Leave marks on the column shaft and steering wheel for

correct installation.
4. Remove the instrument lower panel and disconnect all related connectors.

AFFECTED VIN
14 4G
5. Unscrew the steering column cover bolts and remove it.
6. Disconnect five connectors in the cover.
1. Key switch connector 4. Airbag connector

2. Key hole lamp connector 5. Steering wheel angle sensor
3. Contact coil connector

AFFECTED VIN
4G 15
7. Unscrew the contact coil mounting screw and remove it from multi function switch.
8. Disconnect both left and right connectors of multi function switch and unscrew the multi function switch mounting
bolt to disassemble from steering column.

AFFECTED VIN
16 4G
9. Leave marks on the column shaft and lower shaft.

10. Unscrew the column shaft upper mounting bolts(A) and lower shaft mounting bolt.
Column shaft upper mounting bolts (4-EA) Column shaft upper mounting bolts (2-EA)
11. Remove the steering column shaft from lower shaft.

AFFECTED VIN
4G 17
12. Unscrew the lower shaft housing floor mounting bolt(A) and lower shaft mounting bolt on the steering gear box.

AFFECTED VIN
18 4G
3. STEERING GEAR BOX

Preceding Work
1. Install the safety wedge under both rear wheels

(Put the shifting lever in “P” position and apply the parking brake)
2. Additional safety jack

Because the weight balance move to rear when the sub
frame is removed, safe working condition must be
prepaired.
For this reason, Installing the safety jack to both under
body is important to avoid unexpectable accident.
(The height of safty jack to both side must be same)
16.5 cm
3. The mounting location of suplement lift

The supplement lift is used when you remove or install the sub frame
(Keep in mind the center of gravity of sub frame locate near front axle mounting point)
Front Rear

AFFECTED VIN
4G 19
4. Remove the engine lnsulating brackets from the front sub frame as the
engine hung by an additional lift (crane)
5. Install the engine mounting bracket
Before removal of sub frame, install the special tool (Engine mounting
brackets) on the body frame
RH LH RH LH
Engine insulating Engine mounting

brackets on the sub frame brackets on the body
Part number : A9912 008 2B
RH LH

AFFECTED VIN
20 4G
1. Remove the power steering pipes 2. Remove the front calier (C) and wheel speed sensor (D)
(A: High, Low pressure) and lower arm (Fix the caliper and speed sensor on the body. Disconnect the
shaft (B) at the rear side of syb frame. brake hose clip)
Wheel
Power steering
pipes (Front)
3. Unscrew the power steering pipe mounting 4. Unscrew the knuckle upper bolt (E) and
bracket (1, 2) and release them shock absorber lower bolt/nut (F) and then,
remove the shock absorber from knuckle.

AFFECTED VIN
4G 21
5. Leave mark with a marking painter on the sub frame mounting bolts.
6. Locate two sypplement lifts under sub frame (Front/Rear) and unscrew the sub frame mounting bolts (19mm -
6EA).
And then, drop the lifts slowly.

AFFECTED VIN
22 4G
7. Unscrew the clamp mounting bolt of stabilizer bar and fix to the upper side of axle flange.
8. Remove the coat pin and nut(1), and unscrew the gear box clamp bolt(2) and bush mounting nut(3).
1. Coat pin and nut 2. Clamp mounting bolt
A. Stabilizer
2. Clamp mounting bolt
1. Tie rod end 1. Tie rod end
3. Bush mounting nut
Upper bolt : 70 ~ 90 Nm
Tightening torque
Lower bolt : 70 ~ 90 Nm

AFFECTED VIN
4G 23
9. Disassemble the steering gear box as shown below with arrow mark.
Gear box mounting bolt(Clamp)

: 70 ~ 90 N.m
Sloted nut
Sloted nut : 25 ~ 30 N.m
: 25 ~ 30 N .m
Gear box mounting bolt
(Bushing)
: 70 ~ 90 N.m

AFFECTED VIN
24 4G
Disassembly and Reassembly of

Steering Gear Box
Disassembly
* Describes the basic power steering assembly.
1. Remove the tie rod end boot (a).
2. Remove the feed lines (2) from the cylinder tube in gear
box.
3. Remove the feed lines (1) from the valve housing in gear
box.
4. Unscrew the lock nut (1) and remove the plug (2) and
spring (3).
5. Remove the dust cover (1) and retainer ring (2).

AFFECTED VIN
4G 25
6. Remove the pinion dust cover (lower, 3) and unscrew the

pinion lock nut (4).
[Notice]
Before removing the pinion lock nut, make sure to lock the
pinion gear to prevent it from damaging.
7. Remove the steering pinion (5) from pinion bearing by

tapping the bottom end of steering pinion with a flat drift
and plastic hammer.
[Notice]
Align the center of the drift and the bottom end of steering
pinion.
8. Remove the pinion bearing (6) by tapping it with a long

and flat head drift and plastic hammer.
9. Remove the pinion shaft seal (7), needle bearing (8) and
retaining ring (9).
[Notice]
Do not disassemble the power steering gear housing and

rack gear. Replace it as an assembly if needed.

AFFECTED VIN
26 4G
Reassembly
1. Install the steering pinion gear.
1) Install the retaining ring.
2) Install the needle bearing.
3) Install the pinion shaft seal by tapping it with a long
and flat end drift.
2. Tighten the steering pinion lock nut (4) with a specified

tightening torque.
[Notice]
Make sure that the pinion bearing is not offset with the
steering pinion lock nut.
3. Tighten the steering pinion dust cover (5) with a specified

tightening torque.
1) Install the retaining ring (6).
2) Install the plastic dust cover (7).
4. Install the rack bearing.

• Install the adjusting spring.
• Tighten the adjusting plug with a specified tightening
torque.
• Tighten the lock nut.
• Adjust the preload of steering gear.

AFFECTED VIN
4G 27
5. Install the hydraulic pipes.
6. Install the tie rod end boot.
[Notice]
Apply grease into the ball joint of tie rod end and the boot.

AFFECTED VIN
28 4G
Inspection
Rack Gear Shaft
1. Check the rack gear for deformation and damage.
• Place the V-blocks (1) on the flatten plate.
• Put the rack gear (2 and 4) on the V-blocks.
• Measure the straightness of rack gear with a dial
gauge.
• Check the rack gear for abnormal wear and damage.
2. Check the steering pinion gear for damage.

• Check the pinion gear (1) for abnormal wear and
damage.
• Check the bearing (2) for looseness and operation.
3. Check the tie rod end and the rack and pinion bellows for
damage.
• Check the tie rod end boot (1) for crack and abnormal
wear.
• Check the rack and pinion boot (2) for crack and
abnormal wear.
4. Check the steering gear housing (a) for crack, distortion

and abnormal wear.

AFFECTED VIN
4G 29
5. Check the tie rod end and the tie rod ball joint for damage.
• Check the tie rod end ball joint for operation.
• Check the tie rod ball joint for operation. Check the
tie rod for deflection due to its weight.
6. Replace all the defective components with new ones.
7. Check the tie rod end and the rotating area (1) of tie rod
ball joint for damage.
8. Check the tie rod end and the rack and pinion boot for
crack and abnormal wear.
9. Check the metal components for wear.
• Check the pinion gear for abnormal wear and damage.
• Check the rack gear for abnormal wear and damage.
• Check the steering gear housing for wear and damage.
10. Check the bearings and oil seals for damage.

• Check the pinion shaft seal (1) for wear and leakage.
• Check the needle bearing (2) for wear.
• Check the steering pinion bearing (3) for wear.
11. Replace all the defective components with new ones.

AFFECTED VIN
30 4G
4. STEERING GEAR PUMP AND OIL PIPE

Power Steering Gear Pump Assembly
Preceding Work: 1. Disconnect the battery negative cable.
2. Remove fan belt and drain the power steering oil.
1. Unscrew th pump mounting bolt/nut(1) and disconnect

the oil pipes(2, 3).
Mounting nut (1): 2.0 ~ 2.3 kgm

Tightening torque
Oil pump (2): 4.5 ~ 5.0 kgm
2. Remove the pump clip and disassemble the pump from reservoir tank.
Mounting clip
Reservior tank
Mounting clip
Pump assembly

AFFECTED VIN
4G 31
Power Steering Oil Pipes

Preceding Work: Drain the power steering oil.
1. Disconnect the oil pipes(High, low pressure) frame the steering oil pump, power steering and sub framegear box.
1.Oil pump 2. Gear box
Oil return pipe

(Low pressure)
High pressure pipe
Low pressure pipe
Oil supply pipe

(High pressure)
Pipe mounting bolts
Sub frame
[Notice]
• If two oil pipes ( High, Low pressure ) are installed as

changed, abnormal vibration is detected through steering
handle and this damage to the power steering system.
(Smaller hole diameter for high pressure pipe)

AFFECTED VIN
32 4G
- Layout of high and low pressure pipe
Front
Rear

AFFECTED VIN
4G 33
TROUBLE DIAGNOSIS
Hard steering Lack of lubrication Rubricate & Replace
Abnormal wear or binding of steering ball joint Replace
Damaged or faulty steering gear Replace gear assembly
Improper preload of steering pinion Adjust
Faulty steering shaft joint Replace
Steering fluid leaks Repair or replace
Lack of fluid or air-in system Replenish or bleed
Faulty steering oil pump Replace
Steering pulls to one Damaged or loosened pump drive belt Adjust or replace
side Clogging oil line Repair or replace
Damaged wheel or tire Repair or replace
Faulty suspension system Repair or replace
Damaged steering linkage Repair
Damaged wheel and tire Repair or replace
Faulty brake system Repair or replace
Excessive wheel play Worn steering gear Replace gear assembly
Worn or damaged steering ball joint Replace
Loosened steering gearbox bolts Retighten
Poor return of steering Damaged or binding steering ball joint Replace
wheel Improper preload of steering pinion Replace gear assembly
Steering wheel vibration Damaged steering linkage Replace
(Shimmy) Loosened steering gearbox mounting bolt Retighten
Damaged or binding steering ball joint Replace
Worn or damaged front wheel bearing Replace
Abnormal noise from Loosened steering gearbox mounting bolt Retighten
steering system
Faulty steering gear Replace gear assembly
Steering column linterference Replace
Loosened steering linkage Retighten
Damaged or loosened oil pump drive belt Adjust or replace
Loosened oil pump bracket Retighten
Loosened oil pump mounting bolt Retighten
Air-in system Bleed
Faulty oil pump Replace

AFFECTED VIN
34 4G

Abnormal noise while Loosen steering column mounting nut or bad tightening Retighten
the operation
Worn or damage steering shaft bearing Replace steering column
Loosen inner shaft pinch bolt Retighten
Excessive steering force Worn or damaged steering shaft bearing Replace steering column
Ignition switch bad Defective lock cylinder Replace steering column
turning Defective ignition key Replace ignition key

AFFECTED VIN
4G 35

661 589 13 33 00 Removal of the upper and lower

Ball joint puller end assemblies of front
suspension

AFFECTED VIN
4H 3
Tire And wheel Balancing 2. Breaker
A cord belt between tread and carcass prevents
There are two types of the tire and wheel balancing: static
damages of inner code due to outer shock and
and dynamic.
vibration.
Static balance is the equaldistribution of weight around
3. Carcass
the wheel. assemblies that are statically unbalanced cause
a bouncing action called wheel tramp. This condition may This major part made by pilling code papers of strong
eventually cause uneven tire wear. synthetic fiber forms a structure of tire. Since it
maintains tire pressure and endures applied load and
Dynamic balance is the equal distributio of weight on eeach
shock to tire, it should have a high anti-fatigue
side of the centerline so that when the assembly spins
characteristic.
there is no tendency for it to move frim side to side . As-
semblies that are dynamically unbalanced may cause 4. Side Wall
wheel shimmy. It is provided to improve the comfortable driving by
protecting carcass and cushion movement.
General Balance Precautions
5. Bead
Remove all deposits of foreign material from the inside of
the wheel. A steel wire winding the ending part of carcass code,
coated with rubber film and wrapped with nylon cord
[Caution] papers. It fixes tire to a rim.
Remove stones frim the gread in order to avoid operator

injury during spin balancing
Width
Inspect the tire for any damage. Balance the tire accord-
ing to the equipment manufacturer’s recommendations.
Structure of Tubeless Tube

Inside Outside
Diameter Diameter
Width
Height
The tire structure is different slightly according to the types

of the tire but a various type of the tire has the common
structure as following;
1. Tread
A part (that contacts) road surfaces directly is fixed
on the outsude of carcass and breaker.
It is a strong rubber coat made of high anti-abrasion
rubber. Its running performance depends on is surface
profile.
WHEELS & TIRE CHANGED BY

AFFECTED VIN
4 4H
Conventions for Radial Tire The Relations Between Inflation

P 225 / 65 R - 16 104 T Pressure and Tire
Max Speed :
190 km/h
Excessive Air-Pressure
Life
Load Index : (%)
900 kg Insufficient Air-Pressure
Rim Diameter : 16 inch.
Radial Tire
Air-Pressure to Standard air-Pressure (%)
Aspect Ratio = (Section Height ÷

Section Width) x 100 : 65 %
Section Width : 225 mm The Relations Between Load

and Tire
Passenger Car
Max Speed Symbol Load Index

Limit Speed Limit Speed Life
Symbol Symbol Index
(km/h) (km/h)
F 80 94 670
M 130 95 690
N 140 96 710
P 150 97 730
Load (Standard Ratei 100)
Q 160 98 750
R 170 99 775
S 180 100 800
T 190 101 825
U 200 102 850
H 210 103 875
V 240 104 900
Z Above 240 105 925
CHANGED BY WHEELS & TIRE

AFFECTED VIN
4H 5
2. SPECIFICATION
Wheel Size Aluminum type 6.5J x 16
Wheel nut tightening torque Aluminum wheel 13 ~ 16 kgf.m
Tire Type Radial tire Radial Tire
Inflation pressure (psi) P225/65R16 35 psi
Wheel alignment Toe-in Front 0 ~ 4 mm
Rear 0.4° ± 0.08° (5 mm ± 1 mm)
Camber Front 0° ± 30' (0° ± 0.5°)
Rear -1° ± 30' (-1° ± 0.5°)
Caster 4.5° ± 30'
3. TIRE’S ABNORMAL PHENOMENA

Standing Wave Hydroplaning
High speed Low speed

driving driving
During running the rotating tire repeats deformation and The condition of driving a vehicle fast on the road surface
restoring movement generated in tread. But when the wheel covered with water can cause tires to fail to rotate with a
rotating speed reaches high, the next deformation applied good contact on the surface, so results in remaining them
to tire before restoring last deformation so the trembling a float. This is so-called hydroplaning. It causes brake
wave appears in the tread portion. The lower the tire pres- failure, lower tractive force and losing the steering perfor-
sure the severe the trembling wave appears during the high mance so it is very vulnerable condition.
speed.

AFFECTED VIN
6 4H
4. WHEEL ALIGNMENT
The first responsibility of engineering is to design safe Camber
steering and suspension systems. Each component must
be strong enough to with stand and absorb extreme punish-
ment. Both the steering system and the front and the rear
suspension must function geometrically with the body
Tire center- Perpendicular- Perpendicular- Tire center-
mass. line line line line
The steering and suspension systems require that the front
wheels self-return and that the tire rolling effort and the
road friction be held to a negligible force in order to allow
the customer to direct the vehicle with the least effort and
the most comfort.
A complete wheel alignment check should include mea- Camver (+) Camver 0 Camver (-)
surements of the rear toe and camber.
Toe-in Camber is the tilting of the top of the tire from the vertical
when viewed from the front of the vehicle. When the tires
tilt outward, the camber is positive. When the tires tilt
inward, the camber is negative. The camber angle is mea-
sured in degrees from the vertical. Camber influnces both
directional control and tire wear.
Front side If the vehicle has too much positive camber, the outside
shoulder of the tire will wear. If the vehicle has too much
negative camber, the inside shoulder of the tire will wear.
Camber is measured in degrees and is not adjustable.
Toe-in is the turning in of the tires, while toe-out is the

turning out of the tires from the geometric centerline or
thrust line. The toe ensures parallel rolling of the wheels.
The toe serves to offset the small deflections of the wheel
support system which occur when the vehicle is rolling
forward.
The specified toe angle is the setting which achieves-de-
grees “0°” of toe when the vehicle is moving.
Incorrect toe-in or toe-out will cause tire wear and reduced
fuel economy. As the individual steering and suspension
components wear from vehicle mileage, additional toe will
be needed to compensate for the wear. Always correct
the toe dimension last.

AFFECTED VIN
4H 7
Caster
Front side
Center line Center line
Steering Steering
axle axle
Caster (+) Caster 0 Caster (-)
Caster is the tilting of the uppermost point of the steering

axis either forward or backward from the vertical when
viewed from the side of the vehicle. A backward tilt is posi-
tive and a forward tilt negative. Caster influences direc-
tional control of the steering but does not affect tire wear.
Weak springs or overloading a vehicle will affect caster.
One wheel with more positive caster will pull toward the
center of the car. This condition will cause the car to move
or lean toward the side with the least amount of positive
caster. Caster is measures in degrees and is not
adjustable.

AFFECTED VIN
8 4H
Tire
1. Remove the wheel cap.
2. Support the vehicle with safety jack.

Loosen the wheel nuts and raise the vehicle carefully.
3. Remove the wheel nuts.

AFFECTED VIN
4H 9
[Notice]
• Clean the mating surface of wheel and hub. Do not apply
grease or oil to bolts and nut. It may cause the looseness of
the fasteners.
• Lift up the vehicle until the tire is off approx. 3 mm from
ground.
• Tighten the wheel nuts by the order as shown in the figure
with several steps.
Tightening torque Aluminum wheel: 120 ~ 130 Nm

AFFECTED VIN
10 4H
Spare Tire
1. Prepare the spare tire handle and wheel nut wrench.
2. Install the handle through the hole at the rear side of the
vehicle.
3. Connect the wheel nut wrench at the end of the handle.
4. Turn the wheel nut wrench counterclockwise until the wire is loosened.

AFFECTED VIN
4H 11
5. Pull out the lift plate from spare tire.

6. Put the lift plate into the center of the wheel when
installing.
7. Turn the handle clockwise until it sounds “click”.
8. Remove the handle and the wheel nut wrench.
[Notice]
• Always keep the spare tire available.
• When reinstalling the spare tire, securely fasten it.
• If the lift plate is not in the center position or the spare tire
is not securely fastened, the spare tire may be out of position
during driving.
• If a movement of spare tire is found, check the system and
reinstall in needed.
• The wheel nut tightening surface of the spare tire should
be faced toward ground.
• This device is desined only for manual operation. Never
use the impact type tool to remove the spare tire.
• Store the flat and damaged tire in the trunk.

AFFECTED VIN
12 4H
6. MAINTENANCE AND REPLACEMENT

Separation
1. Fix the tire into the equipment and pull out the valve core
from the tire. Discharge the air inside the tire completely.
[Notice]
The assembly and disassembly of the tire is dangerous
working job. So, only the skillful worker must work this job
following the approved procedures.
2. Tighten the locker in the center of the equipment to

assemble the rim to the equipment.
3. Remove the balance weight on the rim.
4. Separate the tire’s bead from the rim flange using the
approved lubricant.
[Notice]
Do not use silicone, synthetic detergent and gasoline, etc.

AFFECTED VIN
4H 13
5. Apply the lubricant between the rim and the bead.
6. Insert the removal lever between the tire’s bead and the
rim and separate the rim from the tire.
[Notice]
Do not use the tool that may cause any damage such as pipe,
damaged bar.
7. Pull out the opposite bead upward using the lever and
then separate the bead from the rim.
Maintenance
1. Check any damage the rim and replace as needed.
[Notice]
• Do not repair the rim as welding or soldering.
• Replace the new valve as replaces new tire.

AFFECTED VIN
14 4H
Installation
1. Clean the rust, damaged rubber and dust, etc on the
rim’s surface with the brush.
2. Install the rim to the equipment with the valve upward.

3. Tighten the locker in the center of the equipment to
assemble the rim to the equipment.
4. Apply the lubricant at the both bead portions and both

rim’s flange of the tire.
5. Check any foreign material or liquid for the tire inside

and then install to push down the tire.

AFFECTED VIN
4H 15
6. Set the tire pressure to the specifications.
[Notice]
Do not remove the tire from the equipment before setting the
tire pressure.
Specification of the
30 psi (2.1 kg⋅cm2)
tire pressure

AFFECTED VIN
16 4H
7. INSPECTION
Visual Inspection
Condition Cause Action
Rapid wear at Under inflation or lack of rotation Adjust inflation pressure

shoulders
Rapid wear at center Over inflation or rotation
Tread damage Low the inflation pressure
Uneven wear Incorrect camber Adjust camber

Incorrect toe-in

AFFECTED VIN
4H 17

Feathered edge Incorrect toe-in Adjust toe-in
Bold spot Unbalanced wheel Adjust wheel balance
Sharply wear at the tread outside Unbalanced wheel Adjust
Wheel bearing play Check play
Check pre-load
Ball joint play Check
Faulty shock absorber Check

AFFECTED VIN
18 4H
General Inspection
Tread
Inspect the tread condition on the tire surface and various
damages resulting from the foreign material, crack, stone or
nail etc. If there is any damage in the tire, repair or replace it.
Tire Wear
• Measure the depth of the tire tread. If the depth of the tread
is below the specified value, replace the tire.
Limit of the Tread Wear 1.6 mm
• You can see the mark ‘ ’ in the groove, this is the indicator
of the tread wear limit.
• The limit of the tread wear for all season tires are 1.6 mm
as same as the general tires and the platform mark
indicates as ‘ ’.
Tire Inflation Pressure

1. Inflation pressure
Front / Rear 35 psi
2. Inspect the pressure of the tire surface and check the

inflation pressure.
[Notice]
• Lower than recommended pressure can cause tire squeal
on turns, hard steering, tire cord breakage and tire rim
bruises, etc.
• Higher than recommended pressure can cause hard ride,
tire bruising or damage and rapid tread wear at the center
of the tire.
Sufficient Insufficient Excessive

AFFECTED VIN
4H 19
Wheel Runout
Measure wheel runout with an accurate dial indicator. Mea-
surement may be taken with the wheels either on or off the
vehicle, using an accurate mounting surface such as a wheel
balancer. Measurements may be taken with or without the
tire mounted on the wheel.
1. Measure the dial runout and lateral runout on both the
inboard and outboard rim flanges.
Specification 2.66 mm
2. Measure free radial runout on the tire tread.
Specification 2.03 mm
[Notice]
If any measurement exceeds the above specifications, replace
the applicable tires or wheels.
Wheel Balance
Balance is the easiest procedure to perform and should be
done first if the vibration occurs at high speeds or if the tires or
the wheels are replaced.
When proceeding the wheel balancing procedure refer to the
following;
1. Do not the wheel weight over two at the inboard and the
outboard flanges.
2. The total weight ofthe wheel weight should not exceed
the 150 g (3.5 ounces)
3. Balancing the assemblies with the factory aluminum
wheels requires the use of the special nylon-coated, clip-
on wheel weights. Weight point
Balance weight
Balance weight
10 g 20 g 30 g 40 g 50 g 60 g
0.4 oz 0.7 oz 1.10 oz 1.40 oz 1.80 oz 2.10 oz
Balance weight
Weight point

AFFECTED VIN
20 4H
Rotation of Tires
Front and rear tires perform different jobs and can wear differ-
ently depending on the tires of road driven, driving condition,
etc.
The front tires will wear faster than the rear ones. To avoid
uneven wear of tires and to prolong tire life, inspect and rotate
the tires every 5,000 km (3,100 miles). After rotating the tires,
adjust the tire inflation pressures and be sure to check wheel
nuts tightness.
[Notice]
Do not mix different types of tires on the same vehicle such as
radial, bias and bias-belted tires except in emergencies,
because vehicle handling may be seriously affected and may
result in loss of control.

AFFECTED VIN
4H 21
Irregular tire wear Improper tire inflation pressure Adjust
Poor wheel balance Adjust
Improper tire rotation Rotation tires on the
maintenance schedule
Poor toe-in Adjust
Poor adjusting the pre-load of the wheel bearing Adjust
Poor braking performance Adjust
Driving noise, vibration Low tire inflation pressure Adjust
Poor balance of wheels, tires Adjust
Severe vibration due to wheels, tires Adjust or replacement
Irregular tires wear Check and adjust
Rapid wear Excessive tire inflation pressure Adjust
High speed driving with low tire pressure Adjust
Excessive vehicle weight Proper weight

AFFECTED VIN
MEMO
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4I 3
The propeller shaft transfers the power through the transmis-
sion and transfer case to the front/rear axle differential carrier
(final reduction gear). It is manufactured by a thin rounded
steel pipe to have the strong resisting force against the torsion
and bending.
Both ends of propeller shaft are connected to the spider and
the center of propeller shaft is connected to the spline to ac-
commodate the changes of the height and length. The rubber
bushing that covers the intermediate bearing keeps the bal-
ance of rear propeller shaft and absorbs its vibration.
Specification
Structure Yoke and spider type universal joint
Joint type Spider (Needle roller bearing)
Number of spiders Front TOD T/C 1
Rear 2
Outer diameter of spider (mm) φ 17.893
Tube run-out (after installation) below 0.4 mm
Unbalance Below 14.5 g.cm @ 4500 rpm (Front shaft + Full time T/C)
Below 18.0 g.cm @ 4500 rpm (Rear shaft + Full time T/C)
Front shaft dimension M/T(A/T) + 4426 TC (TOD) 495.8 (center position) x φ 50.8 (3.05t)
Length x Outer diameter (mm)
Rear shaft dimension DI engine + M/T(A/T) + 4426 TC (TOD) 606.1 (compressed) x φ72.2(2t)
Length x Outer diameter (mm) + 769.5 x φ 76.2 (2t)
DI engine + M/T + 2WD 923.5 x φ 63.5 (2t)
+ 750.4(compressed) x φ 63.5 (2t)
DI engine + A/T + 2WD 987.7 (compressed) x φ 63.5(2t)
+ 769.5 x φ 63.5 (2t)
Gasoline + M/T + 2WD 923.5 x φ 76.2(2t)
+ 750.4 (compressed) x φ 63.5 (2t)
Gasoline + A/T + 2WD 987.7 (compressed) x φ 76.2(2t)
+ 769.5 x φ 63.5 (2t)
PROPELLER SHAFT CHANGED BY

AFFECTED VIN
4 4I
2. COMPONENTS AND LOCATION

Front Prepeller Shaft Assembly
Bolt Bolt
CV joint Front propeller shaft assembly Universial joint
Rear Prepeller Shaft Assembly
1st rear propeller shaft CV joint 2nd rear propeller shaft
Universial joint
Bolt/washer/nut
Center bearing assembly
Universial joint Bolt
CHANGED BY PROPELLER SHAFT

AFFECTED VIN
4I 5

Removal
Front Propeller Shaft (4WD)

1. Unscrew propeller shaft mounting bolts and remove the shaft from the vehicle. (T/C : 17 mm - 4EA, Axle : 14 mm
- 4EA)
* Leave a guide mark before

disassembly, and refer to
the mark when reinstall

AFFECTED VIN
6 4I
Rear Propeller Shaft

1. Unscrew propeller shaft mounting bolts. (T/C : 17 mm -
4EA, Axle : 14 mm - 4EA)
Center bearing
Axle side T/C side
2. Unscrew the rear propeller shaft center bearing

mounting bolts (17 mm - 2 EA)
* Leave a guide mark

before disassembly,
and refer to the mark
when reinstall.

AFFECTED VIN
4I 7
Installation
1. Installation in the reverse order of removal.
2. Keep the tigtening torque.
3. Keep the guide mark when install.
4. Check and replace parts if defective.
(1) Rear propeller shaft (T/C) (2) Center bearing bracket (3) Rear propeller shaft (Axle)
Tightening torque : 81 ~ 89 Nm Tightening torque : 80 ~ 90 Nm Tightening torque : 70 ~ 80 Nm
3. Rear axle 1. Rear - T/C
2. Center bearing 4. Front axle
5. Front - T/C
(4) Front propeller shaft (Axle) (5) Front propeller shaft (T/C)
Tightening torque : 70 ~ 80 Nm Tightening torque : 81 ~ 89 Nm

AFFECTED VIN
8 4I
4. INSPECTION
Disassembly
1. Place an alignment mark and remove the propeller shaft.
2. Place an alignment on the spiders before removing.
3. Remove the snap ring with snap ring pliers.
4. Tap the yoke shoulder on shaft with copper hammer to

remove the roller bearing. Remove the other bearings with
same manner.
5. If it cannot be removed, hold the welding area with vise
and remove the needle bearing by using a suitable drift
and hammer.
6. Disassemble the universal joint.

The universal joint compensates the angle changes due
to vertical movement of the axle shaft.
7. Remove the intermediate bearing bracket and remove

the bearing with special tool.

AFFECTED VIN
4I 9
Inspection
1. Visual Check
Check the components for wear and crack and replace if
needed.
2. Outer diameter of spider journal
Specified value 17.893 mm

Limit 17.910 mm
3. Clearance between spider journal and bearing
Specified value 0.03 ~ 0.098 mm

Limit 0.25 mm
4. Run-out of propeller shaft

Set up the dial gauge on the center point of propeller
shaft and measure the run-out. If the run-out is out of the
specified range, correct it with press or replace it with
new one.
Limit 0.4 mm
5. Starting torque of universal joint
Specified value 3 ~ 8 kg.cm
6. Major causes of vibration

• Balance weights missing
• Excessive run-out of propeller shaft
• When using the general bolts
• Excessive wear of universal joint
• Stuck in sleeve joint
• Vibration is mainly caused by the angle changes in
front and rear universal joint. It normally occurs when
the vehicle speed is 60 ~ 100 km/h.
AFFECTED VIN
10 4I
Assembly
Clean the components and replace if damaged. Flange yoke
1. Align the alignment marks on the yoke and assemble
the spider, bearing and snap ring.
Spider
Bearing
Yoke Snap ring
2. Apply the grease to the inner lip of needle roller bearing

and assemble the needle roller.
Needle roller bearing
3. Install the yoke bearing shaft on the shaft and insert the
spider. Place the cap on the opposite side and tap it
with plastic hammer to seat it. Adjust the clearance of
Grease
spider below 0.1 mm and install the snap ring.
4. Apply the specified grease on the propeller shaft and

install it.

AFFECTED VIN
4I 11
Vibration Poor installation of sliding joint Adjust
Bending of propeller shaft replace
Incorrect symmetry of universal joint snap rings Adjust
Loose yoke bolt Tighten
Noise Worn or damaged universal joint bearing Replace
Missing universal joint snap ring Adjust and replace
Loose yoke connection Tighten
Worn sliding joint spline Replace
Lack of grease Add

AFFECTED VIN
12 4I

116 589 09 43 00 (P 99 48 003 0A) Centering the clutch disc

Remover and installer
129 589 00 34 00 (P 99 33 002 0B) Removal of bearing

Pulling arms

AFFECTED VIN
4J 3
BRAKE SYSTEM
Brake System Brake Pedal
Even though a driver cuts off the power, while driving, the
vehicle continues to move due to the law of inertia.
Therefore, a braking device is needed to stop the vehicle.
The brake system normally uses the frictional discs that
converts the kinetic energy to the thermal energy by fric-
tional operation.
The brake system consists of the brake disc (front wheel),
brake disc or drum (rear wheel), parking brake (mechanical
type), master cylinder, booster, pedal and supply lines
(pipes and hoses).
Hydraulic Brake
Brake pedal uses the leverage effect to apply bigger force
to the brake master cylinder.
Master Cylinder
This system uses the leverage effect and Pascal’s

principle. When depressing the brake pedal, the pedal
Rear Front
pressure is increased by booster and is delivered to mas-
ter cylinder to generate hydraulic pressure.
The hydraulic pressure generated by the master cylinder
is delivered to the brake caliper through the brake pipes or
The brake master cylinder is designed to convert the force
hoses.
from the brake master cylinder to the high hydraulic
This hydraulic pressure pushes the brake calipers, ac- pressure. The brake system uses the tandem type mas-
cordingly the caliper pads are contacted to brake disc to ter cylinder with in-line 2 pistons.
generate the braking force.
The in-line 2 pistons generate the hydraulic pressure. The
piston cup on the piston keeps the sealing conditions in
cylinder and prevents the oil leaks. The hydraulic pres-
sure generated by the primary piston is delivered to the
front wheels, and the hydraulic pressure generated by the
secondary piston is delivered to the rear wheels.
BRAKE - GENERAL CHANGED BY

AFFECTED VIN
4 4J
Brake Booster
The brake booster is a power assist device for brake
system. It relieves the pedal depressing force by using
the pressure difference between the vacuum pressure gen-
erated by vacuum pump in intake manifold and the atmo-
spheric pressure.
1. Pressure distribution at working 2. Pressure distribution after working
Vacuum pump
When depressing the brake pedal, the push rod (1) in When releasing the brake pedal, the valve plunger (3) re-
booster pushes the poppet (2) and valve plunger (3). The turns back to the original position by return spring (4) and
poppet (2) pushes the power piston seat (5) resulting in the air valve (6) closes. At this time, the vacuum valve (9)
closing the vacuum valve (9). The chamber (A) and (B) in opens and the pressure difference between chamber (A)
power cylinder are isolated and the valve plunger (3) is and (B) in power cylinder is eliminated. Accordingly, the
separated from the poppet (2). And then the air valve (6) power piston (5) returns back to original position by the
opens and air flows into the chamber (B) through filter. reaction of master cylinder (10) and the diaphragm return
Then, the power piston (5) pushes the master cylinder spring (8).
push rod (7) to assist the brake operation.
CHANGED BY BRAKE - GENERAL

AFFECTED VIN
4J 5
2. SPECIFICATION
Item Type & Specification
Front brake type Ventilated disk
Rear brake type Solid disk
Master cylinder type Tendem type
Booster type Tendem booster (Foot control)
Brake fluid capacity, type, replacement period 0.6 (Liter), DOT4, by every 2 years
Brake pipe & hose replacement period Every 20,000 km or 12 months and change if needed
Brake pad, shoe, disk Checking by every 10,000 km

AFFECTED VIN
6 4J
3. COMPONENTS
Return spring
Vacuum pump
Pedal bracket
Gasket
Booster
Vacuum Booster
hose
Brake pedal Switch - Stop lamp

O-ring
Reservoir tank Pad
Pressure sensor Cable - RR
speed sensor Pad
M/T
A/T
Cable - FRT
speed sensor
Brake dust shield Knuckle

Brake dust shield
Hub flange
Hub flange
Knuckle Brake disk
Brake disk
Steering
knuckle assy

AFFECTED VIN
4J 7
Release lever
Parking brake assy
HECU
Cable
Brkt - HECU
Parking brake cable

Damper - rear RH
Parking brake cable
Pad - rear LH
Tension spring
Equalizer
Brake shoe
Adjuster
Return spring - Upper

Return spring - Lower
Knuckle
Operating lever
Brake dust shield
Hub flange
Brake disk

AFFECTED VIN
8 4J
4. MASTER CYLINDER & BOOSTER

ABS system is basically equipped to STAVIC.
Vehicle which adapted ESP system in option has two pressure sensors under master cylinder and these two sensor are
used for BAS (Brake Assist System) system.
Vehicle with ESP Vehicle with ABS
Vacuum Pump
Gasket
Booster
Vacuum hose
O-ring
Brake fluid
reservoir
tank
Master
cylinder
Pressure
sensor
<Vehicle with ESP>
Brake fluid reservoir tank Master cylinder
[Notice]
• Do not disassemble the brake oil pressure sensors These can not be reinstalled of disassembled.
• After reinstall the reserver tank perform a air bleeding of brake system

AFFECTED VIN
4J 9
5. INSPECTION
Air Bleeding (With ABS)
6. Repeat the step 4 through 5 until clear brake fluid
comes out of air bleed screw.
7. Perform the same procedures at each wheel.
[Notice]
Repeat the step 4 through 5 until clear brake fluid comes
out of air bleed screw.
After bleeding the air, make sure that the brake system is
properly operated.
[Notice]
Replace the brake oil at every 2 years.
[Notice]
Bleed air in the following order:
Right rear brake → Left rear brake → Right front brake
→ Left front brake
Check the fluid level repeatedly during air bleeding, and
add fluid if needed.
1. Apply the parking brake and start the engine when

the shift lever is at “P” position.
2. Connect the oil supply device (air bleeding device)
with air compressor to brake reservoir. The oil supply
device should be filled with sufficient oil.
3. Loosen the air bleed screw in caliper and place an
empty container under the screw. 8. Always start to bleed the air at the farthest wheel
4. Bleed the air in each wheel by using diagnostic device from the brake master cylinder. Observe the sequence
(Scanner). At this time, the modulator motor runs for number as shown in the above figure.
180 seconds.
5. Simultaneously, run the oil supply device to supply [Notice]
oil and depress the brake pedal repeatedly. • Always bleed the air after replacing the brake fluid or
This procedure needs at least 3 persons for doing master cylinder, caliper, brake hose and pipe.
below jobs: • Never reuse the used brake fluid.
1. Collect the bleeding oil into the container. • Do not pump the brake pedal too fast. It may cause
2. Depress the brake pedal repeatedly. some troubles for air bleeding operation.
3. Check the conditions of oil supply device. • Be careful not to splash the brake fluid on painted
area or body.
[Notice] • Check the connection areas for leaks after air bleeding.
Keep the brake pedal depressing until the bleed screw is

fully tightened.

AFFECTED VIN
10 4J
After Replacing Master Cylinder

1. Add oil after replacing the master cylinder.
2. Pump the brake pedal several times until the hydraulic
pressure is generated. Then, keep the pedal depressing.
3. Loosen the pipe screw at the outlet port in master cylinder
to bleed the air.
4. Repeat step 3 until clear brake fluid comes out of air
bleed screw.
5. If the hydraulic pressure is not properly generated during
pumping the brake pedal, bleed the at the outlet pipe in
hydraulic unit and wheel.
After Replacing Hydraulic Unit

1. Add oil after replacing the hydraulic unit.
2. Pump the brake pedal several times until the hydraulic
pressure is generated. Then, keep the pedal depressing.
3. Loosen the pipe screw at the outlet port in hydraulic unit
to bleed the air.
4. Repeat step 3 until clear brake fluid comes out of air
bleed screw.
5. If the hydraulic pressure is not properly generated during
pumping the brake pedal, bleed the at the wheel.

AFFECTED VIN
4J 11

Vacuum Hose - Brake Booster
1. Disconnect vacuum hose (A) from brake booster.

2. Remove vacuum hose mounting nut (B).
3. Disconnect vacuum hose (C - Vacuum modulator side).
4. Disconnect vacuum hose & bracket (D)

AFFECTED VIN
12 4J
Brake Fluid Reservoir Tank

1. Open the tank cap and drain the brake oil.
2. Disassemble brake fluid reservoir from master cylinder.
[Notice]
Do not apply excessive force to remore the reservoir.
[Notice]
• Use only specified brake fluid.
• After replacing the brake fluid reservoir be followed air-
breeding job moust.

AFFECTED VIN
4J 13
Master Cylinder (ESP Equipped Vehicle)

Preceding work : Drain the brake fluid
1. Disconnect the brake fluid level switch connector (A).

2. Disconnect brake pipes (B, C) from master cylinder.
3. Remove master cylinder with master cylinder mounting

nuts.
[Notice]
Be careful not to splash the brake fluid onto painted body. If
splashed, immediately clean the contaminated area.

5. Do the air bleeding job.

AFFECTED VIN
14 4J
Brake Booster
Preceding work : Drain the brake fluid
1. Disassembly the master cylinder assembly and remove

clevis pin on the booster push rod.
2. Remove the booster mounting nuts.

3. Disassemble the brake booster from vehicle.
[Notice]
Air-bleeding job must be done after repairing.

AFFECTED VIN
4J 15
Stop Lamp Switch

2. Disconnect the stop lamp switch connector.
3. Unscrew the lamp switch mounting nut and disassemble
the switch.
4. Install in the reverse of removal.
Stop Lamp Switch Check

1. Check if the electrical circuit is closed when the switch
plunger is pushed.

AFFECTED VIN
16 4J
Brake Pedal
1. Remove two stop lamp switch bracket bolts.
2. Remove brake pedal bracket bolts.
3. Disassemble the brake pedal assembly.
Nut
Pad
Stopper
Return spring
Washer
Brake pedal
Bolt
Bracket
5. After installation, hit the brake to check if its operation is

correct.

AFFECTED VIN
4J 17
Brake Pedal Check

Pedal Height / Maximum Stroke
Check the brake pedal with below procedures:
1. Start the engine.
2. Depress the brake pedal around 3 times.
3. Depress the brake pedal with approx. 30 kg and measure
the distance (A) between the upper surface of pedal pad
and the lower dash panel.
4. If the measured value is below the specified value, check
the following causes:
Pad wear, Shoe wear, Air in brake system, Defective
automatic clearance adjuster of rear brake shoe.
5. If the measured value is out of the specified range, adjust
the length of push rod by using lock nut in the brake
booster push rod.
Pedal height
Operating
Specified value (A) 177 mm (from carpet surface) rod
Stop lamp
[Notice]
switch
If the value is out of the specified range, adjust the pedal Operating rod
height by using lock nut of stop lamp switch. lock nut
Stop lamp
switch lock nut
Maximum stroke
Specified value (C) 138 mm
[Notice]
If the value is out of the specified range, adjust the maximum
stroke by using stop lamp and lock nut.

AFFECTED VIN
18 4J
Pedal Free Play

Depress the brake pedal several times to discharge the vacuum
pressure of the power booster. Measure the pedal free play
while pressing the brake pedal by hand.
Specified value 3 ~ 8 mm
If the free play is below the specified value, check if the clear-
ance between the outer case of the stop lamp and the brake
pedal is within the specified range.
If the clearance is out of the specified range, the clearance
between the clevis pin and the brake pedal arm is too large.
Check the components and repair if needed.
Brake Booster Check Normal
1. Let the engine run for 1 ~ 2 minutes and stop it. If the
brake pedal stroke is shortened as pumping the brake
pedal, the system is normal. If not, the system is Faulty
defective.
2. Depress the brake pedal several times with engine off. If
the brake goes down when starting engine with pedal
depressed, the system is normal. If not, the system is
defective.
3. Depress the brake pedal when the engine is running. If
the pedal height is not changed when stop the engine,
the system is normal. If not, the system is defective.
If the above 3 conditions are not satisfied, check the parts
Engine stop
concerned such as valve, vacuum hose, booster, etc.
Engine running

AFFECTED VIN
4J 19
Noise or vehicle vibra- Incorrectly mounted back plate or caliper Repair
tion when applied Loosened bolt of back plate or caliper Retighten
Crack or uneven wear of brake drum or disc Replace
Foreign material inside the brake drum Clean
Pad or lining sticking to contact surface Replace
Excessive clearance between caliper and pad Repair
Uneven contact of pad Repair
Lack of lubrication Lubrication
Loosened suspension Retighten
Pulls to one side when Incorrect tire pressure between left and right Adjust
braking Poor contact of pad or lining Repair
Oil or grease is applied to pad or lining Replace
Bent or uneven wear of drum Replace
Incorrectly mounted wheel cylinder Repair
Faulty auto adjuster Repair
Poor braking Dirty or lack of fluid Replenish or replace
Air in brake system Bleeding
Faulty brake booster Repair
Poor contact of pad or lining Repair
Oil or grease on pad Replace
Over heated rotor due to dragging pad or lining Repair
Clogging brake line Repair
Faulty proportioning valve Repair
Increasing pedal stroke Air in brake system Bleeding
(Pedal goes to floor) Fluid leaking Repair
Excessive clearance between push rod and m/cylinder Adjust
Brake dragging Parking brake is not fully released Repair
Incorrect adjustment of parking brake Adjust
Weak return spring of brake pedal Replace
Incorrect pedal free-play Repair
Broken rear drum brake shoe return spring Replace
Lack of lubrication Lubrication
Damaged master cylinder check valve or piston return spring Replace
Poor parking brake Insufficient clearance between push rod and master cylinder Adjust
Worn brake lining Replace
Dirty brake lining surface by grease or oil Replace
Binding parking brake cable Replace
Excessive lever stroke Adjust lever travel or
check the cable

AFFECTED VIN
20 4J
FRONT BRAKE
Caliper Adjustment of Clearance
The disc brake is normally used for front wheels, however, When the hydraulic pressure is applied to the piston, the
currently it is also used for rear wheels. The floating cali- piston moves to push the pad. The piston seal, which ex-
per type disc brake installed in this vehicle has only one tent considerable pressure against the piston, moves with
brake cylinder at one side of caliper. The hydraulic pres- cylinder.
sure generated by master cylinder pushes the piston to However, the piston seal shape is deformed since the pis-
contact the pad against the disc. The caliper is moved to ton seal is fixed at the cylinder groove as shown in below
contact to the opposite pad. figure.
The brake disc features: When the pressure is released from the piston, the piston
* Excellent radiation due to it is exposed to ambient air comes back to its original position by a restoring and elastic
* Less braking force changes force of the seal.
* No uneven braking When the pad wear is excessive, the piston seal cannot
* Simple structure and operation reach to the desired point because the seal’s deformation
is limited.
Accordingly, the piston always comes back by the de-
Piston
formed distance of piston seal, it keeps the initial clearance.
Pad
Disc
* General description
1. Piston 3. Pad
2. Piston seal a. Clearance
Specifications
Item Specification
Type Ventilated disc type
Inner diameter of caliper cylinder φ 42.9 x 2 mm
Pad thickness 10.5 mm
Disc thickness 26 mm

AFFECTED VIN
4J 21
2. COMPONENTS
For strong and safe brake force, ventilated disk and double piston type is adapted to front brakes.
Brake disk
Caliper
Brake hose
Disk
Caliper carrier
Pad spring Brake pad
Bolt - Caliper
Piston
Brake Caliper assembly

AFFECTED VIN
22 4J
Caliper / Brake Disk

Preceding work : Remove the tire
[Notice]
1. Disconnect brake hose from caliper.
Be careful not to splash the brake oil onto the painted
Tightening torque 20 ~ 30 Nm body.
2. Unscrew two caliper mounting bolts and disassemble the caliper assembly.
3. Unscrew two nuts and disassemble the brake disk.

AFFECTED VIN
4J 23
Brake Pad Change

1. Unscrew brake.
2. Swing up the callper cylinder assembly and hold it not

to damage the hose.
3. Remove the brake pads and replace them with new ones.
4. Compress the brake piston with special tool.
[Notice]
Insert the used pad to compress brake piston.
5. Install the caliper assembly.

AFFECTED VIN
24 4J
Inspection
Clean the dissembled components and visually check the
followings:
• Wear, rust and damage on the cylinder and piston
• Damage, crack and wear on cylinder body and guide pin
• Uneven wear and oil contamination on boot
• Damage and tear on boot
• Scratch and bending on disc plate
Pad Thickness
1. Remove the tire.
2. Measure the pad thickness and replace it if it is below
the wear limit.
New pad thickness Wear limit

10.5 mm 2 mm
Brake Disc Thickness

1. Measure the disc thickness at over four points.
2. If any of measured points is below the wear limit, replace
the brake disc with new one.
New pad thickness Wear limit

28 mm 25.4 mm
Brake Disc Run-out

1. Install the dial gauge on the side of brake disc and
measure the run-out while rotating the brake disc.
2. If the measured value exceeds the limit, replace the brake
disc with new one. Otherwise, it may cause the pedal
vibration and shimmy when braking.
0.03 mm (before installation)

Limit
0.07 mm (when installed)

AFFECTED VIN
4J 25

661 589 16 33 00 (W 99 48 002 0A) Removal of ABS front brake

Front ABS tooth wheel puller tooth wheel
661 589 17 33 00 (W 99 48 003 0A) Installation of ABS front brake

Front ABS tooth wheel installer tooth wheel
Piston Puller Compression of caliper piston

AFFECTED VIN
32 4J
PARKING BRAKE
1. COMPONENTS
Pedal assembly
Equalizer assembly
Return spring - upper

Adjusting bolt
Shoe holding spring
Return spring - lower
Operating lever

AFFECTED VIN
4J 33
Release lever
Release cable
Parking brake switch
Brake damper
Pedal assembly
Pedal
Equalizer assembly
Equalizer bolt
Tension spring
Rear brake cable - LH
Rear brake cable - RH

AFFECTED VIN
34 4J
Pedal Assembly
Preceding work : Remove lower cover - crash pad
1. Release the equalizer bolt.
[Notice]
Replace bolt when reinstall.
2. Remove the clamping ring from pedal assembly and disconnect the brake cable (1).
3. Disconnect the parking brake switch (2).

AFFECTED VIN
4J 35
4. Remove pedal assembly mounting bolts (12 mm) & nuts (12 mm).
Nut
Bolt

AFFECTED VIN
36 4J
Equalizer Assembly
1. Remove the equalizer adjustment bolt (1).

2. Unscrew the mounting bolt (2) in equalizer lever and disconnect front brake cable (3).
3. Disassemble equalizer lever (4) from frame floor mounting.
4. Disconnect rear brake cable (5) and disassemble the equalizer.
Adjustment
1. Park the vehicle on the car lift and set blocks under front
tires.
2. Place the shift lever to “N” (A/T) or “Neutral” (M/T).
3. Release the parking brake.
4. Lift the rear wheels with supplementary lift.
5. Check the brake force as rotating the wheels - specified
hand brake notch : 5
6. If the brake force is not made enough, adjust the parking
brake adjust nut in the brake drum.

AFFECTED VIN
4J 37
Parking Brake Shoe
Components
Adjusting bolt Return spring - upper
Shoe holding spring
Return spring - lower
Operating lever

1. Remove shoe holding spring (2 EA) with plier.
2. Remove upper return spring & adjust bolt.

AFFECTED VIN
38 4J
3. Remove lower return spring and disassemble sperating lever from brake cable.
Adjustment
1. Have the brake shoe contact the inner face of brake disk by winding the brake adjust bolt using a tool (screw
driver), and then, unscrew the bolt by 4 ~ 5 notch. (Clearance between brake disk and brake shoe : 0.2 mm)
2. Check if the wheel become locked when brake force is applied.

AFFECTED VIN
4K 3
ABS SYSTEM
The aim of the ABS is to mmaintain steerability and driving stability and to take the burden off the driver. If the stopping
distance is shorter on some road surfaces (carriageway conditions), this is a gift of physics and not a development aim.
ABS is a device which senses that one or more of the wheels are locking up during braking. It monitors the rotational
speeds of the wheels and reduces hydraulic pressure to any wheel it senses locking up. It is controlled by both
mechanical and electronic components. When you apply the brakes, the ABS will regulate the flow of brake fluid being
delivered to the brake calipers. By the use of electronic computers, the brakes rapidly alternate (at a rate of 30 times per
second) from full pressure to full release.
DRIVING PHYSICS
To give you a better understanding of the tasks and functions of ABS, we will first look at the physics principles.
The Stopping Distance

The stopping distance depends on the vehicle weight and initial speed when braking starts. This also applies for vehicle
with ABS, where ABS always tries to set an optimum brake force on each wheel. As great forces are exerted between
the tires and the carriageway when braking, even with ABS the wheels may scream and rubber is left on the road. With
an ABS skid mark one may be able to clearly recognize the tire profile. The skid mark of an ABS vehicle does not
however leave any hint of the speed of the vehicle in the case of an accident, as it can only be clearly drawn at the start
of braking.
Brake Force on a Wheel

The maximum possible brake force on a wheel depends on the wheel load and the adhesion coefficient between tire and
carriageway. With a low adhesion coefficient the brake force, which can be obtained is very low. You are bound to know
the result already from driving on winter roads. With a high adhesion coefficient on a dry road, the brake force, which can
be obtained, is considerably higher. The brake force, which can be obtained, can be calculated from below formula:
Maximum brake force
FBmax = Vehicle Weight x Adhesion coefficientmh
The braking process cannot be described sufficiently accu-

rately with the brake forces calculated. The values calculated
only apply if the wheel is not locked. In the case of a locking
wheel, the static friction turns into lower sliding friction, with
the result that the stopping distance is increased. This loss of
friction is termed “slip” in specialist literature.
Brake force on a wheel
ABS/ESP SYSTEM CHANGED BY

AFFECTED VIN
4 4K
Slip
The brake slip is the difference between the vehicle speed and the wheel circumference speed. If the wheel locks, the
slip is greatest, that is 100 %. If the wheel is running freely and unbraked, the slip is the lowest, equal to 0 %. Slip can
be calculated from the vehicle speed Vveh and the wheel speed Vw. The equation for this is:
Vveh - Vw
S= X 100 %
Vveh
Vveh = 100 km/h, Vw = 70 km/h
100 - 70
S= X 100 %
100
The slip is 30 %.
Typical slip curves

For the various carriageway conditions the adhesion coeffi-
cients were plotted. The typical course of the curves is al- Dry concrete
ways the same. The only special feature is shown by the
Friction coefficient
curve for freshly fallen snow, for this curve increases at 100 % Wet concrete
slip. In a vehicle without ABS, the wheel locks on braking and
therefore pushes a wedge before it. This wedge of loose sur-
face or freshly fallen snow means and increased resistance
and as a result the stopping distance is shorter. This reduc- Snow
tion in stopping distance is not possible with a vehicle with Ice

ABS, as the wheel does not lock. On these surfaces the stop-
ping distance with ABS is longer than without ABS. The rea-
Slip
son for this is based in physics and not in the Anti-Lock
System. However, as mentioned before, ABS is not about the
stopping distance, but maneuverability and driving stability, <Typical slip curves>
for with ABS you can steer round an obstacle. A device with
locking wheels without ABS cannot be steered. So what use
then is the shorter stopping distance if the vehicle has already
hit the car in front, because you did not have a chance to
steer round the obstacle?
Kamm circle
Before we go into the Kamm circle, you should know that a
tire offers a maximum of 100 % transmissibility. It is all the
same for the tire whether we require 100 % in the direction of
braking or in the direction of the acting lateral force, e.g. when
driving round curves. If we drive into a curve too fast and the
tire requires 100 % transmissibility as cornering force, the tire
cannot transmit any additional brake force. In spite of the ABS Cornering
the car is carried out of the curve. The relationship between side force
brake force B and cornering force S is shown very clearly in
the Kamm circle. If we put a vehicle wheel in this circle, the
relationship becomes even clearer. In this relationship: as long KAMM circle
as the acting forces and the resulting force remain within the Braking force
circle, the vehicle is stable to drive. If a force exceeds the
circle, the vehicle leaves the road.
CHANGED BY ABS/ESP SYSTEM

AFFECTED VIN
4K 5
Brake and cornering force

- Brake force
ABS-Control range
When depressing the brake pedal the brake force increases
to the maximum, then the brake force decreases until the
wheel locks. Stable Unstable
- Cornering force Brake force
The cornering force is a maximum when the wheel is

turning freely with zero slip. When braking the cornering
force falls to zero if the wheel locks (slip 100 %).
- ABS operating range

The operating range starts just before the maximum brake
force and ends in maximum, for the unstable range then
begins, in which no further modulation is possible. The Cornering force
ABS controls the regulation of the brake pressure so that
the brake force only becomes great enough for a sufficient
proportion of cornering force to remain. With ABS we
remain in the Kamm circle as long as the car is driving
Slip
sensibly. We will leave driving physics with these
statements and turn to the braking systems with and
without ABS.
Basic ABS Controls

Brake pressure
Reference speed
Applications of the ABS control unit
Vehicle speed
The signals produced by the wheel sensors are evaluated in
Wheel speed
the electronic control unit. From the information received, the
control unit must first compute the following variables:
- Wheel speed
- Reference speed
- Deceleration
- Slip
Reference speed
The reference speed is the mean, I.e. average speed of all wheel speeds determined by simple approximation.
Simplified ABS control

If, during braking, one wheel speed deviates from the reference speed, the ABS control unit attempts to correct that
wheel speed by modulating the brake pressure until it again matches the reference speed. When all four wheels tend to
lock, all four wheels speeds suddenly deviate from the previously determined reference speed. In that case, the control
cycle is initiated again in order to again correct the wheel speed by modulating the brake pressure.
Selector low control

This control is used for regulating the brake pressure for rear axle during ABS operation. This control uses lower
adhesion coefficient to prevent the rear wheels from locking.

AFFECTED VIN
6 4K
EBD (ELECTRONIC BRAKE FORCE DISTRIBUTION) SYSTEM

System Description
As an add-on logic to the ABS base algorithm, EBD works in
Rearaxle braking force

a range in which the intervention thresholds for ABS control
can not be reached.
EBD ensures that the rear wheels are sensitively monitored
for slip with respect to the front axle. If slip is detected, the
inlet valves for the rear wheels are switched to pressure hold
to prevent a further increase in pressure at the rear-wheel
breaks, thus electronically reproducing a pressure-reduction
function at the rear-wheel brakes.
ABS features an enhanced algorithm which includes control Front axle braking force
of the brake force distribution between the front and rear axles.
This is called Electronic Brake Distribution. In an unloading
Service precautions
car condition the brake efficiency is comparable to the con-
ventional system but for a fully loaden vehicle the efficiency of Observe the following general precautions during any
the EBD system is higher due to the better use of rear axle ABS/TCS service. Failure to adhere to these precau-
braking capability. tions may result in ABS/TCS system damage.
1. Disconnect the EBCM harness connector before
performing the electric welding procedures.
The Benefits of EBD 2. Carefully note the routing of the ABS/TCS wiring
and wiring components during removal. The ABS/
• Elimination of conventional proportioning valve EBD utilizes TCS components are extremely sensitive to EMI
the existing rear axle wheel speed sensor to monitor rear (eletromagnetic interference). Proper mounting is
wheel slip. critical during component service.
• Based on many variables in algorithm a pressure hold, 3. Disconnect the EBCM connector with the ignition
increase and/or decrease pulsetrain may be triggered at OFF.
the rear wheels insuring vehicle stability.
4. Do not hang the suspension components from
• Vehicle approaches the ideal brake force distribution (front the wheel speed sensor cables. The cables may
to rear). be damaged.
• Constant brake force distribution during vehicle lifetime. 5. Do not use petroleum based fluids in the master
• EBD function is monitored via ABS safety logic cylinder. Do not use any containers previously
(conventional proportioning valves are not monitorable). used for petroleum based fluids. Petroleum
• “Keep alive” function. causes swelling and distortion of the rubber
components in the hydraulic brake system,
resulting in water entering the system and
lowering the fluid boiling point.

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4K 7
ON-VEHICLE SERVICE
Service Precautions
[Notice] Electronic system service precautions
Take care to avoid electronic brake control module (HECU)
Brake Fluid may irritate eyes and skin. In case of contact,
take the following actions:
circuit overloading. In testing for opens or shorts, do not
ground or apply voltage to any circuit unless instructed to
• Eye contact - rinse thoroughly with water.
do so by the diagnostic procedure.
• Skin contact - wash with soap and water.
Test circuits only with a high-impedance multi-meter. Never
• Ingestion - consult a physician immediately.
remove or apply power to any control module with the igni-
tion switch in the ON position. Always turn the ignition to
[Notice] the OFF position before removing or connecting battery
cables, fuses or connectors.
To help avoid personal injury due to poor braking. DO
NOT Tap into the vehicle’s brake system to operate a General service precautions
trailer brake system. Disconnect the HECU connector before performing any
vehicle welding work using an electric arc welder.
Do not attempt to disassemble any component designated
[Notice]
as nonserviceable. The hydraulic modulator and the HECU
When fasteners are removed, always reinstall them at the can be seperated. (There is however no access to repair
same location from which they were removed. If a fastener the each components.)
needs to be replaced, use the correct part number fastener
for is not available, a fastener of equal size and strength Bleeding system
(or stronger) may be used. Fasteners that are not reused, Replacement modulators are shipped already filled and
and those requiring thread-locking compound will be bled. In normal procedures requiring removal of the
called out. The correct torque values must be used when modulator, such as to replace the HECU, air will not enter
installing fasteners that require them. If the above the modulator, and normal bleeding will be all that is
procedures are not followed, parts or system damage
needed.
could result.
If air enters the hydraulic modulator, or if an unfilled modu-
lator is installed, use the brake bleeding program in the
[Notice] scan tool to bleed the modulator. Manual bleeding of the
Use only DOT-3 equivalent hydraulic brake fluid. The use hydraulic modulator is not possible.
of DOT-5 (silicone) brake fluid is not recommended.
Reduced brake performance or durability may result.
[Notice]
Avoid spilling brake fluid on any the vehicle’s painted
surfaces, wiring, cables or electrical connectors. Brake
fluid will damage paint and electrical connections. If
any fluid is spilled on the vehicle, flush the area with
water to lessen the damage.

AFFECTED VIN
8 4K
2. COMPONENTS AND LOCATION

Newly introduced ABS has a different shape of integrated hydraulic modulator and HECU (Hydraulic and Electronic
Control Unit) compared to existing ABS. And, the wheel speed sensor uses different method to detect wheel speed. The
basic function of the ABS that maintains the vehicle stability by controlling the steerability of the vehicle when braking
has not been changed.
Wheel speed sensor - Front Wheel speed sensor - Rear
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ABS HECU
ABS & EBD warning lamp

AFFECTED VIN
4K 9
3. INPUT AND OUTPUT DIAGRAM
Battery + (hydraulic valve

and ECU power supply) CAN LO
Battery + CAN HI
(pump supply power)
IG1
H ABS warning lamp

(instrument panel)
Brake switch
E Diagnosis connector pin
Wheel speed sensor (FL)

C no.8
U
Wheel speed sensor (FR)
Ground (pump)
Wheel speed sensor (RL)
Ground (valve)
Wheel speed sensor (RR)

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4. ELECTRICAL CIRCUIT

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5. HYDRAULIC CIRCUIT DIAGRAM

Hydraulic Circuit of ABS
Master cylinder
Primary Secondary
circuit circuit
Damping
chamber
Pump
Low pressure Low pressure

accumulator accumulator
Inlet Inlet Inlet valve

valve valve (all rear
(FR) (FL) wheel)
Outlet valve Outlet valve Outlet valve

(FR) (FL) (all rear wheel)
Wheel (FR) Wheel (FL) Wheel (RR) Wheel (RL)
The vehicle equipped only with the ABS controls the wheel’s braking force using three 3-channel 4-sensor method. The
front wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel
valves system with two inlet valves and two outlet valves. The rear wheels that are the secondary circuit of the brake
system is composed of two wheel speed sensors, one inlet valve and one outlet valve. This system is similar to the one
from the previous model.

AFFECTED VIN
12 4K
ABS Circuit Per ABS Operation Range
Hydraulic Pressure Circuit when ABS is Not Operating
Low pressure
chamber
Pump
Inlet valve
Outlet valve
The hydraulic pressure in the master cylinder increases through the vacuum booster and it is delivered to the wheel via
the normal open inlet valve. At this moment, the normally-closed outlet valve is closed. The speed of the wheel that
hydraulic pressure is delivered reduces gradually .
No Hydraulic Pressure Circuit when ABS is Operating
Low pressure
chamber
Inlet valve
Pump
Outlet valve
Constant pressure
As hydraulic pressure on each wheel increases, the wheel tends to lock. In order to prevent the wheel from locking, the
hydraulic valve modulator operates the inlet valve control solenoid to close the inlet valve and stop the hydraulic pressure
increases. At this moment, the outlet valve is closed. This procedure helps the wheel to maintain a stable hydraulic
pressure.
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4K 13
Pressure Decreases in the Circuit when ABS is Operating
Low pressure
chamber
Pump
Inlet valve
Outlet valve
Pressure decreases
Even when the hydraulic pressure on each circuit is stable, the wheel can be locked as the wheel speed decreases.
This is when the ABS ECU detects the wheel speed and the vehicle speed and gives the optimized braking without
locking the wheels. In order to prevent from hydraulic pressure increases, the inlet valve is closed and the outlet valve is
opened. Also, the oil is sent to the low pressure changer and the wheel speed increases again. The ABS ECU operates
the pump to circulate the oil in the low pressure chamber to the master cylinder. This may make the driver to feel the
brake pedal vibration and some noises.
Pressure Increases in the Circuit when ABS is Operating
Low pressure
chamber
Pump Inlet valve
Outlet valve
Pressure increases
As the wheel speed increases, the inlet valve opens and the wheel’s pressure increases due to the master cylinder
pressure. The oil in the low pressure chamber circulates to the wheel by the pump and the wheel speed decreases as
the hydraulic pressure at wheel increases. This operation continues repetitively until there are no signs that the ECU is
locking the wheels. When the ABS hydraulic pressure control takes place, there may be some vibration and noises at
the brake pedal.

AFFECTED VIN
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6. COMPONENTS DESCRIPTION
HECU (Hydraulic & Electronic
Control Unit)
HECU consists of motor pump (1), solenoid valve (2) and ECU
(3).
ECU connector has 47 pins and the number of valves in valve
body is 6 when equipped with only ABS and 12 when equipped
with ESP system.
Motor Pump
The motor is operated when ABS is activated. The cam-shaped
output shaft of the motor enables the brake system to receive
and supply the brake fluid during the motor operation.
Valve Body
The cam bushing is installed between plungers and it draws
and discharges the brake fluid.

AFFECTED VIN
4K 15
(Pumping)
When the cam pushes the left plunger during motor operation,
the system pressure is generated in the left cylinder. At this
time, the right plunger is expanded by spring force and the
expanded volume of the right cylinder draws the brake fluid.
ECU (Including Solenoid Valves –

ESP Equipped Model)
HECU controls the hydraulic valves by supplying or cutting off
the voltage to solenoid valves depending on the wheel speed
and other information from wheel speed sensors.
The figure shown in left side is for ESP ECU. There are two
channels for front wheels and one channel for rear wheels.
Each channel has one inlet and one outlet valve, therefore,
there are six solenoid valves.
(ECU lower cover)

The electrical components are weak to moisture. To protect
ECU, GoreTex-based plate is used at ECU lower cover. The
vent hall (arrow) allows air to ventilate but does not allow mois-
ture to penetrate.

AFFECTED VIN
16 4K
Active Wheel Speed Sensor

Function of Active Wheel Sensor
The speed sensor used in traditional ABS is made of permanent magnet and transmits the output voltage that changes
as the wheel rotor rotates to the HECU system. New wheel speed sensor detects the wheel speed through the current
value that depends on the resistance that changes according to the magnetic field by using four resisters and supplying
the 12 V power supply to the sensor.
< Front wheel speed sensor > < Rear wheel speed sensor >
< Active type > <Wheatstone bridge>
Active type wheel speed sensor generate square wave insteal of sine wave
Specifications
Item Specifications Reference
Supplying voltage DC 12V
Front: 0.335 ~ 0.945 mm
Air gap Cannot measure the air gap
Rear: 0.309 ~ 0.958 mm
Output current (vehicle speed: at 2.75 km/h) 7mA (Lo) ~ 14mA (Hi) +20 % / -16 %
Front: 19 ~ 25 Nm
Tightening torque 7.5 ~ 20 V
Rear: 6 ~ 10 Nm

AFFECTED VIN
4K 17

HECU Assembly
Preceding Work: Disassemble the battery negative
cable.
1. Unscrew battery mounting bracket bolts (12 mm - 2EA)
and remove battery assembly.
2. Unscrew preheating relay mounting bracket bolts (12 mm

- 2EA) and battery tray mounting bolts (12 mm - 4EA).
3. Disconnect the control unit connector.

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4. Disconnect the primary and secondary master cylinder

pipes from HECU.
5. Disconnect the front and rear wheel brake pipes.

Front Rear RH/LH
Secondary
FL: Front Left
Primary
FR: Front Right
[Notice]
Be careful not to damage the HECU pipe and nut thread when reinstall.
6. Unscrew the HECU mounting nuts (2EA), and remove it.
[Notice]
Do not attempt to disassemble the HECU assembly.

Wrap the end of pipes and HECU to prevent comtaminating.

8. After reinstallation, add some oil and perform the brake
air bleeding.
[Notice]
When you install a new HECU to the vehicle, Coding is excuted automatically.

AFFECTED VIN
4K 19
Front Wheel Speed Sensor

1. Disconnect the battery negative cable.
2. Disconnect the front wheel speed sensor connector.
3. Remove one of self-locking bolt.

Tightening torque
Front wheel speed sensor 19 ~ 25 mm

Airgap 0.369 ~ 1.213 mm
4. Remove wheel speed sensor.

5. When install, clean the sensing area and replace the
self-locking bolt with new one.
Rear Wheel Speed Sensor

2. Disconnect the speed sensor connector.
3. Remove one of self-locking bolt.

4. Remove rear wheel speed sensor.
Tightening torque
Rear wheel speed sensor 19 ~ 25 Nm

Airgap 0.3677 ~ 1.229 mm
5. When install, clean the sensing area and replace the

self-locking bolt with new one.

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System Fuse
The ABS/TCS system fuse and SB2 is located at the fuse
box in engine compartment.
Indicators
The ABS and TCS indicators are in instrument cluster.

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4K 21
ABS FRONT TOOTH WHEEL
Removal
1. Remove the disc brake rotor. Refer to Front Disc Brakes
Section.
2. Remove the ABS front tooth wheel using the ABS tooth
wheel puller (1).
Installation
1. Install the ABS front tooth wheel using the ABS tooth
wheel installer (2).

AFFECTED VIN
22 4K

661 589 16 33 00
ABS tooth wheel puller
661 589 17 33 00
ABS tooth wheel installer

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ESP SYSTEM
Principle of ESP
ESP (Electronic Stability Program) recognizes critical driving conditions, such as panic reactions in dangerous situations,
and stabilizes the vehicle by wheel-individual braking and engine control intervention with no need for actuating the
brake. This system is developed to help the driver avoid the danger of losing the control of the vehicle stability due to
under-steering or over-steering during cornering.
The yaw rate sensor, lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle sensor
under the steering column detect the spin present at any wheels during over-steering, under-steering or cornering. The
ESP ECU controls against over-steering or under-steering during cornering by controlling the vehicle stability using the
input values from the sensors and applying the brakes independently to the corresponding wheels.
The system also controls during cornering by detecting the moment right before the spin and automatically limiting the
engine output (coupled with the ASR system).
Under steering Over steering
Desired
course
With ESP
Desired Without
course ESP
With ESP
Braked
Braked wheel
wheel Without
ESP
Compen-
sating yaw
moment Compen-
Braking force
sating yaw
moment
Braking force
Understeering Oversteering
Understeering is when the steering wheel is steered to a Oversteering is when the steering wheel is steered to a
certain angle during driving and the front tires slip toward certain angle during driving and the rear tires slip outward
the reverse direction of the desired direction. Generally, losing traction. When compared with under steering
vehicles are designed to have under steering. The vehicle vehicles, the controlling of the vehicle is difficult during
can return back to inside of cornering line when the steer- cornering and the vehicle can spin due to rear wheel mo-
ing wheel is steered toward the inside even when the ve- ment when the rear tires lose traction and the vehicle speed
hicle front is slipped outward. As the centrifugal force increases.
increases, the tires can easily lose the traction and the
vehicle tends to slip outward when the curve angle gets
bigger and the speed increases.

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24 4K
ESP controls during under steering ESP controls during oversteering

The ESP system recognizes the directional angle with the The ESP system recognizes the directional angle with
steering wheel angle sensor and senses the slipping route the steering wheel angle sensor and senses the slipping
that occurs reversely against the vehicle cornering direc- route that occurs towards the vehicle cornering direction
tion during understeering with the yaw rate sensor and the during oversteering with the yaw rate sensor and the lat-
lateral sensor. Then the ESP system applies the brake at eral sensor. Then the ESP system applies the brake at
the rear inner wheel to compensate the yaw moment value. the front outer wheel to compensate the yaw moment value.
In this way, the vehicle does not lose its driving direction In this way, the vehicle does not lose its driving direction
and the driver can steer the vehicle as driver intends. and the driver can steer the vehicle as he or she intends.
ESP Control
The ESP system includes the ABS/EBD and ASR systems allowing the system to be able to operate depending to the
vehicle driving conditions. For example, when the brakes are applied during cornering at the speed of 100 km/h, the ABS
system will operate at the same time the ASR or ABD systems operate to reduce the power from the slipping wheel. And
when yaw rate sensor detects the rate exceeding 4¡Æ/seconds, the ESP system is activated to apply the brake force
to the corresponding wheel to compensate the yaw moment with the vehicle stability control function. When various
systems operate simultaneously under a certain situation, there may be vehicle control problems due to internal mal-
function of a system or simultaneous operations. In order to compensate to this problem, the ESP system sets the
priority among systems. The system operates in the order of TCS (ASR or ABD), ESP and ABS. The order may be
changed depending on the vehicle driving situations and driving conditions. As the single-track vehicle model used for
the calculations is only valid for a vehicle moving forward, ESP intervention never takes place during backup.
ESP Operating ESP

range
Turning Turning

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Vehicle Control During Cornering

The figure below shows the vehicle controls by ESP system under various situations such as when the brake pedal is
pressed (or not pressed) during cornering and when the ABS is operating or when just the conventional brake is operat-
ing during braking. It also includes the vehicle conditions when the TCS that is included in the ESP system is operating.
Operations Understeering Control Oversteering Control

ESP auto brake
Only ESP operating Engine

No braking by driver control
ESP auto brake
: Service brake ESP auto brake

(none ABS)
ESP
+
Conventional
brake
(ABS not operating) ESP auto brake
: Service brake
1 : The slip occurs

2 : ABS operation under ESP operation
ESP
+
ABS brake
1 : The slip occurs
under ESP
operation
2 : ABS operation
2 : ASR operation 1 : The slip occurs

under ESP operation
ESP
+ Engine
control
ASR
1 : The slip occurs

under ESP
operation 2 : ASR operation

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HBA (Hydraulic Brake Assist System)

Experienced drivers
Deceleration
Inexperienced drivers
Elderly and physically

weak drivers
Time (s)
(1) Purpose
HBA (Hydraulic Brake Assist) system helps in an emergency braking situation when the driver applies the brake fast,
but not with sufficient pressure, which leads to dangerously long braking distance. ECU recognizes the attempt at full
braking and transmits the signal calling for full brake pressure from the hydraulic booster. An inexperienced, elderly or
physically weak driver may suffer from the accident by not fully pressing the brake pedal when hard braking is required
under emergency. The HBA System increases the braking force under urgent situations to enhance the inputted braking
force from the driver.
Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary, the
HECU system is a safety supplementary system that builds high braking force during initial braking according to
pressure value of the brake pressure sensor and the pressure changes of the pressure sensor intervals.
When the system is designed to apply high braking force when brake pedal is depressed softly by an elderly or
physically weak driver, the vehicle will make abrupt stopping under normal braking situation due to high braking pressure
at each wheels.
(2) Operation
The brake pressure value and the changed value of the pressure sensor are the conditions in which the HBA System
operates. There are 2 pressure sensors under the master cylinder. When the ESP ECU system determines that emer-
gency braking is present, the pump operates, the brake fluid in the master cylinder is sent to the pump and the braking
pressure is delivered to the wheels via the inlet valves.
If the drive depress the brake pedal slowly, the pressure change is not high. In this case, only the conventional brake
system with booster is activated.

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1. HECU: (Hydraulic & Engine 2. Pressure sensor 3. Wheel speed sensor

conrol unit)
ESP Warning lamp
4. Sensor cluster: 5. Steering wheel angle 6. ESP off switch (Electronic

(Yaw rate + lateral sensor + sensor Stability Program Switch)
longitudinal sensor)
2WD vehicle has the longitudinal sensor in the HECU.

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Comparison with ABS System

Specifications
Name Location
ABS ESP
HECU CPU: MCU60 (32 bit) CPU: MCU60 (32 bit)
(Hydraulic & Elec- Clock Frequency: 28 MHz Clock Frequency: 28 MHz Under battery
tronic Control Unit) Memory: 128 ~ 256 KB Memory: 256 ~ 512 KB
Each 4 wheels
Wheel speed sensor Active Type Active Type Front airgap: 0.335 ~ 0.945 mm
Rear airgap: 0.309 ~ 0.958 mm
Steering wheel Maximum angular velocity: 1500°/Sec

N/A Under steering wheel
angle sensor Working voltage: 9 ~ 16 V
2WD: Yaw rate sensor + Lateral sensor
Sensor cluster N/A
4WD: Yaw rate + Lateral sensor + Under front right seat
Longitudinal sensor Integrated in HECU Longitudinal sensor
Pressure sensor N/A Analog Output Under master cylinder

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3. INPUT AND OUTPUT DIAGRAM
Batt. + (voltage to hydraulic v/v) CAN LO
Battery + (voltage to pump) CAN HI
IG1
Brake switch
STICS (Vehicle speed)
ESP switch
A/V Head unit
Signal
A/V system is inoperative while driving
Wheel speed sensor (FL) Ground
Signal Cluster (Vehicle speed)

Wheel speed sensor (FR) Ground
E
Signal S ESP warning lamp
Wheel speed sensor (RL) Ground ESP lamp on while
Signal
P - ESP is in operation (Flicker)
- ESP, ABS system error
- ESP off switch is pushed
Wheel speed sensor (RR) Ground
ABS warning lamp
Power
source
Signal H ABS system error
Pressure sensor 1
Ground ESP buzzer
Power
E While ESP is in operation buzzer work by
source every 0.1sec
Pressure sensor 2
Signal C
Ground
U Diagnostic connector
IG1
ST1
ST2
SWAS
STN Ground (Pump)
Ground
Ground (Valve)
Power
source
CAN-H
Sensor cluster CAN-L
Ground

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4. ELECTRICAL CIRCUIT DIAGRAM

ABS/ESP
Wheel Speed Sensor, Stop Lamp, Diagnosis, Warnung Lamp (ABS/ESP)

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Brake Pressure Sensor, ESP Sensor, Sensor Cluster, ESP OFF Switch

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5. HYDRAULIC CIRCUIT DIAGRAM
Pressure
sensor
Damper Damper
(primary circuit) (secondary circuit)
Separation
valve (NO) Separation valve
(NO)
Damping chamber
Shuttle
Pump Shuttle valve
valve
Low pressure
accumulator
FR FL inlet RR RL
inlet valve valve inlet valve inlet valve
(NO) (NO) (NO) (NO)
FR FL RR RL
outlet outlet outlet outlet
valve(NC) valve(NC) valve(NC) valve(NC)
Wheel (FR) Wheel (FL) Wheel (RR) Wheel (RL)

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System Overview
When equipped with ABS, the braking force at each wheel will be controlled with 3-channel 4-sensor method. And when
equipped with ESP, 4 wheels will be controlled independently with 4-channel method. (When controlling ABS system
only, it will be operated with 3-channel method.) When compared to the vehicle equipped with ABS/EBD only, the
internal hydraulic circuit has a normally-open separation valve and a shuttle valve in primary circuit and in secondary
circuit. When the vehicle brakes are not applied during engine running or when applying the non-ABS operating brakes,
the normally-open separation valve and the inlet valve are open, whereas the normally-closed shuttle valve and the outlet
valve are closed. When the ESP system is operating, the normally-open separation valve will be closed by the solenoid
valve operation and the hydraulic circuit will be established by the shuttle valve. Then, the inlet and outlet valves will be
closed or open depending on the braking pressure increase, decrease or unchanged conditions.
The warning lamp comes on and warning beep sounds when the ESP is operating
When the ESP operates during vehicle movement, the ESP warning lamp on the instrument panel flickers and
beep comes on every 0.1 seconds. The ESP operation shows that the vehicle stability is extremely unstable
and it is used to warn the driver. The ESP system is just a supplementary system for the vehicle motion and it
cannot control the vehicle when it exceeds the physical limits. Do not solely rely on the system but be advised
to drive the vehicle safely.
Driving feeling when the ESP is operating

When the ESP system activates, the driving feeling can be different depending on vehicle driving conditions. For
example, you will feel differently when the ESP system is activated during when ABS is operating with the
brakes applied and when brakes are not applied on a curve. Thus, the ESP system would make the driver feel
more abruptly when the brakes are applied during the ESP system activation.
Noise and vibration that driver senses when the ESP is operating
The ESP system may transfer noise and vibration to the driver due to the pressure changes caused by the
motor and valve operations in a very short period of time. Extreme cornering will trigger the ESP operation and
this will make the driver feel noise and vibration due to sudden brake application. Also, the ESP system controls
the engine output. So, the driver may notice the engine output decrease even when the accelerator pedal is
being applied.

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(1) ESP Hydraulic unit in idling and normal braking position
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Outlet valve
Inlet valve
In this position, the separation valve and the inlet valve are open (normal open), the electrically operated shuttle valve and
the outlet valve are closed. When the brake is applied under these conditions, the brake fluid will be sent to each wheel
via the separation valve and inlet valve.

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(2) When applied ABS (decreased pressure)
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Inlet valve
Outlet valve
The pressure decreases just before the wheel speed drops and the wheels. The inlet valve closes and the outlet valve
opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied.
Then the pump operates to allow fast oil drainage.

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(3) When applied ABS (maintained pressure)
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Inlet valve Outlet valve
The Inlet valve and outlet valve will be closed to maintain the pressure in the hydraulic circuit applied at the wheels. By
closing the valves, the hydraulic pressure at the wheels will not be lost or supplied any more. During ESP operation, the
separation valve closes and only the shuttle valve at the pump opens.

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(4) When applied ABS (increased pressure)
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Outlet valve
Inlet valve
The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed. Then, the pump is
operated.
When ESP operates while the ABS is operating, the pressure will be increased continuously until just before the
corresponding wheel gets locked.

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(5) Hydraulic Diagram of HBA
Low pressure
chamber
Shuttle valve
Separation valve Outlet valve
Inlet valve
Pump
Rear wheel
Outlet valve
Inlet valve
Front wheel
The above figure shows one front and one rear wheel and the same hydraulic circuit forms as in the ESP operation.
When HECU recognizes that it is an emergency and it is required for hard braking, depending on the pressure value of
the brake pressure sensor and pressure changes caused by the pressure sensor timing, it operates the pump immedi-
ately to apply the brake pressure at the wheels.
Then, the pressure in the pump increases until just before the corresponding wheel gets locked. The motor still keeps
rotating and the outlet valve and the separation valve are will stay closed. When the wheel starts to lock, the HBA
function cancels and switches to ABS operation.

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6. COMPONENTS DESCRIPTION
HECU (Hydraulic and Electronic Control Unit)
HECU Installed in a Vehicle
RL: Rear left
Secondary
RR: Rear right
FL: Front left
Primary
FR: Front right
HECU consists of motor pump, solenoid valve and ECU.

ECU connector has 47 pins and the number of valves in valve body is 12 when equipped with ESP(6 valve for ABS/EBD),
and they cannot be disassembled.
Comparison between ESP HECU and ABS/EBD HECU
ABS/EBD HECU (2 ports 3 chnnels) ESP HECU (2 ports 4 chnnels)

AFFECTED VIN
40 4K
ECU (Electronic Control Unit)

The electronic control unit performs the following functions:
- controlling the ABS and ESP
- cotinuous monitoring of all electrical components
In the integrated control unit, the coils of the solenoid valves
are integrated into the control unit housing. The necessary
relays are mounted on the circuit board of the electronic con-
trol unit.
- yaw rate
- G sensor
- lateral/longitudinal acceleration
- pressure in hydraulic system
- wheel speed
- reference speed
- deceleration
- slip
# ABS control
If during braking, one wheel speed deviates from the reference Brake pressure
speed, the ABS control unit attempts to correct that wheel by Reference speed
modulating the brake pressure until it again matches the ref- Vehicle speed
erence speed. When all four wheels tend to lock, all four wheels Wheel speed
speeds suddenly deviate from the previously determined ref-
erence speed. In that case, the control cycle is initiated again
in order to again correct the wheel speed by modulating the
brake pressure.
Hydraulic Control Unit

The pump and the valve body are grouped together in one
housing, forming one compact unit with the electric motor.
Four pairs of valves (4 inlet valves, 4 outlet valves) are provided
for modulating the pressure at the wheels plus two isolating
valves and two electrically operated shuttle valves.
Mote pump Valve body

AFFECTED VIN
4K 41
Connector
Pin no. Name Current Tange Voltage Range ABS ECU

1 Battery (B+) Max. 30 A 0 ~ 18 V O
2 Self diagnosis (K-Line) Max.100 mA 0 ~ 18 V O
3 Steering wheel angle sensor (STN) Max. 10 mA 0 ~18 V -
4 IGN1 Max. 200 mA 0 ~ 18 V O
5 Steering wheel angle sensor ground Max. 100 mA 0V -
6 Sensor cluster power Max. 250 mA 0 ~ 18 V -
7 Steering wheel angle sensor power Max. 10 mA 0 ~ 18 V -
8 - - - -
9 - - - -
10 - - - -
11 CAN (High) Max. 100 mA 0 ~ 18 V O
12 - - - -
13 - - - -
14 - - - -
15 CAN (Low) Max. 100 mA 0 ~ 18 V O
16 Ground Max. 20 A 0V O
17 - - - -
18 Pressure sensor (No.1) power Max. 20 mA 5V -
19 Pressure sensor (No.1) ground Max. 20 mA 0V -
20 Pressure sensor (No.1) signal Max. 10 mA 5 V -
21 Pressure sensor (No.2) ground Max. 20 mA 0 V -
22 Pressure sensor (No.2) power Max. 20 mA 5 V -
23 Pressure sensor (No.2) signal Max. 10 mA 5 V -
24 - - - -
25 Sensor cluster CAN (Low) Max. 10 mA 0 ~ 18 V -
26 - - - -
27 - - - -
28 Steering wheel angle sensor (ST2) Max. 10 mA 1.3 ~ 4.1 V -
29 Sensor cluster CAN (HIGH) Max. 10 mA 0 ~ 18 V -
30 Steering wheel angle sensor (ST1) Max. 10 mA 1.3 ~ 4.1 V -
31 Sensor cluster ground Max. 250 mA 0V -
32 Battery (B+) Max. 20 A 0 ~ 18 V O
33 Wheel speed sensor ground (FR) 3 ~ 45 mA 0V O
34 Wheel speed sensor ground signal (FR) 3 ~ 45 mA 0 ~ 18 V O
35 - - - -
36 Wheel speed sensor ground signal (RL) 3 ~ 45 mA 0 ~ 18 V O
37 Wheel speed sensor ground ground (RL) 3 ~ 45 mA 0V O
38 - - - -
39 - - - -
40 ESP OFF switch Max. 10 mA 0 ~ 18 V -
41 Stop lamp switch Max. 10 mA 0 ~ 18 V O
42 Wheel speed sensor ground ground (RR) 3 ~ 45 mA 0V O
43 Wheel speed sensor ground signal (RR) 3 ~ 45 mA 0 ~ 18 V O
44 ABS warning lamp Max. 20 mA 0 ~ 18 V O
45 Wheel speed sensor ground signal (FL) 3 ~ 45 mA 0 ~ 18 V O
46 Wheel speed sensor ground ground (FL) 3 ~ 45 mA 0V O
47 Ground Max. 30 A 0V O

AFFECTED VIN
42 4K
Wheel Speed Sensor

Active Wheel Sensor
- Measuring bridge with four resisters
- Measuring the current
- Supplying the voltage (12 V)
- Amplifier/comparison measuring device
Function of Active Sensor System

The basic tone wheel and the magnetized encoder wheel to
activate the sensor. When the vehicle is moving, the sine wave
signal is changed in the magnetic field of wheatstone bridge
due to the rotation of tone wheel. This can be done directly by
ABS control unit.
Active Sensor Element of Encoder Wheel

This sensor has the measuring bridge integrated plastic hous-
ing and is fixed to small permanent magnet. Four lead wires Permanent
that receive electrical output value are connected to the IC magnet
integrated plastic housing. Two connecting pins are used for
signal output and voltage supply.
Sensor filament
Specifications
Description Specifications Reference

Supplying voltage DC 12 V
Front: 0.335 ~ 0.945 mm
Air gap Cannot measure the air gap
Rear: 0.309 ~ 0.958 mm
Output current
7 mA (Lo) ~ 14 mA (Hi) +20 % / -16 %
(vehicle speed at 2.75 Km/h)
Front: 19 ~ 25 Nm
Tightening torque 7.5 ~ 20 V
Rear: 6 ~ 10 Nm

AFFECTED VIN
4K 43
SWAS : Steering Wheel Angle Sensor

The steering wheel angle sensor is located between clock spring and multifunction switch. This sensor is used for
recognition of driver’s intends. If the sensor is replaced with new one, it can detect the neutral position after the vehicle
is moving over 20 km/h for more than 5 seconds.
1. Clock spring 2. Multi-function switch 3. SWAS (Steering Wheel Angle Sensor)
Specifications
Working voltage 9 ~ 16 V
Max. output current 10 mA
Detected max. angular velocity 1500°/S
Working temperature -30 ~ 75°C
Supplying voltage 9 ~ 16 V(battery voltage)
When short 0V
When short to sensor Power voltage - 0.7 V
Output voltage (HI) Approx. 3.50 V (3.0 ~ 4.1 V)
Output voltage (LO) Approx. 1.50 V (1.3 ~ 2.0 V)

AFFECTED VIN
44 4K
Steering wheel angle

sensor connector
LED Phototransistor
Steering column Slotted plate
Steering wheel angle
The steering wheel angle sensor is integrated with the phototransistor and the LED and there is a slotted plate between
them. When the inner slotted plate rotates with the steering column shaft when the steering wheel is turned, the voltage
occurs through the holes. The detected voltage will be transmitted to the ESP unit as a pulse from the 3 terminals.
Then, the two voltage pulses are used to get the average value for detecting the steering wheel position and its angle
speed. And the other pulse is used for checking the alignment of the steering wheel.
Steering
Wheel
ESP
Angle
unit
Sensor
(SWAS)
With ESP
Working voltage 9 ~16 V

Number of pulse
45 Pulses /1rev
per revolution
Duty Approx. 50 %
High - V 3.0 ~ 4.1 V
Low - V 1.3 ~ 2.0 V

Detects steering wheel
ST1 and ST2 angle and angular veloc-
ity as an average value
Detects the center value
STN Center line of steering wheel
of steering wheel

AFFECTED VIN
4K 45
Sensor Cluster
The lateral sensor, logitudinal sensor and the yaw rate sensor are important components of the Electronic Stability
Program. The cluster links these sensors to an on-board computer unit and to a CAN interface, incased in a sturdy
housing, that is mounted on the chassis. Its modular concept allows the integration of further sensor functions.
Location
Internal Electric Circuit of Sensor Cluster
Sensor cluster
Power supply Power supply

circuit
Yaw rate sensor
Micro controller
ECU A/D converter
(self diagnosis)
Lateral sensor
CAN Longitudinal sensor

CAN module

AFFECTED VIN
46 4K
Sensor Cluster Circuit
Power
Ground
Power
Sensor cluster ESP unit
Specification
(sensor cluster: yaw rate sensor + lateral acceleration sensor + Longitudinal acceleration sensor)
Supplying voltage Approx. 8 ~ 16 V
Output voltage when stop Approx. 2.5 V (Ignition switch “ON”)
Output range 0.2 ~ 4.8 V
Operation start speed -75°/s ~ +75°/s
Yaw Rate Sensor

The yaw rate sensor relies on the action of micro-scopic tun-
ing forks. The plane in which these forks vibrate shifts when
the car turns around its vertical axis. This shift is evaluated
electronically.
A faulty yaw rate sensor produces an output signal of 0 V.

AFFECTED VIN
4K 47
Installation position
• Tuning forks vertical
• Required accuracy of position: max. ± 3° tolerance to
maintain full comfort
• Failure to maintain the specified installation position will
result in asymmetrical control
Lateral/Longitudinal Acceleration
Sensor
These sensors sense the lateral/longitudinal acceleration of
the vehicle and located in sensor cluster. For 4WD vehicle,
the longitudinal sensor is located in sensor cluster and the
functions are same only except the direction. The lateral ac-
celeration sensor detects the movement of lateral direction
and the longitudinal acceleration sensor detects the move-
ment of longitudinal direction (driving direction).
Between two electrically charged stationary plates having the
same polarity, an electrically charged silicon element having
the opposite polarity is attached to the end of a cantilever
arm. Between these three plates, two electric fields are gen-
erated by the capacitors C1 and C2. The capacitances of C1
and C2 change in response to lateral acceleration. This change
can be used to calculate the direction and amount of lateral/
longitudinal acceleration acting on the vehicle. For 0 g lateral
acceleration, the sensor produces an output signal with a volt-
age of 2.5 V.
The signal of the lateral acceleration sensor alone cannot trig-

ger an ESP intervention.
The ESP sensor cluster can be considered as one module.
The measured value by lateral/longitudinal and yaw rate sen-
sors is transmitted to ESP unit via two CAN lines.
When a sensor is faulty, the sensor cluster produces an out-
put signal of 0 V (fail safe function).

AFFECTED VIN
48 4K
Pressure Sensor
Location
1. Master cylinder 4. Inside of pressure sensor

2. Primary pressure sensor 5. Connector
3. Second pressure sensor
Pressure Sensor Circuit
Ground
• HBA operating conditions with output value from
Power
pressure sensor:
- pressure: 20 bar
Signal output
- pressure deviation: over 1500 bar/sec
<Primary pressure sensor>
- vehicle speed: over 7 km/h
Ground
Power
Signal output
<Secondary pressure sensor> <ESP unit>
Specifications
Supplying voltage 4.75 ~ 5.25 V
Output range 0.25 ~ 4.75 V
Output voltage when stop 2.5 V

AFFECTED VIN
4K 49
Description
a. The pressure sensor senses the driver’s braking
intentions (braking while an ESP intervention is in
progress) and detects the precharging pressure.
b. The sensor consists of two ceramic disks, one of which

is stationary and the other movable. The distance
between these disks changes when pressure is applied.
c. The pressure sensors operate on the principle of changing

capacitance (a).
The distance (s) between the disks and, thus, the
capacitance changes when pressure is applied to the
movable disk by a braking intervention.
Brake not
applied
d. When brake pressure is applied from the master cylinder,

the ceramic disk moves towards the fixed ceramic disk
and the electric charge volume changes accordingly.
Brake
applied

AFFECTED VIN
50 4K
If two signals from pressure sensor deviates from the specified value, HECU determines the sensor is faulty. The sensor
output is analog signal that is proportional to voltage and the HECU recognized the pressure value as signal value
against supplying voltage.
Maximum measurable pressure: 170 bar

Linear changes of about 0.5 volts when the brake is not operating and 4.75 volts when the brake is operating.

AFFECTED VIN
4K 51
ESP OFF Switch

ESP OFF switch is located at center switch panel. When pressing the switch, the ESP warning lamp lights up and ESP
and TCS function is deactivated.
However, the ABS function is still activated.
Automatic coding
When replacing the HECU with new one, it is coded automatically. Therefore, additional coding operation is not needed.
When the existing ECU installed to another vehicle or a new HECU recognizes that the coded data is not matched with
the vehicle, the warning lamp lights up and ABS/ESP is not activated.
The HECU is coded when it is initially installed to the vehicle, and once coded data cannot be changed.
* If DTC C1170 (5170) is generated during automatic coding, clear it with a scan tool to resume automatic coding
process.

AFFECTED VIN
52 4K
WARNING LAMP AND INDICATOR

ESP Warning Lamp Blinking in Control
ESP warning lamp blinks when ESP control is activated. If the activation reaches a certain limitation, a beep sounds to
warn the driver. The ESP warning lamp goes off when ESP function is deactivated. Even when the ESP is operated for
a very short period of time, the ESP warning lamp blinks minimum of 4 times every 175 milliseconds and the buzzer
sounds for at least 1.4 seconds with 100 ms interval.
ON
ESP operation
(including ASR)
OFF
Min. 4 times
ON
ESP warning lamp

OFF
Min. 1.4 sec
ON
ESP buzzer
OFF
ESP System Cancellation Using the ESP OFF Switch

When the ESP switch at the center switch panel is pushed (for over approximately 150 ms), the ESP system will be
cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors. Then, the ESP
warning lamp on the instrument panel comes on.
The detailed operation procedures are as follows:
1) The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms.
2) The switch returns to normal position when the OFF switch is released.
3) The ESP system will be cancelled after approximately 150 ms.
Based on the above procedures, we can see that the ESP system will be cancelled after a certain period (approx. 150
ms) from releasing the switch to the original position. The ESP system does not get canceled immediately when the
ESP warning lamp is turned on by pressing the ESP OFF switch.
When you turn the ESP system off by pressing the ESP switch for over 150 ms, the TCS system is turned off. And the
basic ABS system will operate.

AFFECTED VIN
4K 53
Resuming the ESP System by Using the ESP OFF Switch

The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switch at
the center switch panel is pushed (for over approximately 150 ms) while the ESP system is not operating.
The detailed operation procedures are as follows.
1) The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms.
2) The switch returns to normal position when the OFF switch is released.
3) The ESP system will be resumed after approx. 150 ms.
RELEASE
PUSH
RELEASE
PUSH
HI
ESP operation Disabled range
LO
ESP function ON
(including ASR)
OFF
ON
ESP warning lamp
OFF
[Notice]
• When turning the ignition switch off while the ESP system is activated, the ESP system will be resumed when ignition
switch is turned on again.
• When the vehicle is controlled by ESP system during driving, the ESP OFF switch does not operate.
• The ESP OFF switch operates when it is pushed for over 150 ms. When it is pushed for less than 150 ms, the ESP OFF mode
and the ESP warning lamp will not be changed.
• When the ESP OFF switch is pushed within 350 ms of being turned off, the ESP warning lamp and ESP system will not be
turned on.

AFFECTED VIN
54 4K
ESP OFF Switch Monitoring

When the ESP unit recognizes that the ESP OFF switch is pushed for over 60 seconds, the ESP unit determines it as
a ESP OFF switch malfunction. When the ESP OFF switch is pushed, the ESP system is resumed after 60 seconds.
However, the ESP warning lamp comes on when the ESP OFF switch is pushed (for over 150 ms) and then goes out
when the ESP system is resumed. When the ESP OFF switch returns to normal position, the ESP unit resets the ESP
OFF switch for approx. 3.5 seconds.
Push Release
´
HI
ESP operation
LO
60 sec
3.5 sec
Return to switch signal Reset to normal condition
ON
ESP function
(including ASR) OFF
Cancellation of ESP OFF mode
Turning the ESP warning lamp off
ON
ESP warning lamp
OFF

AFFECTED VIN
4K 55
ESP Warning Lamp Operation Depending on System Conditions

The table shows ESP warning lamp operations when the ESP system is defective or ESP (including TCS function) is
working.
Warning Lamp Controls
EBD ABS ESP ESP Vehicle

EBD ABS ASR ABD yaw
W/L W/L W/L BUZZER control
Initial start ON ON ON OFF X X X X X
(for 1.8 sec) BLINKS INTERMITTENT BEEP
OFF OFF WHEN ESP SOUNDS WHEN ESP O O O O O
Normal mode OPERATION OPERATION
ESP fault OFF OFF ON OFF O O X X X
ABS fault OFF ON ON OFF O X X X X
System fault ON ON ON OFF X X X X X
Low batt. voltage 1 st
OFF ON ON OFF O X X X X
Low batt. voltage 2 nd
ON ON ON OFF X X X X X
High battery voltage ON ON ON OFF X X X X X
High brake pad temp. OFF OFF ON OFF O O **O X O
ESP-OFF mode OFF OFF ON OFF O O X X *O
Entering diag. mode ON ON ON OFF X X X X X
*) When the driver presses the brake pedal during the ESP OFF mode, the yaw control is performed to compensate
the vehicle stability (posture) during ESP operation.
* *) The ASR controls only engine control

AFFECTED VIN
56 4K

HECU Assembly
Preceding Work: Disassemble the battery negative
cable.
1. Unscrew battery mounting bracket bolts (12M - 2EA)
and remove battery assembly.
2. Unscrew preheating relay mounting bracket bolts (12M -

2EA) and battery tray mounting bolts (12M - 4EA).
3. Disconnect the control unit connector.

AFFECTED VIN
4K 57
4. Disconnect the primary and secondary master cylinder

pipes from HECU.
5. Disconnect the front and rear wheel brake pipes.
RL: Rear left
Secondary
RR: Rear right
FL: Front left
Primary
FR: Front right
[Notice]
Be careful not to damage the HECU pipe and nut thread
when reinstall.
6. Unscrew the HECU mounting nuts (2EA), and remove it.
[Notice]
Donot attempt to disassemble the HECU assembly.

Wrap the end of pipes and HECU to prevent comtaminating.

8. After reinstallation, add some oil and perform the brake
air bleeding.
[Notice]
When you install a new HECU to the vehicle, Coding is excuted

automatically.

AFFECTED VIN
58 4K
Steering Wheel Sensor

1. Disconnect the battery negative cable and align the tires straight forward.
2. Remove the airbag module.
3. Unscrew the steering wheel mounting nut and remove the wheel.
4. Remove the I/P panel lower cover.
[Notice]
• Leave marks on the column shaft(A) and on the wheel(B).

AFFECTED VIN
4K 59
5. Remove the steering column upper/lower cover.
6. Remove the contact coil.
7. Remove the steering wheel angle sensor frim the steering

wheel (combi switch).

AFFECTED VIN
60 4K
Sensor Cluster
1. Remove center panel and aircon controller.
2. Disconnect the sensor cluster connector and unscrew

the cluster mounting bolts (2EA).
3. Disassemble the sensor cluster.

AFFECTED VIN
4K 61
8. ABS/ESP TROUBLE DIAGNOSIS

DTC CODE
[O: Applied, X: N/A]
Trouble
Defective Components Descriptions ABS ESP
Code
Cause
- Defective front LH wheel speed sensor
- Short or poor contact wire to sensor
C1011 Wheel speed sensor
Action O O
(5011) front left-electrical
- Check the wheel speed sensor connector and HECU
connector
- Check the harness connection
Cause
- Defective front LH wheel speed sensor
- No signals from wheel speed sensor and tooth wheel
C1012 Wheel speed sensor - Different number of teeth in tooth wheel O O
(5012) front left-other Action
- Check air gap and tooth wheel mounting
- Check the number of teeth in tooth wheel: 48
Cause
- Defective front RH wheel speed sensor
C1021 Wheel speed sensor Action O O
(5021) front right-electrical - Check the wheel speed sensor connector and HECU
connector
Cause
- Defective front RH wheel speed sensor
- Too large air gap between wheel speed sensor and tooth
C1022 Wheel speed sensor wheel O O
(5022) front right-other
- Different number of teeth in tooth wheel
Action
Cause
- Defective rear RH wheel speed sensor
Action O O
(5031) rear right-electrical
- Check the wheel speed sensor connector
- Check the EBCM connector

AFFECTED VIN
62 4K
Trouble
Code
Cause
- Defective rear RH wheel speed sensor
C1032 Wheel speed sensor rear - Too large air gap between wheel speed sensor and
tooth wheel
O O
(5032) right-other
Action
Cause
- Defective rear LH wheel speed sensor
Action O O
(5041) rear left-electrical
- Check the HECU connector
Cause
- Defective rear LH wheel speed sensor
- Too large air gap between wheel speed sensor and
C1042 Wheel speed sensor tooth wheel O O
(5042) rear left-other
Action
Cause
- Abnormal signals from pressure sensor
- Defective pressure sensor or harness
C1051 Action
Pressure sensor X O
(5051)
- Check the pressure sensor connector
- Check the output voltage (stop): 0.5 V
- Check the output voltage (brake applied): 0.25 ~ 4.75 V
Cause
- Internally defective steering wheel angle sensor
- Abnormal signals from steering wheel angle sensor
- Short circuit between supplying voltage output and ground
- Abnormal signal voltage from steering wheel angle sensor
C1061 Steering wheel Angle - Poor installation of steering wheel angle sensor and
X O
(5061) sensor abnormal signal
Action
- Check the harness connection of steering wheel angle
sensor
- Check the working voltage : LOW – 1.3 ~ 2.0 V
HIGH – 3.0 ~ 4.1 V

AFFECTED VIN
4K 63
Trouble
Code
Cause
- Operating voltage exceeds specified range
(Hi: 18.0 ± 1.0 V / Lo: 6.5 ± 0.5 V)
C1073 Sensor cluster -electri- X
- Poor contact or installation of harness O
(5073) cal
Action
- Check the sensor cluster connector
- Others
Cause
- Internally defective HECU
- Abnormal A/D converter voltage: 5.0 ± 3 %
- Abnormal supplying voltage (4.580 ~ 4.960 V) to sensor
cluster
→ Short circuit between supplying voltage output of
sensor cluster and ground
- Poor ground of sensor cluster (0.0 ~ 0.5 V)
→ Short to ground on sensor cluster
C1074
Sensor cluster-internal - Abnormal signals from longitudinal acceleration sensor X O
(5074)
- Abnormal signals from lateral acceleration sensor
- Abnormal signals from yawing sensor
- Poor installation of sensor
- Defective sensor cluster
- Defective or short circuit of CAN communication line
Action
- Replace the sensor
- Initialize the sensor
Cause
C1101 - Low voltage out of specified range (9.7 ± 0.3 V)
Battery under voltage O O
(5101) Action
- Check the supplying voltage
Cause
C1102 - Over voltage out of specified range (18.0 ± 1.0 V)
Battery over voltage O O
(5102) Action
Cause
C1111 - Overheated brake disk due to braking force: over 500°C
Disk temperature is high Action O O
(5111)
- Stop driving for a period of time after turning off the ESP

AFFECTED VIN
64 4K
Trouble
Code
Cause
- Mechanical defective in brake switch
C1201
Brake lamp switch - Defective brake switch harness X O
(5201)
Action
- Check the harness and connector
Cause
- Mechanical defective in ESP OFF switch
C1202 - Defective ESP OFF switch harness (short to ground)
ESP OFF switch X O
(5202)
Action
- Check the harness and connector for ESP OFF switch
Cause
- Abnormal supplying voltage to valve solenoid
C1301
Valve, valve relay Action X X
(5301)
- Check the battery voltage
- Replace the HECU
Cause
- Too low (below 6.0 V) or no supplying voltage to pump
motor
- Over 0.93 V from pump motor voltage
C1311 - Poor contact in pump motor connector
Motor pump O O
(5302) - Poor ground
Action
- Replace the HECU
Cause
- Defective A/D converter, internal voltage regulator, and
C1401
HECU hardware controller O O
(5401)
- Defective sensor and short to supplying voltage line
Action
- Replace the HECU
Cause
- Abnormal signals from sensors
C1501 No calibration or SC
- Poor calibration for sensors X O
(5501) checksum error
Action
- Check and initialize the sensors

AFFECTED VIN
4K 65
Trouble
Code
Cause
- Coding error
- Defective CAN communication line
C1170
Variant coding error - Discrepancy between HECU coding and vehicle coding (O) O
(5170)
Action
- Check the HECU coding and vehicle coding
- Replace the HECU
Cause
C1601 - Defective CAN communication line
CAN bus off (O) O
(5601) Action
- Check CAN communication line
Cause
- Short to CAN communication line
CAN timeout EMS - Overload to CAN communication
C1602 (communication error Action X O
(5602) between engine ECU - Check the engine ECU
and CAN) - Check the CAN communication line
- Check the engine ECU connector
Cause
- Short to CAN communication line
CAN timeout TCU - Overload to CAN communication
C1603
(communication error Action X O
(5603)
between TCU and CAN) - Check the TCU
- Check the CAN communication line
- Check the engine TCU connector
Cause
- Defective communication with TCCU
C1604 CAN timeout 4WD Action
X O
(5604) (can signal error EMS) - Check the TCU
- Check the TCCU connector
- Check the CAN communication line
Cause
C1612 CAN timeout 4WD - Defective signal transmit of Engine ECU
X O
(5612) (can signal error EMS) Action
- Check the engine ECU varient coding

AFFECTED VIN
66 4K
ABS/ESP Sensor Value

No Contnet Unit ESP ABS
1 Wheel Speed Front RH 1 km/h O O
2 Wheel Speed Front LH 1 km/h O O
3 Wheel Speed Rear RH 1 km/h O O
4 Wheel Speed Rear LH 1 km/h O O
5 Battery Voltage 0.1 V O O
6 Longitudinal Acceleration Sensor 0.01 g O X
- : Straight ahead (Fixed Value: 0)
7 Lateral Aceleration Sensor 0.01 g O X
+ : Left Turn (Fixed Value: 0)
8 Yaw Rate Sensor 0.5 deg/s O X
9 Steering Wheel Angle Sensor 5 deg O X
10 Pressur Sensor (Primary) 1 bar O X
(Fixed Value: 0)
11 Pressur Sensor (Secondary) 1 bar O X
(Fixed Value: 0)
12 EBD Control Operation / Non-operation O O
13 BTCS Control Operation / Non-operation O X
14 Engine TCS Control Operation / Non-operation O X
15 ESP Control Operation / Non-operation O X
16 ESP / TCS OFF Switch ON / OFF O X
17 ABS Control Operation / Non-operation O O
18 Stop Lamp Switch ON / OFF O O
[O: Applied, X: N/A]

AFFECTED VIN
4K 67
ABS/ESP Forced Operation

No Name Operation
1 Front LH Inlet Operation / Non-operation
2 Front LH Outlet Valve Operation / Non-operation
3 Front RH Inlet Operation / Non-operation
4 Front RH Outlet Valve Operation / Non-operation
5 Rear (or RL) Inlet Valve (x1) Operation / Non-operation
6 Rear (or RL) Outlet Valve (x1) Operation / Non-operation
7 (Rear RH Inlet Valve (x2)) Operation / Non-operation
8 (Rear RH Outlet Valve (x2)) Operation / Non-operation
9 TCS Valve Primary (x3) Operation / Non-operation
10 TCS Valve Secondary (x3) Operation / Non-operation
11 ESV Valve Primary (x3) Operation / Non-operation
12 ESV Valve Secondary (x3) Operation / Non-operation
13 - -
14 - -
15 Motor Pump Operation / Non-operation

AFFECTED VIN
68 4K
Sensor Initialzation (SCAN 100)
INTIALIZE SENSOR(Only ESP)
INTIALIZE SENSOR
1] LONGITUDINAL ACCEL SENSOR(4WD only)
2] LATERAL ACCEL SENSOR
3] PRESSURE SENSOR
4] ABOVE 1, 2, 3 ALL SENSOR
Select one of the above items
INTIALIZE SENSOR
LONGITUAINAL ACCEL SENSOR(4WD only)

DO YOU START INITIALIZE ? (Yes/No)
CONDITION :
- ENGINE IS NOT RUNNING.
- VEHICLE STATUS IS FLAT.
- DO NOT PUT THE BRAKE PEDAL.
PROCEDURE :
MUST BE FOLLOW THE ABOVE CONDITION.
IF YOU START "INITIALZE SENSOR",
ADART TO AUTOMATIC.

AFFECTED VIN
4K 69
9. AIR BLEEDING
The vehicle equipped only with ABS can use the conventional air bleeding procedure, however, the vehicle equipped with
ESP should use the oil supply device with compressor to bleed the air.
Rear
Front
Oil supply
Oil return
Air bleeding should be done when:

1. After removal and installation of the brake master cylinder.
2. After removal and installation of the ABS HECU.
3. After removal and installation of the brake oil pipes and hoses.
4. After replacing the brake fluid.
5. Braking force is not made properly.

AFFECTED VIN
70 4K
Air bleeding procedures

1. Apply the parking brake and start the engine when the shift lever is at “P” position.
2. Connect the oil supply device (air bleeding device) with air compressor to brake reservoir. The oil supply device
should be filled with sufficient oil.
3. Loosen the air bleed screw in caliper and place an empty container under the screw.
4. Bleed the air in each wheel by using diagnostic device (SCAN 100). At this time, the modulator motor runs for 180
seconds.
5. Simultaneously, run the oil supply device to supply oil and depress the brake pedal repeatedly.
This procedure needs at least 3 persons for doing below jobs:
1) Collect the bleeding oil into the container.
2) Depress the brake pedal repeatedly.
3) Check the conditions of oil supply device.
6. Repeat the step 4 through 5 until clear brake fluid comes out of air bleed screw.
7. Perform the same procedures at each wheel.
Notice
Replace the brake oil at every 2 years.
Notice
• Always bleed the air after replacing the brake fluid or master cylinder, caliper, brake hose and pipe.
• Never reuse the used brake fluid.
• Do not pump the brake pedal too fast. It may cause some troubles for air bleeding operation.
• Be careful not to splash the brake fluid on painted area or body.
• Check the connection areas for leaks after air bleeding.

AFFECTED VIN
2 5A
OVERVIEW
Height adjuster (Driver/passenger)
Front seat belt

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Passenger’s airbag
Passenger’s
Airbag unit (SDM)
Driver’s
Front seat
Fixed type buckle Belt type buckle Driver’s airbag
CHANGED BY BODY INTERIOR

AFFECTED VIN
5A 3
Pretensioner Retractor
Swivel seat (Rear 1st seat)
Rear 1st seat Rear 2nd seat Rear 3rd seat

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Rear 1st seat Rear 2nd seat Rear 3rd seat
BODY INTERIOR CHANGED BY

AFFECTED VIN
4 5A
AIRBAG
1. COMPONENTS
Driver’s Airbag Module
Airbag module
Steering wheel
Contact coil

AFFECTED VIN
5A 5
Passenger’s Airbag Module
Cushion
Retainer
Housing
Inflator
Bracket

AFFECTED VIN
6 5A
2. FUNCTION DESCRIPTION
Bag (Cushion) Airbag Module
• The airbag system performance is influenced on the The driver airbag module is under the center pad of the
cushion size, shape and position. steering wheel.
• The cushion strength is a important parameter on the The passenger airbag module is installed in the instru-
impact absorb effect. ment panel at passenger side.
• Therefore, the control of the airbag performance The driver and passenger side airbag is inside each seat.
depends on cushion size, shape, inflator characteristic
and vent hole size for the gas discharge. [Notice]
• The cushion’s material and folding function to control Do not disassemble the airbag module because
the cushion deployment direction and the performance unintentional deployment of the airbags resulting from
to protect passenger’s face. any damage or interference of the module can cause
injury.
Module Cover/Housing
• It is a type of a container that includes the cushion
and the inflator.
• The module housing functions to deliver the reaction
force between the body structure and the airbag (The
airbag reaction is absorbed generally to the steering
wheel or instrument panel).
• The module cover must be considered in a viewpoint
of protection between exterior, internal units and
cushion. Also the module cover should be designed
not to cause any personal injury for deployment.
Inflator
• The inflator is a type of the direct gas generated device.
• The inflator with initial low pressure provides negative
SDM (Sensing and Diagnostic
restraint effect regarding passengers moving and time.
On the contrary, the inflator with initial high pressure
Module)
allows other components of the airbag to make a 1. The airbag system consists of the module section
excessive impact resulting in any personal injury. (driver, passenger and side), seat belt section and
Thus, the inflator output must be optimized according SDM.
to the characteristic of the vehicle and passenger 2. The SDM has no user-serviceable parts and monitors
moving. the system components continuously. The SDM also
• The discharge gas has no toxicity or inflammability records any faults which are discovered.
and also it is the important parameter to control the 3. The SDM allows the fault codes to be retrieved with a
high temperature for gas firing. scan tool and illuminates a warning lamp that alerts
the driver to any faults.
The SDM located on floor beneath the floor console
assembly. The SDM performs the following functions:
• Impact decision processor function.
• Determine the airbag deployment through the impact
signal of the accelerometer sensor and the safety
sensor.

AFFECTED VIN
5A 7
• Malfunction detection and recording any faults that Contact Coil

are detected.
The contact coil is installed between the steering wheel
Monitor the supplemental restrain system electrical
and the steering column and contains a coil that enables
components and set a diagnostic trouble code when
to contact electrically between the airbag wiring harness,
malfunction is detected.
the driver airbag module and the horn switch.
• Display airbag fault codes
Display airbag fault codes and system status [Notice]
information when connected to a scan tool.
Turning the steering wheel more than three and one-
• Self-diagnosis function quarter turns may damage the clock spring. The contact
Illuminate the AIRBAG indicator to alert the driver to coil should never be disassembled and must be replaced
any fault. if the airbag have been deployed.
• Power supply function

Provide a reserve power source to deploy the airbags
and pretensioners if an accident has disabled the
normal power source.
Accelometer Sensor
The accelerometer sensor electronically represents the
acceleration or deceleration of the vehicle during a frontal
impact.
In this electronic representation, the electrical signal is
proportional to the acceleration or deceleration of the
vehicle.
Safety Sensor
The safety sensor is safety device made up of a dual- [Notice]
contact, electro-mechanical switch that:
Turn the label of the clock spring clockwise to lock and
1. Acts independently of the electronic components. turn the label of the clock spring counterclockwise
2. Connects the acceleration sensor in series in order approximately 2.9 ± 0.2 turns to the neutral positions
to make up for the weak points in the current with the front wheels ahead.
electronic sensor. Align the pointed marks “43 ”.
Micro Controller
This device receives the impact signal from the sensor for
vehicle impact and identifies whether the current condi-
tion is necessary for airbag deployment or not. And then
the controller sends the specified currents to the airbag
ignition circuit as needed.
This device always monitors the airbag system in con-
duction with the diagnostic circuit. When it is detected
any problem, it illuminates the airbag warning indicator to
inform driver of the fault and stores the fault information.

AFFECTED VIN
8 5A
Airbag Warning Lamp Wiring Harness Connectors

The instrument cluster contains an airbag warning indica- If the sensing and diagnostic module (SDM) electrical con-
tor bulb to verify the operation of the AIRBAG indicator nector is not attached properly, a built in shorting bar will
and sensing and diagnostic module (SDM). connect the wire from airbag warning lamp with the SDM
The SDM performs a turn-on test when the ignition is turned ground wire. This turns on the AIRBAG indicator.
ON. The SDM flashes the AIRBAG indicator seven tomes To prevent deployment during servicing, additional short-
by supplying an intermittent ground to the indicator lamp ing bars are located in following locations:
circuit. After flashing seven times, the AIRBAG indicator • Driver airbag module connector
will turn off if no more malfunctions have been detected.
• Passenger airbag module connector
• Driver and passenger side airbag module connector
• SDM wiring harness connector
• Contact coil connector to airbag wiring harness
The shorting bar is only a backup safety device. Always
disable the supplemental restraints system (SRS) before
beginning any service procedure.
Belt Pretensioner
The belt pretensioner enables to retract the driver and the
passenger seat belt webbing to reduce any personal im-
pact when accounted a frontal collision.
Warning Lamp Status Fault Contents

Flash seven times within 7 System OK
seconds and then turn off
Warning lamp stays ON System fault
Internal SDM fault
No turn on Power supply circuit open

and fuse open
Warning lamp circuit open
SDM fault

AFFECTED VIN
5A 9
3. INFLATION OF AIRBAG
Front Airbag Operation (Driver’s and Passenger’s)

The air bag inflates when:
• Frontal impact against a solid concrete wall at over 25 km/h or near-frontal impact within 30 degrees from the center
of the vehicle at both corners
The air bag can inflate when:

• Underbody impact from the road surface; impact against the curb at a very high speed; dropping impact onto the
road surface with a large angle
The air bag does not inflate when:

• Rollover, side impact or rear impact
The air bag seldom inflates when:

• Oblique impact, rollover
• Weak impact in which the sensor is unable to detect (under the inflation requirements)
• Impact against narrow objects such as a telegraph pole or a tree
• The vehicle falls into a drainage or a puddle
• The front of the vehicle crashes into high impact point vehicle such as a truck
• Impact on the hood by falling stones
• The air bag warning lamp is on

AFFECTED VIN
10 5A
4. AIRBAG UNIT (SDM)

System Layout
Driver’s Passenger’s
airbag airbag
Airbag unit
Driver’s seat Passenger’s seat
SDM Specification
Item Specification
Voltage range 9 ~ 16V
Temperature range -30 ~ 85°C
Accelometer dynamic sensing range -50 ~ 50G
Impact record Diagnostic trouble code

AFFECTED VIN
5A 11
5. WIRING DIAGRAM

AFFECTED VIN
12 5A
Possible Cause Action
Ignition “ON” Does the warning lamp blink Yes System OK
Check warning at seven times for 7 sec- No Connect the scan tool to diagnostic connector (ALDL).
lamp on I/P onds and then turn off?
Select the fault code display menu and clear code menu.
Does the fault code display Yes Perform “Diagnostic System Check”.
on the scan tool display? No Check any fuse open.
Replace fuse.
Is there any open in fuse? Yes Disconnect wiring connector.
No Check any wiring short between fuse and wiring connector.
Is there any short in fuse? Yes Repair wiring.
No Disconnect SDM wiring connector.
Check wiring short between connector terminal and SDM
connector terminal.
Is there any short in wiring? Yes Replace airbag wiring.
No Check any open between ALDL connector No.4, No.5 ter-
minal and ground.
Is there any open in wiring? Yes Repair wiring
No Ignition “ON”
Measure voltage at the cigar lighter socket.
Does the voltage indicate 11 Yes Check any open or short between ALDL connector terminal
~ 14 V? and wiring connector terminal.
No Repair the wiring of the cigar lighter socket.
Is there any open or short Yes Repair wiring
in wiring?
No Check any open or short between SDM connector terminal
and wiring connector terminal.
Is there any open or short Yes Replace the airbag wiring.
in wiring?
No Replace the SDM.

AFFECTED VIN
5A 13
Diagnostic Trouble Code

Code Fault Contents Check
1101 High battery voltage Check the alternator voltage
Check the battery
Check the airbag unit terminal
1102 Low battery voltage Check the alternator voltage
Check the battery
Check the airbag unit terminal
1346 Driver’s air bag circuit resistance too low Check the connection of the driver airbag connector.
Check the wiring condition of the driver airbag.
(including clock spring)
Check the bending of the airbag terminal.
1347 Driver’s airbag circuit short to battery voltage Check the connection of the driver airbag connector.
1348 Driver’s airbag circuit short to ground Check the connection of the driver airbag connector.
1349 Driver’s airbag circuit short to battery voltage Check the connection of the driver airbag connector.
1352 Passenger’s airbag circuit resistance too high Check the connection of the passenger airbag connector.
Check the wiring condition of the passenger airbag.
1353 Passenger’s airbag circuit resistance too low Check the connection of the passenger airbag connector.
1354 Passenger’s airbag circuit short to ground Check the connection of the passenger airbag connector.
1355 Passenger’s airbag circuit short to battery Check the connection of the passenger airbag connector.
voltage Check the wiring condition of the passenger airbag.
1361 Driver’s pretensioner circuit resistance too Check the connection of the driver pretensioner connector.
high Check the wiring condition of the driver pretensioner.
1362 Driver’s pretensioner circuit resistance too low Check the connection of the driver pretensioner connector.
Check the wiring condition of the driver pretensioner.

AFFECTED VIN
14 5A
Code Fault Contents Check

1363 Driver’s pretensioner circuit short to ground Check the connection of the driver pretensioner connector.
Check the wiring condition of the driver pretensioner.
1364 Driver’s pretensioner circuit short to bat- Check the connection of the driver pretensioner connector.
tery voltage Check the wiring condition of the driver pretensioner.
1367 Passenger pretensioner circuit, resis- Check the connection of the passenger pretensioner connector.
tance too high Check the wiring condition of the passenger pretensioner.
1368 Passenger pretensioner circuit, resis- Check the connection of the passenger pretensioner connector.
tance too low Check the wiring condition of the passenger pretensioner.
1369 Passenger pretensioner circuit, short to Check the connection of the passenger pretensioner connector.
ground Check the wiring condition of the passenger pretensioner.
1370 Passenger pretensioner circuit, short to Check the connection of the passenger pretensioner connector.
battery voltage Check the wiring condition of the passenger pretensioner.
1620 SDM interal fault Replace the SDM
1650 Front impact memorid Replace the SDM
1651 Side impact (driver) memoried Replace the SDM
1652 Side impact (passenger) memoried Replace the SDM
1657 Belt pretensioner operation memoried Replace the SDM
1670 Secondary front impact memoried Replace the SDM
2500 Warning is faulty • Check the wiring to warning lamp

• Check the warning lamp bulb
• Check the SDM unit terminal
[Notice]
• Use only the scan tool to check the airbag module and the sensing and diagnostic module (SDM). Never measure the
resistance of an airbag module with an ohmmeter. An ohmmeter’s battery can deploy the airbag and cause injury.
• Before testing, disconnect the negative battery cable. Wait 1 minute for the SDM capacitor to discharge. The capacitor
supplies reserve power to deploy the airbags, even if the battery is disconnected. Unintentional deployment of the
airbags can cause injury.
• Do not attempt to repair the supplemental inflatable restraints (SIR) wiring harness. An SIR repair can create a high-
resistance connection which can keep the airbags from deploying when needed, resulting in injury.

AFFECTED VIN
5A 15

Scanner Wheel wrench

AFFECTED VIN
16 5A

Airbag Module(Driver’s Airbag)
Preceding Work: Disconnect the battery negative cable.
1. Align the steering wheel and remove airbag module mounting bolts.
2. Disconnect airbag module and horn connector, and then remove the module from steering wheel.
[Notice]
Pay attention to the connection of airbag module and its

mounting position.

AFFECTED VIN
5A 17
Contact Coil
1. Remove horn, airbag module, steering wheel(1), and lower
panel(2) from steering column.
2. Remove the steering column upper & lower cover.
3. Unscrew the contact coil mounting bolts and remove it from the steering column.

AFFECTED VIN
18 5A
[Notice]
Allgn the contact coil to the right direction. (Refer to the arroow mark in the following picture)
If thealignment of contact coil, is not precise. It could result in a accident due to bad steering condition.
Also, it can damage a contact coil and therefore, can be a reason of airbag failure.

AFFECTED VIN
5A 19
Passenger’s Airbag
2. Remove the I/P panel.
3. Remove the supplementary airbag module.


AFFECTED VIN
20 5A
Airbag Unit (SDM)

Preceding Work: Remove the center facia
1. Remove the center floor duct.
2. Disconnect the SDM and ground connectors.

3. Remove the SDM from the mounting deck.

AFFECTED VIN
5A 21
SEAT BELT
1. COMPONENTS
11 Passengers
Front Seat Belt (3 point)
Height adjuster
Buckle
Pretensioner
Lower anchor
Rear 1st row (3 point + 2 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 2nd row (3 point + 2 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 3rd row (3 point + 2 point)
Upper anchor
Retractor
Buckle
Lower anchor

AFFECTED VIN
22 5A
9 Passengers
Height adjuster
Buckle
Pretensioner
Lower anchor
Rear 1st row (3 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 2nd row (3 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 3rd row (3 point + 2 point)
Upper anchor
Retractor
Buckle
Lower anchor

AFFECTED VIN
5A 23
7 Passengers
Height adjuster
Buckle
Pretensioner
Lower anchor
Rear 1st row (3 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 2nd row (3 point + 2 point)
Upper anchor
Retractor
Buckle
Lower anchor

AFFECTED VIN
24 5A
2. REMOVAL AND INSTALLATION - SEAT BELT

Seat Belt (3 point)
1) Front seat belt
1. Remove front & rear scarf trim. (screw - 6 EA)
Scarf trim
Front Rear
2. Unscrew seat belt upper / lower anchor bolts (17 mm - 2 EA) and remove the seat belt.
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Seat belt anchor (A) Upper anchor (B) Lower anchor

bolts bolt bolt
3. Disconnect the pretensioner connector and unscrew the mounting bolt
Pretensioner

AFFECTED VIN
5A 25
2) Rear 1st / 2nd / 3rd seat belt

1. Unscrew seat belt upper / lower mounting bolts.
Rear 2nd
Rear 3rd seat belt seat belt Rear 1st seat belt
[Notice]
To remove rear 3rd row seat belt, remove the seat from vehicle first.

AFFECTED VIN
26 5A
2. Unscrew the retractor mounting bolts to remove seat belt assembly.
Rear 1st row

seat belt
Rear 2nd row

seat belt
Rear 3rd row

seat belt

AFFECTED VIN
5A 27
Seat Belt (2 point)

1) Rear 1st seat belt
1. Unscrew seat mounting bolts and remove the seat.
[Reference]
• 2-point type seat belt are installed at the center seat of rear 1st / 2nd / 3rd row seat.
• Rear 1st seat have two types of seat belt. Normally it adapts 3 point type, however, it adapts 2 point type seat belt when
swivle.

AFFECTED VIN
28 5A
2. Unscrew the retractor mounting bolt to remove seat belt assembly.

AFFECTED VIN
5A 29
Center Seat Belt

1. Disassemble the seat mounting part on the seat under
cover.
2. Unscrew the seat mounting bolt and remove it.

AFFECTED VIN
30 5A
Buckle
1. Fixed type buckle
Preceding Work: Removal of the seat assembly
1. Remove seat cover.
2. Unscrew the mounting bolt and remove the buckle.

AFFECTED VIN
5A 31
2. Belt type buckle

Preceding Work: Removal of the seat assembly
1. Disconnect the seat connecting cable and unscrew the
seat back mounting bolt to remove it.
2. Remove screws on the seat and pull away the seat cloth.
3. Unscrew the buckle mounting bolt and remove the buckle.

AFFECTED VIN
32 5A
SEAT
1. COMPONENTS
Seat control switch
Sliding control Seat position control Seat height control Reclining control
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Sliding adjust lever
Seat warmer switch
Back flat adjust lever Back supporter (Driver’s seat)

AFFECTED VIN
5A 33
Head rest Back folding adjust lever
Rear 3rd seat back folding adjust lever
Seat sliding adjust lever Seat swivel control lever

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AFFECTED VIN
34 5A
2. SEAT LAYOUT
Layout - 11 Passengers
• Front seat : Move 36 mm from the far

end to the front
• Rear 1st seat : Movable
• Rear 2nd seat: Movable
• Rear 3rd seat : Fixed

AFFECTED VIN
5A 35

end to the front
• Rear 1st seat : Movable
• Rear 2nd seat: Movable

AFFECTED VIN
36 5A

AFFECTED VIN
5A 37
Various Seat Arrangement

• Front seat & rear 1st seat : Semi full flat
• Front seat : Move to the far front

Back semi full flat
• Rear 1st seat : Move to the far end
• Rear 2nd seat: Move to the far end
• Rear 1st & 2nd seat full flat

end to the front
• Rear 1st seat : Move to the far front
Remove head rest
Back full flat
Back semi full flat

AFFECTED VIN
38 5A
• Rear 1st seat (when swiveled)

Center seat jumping
Swiveled
• Rear 1st swiveled and rear 2nd seat back folding while driving

Center seat jumping
Swiveled
Back folding

AFFECTED VIN
5A 39
• Rear 1st seat swiveled and rear 2nd seat back folding (while parking)
• Front seat : Move to the far front

• Rear 1st seat : Middle
Center seat jumping
Swiveled
• Rear 2nd seat: Middle / Back folding
• 8 passengers with loading

end to the front
• Rear 1st seat : Middle
• Rear 2nd seat: Middle
• Rear 3rd seat : Double folding

AFFECTED VIN
40 5A

end to the front
• Rear 2nd seat: Middle
• Rear 3rd seat : Double folding
• Front seat : Move to the far end /

Back folding
• Rear 1st seat : Middle / Back folding
• Rear 2nd seat: Middle / Back folding
• Rear 3rd seat : Middle / Back folding

AFFECTED VIN
5A 41
Entry Way
Rear 1st seat : Folding center seat

Rear 2nd seat : Folding center seat
Rear 3rd seat : Fixed

AFFECTED VIN
42 5A
Sliding of Rear 1st and 2nd Seat
- 4 rail (1.610mm) for rear 1st and 2nd seat sliding

- Rail mounting : Floor bolt type
Seat Sliding distance Seat Sliding distance

Front 228 mm Rear 3rd Fixed
Rear 1st 280 mm Rail overlength 1,610 mm
Rear 2nd 400 mm

AFFECTED VIN
5A 43
Front
Seat
Rear 1st
seat
Rear 2nd
seat
Rear 3rd
seat

AFFECTED VIN
44 5A
Seat Mounting Point

AFFECTED VIN
5A 45
Removable Seat
1. Fold down the seatback of the third row seat while puling
up the seatback reclining lever ( ).
2. Remove the seat rail covers ( )
3. Slide the third row seat to its rear end (arrow direction)
while pulling up the seat sliding lever ( ).
4. Carefully remove the third row seat from the rail by using
the hand grips ( , ) on the seat as shown in the
figure.
5. Install the seat in the reverse order of removal.
[Caution]
• Be careful not to drop the seat when removing it. It may

cause a personal injury.
• Make sure that the seat is securely engaged on the rail
during installation.

AFFECTED VIN
46 5A
4. OPERATION OF SEAT
Front Seat (Driver’s Seat)
1) Components
Seat warmer
connector
Seat position
(up/down motor)
Seat position
(front up/down Seat position
rail) (up/down rail)
Sliding rail Seat position

(rear up/down
motor)
Sliding motor
Reclining motor

AFFECTED VIN
5A 47
2) Operation of seat
• Sliding
: Seat moves from front to rear controllde
by sliding control switch
• Seat position (front up/down)

: Front side of seat moves up/down
controlled by seat position control
switch
• Seat position (rear up/down)

: Rear side of seat moves up/down
controlled by seat position control
switch

AFFECTED VIN
48 5A
• Seat height (up/down)

: Seat moves up/down controlled
by seat height control switch
Seat reclining motor
• Reclining
: Seat back reclining controlled by
seat reclining control switch

AFFECTED VIN
5A 49
3) Seat electrical equipment check
• Disconnect the seat wiring connector and check if the power is supplied (Refer to the wiring diagram)
1) If the power supply has no problem, remove the seat.
2) Check the motor and wiring if damaged.
3) Connect the battery to the seat connector.
4) Control the seat switch and check the opration.
[Notice]
Electrical parts are not supplied by a part separately.

AFFECTED VIN
50 5A
4) Operation of center seat
When seating
When jumping
- Pull up the center seat when to jump

- Push down the center seat when to seat
5) Removal and installation of center seat (jumping seat)
- Unscrew 4 mounting nuts to remove the center seat

AFFECTED VIN
5A 51
Rear Seat
1) Rear 1st seat (swivel seat)
Seat back folding cable
Seat back flat cable
Jumping
mechanism
Sliding cable
Sliding lever
Swivel lever

AFFECTED VIN
52 5A
2) Operation of rear seat (Rear 1st and 2nd seat)
Seat sliding
Front
Rear

AFFECTED VIN
5A 53
3) Seat back flat

- When to recline or to flat fully
Rear 1st
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Rear 2nd
4) Seat back folding

- Fold the rear 1st or 2nd raw seat back to put something on or to utilize it as a table.
Rear
1st/2nd seat

AFFECTED VIN
54 5A
5) Seat swing (Rear 1st seat)

- Turn around seat as the swing lever is pulled.
6) Rear 3rd seat

- Pull the lever behind back seat to fold the back seat.
- Pull the lever under back seat to fold up the seat
- As the seat is folded, disconnect hook and spread out the board

AFFECTED VIN
5A 55
5. SEAT RAIL
Distance (cm)
A. Inner rail 50
B. Inner rail 74
- Outter rail
C. Outter rail 98

1. Remove all rear seats and then, unscrew the seat rail
guide screws.
2. Remove three screws under OVM tool storage.

AFFECTED VIN
56 5A
3. Unscrew the rear seat belt lower anchor bolt.
4. Remove the rear carpet and unscrew the seat rail

mounting bolts.

AFFECTED VIN
5A 57
ACCESSORIES
1. STORAGES
Overhead console
Front door map pocket Glove box
Passenger’s cabinet
Console box
Seat back pocket

AFFECTED VIN
58 5A
1) Console Box
- Foot lamp and a speaker are installed.
Console box - Fixed type

Standard
CD Changer (6 EA) DVD Changer (8 EA)
Components
1. Armrest
2. Console main rid & tray
3. Console rear facia
4. Console main rid cover
5. Rear foot lamp
6. Console main & tray
7. Console main bracket
8. CD Changer cover

AFFECTED VIN
5A 59
Console box - Portable type
When Installed
When used as table ○

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Console box - Portable type

AFFECTED VIN
60 5A

Console box assembly
- Unscrew bolts and nuts to remove console box.
Bolt 10 mm - 2 EA
Nut 10 mm - 2 EA
CD Changer & DVD Changer
- Unscrew the bracket bolts (10 mm - 4 EA) and remove the changer assembly.

AFFECTED VIN
5A 61
2) Glove Box
1. Disconnect the glove box clip (1) and wire.

2. Unscrew the box mounting bolts (4 EA).

AFFECTED VIN
62 5A
3) Overhead Console

1. Unscrew two mounting screws in the sun glass
cabinet and remove the overhead console by using a
tool.
2. Disconnect multi meter and room lamp connector.

And then, remove the console assemble.
3. Unscrew three screws behind the console assembly to remove multi meter.

AFFECTED VIN
5A 63
4) Passenger’s Cabinet
Above glove box

Preceding Work: Removal of glove box and I/P lower panel (passenger)
1. Open the cabinet and remove the mounting screws.
2. Unscrew the passenger’s cabinet mounting screws (LH / RH / center) at the back of lower panel.

AFFECTED VIN
64 5A
2. CONVINIENT DEVICES
Ticket holder Front cup holder
Front cigar lighter
Back table
Power outlet
Rear cigar lighter
A B
Rear cup holder Tea table
A B

AFFECTED VIN
5A 65
1) Front Cup Holder / Cigar Lighter / Power Outlet Assembly

Under I/P center panel
Cup holder Power outlet / cigar lighter

AFFECTED VIN
66 5A

1. Remove cup holder mounting screws (2 EA).
2. Disconnect power outlet and cigar lighter lighter connector and remove the assembly.

AFFECTED VIN
5A 67
2) Rear Cup Holder and Rear Cigar Lighter

Preceding Work: Removal of lower quarter trim and rear 2nd / 3rd seats.
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1. Remove the trim mounting screws shown in the above

picture.
2. Disconnect the cigar lighter and remove the cup holder
assembly.
[Reference]
When to remove rear cigar lighter only, remove the lower
quarter trim and remove the cigar lighter from inside of the
trim.

AFFECTED VIN
68 5A
3) Sunvisor
Driver’s Passenger’s
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- Unscrew the mounting screw and remove it.

- Remove the sunvisor.
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AFFECTED VIN
5A 69
4) Tea Table
[Notice]
• Don’t put a load heavier than 3.5kg on the tea table.

• Don’t use the table while driving to prevent body injury.
1. Remove two upper mounting screws.

2. Remove the tea table.

AFFECTED VIN
70 5A
5) Power Seat Switch Assembly (Driver’s Seat)

Preceding Work: Removal of driver’s seat
1. Remove the power seat nob with a proper tool.

2. Remove seat side cover and unscrew the power seat switch unit mounting screw on the rear.
3. Disconnect the connector.
6) Back Table & Folding Lever
- Unscrew table mounting screws (4 EA).

AFFECTED VIN
5A 71
3. ETC
1) ECM Room Mirror
1. Remove room mirror cover with a screw driver.
2. Disconnect the connector.

3. Pull the room mirror downward to disassemble.

AFFECTED VIN
72 5A
2) Rain Sensing Unit

Rain sensing unit detect the rain fall and control the speed of
wiper operation. This system is operated only when the wiper
switch is put on “Auto” mode.
[Refer th the electrical part] of this manual.

1. Remove the unit with a tool refering the picture below.
2. Disconnect the connector and disassemble the rain

sensing unit.

AFFECTED VIN
5A 73
3) Hand Grip
Passenger’s Overhead
“B” Piller
Rear 1st & 2nd Seat
Rear 1st seat Rear 2nd seat
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AFFECTED VIN
74 5A
4) Fire Extinguisher & OVM Tool

Fire Extinguisher
- Under rear 3rd seat
OVM Tool
- Under rear 3rd seat floor cover.
Components

AFFECTED VIN
5A 75
INSTRUMENT PANEL ASSEMBLY

Preceding Work:
2. Remove all the parts shown on the picture below.
“A” pillar Cluster and center cover “P” pillar
Door molding Center speaker

Center speaker
Door molding
Center console
assembly
Lower panel - passenger
Lower panel - Driver
3. Remove door molding and “A” pillar cover .

4. Remove the I/P panel side cover (LH/RH).
5. Remove the front center speaker , cluster and center
cover assembly .
6. Remove the center console assembly and AV head
unit.

AFFECTED VIN
76 5A
7. Remove the lower panel assembly.

1) Disconnect incar / humidity sensor, 4WD operation
switch, rear wiper switch (2).
8. Remove instrument lower panel assembly (passenger

side).
1) Remove the glove box.
2) Remove the lower inner panel.

AFFECTED VIN
5A 77

1. Disconnect all the connector at the I/P panel.
1) Driver 2) Passenger
1. Sun roof 3. Door connector, floor, seat belt pretensioner
2. Door connector, floor, seat belt pretensioner 7. GPS
16. Earth 8. Audio optic cable connector
17. Earth 9. Rear monitor
18. Earth
12. Brake connector
11. Parking connector

13. Accelator connector
14. Sensor cluster
9. Rear monitor
4. T/M controller & Earth
10. SDM connector
3. LH floor connector

AFFECTED VIN
78 5A
3) Center
5. T/M control connector
7. Earth
8. Earth 10. SDM connector
4) ETC 12. Accelator pedal connector (A)

Aircon module connector (3 point) 13. Brake pedal connector (B)
A B
11. Parking brake connector. 14. Sensor cluster

AFFECTED VIN
5A 79
2. Remove bolt and nut on the instrument panel.
* ICM Box assembly * Driver’s side I/P lower braket * To remove I/P panel, unscrew the steering wheel
(10 mm - 3 EA: Nut) (10 mm - 2 EA:Bolt) mounting bolts (12 mm - 2 EA) and remove the wheel.
1. I/P side mounting bolts 2. Driver’s side I/P inner bolts

(12 mm - 3 EA: LH/RH) (12 mm - 3 EA: LH/RH)
3. Center facia lower bolts 4. I/P inner side mounting bolts

(10 mm - 2 EA: LH/RH) (12 mm - 1 EA: LH/RH)

AFFECTED VIN
80 5A
3. Remove the following parts from the instrument panel.
1. Tweeter speaker 2. Auto light unit / 3. Sun sensor 4. GPS
5. Optical cable 6. Passenger’s airbag module 7. I/P wind blow nozzle housing

AFFECTED VIN
5A 81
4. Remove the panel bracket from the instrument panel.
5. Remove front dust from the instrument panel.

AFFECTED VIN
MEMO
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5B 3
COMPONENTS AND LOCATION

Hood
Roof rack
Front bumper assembly

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Front door Rear door Rear view mirror
BODY EXTERIOR CHANGED BY

AFFECTED VIN
4 5B
Rear view camera

Rear spoiler
Tailgate
Rear bumper assembly Sunroof assembly
Wide ganish assembly
CHANGED BY BODY EXTERIOR

AFFECTED VIN
5B 5
DOOR SYSTEM
1. LAYOUT - FRONT DOOR
B. Outside door handle A. Inside door handle
C. Power window switch
D. Folding switch & Adjustment

switch (Rear view mirrow)
E. Door courtesy lamp F. Door striker & contact switch

AFFECTED VIN
6 5B
Door connector Door hinge Check linkage
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Door latch & crank
Window regulator & motor

Rear view mirror folding unit
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AFFECTED VIN
5B 7
2. LAYOUT - REAR DOOR
Inside handle
Twitter speaker
Door courtesy lamp
Power window switch
Door latch & crank
Window regulator & Motor

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Door hinge Door striker Contact switch Door check linkage

AFFECTED VIN
8 5B
3. OPERATION - WINDOW
Window regulator
Guide rail
Regulator operating cable
Window motor
Operating Process
Power window motor (1) which is controlled by the window switch draws up and down the window regulator (2) and
operating cable. The window glass move up and down with the window regulator.
Window motor Operating cable
Window up/down Window regulator

AFFECTED VIN
5B 9
4. OPERATION - DOOR LOCK / UNLOCK

Front Door
Connecting rod - key cylinder
Door key cylinder

Outside door handle
Lock / Unlock cable
Connecting rod - outside handle
Operating cable - Inside handle
Door latch
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Lock / Unlock
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Inside door handle

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AFFECTED VIN
¢º Operating Process
10 5B
Operating Process
Lock / Unlock (Inside door handle)
→ →
Operation of lock button Operating cable Latch lock / Unlock
Inside handle
→ →
Operation of Inside handle Operating cable Latch open mode
Outside handle
→ →
Operation of outside handle Connecting rod - outside handle Latch open mode
Key cylinder
→ →
Insert key & operation Connecting rod - key cylinder Latch lock / Unlock

AFFECTED VIN
5B 11
Rear Door
Outside door handle
Rock / Unlock cable
Connecting rod - Outside handle
Operating cable - Inside handle
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Lock / Unlock
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Inside door handle

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CHILD / SAFETY mode

AFFECTED VIN
12 5B
Operating Process
Lock / Unlock (Inside door handle)
→ →
Lock button Operating cable Latch lock / Unlock
Inside handle
→ →
Operation of handle Operating cable Open mode - Latch
CHILD / SAFETY mode
Safety (FREE) mode Latch & Crank in operation

AFFECTED VIN
5B 13

Front Door Assembly
Preceding Work: Disassembly of battery cable (-)
1. Door connector 2. Door check link 3. Door hinge
1. Disconnect the door connector (1).

2. Unscrew the check linkage bolt (2) at body side.
3. Unscrew the upper and the lower door hinge bolts (3).
4. Remove the door assembly.

AFFECTED VIN
14 5B
Front Door Trim

Preceding Work: Disassembly of battery terminal (-)
1. Remove five screw rivets at the lower door trim.
2. Remove armrest grip cover and two screws.
3. Remove door handle cover.

4. Remove one screw (Refer to arrow mark).
[Notice]
Disconnect door handle cover with slim tool(driver) from

down side first otherwise, the grip holder can be damaged.

AFFECTED VIN
5B 15
5. After getting some space (1), disassemble door trim from the door panel as pushing up (2).
6. Remove door courtesy lamp connector & outside mirror connector at the inside of door trim.
7. Disconnect the power window switch.
8. Disassemble the front door trim.

AFFECTED VIN
16 5B
Front Door Trim Seal

Preceding Work: Removal of door trim
1. Remove door handle screw (1) and disconnect door handle

cable.
2. Unscrew 4-screws of two brackets.
3. Be careful not to damage the seal.

AFFECTED VIN
5B 17
Window Regulator Assembly

1. Unscrew two mounting bolts and disassemble door window
[Notice]
Be careful not to damage the body coating by window glass.
2. Be careful not to damage the body coating by window glass.

3. Disconnect door window regulator and motor mounting nuts (6 mm - 7 EA).
4. Disassemble window regulator assembly.

AFFECTED VIN
18 5B
Window Motor (Front / Rear)

Preceding Work: Disassemble of window regulator & motor assembly
- Disassemble power window motor mounting bolts (10 mm ~ 3 EA) from the requlator.
Door Latch & Crank Assembly

1. Disconnect key cylinder rod (1), outside handle rod (2) and rear view mirror folding unit connector.
2. Disconnect latch and crank assembly with mounting nuts (Hex - 3 EA).

AFFECTED VIN
5B 19
Rear Lock Striker (Front / Rear)

1. Removal :
1) Disassemble door lock striker with two bolts
2. Installation :
1) Temporarily install door lock striker.
2) Adjust the location of door lock striker and fully
tighten the bolts.
Door Lock Striker Adjustment

1. Removal :
1) Disassemble door lock striker with two bolts
2. Installation :
1) Temporarily install door lock striker.
2) Adjust the location of door lock striker and fully
tighten the bolts.
[Notice]
The door lock striker is an important attaching part that can affect the performance of vital components and systems and
can cause major repair expenses. If replacement becomes necessary, the door lock striker must be replaced by one with the
same part number or with an equivalent part. Do not use a replacement part of lesser quality or of a substitute design. The
specified torque values must be used during reassembly in order to ensure the proper retention of the part.
The door lock striker consists of a striker with two screws that are threaded into a tapped, floating cage plate located in
the appropriate body pillar. This floating cage plate allows the striker to be easily adjusted in or out and up or down. The
door is secured in the closed position when the door lock fork snaps over and engages the striker.

AFFECTED VIN
20 5B
Inside Door Handle

1. Disconnect connecting rod-key cylinder (1) and connecting rod - outside rod handle.
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2. Disassemble outside handle assembly (6 mm - 3 EA).
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AFFECTED VIN
5B 21
Front Door Speaker

- Disconnect the door speaker connector (4 bolts)
Driver’s side
Passenger’s side

AFFECTED VIN
22 5B
Front Door Speaker

- Unscrew 6 bolts to remove door armest grip.
Rear View Mirror Folding Switch

Preceding Work: Removal of door armrest grip
Adjust switch - Rear view mirror
Folding switch - Rear view mirror
- Disassemble adjustment & folding switch assembly (Rear view mirrow)

AFFECTED VIN
5B 23
Door Courtesy Lamp

- Disconnect three clip behind lamp for disassembly (Use driver)
Power Window Switch Assembly

- Disconnect three clip behind lamp for disassembly (Use driver)

AFFECTED VIN
24 5B
Door Trim Molding

- Unscrew 7 - mounting screw to disassemble the molding.
Door Armrest Grip (II)
- Unscrew three mounting screws to disassemble door armrest grip
Door Contact Switch
- Remove a screw and disconnet door contact switch.

AFFECTED VIN
5B 25
Rear Door Assemble

Preceding Work: Disassemble the battery cable (-)
1. Door connector 2. Door check linkage 3. Door hinge
1. Disassemble “B” - pillar cover and disconnect door connector.

2. Remove check linkage mounting bolt from inside.
3. Remove door hinge mounting bolts.
4. Uninstall door assembly.
5. Install in the reverse of removal.

AFFECTED VIN
26 5B
Rear Window Regulator / Glass Run

1. Remove upper guide channel with two bolts, as weather strip is pulled.
2. Remove two screws in carrier plate and disassemble the window glass.

AFFECTED VIN
5B 27
3. Disassemble lower guide channel (two nuts).
4. Remove window regulator & motor mounting nuts (6 mm

- 7 EA)
5. Disconnect power window motor connector.
6. Disassemble power window regulator & window motor

assemble.

AFFECTED VIN
28 5B
Door Latch & Crank Assembly - Rear

1. Disconnect handle rod - outside door (B) and power window unit connector (A)
2. Remove three nuts (C) to disassemble latch & crank assembly.
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AFFECTED VIN
5B 29
Outside Door Handle - Rear

1. Disconnect handle rod - outside handle.
2. Remove three nuts (6 mm - 3 EA).

AFFECTED VIN
30 5B
Rear View Mirror

General information
• Mirror adjustment
When switch-rear view mirror is operated, two motors which of one moves up and down and the other one moves left
and right are shifted to the direction the driver intended (Refer to the picture below).
• Folding
Motor is operated to fold the rear view mirrow when switch is pushed.
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AFFECTED VIN
5B 31
Removal and installation
1. Remove mirror cover and three mounting screws.
[Notice]
Pull out the mirror cover as lifted upward.
2. Disconnect the connector and disassemble the outside mirror assembly.
[Notice]
Be careful not to damage the mounting fastenr guided from inside of the door when handle the mirror.

AFFECTED VIN
32 5B
HOOD / BUMPER & TAILGATE

1. OPERATION - TAILGATE
Tailgate handle
Actuator
Connecting - tailgate handle
Key cylinder
Connecting rod - actuator handle
Connecting rod - key cylinder

Door latch

AFFECTED VIN
5B 33
2. LAYOUT - TAILGATE
Washer nozzle Rear view camera Rear spoiler
Wipre & motor Key cylinder

AFFECTED VIN
34 5B
Door latch Shock absorber
Door hinge
Door striker

AFFECTED VIN
5B 35

Tailgate Assembly
1. Remove tailgate upper & lower trim
2. Disconnect tailgate wiring & connector.
Tailgate main wiring Rear view camera / HMSL Heating wire & Ground

AFFECTED VIN
36 5B
3. Disconnect tailgate washer hose.

4. Disassemble tailgate assembly after remove shock absorber bolts & hinge.
5. Remove hinge cover mounting nut (M6).
6. Remove tailgate hinge mounting nut (M8) frominside.
7. Disassemble tailgate assembly.

AFFECTED VIN
5B 37
Rear Spoiler
1. Remove upper trim - tailgate.
2. Disconnect rear view camera & HMSL (High Mounted Stop Lamp) connector (B).
3. Unscrew spoiler mounting nut (4EA).
1.
3. "A" 2. "B"
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4. Disasemble rear spoiler.

AFFECTED VIN
38 5B
HMSL (High Mounted Stop Lamp)

Preceding Work: Disassembly of rear spoiler
1. Disassembly HMSL cover carefully with slip driver (-).
2. Unscrew two bolts to disassemble HMSL.
Components - Rear Spoiler
Connector
Rear spoiler
Bulb Rear view carmera
HMSL
HMSL cover

AFFECTED VIN
5B 39
Tailgate Trim
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* Inner side view
1. Unscrew two bolts to remove upper trim - tailgate.

2. Unscrew 6 screws to remove lower trim - tailgate.

AFFECTED VIN
40 5B
Wiper & Wiper Motor
Preceding Work: Removal of tailgate trim

1. Unscrew one nut (1) to remove wiper assembly (2) and unwind one mounting nut (3).
2. Disconnect motor connector and disassemble wiper motor assembly with two bolts.

AFFECTED VIN
5B 41
Latch
Latchand
andAcuator
Acuator- -Tailgate
Tailgate
• Latch - Tailgate
1. Disconnect latch wiring connector (1) and connecting rod
(2) at the inside of the door.
2. Unscrew latch mounting nut (6 mm - 3 EA).
• Actuator - Tailgate
1. Disconnect connecting rod at the inside of the tailgate.
2. Unscrew mounting nut (6 mm -2 EA).

AFFECTED VIN
42 5B
3. LAYOUT - COWL ASSY / HOOD
Cowl assembly
Hinge
Cap
Screw
Screw cap
Peace
Hood
Hood seal
- rear
Hinge
Bumper
Hood insulator
Hood over slam

Hood seal - sub
Hood latch handle
Hood seal - Front

Nut
Braket
Cable
Bolt
Hood latch
Key

AFFECTED VIN
5B 43

Hood
Preceding Work: Wrap the body with soft material to prevent from damage
1. Unscrew hood hinge bolts (8 mm - 4ea) and disassemble hood from thevehicle (A).
Adjustment
1. Release the hinge bolts.
2. Have the hood mounted properly. 3. Adjust the height of hood with overslam bumper.

AFFECTED VIN
44 5B
Hood Latch, Cable
Preceding Work: Removal of front bumper assem-

bly (Including head lamp)
1. Disconnect the hood cable from head latch handle.
2. Unscrew hood latch mounting bolts (6 mm - 4EA) and disconnect spring hood cable to disassemble hood latch.
3. Disassemble the hood cable.

AFFECTED VIN
5B 45
Cowl Grill & Insulator
Cowl Grill
1. Disconnect washer hoses at both wiper.
2. Unscrew wiper mounting nuts (14mm - 2EA) and
3. Remove cowl mounting clip (6EA) and screw (4EA).
4. Disassemble left / right cowl grill (Left side first, disassemble washer hose before take the cowl out)
Right
Left

AFFECTED VIN
46 5B
Replacement of Hood Insulation Pad

1. Disconnet the insulation pad with 14 screws.

AFFECTED VIN
5B 47
4. LAYOUT - FRONT BUMPER
Shock absorber - Energy
Upper cover
Bracket - side Bolt
Bumper facia assembly
Bracket - front guide bar Nut
Bolt
Bracket - side
Fog lamp cover

Front guide

AFFECTED VIN
48 5B

Preceding Work: Disconnect the battery negative cable
(1) Disassemble head lamp (2) Disconnect fog lamp connectors
(3) Remove guide bumper with mounting bolts

(8mm x 4ea)

AFFECTED VIN
5B 49
2. Uninstall the bumper assembly
(1) Bumper mounting bolts (Upper cover side - 4EA) (2) Bumper mounting bolts (Head lamp side)
(3) Bumper mounting bolts (Wheel arch side) (4) Upper cover grommet screws.

AFFECTED VIN
50 5B
3. Uninstall bumper facia end shock absorber - Energy

AFFECTED VIN
5B 51
5. LAYOUT - REAR BUMPER
Bracket - Rear bumper
Mounting screw
Mounting Grommet screw
Shock absorber - Energy
Guide cover - Rear bumper
Bumper facia assembly
Bolt
PAS (Parking Aid Sensor)

AFFECTED VIN
52 5B
Rear Bumper Assembly

1. Uninstall 4 items below.
(1) Uninstall rear combi lamp (2) Uninstall extension panel from inside to out side
carefully
(3) Remove mounting grommet screws (4) Remove mud guard / wheel arch mounting screws

AFFECTED VIN
5B 53
2. Disconnect parking aid sensor (3ea) inside of bumper assembly and unscrew mounting bolts to disassemble the
bumper assembly.
3. Disassemble bumper facia and shock absorber - Energy from bumper assembly.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

AFFECTED VIN
54 5B
KEY CYLINDER
1. COMPONENTS
Door handle - Front
Key cylinder
Starting key cylinder & key Key cylinder - Tailgate
Key cylinder
Door handle - Front

AFFECTED VIN
5B 55

Door Key - Front
Preceding Work: Removal of door trim / door handle - outside
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

AFFECTED VIN
56 5B
Tailgate Key
Preceding Work: Removal of failgate trim, seal
1. Disconnect connecting rod from key cylinder.
Connector
2. Unscrew center garnish mounting nuts.

3. Disconnect lamp-license plate connector.

AFFECTED VIN
5B 57
3. Remove the center garnish.
4. Remove two mounting bolts and key cylinder assembly.

AFFECTED VIN
58 5B
SUN ROOF
1. LAYOUT - SUN ROOF
Drain hose (Front)
Drain hose (Rear)

AFFECTED VIN
5B 59
Seal - glass panel
Glass
Glass panel
Wind deflector
Side cover - outter
Side cover - inner

Drain channel
support
Drain channel
support bar RH
Sunshade assembly Drain channel Panel
support bar pin curve on
Return spring Riret roll
Ventilation roof
Front lever Drain lever
spring Slider LH
Front
lever LH Drain lever LH
Main lever LH
Retraction
bar Pin
Breed nail
Prain channel
Frame assembly
Seal - drive tube
Tube cable guide
Frame assembly
Drive tube
Sunroof motor Sunroof control unit

AFFECTED VIN
60 5B
1. Drain hose 2. Control switch 3. Sun shade & glass
4. Control unit 5. Sun roof motor

AFFECTED VIN
5B 61
3. OPERATION
Tilting
Motor actuates the

operating cable
Push the front side of the button when the
glass is closed then, mtor actuate the op-
↓
erating cable to lift up the glass. Push the
rear side of the button to put down the glass.
Mechanical equip-
ment lifts up & down
the glass
Sliding
Motor actuates the

operating cable
push the rear side of the button ↓
to slide the door back.
Mechanical equip-
ment slides the
glass back and forth

AFFECTED VIN
62 5B

Preceding Work: Removal of head lining
1. Disassemble four sun roof drain hose (A).

2. Disconnect sun roof control unit connector (B).
3. Remove sun roof mounting bolts (Refer to arrow mark).

AFFECTED VIN
5B 63
Replacement of Sun Roof Glass
- Remove 6 screws to disassemble sun roof glass.

AFFECTED VIN
64 5B
ACESSORIES
1. ROOF RACK
Front / Rear mounting Center mounting

Preceding Work: Removal of head lining
1. Remove 10 bolts (left / right 5 each), and disassemble
roof rack assembly.
2. Installations reverse order of removal.

AFFECTED VIN
5B 65
2. FUEL FILLER CAP CABLE

Removal and installation
Preceding Work: Removal of front seat / 2nd, 3rd raw seat / scuff trim / lower trim - B pillar /
lower trim - quarter
1. Remove lever mounting screw and cover.
2. Disassemble rear speaker - LH.

3. Press the cable holder by both side key (Refer to arrow mark) and push.
4. Disconnect the cable from cable mounting bracket.

AFFECTED VIN
66 5B
3. BODY JACK POINT
* Rear * Front
[Notice]
Be sure to lift the vehicle only on the deginated jack point otherwise, the vehicle could be body damaged.

AFFECTED VIN
5C 3
BODY COMPONENTS & DISASSEMBLY

1. GENERAL OVERVIEW
Hood & Engine Room
BODY REPAIR CHANGED BY

AFFECTED VIN
4 5C
Floor Panel Assembly
CHANGED BY BODY REPAIR

AFFECTED VIN
5C 5
Side Panel & Rear Wheel House Panel

AFFECTED VIN
6 5C
Roof Panel/Tailgate/Door Panel

AFFECTED VIN
5C 7
2. SIDE GARNISH
A. Wide Garnish
<Wide garnish mounted>
Door wheel arch garnish Front wheel arch garnish
Rear door wide garnish Front door wide garnish
Rear step seal garnish Front step seal garnish

AFFECTED VIN
8 5C
B. Narrow Garnish

AFFECTED VIN
5C 9
BODY DIMENSION
1. EXTERIOR (unit: mm)

AFFECTED VIN
10 5C
2. BODY STRUCTURE (unit: mm)

AFFECTED VIN
5C 11
3. SIDE STRUCTURE (unit: mm)

AFFECTED VIN
12 5C
4. WIND SHIELD (unit: mm)
.2
1321
.2
63
1563.2
.6
15
1500

AFFECTED VIN
5C 13
5. TAILGATE (unit: mm)

AFFECTED VIN
14 5C
6. UNDER BODY I (unit: mm)
732
444
1099.28
2203
1200
930
300
850

AFFECTED VIN
5C 15
7. UNDER BODY II (unit: mm)

AFFECTED VIN
16 5C
8. FLOOR MEMBER (unit: mm)

AFFECTED VIN
5C 17
9. FRONT SUB FRAME (unit: mm)

AFFECTED VIN
18 5C
10. BODY ROOF (unit: mm)

AFFECTED VIN
5C 19
11. FRAME MOUNTING POINT

Front Sub Frame
Rear
Front
[Note]
Front/center/rear each washer is
incompatible. The other parts are
same.

AFFECTED VIN
20 5C
Rear Frame

AFFECTED VIN
5C 21
BODY GAP & ALLOWANCE

1. FRONT

AFFECTED VIN
22 5C
No Item Gap Allowance No Item Gap Allowance

1 40
Hood-outter
2 41 A pillar ~ Fander
~ Bumper-upper 4.6
3 42
Center accord (+1.0)
4 43
(Erro < 0.5)
5 44 Quad ~ Fender
6 HOOD to 6.7 -2 45
7 H/LAMP (+1.0) (0, -0.5) 46
8 47 4.5 0
Fender ~ Front door
9 48 (+1,0) (-1,0)
6.8
10 Fender ~ Head lamp -1.5 ± 1.0 49
(±1)
11 50
12 51 Quad ~ A pillar
13 52
14
15
16 Front bumper
6.8 ± 1.0 -1.5 ± 1.0
17 ~ Head lamp
18
19
20
21
22
23
Fender -0.5
24 4.5 ± 0.5
~ Hood-outter (0, -0.5)
25
26
27
28
29 Fender -2.0
2.4 ± 1.0
30 ~ Front bumper (+1.5, -1.0)
31
32
33
34
35
Glass & Panel
36
37
38
39

AFFECTED VIN
5C 23
2. REAR

AFFECTED VIN
24 5C
No Item Gap Allowance No Item Gap Allowance

1 40 Panel ~ Lamp 5.5 ± 0.5
2 41
Rear lamp 5
3 Roof rail 10 42 0.0
-2 ± 1.0 ~ Taillamp ± 0.5
4 ~ Spoiler-Rear (+1.0) 43
5 44
Tailgate gaenish
6 45 0.5
~ Panel
7 46
8 47 Extensior cover 8
Quarter glass-side 0.8
9 1.9 ± 1.0 48 ~ Tailgate panel ± 1.0
~ Quarter glass-rear
10 49
11 50
Tailgate panel 6
12 51
Quarter glass-rear -1 ~ Bumper ± 1.0
13 5 ± 1.0 52
~ Tailgate glass +1.5, -0.7
14 53
15 54 Garnish ~ Bumper 2.0 2.5
Quarter glass-side 0
16 5 ± 1.0 55 2.2 -2.0
~ Tailgate panel +0, -1 Panel ~ Bumper
17 56 ± 0.5
18 57 Cover ~ Bumper
19 58 Cover ~ Bumper
Tailgate panel
20 2.3 ± 1 59 Panel 3.2 0
~ Tailgate glass
21 60 ~ Fuel door ± 0.5 +0, -1
22 61
23 62 Quarter glass-front 5 -2.2
24 63 ~ Rear door frame +1, -0 +1, -0.5
25 64
26 Quarter glass-side 65
2.0
27 ~ Rear combi 66
Quarter glass-front
28 67 Compressed
~ Side panel
29 68
30 69
31
Combi lamp-rear 0
32 2.2 ± 1.0
~ extension cover ± 1.0
33
34
35 Combi lamp-tailgate
1.8
36 ~ Tailgate
37
38 Gap 1.0 -0.5
39 Panel ~ Lamp 2.0

AFFECTED VIN
2-2 Wiring Diagram for Power Supplies
1. POSITION OF CONNECTOR, GROUND & SPLICE PACK
Electrical Wiring Diagram (LHD)

Wiring Diagram for Power Supplies 2-3
2. COMPONENTS LOCATION

3. CONNECTOR, GROUND & SPLICE PACK INFORMATION

1) CONNECTOR
Connector Number Connecting Wiring

Connector Position Remark
(Pin Number, Color) Harness
C101 (2Pin, Colorless) Engine Room Fuse Box - Engine Engine Room Fuse Box
C102 (20Pin, White) Engine Room Fuse Box - Engine Engine Room Fuse Box
C105 (22Pin, White) Engine Room Fuse Box - Main Engine Room Fuse Box
C108 (4Pin, Colorless) Engine Room Fuse Box - Main Engine Room Fuse Box
C110 (16Pin, White) Engine - Main Engine Room Fuse Box ABS (ESP)
C110 (7Pin, White) Engine - Main Engine Room Fuse Box -ABS(ESP)
C111 (4Pin, Colorless) Engine - Main Engine Room Fuse Box PTC
C111A (12Pin, Black) Engine - Main Engine Room Fuse Box
C112 (1Pin, Gray) Engine - Starter “ST” RR Pre-Heating Unit
C113 (4Pin, Black) Engine - Alternator Alternator
C113 (2Pin, Black) Engine - Alternator Alternator GSL
C114 (42Pin, Black) Engine - Engine Control Right Engine Room Dash PNL
C114 (42Pin, Black) Engine - Engine Control Right Engine Room Dash PNL GSL
C115 (15Pin, Black) Engine - Floor (RH) Under the Coolant Reserve Tank
C115 (8Pin, Black) Engine - Floor (RH) Under the Coolant Reserve Tank GSL
C115A (6Pin, Black) Engine - Floor (RH) Under the Coolant Reserve Tank
C116 (10Pin, Black) Engine - FFH Control Under the FFH
C201 (26Pin, White) Main - Roof Inside Parking Brake
C202 (6Pin, Black) Main - Roof Inside Driver Side Cowl PNL
C203 (40Pin, Gray) Main - ICM Box ICM Box (IP Relay Box)
C204 (20Pin, White) Main - ICM Box ICM Box (IP Relay Box)
C205 (39Pin, Black) Main - Floor (LH) Inside Driver Side Cowl PNL
C206 (2Pin, Yellow) W/H Air-Bag Inside Driver Side Cowl PNL
C207 (2Pin, Black) W/H Air-Bag Inside Driver Under Cover
C208 (14Pin, White) W/H Main Inside Driver Under Cover
C209 (18Pin, White) Main - Floor (LH) Upper the Brake Pedal
C210 (6Pin, White) Main - W/H Air-Bag Behind A/V Unit
C211A (13Pin, White) W/H Air-Bag - W/H Blower Behind Glove Box FATC
C211A (16Pin, White) W/H Air-Bag - W/H Blower Behind Glove Box Manual


(Pin Number, Color) Harness Connector Position Remark
C211B (2Pin, White) W/H Main - W/H Air-Bag Behind A/V Unit
C212 (4Pin, White) W/H Main Behind A/V Unit PTC
C213 (22Pin, White) Main - Floor (LH) FRT TGS Lever
C216 (2Pin, Black) W/H Air-Bag Inside Passenger Side Cowl PNL Pre-tensioner
C217 (20Pin, Green) Main - Floor (RH) Inside Passenger Side Cowl PNL
C218 (20Pin, Red) Main - Floor (RH) Inside Passenger Side Cowl PNL
C219 (20Pin, Yellow) Main - Floor (RH) Inside Passenger Side Cowl PNL
C220 (20Pin, Brown) Main - Floor (RH) Inside Passenger Side Cowl PNL
C221 (20Pin, Gray) Main - Floor (RH) Inside Passenger Side Cowl PNL
C301 (4Pin, White) Floor (LH) - Driver Seat Under the Driver Seat Power Seat (Seat Warmer)
C301A (2Pin, White) W/H Drive Seat Under the Driver Seat Power Seat (Seat Warmer)
C302 (4Pin, White) Floor (RH) - Passenger Seat Under the Passenger Seat Seat Warmer
C303 (4Pin, White) W/H Floor (RH) Under the Passenger Seat
C304 (12Pin, White) Floor (RH) - Floor (LH) RR Left Quarter Trim
C305 (6Pin, Colorless) Floor (RH) - RR A/C RR Right Quarter Trim Dual A/C
C306 (2Pin, White) Floor (RH) RR Right Quarter Trim Glass ANT
C351 (30Pin, White) Main - Drive Door Inside Driver Side Cowl PNL
C361 (30Pin, White) Main - Passenger Door Inside Passenger Side Cowl PNL
C371 (11Pin, White) Floor (LH) - RR Left Door Under Left “B” Filler
C381 (11Pin, White) Floor (RH) - RR Right Door Under Right “B” Filler
C401 (14Pin, White) Floor (LH) - Tail Gate Left Tail Gate Trim
C402 (8Pin, White) Floor (LH) - Tail Gate Upper Tail Gate Trim RR View Camera
C402 (2Pin, White) Floor (LH) - Tail Gate Upper Tail Gate Trim -AV
C901 (6Pin, Black) Floor (LH) - Fuse Sensor FRT Fuel Tank
C902 (12Pin. Black) Floor (LH) - TM T/C Left (Under the Floor) A/T
C902 (4Pin. Black) Floor (LH) - TM T/C Left (Under the Floor) M/T
C903 (8Pin, White) Floor (LH) - W/H Parking Aid Inside the Left RR Bumper Parking Aid
C904 (16Pin, Black) Floor (LH) - W/H EPB/EAS Upper the RR LH Bumper EPB/EAS

2) SPLICE PACK

S202 (14Pin, Black) W/H Main Under the Relay Box RR Left the Cluster
S203 (14Pin, Black) W/H Main Under the Relay Box RR Left the Cluster GND
S204 (14Pin, Black) W/H Main Under the Relay Box RR Center the Cluster ILL
S205 (8Pin, Black) W/H Main Upper the Right Driver Under Cover CAN
S206 (14Pin, Black) W/H Main Inside the Left A/V Head Unit GND
S207 (14Pin, Black) W/H Main Inside the Right A/V Head Unit
S301 (8Pin, Black) W/H Floor (LH) Beside TCU EPB/EAS
• S202
• S203 (GND)

• S204 (ILL)
• S205 (CAN)
• S206 (GND)

• S207
• S301 (EPB/EAS, CAN)

3) GROUND
Connector Connecting Wiring Remark

Number Harness Connector Position
G101 W/H Engine Behind the Washer Tank

G103 W/H Engine Behind the Air Cliner Housing
G201 W/H Main Inside Driver Side Cowl PNL
G203 W/H Air-bag Beside the SDM W/H Air Bag
G204 W/H Main Behind TGS Lever
G205 W/H Main Beside the ENG ECU ECU GND
G206 W/H Main Inside Passenger Side Cowl PNL
G207 W/H Floor (RH) Inside Passenger Side Cowl PNL
G301 W/H Floor (LH) Under Driver Seat
G303 W/H Floor (LH) Inside the LH Quarter Trim
G305 W/H Floor (RH) Inside the RH Quarter Trim
G401 W/H Tail Gate Center the Tail Gate
G402 W/H Floor (LH) Left the Tail Gate
G901 W/H EPB/EAS Inside the LH Quarter Trim EPB/EAS

1. ENG ROOM FUSE BOX

1) SB1 ~ SB5

2) SB6 ~ SB11

3) Ef1 ~ Ef4

4) Ef5

5) Ef6 ~ Ef10

6) Ef11 ~ Ef18

7) Ef19 ~ Ef21

8) Ef22 ~ Ef26

2. I.P FUSE BOX

1) F1 ~ F5

2) F6 ~ F12
30

3) F13 ~ F16

4) F17 ~ F24

5 ) F25 ~ F31

6) F32 ~ F36

SECTION 5
ELECTRICAL WIRING
DIAGRAMS
TABLE OF CONTENTS
1. STARTING & CHARGING ........................................................................................... 5-4
2. PREHEATING UNIT CIRCUIT (XDI) .......................................................................... 5-6
3. ECU (ENGINE CONTROL UNIT - D27DT EU IV) ................................................... 5-8

1) ENG MAIN RELAY, PEDAL MODULE, HFM SENSOR, VALVE, ENG MOUNT .. 5-8
2) FUEL FILTER WARNING LAMP, IMMOBILIZER, SENSOR (FUEL PRESSURE,
CAM SHAFT, BOOSTER PRESSURE, CRANK SHAFT, COOLANT/FUEL TEMP.)
A/CRUISE SW CIRCUIT ....................................................................................... 5-10
3) INJECTOR, CAN LINE, STOP LAMP SW, SENSOR (A/CON, E-GAS), CLUTCH
SW ......................................................................................................................... 5-12
4. ECU (GSL G32) ......................................................................................................... 5-14
1) IGN COIL, CPS, AIR FLOW SENSOR, THROTTLE SENSOR, TPS ............... 5-14
2) O2 SENSOR, PEDAL MODULE, CRUISE CONTROL SW,
STOP LAMP SW .................................................................................................. 5-16
3) INJECTOR, KNOCK SENSOR, IMMOBILIZER, CANISTER PURGE VALVE .... 5-18
5. DIAGNOSIS CIRCUIT ................................................................................................ 5-20
6. TCU (5-SPEED) .......................................................................................................... 5-22

1) START MOTOR, TGS LEVER, CAN LINE .......................................................... 5-22
2) SOLENOID, OIL TEMP. SENSOR, SPEED SENSOR (N2, N3) ....................... 5-24
7. TOD ............................................................................................................................. 5-26
8. CLUSTER .................................................................................................................... 5-28

1) GAUGE(SPEED, RPM, FUEL, TEMP, WARNING LAMP(4WD, FUEL FILTER,
ABS/ESP) .............................................................................................................. 5-28
2) WARNING (EAS, EPB, TGS LEVER, AUTO PARK’G) ...................................... 5-30
3) WARNING (BAT CHANGE, OIL, BRAKE ENG CHCK, AIR BAG, IMMOM SEAT-
BELT) TURN SIGNAL, DEFOGGER, DOOR OPEN .......................................... 5-32
9. CIGAR LIGHTER, POWER OUTLET ....................................................................... 5-34
10. HEAD LAMP, DRL(DAY TIME RUNNING LIGHT) UNIT ....................................... 5-36
11. STOP, BACK UP LAMP CIRCUIT ........................................................................... 5-38
12. P.T.C (POSITIVE TEMPERATURE COEFFICIENT) HEATER .............................. 5-40
13. FATC (FULL AUTO TEMP. CONTROL) CIRCUIT ................................................ 5-42

1) CONDENSOR FAN, AIR MIX, MOTOR, SUN/WATER TEMP SENSOR ........... 5-42
2) FRT BLOWER, ACTUATOR (MODE, INTAKE), AMBIENT SENSOR ............... 5-44
3) RR AIR CON (BLOWER, MODE ACTUATOR) .................................................. 5-46
14. AIR CON (MANUAL) .................................................................................................. 5-48
1) POWER A/C, COMP., MOTOR (MODE, INTAKE, AIR MIX) ............................. 5-48
2) BLOWER MOTOR (FRT, RR) ............................................................................ 5-50
1. STARTING & CHARGING

A. CONNECTOR INFORMATION

C112 (1Pin, Black) Engine - Starter “ST” RR Pre-Heating Unit
C221 (20Pin, Gray) Main - Floor (RH) Inside Passenger Side Cowl PNL Power Sheet (Warmer)
B. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION

2. PREHEATING UNIT CIRCUIT (XDi)


C213 (15Pin, Black) Main - Floor (LH) FRT TGS Lever

3. ECU (ENGINE CONTROL UNIT - D27DT EU IV)

1) ENG MAIN RELAY, PEDAL MODULE, HFM SENSOR, VALVE, ENG MOUNT


C103 (6 Pin, Colorless) Engine Room Fuse Box - Engine Engine Room Fuse Box
C111A (12Pin, Black) Engine - Main Engine Room Fuse Box
C115A (6Pin, Black) Engine - Floor (RH) Under the Coolant Reserve Tank

2) FUEL FILTER WARNING LAMP, IMMOBILIZER, SENSOR (FUEL PRESSURE, CAM SHAFT,
BOOSTER PRESSURE, CRANK SHAFT, COOLANT/FUEL TEMP.) A/CRUISE SW CIRCUIT
D27DT (EU IV) ECU


G102 W/H Main Behind the Washer Tank
G204 W/H Main RR TGS Lever

3) INJECTOR, CAN LINE, STOP LAMP SW, SENSOR (A/CON, E-GAS), CLUTCH SW


C211 (16Pin, White) Main - W/H Air-Bag RR A/V Unit
C221 (20Pin, Gray) Main - Floor (RH) Inside Passenger Side Cowl PNL ECU GND
G205 W/H Main Beside the ENG ECU

4. ECU (GSL G32)

1) IGN COIL, CPS, AIR FLOW SENSOR, THROTTLE SENSOR, TPS
ECU (E32)


C110 (16Pin, White) Engine - Main Engine Room Fuse Box ABS (ESP)

2) O2 SENSOR, PEDAL MODULE, CRUISE CONTROL SW, STOP LAMP SW


S202 (14Pin, Black) W/H Main Under the Relay Box RR Left the cluster

3) INJECTOR, KNOCK SENSOR, IMMOBILIZER, CANISTER PURGE VALVE


C107 (14Pin, White) Engine Room Fuse Box - Main Engine Room Fuse Box GSL
C115 (8Pin, Black) Main - Floor (RH) Under the Coolant Reserve Tank
C901 (6Pin, Black) Floor (LH) - Fuse Sensor FRT Fuel Tank

5. DIAGNOSIS CIRCUIT


C110 (16Pin, White) Engine - Main Engine Room Fuse Box

6. TCU (5-SPEED)
1) START MOTOR, TGS LEVER, CAN LINE


C112 (1Pin, Gray) Engine - Starter “ST” RR Pre-Heating Unit

2) SOLENOID, OIL TEMP. SENSOR, SPEED SENSOR (N2, N3)



C902 (12Pin. Black) Floor (LH) - TM Under the Floor A/T

7. TOD


C221 (20Pin, Gray) Main - Floor (RH) Inside Passenger Side Cowl PNL Power Seat (Seat Warmer)
G204 W/H Main Behind TGS Lever

8. CLUSTER
1) GAUGE(SPEED, RPM, FUEL, TEMP, WARNING LAMP(4WD, FUEL FILTER, ABS/ESP)



2) WARNING (EAS, EPB, TGS LEVER, AUTO PARK’G)


C201 (26Pin, White) Main - Roof Inside Parking Brake
C213 (22Pin, White) Engine - Floor (LH) FRT TGS Lever
C902(12Pin, Black) Floor (LH) - TM T/C Left (Under the Floor) A/T
C902(4Pin, Black)) Floor (LH) - TM T/C Left (Under the Floor) M/T
G206 W/H Main Inside Passenger Side Cowl PNL

3) WARNING (BAT CHANGE, OIL, BRAKE ENG CHCK, AIR BAG, IMMOM SEAT-BELT)
TURN SIGNAL, DEFOGGER, DOOR OPEN



9. CIGAR LIGHTER, POWER OUTLET


C203 (40Pin, Gray) Main - ICM Box CM Box (IP Relay Box)
S204 (14Pin, Black) W/H Main Under the Relay Box RR Center the Cluster
G305 W/H Floor (RH) Inside the RH Quarter Trim

10. HEAD LAMP, DRL(DAY TIME RUNNING LIGHT) UNIT


C219 (20Pin, White) Main - Floor (RH) Inside Passenger Side Cowl PNL

11. STOP, BACK UP LAMP CIRCUIT


C201 (26Pin, White) Main - Roof RR Parking Brake
C304 (12Pin, White) Floor (RH) - Floor (LH) RR Left Quarter Trim
C402 (8Pin, White) Floor (LH) - Tail Gate Upper Tail Gate Trim RR View Camera
C902 (2Pin. Black) Floor (LH) - TM T/C Left (Under the Floor ) M/T
G303 W/H Floor (LH) Inside the Quarter Trim

12. P.T.C (POSITIVE TEMPERATURE COEFFICIENT) HEATER


C111 (4Pin, Colorless) Engine - Main Engine Room Fuse Box PTC
C115 (15Pin, Black) Engine - Floor (RH) Under the Coolant Reserve Tank PTC
C211B (2Pin, White) W/H Main - W/H Air-Bag RR A/V Unit
C212 (4Pin, White) W/H Main RR A/V Unit

13. FATC (FULL AUTO TEMP. CONTROL) CIRCUIT

1) CONDENSOR FAN, AIR MIX, MOTOR, SUN/WATER TEMP SENSOR


C115 (15Pin, Black) Engine - Floor (RH) Under the Coolant Reserve Tank DSL
C211 (16Pin, White) Main - W/H Air-Bag Behide A/V Unit FATC
C211A (13Pin, White) W/H Air-Bag - W/H Blower Behide Glove Box Manual

2) FRT BLOWER, ACTUATOR (MODE, INTAKE), AMBIENT SENSOR


C110 (16Pin, White) Engine - Main Engine Room Fuse Box
C211A (13Pin, White) W/H Air-Bag - W/H Blower RR Glove Box FATC
G204 W/H Main W/H Main

3) RR AIR CON (BLOWER, MODE ACTUATOR)


C201 (26Pin, White) Main - Roof RR Parking Brake

14. AIR CON (MANUAL)

1) POWER A/C, COMP., MOTOR (MODE, INTAKE, AIR MIX)


C115 (15Pin, Black) Engine - Floor (RH) Under the Coolant Reserve Tank XDi
C211A (16Pin, White) W/H Air-Bag - W/H Blower Behind RR Glove Box Manual
C211B (2Pin, White) W/H Main - W/H Air-Bag Behind RR A/V Unit

2) BLOWER MOTOR (FRT, RR)


C201 (26Pin, White) Main - Roof Behind Parking Brake
C211 (16Pin, White) Main - W/H Air-Bag Behind RR A/V Unit
C211A (13Pin, White) W/H Air-Bag - W/H Blower Behind RR Glove Box FATC
G204 W/H Main W/H Main

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GASOLIN ENGINE

GENERAL INFORMATION................... SECTION 1A

ENGINE MECHANICAL ...................... SECTION 1B

ENGINE COOLING ............................... SECTION 1D

ENGINE ELECTRICAL ..........................SECTION 1E

ENGINE CONTROLS ............................ SECTION 1F

ENGINE INTAKE & EXHAUST ............. SECTION 1G

GENERAL INFORMATION CHANGED BY

DESCRIPTION AND OPERATION

CHANGED BY GENERAL INFORMATION

1. HFM sensor 9. Valve tappet 16. Engine mounting bracket

GENERAL INFORMATION CHANGED BY

23. Camshaft adjuster 27. Oil pump drive chain

CHANGED BY GENERAL INFORMATION

DIAGNOSTIC INFORMATION AND PROCEDURE

GENERAL INFORMATION CHANGED BY

COMPRESSION PRESSURE TEST

1. Compression pressure tester 3. Adaptor

Standard Service Data

CHANGED BY GENERAL INFORMATION

Tools Required 6. Compare the measurements of compression pressure

GENERAL INFORMATION CHANGED BY

CYLINDER PRESSURE LEAKAGE TEST

Permissible Pressure Leakage

Cylinder Number by Mark on Vibration Damper at TDC

CHANGED BY GENERAL INFORMATION

9. Connect the connecting hose to tester and measure the

10. Perform the pressure test according to the firing order.

11. Compare the leakage pressure with the specifications.

GENERAL INFORMATION CHANGED BY

CHANGED BY GENERAL INFORMATION

General Diagnosis (Cont’d)

GENERAL INFORMATION CHANGED BY

General Diagnosis (Cont’d)

CHANGED BY GENERAL INFORMATION

General Diagnosis (Cont’d)

GENERAL INFORMATION CHANGED BY

General Diagnosis (Cont’d)

CHANGED BY GENERAL INFORMATION

MSE: Engine Control Module

GENERAL INFORMATION CHANGED BY

CHANGED BY GENERAL INFORMATION

SPECIAL TOOLS AND EQUIPMENT

Name and Part Number

A9912 0012B (001 589 76 21 00)

GENERAL INFORMATION CHANGED BY

CHANGED BY ENGINE MECHANICAL

Removal & Installation Procedure

4. Disconnect the Hot Film Air Mass (HFM) sensor

7. Remove the air cleaner cover. Remove the mounting bolts

8. Remove the hood latch cable and remove the radiator

ENGINE MECHANICAL CHANGED BY

9. Disconnect the each connector.

10. Disconnect the each hose / A/C pipe.

12. Remove the automatic transmission oil cooler line.

CHANGED BY ENGINE MECHANICAL

13. Remove the radiator assembly.

14. Remove the hydraulic pipe of power steering.

Completely drain the oil.

15. Discharge the refrigerant from A/C system, and

16. Remove the fuel feed and return line.

Before removing the fuel lines, release the pressure in

ENGINE MECHANICAL CHANGED BY

17. Separate the vacuum hose for brake booster.