Optima 2001 2.4L Service-Manual

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OPTIMA(MS) > 2001 > G 2.4 DOHC > General Information
General Information > General Information > General Information

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

Vehicle identification number consists of 17 digit.
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1. W.I.C. (World manufacturer's identifier)
KNE/KNA - kia motors corporation
2. Vehicle type
GD - Magentis/Optima
3. Body type
12 - sedan
4. Engine type
8 - 2.7 liter
5. Transaxle (General region)
2 - 5 speed manual
3 - 4 speed automatic
Check digit (To be calculated)
6. Model year
2 - 2002MY, 3 - 2003MY
7. Plant location
5 - Hwasung plant
6 - Sohari plant
8. Sequential number
ENGINE IDENTIFICATION NUMBER LOCATION
• The engine identification number is stamped at the right front side on the top edge of the cylinder block.
ENGINE IDENTIFICATION NUMBER

Engine identification number consists of 11 digits.
1. Engine fuel
G - Gasoline L - LPG D - Diesel
2. Engine range
4 - In line 4 cycle 4 cylinder
6 - V type 4 cycle 6 cylinder
3. Engine development order
B - V6 Engine
J - SIRIUS II DOHC Engine
4. Engine capacity
N - 1836 cc
P - 1997 cc, 1998 cc
S - 2351 cc
V - 2493 cc, 2497 cc
5. Product year
W - 1998 X - 1999 V - 2000 1 - 2001 2 - 2002
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6. Engine production sequence number
000001 - 999999
TRANSAXLE IDENTIFICATION NUMBER LOCATION
DESCRIPTION (MANUAL TRANSAXLE)
1. Model
L : M5G Series.
2. Product year
1 : 2001 2 : 2002
3. Final gear ratio
1766 : 3,882
1665 : 4,063
4. Serial NO.
DESCRIPTION (AUTOMATIC TRANSAXLE)
1. Model
C : KM 175-5 D : KM 175-6 H : F4A33
2. Product year
1 : 2001 2 : 2002
3. Final gear ration
F : 4.350 (KM 175-6) A : 3.958 (F4A33)
4. Classification of detail
AD : 2.4 Liter Engine BD : 2.0/ 2.5 Liter Engine
5. Spare
6. Serial No.
PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas before starting work.
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The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine
compartment to prevent the hood from falling and possibly injuring you.
Assure that the support rod has been released prior to closing the hood. Always double check to be sure the hood
is firmly latched before driving away.
BASIC SAFETY WARNINGS WHEN WORKING ON THE VEHICLE
The following precautions must be followed when jacking up the vehicle.
1. Block wheels.
2. Use only specified jacking positions.
3. Support vehicle with safety stands (jack stands)
4. Never start the engine until you personally make certain the enginecompartment is clear of tools and people.
Never rely on another person to make the inspection-make the inspection yourself.
PREPARATION OF TOOLS AND MEASURING EQUIPMENT
Be sure that all necessary tools and measuring equipment are available before starting work activity.
SPECIAL TOOLS
• Use special tools when they are required.
REMOVAL OF PARTS
• First find the cause of trouble and then make sure whether removing or disassembling is required before starting
the job.
The failure to follow these instructions can lead to serious personal injury or death.
DISASSEMBLY
If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled
in a way that will not affect their performance or external appearance.
1. Inspection of parts
Each part when removed should be carefully inspected for malfunction, deformation, damage, and other
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2. Arrangement of parts
All disassembled parts should be carefully arranged for reassembly.
Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
3. Cleaning parts for reuse

All parts to be reused should be carefully and thoroughly clean-ed by the appropriate method.
PARTS
When replacing factory parts, use genuine parts.
If using non-factory parts, you must ensure that such parts are the equivalent quality of genuine factory parts to
avoid exposing customers to the risk of severe injury or death.
REASSEMBLY
Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
If removed, these parts should be replaced with new ones.
1. Oil seals.
2. Gaskets 3.
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts
Depending on where they are;
1. Sealant should be applied to gaskets.
2. Oil should be applied to moving components of parts.
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3. Specified oil or grease should be applied at the prescribed locations (oil seals, etc.) before assembly.
ADJUSTMENT
Use gauges and testers to correct adjustments to standard values.
ELECTRICAL SYSTEM
1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.
2. Never pull on the wiring when disconnecting connectors.
3. Locking connectors will click when the connector is secure.
4. Handle sensors and relays carefully.
Be careful not to drop them or hit them against other parts.
RUBBER PARTS AND TUBING

• Always prevent gasoline or oil from touching rubber parts or tubing.
BODY DIMENSION MEASUREMENT

1. Basically, all measurements in this manual are taken with a tracking gauge.
2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
3. For measuring dimensions, both projected dimension and actual-measurement dimension are used in this manual.
PROJECTED DIMENSIONS
1. These are the dimensions measured when the measurement points are projected into the reference plane, and are
the reference dimensions used for body alterations.
2. If the length of the tracking gauge probes are adjustable, make the measurement by lengthening one probe by the
amount equivalent to the difference in height of the two surfaces.
ACTUAL-MEASUREMENT DIMENSIONS
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1. These dimensions indicate the actual linear distance between measurement points, and are the reference
dimensions for use if a tracking gauge is used for measurement.
2. Measure by first adjusting both probes to the same length (A=A')
Check the probes and gauge itself to make sure there is no free
play.
MEASUREMENT POINT
1. Measurements should be taken at the center of hole.
CHECKING CABLES AND WIRES

1. Check the terminal for tightness.
2. Check terminals and wires for corrosion by battery electrolyte, etc.

3. Check terminals and wires for open circuit or potential open circuit.
4. Check wire insulation and coating for damage, cracks and degrading.
5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that wires are clamped so as to prevent contact with sharp corners of the vehicle body, etc. or hot parts
(exhaust manifold, pipe, etc.)
9. Check that wires are clamped firmly to secure enough clearance from the fan pulley, fan belt and other rotating or
moving parts.
10. Check that the wires between the fixed parts such as the vehicle body and the vibrating parts such as the engine
are made with adequate allowance for vehicle vibrations.
CHECKING FUSES
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• A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse
block. The fuse is okay if the test lamp comes on when its one lead is connected to the test taps (one at a time)
and the other lead is grounded. (Change the ignition switch position adequately so that the fuse circuit becomes
live.)
SERVICING THE ELECTRICAL SYSTEM

1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground
cable.
In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic code
retained by the computer will be cleared.
Therefore, if necessary, read the diagnostic codes before removing the battery cable.
2. Secure the wiring harnesses by using clamps so that there is no slack. However, for any harness which passes to
the engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine
vibrations tocause the harness to come into contact with any of the surrounding parts, and then secure the harness
by using a clamp.
3. If any section of a wiring harness interferes with the edge of a part, or a corner, wrap the section of the harness
withtape or something similar in order to protect it from damage.
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4. When installing any of the vehicle parts, be careful not to pinch or damage any of the wiring harnesses.
5. Never throw the relays, sensors and electrical parts, or expose them to strong shocks.
6. The electronic parts used in the computer, relays, etc. are easily damaged by heat. If there is a need for service
operations that may cause the temperature to exceed 80°C (176°F), remove the electronic parts beforehand.
7. Loose connectors could troubles. Make sure that the connec-tors are connected securely.
8. When disconnecting a connector, be sure to pull only the connector, not the harness.
9. Disconnect connectors which have catches by pressing in the direction indicated by the arrows in the illustration.
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10. Connect connectors which have catches by inserting the connectors until a "click" noise is heard.
11. When using a circuit tester to perform continuity or voltage checks on connector terminals, insert the test probe
from the harness side. If the connector is a sealed connector, insert the test probe in through the hole in the
rubber cap forthe electrical wires, being careful not to damage the insulation of the wires and continue to insert
the test probe until it contacts the terminal.
12. To avoid overloading the wiring, take the electrical current load of the optional equipment into considerution,
and determine the appropriate wire size.
Permissible current
Nominal size SAE gauge No.
In engine compartment Other areas
0.3 mm² AWG 22 - 5A
0.5 mm² AWG 20 7A 13A
0.85 mm² AWG 18 9A 17A
1.25 mm² AWG 16 12A 22A
2.0 mm² AWG 14 16A 30A
3.0 mm² AWG 12 21A 40A
5.0 mm² AWG 10 31A 54A
PRECAUTIONS FOR A CATALYTIC CONVERTER
If large amounts of unburned gasoline vapors flow into the converter, the gasoline line may overheat and create a
fire hazard. To prevent this, observe the following precautions and explain them to your customer.
1. Use only unleaded gasoline.
2. Avoid prolonged idling.
Avoid running the engine at fast idle speed for more than 10 minutes and at idle speed for more than 20 minutes.
3. Avoid spark jump test.
Spark jump only when absolutely necessary. Perform this test as rapidly as possible and, while testing, never race
the engine.
4. Avoid prolonged engine compression measurement. Engine compression tests must be made as rapidly as
possible.
5. Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load
on the converter.
6. Avoid coasting with ignition turned off and prolonged braking.
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7. Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
SRS SYSTEM COMPONENTS INFORMATION
Failure to carry out service operations in the correct sequence could cause the airbag system to unexpectedly
deploy during servicing, possibly leading to a serious injury or death.
Further, if a mistake is made in servicing the airbag system, it is possible the airbag may fail to operate when
required.
Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read
thefollowing items carefully, then follow the correct procedure described in the repair manual.
1. Malfunction symptoms of the airbag system are difficult to confirm, so the diagnostic codes become the most
important source of information when troubleshooting.
When troubleshooting the airbag system, always inspect the diagnostic codes before disconnecting the battery.
2. Work must be started 30 seconds or longer from the time the ignition switch is turned to the LOCK position and
the negative (-) terminal cable is disconnected from the battery. (The airbag system is equipped with a back-up
power source so that work is started immediately after disconnecting the negative (-) terminal cable of the
battery, the airbag may be deployed.)
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems
will be cancelled. So before starting work, make a record of the contents memorized by the audio memory
system. Then when work is finished, reset the audio system as before and adjust the clock.
3. Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.
4. Never attempt to disassemble and repair the airbag modules, SRSCM, Clock spring and Air-bag wiring harness
in order to reuse it.
5. If the SRSCM or air-bag module have been dropped, or if there are cracks, dents or other defects in the case,
bracket or connector, replace them with new ones.
6. After work on the airbag system is completed, perform the SRS SRI check.
VEHICLE LIFT AND SUPPORT LOCATIONS
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STANDARD PARTS TIGHTENING TORQUE TABLE
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Bolt nominal diameter Pitch Torque Nm (kg.cm, lb.ft)

(mm) (mm) Head Mark 4 Head Mark 7
M5 0.8 3-4 (30-40, 2.2-2.9) 5-6 (50-60, 3.6-4.3)

M6 1.0 5-6 (50-60, 3.6-4.3) 9-11 (90-110, 6.5-8.0)
20-25 (200-250, 14.5-
M8 1.25 12-15 (120-150, 9-11)
18.0)
M10 1.25 25-30 (250-300, 18-22) 30-50 (400-500, 29-36)
M12 1.25 35-45 (350-450, 25-32) 60-80 (600-800, 43-58)
120-140 (1,200-1,400,
M14 1.5 75-85 (750-850, 55-60)
85-100)
110-130 (1,100-1,300, 180-210 (1,800-2,100,
M16 1.5
80-95) 130-150)
160-180 (1,600-1,800, 260-300 (2,600-3,000,
M18 1.5
115-130) 190-215)
220-250 (2,200-2,500, 360-420 (3,600-4,200,
M20 1.5
160-180) 260-300)
290-330 (2,900-3,300, 480-550 (4,800-5,500,
M22 1.5
210-240) 350-400)
360-420 (3,600-4,200, 610-700 (6,100-7,000,
M24 1.5
270-300) 440-505)
1. The torques shown in the table are standard values applicable to tightening performed under the following
conditions:
1. Nuts and bolts are made of steel bar, and galvanized
2. Galvanized plain steel washers are inserted
3. All nuts, bolts, and plain washers are dry
2. The torques shown in the table are not applicable :
1. Spring washers, toothed washers and the like are inserted
2. If plastic parts are fastened
3. If self-tapping screws or self-locking nuts are used
4. If threads and surface are coated with oil
3. It should be standard practice to reduce the torques given in the table to the percentage indicated below
1. If spring washers are used. (85%)
2. If threads and bearing surfaces are stained with oil. (85%)
RECOMMENDED LUBRICANTS AND CAPACITIES tomsn048@gmail.com
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RECOMMENDED LUBRICANTS
Parts Specifications Remarks
For further details, refer to SAE
Engine oil API classification SG or SG/CD
viscosity number
SAE grade number:
Manual transaxle Hypoid gear oil, API-GL-4
SAE 75W/ 90W
GENUINE
Automatic transaxle
DIAMOND ATF SP-II M
Brake Conforming to DOT 3 or equivalent
SAE J310a, Multipurpose grease
Rear wheel bearing
NLGI No.2 or equivalent.
Cooling system High quality ethylene glycol Concentration level 40%
Transaxle linkage, parking brake
cable mechanism, hood lock and
Multipurpose grease NLGI Grade #2
hook, door latch, seat adjuster, trunk
latch, door hinges, trunk hinges
Door hinges, trunk hinges Engine oil
Power steering PSF-3
LUBRICANTS CAPACITIES
Capacities Remarks
3.7 lit (3.91 U.S. qts., 3.26
Oil pan
Imp.qts.)
Engine oil(For 2.0/ 2.4L 0.3 lit (0.32 U.S. qts., 0.26
Oil filter
DOHC Engine) Imp.qts.)
4.0 lit (4.23 U.S. qts., 3.52
Total
Imp.qts.)
4.2 lit (4.44 U.S. qts.,3.69
Oil pan
lmp.qts.)
Engine oil(For 2.5L V6 0.3 lit (0.32 U.S. qts.,0.26
Oil filter
Engine) Imp.qts.)
4.5 lit (4.76 U.S. qts.,3.95
Total
lmp.qts.)
5.5 lit (5.78 U.S. qts., 4.84
Cooling system
Imp.qts.)
2.1 lit (2.2 U.S. qts., 1.8
Manual transaxle
Imp.qts.)
7.8 lit (8.2 U.S. qts., 6.9
Automatic transaxle
Imp.qts.)
1.0 lit (1.05 qts., 0.88
Power steering
lmp.qts.)
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MAINTENANCE SERVICE (CHECKING THE ENGINE OIL)
1. Warm up the engine and turn the ignition off.
2. Remove the filler cap (on the rocker cover), then remove the drain plug and drain the engine oil.
3. Install the drain plug and tighten to specified torque.
Tightening torque :
Drain plug : 35-45 Nm (350-450 kg·cm, 26-32 lb·ft)
4. Fill the crankcase with fresh oil through the filler port.
Drain and Refill (Lit (U.S.qts,
ENGINE Dry Fill lmp.qts.)
W oil filter W O oil filter
DOHC 4.3 (4.52, 3.76) 4.0 (4.23, 3.51) 3.7 (3.91, 3.25)
V-6 - 4.5 (4.76, 3.95) 4.2 (4.43, 3.69)
5. Pull the dipstick out in order to check the oil level.

6. Install the filler plug.
7. Recheck the level of the engine oil after a road test.
REPLACEMENT OF THE ENGINE OIL FILTER

1. Replace the oil fiter at every oil change.
2. Use a filter srench (available commercially) to remove the oil filter.
3. Drain the oil in the filter.
4. Lightly coat the O―ring(1) of the new oil filter with engine oil, and install the filter by hand.
REPLACEMENT OF THE ENGINE OIL FILTER

The air cleaner filter will become dirty during use and the filtering effect will be substantially reduced. Replace with a
new one.
1. Disconnect the air cleaner filter cover clip.
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2. Remove the air filter cover.
The air filter cover should be removed carefully because it includes the air-flow
sensor.
3. Remove the air cleaner filter.

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

The belt tension for V6 engine is automatically adjusted by the auto-tensioner.
ADJUSTMENT OF BELT TENSION
Refer to EM-Section. (For Generator of DOHC Engine)
Refer to HA-Section. (For Compressor)
COOLING SYSTEM
Check the cooling system for damaged hoses, loose or seeping connections, or other possible causes of coolant
leaks.
Antifreeze tomsn048@gmail.com
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The engine cooling system is provided with a mixture of 50% ethylene glycol anti-freeze and 50% water at the time
of manufacture. (For the vehicles of tropical area, the engine cooling system is provided with a mixture of 40%
ethylene glycol anti-freeze and 60% water at the time of manufacture.)
Since the cylinder head and water pump body are made of aluminum alloy casting, be sure to use a 30 to 60%
ethylene glycol antifreeze coolant to provide corrosion protection and freezing prevention.
If the concentration of the antifreeze is below 30%, the anticorrosion property will be adversely affected. In
addition,if the concentration is above 60%, both the antifreezing and engine cooling properties will decrease,
adversely affecting the engine. For these reasons, be sure to maintain the concentration level within the specified
range.
Measurement of Antifreeze Concentration
Run the engine until coolant is fully mixed. Drain some coolant (antifreeze), and measure temperature and specific
gravity of the coolant. Determine concentration and safe working temperature. If the coolant is short of antifreeze,
add antifreeze up to a concentration of 50%. (Tropical Areas : 40%)
Replacement of the Coolant
1. Set the temperature control lever to the hot position.
2. Remove the radiator cap.
Remove cap slowly as the system is pressurized and the coolant may be
hot.
Do not open the cap when engine is hot.
3. Loosen the drain plug to drain the coolant.
4. Drain the coolant from the reserve tank.
5. After draining the coolant, tighten the drain plug securely.
6. Supply the coolant into the radiator until it is filled up to its filler neck.
7. Supply the coolant into the reserve tank.
8. After warming the engine until the thermostat opens, remove the radiator cap and check the coolant level.
9. Supply the coolant into the radiator until it is filled up to its filler neck, and install the radiator cap securely.
10. Fill the reserve tank with coolant up to the "FULL" line.
REPLACEMENT OF IGNITION CABLES
The ignition cables should be replaced periodically with new ones. After replacing, make sure that the ignition cables
and terminals are properly connected and fully seated.
When disconnecting an ignition cable be sure to hold cable cap. If the cable is disconnected by pulling on the cable
alone an open circuit might result.
REPLACEMENT OXYGEN SENSOR

The oxygen sensor is a device which controls the fuel mixture. If the oxygen sensor is damaged, the exhaust-gas
cleaningeffect as well as driveability deteriorates. Therefore, its performance should be checked periodically using
the O2 sensor monitoring function of the scan tool and replaced as necessary.
FUEL SYSTEM (Tank, Lines And Connections) tomsn048@gmail.com
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1. Check for damage or leakage in the fuel lines and connections.
2. Inspect the surface or fuel hoses for heat and mechanical damage. Hard and brittle rubber, cracking, checking,
tears, cuts, abrasions and excessive swelling indicate deterioration of the rubber.
3. If the fabric casing of the rubber hose is exposed by cracks and abrasions in the fuel system, the hoses should be
changed.
MANUAL TRANSAXLE (Inspect oil level)
Inspect each component for evidence of leakage, and check the oil level by removing the filler plug. If the oil is
contaminated, it is necessary to replace it with new oil.
1. With the vehicle parked at a level place, remove the filler plug and make sure that oil level is the same level as the
plug hole.
2. Check to be sure that the transaxle oil is not dirty.
TRANSAXLE OIL (Replace)

1. With the vehicle parked at a level place, remove the magnet plug to drain transaxle oil.
2. Replace packing with a new one and install the magnet plug.
3. Supply transaxle oil (through the filler plug part) until the oil level is the same level as the plug hole.
Transaxle oil total capacity :

2.1 liters (2.2 U.S. qts, 1.8 lmp. qts.)
INSPECT STEERING LINKAGE

1. Check steering wheel freeplay.
Maximum steering wheel freeplay : 30 mm (1.181 in.)
2. Check steering linkage for looseness and damage as follows.

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

1. Check all brake pipes and hoses for damage, wear, cracks, corrosion, leaks, bends, twists.
2. Check all clamps for tightness.
3. Check that the lines are clear of sharp edges, moving parts and the exhaust system.
FRONT DISC BRAKE PADS

Check for fluid contamination and wear. Replace complete set of pads if defective.
If a squealing or scraping noise occurs from the brakes during driving, check the brake pad wear indicator to see if
it is contacting the brake disc. If the brake pad wear indicator is contacting the disc, the brake pad should be
replaced.
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The pads for the right and left wheels should be replaced at the same time. Never “split” orintermix brake pad sets.
All pads must be replaced as a complete set.
Thickness of pad lining "A" [Limit] : 2.0 mm (0.079 in.)
REAR DRUM BRAKE LININGS AND (REAR WHEEL CYLINDERS)

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

1. Visually check the level of the brake fluid in the reserve tank of the master cylinder.
2. The level should be between the "MAX" and "MIN" marks.
3. If the level is lower than the "MIN" marks, add fresh brake fluid up to the "MAX" mark.
CHANGING BRAKE FLUID

1. Refer to BR-Section for air-bleeding procedures.
2. Connect a vinyl tube to the bleeder screw of each wheel cylinder. Put the other end of the vinyl tube into a
container to receive the brake fluid.
3. With a vehicle equipped ABS (Anti-lock Breake System), refer to BR-section.
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4. Depress the brake pedal a few times. Then loosen the bleeder (with the brake pedal still depressed), and tighten
it after the brake fluid stops flowing.
5. Repeat the above operation until to air bubbles are in the brake fluid.
6. Repeat these steps for the other cylinders.
7. Add fresh brake fluid up to the “MAX” level in the reserve tank.
Brake fluid : DOT 3 or equivalent
CHECKING OF THE TIRE INFLATION PRESSUE

Check the tire inflation pressures as follows.
Tire inflation pressure (Check with Tires Cool)
Tire size Front Rear
195/ 70 R 14 207 kPa (30 207 kPa (30
205/ 60 R 15 psi) psi)
ROAD TEST
Drive the vehicle and check for abnormal conditions.
1. Check for oil, fluid, fuel, water and exhaust gas leaks.
2. Check free play of clutch pedal and brake pedal.
3. Check operation of brake booster.
4. Check operation of service brake and parking brake systems.
5. Check stroke of parking brake lever.
6. Check driveability of engine.
7. Check condition of instruments, gauges, indicators, exterior lamps, heater and ventilators.
8. Check abnormal noise of each part.
STEERING AND DRIVE SHAFT BOOTS
1. Aluminum wheels need special attention. If salt or chemicals have adhered to the wheels, they need to be rinsed
off as soon as possible. After cleaning the wheels, apply a coating of wax to prevent corrosion.
2. When cleaning the vehicle with steam, do not apply steam directly onto the aluminum wheels.
A. Clean the hub surface.
B. After finger tightening the wheel nuts, tighten them to specifications.
C. Do not use an impact wrench or push on the wrench with your foot to tighten the wheel nuts.
D. Do not apply oil to the threaded portions.
TIRE CHAINS AND SNOW TIRES
1. Use tire chains only on the front wheels. Do not use tire chains on rear wheels.
2. When using snow tires, use them on all four wheels for maneuverability and safety.
Page 1 of 115
OPTIMA(MS) > 2001 > G 2.4 DOHC > Automatic Transaxle System
Automatic Transaxle System > General Information > Special Service Tools
SPECIAL service TOOLS
Tool
Illustration Use
(Number and Name)
09453-24000 Removal and installation of underdrive clutch
Spring compressor snap ring
09452-21401/0K011 171 002 Installation of oil pump

Guide pin (Use with 09452-21301)
09453-33100 Measurement of the low and reverse brake

Dial gauge extension and the second brake end play
09431-39000 Installation of differential oil seal

Oil seal installer
09432-33800 1. Removal of transfer driven gear taper

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

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

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

Bearing installer output shaft taper roller bearing
09453-21100
Spring compressor
Page 2 of 115
09453-21100 Removal and installation of the low-reverse
Spring compressor brake snap ring (use with 09453-21000)
09455-21000/0K011 430 017 Removal of ball bearing and transfer drive

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

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

Bearing installer (use with 09500-11000)
09453-21000 • Removal and installation of low-reverse

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

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

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

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

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

A/B Clearance dummy plate second brake end plays
Page 3 of 115
09457-39000 Removal and installation of output shaft lock
Special socket (41) nut
SPECIAL SERVICE TOOLS

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

09432-22100
outer race
Bearing outer race installer
(Use with 09500-11000)
09432-33200 Removal of input shaft's gear and ball

Bearing removing plate bearing
09432-33300
Installation of input shaft bearing
Bearing installer
09432-33400 Installation of input shaft bearing outer race

Bearing race installer (Use with 09500-21000)
09455-21100
Installation of differential ball bearing
Bearing installer
09455-32200/0K011 190 008

Removal of differential bearing spacer
Oil seal puller
Page 4 of 115
09495-33000
Removal of ball bearing and gear
Bearing and gear puller
09517-21400 Separation of T/M housing from T/M

Drift assembly
09532-11000 Removal and installation of differential

Differential bearing installer bearing
Installation of output shaft and differential

09532-11500
shaft bearing outer race
Pinion bearing outer race installer
(Use with 09500-11000)
09200-38001(J28467-B) Removal and installation of transaxle

Engine support fixture assembly
Automatic Transaxle System > General Information > Troubleshooting

TROUBLESHOOTING
Symptom Probable cause Remedy
Loose or damaged transaxle and engine mounts Tighten or replace mounts
Inadequate shaft end play Correct end play
Worn or damaged gears Replace gears
Vibration, noise
Use of inadequate grade of gear oil Replace with specified gear oil
Low oil level Replenish
Inadequate engine idle speed Adjust idle speed
Oil leakage Broken or damaged oil seal Replace oil seal
Faulty control cable Replace control cable
Poor contact or wear of synchronizer ring and gear
Correct or replace
Hard shift cone
Weakened synchronizer spring Replace synchronizer spring
Use of inadequate grade of oil Replace with specified gear oil
Replace shift fork or poppet
Worn gear shift fork or broken poppet spring
spring
Page 5 of 115
Jumps out of gear Replace synchronizer hub and
Excessive clearance of synchronizer hub to sleeve spline
sleeve
Worn or damaged gears and/or bearings Replace
Automatic Transaxle System > General Information > Specifications

SPECIFICATIONS (AUTO : F4A42)
Item F4A42-2
3-element, 1-stage, 2-phase
Torque converter type
type
4-speed forward, 1-speed
Transmission type
reverse
Engine displacement 2.4D / 2.7D
Gear ratio 1st 2.842
2nd 1.529
3rd 1.000
4th 0.712
Reverse 2.480
Final gear ratio 3.770
SERVICE SPECIFICATIONS
Items Standard value
Output shaft preload 0.01-0.09 mm
Brake reaction plate end play 0-0.16 mm
Low-reverse brake end play 1.65-2.11mm (F4A42-2)
Second brake end play 0.79-1.25 mm
Underdrive sun gear end play 0.25-0.45 mm
Input shaft end play mm 0.70-1.45 mm
Differential case preload 0.045-0.105 mm
Underdrive clutch end play 1.6-1.8 mm
Reverse and overdrive clutch return 0-0.09 mm
spring end play
Overdrive clutch end play 1.6-1.8 mm
Reverse clutch end play 1.5-1.7 mm
Backlash between differential side 0.025-0.150 mm
gear and pinion
TIGHTENING TORQUE
Items N·m kg·cm lb·ft
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Wiring harness bracket 20-26 200-260 14-18
Control cable bracket 20-26 200-260 14-18
Eye bolt 27-33 270-330 19-23
Oil cooler feed tube 10-12 100-120 7-8
Input shaft speed sensor 10-12 100-120 7-8
Output shaft speed sensor 10-12 100-120 7-8
Manual control lever 18-25 180-250 13-18
Transaxle range switch 10-12 100-120 7-8
Vehicle speed sensor 4-6 40-60 3-4
Valve body cover 8-10 80-100 6-7
Valve body mounting bolt 10-12 100-120 7-8
Oil temperature sensor 10-12 100-120 7-8
Manual control shaft detent 5-7 50-70 4-5
Rear cover 20-26 200-260 14-18
Torque converter housing 42-54 420-540 29-38
Oil pump 20-26 200-260 14-18
Transfer drive gear 16-22 160-220 11-15
Output shaft lock nut 160-180 1600- 110-126
1800
Output shaft bearing retainer 20-26 200-260 14-18
Oil filler plug 29-34 290-340 20-24
Oil drain plug 29-34 290-340 20-24
Transfer drive gear lock nut 180-210 1800- 126-147
2100
Differential drive gear 130-140 1300- 91-98
1400
Valve body 10-12 100-120 7-8
Solenoid valve support 5-7 50-70 4-5
Plate 5-7 50-70 4-5
Pressure check plug 8-10 80-100 6-7
Front roll stopper bracket to subframe 60-80 600-800 43-58
bolts
Front roll stopper insulator bolt and nut 50-65 500-650 36-47
Front roll stopper bracket to transaxle 60-80 600-800 43-58
bolts
Rear roll stopper bracket to subframe 50-65 500-650 36-47
bolts
Rear roll stopper insulator bolt and nut 50-65 500-650 36-47
Page 7 of 115
Rear roll stopper bracket to transaxle 60-80 600-800 43-58
bolts
Transaxle mounting sub bracket nut 60-80 600-800 43-58
Transaxle mounting bracket bolts 60-80 600-800 43-58
Transaxle mounting insulator bolt 90-110 900-1100 65-80
Always follow torque tightening levels. Failure to follow such levels can result in parts breaking if over-tightened or
loosening if under-tightened. In either case, serious personal injury or death could result to the vehicle occupants.
SNAP RING AND SPACER FOR ADJUSTMENT
Identification
Part name Thickness mm
symbol
Thrust washer 1.8 18
(For adjustment of input shaft end play)
2.0 20
2.2 22
2.4 24
2.6 26
2.8 28
Snap ring 1.6 None
(For adjustment of underdrive clutch and overdrive clutch end
1.7 Blue
plays)
1.8 Brown
1.9 None
2.0 Blue
2.1 Brown
2.2 None
2.3 Blue
2.4 Brown
2.5 None
2.6 Blue
2.7 Brown
2.8 None
2.9 Blue
3.0 Brown
Snap ring 2.2 Blue
(For adjustment of low-reverse brake and second brake reaction
2.3 Brown
plates end plays)
2.4 None
2.5 Blue
Pressure plate 1.6 6
Page 8 of 115
(For adjustment of low-reverse brake and second brake end plays) 1.8 1
2.0 0
2.2 2
2.4 4
2.6 6
2.8 8
3.0 D
Snap ring 1.9 None
(For adjustment of reverse clutch end play)
2.0 Blue
2.1 Brown
2.2 None
2.3 Blue
2.4 Brown
2.5 None
2.6 Blue
2.7 Brown
2.8 None
Snap ring 1.48 Brown
(For adjustment of reverse clutch and overdrive clutch spring
1.53 None
retainers en plays)
1.58 Blue
1.63 Brown
Thrust race 1.6 -
(For adjustment of underdrive sun gear end play) 1.7 -
1.8 -
1.9 -
2.0 -
2.1 -
2.2 -
2.3 -
2.4 -
2.5 -
2.6 -
Spacer 1.88 88
(For adjustment of output shaft preload)
1.92 92
1.96 96
2.00 00
Page 9 of 115
2.04 04
2.08 08
2.12 12
2.16 16
2.20 20
2.24 24
2.28 28
2.32 32
2.36 36
2.40 40
2.44 44
2.48 48
2.52 52
2.56 56
2.60 60
2.64 64
2.68 68
2.72 72
2.76 76
Spacer 0.71 71
(For adjustment of differential case preload) 0.74 74
0.77 77
0.80 80
0.83 83
0.86 86
0.89 89
0.92 92
0.95 95
0.98 98
1.01 01
1.04 04
1.07 07
1.10 J
1.13 D
1.16 K
1.19 L
Page 10 of 115
1.22 G
1.25 M
1.28 N
1.31 E
1.34 O
1.37 P
Spacer 0.75-0.82 -
(For adjustment of backlash between differential side gear and
0.83-0.92 -
pinion)
0.93-1.00 -
1.01-1.08 -
1.09-1.16 -
LUBRICATIONS (AUTO:F4A42)
Items Specified lubricant Quantity
Transaxle fluid lit. (U.S. GENUINE DIAMOND 7.8 (8.2,6.9)
qts, Imp,qts.) ATF SP-III
SEALANTS
Items Specified sealant
Rear cover Genuine sealant FMD546, TB1281B
or equivalant
Torque converter housing Genuine sealant FMD546, TB1281B
or equivalant
Valve body cover Genuine sealant FMD546, TB1281B
or equivalant
SPECIFICATIONS
Page 11 of 115
Model M5GF1 M5GF1-1
Type Forward 5 speed, reverse
1 speed
2.4 DOHC 2.7 DOHC
Gear ratio First 3.455 3.231
Second 1.947 ←
Third 1.296 ←
Fourth 0.943 ←
Fifth 0.775 0.775
Reverse 3.455 ←
Final gear ratio 3.882 4.063
SERVICE STANDARD
Standard value mm (in.)
Differential side bearing end play 0.05T-0.10T (0.0019T-0.0039T)
Gear backlash in differential 0.025L-0.150L (0.00095L-0.0057L)
Input front bearing snap ring end play 0.01L-0.12L(0.00038L-0.0045L)
Input rear bearing snap ring end play 0.01L-0.12L(0.00038L-0.0045L)
Output front bearing snap ring end
0.01L-0.12L(0.00038L-0.0045L)
play
Output rear bearing snap ring end play 0.01L-0.09L(0.00038L-0.00342L)
5TH input gear snap ring end play 0.01L-0.05L(0.00038L-0.0019L)
3RD output gear snap ring end play 0.01L-0.05L(0.00038L-0.0019L)
TIGHTENING TORQUE
Standard value N·m kg·cm lb·ft
Release bearing sleeve bolt 5-8 50-80 4-6
Release fork shaft level nut 27-40 270-400 20-29
Select lever 20-27 200-270 15-20
Oil drain plug 30-35 300-350 22-26
Poppet ball 35-42 350-420 26-31
Clutch housing to
35-42 350-420 26-31
transmission case
Speedometer driven gear 4-6 40-60 3-4
Reverse idler bolt 43-55 430-550 32-40
Side cover bolt 10-12 100-120 7-8
Shift control cable bracket 20-27 200-270 15-20
Cylinder and hose assembly 15-22 150-220 11-16
Page 12 of 115
Shift lever bracket 9-14 90-140 7-10
Front roll stopper bracket to
60-80 600-800 43-58
subframe bolts
Front roll stopper insulator
50-65 500-650 36-47
bolt and nut
Front roll stopper bracket to
60-80 600-800 43-58
transaxle bolts
Rear roll stopper bracket to
50-65 500-650 36-47
subframe bolts
Rear roll stopper insulator
50-65 500-650 36-47
bolt and nut
Rear roll stopper bracket to
60-80 600-800 43-58
transaxle bolts
Transaxle mounting sub
60-80 600-800 43-58
bracket nut
Transaxle mounting bracket
60-80 600-800 43-58
bolts
Transaxle mounting insulator
90-110 900-1100 65-80
bolt
Front bearing retainer &
15-22 150-220 10-16
detent body cover bolt
loosening if under-tightened. In either case, serious personal injury or death could result to vehicle occupants.
LUBRICATIONS
Item Recommended sealants and adhesives Quantity
Transaxle gear oil lit. (U.S. qts. Imp.qts) SAE 75W/90 TGO-6 2.1 (2.2, 1.8)
Transaxle input shaft spline CASMOLY L9508 As required
RETINAX AM, MOLYTEX GREASE
Transaxle oil seal lip As required
EP-2
Transaxle case and clutch housing alignment
THREE BOND 1216 As required
surface
Transaxle case and rear cover alignment
THREE BOND 1216 As required
surface
Bearing retain bolt (flush bolt only) THREE BOND 1303 As required
Automatic Transaxle System > Automatic Transaxle System > Flow Diagram
AUTOMATIC TRANSAXLE HYDRAULIC CIRCUIT
Page 13 of 115
PARKING & NEUTRAL
FIRST
Page 14 of 115
SECOND
Page 15 of 115
THIRD
Page 16 of 115
FOURTH
Page 17 of 115
REVERSE
Page 18 of 115
Automatic Transaxle System > Automatic Transaxle System > Description and Operation
ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER
Page 19 of 115
Operating Element and Their Functions

Operating element Code Function
Underdrive clutch UD Connects input shaft and underdrive sun gear
Reverse clutch REV Connects input shaft and reverse sun gear
Overdrive clutch OD Connects input shaft and overdrive planetary carrier
Low-and-reverse brake LR Locks low-and-reverse annulus gear and overdrive
planetary carrier
Second brake 2ND Locks reverse sun gear
Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Components and
Components Location
SECTION VIEW
Page 20 of 115
COMPONENTS
Page 21 of 115
Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Repair
procedures
REMOVAL
1. Remove the drain plug and drain the automatic transaxle fluid.
Page 22 of 115
2. Remove the air cleaner assembly.
3. Remove the control cable.

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

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

12. Remove the automatic transaxle mounting bolts.
13. Remove the engine to automatic transaxle bolts.
Page 23 of 115
14. Remove the automatic transaxle assembly by jack.
1. Engine and transmission mounting insulators should be installed by the specified torque.
2. Mounting bracket installation procedures.
1) Engine mounting bracket.
2) T/M mounting bracket.
3) Rear roll stopper mounting bracket.
4) Front roll stopper mounting bracket.
3. Especially, when installing front roll stopper mounting bracket, be careful not to be crushed the
insulator, If being crushed, idle vibration is high.
INSTALLATION
1. Attach the torque converter on the transaxle side and mount the transaxle assembly onto the engine.
If the torque converter is mounted first on the engine, the oil seal on the transaxle side may be damaged.
Therefore, besure to first assemble the torque converter to the transaxle.
2. Install the transaxle control cable and adjust as follows.

(1) Move the shift lever and the transaxle range switch to the "N" position, and install the control cale.
(2) When connecting the control cable to the transaxle mounting bracket, instal the clip until it contacts the
control cable.
(3) Remove any free-play in the control cable by adjusting nut and then check to see that the selector lever
moves smoothly.
(4) Check to see that the control cable has been adjusted correctly.
3. Installation is the reverse of removal.
DISASSEMBLY
Page 24 of 115
1. Because the automatic transmission is manufactured from highprecision parts, sufficient care must be taken not
to scratch or damage these parts during disassembly and reassembly.
2. The working area should be convered with a rubber mat to keep it clean at all times.
3. Do not wear any cloth gloves and do not use any rags during disassembly. Use nylon cloth or paper towels if
you need to use something.
4. Parts which have been disassembled should all be cleaned. Metal parts can be cleaned with normal detergent
but they should be dried completely using compressed air.
5. Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF) so
that they do not become dirty.
6. If the transmission body has been damaged, disassemble and clean the cooler system also.
1. Remove the torque converter and set aside.
2. Measure the input shaft end play.
3. Remove the left and right roll stopper brackets.

4. Remove the wiring harness bracket.
5. Remove the control cable support bracket.
6. Remove the dipstick.
7. Remove the oil cooler feed tube, gasket, and eye bolt.
8. Remove the input shaft speed sensor and the output shaft speed sensor.
9. Remove the manual control lever, then remove the transaxle range switch.
Page 25 of 115
10. Remove the vehicle speed sensor.
11. Remove the valve body cover.
12. Remove the manual control shaft detent.
13. Disconnect the harness connectors of the valve body.
To prevent damage to transaxle components make sure that the manual control lever and the park/neutral
switch have been removed before attempting to remove the valve body.
The valve body mounting bolts are different lengths. Note the locations of the bolts to aid in assembly.
14. Remove 28 of the valve body mounting bolts. Do not remove the bolts shown in the illustration at this time.
15. Remove the oil temperature sensor.

Page 26 of 115
16. Remove the valve body, gasket, and the 2 steel balls.
Make sure not to lose the 2 steel balls.
17. Remove the solenoid valve wiring harness snap ring.

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

20. Remove the second brake retainer oil seal.
The second brake retainer oil seal must be removed before removing the transaxle powertrain
components from the case or damage to the seal will occur.
Page 27 of 115
21. Remove the 4 accumulator pistons, the 4 large springs, and the 3 small springs.
Number Functional Name
1 Low-Reverse Brake
2 Underdrive Clutch
3 Second Brake
4 Overdrive Clutch
22. Remove the manual control lever shaft pin (roller).

23. Remove the manual control lever shaft.
24. Remove the parking pawl rod.
25. Remove the torque converter housing and 18 mounting bolts. Tap the housing off with a non-metallic hammer.
26. Remove the 2 O-rings from the case.
27. Remove the differential.

Page 28 of 115
28. Remove the main oil filter.
29. Remove oil pump mounting bolts.
The oil pump is not serviceable, it must be replaced as a pump assembly. Do not disassemble the pump
as improper alignment during assembly will cause pump failure and could cause damage to the transaxle.
30. Install the special tool (09452-33100), as shown in the illustration.
31. Remove the oil pump by turning special tool screws clockwise.
32. Remove the oil pump gasket.
33. Remove thrust bearing #1.
34. Grasp the input shaft, then pull out the underdrive clutch and input shaft as an assembly.
Page 29 of 115
36. Remove the underdrive clutch hub.
37. Remove the rear cover and mounting bolts.
38. Remove the thrust race #8.

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

Page 30 of 115
44. Remove the overdrive clutch hub.

46. Remove the planetary reverse sun gear.
47. Remove the second brake piston snap ring.
48. Remove the second brake piston and return spring.
49. Remove the second brake pressure plate, 3 brake discs, and 2 brake plates.
Page 31 of 115
50. Remove the overdrive planetary carrier.
52. Remove the output planetary carrier.

53. Remove the underdrive sun gear.
55. Remove the low/reverse reaction plate snap ring.
56. Remove the low/reverse reaction plate and brake disc.

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57. Remove the low/reverse brake snap ring.
58. Remove the low/reverse 6 brake discs, 5 brake plates, and brake pressure plate.
59. Remove the wave spring.
60. Remove the parking pawl shaft.

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

65. Remove the parking roller support.
Page 33 of 115
66. Remove the snap ring.
67. Remove the spring retainer.

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

Page 34 of 115
74. Remove the output shaft lock nut.
75. Remove the output shaft bearing retainer mounting bolts.
76. Tap out the output shaft, tapered roller bearing, and the collar from the back side.
77. Tap out the bearing outer race and spacer using a suitable driver.

79. Remove the differential bearing outer race and spacer from the torque converter housing.
80. Remove the differential bearing outer race from the transaxle case.
REASSEMBLY
• Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling.
• Never use grease other than blue petrolatum jelly and white Vaseline.
• Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch
disc or brake disc in ATF for at least two hours before assembling them.
• Never apply sealant or adhesive to gaskets.
• When replacing a bushing, replace the assembly which it belongs to.
• Never use any cloth gloves or any rags during reassembly.
Use nylon cloth or paper towels if you need to use something. Change the oil in the cooler system.
Page 35 of 115
1. Tap the differential bearing outer race into the transaxle case using special tools tools (09500-11000 and 09532-
11500).
2. Tap the output shaft bearing outer race into the transaxle case using special tool (09500-11000).
3. Install the spacer and the snap ring.

4. Install the low-reverse brake piston, return spring, and spring retainer.
5. Install the snap ring using special tools (09453-21000). To be sure that you have the correct snap ring, measure
the thickness and compare it to the chart in the service manual.
6. Install the wave spring.
In steps 7 through 9, you will determine the actual clearance between the low-reverse brake discs and
plates when the clutch is released.
7. Replace the pressure plate of the low-reverse brake, then install the brake discs, 5 brake plates and the snap
ring.
Page 36 of 115
8. Install the low and reverse reaction plate and the old snap ring.
9. With a dial indicator installed, move the special tool up and down to measure the end play.
Standard Value:0-0.16 mm (0-0.0063in.)
If the end play is incorrect, measure the old snap rig, then select the proper snap rig from the chart shown in the
service manual and recheck the clearance.
10. Remove the special tool.
In steps 11 through 16, you will determine the actual clearance between the second brake discs and
11. Install the 3 second brake discs and 2 plates.
12. Install the second brake return spring, second brake piston, and snap ring.
13. Install a dial indicator as shown in the illustration.
14. Move up and down, while observing the end play.
15. To determine the proper thickness of the second brake pressure plate.
Standard Value:0.79-4.25 mm (0.0311-0.0492 in.)
16. If the standard value is incorrect, select a pressure plate of the proper thickness from the chart in the service
manual and recheck the clearance.
In steps 18 through 21, you will determine the actual clearance between the low-reverse brake discs and
17. Install the special tool in place of the low/reverse brake pressure plate.
Page 37 of 115
18. Install the 6 brake discs, 5 brake plates and snap ring.
19. Turn the transaxle upside down, install a dial indicator, as shown in the illustration.
20. Move the special tool up and down while observing the end play.
21. To determine the proper thickness of the low/reverse brake pressure plate.
22. If the standard value is incorrect, select a pressure plate of the proper thickness from the chart in the service
manual and recheck the clearance.
24. Install the output shaft.
25. Install the output bearing retainer mounting bolts. Tighten the bolts to 23 Nm (17 lbs·ft) of torque.
26. Install the output shaft collar and tapered roller bearing using special tool (09455-33200).
The output shaft lock nut is left-hand thread.
27. Apply ATF and install the old lock nut and tighten to 167 Nm (123 lb·ft). Loosen the nut 1 full turn, then re-
tighten tospecifications. Do not stake the lock nut unless instructed to do so by the instructor.
28. Install a dial indicator as shown in the illustration.

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29. Move the output shaft in and out to measure the end lay.
30. If the standard value is incorrect, use this formula to select the correct spacer from the chart in the service
manual.
31. Install the output shaft protective cap.
32. Install the transfer drive gear using special tool (09500-11000).
33. Install the 7 transfer gear mounting bolts. Tighten the bolts to 19 Nm(14 lbs·ft).
34. Install the parking pawl, spacer and spring, then install the parking pawl shaft.
35. Install the parking roller support, then the two parking roller support shafts.
Be sure to install the thrust bearing in the proper direction.

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36. Install the underdrive sun gear and thrust bearing #3 to the output planetary carrier.
37. Install the output planetary carrier and thrust bearing #4.
38. Install the overdrive planetary carrier.
Rotating the output shaft will help align the clutch teeth and help the carrier
seat.
39. Install the reverse planetary sun gear.
40. Install the wave spring.

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41. Install the pressure plate, 6 brake discs, and 5 brake plates.
42. Install the snap ring.
43. Install the reaction plate.
45. Install the pressure plate, 3 brake discs, and 2 brake plates.
46. Install the return spring and second brake piston.

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Be sure to install the thrust bearing in the proper

direction.
48. Install thrust bearing #5.

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

54. Using a dial indicator, measure the end play of the underdrive sun gear.
Standard Value:0.25-0.45 mm (0.0098-0.0177 in)
55. If the end play exceeds the standard value, measure the used race with a micrometer and select the proper size
from the chart in the service manual.
56. Reinstall the rear cover and mounting bolts. Tighten the mounting bolts to 23 Nm (17 lbs·ft).
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57. Install the underdrive clutch hub.

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

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

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

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

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

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

TROUBLESHOOTING
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BASIC INSPECTION ITEM ADJUSTMENT (AUTOMATIC TRANSMISSION FLUID CHECK)

1. Drive the vehicle until the fluid temperature rises to the normal temperature (70-80°C).
2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, and
then move the selector lever to the N position.
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4. After wiping off any dirt around the oil level gauge, remove the oil level gauge and check the condition of the fluid.
If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from the
bushesand friction materials, a transmission overhaul may be necessary.
5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is lower than this, pour in
more fluid until the level reaches the HOT mark.
Automatic transmission fluid : GENUINE DIAMOND ATF SP-III
If the fluid level is low, the oil pump will draw in air along with the fluid, which will cause bubbles to form
inside the hydraulic circuit. This will in turn cause the hydraulic pressure to drop, which will result in late
shifting and slipping of the clutches and brakes.
If there is too much fluid, the gears can churn it up into foam and cause the same conditions that can occur
with low fluid levels.
In either case, air bubbles can cause overheating and oxidation of the fluid which can interfere with normal
valve, clutch, and brake operation. Foaming can also result in fluid escaping from the transmission vent, in
which case it may be mistaken for a leak.
6. Securely insert the oil level gauge.
7. The fluid and the oil filters should always be replaced when overhauling the transmission or after the vehicle has
been driven under severe conditions.
The replacement procedures are given below.
Furthermore, the oil filters are special filters which are only to be used for the automatic transmission.
AUTOMATIC TRANSMISSION FLUID (REPLACEMENT)
If you have a fluid changer, use this changer to replace the fluid. If you do not have a fluid changer, replace the fluid
by the following procedure.
1. Disconnect the hose which connects the transmission and the oil cooler (inside the radiator).
2. Start the engine and let the fluid drain out.
Running conditions : N range with engine idling.
The engine should be stopped within one minute after it is started. If the fluid has all drained out before
then, the engine should be stopped at that point.
3. Remove the drain plug from the bottom of the transmission case to drain the fluid.
4. Replace the oil filters.
5. Install the drain plug via the gasket, and tighten it the specified torque.
Tightening torque : 32 Nm (24 lb·ft)

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6. Pour the new fluid in through the oil filler tube.
Stop pouring if the full volume of fluid cannot be poured

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

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

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

Trouble symptom Probable cause
All hydraulic pressures are high Incorrect transmission control cable adjustment
Malfunction of the regulator valve
All hydraulic presures are low Incorrect transmission control cable adjustment
Malfunction of the oil pump
Clogged internal oil filter
Clogged external oil filter
Clogged oil cooler
Malfunction of the relief valve
Incorrect valve body installation
Hydraulic pressure is abnormal in "R" range only Malfunction of the regulator valve
Clogged orifice
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Hydraulic pressure is abnormal in "3" or "4" range only Malfunction of the regulator valve
Clogged orifice
Malfunction of the overdrive solenoid valve
Malfunction of the overdrive pressure control valve
Malfunction of the switch valve
Clogged orifice
Only underdrive hydraulic pressure is abnormal Malfunction of the oil seal K
Malfunction of the oil seal L
Malfunction of the oil seal M
Malfunction of the underdrive solenoid valve
Malfunction of the underdrive pressure control valve
Malfunction of check ball
Clogged orifice
Only reverse clutch hydraulic pressure is abnormal Malfunction of the oil seal A
Malfunction of the oil seal B
Malfunction of the oil seal C
Clogged orifice
Only low and reverse hydraulic pressure is abnormal Malfunction of the oil seal D
Malfunction of the oil seal E
Malfunction of the oil seal F
Malfunction of the overdrive solenoid valve
Malfunction of the overdrive pressure control valve
Malfunction check ball
Clogged orifice
Only second hydraulic pressure is abnormal Malfunction of the oil seal I
Malfunction of the oil seal J
Malfunction of the low and reverse solenoid valve
Malfunction of the low and reverse pressure control
valve
Malfunction of the switch valve
Malfunction of the fail safe valve A
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Clogged orifice
Only torque converter presure is abnormal Pressure Malfunction of the oil seal G
applied to non operating element
Malfunction of the oil seal H
Malfunction of the oil seal O
Malfunction of the second solenoid valve
Malfunction of the second pressure control valve
Malfunction of the fail safe valve B
Clogged orifice
Only torque converter presure is abnormal Malfunction of the oil cooler
Malfunction of the oil seal N
Malfunction of the damper clutch control solenoid valve
Malfunction of the damper clutch control valve
Malfunction of the torque converter pressure control
valve
Clogged orifice
Pressure applied to non operating element Incorrect valve body installation
Incorrect transmission control cable adjustment
Malfunction of the manual valve
DIAGNOSIS FUNCTION
1. Connect HI-SCAN to the connector for diagnosis.
2. Read the output diagnostic trouble codes. Then follow the remedy procedures according to the "DIAGNOSTIC
TRUBLE CODE DESCRIPTION" on the following page.
• As many a maximum of 8 diagnostic trouble codes (in the sequence of occurrence) can be stored in the
Random Access Memory (RAM) incorporated within the control moduel.
• The same diagnostic trouble code can be stored as many as one time.
• If the number of stored diagnostic trouble codes or diagnostic trouble patterns exceeds 8, already
stored diagnostic trouble codes will be erased, in sequence beginning with the oldest.
• Do not disconnect the battery until all diagnostic trouble codes or diagnostic trouble patterns have been
read out, because all stored diagnostic trouble codes or diagnostic trouble patterns will be canceled
when the battery is disconnected.
3. If the fail-safe system is activated and the transaxle is locked in third gear, the diagnostic trouble code in the fail-
safe code description will be stored in the RAM.
Three of these diagnostic trouble codes can be stored.
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4. The cancelation will occur if, with the transaxle locked in third gear, the ignition key is turned to the OFF position,
but the diagnostic trouble code is stored in the RAM.
5. Memorization
A. Up to 8 diagnosis items and 3 fail-safe items can be memorized.
B. If the memory capacity is exceeded, diagnosis and fail-safe items in the memory are overwritten, starting with
the oldest.
C. No code can be memorized more than once.
6. Diagnosis Code Deletion.
A. Automatic Deletion
All diagnosis codes are deleted from memory the 200th time the ATF temperature reaches 50°C after
memorization of the most recent diagnosis code.
B. Forced Deletion
Memorized diagnosis codes can be deleted using the SCAN-TOOL provided the following conditions are
satisfied :
• The i00gnition switch is ON;
• There is no detection pulse from the crank angle sensor
• There is no detection pulse from the output shaft speed sensor
• There is no detection pulse from the vehicle speed sensor
• The fail-safe function is not operational
ROAD TEST
No. Condition Operation Judgement:Value Check item
Ignition switch
1 Ignition switch: OFF Battery voltage (mV) Control relay
(1) ON
Selector lever position
(1) P, (2) R, (3) N,
(1) P, (2) R,
(4) D, (5) 3, (6) 2, Transaxle range switch
(2) N, (4) D
(7) L
(3) 3, (6) 2, (7) L
Ignition switch: ON
Accelerator pedal (1) 400-1,000 mV
Engine: Stopped
2 (1) Released (2) Gradually rises from
Select lever Throttle position sensor
(2) Half depressed (1)
position:P
(3) Depressed (3) 4,500-5,000mV
Brake pedal
(1) ON
(1) Depressed Stop lamp switch
(2) OFF
(2) Released
Ignition switch:ST Starting test with lever P or Starting should be Starting possible or
3
Engine: Stopped N range possible impossible
Drive for 15 minutes or
more so that the automatic Gradually rises to 70-
4 Warming up Oil temperature sensor
fluid temperature becomes 90°C
70-90°C
A C switch
(1) ON
(1) ON Triple pressure switch
(2) OFF
(2) OFF
(1) ON
Idle position switch
(2) OFF
Accelerator pedal
Engine: Idling
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Accelerator pedal (1) 600-925 rpm
Engine: Idling
(1) Released (2) Gradually rises from
5 Selector lever
(2) Half depressed (1)
position:N
Communication with
(1) Data changes
engine-ECU
Should be no abnormal
Selector lever position
shifting shocks
(1) N→D Malfunction when starting
Time lag should be with
(2) N→R
in 2 seconds
(2) 1st, (4) 3rd, (3) 2nd,
Shift condition
(5) 5th
Slector lever position and
vehicle speed (2) 0 , (4) 100 , (3) Low and reverse solenoid
1. Idling in 1st gear 100 , (5) 100 valve
(Vehicle stopped) (2) 0 , (4) 0 , (3) 0
2. Driving at constant Underdrive solenoid valve
, (5) 100
speed of 20km h in
(2) 100 , (4) 100 ,
1st gear Second solenoid valve
(3) 0 , (5) 0
3. Driving at constant
Selector lever (2) 100 , (4) 0 , (3)
speed of 30km h in Overdrive solenoid valve
position:N (Carry out 100 , (5) 0
6 2nd gear
on a flat and straight
road) 4. Driving at 50km h in (1) 0km h
Vehicle speed sensor
3rd gear with (4) 50km h
accelerator fully closed
(4) 1,800-2,100 rpm
5. Driving at constant
speed of 50km h in (4) 1,800-2,100 rpm Input shaft speed sensor
4th gear (Each (3) 0
condition should be (5) Approx. 70-90°C Output shaft speed sensor
maintained for 10 Damper clutch control
seconds or more) (3) Approx. 100-
300rpm solenoid valve
(5) Approx. 0-10rpm
1. Accelerate to 4th gear
at a throttle position Malfunction when sifting
sensor output of
1.5V(accelerator
opening angle of 30 ) Displaced shift points
2. Gently decelerate to a For (1), (2) and (3), the
standstill reading should be the
3. Accelerate to 4th gear same as the specified Does not shift
at a throttle position output shaft torque, and
Selector lever
sensor output of no abnormal shocks
position: D
7 2.5V(accelerator should occur. Does not shift from 1 to 2
(Carry out on a flat
opening angle of 50 ) For (4), (5) and (6), or 2 to 1
and straight road)
4. While driving at 60km downshifting should
h in 4th gear, shift occur immediately after
down to 3rd gear the shifting operation is
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h in 4th gear, shift occur immediately after
down to 3rd gear the shifting operation is Does not shift from 2 to 3
5. While driving at 40km made. or 2 to 3
h in 3rd gear, shift
sown to 2nd gear
6. While driving at 20km Does not shift from 3 to 4
h in 2nd gear, shift or 4 to 3
down to 1st gear
The ratio between input
Selector lever
Move selector lever to R and output speed sensor
position:N (Carry out
8 range drive at contant data should be the same Does not shift
on a flat and
speed of 10km h as the gear ratio when
straightroad).
reversing.
MIL REQUEST ITEM AND DIAGNOSIS CODE

DTC *1
DTC FAIL
No. FAIL CAUSE DTC REMARK
MIL *2 SAFE
*1
OIL OPEN OR +B SHORT O 0713 -
1 0710
TEMPERATURESENSOR GND SHORT O 0712 -
OPEN OR SHORT
2 INPUT SPEED (PG A) 0715 O 0715 O
(GND, +B)
OPEN OR SHORT
3 OUTPUT SPEED (PG B) 0720 O 0720 O
(GND, +B)
4 BRAKE SW OPEN OR +B SHORT - - 0703 -
5 LR (DIR) SOLENOID OPEN OR GND SHORT 0750 O 0750 O
6 UD SOLENOID OPEN OR GND SHORT 0755 O 0755 O
7 2ND SOLENOID OPEN OR GND SHORT 0760 O 0760 O
8 OD SOLENOID OPEN OR GND SHORT 0765 O 0765 O
9 DCC SOLENOID OPEN OR GND SHORT 0740 O 0743 O
OPEN OR GND SHORT O 0707 -
10 INHIBITOR SW +B SHORT OR SHORT 0705
O 0708 -
OF SWITCHS
0750
11 1st Control System abnormal 1st O 0731 O
0755
0755
12 2nd Control System abnormal 2nd O 0732 O
0760
0755
13 3rd Control System abnormal 3rd O 0733 O
0765
0760
14 4th Control System abnormal 4th O 0734 O
0765
15 Reverse Control System abnormal Reverse 0750 O 0736 O
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abnormal SYSTEM
16 DAMPER CLUTCH 0740 O 0740 -
OR STUCK ON
17 A/T CONTROL RELAY OPEN OR GND SHORT 1723 O 1723 O
TCU FAIL OR TCU
18 CAN-BUS OFF - *3- 1630 -
SIDE OPEN/SHORT
ECU FAIL OR ECU
19 CAN-TIME OUT ECU - O 1613 -
SIDE OPEN/SHORT
TCU CAN MI- CAN MI-
20 - *3- 1764 -
COMMALFUNCTION COMMALFUNCTION
OPEN OR SHORT
21 Vehicle Speed Sensor 0500 O 0500 -
(GND, +B)
*1) : TCU transfers only the DTCs related OBD-II to GST through TEST MODE 03.
*2) : TCU transfers all stored DTCs through TEST MODE 13.
*3) : When the CAN communication line is error, CAN ECU illuminates CHECK ENG LAMP.
DIAGNOSTIC TROUBLE CODE DESCRIPTION
DTC No. Diagnosis item Probable cause
Oil temperature sensor output > 4.57 V for
P0713 Open circuit 1 second or longer (oil temperature does not
Oil temperature sensor increase)
P0712 Short circuit Output < 0.49V for 1 second
No input speed sensor output pulse detected
Short circuit open
P0715 Input speed sensor for > 1 second at vehicle speed of > 30
circuit
km/h
At vehicle speed of > 30 km/h, output speed
Short circuit open
P0720 Output speed sensor sensor output < 50% of vehicle speed
circuit
sensor output for > 1 second
Short circuit open At vehicle speed of 6 km h, stop lamp
P0703 Stop lamp switch
circuit switch is ON continuously for 5 minutes
Short circuit open
P0750 LR solenoid valve
circuit
Short circuit open
P0755 UD solenoid valve
circuit
Short circuit open With relay voltage > 10V, open or short
P0760 2nd solenoid valve
circuit circuit is continuously for 0.3 seconds.
Short circuit open
P0765 OD solenoid valve
circuit
Short circuit open
P0743 DCC solenoid valve
circuit
P0731 1st
P0732 2nd After gear shift, output shaft speed sensor
P0733 Gear shift incomplete 3rd output x gear ratio of new gear ≠ input shaft
speed sensor output
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speed sensor output
P0734 4th
P0736 Reverse
System defect DCC solenoid valve drive duty ratio is
P0740 DCC
stuck on 100% for 4 seconds continuously
Earth short circuit After ignition ON, A T control relay
P1723 A/T control relay
open circuit voltage < 7V
P0707 Open circuit No signal is continuous for > 30 seconds
Transaxle range switch
(Inhibitor switch) Above 2 kinds signals are continuous for 30
P0708 Short circuit
seconds
TCM Fail open Receive BUS-OFF information from CAN
P1630 CAN-BUS OFF
short CONTROLLER
ECM Fail open
P1631 CAN-TIME OUT ECU No output signal for 1.5 second
short
CAN CONTROLLER TCU internal circuit Communication error output is continuously
P1764
CIRCUIT mal-function for > 1 second
At vehicle speed of ≥ 30km h, No output
P0500 Vehicle speed sensor Open short
signal for 30 second
INSPECTION CHART FOR DIAGNOSIS CODES

Code Diagnosis item Probable cause
P0713 Oil temperature sensor system Open circuit Malfunction of the oil
P0712 If the oil temperature sensor output voltage is temperature sensor
4.57 V or more even after driving for 10 Malfunction of connector
minutes or more (if the oil temperature does Malfunction of the TCM
not increase), it is judged that there is an
open circuit in the oil temperature sensor and
diagnosis codeP0713 is output.
P0715 Input shaft speed sensor system Short circuit / Open Malfunction of the input shaft
If no output pulse is detected from the input circuit speed sensor
shaft speed sensor for 1 second or more Malfunction of the underdrive
while driving in 3rd or 4th gear at a speed of clutch retainer
30 km/h or more, there is judged to be an Malfunction of connector
open circuit or short. Circuit in the input shaft Malfunction of the TCM
speed sensor and diagnosis code P0715 is
output. If diagnosis code P0715 is output
four times, the transmission is locked into
3rd gear(D range or 3-range) or 2nd gear
(2-range or L-range) as a fail-safe measure,
and the N range lamp flashes at a frequency
of 1 Hz.
P0720 Output shaft speed sensor system Short circuit /Open Malfunction of the wide open
If the output from the output shaft speed circuit throttle switch
sensor is continuously 50% lower than the Malfunction of connector
vehicle speed for 1 second or more while Malfunction of the TCM
driving in 3rd or 4th gear at a speed of 30 Malfunction of solenoid valve
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km/h or more, there is judged to be an open Malfunction of connector
circuit or short-circuit inthe output shaft Malfunction of the TCM
speed sensor and diagnosis code P0720 is
output. If diagnosis code P0720 is output
four times, the transmission is locked into
3rd gear (D range or 3-range) or 2nd gear
(2-range or L-range) as a fail-safe measure,
and the Nrange lamp flashes at a frequency
of 1 Hz.
P1703 Stop lamp switch system Short circuit / Open Malfunction of the stop lamp
If the stop lamp switch is on for 5 minutes or circuit switch
more while driving, it is judged that there is a Malfunction of connector
short circuit in the stop lamp switch and Malfunction of the TCM
diagnosis code P0703 is output.
Short circuit /Open Malfunction of solenoid valve
P0750 Low and reverse solenoid valve system
circuit Malfunction of connector
Malfunction of the TCM
Short circuit /Open
P0755 Underdrive solenoid valve system
circuit
Short circuit /Open
P0760 Second solenoid valve system
circuit
P0765 Overdrive solenoid valve system Short circuit /Open
If the resistance value for a solenoid valve is circuit
tool large or too small, it is judged that there
is a short-circuit or an open circuit in the
solenoid valve and the respective diagnosis
code is output. The transmission is locked
into 3rd gear as a fail-safe measure, and the
N range lamp flashes at a frequency of 1 Hz.
P0743 Damper clutch solenoid valve system Short circuit/ Open Malfunction of the damper clutch
circuit control solenoid valve
Malfunction of connector
P0740 Damper clutch solenoid valve system Defective system
If the resistance value for the damper clutch
control solenoid valve is too small, it is
judged that there is a short circuit or an open
circuit in the damper clutch control solenoid
valve and diagnosis code P0743 in output.
If the drive duty rate for the damper clutch
control solenoid valve is 100% for a
continuous period of 4 seconds or more, it is
judged that there is an abnormality in the
damper clutch control system and diagnosis
code P0740 is output. Whendiagnosis code
P0743 is output, the transmission is locked
into 3rd gear as a fail-safe measure, and the
N range lamp flashes at a frequency of 1 Hz.
P0731 1st gear ratio does not meet the specification Malfunction of the input shaft
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If the output from the output shaft speed sensor multiplied by the 1st speed sensor
gear ratio is not the same as the output from theinput shaft speed Malfunction of the output shaft
sensor after shifting to 1st gear has been completed, diagnosis code speed sensor
P0731 is output. If diagnosis codeP0731 is output four times, the Malfunction of the underdrive
transmission is locked into 3rd gear as a fail-safe measure, and the clutch retainer
N range lamp flashes at a frequency of 1 Hz. Malfunction of the transfer drive
gear or driven gear
Malfunction of the low ad
reverse brake system
Malfunction of the underdrive
clutch system
Noise generated
P0732 2nd gear ratio does not meet the specification Malfunction of the input shaft
If the output from the output shaft speed sensor multiplied by the speed sensor
3rdgear ratio is not the same as the output from the input shaft Malfunction of the output shaft
speed sensorafter shifting to 3rd gear has been completed, diagnosis speed sensor
code P0732 is output. If diagnosis codeP0732 is output four times, Malfunction of the underdrive
the transmission is locked into 3rd gear as a fail-safe measure, and clutch retainer
the N range lamp flashesat a frequency of 1 Hz. Malfunction of the transfer drive
gear or driven gear
clutch system
Malfunction of the overdrive
clutch system
Noise generated
P0733 3rd gear ratio does not meet the specification Malfunction of the input shaft
3rdgear ratio is not the same as the output from the input shaft Malfunction of the output shaft
speed sensor after shifting to 3rd gear has been completed, speed sensor
diagnosis code P0733 is output. If diagnosis code P0733 is output Malfunction of the underdrive
four times, the transmission is locked into3rd gear as a fail-safe clutch retainer
measure, and the N range lamp flashesat a frequency of 1 Hz. Malfunction of the transfer drive
gear or driven gear
clutch system
clutch system
Noise generated
P0734 4th gear ratio does not meet the specification Malfunction of the input shaft
4thgear ratio is not the same as the output from the input shaft speed Malfunction of the output shaft
sensor after shifting to 4th gear has been completed, diagnosis code speed sensor
P0734 is output. If diagnosis code P0734 is output four times, the Malfunction of the underdrive
transmission is locked into3rd gear as a fail-safe measure, and the N clutch retainer
range lamp flashesat a frequency of 1 Hz. Malfunction of the transfer drive
gear or driven gear
Malfunction of the second brake
system
clutch system
Page 64 of 115
Noise generated
P0736 Reverse gear ratio does not meet the specification Malfunction of the input shaft
reverse gear ratio is not the same as the output fromthe input shaft Malfunction of the output shaft
speed sensor after shifting to reverse gear has been completed, speed sensor
diagnosis code P0736 is output. If diagnosis code P0736 is output Malfunction of the underdrive
four times, the transmission is locked into 3rd gear as a fail-safe clutch retainer
measure, and the n range lampflashes at a frequency of 1 Hz. Malfunction of the transfer drive
gear or driven gear
Malfunction of the low and
reverse brake system
Malfunction of the reverse clutch
system
Noise generated
P1723 A/T control relay system Short circuit to Malfunction of the A/T control
If the A/T control relay voltage is less than 7 earth/Open circuit relay
V after the ignition switch has been turned Malfunction of connector
ON, it is judged that there is an open circuit Malfunction of the TCM
or a short-circuit in the A/T control relay
earth and iagnosis code P1723 is output.
Then the transmission is locked into 3rd gar
as a fail-safe measure, and the N range lamp
flashes at a frequency of 1 Hz.
P0707 Transaxle range switch Malfunction of transaxle range
P0708 No signal is continuous for > 30 seconds switch
Above 2 kinds signals are continuous for > 30 second
P1630 CAN-BUS OFF • TCM Fail
• No 3 speed hold fail • TCM side open & short
• No PGA, B fail * PGA : Input shaft speed
• Battry voltage > 10V continuously for 0.5 second sensor
• No engine stop PGB : Output shaft speed
• Receive BUS OFF information from CAN CONTROLLER sensor
P1631 CAN-TIME OUT ECM • ECM fail

• No 3 speed hold fail • ECM side open & short
• No PGA, B fail
• Battry voltage > 10V continuously for 0.5 second
• No engine stop
• No output signal for 1.5 second
P1764 TCM CAN CONTROLLER MALFUNCTION • CAN CONTROLLER circuit
• No 3 speed hold fail malfunction
• No PGA, B fail
• Battry voltage > 10V continuously for 0.5 second
• No engine stop
• Communication error output is continuously for > 1 second
INSPECTION CHART FOR THROUBLE SYMPTOMS

Page 65 of 115
Trouble symptom Probable cause
Communication with HI-SCAN is not possible Malfunction diagnosis line
If communication with the HI-SCAN is not possible, the cause is probably a Malfunction of connector
defective diagnosis line or the TCM is not functioning. Malfunction of the TCM
Driving impossible Starting impossible Malfunction of the engine system
Starting is not possible when the selector lever is in P or Malfunction of the torque
N range. converter
In such cases, the cause is probably a defective engine Malfunction of the oil pump
system, torque converter or oil pump.
Does not move forward Abnormal line pressure
If the vehicle does not move forward when the selector Malfunction of the underdrive
lever is shifted from N to D, 3, 2 or L range while the solenoid valve
engine isidling, the cause is probably abnormal line Malfunction of the underdrive
pressure or a malfunction of the underdrive clutch or clutch
valve body. Malfunction of the valve body
Does not reverse Abnormal reverse clutch
If the vehicle does not reverse when the selector lever is pressure
shifted from N to R range while the engine is idling, the Abnormal low and reverse brake
cause is probably abnormal pressure in the reverse pressure
clutch or low and reverse brake or a malfunction of the Malfunction of the low and
reverse clutch, low and reverse brake or valve body. reverse brake solenoid valve
Malfunction of the reverse clutch
Malfunction of the low and
reverse brake
Malfunction of the valve body
Does not move (forward or reverse) Abnormal line pressure
If the vehicle does not move forward or reverse when Malfunction of power train
the selector lever is shifted to any position while the Malfunction of the oil pump
engine is idling, the cause is probably abnormal line Malfunction of the valve body
pressure or a malfunction of the power train, oil pump or
valve body.
Malfunction when Engine stalling when shifting Malfunction of the engine system
starting If the engine stalls when the selector lever is shifted from Malfunction of the damper clutch
N to D or R range while the engine is idling, the cause is control solenoid valve
probably a malfunction of the engine system, damper Malfunction of the valve body
clutch solenoid valve, valve body or torque converter Malfunction of the torque
(damper clutchmalfunction). converter (Malfunction of the
damper clutch)
Shocks when changing from N to D and large time Abnormal underdrive clutch
lag pressure
If abnormal shocks or a time lag of 2 seconds or more Abnormal low and reverse brake
occur when the selector lever is shifted from N to D pressure
range while the engine is idling, the cause is probably Malfunction of the underdrive
abnormal underdrive clutch pressure or a malfunction of solenoid valve
the underdrive clutch, valve body or idle position switch. Malfunction of the valve body
Malfunction of the idle position
switch
Page 66 of 115
Shocks when changing from N to R and large time Abnormal reverse clutch
lag pressure
If abnormal shocks or a time lag of 2 seconds or more Abnormal low and reverse brake
occur when the selector lever is shifted from N to R pressure
range while the engine is idling, the cause is probably Malfunction of the low and
abnormal reverse clutch pressure or low and reverse reverse solenoid valve
brake pressure, or a malfunction of the reverse clutch, Malfunction of the reverse clutch
low and reverse brake, valve body or idle position Malfunction of the low and
switch. reverse brake
Malfunction of the idle position
switch
Shocks when changing from N to D, N to R and Abnormal line pressure
large time lag Malfunction of the oil pump
If abnormal shocks or a time lag of 2 seconds or more Malfunction of the valve body
occur when the selector lever is shifted from N to D
range and from N to R range while the engine is idling,
the cause is probably abnormal line pressure or a
malfunction of the oil pumpor valve body.
Malfunction when Shocks and running up Abnormal line pressure
shifting If shocks occur when driving due to upshifting or Malfunction of each solenoid
downshifting and the transmission speed becomes higher valve
than the enginespeed, the cause is probably abnormal Malfunction of the oil pump
line pressure or a malfunction of a solenoid valve, oil Malfunction of the valve body
pump, valve body or of a brake or clutch.
Displaced shifting All points Malfunction of the output shaft
points If all shift points are displaced while driving, the cause is speed sensor
probably a malfunction of the output shaft speed sensor, Malfunction of the throttle
TPS or of a solenoid valve. position sensor
Malfunction of each solenoid
valve
Abnormal line pressure
Some points Malfunction of the valve body
If some of the shift points are displaced while driving, the
cause is probably a malfunction of the valve body, or it
is related to control and is not an abnormality.
Does not shift No diagnosis codes Malfunction of the transaxle
If shifting does not occur while driving and no diagnosis range
codes are output, the cause is probably a malfunction of Malfunction of the TCM
the transaxle range switch, or TCM
Malfunction while Poor a acceleration Malfunction of the engine system
driving If acceleration is poor even if downshifting occurs while Malfunction of the brake of
driving, the cause is probably a malfunction of the engine clutch
system or of a brake or clutch.
Vibration Abnormal damper clutch
If vibration occur when driving at constant speed or pressure
when accelerating and deceleration in top range, the Malfunction of the damper clutch
Page 67 of 115
cause is probably abnormal damper clutch pressure or a control solenoid valve
malfunction of the engine system, damper clutch control Malfunction of the torque
solenoid valve, torque converter or valve body. converter
Transaxle range switch system Malfunction of the transaxle
The cause is probably a malfunction of the inhibitor switch circuit, ignition switch range switch
circuit or a defective TCM. Malfunction of the ignition switch
Vehicle speed sensor system Malfunction of the vehicle speed
The cause is probably a defective vehicle speed sensor circuit or a defective sensor
TCM. Malfunction of connector
INSPECTION PROCEDURE 1
Communication with the scan tool Probable cause
If communication with the scan tool is not possible, the Malfunction of diagnostic trouble line
cause is probably a defective diagnostic trouble line or Malfunction of connector
the TCM is not functioning. Malfunction of the TCM
Page 68 of 115
Starting impossible Probable cause
Starting is not possible when the selector lever is in P or Malfunction of the engine system
N range. In such cases, the cause is probably a Malfunction of the torque converter
defective engine system, torque converter or oil pump. Malfunction of the oil pump
Does not move Probable cause
If the vehicle does not move forward when the selector Abnormal line pressure
lever is shifted from N to D,3,2 or L range while the Malfunction of the underdrive solenoid valve
engine is idling, the cause is probably abnormal line Malfunction of the underdrive clutch
pressure or a malfunction of the underdrive clutch or Malfunction of the valve body
valve body.
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Does not reverse Probable cause
If the vehicle does not reverse when the selector lever is Abnormal reverse clutch pressure
shifted from N to R range while the engine is idling, the Abnormal low and reverse brake pressure
cause is probably abnormal pressure in the reverse Malfunction of the low and reverse solenoid valve
clutch or low and reverse brake or a malfunction of the Malfunction of the reverse clutch
reverse clutch, low and reverse brake or valve body. Malfunction of the low and reverse brake
Does not move (forward or reverse) Probable cause
If the vehicle does not move forward or reverse when Abnormal line pressure
the selector lever is shifted to any position while the Malfunction of the underdrive solenoid valve
engine is idling, the cause is probably abnormal line Malfunction of the underdrive clutch
pressure, or a malfunction of the power train, oil pump Malfunction of the valve body
or valve body.
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Engine stalling when shifting Probable cause
If the engine stalls when the selector lever is shifted from Malfunction of the engine system
N to D or R range while the engine is idling, the cause is Malfunction of the damper clutch solenoid
probably a malfunction of the engine system, damper Malfunction of the valve body
clutch solenoid, valve body or torque converter (damper Malfunction of the torque converter
clutch malfunction) (Malfunction of the damper clutch)
Shocks when changing from N to D and range time lag Probable cause
If abnormal shocks or a time lag of 2 second or more Abnormal line pressure
occur when the selector lever is shifted from N to D Malfunction of the underdrive solenoid valve
range while the engine is idling, the cause is probably Malfunction of the underdrive clutch
abnormal underdrive clutch pressure or a malfunction of Malfunction of the valve body
the underdrive clutch,valve body or closed throttle Malfunction of the closed throttle position switch
position switch.
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Shock when changing from N to R and large time lag Probable cause
If abnormal shocks or a time lag of 2 seconds or more Abnormal reverse clutch pressure
occurs when the selector lever is shifted from N to R Abnormal low and reverse brake pressure
range while the engine is idling, the cause is probably Malfunction of the low and reverse solenoid valve
abnormal reverse clutch pressure or low and reverse Malfunction of the reverse clutch
brake pressure, or a malfunction or the reverse clutch, Malfunction of the low and reverse brake
low and reverse brake, valve body or closed throttle Malfunction of the valve body
position switch. Malfunction of the closed throttle position switch
Page 72 of 115
Shocks when changine from N to R and large time lag Probable cause
If abnormal shocks or a time lag of 2 seconds or more Abnormal reverse clutch pressure
occurs when the selector lever is shifted from N to R Abnormal low and reverse brake pressure
range while the engine is idling, the cause is probably Malfunction of the low and reverse solenoid valve
abnormal reverse clutch pressure or low and reverse Malfunction of the reverse clutch
brake pressure, or a malfunction of the reverse clutch, Malfunction of the low and reverse brake
low and reverse brake, valve body or closed throttle Malfunction of the valve body
position switch. Malfunction of the closed throttle position switch
Page 73 of 115
Shocks and running up Probable cause
If shocks occur when driving due to upshifting or Abnormal line pressure
downshifting and the transaxle speed becomes higher Malfunction of each solenoid valve
than the engine speed, the cause is probably abnormal Malfunction of the oil pump
line pressure or a malfunction of a solenoid valve, oil Malfunction of the valve body
pump, valve body or of a brake or clutch. Malfunction of each brake or each clutch
Page 74 of 115
All points (Displaced shifting points) Probable cause
If all shift points are displaced while driving, the cause is Malfunction of the output shaft speed sensor
probably a malfunction of the output shaft speed sensor, Malfunction of the throttle position sensor
TPS or of a solenoid valve. Malfunction of each solenoid valve
Abnormal line pressure
Some points (Displaced shifting points) Probable cause
If some of the shift points are displaced while driving, the Malfunction of the valve body
cause is probably a malfunction of the valve body, or it
is related to control and is not an abnormality.
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No diagnostic trouble codes (Does not shift) Probable cause
If shifting does not occur while driving and no diagnostic Malfunction of the Park/Neutral position switch
trouble codes are output, the cause is probably a Malfunction of the TCM
malfunction of the Park/Neutral position switch, or
TCM.
Poor acceleration Probable cause
If acceleration is poor even if downshifting occurs while Malfunction of the engine system
driving, the cause is probably a malfunction of the engine Malfunction of the brake or clutch
system or of a brake or clutch.
Page 76 of 115
Vibration Probable cause
If vibration occurs when driving at constant speed or Abnormal damper clutch pressure
when accelerating in top range, the cause is probably Malfunction of the engine system
abnormal damper clutch pressure or a malfunction of the Malfunction of the damper clutch solenoid
engine system, damper clutch solenoid, torque converter Malfunction of the torque converter
or valve body. Malfunction of the valve body
SERVICE ADJUSTMENT PROCEDURES

Page 77 of 115
• BRAKE REACTIONPLATE END PLAY ADJUSTMENT
Replace the pressure plate of the low-reverse brake with the special tool, and then install the brake disc, brake
plate and snap ring as shown in the figure.Install the reaction plate and the used snap ring. Move the special tool
to measurethe end play, and then replace the snap ring to adjust the end play to standard value.
Standard value : 0-0.16 mm
• SECOND BRAKE END PLAY ADJUSTMENT

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

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

Page 78 of 115
O.D. I.D. Thickness Symbol O.D. I.D. Thickness Symbol

59 47 1.8 #1 48.9 37 1.6 #8
59 47 2.0 #1 48.9 37 1.7 #8
59 47 2.2 #1 48.9 37 1.8 #8
59 47 2.4 #1 48.9 37 1.9 #8
59 47 2.6 #1 48.9 37 2.0 #8
59 47 2.8 #1 48.9 37 2.1 #8
49 34 3.6 #2 48.9 37 2.2 #8
49 34 3.6 #3 48.9 37 2.3 #8
46 31 3.3 #4 48.9 37 2.4 #8
49 34 3.6 #5 48.9 37 2.5 #8
49 34 3.6 #6 48.9 37 2.6 #8
59 37 2.8 #7 - - - -
Page 79 of 115
• UNDERDRIVE SUN GEAR END PLAY ADJUSTMENT
Install the used thrust race #8, and then the rear cover. Measure end play of the underdrive sun gear. Replace
thrust race #8 to adjust the play to the standard value.
Installing the underdrive clutch hub makes it easy to measure the end play of the underdrive sun gear.
• DIFFERENTIAL CASE PRELOAD ADJUSTMENT

Place a solder (approx. 10 mm in length, 3 mm in diameter) on the torque converter housing as shown in the
figure.
Install the torque converter housing to the transmission case without applying sealant. Tighten its mounting bolts
to the specified torque. Loosen the bolts, and remove the solder. Use a micrometer to measure the thickness (T)
of the pressed solder. Select a-spare which thickness is within the following value.
Standard value : (T 0.045 mm) to (T 0.105 mm)
Automatic Transaxle System > Hydraulic System > Oil Pump > Components and Components Location
COMPONENTS
Page 80 of 115
Automatic Transaxle System > Hydraulic System > Oil Pump > Repair procedures
REASSEMBLY
Oil seal replacement
1. Using the special tool (09452-21200), install the oil seal to the pump housing.
2. Apply a thin coat of automatic transaxle fluid to the lip of the oil seal before installation.
Page 81 of 115
Automatic Transaxle System > Valve Body System > Valve Body > Components and Components
Location
COMPONENTS
INSIDE VALVE BODY

Page 82 of 115
OUTSIDE VALVE BODY

Page 83 of 115
UNDERDRIVE CLUTCH AND INPUT SHAFT

Page 84 of 115
Automatic Transaxle System > Valve Body System > Valve Body > Repair procedures
DISASSEMBLY
1. Remove the input shaft snap ring.
2. Remove the input shaft.
3. Remove the 2 seal rings.
4. Remove the clutch reaction plate snap ring.
Page 85 of 115
5. Remove the clutch reaction plate.
6. Remove the 4 clutch discs and 4 clutch plates.
7. Compress the clutch return springs using special tools, 09453-24000 and 09453-21000 then remove the clutch
spring retainer snap ring.
8. Remove the clutch spring retainer.
9. Remove the D-ring seal.
10. Remove the clutch return spring.
11. Remove the underdrive clutch piston using compressed air.
12. Remove the 2 D-ring seals.
REASSEMBLY
1. Install the 2 D-ring seals.
2. Install the underdrive clutch piston.
3. Install the clutch return spring.
4. Install the D-ring seal.

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

Page 86 of 115
7. Align the spaces between the teeth (A) on the clutch plates, clutch discs, and reaction plate to the outer
circumference hole (B) in the underdrive clutch retainer.
8. Install the 4 clutch discs and the 4 clutch plates.

9. Install the clutch reaction plate with the shear droop toward the clutch disc.
10. Install the clutch reaction plate snap ring.
11. Install special tools, MD998924 and MB991628, as shown, then check the clearance between the snap ring
and the reaction plate using a feeler gauge.
Standard Value : 1.6-1.8 mm
12. If the clearance is correct, measure the old snap ring, then select the correct size from the chart in the service
manual.
13. Install the seal rings.
14. Install the input shaft.
15. Install the input shaft snap ring.
Automatic Transaxle System > Clutch & Brake > Reverse and Overdrive Clutch > Components and
Components Location
COMPONENTS
Page 87 of 115
Automatic Transaxle System > Clutch & Brake > Reverse and Overdrive Clutch > Repair procedures
DISASSEMBLY
Page 88 of 115
1. Remove the overdrive clutch reaction plate snap ring.
2. Remove the overdrive clutch reaction plate.

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

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

5. Install the overdrive clutch piston.
6. Install the clutch return spring.
8. Install the clutch spring retainer.
Page 89 of 115
9. Compress the clutch return springs using special tools, 09453-21000 then install the clutch spring retainer snap
ring.
10. Check the clearance between the snap ring and the return spring retainer
Standard Value : 0-0.09 mm (0-0.0035 in.)
11. If the clearance is incorrect, measure the old snap ring, then select the correct size from the chart in the service
manual.

circumference hole (B) in the reverse clutch retainer.
13. Install the 4 reverse clutch discs and 4 plates.

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

Page 90 of 115
manual.

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

20. Install the overdrive clutch reaction plate.
21. Install the overdrive clutch reaction plate snap ring.
22. Check the clearance between the snap ring and the clutch reaction plate.
manual.
Automatic Transaxle System > Gear System > Input Shaft > Components and Components Location
COMPONENTS
Page 91 of 115
Automatic Transaxle System > Gear System > Input Shaft > Repair procedures
DISASSEMBLY
1. Remove the snap ring and the ball bearing using the special tool (09432-21300).
2. Remove the stopper snap ring, snap ring, 5th and 4th speed gear, needle roller bearing, 4th speed gear sleeve,
synchronizer ring (3rd & 4th), synchronizer spring (1st, 2nd, 3rd, 4th), synchronizer sleeve (3rd & 4th), 3rd
speed gear and needle roller bearing.
INSPECTION (INPUT SHAFT)

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1. Check the outer surface of the input shaft where the needle bearing is mounting for damage or abnormal wear.
2. Check the splines for damage or wear.
SYNCHRONIZER SLEEVE AND HUB

1. Install the synchronizer sleeve on the hub and check that it slides smoothly.
2. Check that the sleeve is free from damage.
3. Check for wear of the hub end surfaces (in contact with each gear).
Replace the synchronizer hub and sleeve as a set.
REASSEMBLY
1. Install the needle roller bearing, 3rd speed gear, synchronizer sleeve (3rd & 4th), synchronizer spring (1st, 2nd,
3rd, 4th), synchronizer ring (3rd & 4th), 4th speed gear sleeve, needle roller bearing, 5th and 4th speed gar, snap
ring and the stopper snap ring using the special tool (09432-33300).
2. Install the snap ring and the ball bearing using special tool (09432-33300).
Automatic Transaxle System > Gear System > Transfer Drive Gear > Components and Components
Location
COMPONENTS
Page 93 of 115
Automatic Transaxle System > Gear System > Transfer Drive Gear > Repair procedures
DISASSEMBLY
1. Loosen the lock nut caulking.
2. Remove the lock by using socket.
REASSEMBLY
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1. Apply ATF to the new lock nut and tighten to the specified torque. And loosen 1 turn and tighten to the specified
torque again.
2. Caulk the lock nut by using punch.
Automatic Transaxle System > Gear System > Output Shaft > Components and Components Location
COMPONENTS
COMPONENTS
Page 95 of 115
Automatic Transaxle System > Gear System > Output Shaft > Repair procedures
REASSEMBLY
Page 96 of 115
1. Remove the transfer driven gear by press.
2. Remove the taper roller bearing.
DISASSEMBLY
1. Remove the taper bearing and the reverse gear using the special tool (03495-33000).
2. Remove the synchronizer ring, synchronizer spring (5th & Rev), sleeve (5th & Rev).
3. Remove the synchronizer hub and the 5th gear using the special tool (03495-33000).
Page 97 of 115
4. Remove the 4th, 3rd, 2nd, 1st gear all together the special tool (09432-33200).
OUTPUT SHAFT (INSPECTION)

1. Check the outer surface of where the needle bearing is mounted for damage or abnormal wear.
2. Check the splines for damage or wear.
NEEDLE BEARING
1. Install the needle bearing on the shaft with the bearing sleeve and gear. Check that it rotates smoothly without
abnormal noise or play.
2. Check the needle bearing cage for distortion.
SYNCHRONIZER RING
1. Check the clutch gear teeth for damage.
2. Check internal surface for damage, wear or broken grooves.
SYNCHRONIZER SLEEVE AND HUB

1. Install the synchronizer sleeve on the hub and check that it slides smoothly.
2. Check that the sleeve is free from damage.
3. Check for wear of the hub end surfaces (in contact with each gear).
Replace the synchronizer hub and sleeve as a set.
GEARS
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1. Check the helical gear and clutch gear teeth for damage or wear.
2. Check the gear cone for rough surfaces, damage or wear.
3. Check the gear bore for damage or wear.
REASSEMBLY
1. Install the needle roller bearing.
2. Install the 1st speed gear.
3. Install the triple cone assembly.
4. Install the synchronizer sleeve and hub.

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5. Install the triple cone assembly.
6. Install the 2nd speed sleeve and the needle roller bearing.
7. Install the 2nd and 3rd speed gear with all together above mentioned using the special tool (09432-22000).
9. Install the 4th speed gear, the 5th speed gear sleeve, the needle roller bearing, the 5th speed gear, the
synchronizer ring (5th), the synchronizer hub and the sleeve (5 & R).
10. Install the needle roller bearing, the reverse gear assembly and the reverse driven gear sleeve.
Page 100 of 115
11. Install the taper bearing with all together above mentioned using the special tool (09432-22000).
Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Repair
procedures
INSPECTION (FOR AUSTRALIA, TAIWAN)
• Check the detent place for wear.
• Check the bushing for wear or damage.
• Check the spring for damage or deterioration.
• Check the pin at the end of the rod assembly for wear.
INSTALLATION
PROCEDURE TO INSTALL THE LOCK CAM
1. Move A/T lever to "P" position to set the key lock cam and the shift lock cam as shown in the figure.
A. Check that the key lock cam is located at "B" by the detent pin.
B. Check that the shift lock cam is located at "A".
2. Check that the key cylinder is at "LOCK".
PROCEDURE FOR ADJUSTING SHIFT LOCK AND KEY LOCK CABLE

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

5. After checking that the portion of the cable end touches the cable fixing pin, fix with the self-tapping bolt.
6. Slightly push the key lock cam to direction "Q".
7. Slightly pull the key lock cable in the direction "G" to stretch the cable. Then fix the cable with the self-tapping
bolt.
8. Check that the key lock and the shift lock cable are secure.
PROCEDURE FOR CHECKING THE SHIFT LOCK
1. When the brake pedal is not depressed, the push button of the shift lever at "P" position must not be operable.
(Shift lever cannot be shifted at the other positions from "P")
2. When the brake pedal stroke is 15-22 mm (with shift lever at "P" postition), the push should be operable without
catching and the shift lever should be shift smoothly to other postitions.
3. When the brake pedal is not depressed, the shift lever should shift smoothly to "P" position from all heading other
positions.
4. The brake pedal must operate smoothly without catching.
5. When the ignition key is at the "LOCK" position, although brake pedal is depressed, the push button should be
operable.
6. The lgnition key must not be able to the turned to the "LOCK" position except in the "P" position.
7. If the shift lever is shifted to the "P" position, the ignition key must turn to the "LOCK" position smoothly.
Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Shift Control >
Components and Components Location
COMPONENT
Page 102 of 115
Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Shift Control >
Repair procedures
REMOVAL
1. Remove the two front console screws.
2. Remove the two rear console screws after moving front seats forward.
3. Remove two seat heater switches on the center panel.
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4. Remove lever panel.
5. Remove the center panel, pulling out the center with hand after loosening two screw panel trim.
6. Remove the 12V power outlet connector pin from the center panel.
7. Remove the console after loosening four screws from the console bracket.
8. Remove the shift lock cable and the key lock cable.
9. Remove the control cable clip and pin from the shift levers.
10. Remove the shift lever mounting bolts and connector.

11. Remove the shift lever assembly.
12. Remove the clip, flange nut from the transaxle sides.
13. Remove the transaxle control cable assembly.
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14. Remove the shift lock cable and the key lock cable.
INSTALLATION
1. Apply a coating of the specified grease to the interior of the adjust bushing.
Specified grease : Chassis grease SAE J310, NLGI No.0
2. Move the shift lever and the transaxle range switch to the "N" position, and install the transaxle control cable.
3. When connecting the control cable to the transaxle mounting bracket, install the clip until it contacts the control
cable, in the position shown in the picture.
4. Install the shift lever assembly and connector.
5. When connecting the control cable to the shift lever mounting bracket, install the clip until it contacts the control
cable.
6. Install the control cable, the key lock cable and the shift cable mounting bolt.
7. Position the console and tighten eight screws.
8. Install the center panel after connecting 12V power outlet pin, then tighten two screws.
9. Install lever panel.

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10. Install two seat heater switches to the center panel.
Automatic Transaxle System > Troubleshooting > P0710

INSPECTION PROCEDURES FOR DIAGNOSTIC TROUBLE CODES
Code No.P0710 Oil temperature sensor system Probable cause
If the oil temperature sensor output voltage is 2.6 V or • Malfunction of the oil temperature sensor
more even after driving for 10 minutes or more (If the oil • Malfunction of connector
temperature does not increase), it is judged that there is • Malfunction of the TCM
an open circuit in the oil temperature sensor and
diagnostic trouble code No.P0710 is output. If the oil
temperature sensor output detects the voltage which
corresponds to 200°C (392°F) or more for more than
one second, it is judged that there is an open circuit in oil
temperature sensor and diagnostic trouble code No.
P0710 is output.

Page 106 of 115
Code No.P0715 input shaft speed sensor system Probable cause
If no output pulse is detected from the input shaft speed Malfunction of the input shaft speed sensor
sensor for 1 second or more while driving in 3rd or 4th Malfunction of the underdrive clutch retainer
gear at a speed of 30 km/h (19 mph) or more, it is Malfunction of connector
judged to be an open circuit or short-circuit in the input Malfunction of the TCM
shaft speed sensor and diagnostic trouble code
No.P0715 is output. If diagnostic trouble code P0715 is
output four times, the transaxle is locked into 3rd gar or
2nd gear as a fail-safe measure

Page 107 of 115
Code No.P0720 Output shaft speed sensor system Probable cause
If the output from the output shaft speed sensor is Malfunction of the output shaft speed sensor
continuously 50% lower than the vehicle speed for 1 Malfunction of the transfer drive gear or driven gear
second or more while driving in 3rd or 4th gear at a Malfunction of connector
speed of 30 km/h or more, it is judged to be an open Malfunction of the TCM
circuit or short-circuit in the output shaft speed sensor
and diagnostic trouble code No.P0720 is output. If
diagnostic trouble code No.P0720 is output four times,
the transmission is locked into 3rd gear or 2nd gear as a
fail-safemeasure.

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Code No.P0731 1st gear incorrect ratio Probable cause
If the output from the output shaft speed sensor Malfunction of the input shaft speed sensor
multiplied by the 1st gear ratio is not the same as the Malfunction of the output shaft speed sensor
output from the input shaft speed sensor after shifting to Malfunction of the underdrive clutch retainer
1st gear has been completed, diagnostic trouble code Malefaction of the transfer drive gear or driven gear
NO.P0731 is output. If diagnostic trouble code Malfunction of the low and reverse brake system
No.P0731 is output four times, the transaxle is locked Malfunction of the underdrive clutch system
into 3rd gear as a fail-safe measure. Noise generated

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Code No.P0732 2nd gear incorrect ratio Probable cause
multiplied by the 2nd gear ratio is not the same as the Malfunction of the output shaft speed sensor
2nd gear has been completed, diagnostic trouble code Malfunction of the transfer drive gear or driven gear
No.P0732 is output. If diagnostic trouble code Malfunction of the second brake system

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Code No.P0733 3rd gear incorrect ratio Probable cause
multiplied by the 3rd gear ratio is not the same as the Malfunction of the output shaft speed sensor
3rd gear has been completed, diagnostic trouble code Malefaction of the transfer drive gear or driven gear

Page 111 of 115
Code No.P0734 4th gear incorrect ratio Probable cause
multiplied by the 4th gear ratio is not the same as the Malfunction of the output shaft speed sensor
4th gear has been completed, diagnostic trouble code Malefaction of the transfer drive gear or driven gear

Page 112 of 115
Code No.P0736 reverse gear incorrect ratio Probable cause
multiplied by the reverse gear ratio is not the same as the Malfunction of the output shaft speed sensor
reverse gear has been completed, diagnostic trouble Malefaction of the transfer drive gear or driven gear
code NO.P0736 is output. If diagnostic trouble code Malfunction of the low and reverse brake system

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Code No.P0743/P0740 Damper clutch solenoid
Probable cause
system
If the resistance value for the torque converter clutch Malfunction of the damper clutch solenoid
solenoid is too large or too small, it is judged that there Malfunction of connector
is a short-circuit or an open circuit in the damper clutch Malfunction of the TCM
solenoid and diagnostic trouble code No.P0743 is
output. If the drive duty rate for the damper clutch
solenoid is 100% for a continuous period of 4 seconds
or more, it is judged that there is an abnormality in the
damper clutch system and diagnostic trouble code
NO.P0740 is output. When diagnostic troublecode
No.P0743 is output, the transaxle is locked into 3rd
gear as a fail-safe measure.
If the lock-up clutch remains engaged for a continuous
period of 10 seconds when the TCM is attempting to
disengage the lock-up clutch, it is judged that the torque
converter clutch is stuck on and diagnostic trouble code
P0740.

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

Code No.P1723 A/T Control relay system Probable cause
If the relay voltage is less than 7 V after the ignition Malfunction of the A T control relay
switch hasbeen turned to ON, it is judged that there is Malfunction of connector
an open circuit or a short-circuit in the A/T control relay Malfunction of the TCM
earth and diagnostic trouble code P1723 is output. The
transaxle is locked into 3rd gear as a fail-safe measure.
Page 115 of 115
Page 1 of 96
OPTIMA(MS) > 2001 > G 2.4 DOHC > Body Electrical System
Body Electrical System > General Information > Description and Operation
DESCRIPTION
EXTERIOR LIGHTS
Refer to Wiring Diagram Manual.
WINDSHIELD WIPER/WASHER
HORN
Problem Possible cause Action
Blown "HORN" fuse Replace fuse
Horn relay failed Replace relay
Horn does not operate
No ground at horn installation Establish ground connection
Horn failed Replace horn
Pull horn button up : Repair or
Horn operates continuously Horn button stuck
replace
INSTRUMENT CLUSTER ASSEMBLY

In vehicle use, if an instrument does not run smoothly or indicate correctly,remove instrument and test it in shop to
determine fault cause. Remove a failedbulb by removing instrument cluster. Other problems and their possible
causesare listed below.
Defective speedometer Replace
Defective speedometer sensor Replace
Speedometer does not work
orshows indicator error Defective wire between speedometer and
Replace
speedometer sensor
Defective printed circuit Replace
Coolant temperature gauge does not
Coolant temperature gauge Replace
work
Coolant temperature sensor unit Replace
Fuel gauge does not work
Fuel gauge sensor unit (fuel tank) Fuel gauge Replace
Instrument cluster illuminationdoes
not work correctly or operate
POWER DOOR
If power door does not operate, refer to WiringDiagram Manual.
POWER MIRROR
If power mirror does not operate, refer toWiring Diagram Manual.
POWER WINDOW
If power window does not operate, refer toWiring Diagram Manual.
Page 2 of 96
RADIO
Radio does not work Radio unit Replace fuse
Radio has static or drift Antenna Replace
Radio has weak reception Antenna cable Replace
Antenna Replace
Radio Replace
One area of vehicle does not Replace speaker
Radio speaker
get radio reception Repair wiring
Radio has no reception Antenna cable Repair or replace cable
Antenna mast damaged or
Antenna mast Replace
broken
REAR DEFROSTER WINDOW

Body Electrical System > General Information > Specifications

INSTRUMENT AND WARNING SYSTEM
SPECIFICATIONS
Warning lamps Bulb wattage (W) Color
Illumination Lighting emitting diode -
High Beam Lighting emitting diode Blue
Low fuel Lighting emitting diode Yellow
Turn signal (LH, RH) Lighting emitting diode Green
Battery (Charge) Lighting emitting diode Red
Oil pressure Lighting emitting diode Red
Air bag 1.5 (bulb) Red
Parking brake Lighting emitting diode Red
Seat belt Lighting emitting diode Red
Check engine 1.5 (bulb) Amber
ABS Lighting emitting diode Yellow
Door open Lighting emitting diode Red
TCS, TCS OFF Lighting emitting diode Yellow
Cruise Lighting emitting diode Green
Fog lamp Lighting emitting diode Green
A/T P Lighting emitting diode Green
R Lighting emitting diode Orange
N Lighting emitting diode Green
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D Lighting emitting diode Green
4 LCD Green
3 LCD Green
2 LCD Green
L LCD Green
Trunk lid open LED Yellow
SERVICE SPECIFICATIONS
Items Specifications
Speedometer
Type Stepper motor type.
Input spec. Hall IC type : 4 pulse/rev.
Indication MILE : At 1026 rpm × 4 pulse/rev. indicate 60 MPH
Standard values
Must tap the speedometer with hand to prevent hysterisis effectswhen inspecting.
Tachometer
Type Stepper type. (4 cyl: 2pulses/ rev, 6 cyl: 3pulses/ rev)
Standard values
Must tap the tachometer with hand to prevent hysterisis effectswhen inspecting.
Fuel gauge
Type Stepper motor type (Zero return type : Pointer should fall intothe "E" point when IG. off).
Standard values
Inspection order : F → E
Temperature
gauge
Type Stepper motor type (Intermedia stability type).
Indication
standard
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Indication
standard
Inspection order : OFF → C → H

Resistance of
temperature
sender
TROUBLESHOOTING
AUDIO
There are six areas where a problem can occur: the wiring harness, the radio, the cassette tape deck, the CD player
the and speakers and the antenna. Troubleshooting enables you to isolate the problem to a particular area.
CHART 1
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CHART 2
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CHART 3
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CHART 4
1.RADIO
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2. TAPE
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CHART 5
1. CD WILL NOT BE ACCEPTED
2. NO SOUND
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3. CD SOUND SKIPS
1. Sound sometimes skips during parking.
2. Sound sometimes skips during driving.

(Stop vehicle, and check it.)
(Check by using a CD which is free of scratches, dirt or other abnormalities.)
4. SOUND QUALITY IS POOR

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5. CD WILL NOT EJECT
6. NO SOUND FROM ONE SPEAKER
CHART 6
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CHART 7
CHART 8
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CHART 9
CHART 10
1. MOTOR ANTENNA WON'T EXTEND OR RETRACT
Clean and polish the surface of the antenna rod.
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2. MOTOR ANTENNA EXTENDS AND RETRACTS BUT DOES NOT RECEIVE
TROUBLESHOOTING
Page 15 of 96
Symptom Possible cause Remedy
One lamp does not light (all exterior) Bulb burnt out Replace bulb
Socket, wire or ground faulty Repair as necessary
Headlamps do not light Fuse blown Replace fuse
Headlamp relay faulty Check relay
Lighting switch faulty Check switch
Wiring or ground faulty Repair as necessary
Tail and licence lamp do not light Tail lamp fuse blown Replace fuse
Fuse blown Replace fuse
Taillamp relay faulty Check relay
Lighting switch faulty Check switch
Wiring or ground faulty Repair if necessary
Stop lamps do not light Fuse blown Replace fuse
Stop lamp switch faulty Adjust or replace
Wiring or ground faulty switch
Stop lamp relay faulty Repair as necessary
Replace relay
Stop lamps stay on Stop lamp switch faulty Adjust or replace
Stop lamp relay faulty switch
Replace relay
Instrument lamps do not light Rheostat faulty Replace rheostat
(taillamps light) Wiring or ground faulty Repair if necessary
Turn signal does not flash on one side Bulb burned out Replace bulb
Turn signal switch faulty Check switch
Turn signal does not operate Fuse blown Replace fuse
Flasher faulty Check flasher
Turn signal switch faulty Check switch
Hazard warning lamps do not operate Fuse blown Replace fuse
Flasher faulty Check flasher
Hazard switch faulty Check switch
Flasher rate too slow or too fast Lamps are of wattage smaller or larger than is Replace lamps
specified for use Replace flasher
Defective flasher
Back up lamps do not light Back up fuse blown Check for short,
Back up lamp switch faulty replace fuse
Damaged wiring or poor grounding Check switch
Repair if necessary
Overhead console and luggage lamp Sunroof fuse blown Replace fuse
do not light Wiring or ground faulty Repair if necessary
Specifications
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Tightening specifications
Item Description Tightening torque
Sunroof Glass panel mounting nuts 35~52 lb-in(4~6 N.m, 40~60 kg-cm)
Sunroof mounting bolts 61~95 lb-in(7~11 N.m, 70~110 kg-cm)
Sunroof mounting nuts 35~52 lb-in(4~6 N.m, 40~60 kg-cm)
General specifications
Item Description Specification
Rear window defroster Grid line center voltage 6V
Windshield wiper washer system Motor specification 12V DC
Body Electrical System > Audio > Audio Unit > Repair procedures
INSTALLATION OF RADIO EQUIPMENT
The electronic control systems have been designed so that external radio waves will not interfere with their
operation.However, if the antenna or cable of the amateur transceiver is routed near the computers, it may affect the
operationof the computers, even if the output of the transceiver is no more than 25W.
To protect each of the computers from interference by transmitter (hum, transceiver, etc.) the following should be
observed.
1. Install the antenna on the roof or rear bumper.
2. Because radio waves are emitted from the coaxial cable of the antenna, keep it 200 mm (8 in.) away from the
computers and the wiring harness. If the cable must cross the wiring harness, route it so that it runs at right angles
to the wiringharness.
3. The antenna and the cable should be well matched, and the standing-wave ratio* should be kept low.
4. A transmitter having a large output should not be installed in the vehicle.
5. After installation of transmitter, run the engine at idle, emit radio waves from the transmitter and make sure that
the engine is not affected.
*STANDING-WAVE RATIO
1. STANDING-WAVE RATIO If an antenna and a cable having different impedances are connected, the input
impedance Zi will vary in accordance with the length of the cable and the frequency of the transmitter, and the
voltage distribution will also vary in accordance with the location.
The ratio between this maximum voltage and minimum voltage is called the standing-wave ratio. It can also be
representedby the ratio between the impedances of the antenna and the cable.
The amount of radio waves emitted from the cable increases as the standing-wave ratio increases, and this
increases the possibility of the electronic components being adversely affected.
INSTALLATION
Audio Remote control
Page 17 of 96
REMOVAL
Audio Remote control
1. Disconnect the negative (-) battery terminal.
2. Remove the center facia panel and disconnect the wire connectors.
3. Remove the 4 screws holding the audio unit then remove the audio assembly.
4. Disconnect the power connector and antenna cable jack from the audio unit.
Tape head and capstan cleaning

1. To obtain optimum performance, clean the head and capstan as often as necessary, depending upon frequency of
use and tape cleanness.
2. To clean the tape head and capstan, use a cotton swab dipped in ordinary rubbing alcohol. Wipe the head and
capstan.
Body Electrical System > Audio > Speakers > Repair procedures
Speaker checking
Page 18 of 96
1. Check the speaker by using an ohmmeter If an ohmmeter indicates the impedance of the speaker when checking
between the speaker (+) and speaker (-) of the same channel, the speaker is okay.
2. If clicking sound is emitted from the speaker when the ohmmeter plugs touch the speaker terminals, the speaker
is okay.
Body Electrical System > Audio > Antenna > Description and Operation
Description and operation
The antenna is an intergral part of the AM/FM radio. The antenna is mounted to left rear fender and receives AM
and FM signals which are sent through antenna cable to the radio.
Body Electrical System > Audio > Antenna > Repair procedures
REMOVAL
Antenna Cable
1. Remove one screw from center panel trim.
2. Pull out center panel trim.
3. Remove four screws that secure radio to center panel.
4. Remove connectors from rear of radio.
5. Disconnect antenna cable connector from antenna.
6. Remove antenna cable connector from antenna.
7. Pull carpet back toward driver seat.
8. Remove antenna cable.
REMOVAL
Antenna Mast
Remove antenna mast from antenna mount by unscrewing antenna mast from mount
REMOVAL
Antenna Mount
1. Remove antenna mast by unscrewing antenna mast from mount
2. Remove bezel nut from antenna
3. Disconnect antenna cable from antenna
4. Remove one nut from antenna mount support
5. Remove antenna mount from bottom.
Page 19 of 96
INSTALLATION
Antenna Cable
Install in reverse order of removal.
INSTALLATION
Antenna Mast
Install antenna mast into antenna mount by screwing antenna mast into mount.
INSTALLATION
Antenna Mount
1. Install antenna mount
2. Connect antenna cable connector to antenna
3. Install bezel nut
4. Install antenna mast
Power antenna inspection

1. Disconnect the 3P connector from the motor.
2. Check battery voltage is measured between terminal 1 and terminal 3 at all time.
3. Check if the battery voltage is measured between terminal 2 and termianl 3 when ignition switch and audio switch
is turned on.
4. Connect battery source to terminal 2 and terminal 1 of component side and check that motor operates (Antenna
moves up).
5. Then, disconnect battery source from terminal 2 and check that motor operates (Antenna moves down).
Ohmmeter measurement locations Result
Circuits from F to A, B, C, D and E Continuity
Circuit between G and H Continuity
Circuit from H to A, B, C, D and E No continuity
Page 20 of 96
Power antenna inspection

1. Disconnect the 3P connector from the motor.
2. Check battery voltage is measured between terminal 1 and terminal 3 at all time.
3. Check if the battery voltage is measured between terminal 2 and termianl 3 when ignition switch and audio switch
is turned on.
4. Connect battery source to terminal 2 and terminal 1 of component side and check that motor operates (Antenna
moves up).
5. Then, disconnect battery source from terminal 2 and check that motor operates (Antenna moves down).
Ohmmeter measurement locations Result
Circuits from F to A, B, C, D and E Continuity
Circuit between G and H Continuity
Circuit from H to A, B, C, D and E No continuity
Page 21 of 96
Body Electrical System > Audio > Audio Remote control > Repair procedures
REMOVAL AND INSTALLATION
1. Disconnect negative battery terminal.
2. Loosen mounting screws and remove the audio remote control switch.
Steering wheel remocon switch inspection

1. Check if the resistance is measured between terminal 1 and 3.
2. If the resistance between terminal 1 and 3 as not specified, replace the steering wheel remocon switch.
MODE MUTE VOL ↑ VOL ↑
Resistance 2.2kΩ 3.2kΩ 4.2kΩ 6.4kΩ
Page 22 of 96
Body Electrical System > Multifunction switch > Multi Function Switch > General Safety Information
and Caution
WARNING
Prior to removing of the multifunction switch assembly in vehicles equipped with air bags, be careful to comply with
the following warning instructions in order to prevent serious personal injury or death.
• Never attempt to disassemble or repair the air bag module or clock spring. If faulty, replace it.
• Do not drop the air bag module or clock spring or allow contact with water, grease or oil. Replace if a dent,
crack, deformation or rust are detected.
• The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward. Do
not place anything on top of it.
• Do not expose the air bag module to temperatures over 90°C (200°F).
• After deployment of an air bag, replace the clock spring with a new one.
• Wear gloves and safety glasses when handling an air bag that has already been deployed.
• An undeployed air bag module should only be disposed of in accordance with the procedures mentioned in the
restraints section.
• When you disconnect the air bag module-clock spring connector, take care not to apply excesive force to it.
• The removed air bag module should be stored in a clean, dry place.
• Prior to installing the clock spring, align the mating mark and "NEUTRAL" position indicator of the clock spring,
and after turning the front wheels to the straight-ahead position, install the clock spring to the column switch. If
the mating mark of the clock spring is not properly aligned, the steering wheel may not completely rotate during a
turn, or the flat cable within the clock spring may be severed, obstructing normal operation of the SRS and
possibly leading to serious injury to the vehicle's driver. To inspect the clock spring, refer to the restraints section.
Body Electrical System > Multifunction switch > Multi Function Switch > Components and Components
Location
COMPONENTS
Page 23 of 96
Body Electrical System > Multifunction switch > Multi Function Switch > Repair procedures
INSPECTION
Page 24 of 96
1. Check the continuity between the terminals while operating the switch.
Lighting switch
Dimmer and passing switch
Turn signal and lane change switch
Front fog switch
Wiper and intermittent volume
Body Electrical System > Horn > Horn > Description and Operation
DESCRIPTION AND OPERATION
The vehicle is equipped with two horns mounted behind front bumper near the center. Operation of horn is
controlled by a switch (horn button) located on steering wheel. Electrical power from positive side of battery is
applied to a horn relay located in the engine compartment fuse box. When horn button is pressed, horn relay is
energized, and electrical power is directed through the switch in the horn relay to the horn. The circuit is completed
by grounding the horn, and the horn sounds. When the horn button is released, springs force button upward to open
horn switch. This is also known as a momentary switch. When this occurs, the relay is de-energized and horn
operation stops.
Page 25 of 96
Body Electrical System > Horn > Horn > Components and Components Location
COMPONENTS
Body Electrical System > Horn > Horn > Repair procedures
REMOVAL
Horn
1. Disconnect negative battery cable.
2. Disconnect horn wire.
3. Remove one bolt and remove horn.
REMOVAL
Horn Relay
2. Disconnect horn relay from fuse box in engine compartment.
Page 26 of 96
INSTALLATION
Horn
Horn is electrically grounded through mounting. Be sure that metal-to-metal contact is established before installing
attaching bolt.
2. Position horn on chassis and install one bolts.
3. Connect two wires to horn.
4. Connect negative battery cable.
INSPECTION
1. Test the horn by connecting battery voltage to the 1 and 2 terminals.
2. The horn should sound, if the horn fails to sound, replace it.
ADJUSTMENT
Operate the horn, and adjust the tone to a suitable level by turning the adjusting screw.
After the adjustment, apply a small amount of paint around the screw head to keep it from loosening.
Body Electrical System > Keyless Entry And > Schematic Diagrams
CIRCUIT DIAGRAM
Page 27 of 96
Body Electrical System > Keyless Entry And > Description and Operation
DESCRIPTION
Page 28 of 96
1. The keyless entry and burglar alarm system consists of ETACS components and some other parts.
Without a key, the keyless entry system is able to lock and unlock all the doors at a distance, transmitting a weak
radio wave from a transmitter.
Body Electrical System > Keyless Entry And > Repair procedures
INSPECTION OF COMPONENTS
Transmitter
1. Check that the red light flickers when the door lock button or unlock button is pressed on the transmitter.
2. Remove the battery and check voltage if the red light does't flicker.
Standard value : 3V
3. Replace the battery if voltage is below 3V and replace the remote control switch if it is inoperable after replacing
the battery.
Battery : Lithium CR2032 (3V, 220mA/h)
Transmitter Code Saving Methood

1. Using code saving switch.
(1) Remove the center facia panel.
Don't disconnect the negative (-) battery terminal.

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(2) To store new codes :
A. Activate the keyless entry/receiver unit and change the code saving switch of the receiver unit from "OFF"
to "SET".
B. Press door lock and door unlook buttons of the transmitter for 1 second simultaneously.
C. Press door lock or door unlock buttons of the transmitter for 1 second again.
D. Save the 2nd transmitter codes in the same manner.
(3) Return the code saving switch of the receiver unit from "OFF" to "SET".
(4) Check the operation of the keyless entry system.
(5) Install the center facia panel.
2. Using Hi-Scan
(1) To store transmitter code, first connect keyless adapter to DLC (Data Link Connector) cable of hi-scan as
shown in the illustration.
(2) After connecting keyless adapter to the multi purpose check connector (10 pins) beside data link connector
in driver side crash pad lower panel, turn the power on hi-scan.
(3) Select "18. OPTIMA (MAGENTIS)" and then do "06. CODE SAVING".
(4) After selecting "06. CODE SAVING" menu, press "ENTER" key, then the screen will be shown as below.
[With Immobilizer]
PUT THE IG.KEY[ON] POSITION
AND WAIT 5 SECONDS.
[With Immobilizer]
REMOVE THE IG.KEY FROM KEY CYLINDER.
PRESS[ENTER], IF YOU ARE READY!
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(5) After removing the ignition key from key cylinder, press "ENTER" key, then the screen will be shown as
below.
[CODE SAVING METHOD]

1. PRESS [LOCK] AND [UNLOCK] BUTTONS OF THE TRANSMITTER FOR 1
SECONDSIMULTANEOUSLY
2. PRESS THE [LOCK] OR [UNLOCK] BUTTON FOR 1 SECOND AGAIN
3. SAVE THE 2ND TRANSMITTERY IN THE SAME MANNER ABOVE
4. PRESS [ENTER], IF YOU ARE READY!
(6) Press "ENTER" key, If you are ready.

As a above message follow step 1 to 3 within 10 seconds and then code saving is completed.
(7) Remove the Hi-Scan and then check the operation of the keyless entry system.
Body Electrical System > Keyless Entry And > Specifications

SPECIFICATIONS
Power source Lithium 3V battery (1EA)
Transmissible distance 10m or more
2 years or more (at 20 times
Life of battery
Keyless entry transmitter per day)
Door lock, door unlock, trunk
Button
lid open
Transmission frequency 315 MHz
Operating voltage DC 9V - 16V
Operating temperature range -30°C ± 80°C
Receiver Maximum standby current 3mA or less
Door lock door unlock trunk
Output pattern
lid open
ANTI-THEFT FUNCTION
1. Arm function
Time specification
T : 0.5 sec.
T : 0.1 ± 0.1 sec.
T : Max 0.6 sec.
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2. Disarm function
Time specification
T : 0.5 sec.
T : 1 ± 0.1 sec.
T : 30 sec.
3. Alarm function
(1) Time specification
T : 27 - 30 sec.
T : 10 - 13 sec.
T : 0.5 ± 0.1 sec.
(2) Battery is separated during the alarm state
(3) New alarm occurs during the alarm state

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(4) TX trunk unlock button pressed
Time specification
T : 0.5 sec.
(5) TX unlock button pressed during the alarm state

Time specification
T : 0.5 sec.
(6) TX lock button pressed when the door opened during the alarm state
Time specification
T : 0.5 sec.
T : 1.0 ± 0.1 sec.
(7) TX lock button pressed when the door closed during the alarm state
Time specification
T : 0.5 sec.
T : 1.0 ± 0.1 sec.
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(8) New alarm occurs when all doors closed & lock after the alarm state
Time specification
T : 27 - 30 sec.
T : 10 - 13 sec.
T : 0.5 ± 0.1 sec.
(9) New alarm occurs when some doors opend after the alarm state
(10) In case of using the door key.

T : 2 sec
4. Alarm cancel
T : 30 sec.
Body Electrical System > ETACS (Electronic Time > ETACS Module > Repair procedures
REMOVAL
1. Disconnect the negative (-) battery terminal.
2. Remove the lower crash pad .
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3. Remove the bolts holding the ETACS moduld and disconnect the connectors.
INSTALLATION
OPERATION CHECK OF COMPONENTS

While operating the components, check whether the operations are normal with timing chart.
Body Electrical System > ETACS (Electronic Time > ETACS Module > Specifications
ETACS FUNCTION
1. Variable intermittent wiper
Time specification
T : Max. 0.3 sec.
T : Time of wiper motor 1 rotation. (0.6-0.8 sec.)
T : 2.2 ± 0.2 sec. (VR=0kΩ) ~ 10.0 ± 1.0 sec. (VR=50 kΩ)
2. Washer
T : 0.3 sec
T : 2.5 ~ 3.8 sec
(2) This function should be operated preferentially even though the variable intermittent wiper is operating.
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3. Rear window defogger
Time specification
T : 60m sec.
T : 20 ± 1 Min.
4. Seat belt warning

Time specification
T : 6 ± 1 sec.
T : 0.45 ± 0.1 sec.
T : 0.3 ± 0.1 sec.
5. Ignition key hole illumination

Time specification
T : 10 ± 1.0 sec.
T : 0 - 10 sec.
6. Delayed out room lamp

Time specification
T : 5.5 ± 0.5 sec.
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7. Key operated warning
Time specification
T , T : 0.45 ± 0.1 sec.
8. Ignition key reminder

Time specification
T : 0.5 sec.
T : 0 - 0.5 sec.
9. Outside Door key illumination (Without burglar alarm)

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

Time specification
T : 30 ± 3 sec.
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11. Central door lock/unlock (without burglar alarm)
Time specification
T : 0.5 ± 0.1 sec.
12. Central door lock/unlock (without burglar alarm)

(1) When using the door key
Time specification
T : 0.5 ± 0.1 sec.
(2) When using the door lock switch

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

Time specification
T : 0.5 ± 0.1 sec.
13. Tail lamp auto cut

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14. Rear fog lamp control
Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Repair procedures
REMOVAL
1. Using the relay remover (09912-38000), remove the relay.
INSPECTIN
Fusible Link
1. Check for a burnt fusible link with an ohmmeter.
2. If a fusible link burns out, there is a short or some other problem in the circuit.
Carefully determine the cause and correct it before replacing the fusible link.
The fusible link will burn out within 15 seconds if a higher than specified current flows through the
circuit.
Relays
1. Remove the head lamp and tail lamp relays from engine compartment relay box.
2. Check for continuity between the terminals.
Fuses
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1. Be sure there is no play in the fuse holders, and that the holders hold the fuses securely.
2. Are fuse capacities for each circuit correct?
3. Are there any blown fuse?
If a fuse is to be replaced, be sure to use a new fuse of the specified capacity. Always determine why the fuse
blew first and completely eliminate the problem before installing a new fuse.
Never use a fuse of higher capacity than specified.
Body Electrical System > Indicators And Gauges > Instrument Cluster > Schematic Diagrams
CIRCUIT DIAGRAM
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Body Electrical System > Indicators And Gauges > Instrument Cluster > Description and Operation
Instrument cluster
Instrument cluster assembly houses driver-operated switches and controls. An analog electric speedometer, stepper
motor-driven odometer, trip meter analog fuel gauge, temperature gauge, and information/warning center are located
in cluster.Center information/warnings include:
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1. Engine oil pressure warning
2. ABS warning
3. Check engine (MIL) warning
4. Rear window defroster indicator
5. Brake warning
6. Charge warning
7. Safety belt warning
8. High beam indicator
9. Door open warning
10. Parking brake indicator
11. Air bag warning
12. Accessory (ACC) indicator
13. Low fuel warning
14. Hazard warning
15. Turn signal indicators
Instrument cluster electrical connectors are located at rear of assembly. When assembly is removed, instrument
panel electrical harness connectors are disconnected. A printed circuit board is mounted on back of instrument
cluster. It transfers electrical power to cluster. Instruments are removed from cluster after cluster has been removed
and bezel/lens has been removed from cluster case. Instrument cluster trim electrical connectors are located at rear
of trim switchesand are disconnected when cluster trim is removed. When ignition is in "ON" position, instrument
and switch lights arechecked.If any light is inoperative, a replacement of failed bulb should be made.
METERS AND GAUGES
• Engine coolant temperature gauge
Engine coolant temperature gauge in instrument cluster indicates temperature of engine coolant with ignition
switch in "ON" position. A sending unit in engine changes resistance with temperature.
• Fuel gauge
Electrical fuel gauge system consists of an electrical panel gauge and a fuel tank sender device. Fuel gauge
indicates quantity of fuel in fuel tank only when ignition is turned to "ON" position. When ignition switch is turned
to "ACC" or "LOCK" positions, pointer does not point to correct fuel level.
• Speedometer/Odometer/Trip meter
This instrument cluster assembly includes a speedometer, an odometer and a trip meter. Speedometer indicates
speed. Odometer records total road mileage. Trip meter records trip mileage. Indicator needle is electrically
driven by a precisionDC motor circuit. Speed information source is a speed sensor on transmission. Odometer
and trip meter consist of numbered wheels that are electrically driven by a DC stepper motor.
• Tachometer
Tachometer indicates engine speed in rpm (revolutions per minute) with engine running. A wire to "TACH"
connector on ignition module measures ignition pulses of module. An electronic circuit on tachometer converts
these pulses to rpm data.
When removing or installing any electrical units, disconnect negative battery cable to prevent possible short
circuits which could lead to personal injury and/or property damage.
When replacing odometer assembly, law requires odometer reading of replacement unit to be set to same
mileage as prior odometer. If mileage cannot be set, law requires that replacement odometer be set at zero and a
label be installed on driver´s door frame to show previous odometer reading and date of replacement.
SWITCHES
• Defroster
Defroster switch turns on window defroster and indicates defrosting is in operation.
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• Hazard warning
Hazard warning switch turns on hazard warning flashers. Both turn signal indicators blink at same time when
hazard condition switch is turned "ON".
• Wipers
Wiper switch controls operation of windshield wipers.
WARNING AND INDICATOR LAMPS
• Accessory ("ACC") indicator
Accessory ("ACC") indicator illuminates when radio or other accessory is being operated and ignition switch is in
"ACC"position.
• Anti-lock brake system (ABS) warning
ABS warning lamp illuminates when ABS control unit detects a malfunction of anti-lock brake system.
• Brake warning
"BRAKE" warning lamp illuminates when brake fluid drops below a safe level with ignition switch in "ON"
position as a bulb check. Brake fluid warning switch is located at master cylinder tank. Float grounds lamp circuit
when brake fluid goes below central position, causing lamp to illuminate.
• Charge warning
"CHARGE" warning lamp is a red lamp in instrument cluster. "CHARGE" warning lamp illuminates when
generator does not charge battery sufficiently.
• Check engine (malfunction indicator light)
"CHECK ENGINE" lamp in instrument cluster warning center illuminates during engine starting. It may stay on a
short timeafter engine starts. If warning illuminates while driving, ECM has detected a fault in the engine
management system.
• Door open warning
"DOOR" warning lamp indicates a door is open when ignition is turned "ON".
• Engine oil pressure warning
"OIL" warning lamp illuminates whenever oil pressure is low with engine on. A sending unit in engine block
changes resistance with oil pressure. Lamp illuminates for several seconds after starting engine and goes off when
normal oil pressure is reached.
• High beam indicator
High beam indicator lamp illuminates when engine is on and driver switches headlights to high beam position or
uses "flash-to-pass" control. Lamp goes off when headlights are switched from high beam.
• Low fuel warning
Low fuel warning lamp indicates a fuel tank low fuel condition.
• Parking brake indicator
Parking brake indicator illuminates when parking brake is in upward-locked position and ignition switch is turned
"ON"..
• Rear defroster ("R-DEF") indicator
Rear defroster "R-DEF" indicator lamp indicates rear window defroster is on.
• Safety belt warning
"BELTS" warning lamp illuminates and an audio warning is given when ignition switch is in "ON" position with
either front door open and/or driver´s safety belt not fastened. Warning lamp goes out when driver´s safety belt is
fastened.
• Turn signal indicators
Turn signal indicators illuminate when right or left turn signal controls are operated.
Body Electrical System > Indicators And Gauges > Instrument Cluster > Components and Components
Location
COMPONENETS
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Body Electrical System > Indicators And Gauges > Instrument Cluster > Repair procedures
REMOVAL
Bezel/Lens
1. Do not touch face of a gauge or back of lens with fingers. It will leave a permanent fingerprint.
2. Use care in removing instruments from instrument cluster case. Make sure instruments are face-up when
separating bezel/lens from cluster case.
1. With instrument cluster bezel/lens downward on a soft, clean shop cloth, press on each of bezel tabs going out
around unit while using pressure between bezel/lens and cluster. Do not remove bezel/lens. Make sure each tab is
not in a locked position in its mating slot.
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2. Place instrument cluster case on its back, bezel/ lens facing up, and carefully pull bezel/lens away from cluster
case.
REMOVAL
Instrument Cluster
1. Remove three screws from instrument cluster trim.
2. Remove four mounting screws.
3. Pull cluster from instrument panel.
4. Disconnect two connectors.
5. Remove instrument cluster.
REMOVAL
Switches
1. Remove lower LH cover.
2. Push on mounting tabs on switch housing while pressing on switch until tabs clear cluster trim switch housing.
3. Continue pushing on end of switch until it is clear of trim.
INSTALLATION
Bezel/Lens
1. Install in reverse order of removal.
INSTALLATION
Instrument Cluster
1. Place cluster in instrument panel.
2. Connect two connectors.
3. Push cluster into instrument panel.
4. Install four cluster mounting screws.
5. Install three screws on instrument cluster trim.
INSTALLATION
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Switches
1. Mount switch in lower LH cover.
2. Press on switch until tabs on switch lock into place.
INSPECTION
Bezel/lens
Inspect bezel/lens for sign of any damage. Repair or replace bezel or lens as necessary.
Instrument Cluster
Inspect switch for damage, wear, or failed switch bulb and replace as necessary.
Switches
Inspect cluster for signs of any damage and replace damaged part as necessary.
Body Electrical System > Indicators And Gauges > Fuel Gauge > Repair procedures
INSPECTION
1. Connect the positive (+) lead from battery to terminal 1 and negative (-) lead to terminal 2.
2. Connect the variable resistance to terminal 3 and terminal 2.
3. Varies the variable resistance.
4. Check that the fuel gauge pointer moves. If the operation is not as specified, replace the gauge.
Resistance (Ω) Gauge level
95 E
32.5 1/2
7 F
Body Electrical System > Indicators And Gauges > Engine Coolant Temperature Gauge > Repair
procedures
INSPECTION
1. Connect the positive (+) lead from battery to terminal 1 and negative (-) lead to terminal 2.
2. Connect the variable resistance to terminal 3 and terminal 2.
3. Varies the variable resistance.
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4. Check that the temperature gauge pointer moves. If the operation is not as specified, replace the gauge.
Resistance (Ω) Gauge level
153 -40°
66-29 -7°
20 +35°
16.5 +40°
Body Electrical System > Indicators And Gauges > Tachometer > Repair procedures
INSPECTION
1. Connect a tune-up test tachometer and start the engine.
2. Compare the tester and tachometer indications. If the difference is excessive, replace the tachometer.
• Reversing the connections of the tachometer will damage the transistor and diodes inside.
• When removing or installing the tachometer, be careful not to drop it or subject it to severe
shock.
Revolution 1,000 2,000 3,000 4,000 5,000 6,000 8,000 Remark

(rpm)
Tolerance ±120 ±140 ±170 ±170 ±200 ±240 ±260 DOHC
(rpm)
Body Electrical System > Indicators And Gauges > Speedometer > Repair procedures
INSPECTION
1. Adjust the pressure of the tires to the specified level.
2. Set the vehicle onto a speedometer tester and use wheel chocks to hold the front wheels.
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3. Check if the speedometer indicator range is within the standard values.
Do not operate the clutch suddenly or increase/ decrease speed rapidly while testing.
Tire wear and tire over or under inflation will increase the indication error. Pointer vibration can be caused
by a loose or dry speedo-meter cable.
Velocity 10 20 40 60 80 100 120 140 150 Remark

(MPH)
Tolerance 10 - 20 - 40 - 60 - 80.3 - 100.3 - 120.3 - 140.3 - 150.3 - EXCEPT
(MPH) 12.5 22 42.5 63.4 84.1 104.7 125.3 145.9 155.9 U.S.A
8.5 - 18.5 - 38.5 - 58.3 - 78 - 97.7 - 117.5 - 137.3 - 147.3 - U.S.A
11.5 21.5 41.5 61.7 82 102.3 122.5 142.7 152.7
Body Electrical System > Indicators And Gauges > Parking Brake Switch > Repair procedures
NSPECTION
The parking brake switch is a push type and located under the parking brake lever. To adjust, move the switch
mount up and down with the parking brake lever released all the way.
Body Electrical System > Power Door Locks > Power Door Lock > Description and Operation
Power door lock system is comprised of door lock assembly, inside door handle, outside door handle, door lock
cylinder,and door lock switch. This system is installed on all doors of vehicle. System is activated by driver´s side
door which has a manual door lock system and a door lock switch. Switch is connected to door lock relay which is
located under left side of instrument panel.
Door lock assembly has four remote control rods. One is attached to inside door handle(inside door lock rod).
Second is attached to inside door handle (inside door handle rod). Third is attached to outside door handle (outside
door handle rod). Fourth rod is attached to lock cylinder of outside door handle (lock cylinderrod).
Depressing door lock switch in inside door handle locks and unlocks remaining three doors of vehicle.
Depressingdriver´s side switch and closing door while holding outside handle locks all four doors. Opening this door
with a keyautomatically unlocks all four doors.
When door lock switch of front passenger door is depressed, and this door is closed, all doors lock. Two rear
doors are locked by depressing door lock switch and closing doors. These doors also have child safety locks which,
when activated, prohibit opening doors from inside vehicle.
Body Electrical System > Power Door Locks > Power Door Lock > Components and Components
Location
COMPONENTS
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Body Electrical System > Power Door Locks > Power Door Lock > Repair procedures
REMOVAL
Power Door Lock Assembly (On-Vehicle Service Proceedure)
2. Remove door trim. Refer to "Trim"in this section.
3. Remove inside door handle assembly.
(1) Disconnect two remote control rods from door lock assembly.
(2) Remove two screws from inside door handle.
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4. Remove two screws from pull handle bracket.
5. Peel off plastic door screen carefully by pulling it away gradually from door frame.
Peel plastic moisture barrier off carefully so that it can be reused.

6. Remove door lock assembly.
(1) Disconnect two remote control rods from outside door handle assembly.
(2) Disconnect door lock actuator connector.
(3) Remove two mounting nuts from door lock actuator.
(4) Remove one screw from rod cover of inside door handle.
(5) Remove three screws from door lock assembly and remove assembly from access hole.
7. Remove outside door handle assembly.

(1) Disconnect door lock cylinder connector.
(2) Remove two mounting bolts from outside handle assembly.
(3) Remove door lock cylinder from outside handle assembly.
(4) Push (1) side and pull (2) side with wrenching outside handle upside.
REMOVAL
Inside Door Handle
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2. Remove door trim.
REMOVAL
Outside Door Handle
6. Disconnect outside door handle rod of door lock assembly from outside door handle.
7. Disconnect door lock cylinder rod of door lock assembly from door lock cylinder of outside door handle.
(1) Remove outside door handle assembly.
(5) Push (A) side and pull (B) side with wrenching outside handle upside.
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INSTALLATION
Power Door Lock Assembly (On-Vehicle Service Proceedure)
1. Install outside door handle assembly.
(1) Position glass guide as originally positioned through access hole.
(2) Install door lock cylinder on outside handle assembly .
(3) Install two mounting bolts.
Tighten mounting bolts to : 61~95 Ib-in (7-11 N·m, 70-110 kg-cm)
(4) Connect door lock cylinder connector.
2. Install door lock assembly.

(1) Position it as originally positioned through access hole.
(2) Install three mounting screws.
Tighten mounting screws to : 69~95 Ib-in (8-11 N·m, 80-110 kg-cm)
(3) Install one screw on rod cover of inside handle.

(4) Install two mounting nuts on door lock actuator.
(5) Connect two remote control rods on outside handle.
(6) Connect door lock actuator connector.
3. Install plastic door screen.

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

(1) Install two mounting screws.
(2) Connector two remote control rods of door lock assembly.
6. Install door trim.

INSTALLATION
Inside Door Handle

INSTALLATION
Outside Door Handle
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(1) Position outside door handle as originally positioned through access hole.
(2) Install door lock cylinder on outside door handle assembly .
Tighten mounting bolts to : 61-95Ib-in (7-11 N.m, 70-110 kg-cm)
2. Connect door lock cylinder rod of door lock assembly to door lock cylinder of outside door handle.
3. Connect outside door handle rod of door lock assembly to outside door handle.
(3) Pull out remote control rod for inside door handle through plastic door screen.
6. Install inside door handle.


Body Electrical System > Power Door Locks > Power Door Lock Actuators > Repair procedures
INSPECTION
Door lock control actuator
1. Disconnect the actuator connector from the wiring harness.
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2. Apply battery voltage (DC 12 V) to each terminal as shown in the table below and confirm that the actuator
makes corresponding operation.
Body Electrical System > Power Door Mirrors > Description and Operation
Outside rearview mirror assembly is comprised of mirror glass, a mirror frame (which holds mirror glass), a motor, a
wire harness, and garnish. Each outside rearview mirror can be adjusted in four directions from inside vehicle.
Body Electrical System > Power Door Mirrors > Components and Components Location
COMPONENTS
Outside Rearview Mirror Assembly
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Power Door Mirror
Body Electrical System > Power Door Mirrors > Repair procedures
REMOVAL
1. Disconnect negative battery cable,
2. Remove garnish.
3. Remove three rearview mirror assembly retaining bolts.
4. Pull out outside rearview mirror assembly and disconnect harness connector.
5. Remove outside rearview mirror assembly.
INSTALLATION
1. Position outside rearview mirror assembly on door.
2. Install three retaining bolts.
3. Connect harness connector.
4. Install garnish.
Body Electrical System > Power Door Mirrors > Power out side mirror switch > Repair procedures
Mirror switch
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1. Remove the power window main switch.
2. Disconnect the outside rear view mirror connector from the harness.
3. Operate the switch and check for continuity between the terminals. If continuity is not as specified, replace the
mirror switch.
Body Electrical System > Power Door Mirrors > Power Door Mirror Actuator > Repair procedures
Mirror actuator
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1. Apply battery voltage to each terminal as shown in the table and confirm that the mirror operates properly.
Mirror Heating
1. Apply battery voltage to each terminal as shown in the table and confirm that the mirror operates properly.
Body Electrical System > Power Windows > Description and Operation
Power window system allows front and rear side door windows to be operated electrically. Each window is raised
or lowered using a bi-directional electric motor attached by continuous cable to window regulator.
Window motors are controlled by switches mounted on front and rear side doors. Driver´s door contains main
power window switch assembly that controls each of other three doors.
Body Electrical System > Power Windows > Components and Components Location
COMPONENTS
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Power Window
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Body Electrical System > Power Windows > Repair procedures

REMOVAL
Power Window Regulator
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6. Remove window glass.
(1) Reconnect window operating switch.
(2) Connect negative battery cable.
(3) Trun ignition "ON" and position window glass about halfway.
(4) Trun ignition "OFF".
(5) Remove glass run channel.
(6) Remove two glass mounting bolts from window regulator assembly.
(7) Remove glass carefully; hold glass from both its inner and outer surfaces. While tilting it toward hinge side of
door, pull it out from outside door frame.
(8) Disconnect negative battery cable.
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7. Remove regulator assembly.
(1) Disconnect window regulator motor connector.
(2) Remove seven nuts from door frame.
(3) Remove window regulator assembly from out of access hole.
REMOVAL
Window glass

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(3) Trun ignition "ON" and position window glass about halfway.
(4) Trun ignition "OFF".
INSTALLATION
Power Window Regulator
1. Install regulator assembly.
(1) Position regulator assembly through access hole.
(2) Install seven mounting nuts.
(3) Connect electrical connector for motor of regulator assembly.
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2. Install window glass
(1) Position glass carefully:
Hold glass from both its inner and outer surfaces. While tilting it towards hinge side of door, place it on small
bracket on window regulator assembly.
(2) Loosely install two glass mounting bolts on window regulator assembly.
(5) Turn "ON" ignition and move glass up and down to ensure proper function.
(6) Make adjustments as necessary.
(7) Turn "OFF" ignition.
(8) Disconnect window operating switch.
(10) Tighten two glass mounting bolts on power window regulator assembly.
Tighten two bolts to : 69~104 Ib-in (8~12 N.m, 80~120 kg-cm)
3. Install run channel. Use soap and water for lubrication.

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(2) Connect two remote control rods of door lock assembly.
7. Install door trim. Refer to "Trim" in this section.

INSTALLATION
WIndow Glass
1. Install window glass.
(1) Position glass carefully: Hold glass from both its inner and outer surfaces. While tilting it towards hinge side of
door, place it on small bracket on window regulator assembly.

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(1) Install plastic door screen.


Body Electrical System > Power Windows > Power Window Motor > Repair procedures
Power winow regulator motor
1. Connect the motor terminals directly to the battery and check that the motor operates smoothly. Next, reverse
the polarity and check that the motor operates smoothly in the reverse direction. If the operation is abnormal,
replace the motor.
Body Electrical System > Power Windows > Power Window Switch > Repair procedures
INSPECTION
Power window main switch
1. Disconnect the power window main switch.
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2. Operate the switch, and check for continuity between the terminals.
3. If continuity is not as specified, replace the switch.

Power window main switch
Door lock switch

Window lock switch
Power window sub-switch

1. Operate the switch, and check for the continuity between the terminals.
Body Electrical System > Rear Window Defogger > Description and Operation
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Rear window is equipped with heating elements that clear condensation, frost and light show. Baked inside surface,
heating elements, or grid lines, are connected to vertical buss bar lines that comprise an electrical circuit.
When dash-mounted switch is pressed, electric current is supplied through defrost relay in fuse box of engine
compartment. Should rear glass not be cleared, switch must be pressed again for another 15 minutes heating cycle.
Body Electrical System > Rear Window Defogger > Repair procedures
INSPECTION
1. With engine running, push defroster switch "ON".
2. Connect negative (-) terminal of a voltmeter to vehicle ground.
3. Using voltmeter positive (+) probe, test center of each grid line for about 6 volts.
4. If voltmeter reading is more than 6 volts, grid line is broken between center and grounded (GND) end.
5. If voltmeter reading is less than 6 volts, or 0 volts, grid line is broken between center and battery feed wire end.
Body Electrical System > Rear Window Defogger > Rear Window Defogger Printed Heater > Repair
procedures
INSPECTION
Printed Heater Line
Wrap tin foil around the end of the voltmeter test lead to prevent damaging the heater line. Apply finger pressure
on the tin foil, moving the tin foil along the grid line to check for open circuits.
1. Turn on the defogger switch and use a voltmeter to measure the voltage of each heater line at the glass center
point. If a voltage of approximately 6V is indicated by the voltmeter, the heater line of the rear window is
considered satisfactory.
2. If a heater line is burned out between the center point and (+) terminal, voltmeter indicates 12 volts.
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3. If a heater line is burned out between the center point and (-) terminal, the voltmeter indicates 0 volt.
4. To check for open circuits, slowly move the test lead in the direction that the open circuit seems to exist. Try to
find a point where a voltage is generated or changes to 0V. The point where the voltage has changed is the open-
circuited point.
5. Use an ohmmeter to measure the resistance of each heater line between a terminal and the center of a grid line
and between the same terminal and the center of one adjacent heater line after another with defogger OFF. The
section involving a broken heater line indicates resistance twice as that in other section. In the affected section,
move the test lead to a position where resistance sharply changes.
Repair of broken heater line

Provide the following items:
1. Conductive paint.
2. Paint thinner.
3. Masking tape.
4. Silicone remover.
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5. Thin brush
Wipe the glass adjacent to the broken heater line, clean with silicone remover and attach the masking tape as
shown. Shake the conductive paint container well, and apply three coats with a brush at intervals of about 15
minutes apart. Remove the tape and allow sufficient time for drying before applying power. For a better finish,
scrape away excess deposits with a knife after completely dried. (allow 24 hours)
After repairing, clean the glass with a soft dry cloth or wipe along the grid line with a slightly moistened
cloth.
Body Electrical System > Windshield Wiper/Washer > Description and Operation
WASHER SYSTEM
This is equipped with a variable speed (intermittent), modular wiper/washer system. Wiper system consists of a
wiper motor, a wiper link assembly, and two wiper arms with blades. Washer assembly consists of a washer tank, a
washer motor,twowasher nozzles, and connecting hoses. Both systems are then connected to a wiper lever and a
timer unit in steering column combination switch.
• Hoses
Washer hoses are neoprene lines that carry washer fluid to washer nozzles. There are three hose pieces, a three-
port hose joint, and a two-port hose joint. Hoses can be replaced individually. Washer hose system also has
three replaceablehold-down clips.
• Lever Assembly
Wiper assembly is located in combination switch on steering column. For switch-related electrical problems,refer
to Wiring Diagram Manual. For removal procedures, refer to Group ST, Steering System.
• Motor
Washer motor pumps washer fluid to washer nozzles. It is a single speed 12V DC motor to a pump mechanism.
It is a replaceable item.
• Nozzles
Washer nozzles deliver washer fluid directly to windshield. Nozzles are replaceable as an individual item.
• Tank Assembly
Washer tank assembly stores washer fluid used by washer system. It is a plastic assembly with a fill port and a
connection port to washer motor. It is a replaceable item.
• Timer Unit
Timer unit controls intermittent operation of wiper system. It is part of wiper unit assembly in steering column
combination switch. For unit-related electrical problems,refer to Wiring Diagram Manual. For removal
procedures, refer to Group ST, Steering System.
Wiper system
• Arm
Wiper arms are metal arms which pull wiper blades across windshield. They are spring-loaded to firmly hold
blades onto windshield during operation of wiper system. They are individual units consisting of a driver´s side
and a passenger sidearm.
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• Blades
Wiper blades are metal frames with rubber inserts. They are available as a unit, or inserts can be replaced
separately.
• Link assembly
Wiper link assembly connects wiper motor to wiper arms. It consists of two connecting rods and two pivot units.
When inoperation, assembly converts wiper motor's rotational motion into proper left/right movement needed by
wiper arms. Iffaulty, it can be disassembled, but replacement of full assembly is recommended.
• Motor and bracket
Motor is a 12V DC, two-speed unit which provides power to wiper system. It is connected to a transmission
(gear box) inmounting bracket which reduces motor rpm and increases torque. This low rpm, high torque motion
is then transmitted to wiper link assembly. Motor and bracket are a single, replaceable item.
Body Electrical System > Windshield Wiper/Washer > Components and Components Location
COMPONENTS
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Body Electrical System > Windshield Wiper/Washer > Windshield Wiper/Washer Switch > Components
and Components Location
COMPONENTS
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Body Electrical System > Windshield Wiper/Washer > Windshield Wiper/Washer Switch > Repair
procedures
REMOVAL
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1. Remove the wiper arm.
Care must be taken not to scratch in the engine

hood.
2. Remove the cowl top cover.
3. Disconnect the windshield wiper motor connector and remove the windshield wiper motor and the link.
Tightening torque : 0.7-1.1kgf.m(5.1 - 8.0 lb.ft)
INSPECTION
Switch
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1. Check the switch for continuity between the terminals.
Wiper and intermittent volume switch
Wiper switch
If continuity is not as specified, replace the wiper and washer switch.
Body Electrical System > Windshield Wiper/Washer > Front Wiper Motor > Repair procedures
REMOVAL
2. Remove wiper arms and blades. Refer to "Windshield Wiper/Washer System" in this section.
3. Remove nuts and fasteners from cowl vent.
4. Remove wiper motor and link assembly.
(1) Disconnect wiper motor harness connector.

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

(2) Install and tighten two mounting bolts.
(3) Connect wiper motor harness connector.
3. Place cowl vent in position and install nuts and fasteners.
INSPECTION
Speed operation check
1. Remove the connector from the wiper motor.
2. Attach the positive (+) lead from the battery to terminal 6 and the negative (-) lead to terminal 3.
3. Check that the motor operates at low speed.

4. Connect the positive (+) lead from the battery to terminal 6 and the negative (-) lead to terminal 2.
5. Check that the motor operates at high speed.
Automatic stop operation check
1. Operate the motor at low speed.
2. Stop the motor operation anywhere except the off position by disconnecting terminal 5.
3. Connect terminals 5 and 3.
4. Connect the positive (+) lead from the battery to terminal 6 and the negative (-) lead to terminal 1.
5. Check that the motor stops at the off position.
Wiper Motor
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1. Check for continuity between terminals using an ohmmeter.
2. If continuity is not as specified, replace motor.

3. Check motor's operation by connecting it to a 12V DC source.
Connected position
12V Ground Speed
Terminal "5" Terminal "6" LOW
Terminal "3" Terminal "6" HIGH
Body Electrical System > Windshield Wiper/Washer > Wiper Arm > Repair procedures
REMOVAL
Wiper Arm
1. Before removal check that wiper has stopped at its off position.
2. Remove nut cover and then wiper arm nut.
3. Check that arms are marked "Dr" (Driver Side) and "As" (Passenger Side). If not, mark them before removal.
4. Remove wiper arms.
REMOVAL
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Windshield Wiper Blade
1. Raise wiper arm off windshield into upright locked position.
2. Pivot blade until locking tab is exposed and then press in.
3. Slide wiper blade down arm until hook has separated from blade.
4. Slide blade up arm until it clears hook.
REMOVAL
Link Assembly
1. Remove wiper arms and blades. Refer to "Windshield Wiper/Washer System" in this section.
2. Remove nuts and fasteners from cowl vent.
3. Remove wiper motor and wiper link assembly.
(1) Disconnect wiper motor harness connector.

(2) Remove two mounting bolts from assembly.
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INSTALLATION
Wiper Arm
1. Starting with passenger side arm, place wiper arms on pivot shaft.
2. Install nut and tighten.
You should not run windshield wipers on a dry

windshield.
3. Install nut cover and check arm movement across windshield. Wiper arms should stop 1.18 inch (30 mm) (Driver
side) and 1.46 inch (37 mm) (Passenger side) from lower edge of windshield.
INSTALLATION
Windshield Wiper Blade
1. Place new blade on wiper arm, taking care that open side of hook is facing connection point.
2. Move blade (left or right) until connection point is at opening of hook.
3. Push blade into hook until lock tab sets.
4. Lower wiper arm to windshield.
INSTALLATION
1. Install two bolts on wiper motor and link assembly.
2. Connect wiper motor harness connector.
3. Place cowl vent in position and install nuts and fasteners.
4. Install wiper arms and blades. Refer to "Windshield wiper/washer system" in this section.
5. Check system movement. Wiper arms should stop 1.18 inch (30 mm) (Driver side) and 1.46 inch (37 mm)
(Passenger side) from lower windshield edge.
INSPECTION
Link Assembly
1. Check for any resistance by moving each part of link assembly by hand.
2. If any resistance is found, remove linkage and apply grease to indicated joints.
Body Electrical System > Windshield Wiper/Washer > Front Washer Motor > Repair procedures
REMOVAL
Washer Hose
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1. Disconnect washer nozzles from hood panel.
2. Unclip hoses from hood clips.
3. Disconnect hose clips on side panel.
4. Disconnect hose from washer motor.
REMOVAL
Washer Motor
2. Remove fasteners and bolt from mud guard and gently pull mud guard downward fully.
3. Remove two bolts on washer tank.
4. Remove hose connector from washer motor.

5. Remove washer motor and washer tank.
6. Drain washer tank and then separate washer motor from washer tank.
REMOVAL
Washer nozzle
1. Release holding clip by inserting a thin screwdriver between nozzle and bushing.
2. Remove nozzle from hood and then disconnect nozzle from neoprene hose.
INSTALLATION
Washer Hose
Reverse removal procedures
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INSTALLATION
Washer Motor
INSTALLATION
Washer nozzle
1. Connect nozzle to neoprene hose.
2. Face nozzle exit towards windshield and push in place on hood.
INSPECTION
1. Check for continuity between positive terminal and negative terminal using an ohmmeter.
2. Check motor function by connecting it to a 12V DC source.
3. Visually inspect washer tank for cracks or damage.
INSPECTION
1. Check for continuity between positive terminal and negative terminal using an ohmmeter.
2. Check motor function by connecting it to a 12V DC source.
3. Visually inspect washer tank for cracks or damage.
ADJUSTMENT
Washer Nozzle
1. Spray should center on driver and passenger sides of front windshield. If off-line, adjust by slightly turning the
nozzle.
2. If clogged or restricted, use a needle or wire to clear nozzle exit.
Body Electrical System > Electro chromic Inside > Description and Operation
DESCRIPTION
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The electrochromic (EC) inside rear view mirror receives power, ground and a reverse signal on the three wires that
connect to it. It uses two light sensors to sense glare.
1. The forward facing sensor determines if the outside light levels are low enough for the mirror to operate.
2. The rearward facing sensor detects glare from lights behind the mirror. When glare is detected, it outputs a signal
to the mirror to dim at the required level.
3. The mirror dims to the level as directed by the rearward facing sensor. When the glare is no longer detected, the
mirror returns to normal.
Body Electrical System > Electro chromic Inside > Repair procedures
INSPECTION
To determine if the EC mirror will dim, check it as below procedure.
1. Turn the ignition key to the "ON" position.
2. Cover the forward facing sensor.
3. Shine a flashlight into the rearward facing sensor.
4. The mirror should dim as soon as the rearward facing sensor detects the high light level.
If this test is performed in a bright area, the mirror may darken as soon as the forward facing sensor is
covered.
5. Put the vehicle into reverse, the mirror should not dim.
6. Aim a flashlight at the forward sensor and another flashlight at the rearward sensor the mirror should not darken.
Body Electrical System > Lighting System > Description and Operation
Exterior lights consist of six lighting systems: headlights, turn-signal lights, parking lights, hazard lights, brake lights,
and license plate lights (rear only). Six systems include left and right headlight and combination light assemblies, left
and right rear combination light assemblies, a rear high-mounted brake light assembly, and two license platelight
assemblies (for rear license only). All lights are powered by 12-volt electrical system.
Body Electrical System > Lighting System > Components and Components Location
COMPONENTS
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Body Electrical System > Lighting System > Head Lamps > Description and Operation
Headlight/Combination light assembly
Headlight/Combination light assembly is aerodynamically shaped to match contours of body. Light assembly is
attached to body with two bolts.
This light assemly contains three bulbs. Two bulbs function as headlight, other as combination light. Headlight bulb is
of single-filament halogen type.
Single filament is energized separately to provide high and low beams. An O-ring seals bulb installation to prevent
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foreign matter from entering headlight assembly. Bulb can be removed/installed from engine compartment without
removing light assembly. Each headlight can be adjusted to move beam up, down, left or right. Four adjustment
screws for each headlight assembly are reached through holes in body structure, directly behind headlight assembly.
Four screws can adjust (up, down, left or right )low and high headlight beams separately.
Front combination light contains two functions as hazard/turn signal light, and also as position/parking light. The turn
signals are controlled by the combination switch located on the steering column. The hazard lights are turned on/off
by the switch located on the center panel.
Body Electrical System > Lighting System > Head Lamps > Repair procedures
Removal
Headlight/Combination Light Assembly
1. Open hood. Disconnect negative battery cable.
2. Remove two bolts attaching headlight and combination light assembly to vehicle.
3. Pull headlight and combination light assembly forward clear of vehicle.

4. Rotate back cover counterclockwise to disengage from light assembly.
5. Pull socket with bulb straight out of headlight and combination light assembly.
REPLACEMENTS
Headlight and Combination Light Bulb
2. Disconnect electrical connector from headlight and combination light assembly.
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3. Remove back cover by pushing in on cover, then rotating cover counterclockwise to disengage from headlight
and combination light assembly.
The headlight bulb is filled with a gas which is under pressure. Damage to glass part of bulb can cause bulb
to explode causing possible personal injury.
Use care when handling halogen headlight bulb. Do not touch glass part of bulb with bare hands. Oil from
skin can cause bulb to fail.
4. Pull socket with bulb straight back and remove it from headlight and combination light assembly.
5. If bulb has failed, place it in new bulb carton and dispose of properly.
6. Hold replacement bulb by base, or use clean cloth or paper to avoid touching glass, and install bulb in socket.
7. Align slots on bulb with corresponding bosses on headlight assembly. Insert bulb into headlight and combination
light assembly.
8. Install back cover to hold bulb in place.
9. Connect electrical connector.
Installation
Headlight/Combination Light Assembly
1. With bulb installed in socket, align grooves of socket with bosses on headlight and combination light assembly
and insert socket into headlight and combination light assembly.
2. Align back cover with headlight and combination light assembly and install, turning clockwise until properly
engaged.
3. Position headlight and combination light assembly on vehicle.
4. Connect electrical connector to headlight and combination light assembly.
5. Install two bolts.
DISASSEMBLY
Headlight and Combination Light
1. Turn back cover counterclockwise to disengage, then move away from assembly.
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2. Pull bulb straight out of assembly.
REASSEMBLY
Headlight and Combination Light
1. Push bulb into back of headlight and combination assembly.
2. Position back cover to headlight and combination light and turn clockwise to engage.
PRE-AIMING INSTRUCTIONS
The headlamps should be aimed with the proper beam-setting equipment, and in accordance with the equipment
manufacture's instructions.
If there are any regulations pertinent to the aiming of headlamps in the area where the vehicle is to be used, adjust
so as to meet those requirements.
Alternately turn the adjusting bolts to adjust the headlamp aiming. If beam-setting equipment is not available,
proceed as follows :
1. Inflate the tires to the specified pressure and remove the load from the vehicle except a driver, spare tire, tool.
2. The vehicle should be placed on the flat floor.
3. Draw vetical lines (Vertical lines passing through respective headlamp centers) and a horizontal line (Horizontal
line passing through center of headlamps) on the screen.
4. With the headlamp and battery normal condition, aim the headlamps.
Make the vertical and horizontal adjustment of the lower beam to the standard values by using the adjusting
knobs.
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Head lamp (Low beam)

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The horizontal direction is non-adjustable. If the deviation of the light beam axis exceeds the standard value, check
tobe sure that the mounting location of some other point is not defective.
W : Distance between the low head lamp bulb center.
H : Height between the head lamp bulb center and ground.
L : Distance between the head lamp bulb center and screen.
V/LAMP (LOW BEAM)
Vehicle Condition "H1" "W1" "L"
Vacant Vehicle Condition 628 1308 3000
Condition of 1 person taken a
612 1306 3000
Vehicle
Be sure to adjust the aiming adjustment screw in the tightening direction.
The reflectors for low beam and high beam have been combined into a single part, so if the low beam adjustment is
made, high beam adjustment is not necessary.
Body Electrical System > Lighting System > Combination Lamp > Description and Operation
Combination Light Assembly (Rear)
Rear combination light assembly is aerodynamically shaped to follow body contours. Lens is three-colored: amber
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(hazard/turn signal), translucent (backup) and red (tail/brake). Rear combination light assembly contains four bulbs.
Two of four bulbs are single-filament and are used in hazard/turn signal and backup light circuits. Other bulbs are
dual filament ; one-filamentfunctions as brake light and other as tail light. A plastic bulb holder mounts four lamps and
associated wiring. Bulb holder can be removed from inside vehicle for bulb replacement.
Brake light bulb is turned on/off by a brake light switch mounted near brake pedal and actuated by movement of
brake pedal. Refer to Group BR, Brake System, for adjustment of brake (stop) light switch.
Backup light is turned on/off by a switch mounted on transaxle. When transaxle is shifted into reverse gear, switch is
closed to turn on backup lights.
The turn signals are controlled by the combination switch located on the steering column. The hazard lights are
turned on/off by the switch located on the lower LH cover.
The flasher unit which controls the hazard light operation is located under the left side of instrument panel.
Body Electrical System > Lighting System > Combination Lamp > Repair procedures
REMOVAL
Rear Combination Light Assembly (Outside)
2. Remove two bolts from service hole cover.
3. Remove four nuts attaching rear combination light assembly to vehicle.
4. Disconnect electrical connector.
5. Remove light assembly.
REMOVAL
Rear Combination Light Assembly (Inside)
2. Remove three screws and thirteen fasteners from trunk lid trim.
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3. Remove back panel molding assembly.
(1) Disconnect electrical connector.
(2) Remove one screw from outside of trunk lid.
(3) Remove thirteen nuts from trunk lid.
4. Remove four screws from light assembly.
INSTALLATION
1. Position light assembly on vehicle with studs through mounting holes on vehicle.
3. Install four nuts on rear combination light.
4. Install two bolts on service hole cover.
INSTALLATION
1. Position light assembly on back panel molding assembly.
2. Install four screws on light assembly.
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3. Install back panel molding assembly.
(1) Install thirteen nuts on trunk lid.
(2) Install one screw on outside of trunk lid.
(3) Connect electrical connector.
4. Install three screws and thirteen fasteners on trunk lid trim.
REPLACEMENT
2. Remove two bolts from service hole cover.
3. With bulb holder disengaged,pull bulb holder carefully forward relative to vehicle, and remove from light
assembly. Disconnect electrical connector.
4. Remove bulb as required from bulb holder.
5. Install new bulb of proper type, as shown on bulb holder.
6. Position bulb holder on light assembly and press to engage with light assembly.
7. Install two bolts on service hole cover.

2. Remove fasteners and screws from trunk lid trim.
4. With bulb holder disengaged, pull bulb holder carefully forward relative to vehicle, and remove from light
assembly.
5. Remove bulb as required from bulb holder.
6. Install new bulb of proper type, as shown on bulb holder.
7. Position bulb holder on light assembly and press to engage with light assembly.
8. Install fasteners and screws on trunk lid trim.
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DISASSEMBLY
Rear Combination Light Assembly
All parts except the lens-housing assembly is interchangeable from left to right.
1. Remove bulb holder from lens-housing assembly.
2. Remove bulbs from bulb holder.
REASSEMBLY
Rear Combination Light Assembly
All parts except the lens-housing assembly is interchangeable from left to right.
1. Install bulbs in bulb holder in accordance with instructions on bulb holder.
Body Electrical System > License Lamps > License Lamps > Description and Operation
License plate light assembly
Two license plate light assemblies are installed in trunk lid above license plate mount. Each light assembly has one
bulb. Both bulbs are turned on when headlights and position lights (parking lights) are on. Each bulb is protected by
a translucent plastic lens attached with two screws. Bulb can be removed/installed by removing two screws and
plastic lens.
Body Electrical System > License Lamps > License Lamps > Repair procedures
REPLACEMENTS
2. Remove two screws attaching license plate light assembly.
3. Remove bulb.
4. Install replacement bulb.
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5. Install lens with two screws.
Disassembly
1. Remove two screws attaching each lens; remove each lens from bracket.
2. Remove bulbs.
3. Remove wiring harness from bracket.
Reassembly
1. Install wiring harness on bracket.
2. Install bulbs.
3. Install each lens with two screws.
Body Electrical System > High Mounted stop lamp > High Mounted stop lamp > Description and
Operation
High-mounted brake light assembly is mounted on package tray assembly. Lens is red and visible through rear
window. Assembly has one bulb. Light is turned on/off by a brake light switch mounted near brake pedal and
actuated by movement of brake pedal.
Body Electrical System > High Mounted stop lamp > High Mounted stop lamp > Repair procedures
REMOVAL
High-Mounted Brake Lights
2. Open trunk lid.
3. Remove two nuts that attach light assembly to vehicle.
4. Disconnect electrical connector from light assembly; remove light assembly.
REPLACEMENT
High-Mounted Brake Light Assembly Bulb
2. Open trunk lid.
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3. Remove socket from light assembly.
4. Remove bulb from socket.

5. Install replacement bulb in socket.
Installation
1. Connect electrical connector to light assembly.
2. Position light assembly on package tray.
3. Install two nuts attaching light to vehicle.
4. Connector negative battery cable.
Disassembly
High-Mounted Brake Light Assembly
1. Remove socket from light assembly.
2. Remove bulb from socket.
REASSEMBLY
High-Mount Brake Light Assembly
1. Install bulb.
2. Install socket on light assembly.
Body Electrical System > Daytime Running Lights > Schematic Diagrams
CIRCUIT DIAGRAM
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Body Electrical System > Daytime Running Lights > Repair procedures
INSPECTION
Operation Check
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1. Check that the light operate according to the following timing chart.
Page 1 of 65
OPTIMA(MS) > 2001 > G 2.4 DOHC > Brake System
Brake System > General Information > Special Service Tools

SPECIAL TOOLS
Tool
(Number and Illustration Use
Name)
09581- Pushing back of the front disc and rear disc brake piston
11000/0K130 430
017A
Piston expander
09526-11001 Removal or installation of FRONT HUB and DISC

Axle shaft puller
Brake System > General Information > Repair procedures

SERVICE BRAKE PEDAL INSPECTION AND ADJUSTMENT
1. Turn the stop lamp switch until the clearance between the stop lamp switch outer case and pedal arm reaches the
standard value, and secure the stop lamp switch with the lock nut.
Clearance between pedal and stop lamp switch "A" : 0.5-1.0 mm (0.02-0.039 in.)
2. Free play of brake pedal.
Free play of brake pedal : 3-8 mm (0.12-0.32 in.)

Page 2 of 65
3. Start the engine, apply the brake pedal with approximately 500 N (50kg, 110 lbs.) of force, and measure the
clearance between the brake pedal and the floor board.
Pedal to floor board clearance "C"

when pedal is depressed 50 kg (110 lb.) force : 75 mm (2.95 in.) or more
when pedal is fully depressed without brake fluid : 35 mm (1.378 in.) or more
BRAKE BOOSTER OPERATION TEST(TEST WITHOUT A TESTER)

For a simple check of brake booster operation, make the following tests.
1. Run the engine for one or two minutes, and then stop it. Depress the brake pedal several times at normal foot
pressure. If the pedal goes down deepest the first time, but gradually rises after the second or third time, the
brake booster is functioning properly. Go to step 2.
2. With the engine stopped, depress the brake pedal several times. Depress the brake pedal and start the engine. If
the pedal goes down slightly, the booster is in good condition. Go to step 3.
3. With the engine running, depress the brake pedal and then stop the engine. Hold the pedal depressed for 30
seconds. If the pedal height does not change, the booster is in good condition. If one of the above three tests is
not okay, check the vacuum hoses, and the brake booster, and make any necessary corrections. If all tests OK,
unit is good.
BLEEDING OF BRAKE SYSTEM

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

immediately.
When bleeding by pressurized fluid, do not depress the brake pedal.
2. Connect the vinyl tube to the wheel cylinder bleeder plug, and insert the other end of the tube in a half full
container of brake fluid.
3. Slowly pump the brake pedal several times.
4. While depressing the brake pedal fully, loosen the bleeder plug until fluid starts to run out. Then close the bleeder
plug.
5. Repeat the 3 and 4 until there are no more bubbles in the fluid.
6. Tighten the bleeder plug screw.
Bleeder screw tightening torque : 7-13 Nm (70-130 kg·cm, 5-9.6 lb·ft)
7. Repeat the above procedure for each wheel in the sequence shown in the illustration.
PARKING BRAKE STROKE ADJUSTMENT

1. Loosen parking brake cable using adjusting nut (Rotate counter clockwise).
2. Push the brake pedal 20 times a force approx. 196 N (20kg, 44 lbs.)
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3. Tighten parking brake cable using adjusting nut (Rotate clockwise).
4. Pull the brake lever with a force of approx. 196 N (20 kg, 44 lbs.), and count the number of clicks.
Parking brake lever stroke [Standard value] : 8-9 clicks
5. If the number of notches is not the standard value, adjust the cable length with the adjusting nut of the equalizer.
6. The indicator light will go out when the brake lever is fully released, and will light with the lever pulled one notch.
If it does not operate, replace it.
7. After the adjustment, check that the rear brakes do not drag with the parking brake lever released.
Brake System > General Information > Specifications

SPECIFICATION
Type Tandem type
CBS 23.8 mm (0.94 in.)
Master cylinder I.D.
ABS 25.4 mm (1.0 in.)
Fluid level sensor Provided
Type Vacuum type with tandem booster
CBS 7 + 8 in.
Effective dia.
Brake booster ABS 8 + 9 in.
CBS 7.0 : 1
Boosting ratio
ABS 7.5 : 1
Cut-in pressure (Split point) 3.43 MPa (35 kg/cm², 498 psi)
Proportioning valve
Decompression ratio 0.32 : 1
Type Floating type with ventilated disc
Disc O.D. 257 mm (10.118 in.)
Front brake Disc thickness 24.5 mm (0.965 in.)
Pad thickness 10.75 mm (0.423 in.)
Page 5 of 65
Cylinder I.D. 57.2 mm (2.252 in.)
Type Leading-trailing drum
Drum I.D. 228.6 mm (9 in.)
Rear drum brake Brake lining thickness 4.5 mm (0.177 in.)
Cylinder I.D. 19.05 mm (0.75 in.)
Clearance adjustment Automatic
Type Floating type with solid disc
Disc O.D. 262 mm (10.31 in.)
Rear disc brake Disc thickness 10 mm (0.39 in.)
Pad thickness 10 mm (0.39 in.)
Cylinder I.D. 34 mm (1.34 in.)
Mechanical brake acting on rear
Type
wheels
Parking brake
Braking type Lever type
Cable arrangement V type
O.D. = Outer diameter

I.D. = Inner diameter
ABS = Anti-lock Brake System
CBS = Conventional Brake System
SERVICE STANDARD
Brake pedal height 176 ± 0.3 mm (6.93 ± 0.01 in.)
Stop lamp switch outer case to pedal stopper
0.5-1.0 mm (0.020-0.040 in.)
clearance
Brake pedal free play 3-8 mm (0.118-0.315 in.)
Standard value Brake pedal to floorboard clearance 44 mm (1.732 in.) or more
Booster push rod to master cylinder piston
0 (at 500 mmHg vacuum)
clearance
Parking brake lever stroke (when lever assembly
8-9 clicks
is pulled with 196 N(20 kg, 44 lb) force)
Front disc brake pad thickness 2.0 mm (0.079 in.)
Front disc thickness (minimum) 22.4 mm (0.88 in.)
Front disc runout 0.03 mm (0.0012 in.)
Front disc thickness variation 0.005 mm (0.0002 in.)
Service limit Drum brake lining thickness 1.5 mm (0.059 in.)
Brake drum I.D. (maximum) 230.6 mm (9.079 in.)
Wheel cylinder to piston clearance 0.15 mm (0.006 in.)
Rear disc brake pad thickness 2.0 mm (0.079 in.)
Rear disc thickness 8.4 mm (0.33 in.)
Page 6 of 65
TIGHTENING TORQUE
Nm kg·cm lb·ft
Master cylinder to booster 8-12 80-120 5.9-8.8
mounting nut
Brake booster mounting nut 13-16 130-160 9.6-11.8
Bleeder screw 7-13 70-130 5-9.6
Brake tube flare nut, brake 13-17 130-170 9-12
hose
Proportioning valve mounting 35-55 350-550 26-41
to master cylinder
Caliper guide rod bolt 22-32 220-320 16-24
Caliper assembly to knuckle 69-85 690-850 51-63
Brake hose to front caliper 25-30 250-300 18-22
Wheel cylinder mounting bolt 12-18 120-180 8.8-13
Brake booster vaccum hose 15-18 150-180 11-13
fitting to surge tank
LUBRICANTS
Recommended lubricant Quantity
Brake fluid DOT 3 or equivalent As required
Brake pedal bushing and brake pedal bolt Chassis grease SAE J310, NLGI No.0 As required
Clevis pin Wheel bearing grease SAE J310, NLGI No.2 As required
Parking brake shoe and backing plate Bearing grease, NLGI No.0-1 As required
contact surfaces
Sliding parts of the ratchet or the ratchet Multipurpose grease SAE J310, NLGI No.2 As required
pawl.
TIGHTENING TORQUE(ABS)
Page 7 of 65
Nm kg·cm lb·ft
Sensor mounting Front 8 - 9.5 80 - 95 5.6 - 6.7
bolt on the brake
plate Rear 15.5 - 16.5 155 - 165 11 - 12
Hydraulic & electronic unit
8 - 10 80 - 100 5.6 - 6.9
mounting bolt
Hydraulic & electronic unit
9 - 10 90 - 100 6.2 - 6.9
mounting bracket bolt
Six brake tubes on the Hydraulic
13 - 17 130 - 170 9 - 12
Unit
GENERAL
SPECIFICATIONS
Part Item Standard value Remark
ABS, TCS, EBD
Operating voltage 10V - 16V
Intergrated control unit
ECU
Communicate ECU &
Operating temp -40 - 110°C
TCU with CAN
W/ABS W/ABS, TCS, TCS OFF,
EBD common
TCS · BRAKE
Warning Operating voltage 12V
Lamp TCS OFF Consumption current 80mA 1. Parking
2. Brake oil
BRAKE (EBD) 3. EBD fail
Internal resistance 1275 - 1495Ω Ambient temperature
Insulation resistance X > 1 MΩ Front, Rear common
Minimum P·P volt : 150
Wheel Speed Sensor Output Voltage 0.15 - 50V
mV
Tone wheel 47T
Air gap 0.2 mm - 1.1 mm
Weight 3.0 kg
Motor 12V, 35A
Motor power 180W
Pump capacity 5.5 cc/sec NO : Cormal Open
HECU
NC : Normal Close
(Hydraulic and Electronic Accumulator amount 3.0 cc
TC : Traction Control
Control Unit)
NO HS : Hydraulic Shuttle
NC Operating voltage : 12V
Valve
TC Consumption current : 25A
HS
Page 8 of 65
Brake System > Brake System > Brake Booster > Components and Components Location
COMPONENTS
Brake System > Brake System > Brake Booster > Repair procedures
REMOVAL
1. Remove the master cylinder.
2. Remove the vacuum hose.
3. Remove the operating rod from the brake pedal.
4. Loosen the booster mounting nuts to remove the booster assembly.
INSTALLATION
1. Install the master cylinder.
2. Attach the booster/master cylinder to the dash panel.
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3. Reinstall the vacuum hose securely to prevent vacuum leaks.
4. Couple the operating rod with the brake pedal.
5. Bleed the system.
Do not attempt to disassemble the brake booster. It´s not

serviceable.
CHECK VALVE OPERATING TEST
Brake System > Brake System > Master Cylinder > Components and Components Location
COMPONENTS
Page 10 of 65
Brake System > Brake System > Master Cylinder > Repair procedures
REMOVAL
1. Detach the brake tubes from the master cylinder, and then install the plugs.
Do not let brake fluid remain on a painted surface. Wash it off

immediately.
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2. Remove the master cylinder mounting nuts, and then lift out the master cylinder.
INSTALLATION
1. Inspect the length of output rod and adjust (8.25 ± 0.125 mm).
2. Install the master cylinder on the brake booster.
3. Connect the brake tubes to the master cylinder.
4. Fill brake reservoir with brake fluid and bleed the system.
DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.
2. Remove reservoir from the master cylinder.
When bleeding by pressurized fluid, do not press the brake

pedal.
3. Using snap ring pliers, remove the retaining ring.

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

3. Push the pistons in with a screwdrive and install the retaining ring.
4. Using a screwdriver, push the piston all the way and install the piston stopper.
5. Mount the two grommets.
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6. Install the reservoir onto the cylinder.
Brake System > Brake System > Proportioning Valve > Description and Operation
PROPORTIONING VALVE
1. Do not disassemble the proportioning valve. The proportioning valve makes the ideal distribution of a fluid
pressure to the front and rear brakes to prevent the brakes from skidding in the event of rear wheel lock and to
obtain a higher brake efficiency within the range of service brake application.
PROPORTIONING VALVE FUNCTION TEST

1. Connect two pressure gauges, one each to the input side and output side of the proportioning valve.
Be sure to bleed the system after you connect the pressure gauges.
2. With the brakes applied, measure the input pressure and the output pressure. If the measured pressures are
within the permissible ranges as illustrated, the proportioning valve is good.
3. Reconnect the brake lines in original position and bleed the system.
This figure shows characteristics of the proportioning valve during pressure

increase.
DRUM DISC
A 35 20
B 49.4 39.2
C 68.6 58.4
Page 14 of 65
Brake System > Brake System > Brake Line > Components and Components Location
COMPONENTS
Brake System > Brake System > Brake Line > Repair procedures
INSPECTION
Page 15 of 65
1. Check the brake tubes for cracks, crimps and corrosion.
2. Check the brake hoses for cracks, damage and leakage.
3. Check the brake tube flare nuts for damage and leakage.
INSTALLATION
1. Install the brake hoses without twisting them.
2. The brake tubes should be installed away from edges, weld beads or moving parts.
3. Tighten the connections to the specified torque.
Flare nuts : 13-17 Nm (130-170 kg·cm, 9-12 lb·ft)

Brake hose to front caliper : 25-30 Nm (250-300 kg·cm, 18-22 lb·ft)
Brake System > Brake System > Brake Pedal > Components and Components Location
COMPONENTS
Page 16 of 65
Brake System > Brake System > Brake Pedal > Repair procedures
REMOVAL
1. Remove the lower crash pad assembly (Refer to Body Group)
2. Remove the brake pedal return spring.
3. Remove the steering support member.
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4. Remove the stop lamp switch and disconnect the clutch switch connector (Vehicle with automatic speed control
system only).
5. Remove the cotter pin and clevis pin.
6. Detach the stopper and washer from the right side pedal support member.
7. Loosen the booster mounting nut and remove the right side pedal support member.
8. Remove the brake pedal to the driver´s compartment.
Remove the pedal rod bushing and wave washer.
9. Loosen the pedal support member installation bolt and nut, then remove the left side pedal support member.
INSTALLATION
1. Installation is the reverse of removal procedure.
1. Coat the specified grease to the inner surface of the bushings. Specified grease : Chassis grease SAE
J310, NLGI No.0
2. Before insert the clevis pin, apply the specified grease to the clevis pin and washer.
INSPECTION
1. Check the bushing for wear.
2. Check the brake pedal for bending or twisting.
3. Check the brake pedal return spring for damage.
Brake System > Brake System > Front Dinode Brake > Components and Components Location
COMPONENTS
Page 18 of 65
Brake System > Brake System > Front Dinode Brake > Repair procedures
REPLACEMENT OF BRAKE PADS
1. If a squeaking noise occurs from the front brake while driving and braking, inspect the brake pads.
REMOVAL
Front Disc Brake
1. Remove the wheel and tire.
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2. Check the pad thickness through the cylinder inspection hole.
Standard value Service limit
Pad lining thickness
10.75 (0.423) 2.0 (0.079)
mm (in.)
If the pad lining thickness is out of specification, replace the pads.
3. Remove two bolts from the torque plate and remove the brake cylinder.
4. Remove the brake cylinder and suspend it with wire.
Do not disconnect the brake hose.

5. Remove the pads.
Be careful not to depress the brake pedal while disassembling the

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

2. Position the pad with its pad wear sensor upward on piston side.
3. Remove rust before position the pad clip or replace new one if it is
damaged.
3. Press in piston with a hammer handle or equivalent.
4. Lower and insert the brake cylinder carefully so as not to damage the boot.
5. Install the two guide rod bolts and tighten.
Guide rod bolt : 22-32 Nm (220-320 kg·cm, 16-24 lb·ft)
INSTALLATION
Caliper Assembly
1. Install the pads and brake cylinder.
2. Install the brake hose to the caliper.
Bleeder screw tightening torque : 7-13 N·m (70-130 kg·cm, 5-9.6 lb·ft)
3. Fill brake reservoir with brake fluid.

INSPECTION
Front Disc Brake
1. Check the pads for wear or oil contamination.
Replace or correct if necessary.
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2. Check the shims for damaged or deformed.
INSPECTION
Caliper Assembly
1. Check the caliper body cylinder inner surface for wear, damage and/or corrosion.
2. Check the piston for wear, damage and/or corrosion.
3. Check the caliper body and sleeve for wear.
4. Check pads for deformation, metal backing for damage, and for oil on the pads.
5. Check the wear indicator for damage.
6. Inspect the brake disc using a dial indicator and micrometer.
Machine or replace as necessary.
Thichness of disc
24.5 (0.964 in.) 22.4 (0.88)
mm (in.)
Runout of disc mm
- 0.03 (0.0012)
(in.)
Disc thickness
- 0.005 (0.0002)
variation
7. If necessary, replace the brake disc.

(1) Jack up the vehicle and support it with jack stands.
(2) Remove the wheel and tire.
(3) Remove the front wheel brake assembly from the knuckle and suspend it with a wire.
(4) Remove the front disc from the hub.
FRONT BRAKE DISC RUN-OUT CORRECTION
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1. If the run-out of the brake disc is equivalent to or exceeds the limit specification, replace the disc and hub, and
then measure the run-out again.
(1) Before removing the brake disc, chalk both sides of the wheel stud on the side at which run-out is greatest.
(2) Remove the brake disc, and then place a dial gauge as shown in the illustration; then move the hub in the axial
direction and measure the play.
Limit : 0.02 mm (0.0012 in.)
If the play is equivalent to or exceeds the limit, disassemble the hub knuckle and check each part.
(3) If the play does not exceed the limit specification, install the brake disc at a position 180° from the chalk
mark, and then check the run-out of the brake disc once again.
2. If the run-out cannot be corrected by changing the phase of the brake disc, replace the brake disc or turn rotor
with anon the car type brake lathe ("MAD, DL-8700PF" or equivalent). Be sure to follow the exact brake lathe
manufacturer instructions. Rotors turned on the vehicle will often have a lower run-out than a new brake disc.
FRONT BRAKE DISC THICKNESS CHECK

1. Using a micrometer, measure disc thickness at eight positions, approximately 45° apart and 10 mm (0.39 in.) in
from the outer edge of the disc.
Brake disc thickness

Standard value : 24.5 mm (0.965 in.)
Limit : 22.4 mm (0.88 in.)
Thickness variation (at least 8 positions)
The difference between any thickness measurements should not be more than 0.005 mm (0.0002
in.).
2. If the disc is beyond the limits for thickness, remove it and install a new one. If thickness variation exceeds the
specification, replace the brake disc or turn rotor with an on the car type brake lathe ("MAD. DL-8700PF" or
equivalent). Besure to follow the exact brake lathe manufacturer instructions.
Page 23 of 65
DISASSEMBLY
Caliper Assembly
1. Loosen the caliper attaching guide bolts and separate the caliper.
2. Remove the boot ring using a flat blade screwdriver.

3. Remove the piston boot.
4. Remove the piston by applying compressed air through the brake hose fitting hole.
Do not place your fingers in front of the piston when using compressed air.
5. Using a screwdriver, remove the piston seal carefully so as not to damage the cylinder wall.
6. Clean the outer surface of the piston and the inner surface of the cylinder with the specified brake fluid.
REASSEMBLY
Front Disc Brake
1. Clean the components with isopropyl alcohol except pad and shim.
2. Install the piston seal.
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3. After applying specified brake fluid to the piston outer surface, install the piston into the cylinder.
4. Install the piston boot and boot ring.
5. Install the guide pin boots and guide pin.
INSPECTION
Front Disc Brake
1. Check the pads for wear or oil contamination.
Replace or correct if necessary.
2. Check the shims for damaged or deformed.
INSPECTION
Caliper Assembly
1. Check the caliper body cylinder inner surface for wear, damage and/or corrosion.
2. Check the piston for wear, damage and/or corrosion.
3. Check the caliper body and sleeve for wear.
4. Check pads for deformation, metal backing for damage, and for oil on the pads.
5. Check the wear indicator for damage.
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6. Inspect the brake disc using a dial indicator and micrometer.
Machine or replace as necessary.
Thichness of disc
24.5 (0.964 in.) 22.4 (0.88)
mm (in.)
Runout of disc mm
- 0.03 (0.0012)
(in.)
Disc thickness
- 0.005 (0.0002)
variation
7. If necessary, replace the brake disc.

(1) Jack up the vehicle and support it with jack stands.
(2) Remove the wheel and tire.
(3) Remove the front wheel brake assembly from the knuckle and suspend it with a wire.
(4) Remove the front disc from the hub.
FRONT BRAKE DISC RUN-OUT CORRECTION
1. If the run-out of the brake disc is equivalent to or exceeds the limit specification, replace the disc and hub, and
then measure the run-out again.
(1) Before removing the brake disc, chalk both sides of the wheel stud on the side at which run-out is greatest.
(2) Remove the brake disc, and then place a dial gauge as shown in the illustration; then move the hub in the axial
direction and measure the play.
Limit : 0.02 mm (0.0012 in.)
If the play is equivalent to or exceeds the limit, disassemble the hub knuckle and check each part.
Page 26 of 65
(3) If the play does not exceed the limit specification, install the brake disc at a position 180° from the chalk
mark, and then check the run-out of the brake disc once again.
2. If the run-out cannot be corrected by changing the phase of the brake disc, replace the brake disc or turn rotor
with anon the car type brake lathe ("MAD, DL-8700PF" or equivalent). Be sure to follow the exact brake lathe
manufacturer instructions. Rotors turned on the vehicle will often have a lower run-out than a new brake disc.
FRONT BRAKE DISC THICKNESS CHECK

1. Using a micrometer, measure disc thickness at eight positions, approximately 45° apart and 10 mm (0.39 in.) in
from the outer edge of the disc.
Brake disc thickness

Standard value : 24.5 mm (0.965 in.)
Limit : 22.4 mm (0.88 in.)
Thickness variation (at least 8 positions)
The difference between any thickness measurements should not be more than 0.005 mm (0.0002
in.).
2. If the disc is beyond the limits for thickness, remove it and install a new one. If thickness variation exceeds the
specification, replace the brake disc or turn rotor with an on the car type brake lathe ("MAD. DL-8700PF" or
equivalent). Besure to follow the exact brake lathe manufacturer instructions.
Brake System > Brake System > Rear Dinode Brake > Components and Components Location
COMPONENTS
Brake System > Brake System > Rear Dinode Brake > Repair procedures
Page 27 of 65
REMOVAL
Disc Brake Pad
1. The procedure is the same with front disc brake pad.
INSTALLATION
Disc Brake Pad
1. Before replacing the brake pads, remove brake fluid from the master cylinder reservoir until it is half full.
INSPECTION
Disc Brake Pad
1. Check the pads for wear or oil contamination and replace if necessary.
The pads for the right and left wheels should be replaced at the same time.
Pad thickness wear limit ; 2.0 mm
2. Check the leading and trailing shoe keys and retaining screw for damage, or wear. Replace the keys and retaining
screw at the same time the pads are replaced.
3. Check for worn or damaged dust boots if dust or mud has entered the caliper assembly through this seal, the
caliper assembly must be replaced or rebuilt.
DISASSEMBLY
Caliper
1. Remove the caliper mounting bolts, and the caliper assembly.
2. Remove the carrier bolt, and the carrier with brake pad.
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3. Remove the piston boot.
4. Remove the piston assy.
5. Remove piston seal with finger tip.
Do not use sharpened tools to prevent damage to the inner surface

cylinder.
REASSEMBLY
Caliper
1. Check for worn, damaged, or rusted piston bore and piston.
Replace the damaged parts if necessary.
2. Check for damaged piston seal, boot, and pin insulators.
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3. Apply a recommended lubricant to the fallowing parts.
Parts Recommended lubricant Quantity
Piston seal Brake fluid (Dot 3 or Dot 4) As required
Cylinder inner side Brake fluid (Dot 3 or Dot 4) As required
Piston boot Brake fluid (Dot 3 or Dot 4) As required
Piston outer surface Brake fluid (Dot 3 or Dot 4) As required
Guide-rod insulators Rubber grease As required
4. Push the piston into the caliper.
5. Align the piston matching mark to upward as shown in illustration.
Brake System > Brake System > Rear Drum Brake > Components and Components Location
COMPONENTS
Page 30 of 65
Brake System > Brake System > Rear Drum Brake > Repair procedures
REMOVAL
Rear drum Brake
1. Remove the wheel and tire, then remove the brake drum.
If the brake drum is difficult to remove, insert bolts into the threaded holes of the drum, then
remove it.
2. After removing the rear hub bearing flange nut, remove the rear hub with the brake drum.
3. Remove the shoe return spring, cylinder end shoe spring, the shoe hold down spring.
Page 31 of 65
4. Remove the shoes and adjuster as an assembly.
INSTALLATION
Rear drum Brake
1. Apply the specified grease to the locations indicated in the illustration and to each component.
(1) Shoe and backing plate contact surfaces .
(2) Shoe and anchor plate contact surfaces.
Recommended grease : Multipurpose grease SAE J310, NLGI No.2
2. Install the shoe hold down pin.
3. Assemble the return spring by pressing the push rod.
Split pin and hub cap must not be reused.

4. Check the outside dimension and correct it using auto-adjuster (227.6-228.1 mm).
5. Do the parking brake stroke adjustment after assembling lining.
REPLACEMENT
Page 32 of 65
Wheel Cylinder
1. Remove the brake shoe.
2. Disconnect the brake tube.
3. Remove the wheel cylinder assembly.
4. Remove the dust boot.

5. Remove the piston and piston cup.
6. Drive out the return spring.
7. Before assembling the wheel cylinder, inspect the following.
(1) Check the cylinder and piston for wear, damage and rust.
[ ] Standard value
Clearance of piston and 0.039-0.089
cylinder (mm)
(2) Check the cylinder body for damage and cracks.

(3) Check the contact surface of the piston and shoes for wear.
(4) Check the piston spring for looseness.
8. Assembly is the reverse of the removal.
1. Clean the cylinder with isopropyl alcohol before

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

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

4. Inspect the wheel cylinder outside for excessive wear and damage.
5. Inspect the backing plate for wear or damage.
Brake System > Brake System > Troubleshooting

TROUBLESHOOTING
Vehicle pulls to one side when brakes Grease or oil on pad or lining surface Replace
are applied
Inadequate contact of pad or lining Correct
Auto adjuster malfunction Adjust
Drum eccentricity or uneven wear Repair or replace as necessary
Insufficient braking power Low or deteriorated brake fluid Refill or change
Air in brake system Bleed air
Overheated brake rotor due to Correct
dragging of pad or lining
Grease or oil on pad or lining surface Replace
Inadequate contact of pad or lining Correct
Brake booster malfunction Correct
Page 34 of 65
Clogged brake line Correct
Proportioning valve malfunction Replace
Increased pedal stroke Air in the brake system Bleed air
(Reduced pedal to floorboard Worn lining or pad Replace
clearance)
Broken vacuum hose Replace
Brake fluid leaks Correct
Excessive push rod to master cylinder Adjust
clearance
Faulty master cylinder Replace
Brake drag Incomplete release of parking brake Correct
Incorrect parking brake adjustment Adjust
Worn brake pedal return spring Replace
Broken rear drum brake shoe return Replace
spring
Lack of lubrication in sliding parts Lubricate
Improper push rod to master cylinder Adjust
clearance
Faulty master cylinder piston return Replace
spring
Clogged master cylinder return port Correct
Insufficient parking brake function Worn brake lining or pad Replace
Excessive parking brake lever stroke Adjust the parking brake lever
stroke or check the parking
brake cable routing
Grease or oil on lining or pad surface Do the lining BED-IN
Auto adjuster malfunction Replace
Parking brake cable sticking Adjust
Scraping or grinding noise when Worn brake lining or pad Replace
brakes are applied Caliper to wheel interference Correct or replace
Dust cover to disc interference Correct or replace
Bent brake backing plate Correct or replace
Cracked drums or brake disc Correct or replace
Squealing, groaning or chattering noise Worn brake pad anti-squeak shim Replace
when brakes are applied
Brake drums and linings, discs and Correct or replace
pads worn or scored
Improper lining parts Correct or replace
Disc brake-burred or rusted calipers Clean or deburr
Page 35 of 65
Dirty, greased, contaminated or glazed Clean or replace
linings
Drum brakes-weak, damaged or Correct or replace
incorrect shoe hold-down springs,
loose or damaged shoe hold-down
pins and springs
Squealing noise when brakes are not Bent or warped backing plate causing
Replace
applied interference with drum
Improper machining of drum causing
Replace drum
interference with backing plate or shoe
Disc brakes-rusted, stuck Lubricate or replace
Drum brakes-weak-damaged or
Replace
incorrect shoe-to-shoe spring
Loose or extra parts in brakes Retighten
Improper positioning of pads in caliper Correct
Improper installation of support
Correct
mounting to caliper body
Poor return of brake booster or master
Replace
cylinder or wheel cylinder
Incorrect brake pedal or booster
Adjust
push-rod
Groaning, clicking or rattling noise Stones or foreign substances trapped Remove foreign substances
when brakes are not applied inside wheel covers
Loose wheel nuts Retighten
Disc brakes-failure of shim Replace
Disc brakes-loose installation bolt Retighten
Worn, damaged or dry wheel bearings Lubricate or replace
Disc brakes-wear on guide rod Replace
Incorrect brake pedal or booster Adjust
push-rod
Brake System > Parking Brake System > Parking Brake Assembly > Components and Components
Location
COMPONENTS
Page 36 of 65
Brake System > Parking Brake System > Parking Brake Assembly > Repair procedures
REMOVAL
1. Remove the main floor console.
2. Detach the parking brake switch.
3. Remove the parking brake lever.

4. Remove the parking brake lever from the parking brake cable.
5. Remove the rear seat cushion and take up the carpet.
6. Remove the parking brake cable clamp and grommet.
7. Move the center muffler heat protector center panel to the front.
8. Remove the washer assembled bolt and detach the clamp bracket.
9. Remove the tire assembly and the brake drum.
10. Remove the rear hub assembly.
11. Remove the springs and shoe hold down pins.
12. Remove the cable clip.
13. Disconnect the cable end from the trailing shoe.
Page 37 of 65
14. Drive out the parking brake cable to the under body side.
INSTALLATION
1. Check the parking brake cables for an identification mark paint or wind tape and install as appropriate on the left
and right sides.
Identification color
[ ] Left side Right side
Rear disc brake None White
Rear drum brake Red Yellow
2. Set the adjuster lever all the way back when installing the shoe-to-shoe spring.
3. Install the grommet in the direction shown in the illustration.
4. Apply a coating of the specified grease to each sliding parts of the ratchet plate or the ratchet pawl.
Specified grease : Multipurpose grease SAE J310, NLGI No.2

Page 38 of 65
5. After installing the cable adjuster, adjust the parking brake lever stroke.
SERVICE ADJUSTMENT
1. After replacing the parking lever.
Perform the cable adjustment after pulling parking brake lever 4-5 times as full stroke.
2. After replacing the cable.
(1) In case of drum brake
Adjust the outer diameter of the drum brake lining to ф227.6-228.1 mm (Refer to page BR-30). After
installing the drum, perform the cable adjustment.
(2) In case of D.I.H (Drum In Hat)
Remove the adjusting hole plug and then turn the adjusting wheel to the direction of the arrow unit the disc
won't rotate by tangential force of 3 Kgf using a screw driver (flat tip (-)).
Rotate the adjustor as much as 5 notches to the opposite direction of the arrow (Shoe clearance 0.19mm
(0.0075 in) each sice).
3. After replacing brake lining (Bed-in procedure)

(1) Pull the parking lever as much as 4~5 notches (or 9 kg·f).
(2) Drive the vehicle about 400m at the speed of 50 KPH.
(3) Stop the vehicle for 2 minutes.
(4) Check the stroke of the parking brake.
SERVICE ADJUSTMENT
1. After replacing the parking lever.
Perform the cable adjustment after pulling parking brake lever 4-5 times as full stroke.
Page 39 of 65
2. After replacing the cable.
(1) In case of drum brake
Adjust the outer diameter of the drum brake lining to ф227.6-228.1 mm (Refer to page BR-30). After
installing the drum, perform the cable adjustment.
(2) In case of D.I.H (Drum In Hat)
Remove the adjusting hole plug and then turn the adjusting wheel to the direction of the arrow unit the disc
won't rotate by tangential force of 3 Kgf using a screw driver (flat tip (-)).
Rotate the adjustor as much as 5 notches to the opposite direction of the arrow (Shoe clearance 0.19mm
(0.0075 in) each sice).
3. After replacing brake lining (Bed-in procedure)

(1) Pull the parking lever as much as 4~5 notches (or 9 kg·f).
(2) Drive the vehicle about 400m at the speed of 50 KPH.
(3) Stop the vehicle for 2 minutes.
(4) Check the stroke of the parking brake.
Brake System > ABS(Anti-Lock Brake System) > Schematic Diagrams

DIAGRAM OF INPUT/OUTPUT FOR HECU
Page 40 of 65
Brake System > ABS(Anti-Lock Brake System) > Flow Diagram

SYSTEM DIAGRAM
Page 41 of 65
SYSTEM DIAGRAM
Page 42 of 65
Brake System > ABS(Anti-Lock Brake System) > Description and Operation
DESCRIPTION
Page 43 of 65
The Anti-Lock Brake System (ABS) controls the hydraulic brake pressure of all four gear wheels during sudden
braking andbraking on hazardous road surfaces, preventing the wheels from locking. This ABS provides the
following benefits.
1. Enables steering around obstacles with a greater degree of certainty even during panic braking.
2. Enables stopping during panic braking while allowing stability and steerability to a minimum, even on curves.
In case a malfunction occurs, a diagnosis function and fail-safe system have been included for serviceability.
The feeling of vibration in the pedal under emergency braking is not evidence of a system malfunction.
The traction control is a variable system designed to enhance traction during acceleration. It does so by determining
the optimum amount of wheel spin for any given driving situation, then suppressing surplus engine power accordingly.
The integrated control unit (HECU) gets signals about the vehicle's speed, direction and road conditions from
sensors atthe wheels and the steering column. Based on these signals, the control unit will determine the optimum
amount of wheelspin. Because the system is variable, the control unit may determine, depending on the driving
conditions, that some wheel spin is beneficial (thus enhancing straight-line acceleration), or that no wheel spin is
beneficial (thus enhancing cornering). For any given driving situation, the control unit will determine the amount of
wheel spin best suited to thedriver's needs. The system is automatically ready whenever the engine is started, but can
be manually canceled with theTCS switch.
However, once actuated, the system cannot be canceled until it is once again in the ready state.
EBD (Electronic Brake-force Distribution)
The EBD is additionally applied instead of the proportioning valve to make the ideal distribution of a fluid pressure
tothe front and rear brake to prevent the brakes from skidding in the event of rear wheel lock and to obtain a higher
brake efficiency within the range of service brake application.
Page 44 of 65
1. ADVANTAGES
A. Function improvement of base-brake system
B. Compensation of different friction coefficients
C. Elimination of proportioning valve
D. Failure recognition by warning lamp
COMPARISON BETWEEN WITH P-VALVE AND WITH EBD
INSPECTION AT HECU TEMINALS

TERMINAL VOLTAGE CHART
Terminal No. Description Condition Output

· Battery power source 1
9 Always System voltage
· Solenoid valve power source
8 Ground Always - In ABS & TCS control
Diagnosis interface terminal (K-
7 Connect the Hi-Scan
Line)
6 Wheel speed sensor (Left rear)
2 Wheel speed sensor (Left front) Resistance
20 Wheel speed sensor (Right front) R = 1275 - 1495Ω
22 Wheel speed sensor (Right rear)
5 Wheel speed sensor (Left rear)
1 Wheel speed sensor (Left front)
19 Wheel speed sensor (Right front)
23 Wheel speed sensor (Right rear)
Page 45 of 65
Over voltage detection
16 V < V < 21 V
4 Power input via ignition 2 switch Ignition 2 condition
Suspend voltage detection
8 V < V < 10 V
3, 15, 12, 20 Not used
· Battery power source 2
25 Always
· Motor power source
24 Ground - 2 (Motor) G07
16 ABS and EBD warning lamp
13 TCS off switch
14 TCS function lamp
11 CAN-High
10 CAN - Low
18 Stop lamp switch
17 TCS warning lamp & off lamp
DESCRIPTION
TCS FUNCTION
1. Driving control
When the drive wheel speed exceeds the vehicle speed by a given amount, the HECU judges that the drive
wheels are slipping, and it outputs the traction control signal to reduce engine power.
2. Rough road control
Based on signals from the wheel sensors, the control unit detects a rough road based on frequency of wheel
rotational vibration. The control unit then signals the TCS control valve actuator and ECM to relax engine power,
thus improving acceleration efficiency.
3. Grip control
Based on signals about wheel speed, the control unit determines the efficiency of the grip of the tires on the road
and signals the TCS control valve actuator and ECM relax engine power if necessary, thus improving grip.
Brake System > ABS(Anti-Lock Brake System) > ABS Control Module > Components and
Components Location
COMPONENTS
HECU (Hydraulic and Electronic Control Unit)
Page 46 of 65
Brake System > ABS(Anti-Lock Brake System) > ABS Control Module > Repair procedures
REMOVAL
HECU (Hydraulic and Electonic Control Unit)
1. Disconnect the HECU (Hydraulic and Electonic Control Unit) connector.
2. Disconnect the brake tubes from the HECU.
3. Remove the HECU bracket mounting bolt and remove the HECU.
1. Never attempt to disassemble the HECU.

2. The HECU must be transported and stored in upright position and with sealed
ports.
The HECU must not be drained.
3. It will cause the HECU to fail if you don't keep.
INSTALLATION
HECU (Hydraulic and Electonic Control Unit)
1. Follow the reverse order of removal.
Page 47 of 65
2. Tighten the modulator mounting bolts and brake tube nuts to the specified torque.
HECU mounting bolt : 8-10Nm (80-100 kg·cm, 5.6-6.9 lb·ft)

Brake tube nut : 13-17 Nm (130-170 kg·cm, 9-12 lb·ft)
Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Components and
Components Location
COMPONENTS
Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Repair procedures
REMOVAL
Front Wheel Speed Sensor
1. Remove the front wheel speed sensor mounting bolt.
Page 48 of 65
2. Remove the front wheel speed sensor after disonnecting the wheel speed sensor connector.
Rear Wheel Speed Sensor

1. Remove the rear seat cushion.
2. Remove the rear pillar trim assembly.
3. Remove the tire assembly.
4. Remove the rear wheel speed sensor after disconnection the wheel speed sensor connector.
INSPECTION
Rear Wheel Speed Sensor
1. Connect an ohmmeter betweem the wheel speed sensor terminals and measure the resistance.
Service standard
Front : 1275-1495Ω
Rear : 1275-1495Ω
Page 49 of 65
2. Connect a voltmeter between the wheel speed sensor terminals, and measure the voltage by turning the wheel.
Set the voltmeter to measure AC voltage.

Service standard : AC voltage detected.
Brake System > ABS(Anti-Lock Brake System) > Troubleshooting

BLEEDING BRAKE SYSTEM
This procedure should be used to insure adequated bleeding and filling of ABS unit, brake lines, master cylinder.
1. Remove the reservoir cap and fill the brake reservoir with brake fluid.
Do not allow brake fluid remain on a painted surface.

Wash it off immediately.
When bleeding by pressured fluid, do not depress the brake pedal.
Recommended fluid : DOT3 or equivalent
2. Connect the clear plastic tube to the wheel cylinder bleeder plug and insert the other end of tube in a half filled
clear plastic bottle.
Page 50 of 65
3. Connect Hi-Scan to Data Link Connector located undermeath the dash panel.
4. Select and operate according to the instruction on the Hi-Scan screen.
You have to obey maximum operating time (60sec) of ABS motor with Hi-Scan to prevent motor pump
burnt.
Do not exceed the maximum pump operating time (60 seconds maximum) when operating the ABS motor
with the scan tool. If the pump operating time is exceeded, damage to the pump motor could occur.
5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without
bubbles.
Then close the bleeder screw.
6. Repeat the step 5. until there are no more bubbles in the fluid for each wheel in the sequence shown in the
illustration.
7. Tighten the bleeder screw.
Bleeder screw tightening torque : 7-13 Nm (70-130 kg·cm, 5-9.6 lb·ft)
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Page 51 of 65
* Using the customer prolem analysis heck sheet for reference, ask the customer in as much detail as possible about
the problem.
NOTES WITH REGARD TO DIAGNOSIS
The phenomena listed in the following table are not abnormal.
Phenomenon Explanation of phenomenon
When starting the engine, a thudding sound can sometimes be heard coming from inside the
System check sound engine compartment, but this isbecause the system operation check is being performed, and
is not an abnormality.
1. Sound of the motor inside the ABS hydraulic unit operation(whine).
2. Sound is generated along with vibration of the brake pedal(scraping).
ABS operation sound 3. When ABS operates, sound is generated from the vehicle chassis due to repeated brake
application and release.
4. (Thump : suspension; squeak: tires)
For road surfaces such as snow-covered roads and gravel roads, the braking distance for
ABS operation
vehicles with ABS can sometimes be longer than that for other vehicle. This is explained in
(Long brakeing
the vehicle owner's manual. Advise the customer to read their vehicle owner's manual
distance)
thoroughly and to lower the vehicle speed and be cautious on such road surfaces.
Diagnosis detection condition can vary depending on the diagnosis code.

Make sure that checking requirements listed in the "Comment" are satisfied when checking the trouble symptom
again after the diagnosis code has been erased.
Page 52 of 65
HI-SCAN CHECK
1. Turn the ignition OFF.
2. Connect the hi-scan to the data link connector located under-neath low crash pad panel.
3. Turn the ignition ON.
4. Use the hi-scan to check the self-diagnosis codes.
5. After completion of the repair or correction of the problems, turn the ignition switch; then erase the stored faults
codes using the clear key.
Page 53 of 65
6. Disconnect the hi-scan.
CONNECTOR CHECK
1. Remove the battery negative (-) terminal.
2. Disconnect the connectors and check terminals follow the troubleshooting procedure.
When you check terminals, be sure to use enough small pin which is not damaged to the connector
terminals.
INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES
Inspect according to the inspection chart that is appropriate for the malfunction code.
DTC on Hi-
Description Memory
Scan
C1103 Voltage out of range (Under and over voltage) O
C1200 FL wheel sensor : Open or short to GND O
C1201 FL wheel sensor : Speed jump or wrong exciter O
C1202 FL wheel sensor : Air-gap error O
C1203 FR wheel sensor : Open or short to GND O
C1204 FR wheel sensor : Speed jump or wrong exciter O
C1205 FR wheel sensor : Air-gap error O
C1206 RL wheel sensor : Open or short to GND O
C1207 RL wheel sensor : Speed jump or wrong exciter O
C1208 RL wheel sensor : Air-gap error O
C1209 RR wheel sensor : Open or short to GND O
C1210 RR wheel sensor : Speed jump or wrong exciter O
C1211 RR wheel sensor : Air-gap error O
C1604 ECU Hardware error O
C1605 CAN hardware error O
C1610 CAN bus off error O
C1611 CAN timeout EMS O
C1612 CAN timeout TCU O
C1613 CAN transmission unmatching O
C2112 Main relay, fuse O
C2114 Disturbance (Including valve failure) O
C2402 Motor pump O
Page 54 of 65
ACTUATOR DRIVING
No. Description Recognition Remark
01 Motor Motor pump relay operation (Click sounds)
02 Front left valve (In) Front left solenoid valve operation (Click sounds)
03 Front right valve (In) Front right solenoid valve operation (Click sounds)
04 Rear left valve (In) Rear left solenoid valve operation (Click sounds) Actuation time
is limited to
05 Rear right valve (In) Rear right solenoid valve operation (Click sounds)
MAX. 20
06 Front left valve (Out) Front left solenoid valve operation (Click sounds) seconds
07 Front right valve (Out) Front right solenoid valve operation (Click sounds)
08 Rear left valve (Out) Rear left solenoid valve operation (Click sounds)
09 Rear right Valve (Out) Rear right solenoid valve operation (Click sounds)
CURRENT DATA
No. Description Full description Remark
FL wheel speed
12 Front left wheel speed sensor
SNSR
FR wheel speed
13 Front right wheel speed sensor
SNSR
RL wheel speed
14 Rear left wheel speed sensor
SNSR
RR wheel speed
15 Rear right wheel speed sensor
SNSR
17 ABS SRI status Warning lamp
18 Brake SW Brake switch
20 Motor pump relay Motor relay Minimum
level is V ≥
21 Valve relay Valve relay 10 kgh
22 Motor pump status Motor
23 FL valve (In) Front left valve (In).
24 FR valve (In) Front right valve (In)
25 RL valve (In) Rear left valve (In)
26 RR valve (In) Rear right valve (In)
27 FL valve (Out) Front left valve (Out)
28 FR valve (Out) Front right valve (Out)
29 RL valve (Out) Rear left valve (Out)
30 RR valve (Out) Rear right valve (Out)
ABS WARNING LAMP INSPECTION

Check that the ABS warning lamp illuminates as follows.
Page 55 of 65
1. When the ignition key is turned to "ON", the ABS warning lamp illuminates for approximately 2 second and then
switches off.
INSPECTION CHART FOR TROUBLE SYMPTOMS

Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Inspection procedure
Trouble symptom
No.
Communication with Hi-Scan is Communication with all system is not possible. 1
not possible Communication with ABS only in not possible. 2
When the ignition key is turned to "ON" (engine stopped), the ABS warning lamp does not
3
illuminate.
After the engine start, the lmap remains illuminated 4
Unequal braking power on both sides 5
Insufficient braking power
ABS operates under normal braking conditions
Faulty ABS operation
ABS operates before vehicle stops under normal
braking conditions
Large brake pedal vibration (Caution 2.)
During ABS operation, the brake pedal may vibrate or may not be able to be depressed. This does not mean that
the system is defective.
Such phonomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels
from locking. That is what the system is designed to do.
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
Inspection Procedure 1
Communication with Hi-Scan is not possible.
Probable cause
(Communication with all systems is not possible.)
[Comment]
· Malfunction of connector
The reason is probably a defect in the power supply
· Malfunction of wiring harness
system (Including ground) for the diagnosis line.
Page 56 of 65
Communication with Hi-Scan is not possible.
Probable cause
(Communication with ABS only is not possible.)
[Comment]
· Blown fuse
When communication with Hi-Scan is not possible, the
· Malfunction of wiring harness or connector
cause is probably an open circuit in the HECU power
· Malfunction of HECU
circuit or an open circuit in the diagnosis output circuit.
Page 57 of 65
When ignition key is turned to "ON" (engine
Probable cause
stopped), ABS warning lamp does not illuminate
[Comment]
When current flows in the HECU, the ABS relay turns
from on to off as the initial check. So the ABS warning
lamp will illuminate when the ABS relay is off even if
there is a problem with the circuit between the ABS
· Blown fuse
warning lamp and the HECU.
· Burnt out ABS warning lamp bulb
Therefore, if the lamp does not illuminate, the cause may
be : an open circuit in the lamp power supply circuit, a
blownlamp bulb, an open circuit in both the circuit
between the ABS warning lamp and the HECU and in
the circuit between theABS warning lamp and the ABS
relay
Even after the engine is started, the ABS warning
Probable cause
lamp remains illuminated
[Comment] · Malfunction of combination meter
The cause is probably a short-circuit in the ABS warning · Malfunction of HECU
lamp illumination circuit · Malfunction of wiring harness
This trouble symptom is limited to cases where communication with the Hi-Scan is possible (HECU power supply is
normal) and the diagnosis code is a normal diagnosis code.
Page 58 of 65
Brake operation is abnormal Probable cause
· Improper installation of wheel speed sensor
· Incorrect sensor harness contact
[Comment]
· Foreign material adhering to wheel speed sensor
This varies depending on the driving conditions and the
· Malfunction of wheel speed sensor
road surface conditions, so problem diagnosis is difficult.
· Malfunction of rotor
However, if a normal diagnosis code is displayed, carry
· Malfunction of wheel bearing
the following inspection.
· Malfunction of hydraulic unit
Page 59 of 65
ABS OPERATION CHECK (Wheel Speed Sensor Output Voltage Check)

1. Lift up the vehicle and release the parking brake.
2. Disconnect the HECU harness connector and measure from the harness side connector.
Be sure to remove the connector double lock and insert the probe into the harness side. Inserting it into the
terminal side will result in a bad connection.
Page 60 of 65
3. Rotate the wheel to be measured at approximately 1/2-1 rotation per second, and check the output voltage using
a circuit tester or an oscilloscope.
Wheel speed sensor Front left Front right Rear left Rear right
2 20 6 23
Terminal No.
1 19 5 22
Output voltage
When measuring with an oscilloscope : 100 mV p-p or more
Brake System > Troubleshooting > C1200

INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES
DTC No. C1200, C1203, C1206, C1209
Probable cause
Wheel speed sensor open or short to GND circuit
[Comment] · Malfunction of wheel speed sensor
The HECU determines that an open or short circuit · Malfunction of wiring harness or connector
occurs in more than one line of wheel speed sensors · Malfunction of HECU
Page 61 of 65

DTC No. C1201, C1204, C1207, C1210
Probable cause
(Speed jump or wrong exciter)
[Comment] · Malfunction of wheel speed sensor
A wheel speed sensor outputs an abnormal · Malfunction of rotor
signal · Malfunction of wheel bearing
(other than an open short-circuit) · Malfunction of wiring harness or connector
Page 62 of 65

DTC No. C1202, C1205, C1208, C1211 (Air
Probable cause
gap error)
· Malfunction of wheel speed sensor
[Comment]
· Malfunction of rotor
A wheel speed sensor outputs no signal

Page 63 of 65
DTC No. C1604 ECU Hardware (Error valve
Probable cause
failure)
[Comment]
The HECU always monitors the solenoid valve drive
· Malfunction of wiring harness
circuit. It determines that there is an open or short-circuit
in the solenoid coil or in a harness : When no current
flows in the solenoid even though the HECU turns on it,
and vice versa.

DTC No. C1605 CAN hardware error Probable cause
· Interence by means of electronic wave
· Mismatching of the calculation between main and
[Repair]
sub processor
Replace the HECU
· Defects of the valve coil and valve coil operating
circuit element

DTC No. C1610 CAN bus off error Probable cause
[Repair]
· CAN bus cable open or short to ground or
Inspect CAN bus wiring
battery
Check the HECU, TCM, or ECM connectors

DTC No. C1611 CAN timeout EMS Probable cause
· In case of no message from EMS or TCM during 500
[Repair]
ms.
Inspect the EMS or TCM according to the instruction of
· In case of A/T or M/T signal mismatch the EMS and
Engine or TM Group.
TCM message.

Page 64 of 65
DTC No. C1612 CAN timeout TCM Probable cause
[Repair]
ms.
Engine or TM Group.
TCM message.

DTC No. C1613 CAN transmission unmatching Probable cause
[Repair]
ms.
Engine or TM Group.
TCM message.

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

Page 65 of 65
DTC No. C2114 Disturbance Probable cause
· Interence by means of electronic wave
· Mismatching of the calculation between main
[Repair]
and sub processor
Replace the HECU
· Defects of the valve coil and valve coil
operating circuit element

DTC No. C2402 Electrical (Pump-motor) Probable cause
[Comment]
When the motor power line is normal but no signal
isinput to the motor monitor line when the motor power
line is faulty.
Because force-driving of the motor by means of the actuator test will drain the battery, the engine should be started
and left to run for a while after testing is completed.
Page 1 of 22
OPTIMA(MS) > 2001 > G 2.4 DOHC > Clutch System
Clutch System > General Information > Special Service Tools

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

TRANSAXLE RANGE SWITCH CONTINUITY
1. Terminal No.
SPORTS MODE SWITCH INSPECTION (F4A42-2 & 2.5L)

Page 2 of 22
1. Inspection
CHECK TRANSAXLE RANGE SWITCH AND CONTROL CABLE ADJUSTMENT

1. Set the selector lever to the "N" position.
2. Loosen the control cable to manual control lever coupling nut to free the cable and lever.
3. Set the manual control lever to the neutral position.
4. Loosen the transaxle range switch body mounting bolts and then turn the transaxle range switch body so the hole
in the end of the manual control lever and the hole (cross section A-A in the figure) in the flange of the transaxle
range switch body flange are aligned.
5. Tighten the transaxle range switch body mounting bolts to the specified torque. Be careful at this time that the
position of the switch body is not changed.
Page 3 of 22
6. Gently push the transmission control cable in the direction of the arrow, and then tighten the adjusting nut.
7. Check that the selector lever is in the "N" position.
8. Check that each range on the transmission side operates and functions correctly for each position of the selector
lever.
A/T CONTROL COMPONENT CHECK

1. THROTTLE POSITION SENSOR CHECK.
(1) Disconnect the throttle position sensor connector.
(2) Measure the resistance between the throttle position sensor side connector terminal 2 and terminal 3.
Standard value : 1.6-2.4 kΩ
(3) Measure the resistance between the throttle position sensor side connector terminal 1 and terminal 3.
Normal condition :
Throttle valve slowly open until fully open from the Changes smoothly in proportion to the opening angle
idle position of the throttle valve
Page 4 of 22
(4) If the resistance is outside the standard value, or if it doesn't change smoothly, replace the throttle position
sensor.
2. OIL TEMPERATURE SENSOR CHECK
(1) Remove the oil temperature sensor.
(2) Measure the resistance between terminals No.1 and No.2 of the oil temperature sensor connector.
Standard value :
Oil temperature (°C) Resistance (KΩ)
0 16.7-20.5
100 0.57-0.69
3. VEHICLE SPEED SENSOR CHECK

(1) Remove the vehicle speed sensor and connect 3-10 KΩ resistance as shoen in the illustration.
(2) Turn the shaft of the vehicle speed sensor and check that there is voltage between terminals 2-3 (1 turn=4
pulses).
4. A/T CONTROL RELAY CHECK

(1) Remove the A/T control relay.
(2) Use jumper wires to connect A/T control relay terminal (2) to the battery (―) terminal and terminal (4) to the
battery (+) terminal.
(3) Check the continuity between terminal (1) and terminal (3) of the A/T control relay when the jumper wires
are connected to and disconnected from the battery.
Jumper wire Continuity between terminals No.1
Connected Continuity
Disconnected No continuity
Page 5 of 22
(4) If there is a problem, replace the A/T control relay.
5. SOLENOID VALVE CHECK
(1) Disconnect the solenoid valve connector
Inspection
TROUBLESHOOTING
Insufficient pedal free play Adjust
Clutch slipping Clogged hydraulic system Correct or replace
○ Car will not respond to engine speed Excessive wear of clutch disc facing parts
during acceleration Hardened clutch disc facing, or oil on Replace
○ Insufficient car speed surface Replace
○ Lack of power during uphill driving Damaged pressure plate of flywheel Replace
Weak or broken pressure spring Replace
Excessive pedal free play
Hydraulic system fluid leaks, air rapping or Adjust
Difficult gear shifting clogging Repair or replace
(gear noise during shifting) Unusual wear or corrosion of clutch disc Replace
spring Replace
Excessive vibration (distortion) of clutch disc
Insufficient play of clutch pedal Adjust
When clutch is not used
Excessive wear of clutch disc facing Replace
A noise is heard after Unusual wear and/or damage of release
Relpace
clutch is disengaged bearing
Insuffcient grease on the sliding surface of
Clutch noisy Repair
A noise is heard when bearing sleeve
clutch is disengaged Improperly installed clutch assembly or
Repair
bearing
Page 6 of 22
A noise is heard when car
is suddenly rolled of with Damaged pilot bushing Replace
clutch partially engaged
Insufficient lubrication of clutch pedal Repair
Insufficient lubrication of spline part of cluth
Repair
disc
Hard pedal effort Insufficient lubrication of clutch release lever
Repair
shaft
Insufficient lubrication of front bearing
Repair
retainer

Clutch pedal free play excessive
Adjust pedal free play
Clutch release cylinder faulty
Repair release cylinder
Clutch disc out of true, runout is excessive or lining
hare to shift or will not shift Inspect clutch disc
broken
Repair as necessary
Spline on input shaft or clutch disc dirty or burred
Replace clutch cover
Clutch pressure plate faulty
Clutch pedal free play insufficient Adjust pedal free play
Clogged hydraulic system Repair or replace pats
Clutch slips Clutch disc lining oily or worn out Instect clutch disc
Pressure plate faulty Replace clutch cover
Release fork binding Inspect release fork
Clutch disc lining only or worn out Inspect clutch disc
Pressure plate faulty Replace clutch cover
Clutch grabs/chatters Clutch diaphragm spring bent Replace clutch cover
Worn of broken torsion spring Replace clutch disc
Engine mounts loose Repair as necessary
Replace clutch pedal
Damaged clutch pedal bushing
bushing
Loose part inside housing
Clutch noisy Repair as necessary
Release bearing worn or dirty
Replace release bearing
Release fork or linkage sticks
Repair as necessary
Clutch System > General Information > Repair procedures

CLUTCH SYSTEM
Service adjustment procedures clutch pedal inspection and adjustment
1. Measure the clutch pedal height (From the face of the pedal pad to the floor) and the clutch pedal clevis pin play
(measured at the face of the pedal pad).
Standard value : (A) 1-3 mm (0.04-0.11 in.)

Page 7 of 22
2. If the clutch pedal clevis pin free-play is not within the standard value range, adjust as follows :
A. Turn and adjust the bolt, then secure by tightening the lock nut.
After the adjustment, tighten the bolt until it reaches the pedal stopper, and then tighten the lock
nut.
B. Turn the push rod to agree with the standard value and then secure the push rod with the lock nut.
3. After completing the adjustments, check that the clutch pedal free play (measurd at the face of the pedal pad)
within the standard value ranges.
Standard value : 6-13 mm(0.2-0.5in)
4. If the clutch pedal free play and the distance between the clutch pedal and the floor board when the clutch is
disengaged do not meet with the standard values, it may be the result of either air in the hydraulic system or a
faulty master cylinder or clutch. Bleed the air or disassemble and inspect the master cylinder or clutch.
BLEEDING
Whenever the clutch tube, the clutch hose, and/or the clutch master cylinder have been removed, of if the clutch
pedal is spongy, bleed the system.
Page 8 of 22
Use the specified fluid. Avoid mixing different brands of fluid.

Specified fluid : SAE J703 (DOT3)
1. Loosen the bleeder screw at the clutch release cylinder.
2. Push the clutch pedal down slowly untion all is expelled.
3. Hold the clutch pedal down unitl the bleeder is retightened.
4. Refill the clutch master cylinder with the specified fluid.
The rapidly-repeated operation or the clutch pedal in B-C range may cause the release cylinder's position
to be forced out from the release cylinder body during the air bleeding, repress the clutch pedal agter it
returns to the "A" point completely.
Clutch System > General Information > Specifications

GENERAL
SPECIFICATIONS
Clutch operating method Hydraulic type
Type Single dry with diaphragm.
Clutch disc Facing diameter(Outside ×
225 × 150(8.9 × 5.9) ; 2.4L, 2.7L
Inside)mm(in.)
Clutch cover Type Diaphragm spring strap

assembly Setting load N (lb) 500-5800(1212-1302) ; 2.4L, 2.7L
Clutch release
I.D. mm(in.) 20.64(0.81)
cylinder
Cluch master
I.D. mm(in.) 15.87(0.62)
cylinder
SERVICE STANDARD
Page 9 of 22
Clutch disc thickness [When
8.3-8.9 mm (0.327-0.350 in.) ; 2.4L, 2.7L
free]
Standard value Clutch pedal height 180.5 ± 0.3 mm
Clutch pedal free play 6-13 mm (0.24-0.51 in.)
Clutch pedal stroke 150 mm (5.90 in.)
Clutch disc rivet sink 0.3 mm (0.012 in.)
Diaphragm spring end height
0.5 mm (0.02 in.)
difference
Limit Clutch release cylinder
0.15 mm (0.006 in.)
clearance to piston
Clutch master cylinder
0.15 mm (0.006 in.)
clearance to piston
TIGHTENING TORQUE
Item Nm Kg·cm lb·ft
Clutch pedal to pedal support
250-
member 25-35 18-25
350
(Clutch pedal bracket)
Clutch master cylinder mounting
8-12 80-120 6-9
bolt
120-
Clutch tube flare nut 12-16 9-12
160
Clutch release cylinder mounting 150-
15-22 11-16
bolt 220
Clutch release cylinder union bolt 25 250 18
Clutch cover assembly (2.4L, 200-
20-27 15-20
2.5L) 270
Clutch master cylinder push rod 100-
10-15 7-11
lock nut 150
Clutch master cylinder reservoir 8-10 80-100 6-7
Ignition lock switch 8-10 80-100 6-7
Clutch member 8-12 80-100 6-9
LUBRICANTS
Page 10 of 22
Items Specified lubricants Quantity
Contant surface of release bearing and fulcrum of clutch
CASMOLY L 9508 As required
release fork
Inner surface of clutch release bearing CASMOLY L 9508 As required
Inner surface of clutch release cylinder and outer
Brake fluid DOT 3 As required
circumference of piston and cup
Inner surface of clutch disc spline CASMOLY L 9508 As required
Inner surface of clutch master cylinder and outer
Brake fluid DOT 3 As required
circumference of piston assembly
Wheel bearing grease SAE J310,
Clutch master cylinder push rod, clevis pin and washer As required
NLGI No.1
Clutch pedal shaft and bushings Chassis grease SAE J310, NLGl No.1 As required
Contact portion of release fork to release cylinder push
CASMOLY L 9508 As required
rod
Input shaft spline CASMOLY L9508 As required
Clutch System > Clutch System > Clutch Cover And Dinode > Components and Components Location
COMPONENT
Page 11 of 22
Clutch System > Clutch System > Clutch Cover And Dinode > Repair procedures
REMOVAL
1. To remove the transaxle assembly, first remove the air cleaner joint, mounting bracket, and wiring etc.
2. Remove the release lever.

A. Loose the release lever nut and washer.
B. Remove the clevis pin and snap ring from the release cylinder.
C. Remove the release lever.
It is impossible to remove transaxle assembly without doing this step. Because, clutch cover, release
bearing and release fork are combined together.
3. Loose the bolts attached to the release cylinder and remove the release cylinder.
4. Remove the transaxle assembly, after removing each bolt which connect the transaxle assembly and engine
5. In the state that the clutch cover is attached to the flywheel remove the release bearing using appropriate tool as
shown.
A. Rotate the release bearing in the easy direction in order to examine the snap ring.
B. Insert the tool under the wave washer as shown in the illustration and locate in the center of snap ring.
C. Widen the space of snap ring by pushing the bearing as shown in the ullustration.
D. The snap ring -widen state is like as shown the figure.
Page 12 of 22
E. In the snap ring-widen state pull out the release bearing ansd remove it.
6. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from fallling.
7. Loose the bolts which attach the clutch cover tothe flysheel tin a star pattern. Loosen the bolts in succession, one
or two turns at a time, to avoid bending the cover flange.
Do not clean the clutch disc of release bearing with clreaning solvent.
8. Remove the release fork shaft and bushing.
INSTALLATION
1. Apply multipurpowe grease to the spline of disc.
Grease : CASMOLY L9508
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease' It can
cause clutch slippage and judder.
2. Install the clutch disc assembly to he flywheel using special tool (09411-11000).
3. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a
star pattern.
Tightenint torque clutch cover bolt : 2.4L/2.7L - 20-27 Nm (200-270 kg·cm, 15-20 Ib·ft)
Page 13 of 22
4. Align the bearing to the release fork and then install ti to the sleeve of gousig.
Apply multiprpose rease (CASMOLY L9508) to the grease gome of bearing sleeve and contac point of
release fork.
5. Install the release lever to the release fork.
If transaxle assembly is installed to engine without doing this step, release bearing can be separated
according as the release fork rotates free.
6. Install the transaxle assembly to the engine.
7. After finishing step 6, pushing the release lever to the arrow mark it is sounded click that the release bearingand
clutch cover are aligned correctly.
Release lever operation range : 3° or less
If the range is over 3° it is a sympotom that the release bearing and clutch cover are not aligned correctly. So,
push the release lever other arrow mark one more time.
INSPECTION
Page 14 of 22
1. CLUTCH COVER ASSEMBLY
(1) Clean the dust on the clutch housing using the vacuum brush or dry floorcloth and ought not to use the
compressed air absolutely. Check the oil leakage in eginerear bearing oil seal and transaxle front oil seal. If
leaky, repair them.
(2) Tsolutely. Check the oil leakage in eginerear bearing oil seal and transaxle front oil seal. If leaky, repair them.
(3) Check thefriction surface of flysheel for colorchange, partial dmage, small crack and wear
(4) Don't touch the clutch disc with the contaminated gands or gloves. REplace the clurhc dise, if the facing is
stained with oil or grease. Measure the rivet sing and replace the clruth dise, if it is less than 3 mm.
Limit : 0.3 mm (0.012 in.)
(5) Check the hub spine and torsion spring of clutch disc for cwcessive wear.
(6) Clean the friction surface of pressure plate with cleaning solvent.
(7) Measure the flat of pressure plate with a square. If it exceeds 0.5mm, replace it. Check the pressure plate
surface of wear, cracks and color change.
(8) Check that the three-dowel on the flywheel is installed completely.
2. CLUTCH RELEASE BEARING
The release bearing is packed with grease. Do not use cleaning solvent or oil.
(1) Check the bearing for sezure, damage or abnormal noise. Also check the diapgragm spring contaction goints
fo wear.
(2) Replace the bearing if the release fork contaciton goints are worn abnormally.
3. CLUTCH RELEASE FORK
If there is abnormal wear at the pont of contact with the bearing, replace the release fork.
Clutch System > Clutch System > Clutch Master Cylinder > Components and Components Location
COMPONENTS
CLUTCH MASTER CYLINDER AND TUBE
Page 15 of 22
CLUTCHMASTER CYLINDER
Page 16 of 22
Clutch System > Clutch System > Clutch Master Cylinder > Repair procedures
DISASSEMBLY
1. Drain the clutch fluid through the bleed plug.
2. Remove clevis pin, split pin (cotter pin) and washer.

3. Disconnect the clutch tube (master cylinder side).
4. Remove the master cylinder mounting bolt.
5. Remove the clutch line clips.
6. Hold the nut on the clutch gose and loosen the flare nut on the clutch tube.
7. Remove the clip from the clutch gose to remove clutch hose from bracket.
8. Remove the clutch tube.

9. Disconnect the clutch tube (release cylinder side).
REASSEMBLY
Page 17 of 22
1. Connect the clutch tube (release cylinder side).
2. Temporarily tighten the flare nut by hand, then tighten it to the specified torque, being careful that the clutch hose
does no become twisted.
3. Install the clutch tube and clips.
4. Install the master cylinder.
5. Apply the specigied grease to the clevispin and washer.
Wheel bearing grase SAE G310, NLGI No.2
6. Install the push rod to the clutch pedal.

7. Pour the clutch fluid into the clutch master cylinder.
8. Bleed the clutch system.
INSPECTION
Page 18 of 22
Check the clutch hose or tube for cracks or clogging.
INSPECTION
1. Check inside of cylinder body for rust, pitting or scoring.
2. Check the piston cup for wear or distortion.

3. Check the piston for rust, pitting or scoring.
4. Check the clutch tube line for obstructions.
5. Measure the master cylinder inside diameyer and the piston outside diameter with a cylinder gauge micrometer.
Measure the inside diameterof the master cylinder at three places(bottom, middle, and top) in
perpendicular directions.
6. If the master cylinder -to-piston clearance exceeds the limit, replace the master cylinder and /or piston assembly.
DISASSEMBLY
1. Remove the piston stop ring.
2. Pull out the push rod and piston assembly.

3. Remove the reservoir band, reservoir cap and reservoir.
1. Use care not to damage the master cylinder body anad piston
assembly.
2. Do not disassemble the piston assembly.
REASSEMBLY
1. Apply the specified fluid to the inner surface of the master cylinder body and to the entire periphery of the piston
assembly.
Page 19 of 22
2. Install the piston assembly.
Specified fluid : Brake fluid DOT 3
Clutch System > Clutch System > Clutch Pedal > Components and Components Location
COMPONENTS
Clutch System > Clutch System > Clutch Pedal > Repair procedures
DISASSEMBLY
1. Disassemble the cotter pin, washer and clevis pin.
Page 20 of 22
2. Disassemble the clutch pedal mounting bolt.
INSPECTION
1. Check the pedal shaft and bushing for wear.
2. Check the clutch pedal for bending or torsion.
3. Check the clutch return spring for damage or deterioration.
4. Check the pedal pad for damage or wear.
Ignition Lock Switch Inspection
1. Remove the ignition lock switch and check continuity between the terminals. If the continuity is not as specified,
replce the switch.
REASSEMBLY
1. Apply the specified grease to the clutch pedal and bushings.
Chassis grease SAE J310, NLGI No.1
2. Install the clutch pedal mounting bolt.

3. Apply the specified grease to the clevis pin and washer.
Wheel bearing grease SAE J310, NLGI No.2

Page 21 of 22
4. Install the push rod to the clutch pedal.
5. Adjust the clutch pedal clevis pin play.
Clutch System > Clutch System > Clutch Release Cylinder > Components and Components Location
COMPONENTS
Clutch System > Clutch System > Clutch Release Cylinder > Repair procedures
REMOVAL
1. Remove the clutch gose, valve plate, spring, push rod and boot.
2. Remove any dirt from the piston bore opening of the release cylinder.
3. Remove the piston from the repease cylinder using compressed air.
1. Cover with rags to prevent the piston from popping out and causing injury.
2. Apply compressed air slowly to prevent the fluid from splashing in your eyes or on your
skin.
Page 22 of 22
INSTALLATION
1. Coat the clevis pin with the specified grease. Align the gose in the end of the release cylinder push rod witch that
of the clutch release fork shaft, and insert the clevis pin into the holes.
Specified grease : CASMOLY L9508
2. Install the clutch release cylinder and the clutch tube.
INSPECTION
1. Check the clutch release cylinder for fluid leakage.
2. Check the clutch release cylinder bolts for damage.
3. Check the release cylinder bore for rust and damage.
4. Measure the release cylinder bore at threelocations (bottom, middle and top) with a cylinder gauge and relpace
the release clinder assembly if the bore-to -piston clearance to exceeds the limit.
Limit : Clearance to piston 0.15 mm (0.006 in.)
REASSEMBLY
1. Apply specified brake fluid to the release cylinder bore and the outer surface of the piston and piston cup, and
push the piston cup assembly inthe cylinder.
Use the specified fluid : Brake fluid DOT3
2. Install the cluteh hose, valve plate, spring, push rod and boot.
Page 1 of 31
OPTIMA(MS) > 2001 > G 2.4 DOHC > Driveshaft and axle
Driveshaft and axle > General Information > Special Service Tools
SPECIAL TOOLS
Tool (Number and
Illustration Use
Name)
1. Removal of center bearing
09216-21100
2. Press-fitting of the front wheel bearing outer
Mount bushing remover
race.
and installer
(use with 09495-33100)
09216-21600
Removal of the wheel bearing outer race
Mount bushing remover
(use with 09216-22100)
and installer arbor
09216-22100
Removal of wheel bearing outer race
Mounting bushing remover
(use with 09216-21600)
and installation base
09221-21000/09221-
M2000 Press fitting of hub bearing
Camshaft oil seal installer
09432-11000
Removal of tone wheel
Mainshaft bearing puller
09432-33300
Installation of center bearing
Bearing installer
Removal and installation of the rear axle carrier

09453-33000B
bushing
Snap ring installer
(use with 09545-21100)
09455-21000/0K011 430 Removal of the bearing inner race from the front
017 hub.
Bearing and gear puller (use with 09545-34100)
09495-33100 Removal and installation of the center bearing.

Center bearing remover, Installation of the inner dust seal (use with 09216-
installer 21100)
Page 2 of 31
09517-21500
Front hub remover and Measurement of wheel bearing pre-load
installer
09517-43001
Removal of center bearing bracket
Bearing puller
09532-11600 Measurement of the wheel bearing pre-load (use

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

Lower arm bushing hub
remover and installer >(use with 09455-21000/0K011 430 017)
0k670-321-019 Removal of the tie rod end from the knuckle and
Tie rod end remover the upper arm from theknuckle.
Driveshaft and axle > General Information > Troubleshooting

TROUBLESHOOTING
Scoring of drive shaft ball joint Replace
Wear, rattle or scoring wheel bearing Replace
Vehicle pulls to one side
Adjust or
Defective front suspension and steering
replace
Wear, damage or bending of drive shaft Replace
Vibration Drive shaft rattle and hub serration Replace
Wear, rattle or sintering of wheel bearing Replace
Adjust or
Defective wheel balance
replace
Shimmy
Adjust or
replace
Wear, damage or bending of drive shaft Replace
Page 3 of 31
Rattle of drive shaft and hub serration Replace
Rattle of drive shaft and side gear serration Replace
Excessive noise Wear, rattle or scoring of wheel bearing Replace

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

TIGHTENING TORQUE
Nm kg·cm lb·ft
Drive shaft nut 200-250 2000-2600 148-192
Lower arm ball joint to
100-120 1000-1200 74-88
knuckle
Tie rod end to knuckle 24-34 240-340 18-25
Stabilizer link mounting nut 35-45 350-450 26-33
Brake caliper to knuckle 69-85 690-850 51-62
Upper arm to knuckle 35-45 350-450 26-33
Brake caliper to carrier 50-60 500-600 36-44
Rear axle carrier to hub
70-90 700-900 52-66
mounting bolt
Rear hub bearing flange nut 200-260 2000-2600 148-191
Rear axle carrier stud bolt 90-110 900-1100 66-81
Wheel nut 90-110 900-1100 66-81
Center arm to carrier nut 60-72 600-720 44-53
Assist arm to carrier nut 100-120 1000-1200 74-88
Shock absorber lower
80-90 8000-900 59-66
mounting bolt
Trailing arm to carrier nut 100-120 1000-1200 74-88
Rear upper arm to carrier
100-120 1000-1200 74-88
nut
GENERAL SPECIFICATIONS
Page 4 of 31
Joint type 2.4L M/T 2.4L A/T 2.7L M/T 2.7L A/T
Drive shaft Outer B.J. B.J. B.J. A.C.
Inner T.J. T.J. D.O.J. G.I.
Miximum Outer 46.5° 46.5° 46.5° 45°
permissible
angle Inner 23° 23° 22° 21°
Type Radial ball bearing
Center bearing
(V6 ENG.) Dimension (O.D. × I.D.)
62 × 30 (2.44 × 1.18)
mm (in.)
Inner shaft
Length mm (in.) 387.7 (15.3)
(V6 ENG)
Type Double row angular contact ball bearing
Wheel bearing Dimension (O.D. × I.D.)
80 × 42 (3.15 × 1.65)
mm (in.)
Abbreviations
B.J. : Birfield joint
A.C. : Angular Contact (GKN)
D.O.J. : Double offset joint
G.I. : Glaenzer Interior (GKN)
T.J. : Tripod joint
SERVICE STANDARD
Limit
Hub end play mm (in.) 0.0008 (0.0003)
Front wheel bearing
Nm (kg·cm, lb·in.) 1.8 (18, 16)
starting torque
Rear wheel bearing
N (kg·cm, lb·in.) 28 (18, 16)
starting torque
Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Components and Components
Location
COMPONENTS
Page 5 of 31
COMPONENTS
Page 6 of 31
COMPONENTS
Page 7 of 31
COMPONENTS
Page 8 of 31
Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Repair procedures
REMOVAL
2. Drain the gear oil or transaxle fluid.

3. Remove the split pin and drive shaft nut from the front hub.
Page 9 of 31
4. Remove the 2 bolts and disconnect the ball joint from the knuckle.
5. Using a plastic hammer, disconnect the drive shaft from the axle hub.
6. Push the axle hub toward the outside of the vehicle, and separate the drive shaft from the axle hub.
7. Insert a pry bar between the center bearing bracket and the drive shaft, and then pry the drive shaft from the
transaxle. (V6 ENG.)
Do not pull on the drive shaft; doing so will damage the D.O.J. or T.J.: be sure to use the pry bar.
8. Insert a pry bar between the transaxle case and the drive shaft,and pry the drive shaft from the transaxle
(EXCEPT V6 ENG.).
1. Do not pull on the drive shaft; doing so will damage the D.O.J.; be sure to use the pry bar.
2. Do not insert the pry bar deeply enough to damage the oil seal.
Page 10 of 31
Do not apply the vehicle weight to the wheel bearing while the drive shaft is disconnected. If the vehicle's
weight mustbe applied (because of vehicle movement or some other reason), use the special tool to hold
the wheel bearing, as shown in the figure.
9. After releasing the auto tensioner, remove the drive belt.(V6 ENG.)
10. Remove the alternator assembly (V6 ENG.)

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

13. Using the special tool, remove the tone wheel.
INSTALLATION
1. Coat gear oil to the drive shaft splines and differential case sliding surface.
Page 11 of 31
2. Before installing the drive shaft, set the opening side of circlip facing downward.
3. After installation, check that the drive shaft cannot be removed by hand.
4. Install the washer under the drive shaft nut with facing the convex side outward as shown in the illustration.
5. Tighten the following parts to the specified torque.
Nm (kg·cm, lb·ft)
200-260 (2000-2600, 148-
Drive shaft nut
192)
Lower arm ball joint to knuckle 100-120 (1000-1200, 74-88)
INSPECTION
1. Check the drive shaft boots for damage and deterioration.
2. Check the splines for wear and damage.
INSPECTION AFTER DISASSEMBLY

1. Check the drive shaft spline part for wear or damage.
2. Check for entry of water and/or foreign material into B.J.
3. Check the spider assembly for roller rotation, wear or corrosion.
4. Check the groove inside T.J. case for wear or corrosion.
5. Check the dynamic damper for damage or cracking.
DISASSEMBLY
1. The drive shaft joint use special grease. do not substitute with another type of grease.
2. The boot band should be replaced with new one.
Page 12 of 31
1. Remove the D.O.J. and B.J. boot bands.
Be careful not to damage the boot.
2. Remove the circlip, then remove the D.O.J. outer race.
3. Remove the snap ring, then remove the D.O.J. inner race, the D.O.J. cage, and the balls as a unit.
4. Clean the D.O.J. inner race, the D.O.J. cage, and the balls, without disassembling them.
1. Be careful that the balls do not drop out of the cage.

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

6. Remove the D.O.J. boot and B.J. boot.
1. If the boots can be reused, wrap vinyl tape around the drive shaft splines so that the boots are not
damaged when they are removed.
2. Do not disassemble the B.J.
Page 13 of 31
DISASSEMBLY
1. Do not disassemble the spider assembly.

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

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

• The drive shaft joint uses special grease. Do not substitute with another type of grease.
• The boot clamp should be replaced with a new one
• The boot should be replaced with a new one.
1. Using a side cutter, cut the G.I. and A.C. big clamps and remove them.
Page 14 of 31
2. Using a brass bar and hammer, remove the G.I. and A.C. small clamps.
3. Place amatch marks on the tripod and tulip.
Do not punch the mark.

4. Remove the tulip assembly from the drive shaft.
5. Using a snap ring expander, remove the snap ring.
6. Place a matchmark on the tripod and joint shaft.

7. Using a brass bar and hammer, remove the tripod from the joint shaft.
8. Remove the A.C. boot clamps and pull out the G.I. boot and A.C. boot.
REASSEMBLY
1. Wrap tape around the drive shaft splines (T.J. side) to prevent damage to the boots.
Page 15 of 31
2. Apply grease to the drive shaft and install the boots.
Recommended lubricant :
B.J. Boot grease : CENTOPLEX 278M/136K
T.J. Boot grease : KLK TJ41-182
3. To install the dynamic damper, keep the B.J. and shaft in a straight line and secure the dynamic damper in the
direction illustrated and install the small boot band.
4. Apply grease into the T.J. boot and install the boot.
T.J. boot grease gr. (2.4L M/T, A/T)

In the joint : 100 ± 3
In the boot : 45 ± 3
5. Add specified grease to the B.J. as much as wiped away at the time of inspection.
B.J. boot grease gr. (2.4L M/T, A/T)

6. Install the boots.

7. Tighten the B.J. boot bands.
Page 16 of 31
8. To control the air in the T.J. boot, keep the specified distance between the boot bands when they are tightened.
Standard value (A) mm (in.)
LH side RH side
2.4L M/T, A/T 525 ± 2 (20.7 ± 0.08) 838 ± 2 (33 ± 0.08)
9. Tighten the T.J. boot bands.

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

Grease quantity (gr.)
Page 17 of 31
7. Apply specified grease to the G.I. joint and boot.
Specified grease : One luber GKN

Grease quantity (gr.)
8. Align the matchmarks and install the G.I. joint to the shaft.
9. Install the boots.
• Make sure that 2 boots are on the shaft

groove.
• Make sure that the 2 boots are not stretched.
10. Position the holes in the clamp's free end to the closing hooks.
11. Using pliers, secure the clamps.
Clearance (A)
A.C. big clamp : 2.0 mm (0.079 in.) or less
A.C. small clamp : 1.8 mm (0.071 in.) or less
Page 18 of 31
12. To control air in the G.I. boot, keep the specified distance between the boot clamps when they are tightened.
Standard value (A, B) mm(in.)
LH side RH side
523.1 ± 2 543.6 ± 2
(20.59 ± 0.08) (21.4 ± 0.08)
13. Holding the G.I. big clamp near the closing hook, using long noise pliers, position the hole the the clamps free
end over the cosing hook.
14. Secure the clamp by drawing the closing hooks together.

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

Page 19 of 31
1. Check the drive shaft spline part for wear or damage.
2. Check for entry of water and/or foreign material into B.J.
3. Check the spider assembly for roller rotation, wear or corrosion.
4. Check the groove inside T.J. case for wear or corrosion.
5. Check the dynamic damper for damage or cracking.
Driveshaft and axle > Driveshaft Assembly > Center Bearing And Inner Shaft > Components and
Components Location
COMPONENTS
Driveshaft and axle > Driveshaft Assembly > Center Bearing And Inner Shaft > Repair procedures
DISASSEMBLY
1. Using the special tool, disassemble the center bearing bracket from the inner shaft.
Page 20 of 31
2. Using the special tool, press out the center bearing from the outside to the inside direction of the center bearing
bracket as shown in the illustration.
INSPECTION
1. Check the inner shaft for damage, bending or rust.
2. Check the inner shaft splines for wear or damage.
3. Check the center bearing for scoring, discoloration and roughness of the roller joumal's moving surfaces.
REASSEMBLY
1. Apply multipurpose grease to the center bearing and inside the center bearing bracket.
2. Using the special tools, press the center bearing into the center beairng bracket.
3. Apply multipurpose grease to the rear surface of all dust seals.
Recommended grease : LIG-2 or Sunlight No.2

Inner dust seal : 7-10 g (0.25-0.35 oz)
Outer dust seal : 4-6 g (0.14-0.21 oz)
Page 21 of 31
4. Using the special tool, tap in the outer dust seal and inner dust seal in that order until they are flush with the edge
of the center bearing bracket.
When applying grease, make sure that it does not adhere to anything outside the lip.
5. Using the special tool, support the center bearing as shown in the figure, then press in the inner shaft.
Driveshaft and axle > Front Axle Assembly > Front Hub / Axle > Components and Components
Location
COMPONENTS
Page 22 of 31
Driveshaft and axle > Front Axle Assembly > Front Hub / Axle > Repair procedures
REMOVAL
1. Lift up the vehicle and remove the wheel and tire.
2. Disconnect the wheel speed sensor from the knuckle.

3. Disconnect the brake hose from the knuckle.
Page 23 of 31
4. Remove the caliper assembly and suspend it with wire.
5. Remove the split pin and drive shaft nut from the front hub.
6. Remove the 2 bolts and disconnect the ball joint from the knuckle.
7. Using a plastic hammer, disconnect the drive shaft from the axle hub.
8. Using the special tool, disconnect the tie rod end from the knuckle.
1. Be sure to tie a cord to the special tool and to a nearby

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

12. Installation is reverse of removal.
Page 24 of 31
DISASSEMBLY
1. Remove the brake disc from the hub.

3. Using the special tool, disconnect the hub from the knuckle.
4. Using the special tool, remove the wheel bearing inner race from the hub.
5. Using the special tool, remove the wheel bearing outer race from the knuckle.
INSPECTION
1. Check the hub for cracks and splines for wear.
2. Check the snap ring for crack or damage.
3. Check the knuckle inner surface for scoring and cracks.
REASSEMBLY
1. Apply thin coat of multi-purpose grease to the knuckle and bearing contact surface.
Page 25 of 31
2. Using the special tool, press-in the bearing to the knuckle.
1. Do not press the inner race of wheel bearing. That will cause damage of the bearing
assembly.
2. When installing bearing assembly, always use the new one.
3. Install the snap ring into the groove of knuckle.
4. Using the special tool, press-in the hub to the knuckle.
Do not press the outer race of the wheel bearing.

That will cause damage of the bearing assembly.
5. Tighten the hub to the knuckle to 200 Nm (2000 kg·cm, 148 lb·ft) with the special tool.
6. Rotate the hub to seat the bearing.

Page 26 of 31
7. Measure the wheel bearing starting torque.
Standard value :
Starting torque : 1.8 Nm (18 kg·cm, 16 lb·ft) or less
8. Measure to determine whether the end play of the hub is within the specified limit or not.
Standard value :
Hub end play : 0.008 mm (0.0003 in.) or less

10. Install the disc to the hub.
Driveshaft and axle > Rear Axle Assembly > Rear Hub / Carrier > Components and Components
Location
COMPONENTS
Rear Axle/Carrier
Page 27 of 31
Driveshaft and axle > Rear Axle Assembly > Rear Hub / Carrier > Repair procedures
REMOVAL
Rear Axle/Carrier
1. Release the parking brake.

3. Remove the wheel speed sensor from the carrier.
4. Remove the caliper assembly from the carrier and suspend it with a wire.
5. Remove the brake disc.
6. Remove the rear axle hub mounting 4 bolts.
Page 28 of 31
7. Using the special tool, remove the tone wheel.
8. Remove the carrier assembly.
9. Raise the crimped portion of the flange nut and remove the flange nut.
10. While supporting the flange area of the bearing outer race, press-out the rear axle hub
11. Using the special tool, remove the bearing inner race from the axle hub.
12. Using the special tool, remove the 2 bushings from the carrier.
Page 29 of 31
INSTALLATION
Rear Axle/Carrier
1. Using the special tool, press-in the 2 bushings to the carrier.
2. Apply thin coat of multi-purpose grease to the hub and bearing contact surface.
3. Using the special tool, press-in the bearing to the hub.
1. Do not press the outer race of the bearing.

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

Page 30 of 31
6. Fit the hub and bearing assembly to the brake backing plate so that the rounded area of the bearing outer race is
placed facing upward.
If it is difficult to fit, adjust the parking brake adjusting nut to enlarge the space of the shoe and lining
assembly.
7. Tighten the 4 bolts to the specified torque.
8. Install brake disc.

9. Install the caliper assembly to the carrier.
10. Rotate the hub to seat the bearing.
11. Using a spring balance, measure the wheel bearing starting torque.
Standard value
Starting torque : 28N (18 kg·cm, 16 lb·in) or less
Page 31 of 31
12. Measure to determine whether the end play of the hub is within the specified limit or not.
Standard value
Hub end play : 0.008 mm (0.0003 in.) or less
13. Install the wheel speed sensor to the carrier.

14. Install the parking brake.
15. Adjust the parking brake lever stroke.
(Refer to section BR-Parking brake)
INSPECTION
1. Check the rear hub bearing for wear or damage.
2. Check the rear tone wheel for chipped teeth.
3. Check the hub inner surface for scoring.
4. Check the carrier for crack
Page 1 of 25
OPTIMA(MS) > 2001 > G 2.4 DOHC > Emission Control System
Emission Control System > General Information > Specifications

TIGHTENING TORQUE
Item Nm kg·cm lb·ft
Positive
crankcase
8-12 80-120 6-9
ventilation
valve
SPECIFICATIONS
Components Function Remarks
Crankcase Emission System HC reduction
Positive Crankcase Ventilation Variable flow rate type
(PCV) valve
Evaporative Emission System HC reduction
EVAP Canister
EVAP Canister Purge Solenoid Duty control solenoid valve
Valve
Exhaust Emission System
MFI system CO, HC, NOx reduction Heated oxygen sensor feedback
(air-fuel mixture control device) type
Three-way catalytic converter CO, HC, NOx reduction Monolith type
Exhaust gas recirculation system NOx reduction
[2.4 DOHC only]
EGR valve Single type
Manifold absolute pressure sensor EGR Monitoring Electric pressure type
EVAP : Evaporative Emission
Emission Control System > Crankcase Emission Control System > Schematic Diagrams
SCHEMATIC DRAWING
Page 2 of 25
POSITIVE CRANKCASE VENTILATION(PCV) VALVE

Components
Page 3 of 25
Emission Control System > Crankcase Emission Control System > Description and Operation
PCV VALVE OPERATION
Page 4 of 25
Engine condition Not running Engine condition Idling decelerating

PCV valve Not operating PCV valve Fully operating
Vacuum passage Restricted Vacuum passage Small
Accelerating and high

Engine condition Normal operation Engine condition
load
PCV valve Properly operating PCV valve Slightly operating
Vacuum passage Large Vacuum passage Much large
Emission Control System > Crankcase Emission Control System > Components and Components
Location
EMISSION CONTROLS LOCATION
Page 5 of 25
Page 6 of 25
EVAP Canister Purge Solenoid
A. PCV valve B.
Valve
C. EVAP Canister D. Catalytic Converter (MCC)
E. Catalytic Converter (UCC) F. Two-way Valve
G. EGR valve H. EGR Solenoid valve
Emission Control System > Evaporative Emission Control System > Purge Control Solenoid Valve
(PCSV) > Repair procedures
EVAP Canister Purge Solenoid Valve
Page 7 of 25
The EVAP Canister Purge Solenoid Valve is controlled by the ECM; when the engine coolant temperature is low,
and also during idling, the valve closes so that evaporated fuel is not drawn into the surge tank. After engine warm-
up during ordinary driving, it opens to let the stored vapors flow into the surge tank.
INSPECTION
When disconnecting the vacuum hose, make an identification mark on it so that it can be reconnected to its original
position.
1. Disconnect the vacuum hose (black with red stripe) from the solenoid valve.
2. Detach the harness connector.
3. Connect a vacuum pump to the nipple to which the red-striped vacuum hose was connected.
4. Apply vacuum and check when voltage is applied to the EVAP Canister Purge Solenoid Valve and when the
voltage is discontinued.
Battery voltage Normal condition

When applied Vacuum is released
When discontinued Vacuum is maintained
Page 8 of 25
5. Measure the current between the terminals of the solenoid valve.
EVAP Canister Purge Solenoid Vave

Coil at 20°C (68°F) : 0.45A or below (at 12V)
Coil resistance : 24.5 - 27.5 Ω [at 20°C (68°F)]
Emission Control System > Evaporative Emission Control System > Description and Operation
DESCRIPTION
On-Board Refueling Vapor Recovery (ORVR) system is properly designed to prevent the fuel tank vapor (HC)
emission during refueling at the gas station.
This system consists of fuel vent valve (ORVR), fuel shut-off valve, fuel cut valve (roll over), two way valve
(pressure/vacuum relief), fuel liquid/vapor separator which is installed beside the filler pipe, charcoal canister which is
mounted under the rear floor LH side member with protector, tubes and miscellaneous connections.
While refueling, the flow and column of the refueling draws the ambient air into the filler pipe so as not to emit fuel
vapor in the air. The fuel vapor in the tank is then forced to flow into the canister via the fill vent valve and the fuel
liquid/vapor separator which isolates liquid fuel ingredient and transfers the pure vapor to the carbon canister.
While the engine is operating, the trapped vapor emission in the canister is drawn and fed by the intake manifold
vacuum into the engine combustion chamber. According to this purge process, the carbon canister is purged and
recovers its adsorbing capability.
Page 9 of 25
Emission Control System > Evaporative Emission Control System > Repair procedures
CANISTER
For monitor, there are a CCV and an air filter as the illustration.
1. Look for loose connections, sharp bends or damage to the fuel vapor lines.
2. Look for distortion, cracks or fuel leakage.

3. After removing the EVAP Canister, inspect for cracks or damage.
Check of canister close valve operating

1. Connect the CCV pins to a wire as shown.
2. At idle, disconnect the CCV connector.
3. Inspect that CCV is close when attaching the wire to (-) of battery.
Page 10 of 25
4. Inspect that CCV is open when detaching the wire from (-) of battery.
In this case, if you use a very thin paper and attach it to hose to CCV, you can check easy the CCV
condition.
(1) If the paper is absorbed into or out, CCV is open.
(2) If not, CCV is close.
Two-way valve
1. Inspect that air flows as shown.
2. Check to connect correctly such as the arrow mark on the valve.
Air filter
Look for distortion, cracks.
Fuel Tank Pressure Sensor
Page 11 of 25
1. This is the sensor to detect the fuel tank leakage in way which it measures the differential pressure between the
inside and outside of the fuel tank.
Inspection
Check thatfuel level is over 15 . If not, this inspection is not available.
The vehicle must be in turn-on and at idle. Don't forget it.
Overfill Limiter(Two way valve)
1. To inspect the overfill limiter(twq-way valve), refer to Fuel tank.
Fuel Filer Cap

1. Check the gasket of the fuel cap, and the filler cap inself, for damage or deformation. Replace the cap if
necessary.
Emission Control System > Troubleshooting > P0401

TROUBLESHOOTING
Page 12 of 25
Diagnostic trouble code No. P0401 EGR system malfunction
Related items · Blocked and/or leakage vacuum tube between EGR
control valve and intake manifold vacuum port
· Blocked and/or leakage tube between EGR solenoid
valve and intake manifold port
· Misplaced, loose or corroded terminals at MAPSm
EGR solenoid valve
· Leakage in EGR control valve
· Poor connection vacuum tubes
· Stuck closed EGR control valve
· Stuck open EGR control valve
If any codes relating to EGR solenoid valve or

MAPS are present, do all repairs associated with
them before proceeding with this troubleshooting
procedure
Step Inspection Action

First check for DTC relating to EGR Yes First repair all other malfunctions on DTCs.
1 solenoid valve or MAPS.
Do DTCs exist? No Go to step 2.
Thoroughly check all vacuum hoses and
EGR pipes between :
Yes Go to step 3.
1) Throttle body and EGR solenoid valve
2) Throttle body and EGR control valve
3) EGR control valve and EGR solenoid
valve
4) EGR control valve and exhaust manifold Replace all cracked/damaged hoses or
No
pipes.
5) EGR control valve and intake manifold
Are vacuum hoses and EGR pipes OK?
Check EGR control valve for being tightly Yes Go to step 4.
3 installed.
Is EGR control valve installation OK? No Repair as necessary.
Remove EGR control valve and check for
excessive carbon deposits and sticking per
following check :
Draw a vacuum at nipple and verify EGR Thoroughly check for loose, bent or
control valve holds vacuum. Yes corroded terminals at all connectors in
Blow air into hose removed from exhaust circuit.
manifold and verify air escapes
Remove a vacuum at nipple and below an air
into hose any verify air does not escape from
port.
4
Repeat this procedure 4 or 5 times to ensure
EGR control valve reliability
Is EGR control valve moving freely and is
Page 13 of 25
not carbon foulde? Temporarily install a known good EGR
control valve and check for proper
No
operation. If problem is corrected replace
EGR control valve.
While EGR control valve is removed,
inspect removed hose for obstructions.
Repair or replace as necessary.
Clean MAPS and check for MAPS and

Check MAPS for contamination, housing for source of leak and repair as
deterioration or damage. Yes
5 necessary. If damaged or deteriorated,
Is MAPS contaminated, deteriorated or replace.
damaged?
No Go to step 6.
Thoroughly check for loose, bent or
corroded connectors at ECM and MAPS. Yes Go to step 8.
With ignition off, disconnect ECM and
MAPS connectors.
Measure resistance between MAPS and
ECM on three circuits. Open circuit between MAPS harness
6 connector and ECM harness connector.
· Specifications : below 1Ω
Measure voltage between MAPS reference Short circuit to chassis ground between
No
power terminal and chassis ground. harness connector and ECM harness
· Specifications : approximately 5V connector.
Is the resistance or voltage within the Repair as necessary
specifications?
Start an engine and allow an engine to warm
up to operating temperature. With engine Yes Go to step 9.
idling, measure voltage at MAPS output
terminal.
Open throttle suddenly and verify that
7 voltage increases :
If wiring and connections are all okay,
· 0.8~2.4 V at idle
temporarily install a known good MAPS and
· raise from 0.8~2.4 V at open throttle No
check for proper operation. If problem is
suddenly
corrected, replace MAPS.
Is idle voltage within specifications and do
voltage readings increase?
Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with
8
SCAN TOOL connected and monitor for pending codes.

TROUBLESHOOTING
Diagnostic trouble code
EGR system solenoid valve circuit malfunction
No. P0403
Related items · Open between EGR solenoid valve and ECM
· Short to battery EGR solenoid valve and ECM
· Short to between EGR solenoid valve wires
· Faulty EGR solenoid valve
Page 14 of 25

Thoroughly check EGR valve for loose, Yes Repair as necessary.
1 bent, corroded, conteminated, deteriorated .
Is any problem pressent No Gi step 4.
Tun igniton to OFF and isconnect EGR
valve conncovot. Yes Go to step 3.
Turn ignition to ON and measure voltage of
EGR Open circuit or short circuit to chassis
2
valve power circuit between EGR valve ground between EGR valve harness
harness connector and chassis ground. No
connector and main relay.
· Specification : approximately B+ Repair as necessary.
Is voltage within specification?
Check EGR valve for poor terminal contacts
Turn ignition to OFF. due to oxidation, bent deformed, or
EGR valve connector is still disconnected. Yes
misplaced terminals.
Measure resistance between EGR valve Repair as necessary.
3
battery power and signal terminal.
· Specification : 30~34 Ω @ 20°C (68°F) Temporarily install a known good EGR valve
Is resistance within specification? No and check for proper operation. If problem
is corrected, replace EGR valve.
Turn ignition to OFF and disconnect ECM
connector. Yes Go to step 5.
Measure resistance of EGR valve signal
4 circuit between EGR valve harness Open circuit between EGR valve harness
connector and ECM harness connector. No connector and ECM harness connector.
· Specification : below 1Ω Repair as necessary
Does resistance indicate continuity circuit?
ECM connector EGR valve connector is still Temporarily install a known good EGR
disconnected. Yes VALVE and check for proper operation. If
Measure resistance between EGR valve problem is corrected, replace EGR valve.
harness connector and chassis ground at Short circuit to chassis ground between EGR
5 EGR valve signal circuit. valve harness connector and ECM harness
Measure resistance between EGR valve connector.
battery voltage circuit and signal circuit. No
Short circuit between EGR valve battery
· Specification : infinite power circuit and signal circuit.
Does resistance indicate open circuit? Repair as necessary.
6

TROUBLESHOOTING
Page 15 of 25
Diagnostic trouble code No.
Main catalyst efficiency deterioration (bank 1)
P0421
Related items · Catalytic converter deteriorated
If any codes relating to HO2S sensor. MAFS, injectors, a

P0171~P0172 are present, do all repairs associated with them
before proceeding with this troubleshooting procedure.

Connect SCAN TOOL to data link
connector or OBD-II check connector. Do all repairs associated with those codes
Yes
Turn ignition to ON and check other DTCs. before proceeding this procedure.
1
Are DTC P0300~P0304m P0115, P0116,
P0125, P0128, P0130~P0135, No Go to step 2.
P0136~0141, and/or P0171~P0172 set?
Start engine and warm up to operating
temperature. Yes Replace catalytic converter.
Using SCAN TOOL monitor both front
2
HO2S and rear HO2S signals.
Do both signals switch lean to rich and rich No Go to step 3.
to lean?
Release fuel pressure and attach fuel
pressure gauge to service port on fuel rail. Yes Go to step 4.
Start an engine and warm up to operating
3 temperature. Check for fuel pressure at idle.
· Fuel pressure at idle : 46~49 psi (320~340
kPa, 3.26~3.47 kg/cm²) No Check fuel delivery system.
Is fuel pressure within specification?
Check exhaust system for leaks, cranks,
Yes Go to step 5.
loose connection (especially exhaust
4
manifold, catalyst around rear HO2S, etc)
Is exhaust system okay? No Repair or replace as necessary.
Check for any split, disconnected or

Yes Go to step 6.
perforated vacuum hoses. Also, check PCV
5
valve for proper operation.
No Replace faulty vacuum hoses or PCV.
Are vacuum hoses and PCV okay?
Check for fuel injector operation. Yes Go to step 7.
6 Are fuel injectors working normal and
dispensing proper volume? No Repair as necessary.
Check intake system for leaks,cracks, loose
connection as following items:
· Throttle body gasket Yes Replace catalytic converter as necessary.
Page 16 of 25
· Gasket between intake manifold and surge
7 tank
· Seals between intake manifold and fuel
injectors No Repair or replace as necessary.
· Seals between surge tank and PCV valves
Is intake system okay?
8

TROUBLESHOOTING
EVAP emission control system purge solenoid valve stuck opened
P0441
Related items · Purge solenoid valve stuck opened

Connect SCAN TOOL to data link Do all repairs associated with those codes
connector or OBD-II check connector. Turn Yes
1 before proceeding this procedure.
ignition to ON and check other DTC.
Is DTC P0443 set? No Go to step 2.
Turn ignition to OFF and disconnect vacuum
Yes Go to step 2.
hose from PSV.
2 Start engine and put a finger on the open end
Repair or replace vacuum hose as
of vacuum hose. No
Is intake manifold felt? necessary.
Turn ignition OFF and disconnect hose

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

TROUBLESHOOTING
Page 17 of 25
EVAP emission control system small leak detected (1mm/0.5mm)
P0442
EVAP emission control system large leak detected
P0445
Related items · Fuel filler cap loose or missing
· Fuel filler cap o-ring missing or damaged
· Faulty or damaged fuel filler pipe
· Leaking, disconnected or plugged fuel vapor lines
· Fuel in lines due to faulty Rollover Valve (RV), On-Board Refueling Vapor-
Recovery Valve (ORVR valve)
· Canister close valve clogged, stuck open or closed
· Improperly installed purge solenoid valve (PSV)
· PSV stuck open or closed
· Faulty fuel tank pressure sensor
· Leaking canister or catch tank
If any codes relating to FTPS, CCV, or PSV circuits are present, do all
repairs associated with codes before proceeding with this troubleshooting
procedure.

Yes
Turn ignition to ON and check any other before proceeding this procedure.
1
DTCs.
Is DTC P0441, P0443, P0451, P0452, or No Go to step 2.
P0453 set?
Problem is intermittent or was repaired and
Using SCAN TOOL proceed EVAP engine control module memory was not
Yes
2 leakage test. cleared. Check terminal connections at
Is EVAP system okay? ECM and PSV.
No Go to step 3.
Check fuel filler cap for being tightly
installed, has o-ring seal installed and is in Yes Go to step 4.
good condition.
3 Verify cap releases vacuum at specified
values (approximately 2psi pressure and
approximately 1.5 inches hg vacuum). No Replace fuel filler cap.
Are cap, o-ring and release pressures OK?
Check fuel filler pipe for cracks, damage and Yes Go to step 5.
4 o-ring seat for deformation.
Is fuel filler pipe OK? No Replace fuel filler pipe.
Thoroughly check all fuel vapor hoses and
hose clamps between :
1) canister and rollover/ORVR valves Yes Go to step 6.
Page 18 of 25
2) canister and CCV
3) canister and PSV
5
4) PSV and intake manifold
(At this point, also verify arrow on PSV is Replace all craked/damaged hoses or loose
pointing towards intake manifold. If it is not, No
clamps.
reverse installation).
Are vapors hoses and clamps OK?
Turn ignition to OFF and remove FTPS
access plate. Remove FTPS from tank unit. Yes Go to step 7.
Turn ignition to ON (engine OFF) and
6 monitor FTPS output voltage with SCAN Temporarily install a known good FTPS and
TOOL. No check for proper operation. If problem is
· Specifications : 2~3V corrected replace FTPS.
leading from PSV to intake manifold at PSV.
Draw a vacuum at nipple and verify PSV Yes Go to step 8.
holds vacuum.
Turn ignition to ON and jumper a wire to
7 chassis ground at PSV control terminal 1
(should hear a faint click from PSV). Temporarily install a known good PSV and
Vacuum should bleed off. No check for proper operation. If problem is
Repeat this procedure 4 or 5 times to ensure corrected replace PSV.
PSV reliability.
Is PSV working propely?
connecting CCV to canister. Blow air into
hose removed from canister and verify air Yes Go to step 9.
escapes
Turn ignition to ON and jumper a wire to
8 chassis ground at CCV control terminal 1.
Blow an air into hose and verify air does not Temporarily install a known good CCV and
escape from port. No check for proper operation. If problem is
Repeat this procedure 4 or 5 times to ensure corrected replace CCV.
CCV reliability.
Is CCV working properly?
Thoroughly check fuel gas leaks, cracks,
damages of the following items :
· Fuel filler cap Yes Go to step 10.
· Fuel vent valve (ORVR)
9 · Fuel cut valve (Rollover valve)
· FTPS
· EVAP hoses No Repair or replace as necessary.
· Canister
Are the above items okay?
10
Page 19 of 25
1) This DTC P0455 may be set in the ECM memory and MIL illuminates if engine is running for running for
refuelling (i.e.if engine is running when fuel filler cap is opened).
2) Emphasize the following Caution to customers to prevent concern causing unnecessary repairs.
1) Always stop engine before refueling

2) If you open the fuel filler cap when engine is running.
3) If is possible that ECM detects evaporative emission large leak (DTCP0445) and allow MIL to illuminate even
if the evaporative emission system is normal (no leak).

TROUBLESHOOTING
EVAP emission control system purge solenoid valve circuit malfunction
P0443
Related items · Open or short between main relay and purge solenoid valve
· Open or short between purge solenoid valve and ECM
· Faulty purge solenoid valve

Thoroughly check PSV for loose, bent,
Yes Repair as necessary.
corroded, contaminated, deteriorated or
1
damaged connectors.
No Go to step 2.
Is any problem present?
Turn ignition to OFF and disconnect PSV
Yes Go to step 3.
connector.
Open circuit or short circuit to chassis
2 PSV power circuit between PSV harness
ground between PSV harness connector and
connector and chassis ground. No
main relay.
· Specification : approximately B+
Repair as necessary.
Check PSV for poor terminal contacts due
Turn ignition to OFF. to oxidation, bent deformed, or misplaced
PSV connector is still disconnected. Yes
terminals.
Measure resistance between PSV battery Repair as necessary.
3
power and signal terminal.
· Specification : 20~32Ω @ 20°C (68°F) Temporarily install a known good PSV and
Is resistance within specification? No check for proper operation. If problem is
corrected, replace PSV.
Measure resistance of PSV signal circuit
4 between PSV harness connector and ECM Open circuit between PSV harness
harness connector No connector and ECM harness connector.
Page 20 of 25
ECM connector PSV connector is still Temporarily install a known good PSV and
disconnected. Yes check for proper operation. If problem is
Measure resistance between PSV harness corrected, replace PSV.
connector and chassis ground at PSV signal Short circuit to chassis ground between PSV
5 circuit. harness connector and ECM harness
Measure resistance between PSV battery connector.
voltage circuit and signal circuit. No
Short circuit between PSV battery power
· Specification : infinite circuit and signal circuit.
6

TROUBLESHOOTING
EVAP emission control system vent circuit malfunction
No. P0446
Related items · Open or short to chassis ground between main relay and CCV
· Open or short to between between CCV ad ECM
· Short to chassis ground between CCV and ECM
· Faulty CCV

Thoroughly check CCV for loose, bent,
1
damaged connectors.
Is any problem present? No Go to step 2.
Turn ignition to OFF and disconnect CCV

Yes Go to step 3.
connector.
Measure voltage between CCV power
2 Temporarily install a known good CCV and
terminal and signal terminal.
No check for proper operation. If problem is
· Specification : 23~26Ω @ 20°C (68°F)
corrected, replace CCV.
Is resistance within specification?
Turn ignition to ON and measure voltage of Yes Go to step 4.
CCV power circuit between CCV harness Open circuit or short circuit to chassis
3 connector and chassis ground ground between CCV harness connector
· Specification : approximately B+ No
and main relay.
Is voltage within specification? Repair as necessary.
Measure resistance of PSV signal circuit
4 between PSV harness connector and ECM Open circuit between CCV harness
harness connector No connector and ECM harness connector.
Page 21 of 25
Temporarily install a known good CCV and
Measure resistance between CCV harness Yes check for proper operation. If problem is
connector and chassis ground at CCV signal corrected, replace CCV.
5 circuit. Short circuit to chassis ground between
· Specification : infinite CCV harness connector and ECM harness
Does resistance indicate open circuit? No
connector.
6

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

Connect SCAN TOOl to data link Do all repairs associated with those codes
connector or OBD-II check connector. Turn Yes
ignition to ON and check any other DTCs.
Is DTC P0446, P0452, or P0453 set? No Go to step 2.
Using SCAN TOOL monitor FTPS voltage engine control module memory was not
signals. Yes
2 cleared. Check terminal connections at
· Specification : 2.2~2.8V ECM and FTPS.
No Go to step 3.
Thoroughly check FTPS for loose, bent,
3
damaged connectors.
No Go to step 4.
Turn ignition to OFF and disconnect ECM Yes Go to step 5.
connector. Turn ignition to ON and measure
voltage of FTPS reference power circuit If voltage is above specification, short circuit
4 between FTPS harness connector and to battery.
chassis ground. No If voltage is below specification, open circuit
· Specification : 4.8~5.2V or short circuit to chassis ground.
Turn ignition to ON. Yes Go to step 6.
Measure voltage of FTPS signal circuit
Page 22 of 25
between FTPS harness connector and Short circuit to power between FTPS
5 harness connector and ECM harness
chassis ground. No
· Specifications : below 0.5V connector.
Is voltage within specifications? Repair as necessary.
Turn ignition to OFf and disconnect ECM
connector.
Measure resistance of FTPS signal circuit Yes Go to step 7.
between FTPS harness connector and ECM
harness connector.
6 Mrasure resistance of FTPS ground circuit
between FTPS harness connector and ECM Open circuit between FTPS harness
harness connector. No connector and ECM harness connector.
· Specifications : below 1Ω Repair as necessary.
Does each resistance indicate continuity
circuit?
Temporarily install a known good FTPS and
Measure resistance between FTPS harness Yes check for proper operation. If problem is
connector and ECM harness connector at corrected, replace FTPS.
7 FTPS signal circuit and ground circuit. Short circuit to chassis ground between
· Specifications : infinite FTPS harness connector and ECM harness
Does each resistance open circuit? No
connector.
Remove CCV and blow through hose and Thorughly check for loose, bent, or
verify air escapes from port on back of corroded terminal between FTPS, CCV and
CCV. Yes
ECM.
Connect battery positive to one terminal on Repair as necessary.
8
CCV and battery negative to the other
terminal. Verify air does not escape from Temporarily install a known good CCV and
back of CCV. No check for proper operation. If problem is
Does CCV operate properly? corrected, replace CCV.
9

TROUBLESHOOTING
EVAP emission control system pressure snesor low input
No. P0452
EVAP emission control system pressure sensor high input
No. P0453
Related items · Open or short to battery between FTPS and ECM
· Short to chassis ground between FTPS and ECM
· Poor connections between FTPS and ECM
· Misplaced, loose or corroded terminals
· Faulty FTPS
Page 23 of 25
Connect SCAN TOOL to data link Problem is intermittent or was repaired and
connector or OBD-II check connector. engine control module memory was not
Using SCAN TOOL monitor FTPS voltage Yes
signals. ECM and FTPS.
· Specification : 2.2~2.8V
Is voltage within specification? No Go to step 2.
Thoroughly check FTPS for loose, bent,
corrded, contaminated, deteriorated or
2
damaged connectors.
No Go to step 3.
Turn ignition to OFF and disconnect ECM Yes Go to step 4.
voltage of FTPS reference power circuit If voltage is above specification, short circuit
3 between FTPS harness connector and ECM to battery.
harness connector. No If voltage is below specification, open circuit
· Specification : 4.8~5.2V or short circuit to chassis ground.
between FTPS harness connector and Short circuit to power between FTPS
chassis ground. No
connector.
Measure resistance of FTPS signal circuit Yes Go to step 6.
between FTPS harness connector and ECM
harness connector.
5 Measure resistance of FTPS ground circuit
between FTPS harness connector and ECM Open circuit between FTPS harness
circuit?
Temporarily install a known good FTPS and
Measure resistance between FTPS harness Yes check for proper operation. If problem is
connector and ECM harness connector at corrected, replace FTPS.
6 FTPS signal circuit and ground circuit. Short circuit to chassis ground between
· Specifications : infinite FTPS harness connector and ECM harness
Does each resistance open circuit? No
connector.
7

Page 24 of 25
TROUBLESHOOTING
Manifold abolute pressure sensor (EGR mode 3)
No. P1102
Manifold absolute pressure sensor (EGR mode 2)
No. P1103
Related items · Poor connections between MAPS and ECM
· Foreign materials fouled MAPS
· Stuck closed EGR control valve
· Stuck open EGR control valve
· Faulty MAPs

Clean MAPS and check for MAPS and
Check MAPS for contamination, housion for source of leak and repair as
1 necessary. If damaged or deteriorated,
Is MAPS contaminated, deteriorated or replace.
damaged?
No Go to step 2.
corroded connectors at ECM and MAPS. Yes Go to step 3.
With ignition off, disconnect ECM and
MAPS connectors.
Measure resistance between MAPS and
ECM on three circuits. Open circuit between MAPS harness
2 connector and ECM harness connector.
Measure voltage between MAPS reference Short circuit to chassis ground between
No
power terminal and chassis ground. harness connector and ECM harness
· Specifications : approximately 5V connector.
Is the resistanceor voltage within the Repair as necessary.
specifications?
Start an engine and allow an engine to warm
up to operating temperature. With engine
Yes Go to step 4.
idling, mesure voltage at MAPS signal output
terminal.
Open throttle suddenly and verify that
3 voltage increases :
If wiring and connections are okay,
· 0.8~2.4 V @ idle
temporarily install a known good MAPS and
· Raise from 0.8~2.4 V @ open throttle No
check for proper operation. If problem is
suddenly
corrected, replace MAPS.
Is idle voltage within specifications and do
voltage readings increase?
Remove EGR control valve and check for
excessive carbon deposits and sticking per
following check :
Draw a vacuum at nipple and verify EGR Thoroughly check for loose, bent or
control valve holds vacuum. Yes corroded terminals at all connectors in
Blow air into hose removed from exhaust
Page 25 of 25
Blow air into hose removed from exhaust circuit.
manifold and verify air escapes.
Remove a vacuum at nipple and below an air
into hose and verify air does not escape from
port.
4
Repeat this procedure 4 or 5 times to ensure
EGR control valve reliability.
not carbon fouled? Temporarily install a known good EGR
control valve and check for proper
No
operation. If problem is corrected replace
EGR control valve.
While EGR control valve is removed,
inspect removed hose for obstructions.
Repair or replace as necessary.
5
Page 1 of 34
OPTIMA(MS) > 2001 > G 2.4 DOHC > Engine Electrical System
Engine Electrical System > General Information > Troubleshooting

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

GENERAL
Charging system
Charging warning indicator does not light with ignition Fuse blown Check fuses
switch "ON" and engine off Light burned out Replace light
Wiring connection loose Tighten loose connections
Electronic voltage regulator Replace voltage regulator
faulty
Charging warning indicator does not go out with engine Drive belt loose or worn Adjust tension or replace
running (Battery requires frequent recharging) drive belt
Battery cables loose, Repair or replace cables
corroded or worn
Fuse blown Check fuses
Fusible link blown Replace fusible link
Electronic voltage regulator Test generator
or generator faulty
Wiring faulty Repair wiring
Engine hesitates/poor acceleration Drive belt loose or worn Adjust tension or replace
Overcharge drive belt
Page 2 of 34
Wiring connection loose or Tighten loose connection
open circuit or repair wiring
Poor grounding Repair
Electronic voltage regulator Test generator
or generator faulty
Worn battery Replace battery
Electronic voltage regulator Replace voltage regulator
faulty
Voltage sensing wire faulty Repair wire
Starting system
Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or worn Repair or replace cables
Transaxle range switch faulty (Vehicle with Adjust or replace switch
automatic transaxle only)
Starter motor faulty Repair starter motor
Ignition switch faulty Replace ignition switch
Ignition lock switch faulty Replace ignition lock switch
Engine cranks slowly Battery charge low Charge or replace battery
Battery cables loose, corroded or worn Repair or replace cables
Starter motor faulty Repair starter motor
Starter keeps running Starter motor faulty Repair starter motor
Ignition switch faulty Replace ignition switch
Starter spins but engine will Short in wiring Repair wiring
not crank
Pinion gear teeth broken or starter motor faulty Repair starter motor
Ring gear teeth broken Replace flywheel ring gear or
torque converter
TIGHTENING TORQUE
Page 3 of 34
Items N·m Kg·cm lb·ft
Generator
terminal 5-7 50-70 3.6-5.1
(B+)
Starter
motor
10-12 100-120 7.3-8.7
terminal
(B+)
Battery
4-6 40-60 2.9-4.3
terminal
Spark plug 20-30 200-300 15-21
SPECIFICATIONS
Ignition coil
2.4 Liter Engine V6 Engine
Type Mold coil
Primary coil
0.78 (Ω) 0.75 ± 10 (Ω)
resistance
Secondary coil
20 (KΩ) 13.3 ± 15 (Ω)
resistance
Starter motor
All Engine
Reduction drive(with
Type
planetary gear)
Voltage 12V
Output 1.2 Kw
No-load characteristics
Terminal voltage 11A
Amperage 90A
Speed 2,800 RPM MIN.
Number of pinion teenth 8
0.5-2.0mm (0.0197-0.079
Pinion gap
in.)
Pre-Troubleshooting
Before commencing troubleshooting, inspect each of the following sections, and if there is an abnormality, carry out
a repair.
1. Check if the installation and connection routes of the cables and vacuum hoses of the cruise vacuum pump
assembly, actuator and pulley assembly are all normal.
2. Check if the pulley assembly and the movement of all cables are all working smoothly.
Page 4 of 34
3. Check if there is no excessive play or tension in each cable.
TROUBLESHOOTING PROCEDURES
First, select the applicable malfunction symptom from the Trouble Symptom charts. Determine the condition of all
function circuits.
1. Make the following preliminary inspections.
A. Check that the installation of the actuator, accelerator cable are correct, and that the cables and links are
securely connected.
B. Check that the accelerator pedal moves smoothly.
C. Adjust the cable so there is not excessive tension or excessive play on the accelerator cable.
D. Check that the actuator & unit assembly, cruise main and control switch and the connector of each cancel
switch are connected securely.
2. Check in the sequence indicated in the Trouble Symptom chart.
3. If these checks indicate a normal condition, replace the cruise control module.
Trouble Symptom 1
Page 5 of 34
Trouble Symptom 2
Trouble symptom Probable cause Remedy
The set vehicle speed varies greatly Malfunction of the vehicle speed Repair the vehicle speed sensor
upward or downward sensor circuit system, or replace the part
"Surging" (repeated alternating acceleration
Malfunction of the speedometer
and deceleration) occurs after setting
carble or speedometer drive gear
Cruise vacuum pump circuit poor Repair the actuator system, or
contact replace the part
Malfunction of the actuator & unit Replace the actuator & unit
Trouble Symptom 3
The CC system is not canceled when the Damaged or disconnected wiring of Repair the harness or replace
brake pedal is depressed the stop lamp switch the stop lamp switch
Cruise vacuum pump drive circuit Repair the harness or replace
short-circuit the vacuum pump
Malfunction of the actuator & unit Replace actuator & unit
Trouble Symptom 5
Cannot decelerate (coast) by Temporary damaged or disconnected wiring of Repair the harness or replace
using the SET switch SET switch input circuit the SET switch
Actuator circuit poor contact Repair the harness or replace
Malfunction of the actuator the actuator
Trouble Symptom 4
The CC system is not canceled when the shift lever is Damaged or disconncted Repair the harness or
moved to the "N" position (It is canceled, however, wiring of inhibitor switch repair or replace the
when the brake pedal is depressed) input circuit inhibitor switch
Improper adjustment of
inhibitor switch
Malfunction of the actuator Replace the actuator &
& unit unit
Trouble Symptom 6
Page 6 of 34
Cannot accelerate or resume speed Damaged or disconnected wiring, or short Repair the harness or replace
by using the RESUME switch circuit, or RESUME switch input circuit the RESUME switch
the actuator
Malfunction of the actuator
Trouble Symptom 7
CC system can be set while driving at a vehicle speed Malfunction of the vehicle- Repair the vehicle speed
of less than 40km/h (25mph), or there is no automatic speed sensor circuit sensor system, or replace
cancellation at that speed the part
cable of the speedometer drive
gear
Malfunction of the actuator & Replace the actuator &
unit unit
Trouble Symptom 8
The cruise main switch indicator lamp does not Damaged or disconnected bulb of cruise Repair the harness or
illuminate (But CC system is normal) main switch indicator lamp replace the part
Harness damaged or disconnected
Trouble Symptom 9
Malfunction of control function by ON/OFF Malfunction of circuit related to idle Repair the harness or
switching of idle switch switch function replace the part
Malfunction of the actuator & unit
Trouble Symptom 9
Overdrive is not canceled during Malfunction of circuit related to overdrive Repair the harness or
fixed speed driving cancelation, or malfunction of actuator & unit replace the part
No shift to overdrive during
manual driving
SPECIFICATIONS
Spark plug
Page 7 of 34
2.4 Liter
V6 Engine
Engine
PGR5C-11 PFR5N-11
NGK
PFR5N-11
Chempion RN10PYP4 RC10PYP4
1.0-1.1mm (0.039~0.043
Plug gap
in.)
Generator
All Engines
Type Battery voltage sensing
Rated output 13.5 V 95A
Voltage regulator type Electronic built-in type
Regulator setting voltage 14.4 ± 0.3V
Temperature
-10 ± 3 mV/°C
compensation
Battery
2.4 Liter Engine V6 Engine
Type MF68AH(20HR) MF68AH (20HR)
Cold cranking [at-
540 A or more 540 A or more
17.8°C(0°F)]
Reserve capacity 110 min 110 min
Specific gravity [at
1.280 ± 0.01 1.280±0.01
25°C(77°F)]
COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a termintain
voltave of 7.2 or greater at a specified temperature. RESERVE CAPACITY RATING is the amount of tome a
battery can deliver 25A and maintain a minimum terminal voltage of 10.5 at 26.7°C(80°F).
Engine Electrical System > Ignition System > Ignition Coil > Repair procedures
IGNITION COIL (2.4 Liter Engine : Power Transistor Bulilt-in)
Page 8 of 34
1. Measurement of the primary coil resistance
Connect the negative (-) terminal of a 3V power supply to terminal 2 of the power transistor; then check whether
there is continuity between terminal 3 and terminal 2 when terminal 1 and the positive (+) terminal are connected
and disconnected.
Terminal 1 and (+) terminal Terminal 3 and terminal 2

Connected Continuity (Approximately 0.78Ω)
Replace the power transistor if there is a malfunction.

2. Measurement of the secondary coil resistance
Measure the resistance between the high-voltage terminals of the ignition coil.
Standard value: Approximately 20 kΩ

INSPECTION
Ignition coil(2.4 Liter Engine : Power Transistor Bulit-in)
1. Measurement of the primary coil resistance
Connect the negative (-)terminal of a 3V power supply to terminal 2 of the power transister; then check whether
there is contnuity between terminal 3 and terminal 2 when terminal 1 and the positive (+) terminal are connected
and disconneted.
Terminal 1 and ( ) terminal Terminal 3 and terminal 2
Connected Continuity(Approximately 0.78Ω)
Page 9 of 34
2. Measurement of the secondary coil resistance
Measurement the resistance between the high-voltage terminals of the ignition coil.
Standard value : Approximately 20kΩ
Engine Electrical System > Charging System > Alternator > Repair procedures
REPLACEMENT
Brush
1. Measure the length of the brush protrusion shown in the illustration, and replace the brush if the measured value is
below the limit value.
Limint : 2mm(0.079 in.) or less
2. The brush can be removed if the solder of the brush lead wire is removed.
3. When installing a new brush, insert the brush into the holder, and then solder the lead wire.
DISASSEMBLY
1. Remove the four through bolts.
Page 10 of 34
2. Insert a flat screwdriver between the front bracket and stator core, and pry downward.
1. Do not insert the screwdriver too deeply, as there is a danger of damaging the stator coil.
2. The rear cover may be hard to remove because a ring is used to lock the outer race of the rear bearing.
To facilitate removal of rear cover, heat just the bearing box section with a 200-watt soldering iron. Do
not use a heat gun as it may damage the diode assembly.
3. Secure the rotor in a vise with the pulley side up.
Be careful that the vise jaws do not damage the

rotor.
4. Remove the pulley nut spring washer, pulley, and spacer.

5. Remove the front bracket and two seals.
6. Remove the rotor from the vise.
7. Remove the brush holder screws, rectifier screws, and nut from the "B" terminal.
8. Remove the stator assembly from the rear bracket.
9. Detach the slinger from the brush holder.
Page 11 of 34
10. When the stator is to be removed, unsolder the three stator leads to the main diodes on the rectifier.
1. When soldering or unsoldering, make sure that heat from soldering iron is not transmitted to the diodes
for a long period.
2. Do not exert excessive force on the leads of the diodes.
11. When separating the rectifier form the brush holder, unsolder the two plates soldered to the rectifier.
OUTPUT CURRENT TEST

This test judges whether or not the generator gives an output current that is equivalent to the nominal output.
1. Preparation
(1) Prior to the test, check the following items and correct as necessary.
A. Check the battery installed in the vehicle to ensure that it is in good condition. The battery checking
method is described in "BATTERY".
IMMPORT : The battery that is used to test to test output current should be on one that has been partially
discharged. With a fully charge battery, the test may not be sonducted correctly due to an insufficient
load.
B. Check the tension of the generator drive belt. The belt tension check method is described in the section
"COOL-ING".
(2) Turn off the ignition switch.
(3) Disconnect the battery ground cable.
(4) Disconnect the generator output wire from the generator "B" terminal.
(5) Connect a DC ammeter (0 to 100A) in series between the "B" terminal and the disconnected output wire. Be
sure to connect the (-) lead wire of the ammeter to the disconnected output wire.
Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
(6) Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the
generator "B" terminal and (-) lead wire to a good ground.
(7) Attach an engine tachometer and connect the battery ground cable.
(8) Leave the engine hood open.
Page 12 of 34
2. Test
(1) Check to see that the voltmeter reads the same value as the battery voltage. If the voltmeter reads 0V, and
open circuit in the wire between the generator "B"terminal and battery (-)terminal, a blown fusible link or
poor grounding is suspected.
(2) Start the engine and turn on the headlights.
(3) Set the headlights to high beam and the heater blower switch to HIGH, quickly increase the engine speed to
2,500 rpm and read the maximum output current value indicated by the ammeter.
After the engine start up, the charging current quickly drops. Therefore, the above operation must be
done quickly to read the maximum current value correctly.
3. Result
(1) The ammeter reading must be higher than the limit value. If it is lower but the generator output wire is in good
condition, remove the generator from the vehicle and test it.
Limit value : 63A min : 95A generator
• The nominal output current value is shown on the nameplate affixed to the generator body.
• The output current value changes with the electrical load and the temperature of the generator itself.
Therefore, the nominal output current many not be obtained. If such is the case, keep the headlights
on to cause discharge of the battery, or use the lights of another vehicle to increase the electrical
load. The nominal output current may not be obtained if the temperature of the generator itself or
ambient temperature is too high. In such a case, reduce the temperature before testing again.
(2) Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
(3) Disconnect the battery ground cable.
(4) Remove the ammeter and voltmeter and the engine tachometer.
(5) Connect the generator output wire to the generator "B" terminal.
Page 13 of 34
(6) Connect the battery ground cable.
Engine Electrical System > Charging System > Repair procedures

INSPECTION
Generator Output Line Voltage drop Test
This test determines the condition of the wiring from the generator "B" terminal to the battery (+) terminal (including
the fusible link)
1. Be sure to check the following before testing :
A. Generator installation and wiring connections
B. Generator drive belt tension
C. Fusible link.
D. Abnormal noise from the generator while the engine is running.
2. Turn the ignition switch to the OFF position.
3. Disconnect the negative battery cable.
4. Disconnect the generator output wire from the generator "B" terminal. Connect a DC test ammeter with a range
of 0-100A in series between the "B" terminal and the disconnected output wire. (Connect the (+) lead of the
ammeter to the "B" terminal. Connect the (-) lead of the ammeter to the disconnected output wire.)
An inductive-type ammeter which enables measurements to be taken without disconnecting the generator
output wire is recommended.
Using this equipment will lessen the possibility of a voltage drop caused by a loose "B" terminal connection.
Page 14 of 34
5. Connect a digital-type voltmeter between the generator "B" terminal and the battery (+) terminal.
(Connect the (+) lead of the voltmeter to the "B" terminal. Connect the (-) lead of the voltmeter to the battery (+)
cable.)
6. Reconnect the negative battery cable.
7. Connect a tachometer or the scan tool.
9. With the engine running at approx. 2500 r/min, turn the headlights and other lights on and off to adjust the
generator load on the ammeter slightly above 30A.
Decrease the engine speed gradually until the value displayed on the ammeter is 30 A. Take a reading of the
value displayed on the voltmeter at this time.
Limit : max. 0.3V
When the generator output is high and the value displayed on the ammeter does not decrease until 30A, set
the value to40A. Read the value displayed on the voltmeter. In this case the limit becomes max. 0.4V.
10. If the value displayed on the voltmeter is still above the limit, a malfunction in the generator output wire may
exist. Check the wiring between the generator "B" terminal and the battery (+) terminal (including fusible link).
If a terminal is not sufficiently tight or if the harness has become discolored due to overheating, properly repair
the problem and perform the test again.
11. After the test, run the engine at idle.
12. Turn off all lights and turn the ignition switch to the OFF position.
13. Disconnect the tachometer or the scan tool.
15. Disconnect the ammeter and voltmeter.
16. Connect the generator output wire to the generator "B" terminal.
17. Connect the negative battery cable.
Output Current Test
Page 15 of 34
This test determines if the generator output current is normal.

1. Before testing, be sure to check the following :
B. Battery
The battery used should be slightly discharged. The load needed by a fully-charged battery is
insufficient for an accurate test.
C. Generator drive belt tension.

D. Fusible link.
E. Abnormal noise from the generator while the engine is running.
Page 16 of 34
4. Disconnect the generator output wire from the generator "B" terminal. Connect a DC test ammeter with a range
of 0-100 A in series between the "B" terminal and the disconnected output wire. (Connect the (+) lead of the
ammeter to the "B"terminal. Connect the (-) lead of the ammeter to the disconnected output wire.)
Never use clips to connect the line. Use bolts and nuts otherwise loose connections (e.g. using clips) may
lead to a serious accident and personal injury because of the high current.
An inductive-type ammeter which enables measurements to be taken without disconnecting the generator
output wire is recommended.
5. Connect a voltmeter with a range of 0-20 V between the generator "B" terminal and the ground. (Connect the (+)
lead of the voltmeter to the "B" terminal, and then connect the (-) lead of the voltmeter to the ground.)
8. Leave the hood open.
9. Check that the reading on the voltmeter is equal to battery voltage.
If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the generator
"B" terminal and the battery (+) terminal
10. Start the engine, and turn the headlights on.

11. Switch the headlights to high beam, turn the heater blower switch to High, increase the engine speed to approx.
2,500 r/min, and read the maximum current output displayed on the ammeter.
Limit : 70 of nominal output current
• For the nominal current output, refer to the Generator Specifications.

• Because the current from the battery will soon drop after the engine is started, Step #10 should be
carried out as quickly as possible in order to obtain the maximum current output value.
• The current output value will depend on the electrical load and the temperature of the generator body.
• If insufficient electrical load is used while testing, the specified level of current may not be output even
though thegenerator is normal
• The specified level of current also may not be output if the temperature of the generator body and/or
ambient temperature is too high. In such cases, allow the generator to cool before testing.
12. The reading on the ammeter should be above the limit value. If the reading is below the limit value and the
generator output wire is normal, remove the generator from the engine and check the generator.
13. Run the engine at idle speed after the test.
15. Disconnect the tachometer or the scan tool.
17. Disconnect the ammeter and voltmeter.
18. Connect the generator output wire to the generator "B" terminal.
Reguled Voltage Test
Page 17 of 34
This test determines if the voltage regulator is correctly controlling the generator output voltage.
1. Be sure to check the following :
B. Battery fully charged.
C. Generator drive belt tension.
D. Fusible link.
E. Abnormal noise from the generator while the engine is running.
2. Turn the ignition switch to the OFF position
4. Connect a digital-type voltmeter between the generator "S" terminal and the ground.
(Connect the (+) lead of the volt meter to the "S" terminal. Connect the (-) lead of the voltmeter to a secure
ground or to the battery (-) terminal.)
5. Disconnect the generator output wire from the generator "B" terminal.
6. Connect a DC test ammeter with a range of 0-100A in series between the "B" terminal and the disconnected
output wire. (Connect the (+) lead of the ammeter to the "B" terminal. Connect the (-) lead of the ammeter to the
disconnected output wire.)
7. Reconnect the negative battery cable.
Check that the reading on the voltmeter is equal to the battery voltage.
If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the generator
"S" terminal and the battery (+) terminal.
9. Make sure all lights and accessories are off.
11. Increase the engine speed to approx. 2,500 r./min.
Page 18 of 34
12. Read the voltmeter when the current output by the generator becomes 10 A or less.
13. If the voltage reading conforms to the value in the voltage regulation table, the voltage regulator is operating
normally.
If the voltage is not within the standard value, a malfunction of the voltage regulator or of the generator exists.
Engine Electrical System > Starting System > Starter > Repair procedures
REPLACEMENT OF BRUSHES AND SPRINGS
1. Brushes that are worn beyond wear limit line, or oil-soaked, should be replaced.
2. When replacing field coil brushes, crush worn brush with pliers, taking care not to damage pigtail.
3. Sand pigtail end with sandpaper to ensure good soldering.

4. Insert pigtail into hole provided in new brush and solder it. Make sure that pigtail and excess solder do not come
out onto brush surface.
5. When replacing ground brush, slide the brush from brush holder by prying retaining spring back.
INSPECTION
1. Commutaaor
(1) Place the armature on a pair of V-blocks, and check the deflection by using a dial gauge.
Standard value :
Armature deflection : 0.05 mm (0.002 in.)
Limit :
Page 19 of 34
(2) Check the outr diameter of the commutator.
Standard value :
Outer diameter of the commutator : 29.4 mm (1.157 in.)
Limit :
(3) Check the depth of the undercut between segments.
Standard value :
Depth of the undercut between segments : 0.5 mm (0.020 in.)
Limit :
2. Brush Holder
Check for continuity between the brush holder plate and the brush holder. The normal condition is no continuity.
Page 20 of 34
3. Overrunning Clutch
(1) While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but
should not rotate in opposite direction. If clutch does not function properly, replace overrunning clutch
assembly.
(2) Inspect pinion for wear or burrs. If pinion is worn or burred, replace overrunning clutch assembly. If pinion is
damaged, also inspect ring gear for wear or burrs.
4. Front and Rear Bracket Bushing

Inspect bushing for wear or burrs. If bushing is worn or burred, replace front bracket assembly or rear bracket
assembly.
ASSEMBLY
The stop ring and snap ring
1. Using a suitable pulling tool, pull overrunning clutch stop ring over snap ring.
DISASSEMBLY
Snap ring and Stop ring
1. Press the stop ring to the snap ring side using a socket wrench, to the snap ring side.
2. After removing the snap ring(using snap-ring pliers), remove the stop ring and the overrunning clutch.
INSPECTION
Page 21 of 34
1. Commutaaor
(1) Place the armature on a pair of V-blocks, and check the deflection by using a dial gauge.
Standard value :
Limit :
(2) Check the outr diameter of the commutator.
Standard value :
Limit :
(3) Check the depth of the undercut between segments.
Standard value :
Limit :
Page 22 of 34
2. Brush Holder
Check for continuity between the brush holder plate and the brush holder. The normal condition is no continuity.
3. Overrunning Clutch
(1) While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but
should not rotate in opposite direction. If clutch does not function properly, replace overrunning clutch
assembly.
(2) Inspect pinion for wear or burrs. If pinion is worn or burred, replace overrunning clutch assembly. If pinion is
damaged, also inspect ring gear for wear or burrs.
4. Front and Rear Bracket Bushing

Inspect bushing for wear or burrs. If bushing is worn or burred, replace front bracket assembly or rear bracket
assembly.
Engine Electrical System > Cruise Control System > Cruise Control Switch > Repair procedures
INSPECTION
1. Operate the switch, and check for the continuity between the terminals.
Engine Electrical System > Cruise Control System > Cruise Control Cable > Repair procedures
Page 23 of 34
ADJUSTMENT
Prior to proceeding with the final cable adjustment, make sure that the lever attached to throttle valve is in the normal
idle position.
1. Assemble the cable to actuator & unit assembly.
2. Tightn nut "b" after pulled cable tightly.
3. Back nut "b" off one turn.
4. Tighten nut "a".
5. Cable should have approximately 1mm off slack with actuator & unit against stop.
Engine Electrical System > Cruise Control System > Description and Operation
Component Parts and Function Outline
COMPONENT PART FUNCTION
Vehicle-speed sensor Converts vehicle speed to pulse.
Actuator & unit assembly Receives signals from sensor and control switches;
CCM controls all automatic speed control functions.
And regulates the throttle valve to the set opening by
signals from the actuator unit assembly.
Control switch CRUISE main switch Switch for automatic speed control power supply.
SET switch Controls automatic speed control functions by SET
RESUME switch (COAST) and RESUME (ACCEL).
Illuminates when CRUISE main switch is ON (Built into
CRUISE main switch indicator
cluster).
Cancel switch Stop lamp switch/Clutch switch
(M/T) Sends cancel signals to the actuator unit assembly.
Sransaxle range switch
Controls the overdrive ON and OFF, based on signals
ELC 4-speed automatic transaxle control module
from the actuator unit assembly for the CC.
*CC : Cruise Control
Engine Electrical System > Cruise Control System > Components and Components Location
COMPONENTS LOCATION
Page 24 of 34
Engine Electrical System > Cruise Control System > Troubleshooting

CRUSE CONTROL SYSTEM
Pre-Troubleshooting
Before commencing troubleshooting, inspect each of the following sections, and if there is an abnormality, carry out
a repair.
1. Check if the installation and connection routes of the cables and vacuum hoses of the cruise vacuum pump
assembly, actuator and pulley assembly are all normal.
2. Check if the pulley assembly and the movement of all cables are all working smoothly.
3. Check if there is no excessive play or tension in each cable.
First, select the applicable malfunction symptom from the Trouble Symptom charts. Determine the condition of all
function circuits.
1. Make the following preliminary inspections.
A. Check that the installation of the actuator, accelerator cable are correct, and that the cables and links are
securely connected.
B. Check that the accelerator pedal moves smoothly.
C. Adjust the cable so there is not excessive tension or excessive play on the accelerator cable.
D. Check that the actuator & unit assembly, cruise main and control switch and the connector of each cancel
switch are connected securely.
2. Check in the sequence indicated in the Trouble Symptom chart.
3. If these checks indicate a normal condition, replace the cruise control module.
TROUBLE SYMPTOM CHARTS
Trouble Symptom 1
Page 25 of 34
Trouble Symptom 2
The set vehicle speed varies greatly Malfunction of the vehicle speed Repair the vehicle speed sensor
upward or downward sensor circuit system, or replace the part
"Surging" (repeated alternating acceleration
and deceleration) occurs after setting carble or speedometer drive gear
Cruise vacuum pump circuit poor Repair the actuator system, or
contact replace the part
Trouble Symptom 3
Page 26 of 34
The CC system is not canceled when the Damaged or disconnected wiring of Repair the harness or replace
brake pedal is depressed the stop lamp switch the stop lamp switch
Cruise vacuum pump drive circuit Repair the harness or replace
short-circuit the vacuum pump
Malfunction of the actuator & unit Replace actuator & unit
Trouble Symptom 4
TTrouble symptom Probable cause Remedy
The CC system is not canceled when the shift lever is Damaged or disconncted Repair the harness or
moved to the "N" position (It is canceled, however, wiring of inhibitor switch repair or replace the
when the brake pedal is depressed) input circuit inhibitor switch
Improper adjustment of
inhibitor switch
Malfunction of the actuator Replace the actuator &
& unit unit
Trouble Symptom 5
Cannot decelerate (coast) by Temporary damaged or disconnected wiring of Repair the harness or replace
using the SET switch SET switch input circuit the SET switch
Trouble Symptom 6
Cannot accelerate or resume speed Damaged or disconnected wiring, or short Repair the harness or replace
by using the RESUME switch circuit, or RESUME switch input circuit the RESUME switch
Trouble Symptom 7
CC system can be set while driving at a vehicle speed Malfunction of the vehicle- Repair the vehicle speed
of less than 40km/h (25mph), or there is no automatic speed sensor circuit sensor system, or replace
cancellation at that speed
Malfunction of the speedometer the part
cable of the speedometer drive
gear
Malfunction of the actuator & Replace the actuator &
unit unit
Page 27 of 34
Trouble Symptom 8
The cruise main switch indicator lamp does not Damaged or disconnected bulb of cruise Repair the harness or
illuminate (But CC system is normal) main switch indicator lamp replace the part
Harness damaged or disconnected
Trouble Symptom 9
Malfunction of control function by ON/OFF Malfunction of circuit related to idle Repair the harness or
switching of idle switch switch function replace the part
Malfunction of the actuator & unit
Trouble Symptom 10
Overdrive is not canceled during fixed Malfunction of circuit related to Repair the harness or replace the part
speed driving overdrive cancelation, or
malfunction of actuator & unit
No shift to overdrive during manual
driving
Engine Electrical System > Cruise Control System > Repair procedures
REMOVAL
1. Remove the battery negative terminal.
2. Disconnect the accelerator cable and cruise control cable from throttle assembly by turning the throttle lever to
the full open position.
3. Disconnect the accelerator cable from accelerator pedal connection.
4. Remove the actuator & unit assembly mounting bolt.
INSTALLATION
Installation is the reverse order of removal.
Page 28 of 34
INSPECTION
1. Stop lamp switch
After operating the stop lamp switch, check for continuity between the terminals.
2. Condition
A. Turn A/C and all lights OFF. Inspect and adjust at no load.
B. Warm engine until stabilized at idle. Confirm idle speed is at specified RPM.
C. Then, ignition switch OFF.
(1) Confirm there are no sharp bends in cables.
(2) Depress the accelerator pedal and check if the throttle lever moves smoothly from fully closed to fully open.
(3) Check inner cables for correct slack.
(4) If there is too much slack or no slack, adjust play by the following procedures.
3. Serivce hint
(1) If the cable is very loose, the loss of speed going uphill will be large.
(2) If the cable is too tight, the idle RPM will become high.
Engine Electrical System > Troubleshooting > C1103

DTC No. C1103 Voltage out of range (Under and
Probable cause
over voltage)
[Comment]
The voltage of the HECU power supply drops lower or
rises higher than specified value.
If the voltage returns to the specified value, this code is
no longer output.
Page 29 of 34
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to standard
value, this code is no longer output.
Before carrying out the following inspection, check the battery level, and refill it if necessary.
Engine Electrical System > Troubleshooting > P0300

TROUBLESHOOTING
Random misfire detected
P0300
Cylinder 1 misfire detected
P0301
P0302
P0303
Cylinder 4 msifire detected
P0303
Related items · Vacuum leak in air intake system
· CKPS circuit malfunction
· Ignition circuit malfunction
· Faulty ignition coil or plug wire
· Spark plug malfunction
· Low compression due to blown head gasket, leaking valve or piston ring
· Low/high fuel pressure due to faulty pressure regulator, restricated fuel lines,
plugged fuel filter or faulty fuel pump
· Fuel injector circuit malfunction
· Faulty fuel injector
Page 30 of 34
If any injectors, HO2S, ECTS, and MAFS codes are present, do all
repairs associated with those codes before proceeding this
troubleshooting guide.

connector or OBD-II check connector. Yes
Turn ignition to ON and monitor DTCs.
Are any other codes set? No Go to step 2.
Check for any split, disconnected or Yes Go to step 3.
perforated vacuum hoses. Also, check PCV
2
valve for proper operation.
No Replace faulty vacuum hoses or PCV.
Are vacuum hoses and PCV okay?
Turn ignition to OFF and disconnect ignition Yes Go to step 4.
coil connector.
3 ignition coil battery voltage between ignition Open circuit or short circuit to chassis
coil harness connector and chassis ground. ground between ignition coil harness
No
· Specification : approximately B+ connector and main relay.
Is battery voltage within specifications? Repair as necessary.
Trun ignition to OFF and check ignition coils

and plug wires for cracks or carbon tracing. Yes Go to step 5.
Check resistance of primary coils (0.78+-10
4 Ω at 20°C).
Check for resistance of plug wires (16KΩ
per 1m). No Repair or replace as necessary.
Are ignition coils and plug wires OK?
Disconnect CKP connector and measure
resistance between CKP terminal 2 and
terminal 3 (800~900Ω at 20°C)
corroded terminals between CKPS and
Remove CKPS and calculate air gap
ECM.
between sensor and flywheel/torque Yes
Meaure resistance between CKPS terminal
converter (0.3~1.7 mm<0.012~0.067 3 and chassis ground (1<Ω).
5 in>){measure distance from hosing to teeth Repair as necessary.
on flywhee/torque converter (measurement
"A") and from mounting surface on sensor to
sensor tip (measurement "B") subtract "B"
from "A" = air gap}.
Are air gap and resistance measurements No Repair as necessary.
within specifications?
Release fuel pressure and attach fuel
pressure gauge to service port on fuel rail. Yes Go to step 7.
Start an engine and warm up to operating
kPa, 3.26~3.47 kg/cm²)
Page 31 of 34
kPa, 3.26~3.47 kg/cm²) No Check fuel delivery system
Is fuel pressure within specification?
Remove spark plugs and check gap
(0.7~0.8 mm 0.027~0.031 in ) and plug Yes Go to step 9.
7 condition.
Are spark plugs gapped properly and in No Repair as necessary.
good condition?
Perform compression test approximately Yes Go to step 10.
(184 psi, 1275 kPa, 13.0 kg/cm²) at 300
8 rpm (no more than 10 between highest
Perform leak down test to determine source
and lowest cylinder) . No
of low compression and repair as necessary.
Is compression OK?
9

TROUBLESHOOTING
Ignition failure system circuit malfunction
No. P0320
Related items · Open or short between ignition failure sensor and ECM
· Open or short between ignition failure sensor and ignition coil
· Open between ignition failure sensor and chassis ground
· Faulty ignition failure sensor
Stpe Inspection Action
Disconnect ignition failure sensor connector. Yes Go to step 2.

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

terminal 3 and chassis ground. Open circuit or short circuit to chassis
2
· Specification : approximately 5V No ground between IFS terminal 3 and ECM.
Is measured voltage within specification? Repair as necessary.
Measure resistance between IFS terminal 4 Yes Go to step 4.
and chassis ground. Open circuit between IFS terminal 4 and
3
· Specification : approximately 1Ω No chassis ground.
Is measured resistance within specification? Repair as necessary.
Turn ignition switch to OFF and reconnect corroded terminals at IFS.
ignition failure sensor. Yes If OK, temporarily install a known good IFS
Turn igniton switch to ON and measure
Page 32 of 34
Turn igniton switch to ON and measure and check for proper operation. If problem
4 voltage between IFS terminal 2 and chassis is corrected, replace IFS.
ground
· Specification : approximately B+ Open circuit or short circuit to chassis
Is measured voltage within specification? No ground between IFS and ignition coil.
Repair as necessary
5

TROUBLESHOOTING
Ignition coil primary/secondary circuit malfunction
No. P0350
Related items · Open or short between ignition coil and ECM
· Open or short between ignition coil and spark plug
· Short between ignition coil wires
· Faulty ignition coil
· Poor connection at ignition coil
· Faulty ignition system

Using SCAN TOOL and monitor any Do all repairs associated with those codes
DTCs. Yes
Is DTC P0300, P0301, P0302, P0303, or
P0304 set? No Go to step 2.
Yes
2 Start engine and monitor spark plug signal cleared. Check terminal connections at
pattern. ECM and ignition coils.
Is signal pattern normal? No Go to step 3.
Thoroughly check all coils and spark plug
wires for loose, bent, corroded, Yes Repair as necessary.
3 contaminated, deteriorated or damaged
connectors. No Go to step 4.
Start engine. Yes Go to step 5.
Using SCAN TOOL monitor spark plug
4 Verify what ignition coil is problem and go to
signal pattern. No
Are all signal patterns normal? step 5.
Turn ignition to OFF and disconnect ignition Yes Go to step 6.
coil connector.
Turn ignition to ON and measure voltage
between ignition coil power circuit from Open circuit or short circuit to chassis
5 ground between ignition coil harness
ignition coil harness connector to ignition
failure sensor connectorand chassis ground. No
connector and ignition failure sensor
Page 33 of 34
failure sensor connectorand chassis ground.
· Specification : approximately B+ connector.

connector.
Yes Go to step 7.
Measure resistance of ignition coil signal
circuit between ignition coil harness
connector and ECM harness connector.
6 Measure resistance of ignition coil ground
Open circuit between ignition coil harness
circuit between ignition coil harness
connector and ECM harness connector
connector and chasis ground. No
· Specifications : below 1Ω and/or chassis ground.
circuit?
Measure voltage of ignition coil signal circuit
between ignition coil harness connector and Short circuit to power between ignition coil
chassis ground. No
Temporarily install a known good ignition
Turn ignition to OFF. Yes coil and check for proper operation. If
Measures resistance between ignition coil problem is corrected, replace ignition coil.
harness connector and chassis ground at
8 Short circuit to chassis ground between
ignition coil signal circuit.
· Specifications : infinite ignition coil harness connector and chassis
No
Does resistance indicate open circuit? ground.
9

TROUBLSHOOTING
Diagnostic trouble
Battery backup line malfunction
code No. P0560
Related items · Open or short between ECM and battery
· ECM intermal faulty
Page 34 of 34
Thoroughly check for poor connection,
Turn ignition to OFF and disconnect ECM misplaced, corroded terminals at ECM
Yes
connector. connector.
Measure voltage of backup circuit between Repair as necessary.
1
battery and chassis ground. Open circuit or short circuit to chassis
· Specification : approximately B+ ground between ECM harness connector
Is voltage within specification? No
and battery.
· Temporarily install a known good ECM and check for proper operation. If problem is corrected
replace ECM.
2
· Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with

TROUBLESHOOTING
Spark timing adjustment
No. P1330
Related items · Short to GND between ROM change tool (RCT) and ECM
Turn ignition to OFF and disconnect ECM Problem is intermittent or was repaired and
connector. engine control module memory was not
Yes
Measure resistance between RCT harness cleared. Check connectors at ECM and
1 connector and chassis ground at spark timing RCT.
adjustment circuit. Short circuit to chassis ground between RCT
· Specifications : infinite No and ECM harness connector.
2
Page 1 of 101
OPTIMA(MS) > 2001 > G 2.4 DOHC > Engine Mechanical System
Engine Mechanical System > General Information > General Information

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

1. Position a vehicle on a level surface.
2. Stop the engine
In the case of a vehicle that has been out of service for a prolonged period, run the engine for several
minutes.
Stop the engine and wait 5 minutes at least, and then check the oil level.
Page 2 of 101
3. Check that the engine oil level is within the level range indicated on the oil dipstick. If the oil level is found to have
fallen to the lower limit (the "MIN" mark), refill to the "MAX" mark.
When refilling, use the same type of engine oil as the one currently being used.
4. Check that the oil is not dirty or mixed with coolant or gasoline and it has the proper viscosity.
SELECTION OF ENGINE OIL
Recommended AP classification : SG OR SG CD, SH OR SH CD
Reconnended SAE viscosity grades
1. Restricted by driving and climate condition.

2. Not recommended for sustained high speed vehicle operation.
Page 3 of 101
For best performance and for maximum protection for all types of operation, select only those lubricants
1. Confirm the requirements of the API classification.
2. Have proper SAE grade number for expected ambient temperature range. Lubricant which do not have both a
SAE grade numberand an API service classification on the container should not be used.
CHANGING ENGINE OIL
1. Run the engine until it reaches normal operating temperature.
2. Stop the engine.
3. Remove the oil filler cap (on rocker cover) and the drain plug (on the oil pan). Drain the engine oil.
4. Re-install and tighten the drain plug to the specified torque.
Tightening torque
Drain plug : 35-45 Nm (350-450 kg.cm, 25-33 lb.ft)
5. Fill the crankcase with new engine oil through the oil filler cap opening.
Capacity
Drain and refill :
Without oil filter : 4.0 lit (4.23 U.S.qts., 3.51 lmp.qts.)
With oil filter : 4.3 lit (4.5 U.S.qts., 3.8 lmp.qts)
Do not overfill the crankcase.

This will cause oil aeration and loss of oil pressure.
6. Install the oil filler cap.
7. Start and run the engine.
8. Stop the engine and then check the oil level.
Add oil if necessary.
REPLACING THE OIL FILTER
1. All Kia engines are equipped with a high quality, throw-away oil filter. This filter is recommended as a
replacement filter on all vehicles. The quality of replacement filters is various considerably. High guality
replacement filters shouldbe used to assure the most efficient service. Make sure that the rubber gasket from the
old oil filter is completely removed from the contact surface on the engine block before installing the new filter.
Page 4 of 101
2. Use a filter wrench to remove the oil filter
3. Before installing the new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket.
4. Tighten the oil filter to the specified torque.
Oil filter : 17-25 Nm (170-250 kg.cm, 12-28 lb.ft)
5. Start and run the engine and check for engine oil leak.
6. After stopping the engine, check the oil level and add oil as necessary.
ADJUSTING DRIVE BELTS TENSION
1. Check that the belts are not damaged and are properly fit into the pulley grooves.
1. When installing the V-ribbed belt, check that the V-ribs are properly in alignment.
2. If noise or slippage is detected, check the belt for wear, damage, or breakage on the pulley contact
surface, and checkthe pulley for scoring. Also check the degree that the belt is deflected.
2. Apply 100 N (22 lbs.) force to the belt back midway between the pulleys as shown in the illustration, measure
the amount of deflection with a tension gauge.
Standard value :
Adjustment
Items Inspection
New Used
For generator Deflection 7.7-12.3 6.3-7.3 8.4-10.6
mm (in.) (0.303-0.484) (0.248-0.287) (0.330-0.417)
Tension 300-500 550-650 350-450
N (lb) (66-110) (121-143) (77-99)
For air conditiner
compressor and Deflection 11.7-15.3 8.8-11.0 12.5-14.3
power steering oil mm (in.) (0.46-0.6) (0.35-0.43) (0.5-0.56)
pump
Page 5 of 101
1. The belt tension must be measured between the specified pulleys.

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

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

1. When measuring, be sure to turn reset button in the arrow direction to set the gauge needle to the RESET
position.
2. If the tension gauge is removed from the belt, the needle will still indicate the tension. Read the tension value after
removing the gauge.
Adjusting the Generator belt

Page 6 of 101
If the belt is too loose, there will cause noise or sudden wear.
If the belt is too tight, the Engine coolant pump bearing or the generator will get damaged.
1. Loosen the generator nut "A" and the tension adjuster lock bolt "B".
2. Using the tension adjuster bolt, adjust the belt tension to the specification.
3. Tighten the adjuster lock bolt "B".
4. Tighten the generator nut "A".
5. Check the tension or the deflection of belt, readjust if necessary.
Generator Belt Adjustment

Tighten torque
Generatir A : 34-54Nm (340--540 kg.cm, 25-39 lb.ft)
Adjuster lock bolt B : 20-25 Nm (200-250 kg.cm, 14-18 lb.ft)
Tension adjuster bolt : 8-12 Nm (80-120 kg.cm, 6-8 lb.ft)
Adjusting the Belt Power Steering and Air conditioner

1. Loosen the tension pulley adjustment bolt A.
2. Adjust the belt deflection with adjustment bolt B.
3. Tighten the fixing bolt A.
4. Re-check the belt deflection and re-adjust, if necessary.
Before re-checking, crank the engine one or more

revoltions.
Checking Lash Adjusters Check

If an abnormal noise is heard from the lash adjusters (tappets), check as follows ;
1. While installed to the cylinder head, press the part where the rocker arm contacts the lash adjuster at the very
top. Ifthe adjuster is normal, the part pressed will feel very hard.
2. If it always moves easily downward when pressed, there is a malfunction of the lash adjuster and it should be
replaced with a new one.
Page 7 of 101
3. If it feels spongy or elastic, probably oil mixed with air has entered the lash adjuster, so follow the steps below.
A. Check whether the amount of oil is too much or is not enough.
B. Check whether the reason why air is mixed with oil is a damaged oil screen or oil screen gasket. After
repairing the cause of the air leak, warm up the engine and then drive the vehicle at low speed for a while.
Stop the engine and leave it off a few minutes ; then re―start the engine and drive at low speed. Repeat this
proce dureseveral times during the course of about one hour so as to remove the air from the oil.
CHECKING COOLANT LEAK
1. Loosen the radiator cap.
2. Confirm that the coolant level is up to the filler neck.
3. Install a radiator cap tester in the radiator filler neck and apply 150 kPa (21 psi, 1.53 kg/cm²) pressure. Hold if
for two minutes inthat condition, while checking for leakage from the radiator, hose or connections.
1. Radiator coolant may be extremely hot. Do not open the system because hot, or scalding Engine
coolant could spray out causing severe burns and blindness.
Allow the vehicle to cool to ambient air temperature before servicing this system.
2. Be sure to completely clean away any moisture from the places checked.
3. When the tester is removed, be careful not to spill any coolant from it.
4. Be careful, when installing and removing the tester and when testing, not to deform the filler neck of the
radiator.
4. If there is leakage, repair or replace the appropriate part.

RADIATOR CAP PRESSURE TEST
1. Use an adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops moving.
Main valve opening pressure : 96.1-124.5 kPa (0.98 -1.27 kg/m², 13.94-18.06 psi)
Main valve closing pressure : 83.4kPa (0.85 kg/cm², 12.1 psi)
3. Check that the pressure level is maintained at or above the limit.

4. Replace the radiator cap if the reading does not remain at or above the limit.
Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an
improper indication.
Page 8 of 101
SPECIFIC GRAVITY TEST
1. Measure the specific gravity of the coolant with a hydrometer.
2. Measure the coolant temperature, and calculate the concentration from the relation between the specific gravity
and temperature, using the following table for reference.
RELATION BETWEEM COOLANT CONCEMTRATION AND SPECIFIC GRAVITY
Coolant temperature °C(F°) and specific gravity Safe Coolant

Freezing
operating concentration
temperature
temperature (specific
10(20) 20(68) 30(86) 40(104) 50(122) °C(F°)
°C(F°) volume)
1.054 1.050 1.046 1.042 1.036 -16(3.2) -11(-12.2) 30
1.063 1.058 1.054 1.049 1.044 -20(-4) -15(5) 35
1.071 1.067 1.062 1.057 1.052 -25(-13) -20(-4) 40
1.079 1.074 1.069 1.064 1.058 -30(-22) -25(-13) 45
1.087 1.082 1.076 1.070 1.064 -36(-32.8) -31(-23.8) 50
1.095 1.090 1.084 1.077 1.070 -42(-44) -37(-35) 55
1.103 1.098 1.092 1.084 1.076 -50(-58) -45(-49) 60
The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant temperature
of 20°C (68°F).
If the concentration of the coolant is below 30%, the anti-corrosion property will be adversely affected. In
addition, if the concentration is above 60%, both the anti-freeze and engine cooling properties will decrease,
affecting the engineadversely. For these reasons, be sure to maintain the concentration level within the specified
range.
Do not use together with another brand's product.
RECOMMENDED COOLANT
Mixture ratio of anti-freeze on
Antifreeze
coolant
ETHYLENE GLYCOL 50 [Except tropical areas]
BASE FOR ALUMINUM 40 [Tropical areas]
Engine Mechanical System > General Information > Special Service Tools
Page 9 of 101
Tool
Illustation Use
(Number and name)
Installation of the crankshaft front oil
09214-32000/09214-M2001 seal
Crankshaft front oil seal installer (use with 09214-32100/09214-
M2100)
Installation of the crankshaft front oil
09214-32100 / 09214-M2100 seal
Crankshaft front oil seal guide (use with 09214-32000/09214-
M001)
Installation of the camshaft oil seal

09221-21000 / 09221-M2000
(use with 09221-21100/09211-
Camshaft oil seal installer
M2100)
09221-21100 / 09221-M2100 Used as a guide when pressing in the

Camshaft oil seal guide camshaft oil seal
Removal and installation of the inlet

09222-28000/0K993 120 001 or exhaust
Valve spring compressor (use with 09222-28100/0K993 120
004)
09222-21100
Installation of the valve stem oil seal
Valve stem oil seal installer
09222-21200 A/B / 09222-M2200

Removal and installation of the valve
A/B
guide
Valve guide installer
09231-38000 Fixing the camshaft when replacing

Camshaft locking tool the timing belt
1. Installation of the engine rear oil

09231-21000/09231-M2000 seal
Crankshaft rear oil seal installer 2. Installation of the crankshaft rear
oil seal
09260-32000 Removal and installation of oil

Oil pressure switch wrench pressure switch
Page 10 of 101
09221-32001 / 09221-M2001 Removal and installation of the

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

Counter balance shaft bearing puller balance shaft
Removal of rear bearing of counter

09212-32100 / 09212-M2100
balance shaft
Counter balance shaft bearing puller
(use with 09212-32300)
09212-32200 Installation of counter balance shaft

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

09212-32300 balance shaft rear bearing
Guide plate (use with 09212-32100 / 09212-
M2100, 09212-32200)
09213-33000 Removal and installation of front case

Plug cap wrench cap plug
Engine Mechanical System > General Information > Troubleshooting

TROBLESHOOTING
Sympton Probable cause Remedy
Low compression Blown cylinder head gasket Replace gasket
Worn or damaged piston rings Replace rings
Repair or replace piston and/or
Worn piston or cylinde
cylinder block
Repair or replace valve amd/or
Worn or damaged valve seat
seat ring
Oil pressure drop Low engine oil level Check engine level
Fauty oil pressure switch Replace
Clogged oil filter Replace
Worn oil pump gears or cover Replace
Thin or diluted engine oil Change and find out cause
Oil relief valve stuck(open) Repair
Page 11 of 101
Excessive bearing clearance Replace
High oil pressure Oil relief valve stuck(closed) Repair
Excessive engine rolling and Loose engine roll stopper(front, rear) Re―tighten
vibration Loose transaxle mount bracket Re―tighten
Loose engine mount bracket Re―tighten
Loose center member Re―tighten
Broken transaxle mount insulator Replace
Broken engine mount insulator Replace
Broken engine roll stopper insulator Replace
Noisy valves Thin or diluted engine oil (low oil pressure) Change
Worn or damaged valve stem or valve guide Replace
Connecting rod and main Insufficient oil supply Check engine oil level
bearing noise
Thin or diluted engine oil Change and find out cause
Excessive bearing clearance Replace
Adjust belt tension or Replace
Timing belt noise Incorrect belt tension(Auto tensioner)
auto tensioner
Low coolant level Leakage of coolant
-Damaged radiator core joint
Replace
-Corroded or cracked hoses (radiator hose,
Replace
heater hose, etc)
Faulty radiator cap valve or setting of spring Replace
Faulty thermostat Replace
Faulty engine coolant pump Replace
Clogged rediator Foreign material in coolant Replace
Abnormally high coolant Faulty thermostat Replace
temperature
Faulty rediator cap Replace
Restriction of flow in cooling system Replace
Loose or missing drive belt Adjust or replace
Faulty engine coolant pump Replace
Faulty temperature gauge or wiring Repair or replace
Faulty electric fan Repair or replace
Faulty thermo―sensor on radoator Repair or replace
Insufficient coolant Refill coolant
Abnormally low coolant Faulty thermostat Replace
temperature Faulty temperature gauge or wiring Replace or replace
Leakage from oil cooling system Loose hose and pipe connection Retighten
Blocked or collapsed hose and pipe Replace
Page 12 of 101
Inoperative electrical cooling
Damaged Replace or repair
system
Exhaust gas leakage Loose connections Retighten
Broken pipe or muffler Repair or replace
Abnormal noise Detached baffle plate in muffler Replace
Broken rubber hanger Replace
Pipe or muffler contacting vehicle body Correct
Broken pipe or muffler Repair or replace
Engine Mechanical System > General Information > Specifications

SPECIFICATION
Description Specification Limit
General In-line, Double Overhead
Type
Camshaft
Number of cylinders 4
2.4L Eng.
Bore 86.5mm(3.41 in.)
Stroke 100 mm(3.94 in.)
Total Compression ratio 2351cc(143.5 cu. in.)
displacement Firing order 10
Idle R.P.M 1-3-4-2
Ignition timing at idling speed BTDC 5°±2°
Valve timing Intake Opens (BTDC) 12°
valve(2.4L
Eng.) Closes(ABTC) 56°
Exhaust valve Opens(BBTC) 54°
Closes(ATDC) 14°
Cylinder head Flatness of gasket surface Max. 0.03mm(0.0012 in.) 0.2mm(0.008 in.)
Flatness of manifold mounting surface 0.15 mm(0.0059 in.) 0.3mm(0.012 in.)
Dimensions Intake 0.3mm(0.012 35.300-35.325mm (1.3898-
for reworking in.) O.S 1.3907 in.)
oversize valve
0.6mm(0.024 35.600-35.625 mm (1.4016-
seat hole
in.) O.S 1.4026 in.)
Exhaust 0.3mm(0.012 33.300-33.325 mm (1.3110-
in.) O.S 1.3120 in.)
0.6mm(0.024 33.600-33.625 mm (1.3898-
in.) O.S 1.3907 in.)
Dimensions
Page 13 of 101
Dimensions 12.050-12.068mm(0.4744-
0.05mm(0.002 in.) O.S
for reworking 0.4751 in.)
oversize valve
12.250-12.068mm(0.4744-
seat hole(both 0.25mm(0.010 in.) O.S
0.4751 in.)
intake and
exhaust) 12.500-12.518mm(0.4921-
0.50mm(0.020 in.) O.S
0.4928 in.)
Camshaft Cam height 34.993mm(1.3777
Intake 35.493mm(1.3974 in.)
in.)
34.817mm(1.3707
Exhaust 35.317mm(1.3904 in.)
in.)
Journal O.D. 26mm(1.02 in.)
0.040-0.076mm(0.0020-
Bearing oil clearance
0.0029)
End play 0.1-0.2mm(0.004-0.008 in.)
Valve Valve lengh Intake 109.5mm(4.311 in.)
Exhaust 109.7mm(4.319 in.)
Stem O.D. 6.565-6.580mm(0.2585-
Intake
0.2591 in.)
6.530-6.550(0.2571-0.2579
Exhaust
in.)
Face angle 45-45.5°
Thickness of Intake 1.0mm(0.040 in.) 0.7mm(0.028 in.)
valve
head(margin) Exhaust 1.5mm(0.059 in.) 1.0mm(0.040 in.)
Valve stem to 0.020-0.047mm(0.0008- 0.10mm(0.0040
Intake
valve guide 0.0019 in.) in.)
clearance 0.050-0.085mm(0.0020- 0.15mm(0.0059
Exhaust
0.0033 in.) in.)
Valve guide Length Intake 45.5mm(1.791 in.)
Exhaust 50.5mm(1.988 in.)
0.05, 0.25, 0.50mm(0.002,
Service size
0.010, 0.020 in.) oversize
Valve seat Width of seat contact 0.9-1.0mm(0.035-0.051 in.)
Seat angle 44-44.5
0.3mm(0.012 in.),
Service size
0.6mm(0.024 in.) oversize
Valve spring 44.82 mm(1.765
Free length 45.82mm(1.804 in.)
in.)
248 N(55lb) at instakked
Load
hught
Out of squareness Less than 1.5° 4°
Page 14 of 101
Cylinder Cylinder bore 86.5-86.53
block Less than 0.01mm(0.0004
Out-of-roundness and taper of cylinder bore
in.)
Less than 0.05mm(0.0020
Flatness of gasket surface
in.)
Piston 84.97-
O.D 85.00mm(85.00mm(3.4055-
3.4067)
0.02-0.04mm(0.0008-
Piston-to-cylinder clearance
0.0012 in.)
Ring groove 1.21-1.23mm(0.0476-
No. 1
width 0.0484 in.)
1.51-1.53mm(0.0595-
No. 2
0.0602 in.)
2.81-2.83mm(0.1106-
Oil
0.1114 in.)
Piston ring Side 0.03-0.07mm(0.0012-
No. 1 0.1mm(0.004 in.)
clearance 0.0028 in.)
0.02-0.06mm(0.0008-
No.2 0.1mm(0.004 in.)
0.0024 in.)
End gap 0.25-0.0020mm(0.0098-
No. 1
0.0138 in.)
0.20-0.06mm(0.0157-
No.2
0.0216 in.)
0.10-0.40mm(0.0039-
Oil ring side rail
0.0157 in.)
Connecting 0.05mm(0.0020 in.) or less
Bend
rod per 100mm(3.937 in.)
0.1mm(0.004 in.) or less per
Twist
100mm(3.937 in.)
Connecting rod big end to crankshaft side 0.10-0.25mm(0.0040-
0.4mm(0.0157 in.)
clearance 0.0098 in.)
7,500-17,500 N(1,653-
Pistion pin press-in load
3,858 lb)
Connecting Oil clearance No. 1, 2, 4, 5: 0.018-
0.1mm(0.004 in.)
rod bearing 0.036mm
No. 3: 0.024-
0.042mm(0.0009-0.0016 in.)
Crankshaft 44.980-45.000mm(1.7709-
Pin O.D.
1.7717 in.)
56.982-57.000mm(2.2434-
Journal O.D.
2.2442 in.)
Page 15 of 101
Out-of roundness of journal and pin
in.)
Taper of journal and pin
in.)
0.05-0.25mm(0.0020- 0.25mm(0.0098
End play
0.0098 in.) in.)
0.13mm(0.0051
Flywheel Runout
in.)
Oil pressure at curb idle speed
80kPa(11.4 psi) or more
[Oil tempreature is 75 to 90°C(167 to 194F°)]
Oil pump Tip clearance 0.160-0.205mm(0.0063- 0.25mm(0.0098
Drive gear
0.0081 in.) in.)
0.180-0.205mm(0.0071- 0.25mm(0.0098
Driven gear
0.0081 in.) in.)
Side 0.08-0.14mm(0.0031- 0.25mm(0.0098
Drive gear
clearance 0.0055 in.) in.)
0.06-0.12mm(0.0024- 0.25mm(0.0098
Driven gear
0.0047 in.) in.)
Relief spring Free length 46.6mm(1.835 in.)
Load [61N(13.5 lb)] 40.1 mm(1.579 in.)
Right silent 41.959-41.975mm(1.6519-
Front journal diameter
shaft 1.6526 in.)
40.951-40.967mm(1.6122-
Rear journal diameter
1.6129 in.)
Oil clearance 0.020-0.0061mm(0.020-
Front
0.054mm(0.0008-0.0021 in.)
0.0042-0.0083mm(0.0017-
Rear
0.0033 in.)
Engine coolant cooling,
Cooling method forced circulation with water
pump(Driven belt)
Cooling 7.3 lit(7.7 u.s.qts., 6.4
Quantity
system lmp.qts)[For DOHC]
Thermostat Wax pellet type with jiggle
Type
valve
Normal opening temperature 82°C(179.6F°)
80.5°C-83.5°C(176.9-
Opening temperature range
182.3F°)
Wide open temperature 95°C(203F°)
Radiatior cap 86.1-124.5kPa(0.98-1.27kg
Main valve opening pressure
cm², 13.94-18.06psi)
Page 16 of 101
83.4 kPa(0.85kg cm², 12.1
Main valve closing pressure
psi)
-6.86 kPa(-0.07kg cm²-
Vacuum valve opening pressure
1.00 psi)
Air cleaner Type Dry type
Element Unwoven cloth type
Exhaust Muffler Expansion resonance
Suspension system Rubber hangers
SERVICE STANDARD
Standard value
Coolant Tropical area 40
concentration Other area 50
LUBRICANT
Ethylene glycol base for
Engine coolant
aluminum radiator
SELANT
Three bond No.2310 or
Engine coolant temperature sender
equivalent
Engine coolant temperature sender LOCTITE 962T or equivalent
• O.D. = Outer Diameter

• I.D. = Inner Diameter
• O.S. = Oversize Diameter
• U.S. = Undersize Diameter
TIGHTENING TORQUE
Nm kg.cm lb.ft
Engine mounting insulator bolt [12x15 mm
90-110 900-1100 65-80
(0.4724×0.5906 in.)]
Engine mounting bracket nuts 60-80 600-800 43-58
Engine mounting bracketbolts[12×60 mm
60-80 600-800 43-58
(0.4724×2.3622 in.)]
Front roll stopper bracket to sub frame bolts 60-80 600-800 43-58
Front roll stopper insulator bolt and
50-65 500-650 36-47
nut[10×85mm (0.3937×3.3465 in.)]
Front roll stopper bracket to transaxle bolts 60-80 600-800 43-58
Rear roll stopper bracket to sub frame bolts 50-65 500-650 36-47
Rear roll stopper insulator bolt and nut 50-65 500-650 36-47
Page 17 of 101
Rear roll stopper bracket to transaxle bolts 60-80 600-800 43-58
Transaxle mounting sub bracket nut 60-80 600-800 43-58
Transaxle mounting bracket bolts 60-80 600-800 43-58
Transxle mounting bracket insulator to
90-110 900-1100 65-80
bolt[12×15mm(0.4724×0.5906 in.)]
Air conditiner compressor to bracket 23-27 230-270 17-20
Power steering oil pump to braacket 35-45 350-450 25-33
Front exhaust pipe to exhaust manifold 30-40 300-400 22-29
Rocker cover bolt 8-10 80-100 6-7
Center cover bolt 4-5 40-50 3-3.6
Camshaft sprocket bolt 80-100 800-1000 58-72
Camshaft bearing cap bolt 19-21 190-210 14-15
Crankshaft position sensor 10-13 100-130 7-9
Cam position sensing cylinder bolt 15-22 150-220 11-16
Throttle body stay 15-22 150-220 11-16
Air cleaner body installation bolt 8-10 80-100 6-7
Crankshaft sprocket bolt 110-130 1100-1300 80-94
Crankshaft pulley to crankshaft sprocket 20-30 200-300 14-22
Cylinder head bolt 20-90 90° Releas 200-90 90°
Without changing 14 Releas all bolt
(Cold engine) all bolt 20 90° Releas all bolt 200
parts 14 90° 90°
90° 90° 90°
Without changing
20 90° 90° 200 90° 90° 14 90° 90°
parts
Intake manifold stay 18-25 180-250 13-18
Tensioner pulley bracket bolt 23-27 230-270 17-20
Auto tensioner bolt 20-27 200-270 14-20
Tensioner pulley bolt 43-55 430-550 31-40
Idle pulley bolt 45-55 450-550 33-40
Front exhaust pipe clamp bolt 20-30 200-300 14-22
Oil pan 10-12 100-120 7-9
Oil pan drain plug 35-45 350-450 25-33
Oil screen 15-22 150-220 11-16
Oil pump sprocket nut 50-60 500-600 36-43
Oil pressure switch 8-12 80-120 5.8-8.7
Oil filter bracket bolt 20-27 200-270 14-20
Oil pump cover bolt 15-18 150-180 11-13
Oil seal case bolt 10-12 100-120 7-9
Page 18 of 101
Plug cap 20-27 200-270 14-20
Oil pump case bolt(M8) 20-27 200-270 14-20
Driven gear bolt 34-40 340-400 25-29
Engine coolant pump pulley bolt 8-10 80-100 6-7
Timing belt upper cover 8-10 80-100 6-7
Timing belt lower cover 8-10 80-100 6-7
Relief plug 40-50 400-500 29-36
Flywheel 130-140 1300-1400 94-101
Drive plate 130-140 1300-1400 94-101
Timing belt rear right cover 10-12 100-120 7-9
Timing belt rear left cover(lower)
-bolt also securing left engine support 30-42 300-420 22-30
bracket
Timing belt rear left cover(upper) 10-12 100-120 7-9
180-220
Connecting rod cap bolt 18-22 (90°~94°) 13-16 (90°~94°)
(90°~94°)
Crankshaft bearing cap bolt 25 (90°~94°) 250 (90°~94°) 18 (90°~94°)
Engine hanger M8 25-30 250-300 8-22
M10 35-55 350-550 25-40
Generator support bolt 20-25 200-250 14-18
Generator brace bolt (4T) 12-15 120-150 9-11
(5T) 20-27 200-270 14-20
Engine coolant pump
Head mark "7"bolt 15-22 150-220 11-15
to cylinder block bolt
Engine coolant temperature gauge unit 10-12 100-120 7-9
Engine coolant temperature sensor 20-40 200-400 14-29
Engine coolant outlet fitting attaching bolt 10-15 100-150 7-11
Air cleaner mounting bolts 8-10 80-100 6-7
Resonator mounting bolt 8-10 80-100 6-7
Resonator mounting nut 4-6 40-60 35-47 lb.in
Delivery pipe bolt to engine 10-13 100-130 7-9
Accelerator cable bolts to intake manifold 4-6 40-60 35-47 lb.in
Throttle body to intake manifold 15-22 150-220 11-16
Intake manifold stay bolts 18-22 180-220 13-18
Intake manifold (M8) 15-20 150-120 11-14
mounting bolt (M10) 18-25 180-250 13-18
Intake manifold mounting nut 30-42 300-420 22-30
Page 19 of 101
Tension rod bracket bolt to tension rod 35-55 350-550 25-40
Ignition coil bolts 8-12 80-120 6-9
Power transsistor bolts 10-12 100-120 7-9
EGR valve bolts 17-26 170-260 12-19
EGR temperature sensor(California) 10-12 100-120 7-9
Front exhaust pipe nuts to exhaust manifold 30-40 300-400 22-29
Front exhaust pipe bolt to engine 20-30 200-300 14-22
Center exhaust pipe nuts to catalytic
30-40 300-400 22-29
converter
Center exhaust pipe bolts to main muffler 30-40 300-400 22-29
Center exhaust pipe bolt to bracket 10-15 100-150 7-11
Hanger bolt to body M8 25-30 250-300 18-22
M10 35-55 350-550 25-40
Hanger bolt to main muffler 10-15 100-150 7-11
Exhaust manifold nuts M8 25-30 250-300 18-22
to engine nut
M10 35-55 350-550 25-40
Oxygen sensor 40-50 400-500 29-36
Heat protector bolt to exhaust manifold 12-15 120-150 9-11
Engine Mechanical System > Timing System > Timing Belt > Components and Components Location
COMPONENTS
Page 20 of 101
Engine Mechanical System > Timing System > Timing Belt > Repair procedures
REMOVAL
1. Remove the crankshaft pulley, engine coolant pump pulley and drive belt.
2. Remove the timing belt cover.
Page 21 of 101
3. Turn the crankshaft clockwise and align the timing marks so as to bring the No. 1 cylinder to compression top-
dead-center position.
At this time the timing marks of the camshaft sprocket and the timing marks of the rocker cover should coincide,
and thedowel pin of the camshaft sprocket should be at the upper side.
Remove the auto tensioner.
Rotate the crankshaft clockwise.

4. Remove the timing belt.
If the timing belt is reused, make an arrow mark indicating the turning direction (or the front of the engine)
to make sure that the belt is reinstalled in the same direction as before.
5. Remove the camshaft sprockets.
Be careful not to damage the cylinder head with the

wrench.
Page 22 of 101
6. When the oil pump sprocket nut is removed, first remove the plug at left side of the cylinder block and insert a
screwdriver to check the left counter balance shaft in position. Screwdriver used for this purpose should have a
shaft 8 mm (0.3 in.) in diameter which can be inserted more than 60 mm (2.36 in.)
7. Remove the oil pump sprocket retaining nut and remove the oil pump sprocket.
8. Loosen the right counter balance shaft sprocket mounting bolt until it can be loosened by hand.
9. Next, remove tensioner "B" and remove timing belt "B".
After timing belt "B" has been removed, do not attempt to loosen bolt while holding sprocket with pliers,
etc.
10. Remove the crankshaft sprocket "B" from crankshaft.
INSTALLATION
1. Install crankshaft sprocket "B" into crankshaft.
Pay special attention to the direction of the flange. If it is installed in the wrong direction, a broken belt
could result from it.
2. Lightly apply engine oil to the outer surface of spacer, and then install the spacer to the right counter balance
shaft. Be sure to install as the direction shown in illustration.
Page 23 of 101
3. Install the counter balance shaft sprocket onto the right counter balance shaft, and then tighten flange bolt by hand
tightly.
4. Align the timing mark on each sprocket with the corresponding timing mark on the front case.
5. When the timing belt "B" is installed, make certain that tension side has no slack. Install tensioner "B" in the center
of pulley located on the left side of mounting bolt.
6. Lift tensioner "B" to tighten the timing belt "B" so that its tension side will be pulled tight. In this condition, tighten a
bolt to secure tensioner "B". when a bolt is tightened, be careful to prevent from turning together. If the shaft is
turned together, the belt will be overtightened.
7. Check to ensure that timing marks are in alignment.

8. Check to ensure that when the center of span on the tension side is depressed with index finger in direction of
arrow, deflection of belt is within specification.
Belt deflection : 5-7 mm (0.2-0.3 in.)

Page 24 of 101
9. Install and crankshaft sprocket onto crankshaft. Be sure to install as the direction shown in illustration.
Pay attention to direction of flange. If it is installed in wrong direction, a broken belt could
result.
10. Install the special washer and sprocket bolt to crankshaft, and then tighten the sprocket bolt.
Tightening torque
Crankshaft sprocket bolt : 110-130 Nm (1100-1300 kg.cm, 80-94 lb.ft)
11. Insert a screwdriver through the plug hole in left side of cylinder block to keep shaft in position.
12. Install the oil pump sprocket, and tighten the nut to the specified torque.
Page 25 of 101
13. Install the camshaft sprocket and tighten the bolt to the specified torque.
Tightening torque
Camshaft sprocket bolt : 80-100 Nm (800-1000 kg.cm, 56-72 lb.ft)
14. Install the auto tensioner.
Leave the set pin installed in the auto tensioner
If the auto tensioner rod is in its fully extended position, reset it as follows.
1. Clamp it in the vise with soft jaws in a level position.

Apply a plain washer if there is a plug at the bottom of the auto tensioner.
2. Push in the rod slowly with the vise until the set hole A in the rod is aligned with the set hole B in the
cylinder.
Page 26 of 101
15. Install the tensioner pulley onto the tensioner arm.
Leave the set pin installed in the auto

tensioner.
16. After installing the crankshaft sensor, set the timing mark of sprocket correctly.
1. Before installing timing belt, if the timing marks of cam shaft sprocket and rocker cover are not
cincide, do not rotatethe cam shaft sprocket more than 2 teeth of sprocket in any direction
Rotating sprocket more than 2 teeth makes valve and poston be touched each other.
2. In case of rotating the cam shaft sprocket in avoidably more than 2 teeth, rotate the cam shaft
sprocket after rotating crank shaft sprocket counter clockwise on basis of timing mark.
17. Align the crnkshaft sprocket timing marks.

18. Align the oil pump sporcket timing marks.
19. Install the timing belt around the tensioner pulley and crankshaft sprocket. Then secure the timing belt onto the
tensioner pulley with your left hand.
20. Pulling the belt with your right hand, install it around the oil pump sprocket.
21. Install the belt around the idler pulley.
22. Install it around the intake camshaft sprocket.
23. Turn the exhaust camshaft sprocket one tooth clockwise to align its timing mark with the cylinder head top
surface [see illustration in step 15]. then, pulling hands, install it sround the exhaust camshaft sprocket.
24. Gently raise the tensioner pulley as shown by the arrow so that the belt can't sag, and temporarily tighten the
center bolt.
Page 27 of 101
25. Check again whether the timing mark of each sprocket is correct or not.
26. Remove the fixed wire that is attached to auto tensioner.

27. Rotate the crankshaft two complete turns clockwise and leave it for about 15 minutes. Then, measure the auto
tensioner protrusion "A"(distance between the tensioner arm and auto tensioner body) to ensure that it is up to
specification.
Standard value : 6-9mm(0.24-0.35 in.)
28. Install the timing belt lower cover and the timing belt upper cover.
Page 28 of 101
INSPECTION
Sprockets, Tensioner Pulley, and Idler Pulley
1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks,
or damage.
Replace as necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth pulley rotation and check for play or noise.
Replace as necessary.
3. Replace if there is grease leak.

Auto Tensioner
1. Check the auto tensioner for leak and replace as necessary.
2. Check the rod end for wear or damage and replace as necessary.
3. Measure the rod protrusion. If it is out of specification, replace the auto tensioner.
Standard value : 14.5mm (0.57 in.)

Page 29 of 101
4. Using a vise soft jaws push the auto tensioner rod. If the rod can be easily retracted, replace the auto tensioner.
Youshould feel a great deal of resistance when pushing the rod in.
Clamp the auto tensioner in the vise so that it can be level. Use soft jaws in the vise to avoid damaging the
auto tensioner.
Timing Belt
1. Check the belt for oil or dust deposits. Replace if necessary.
Small deposits should be wiped away with a dry cloth or paper.
Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the belt in detail. If the following flaws are evident,
replace the belt with a new one.
Description Flaw conditions
1. Hardened back surface rubber Back surface glossy. Non-elastic and so hard that when
a finger nail is forced into it, no mark is produced.
2. Cracked back surface rubber
3. Cracked or separating canvas
4. Badly worn teeth (initial stage) Canvas on load side tooth flank worn (Fluffy canvas
Page 30 of 101
fibers, rubber gone and color changed to white, and
unclear canvas texture)
5. Badly worn teeth (last stage) Canvas on load side tooth flank worn down and rubber
exposed (tooth width reduced)
6. Cracked tooth bottom
7. Missing tooth
8. Side of belt worn NOTE

Normal belt should have preisely cut sides as if
produced by a sharp knife.
9. Side of belt cracked
Engine Mechanical System > Cylinder Head Assembly > Camshaft > Components and Components
Location
COMPONENTS
Page 31 of 101
Engine Mechanical System > Cylinder Head Assembly > Camshaft > Repair procedures
REMOVAL
1. Disconnect the negative terminal from battery.
2. Drain the engine coolant.
3. Remove the breather hose between the air cleaner and the rocker cover.
4. Remove the air cleaner.
Page 32 of 101
5. Remove the timing belt cover.
6. Remove the rocker cover, crank angle sensor.
7. Loosen the camshaft, sprocket bolts and remove the camshaft sprockets.
8. Loosen the bearing cap bolts and remove the bearing caps, camshafts, rocker arms, lash adjusters.
1. Install the camshafts on the cylinder head.
1. Apply engine oil to journals and cams of the cam shafts.

2. The intake camshaft has a slit on its rear end for driving the crankshaft position
sensor.
2. Install the bearing caps. Check the markings on the caps for intake/exhaust identification symbol.
R : Intake camshaft
L : Exhaust camshaft
3. Check that the camshaft can be easily turned by hand. After checking, remove the bearing caps and the
camshafts, and then install the rocker arms.
4. Make sure that the dowel pins on the camshaft sprocket end are located on the top.
Page 33 of 101
5. Tighten the bearing caps to the specified torque in two or three steps as shown.
Tighten the rocker arms uniformly.
Tightening torque
Rocker arm bolts : 19-21 Nm (190-210 kg.cm, 14-15 lb.ft)
6. Using special tools, Camshaft Oil Seal Installer and guide (09221-21000, 09221-21100), press fit the camshaft
oil seal.
Be sure to apply engine oil to the external surface of the oil seal.
Insert the oil seal along the camshaft front end and install by driving the installer with a hammer until the oil seal is
fully seated.
7. Install the camshaft sprockets to the specified torque.
Tightening torque
Camshaft sprocket bolts : 80-100 Nm (800-1000 kg.cm, 58-72 lb.ft)
Page 34 of 101
8. Install the rocker cover. Apply sealant as shown.
Tightening torque
Rocker cover bolts : 8-10 Nm (80-100 kg.cm, 6-7 lb.ft)
Center cover bolts : 4-5 Nm (40-50 kg.cm, 3-3.6 lb.ft)
Sealant
A Portion : Threebond No. 1212D or equivalent
B Portion : Threebond No. 1212D or equivalent
Bolt length x Diameter
Center cover bolt : 16 mm × 6 m
Rocker cover bolt : special bolt
9. Install the spark plugs, ignition coil, connect the connector and then install the center cover.
10. Locate the dowel pin on the sprocket side of the exhaust cam shaft.
11. Align the notch of the camshaft sensor to the hole in camshaft (intake manifold side) and tighten the bolts.
The camshaft position sensor can be installed even when the punch mark is positioned opposite the notch;
however, the position results in incorrect fuel injection and ignition timings.
Page 35 of 101
12. Install the camshaft position sensor on the cylinder head.
INSPECTION
Rocker Arms
1. Check rotation of the roller. If it does not rotate smoothly or if looseness is evident, replace it.
2. Check the roller and replace if there are any dent, damage or signs of bearing seizure.
3. Check the valve contact surface for possible damage or seizure and replace as necessary.
Camshafts
1. Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is damaged or worn excessively, replace the camshaft.
Cam height
[Standard]
Intake : 35.493 mm (1.3974 in.)
Exhaust : 35.317 mm (1.3904 in.)
[Limit]
Intake : 34.993 mm (1.3777 in.)
Exhaust : 34.817 mm (1.3707 in.)
Engine Mechanical System > Cylinder Head Assembly > Cylinder Head > Components and
Components Location
COMPONENTS
Page 36 of 101
Engine Mechanical System > Cylinder Head Assembly > Cylinder Head > Repair procedures
INSPECTION
1. Check the cylinder head for cracks damage and coolant leakage. If cracked, replace the cylinder head.
2. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed
air to them to make certain that the passages are not clogged.
Page 37 of 101
3. Check the cylinder head gasket surface for flatness by using a straight edge in the direction of A, B, ... as shown.
If flatness exceeds service limit in any direction, either replace the cylinder head, or lightly machine the cylinder
head gasket surface.
Flatness of cylinder head gasket surface

[Standard dimension] : Less than 0.05 mm (0.002 in.)
[Limit] : 0.2 mm (0.008 in.)
REMOVAL
1. Remove the cylinder head bolts as shaown in the illustration.
2. Using 12mm socket, remove the retainer lock. Next remove the spring retainer, valve spring seat and valve.
Keep these parts so that they can be reinstalled in their orgnal positions.
Page 38 of 101
3. Remove the valve stem seals with pliers, and discard.
Do not reuse the valve stem seals.
Engine Mechanical System > Cylinder Head Assembly > Valve > Repair procedures
INSPECTION
1. Using a wire brush, clean the valve thoroughly
2. Check each valve for wear, damage and distortion of head and stem at B. Repair or correct if necessary.
If stem end A is pitted or worn, resurface as necessary. This correction must be limited to a minimum. Also
resurface the valve face.
Replace the valve if the margin has decreased to less than the service limit.
Margin
[Standard dimension]
Intake : 1.0mm(0.040 in.)
Exhaust : 1.5 mm(0.059 in.)
[Limit]
Intake : 0.7 mm(0.028 in.)
Exhaust : 1.0 mm(0.040 in.)
Valve Spring
1. Check free length and tension of the valve spring. If they exceed the service limit, replace the spring.
Page 39 of 101
2. Using a square, test the squareness of each spring. If the spring is excessively out of square, replace it.
Valve spring
[Standard Value]
Free height : 45.82 mm (1.804 in.)
Load : 248 N (55 lb)at installed height
Out of square : 1.5° or less
[Limit]
Free height : -1.0 mm (-0.039 in.)
Out of square : 4°
Valve Guides
1. Check the valve stem-to-guide clearance. If the clearance exceeds the service limit, replace the valve guide with
the next oversize part..
Valve stem-to-guide clearance

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

Page 40 of 101
1. Check the valve seat for overheating and improper contact with the valve face. Recondition or replace the seat if
necessary.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, and
thenrecondition the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact
width should be within specifications and centered on the valve face.
Procedures for Replacing Valve Seat Insert

1. Any valve seat insert that has been worn over the service limit should be removed at normal temperature after
cutting away most of the insert wall using valve seat cutters as shown in Fig. "A".
2. After removing the seat insert, machine the seat insert bore using a reamer or a cutter. Cut to the size shown in
the table.
3. Heat the cylinder head to about 250°C (480°F) and press in the oversize seat insert. The oversize seat insert
should be at normal room temperature for installation. After installing a new valve seat insert, resurface the valve
seat using the same procedure as in paragraph 1. in Valve Seat Insert.
Valve Seat Insert Oversizes
Seat insert height
Size Cylinder head I.D.
Description Size mm(in.) H
mark mm( in.)
mm( in.)
8.4-8.6 (0.330-
35.300-35.325 (1.3898-
Inatake valve seat 0.3 (0.012) O.S. 30 0.338)
1.3907)
insert 0.6 (0.024) O.S. 60 8.7-8.9 (0.342-
35.600-35.625(1.4016-1.4026)
0.350)
8.0-8.2 (0.314-
Exhaust valve seat 0.3 (0.012) O.S. 30 0.322) 33.300-33.325(1.3110-1.3120)
insert 0.6 (0.024) O.S. 60 8.3-8.5(0.326- 33.600-33.625(1.3228-1.3238)
0.334)
Page 41 of 101
Procedures for Replacing Valve Guide

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

2. Apply engine oil to sloding and rotating parts.
Page 42 of 101
1. Afrter installing the spring seat, fit the stem seal onto the valve guide.
Fit seal in by lightly tapping the Specical Tool, Valve Stem Oil Seal Installer.
The seal is installed in the specified position by means of the special tool. Incorrect installation of the seal will
adversely affect the lip I.D. and eccentricity, resulting in oil leakage down the valve guldes. Whem install,
thesefore, be careful not to twist the seal. Do not reuse old seals.
2. Apply engine oil to each valve. Insert the valves into the valve guides. Avoid inserting the valve into the seal by
fore.
After inserting, check that the valve moves smoothly.
3. Install spring and spring retainers.
Valve spring should be installed with enamel coated side toward the valve spring retainer.
4. Using the special tool, Valve Spring Compressor (09221-29100) remove the retainer lock. Next remove the
spring retainer, valve spring, spring seat and valve.
Keep these parts so that they can be reinstalled in their original positions.
5. Clean all gaket surfaces of the cylinder block and cylinder head.
6. Install a new cylinder head gasket onto the cylinder head assembly. Do not apply sealant to the gasket and do not
reuse the oil cylinder head gasket.
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7. Install the cylinder head bolts as shown in the illustration.
Check and measure the length of bolt.
Maximum length : 99.4 ± 0.35 mm(3.9 in.)
8. Tighten the bolts according to the following procedure.

Procedures for Installing Cylinder Head(With Replace Head Bolts)
STEP OPERATION REMARKS
Tighten to 20Nm
1 Carry out as ahown in the illustration
(200kg·cm, 14lb·ft)
As shown in the illustration. Mark the head of the
2 Tighten 90° of a turn
cylinder head bolt and cylinder head by paint.
3 Fulley loosen Carry out as the reverse order of the illustration.
Tighten to 20Nm
4 Carry out as shown in the illustration.
(200kg·cm, 14lb·ft)
5 Tighten 90° of a turn
As shown in the illustration. Check that the painted
6 Tighten 90° of a turn mark of the head bolt is linded up with that of the
cylinder head.
Page 44 of 101
Procedures for installing cylinder head(Without replaceing head bolts)

STEP OPERATION REMARK
Tighten to 2Nm
1 Carry out as shown in the illustration.
(20kg·m, 0.14lb·ft)
2 Tighten 90° of turn
As shown in the illustration. check that the painted
3 Tighten 90° of turn mark of the head bolt is lined up with that of the
cylinder head.
Engine Mechanical System > Engine And Transaxle Assembly > Engine And Transaxle Assembly >
Repair procedures
REMOVAL
1. Remove the battery.
2. Detach the air cleaner.
3. Disconnect the connectors for the backup lamp and engine harness.
4. For a vehicle with a 5-speed manual transaxle, disconnect the select control valve connector.
Page 45 of 101
5. Disconnect the connectors for the generator harness and the oil pressure gauge wiring.
6. Drain the engine coolant.

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

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

14. For vehicles with a manual transaxle, remove the clutch cable from the transaxle.
15. For vehicles with an automatic transaxle, remove the control cable from the transaxle.
16. For vehicles with manual transaxle, remove the shift control rod and extension rod.
Page 46 of 101
17. Disconnect the connector of the vehicle speed sensor from the transaxle.
18. Separate the column shaft from the steering gear box.
19. Remove the engine mounting insulator.
20. Remove the transaxle mounting insulator.

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

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

5. Refill the transaxle fluid, test its operation, and check for leak.
6. Check for the operation of the transaxle control cable and accelerator cable. Adjust as necessary.
7. Check for proper operation of each of the various gauges.
Engine Mechanical System > Cylinder Block > Balance Shaft > Components and Components Location
COMPONENTS
Page 50 of 101
Engine Mechanical System > Cylinder Block > Balance Shaft > Repair procedures
REPLACEMENT
1. Using a special tool, remove the right counter balance shaft front bearing from the cylinder block.
2. Using a special tool, remove the right counter balance shaft rear bearing from the cylinder block.
Page 51 of 101
3. Using a special tool, remove the left counter balance shaft rear bearing from cylinder block. At this time, install
special tool on the front surface of cylinder block to hold the bearing puller.
4. Using a special tool, install the left counter balance shaft rear bearing to the cylinder block.
1. Apply engine oil to the rear bearing outer circumference and bearing hole in cylinder
block.
2. The left rear bearing has no oil holes.
5. Using a special tool, install the right counter balance shaft rear bearing to the cylinder block.
1. Apply engine oil to the outer surface of bearing.

2. Make sure that the bearing oil hole is aligned with the oil hole of cylinder block.
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6. Using a special tool, install the right counter balance shaft front bearing to the cylinder block.
Make sure that the bearing oil hole is aligned with the oil hole of cylinder block.
INSPECTION
Check journals for wear or seizure. If excessive wear or seizure is evident, check the bearing carefully. If necessary,
replace the counter balance shaft bearing or both.
Engine Mechanical System > Cylinder Block > Piston and Connecting Rod > Components and
Components Location
COMPONENTS
Page 53 of 101
COMPONENTS
Page 54 of 101
Engine Mechanical System > Cylinder Block > Piston and Connecting Rod > Repair procedures
REMOVAL
Keep the bearing in order with their corresponding connecting rods (according to cylinder numbers) for proper
ressembly.
1. Remove the connecting rod cap nuts and them remove the caps and the big end lower bearing.
2. Push each piston-connecting rod assembly toward the top of the cylinder.
REMOVAL
Pinsto Pin
1. Use the special tools (09234-33001), to disassemble and reassemble the piston and connecting rod.
Page 55 of 101
2. Place the proper insert in the fork of the tool. Position the insert between the connecting rod and the piston.
3. Insert the proper tool for removal through the hole in the arch of the tool.
Center the piston, rod and pin assembly with the removal arbor.
4. Press the piston pin out of the connecting rod.
5. Install proper pin guide (refer to application chart) through piston and into connecting rod. Hand tap pin guide
into piston for proper retention. Drop piston pin into the other side of the piston.
The pin guide centers the conneting rod in the pistion.

When the piston, connecting rod, piston pin and pin guide assembly are positioned on the fork of the tool,
the pin guidewill also center this assembly in the tool. If a pin guide that is too small is used, the piston
assembly will not be located centrally in the tool, and damage may occur to the fork and/or the insert of the
tool.
6. Install the piston assembly onto the fork assembly of tool. The tool will support connecting rod at the piston pin.
7. Adjust the installing arbor to the proper length by turning the numbered sleeve on the lettered shaft until the
specified alpha numeric setting from the application chart is obtained.
Turn knurled nut to lock numbered sleeve on shaft.
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8. Insert the installing arbor through the hole in the arch of the tool.
Press the piston pin into the connecting rod until the sleeve on the installing srbor contacts the top of the tool
arch.The pin guide will fall out of the connecting rod as the piston pin is pressed in.
Do not exceed 5000 pounds of force when stopping the installing ardor sleeve against the arch.
INSTALLATION
1. Install the spacer.
2. Install the upper side. To install the side rail, frist put one end of the side rail between piston ring groove and
spacer, hole it down firmly, and then press down the portion shich is to be inserted into groove with a finger as
illustrated.
Do not use piston ring expander when installing the side rail.
3. Install the lower side rail by same procedure as Step 2.
Page 57 of 101
4. Using the piston ring expander, install No.2 piston ring.
5. Install No.1 piston ring.

6. Apply engine oil around a piston and piston rings.
7. Position each ring end gap as far apart from neighboring gaps as possible. Make sure that gaps are not positional
in thrust and pin directions.
8. Hold piston rings firmly in a piston ring compressor as they are inserted into cylinder.
9. Make sure that the front mark of piston and front mark (identification mark) of connecting rod are direced
toward front of engine.
10. When connecting rod cap is installed, make sure that cylinder numders put on rod and cap at disassembly
match.
11. When new connecting rod is installed, make sure that notches for holding bearing in place are on same side.
12. Tighten the connecting rod cap nuts.
Tightening torque
Connecting rod cap nuts : 18-22Nm(180-220kg.cm, 13-16lb.ft) (90°~94°)
13. Check connecting rod side clearance.
Side clearance : 0.10-0.25mm(0.004-0.0098 in.)

Limit : 0.4mm(0.0157 in.)
Page 58 of 101
INSPECTION
1. When the connecting rod cap is installed, make sure that cylinder number put on the end cap disassembly match.
When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the
same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end, and also if it has step wear in, or a
severly rough surface on, the inside diameter of the small end.
INSPECTION
Piston and Piston Pins
1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective.
2. Check each piston ring for breakage, damage and abnormal wear. Replace the defective rings. When the piston
requires replacement, its rings should also be replaced.
3. Check the piston pin fits in the piston pin hole. Replace any piston and pin assembly that is defective.
The piston pin must be smoothly pressed by hand into the pin hole at room temperature.
Piston Rings
1. Measure the piston ring side clearance. If the measured value exceeds the service limit, insert a new ring in a ring
groove to measure the side clearance. If the clearance still exceeds the service limit, replace the piston and rings
together.
[Standard value]
Piston ring side clearance : No.1 : 0.03-0.07mm (0.0012-0.0028 in.) No.2 : 0.02-0.06 mm
(0.0008-0.0024 in.)
[Limit] : 0.1 mm (0.004 in.)
Page 59 of 101
2. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to
the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds
the service limit, replace the piston ring
Piston ring end gap

No.1 : 0.25-0.35 mm (0.0098-0.0138 in.)
No.2 : 0.40-0.55 mm (0.0157-0.0216 in.)
Oil ring side rail : 0.10-0.40 mm (0.0039-0.0157 in.)
No.1, No.2 : 0.8mm(0.031in.)
Oil ring side rail : 1.0 mm (0.039 in.)
Engine Mechanical System > Cylinder Block > Crankshaft > Components and Components Location
COMPONENTS
Page 60 of 101
Engine Mechanical System > Cylinder Block > Crankshaft > Repair procedures
INSPECTION
1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check oil holes for clogging.
Correct or replace any defective part.
Page 61 of 101
2. Inspect out-of-roundness and taper of crankshaft journal and pin.
Standard value
Crankshaft journal O.D : 56.982-57.000mm(2.2434-2.2442.in.)
Crankshaft pin O.D : 44.980-45.000 mm (1.7709-1.7717in.)
Main Bearings and Connecting Rod Bearings

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

Plastigauge may be used to measure the clearance.
1. Remove oil and grease and any other dirt from bearings and journals.
2. Cut plastigauge to the same length as the width of the bearing and place it in parallel with the journal, off oil holes.
Page 62 of 101
3. Install the crankshaft, bearings and caps and tighten them to the specified torques. During this operation, do not
turn the crank shaft. Remove the caps. Measure the width of the plastigauge at the widest part by using a scale
printed on the gauge package.
If the clearance exceeds the service limit, the bearing should be replaced.
When installing a new crankshaft, be sure to use standard size of bearings.
If the clearance exceeds the service limit, the bearing should be replaced.
When installing a new crankshaft, be sure to use standard size of bearing.
Oil Seal
Check front and rear oil seals for damage or worn lips. Replace any seat that is defective.
Bearing Caps
1. After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct. If the
end play exceeds the limit, replace crankshaft bearings.

Limit : 0.25 mm (0.0098 in.)
Drive Plate
Replace deformed, damaged, or cracked drive plates.
INSPECTION
1. Check the clutch disc contacting surface of the flywheel for damage and wear. Replace the flywheel if excessively
damaged or worn
2. Check the clutch disc contacting surface of the flywheel for runout.
Limit
Flywheel run-out : 0.13 mm (0.0051 in.)
3. Check the ring gear for damage, cracks and wear, and replace if necessary.
REMOVAL
1. Remove the timing belt train, front case, flywheel cylinder head assembly and oil pan. For details, refer to
respective chapters.
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.
Mark the main bearing caps to be reassembled in the original position and
direction.
4. Remove the main bearing caps and remove the crankshaft.
Keep the bearings in order according to the cap number
INSTALLATION
1. Install grooved main bearing (upper bearing) and thrust bearing on cylinder block side.
Page 63 of 101
2. Install grooveless main bearing (lower bearing) on main bearing cap side.
3. Install crankshaft. Apply engine oil to journal and pin.

4. Caps should be installed with arrow mark directed toward front of engine. Cap number must be correct.
5. Tighten cap bolts to specified torque in sequence of center No.2, No.4, front and rear caps.
Tightening torque
Main bearing cap bolts : 25 Nm(250, 18 lb.ft) + (90°~94°)
6. Cap bolts should be tightened evenly in from 4 to 5 stages before they are tightened to specified torque.
7. Make certain that crankshaft turns freely and has proper end play.
8. Using a special tool install oil seal in oil seal case.
9. Install the oil seal into the oil seal case so that the oil hole in the separator is directed downward (arrow in
illustration).
10. Install the new oil seal case gasket and oil seal case assembly.
11. Install the rear plate to the cylinder block.
12. Install the flywheel assembly and tighten the bolts to the specified torque.
Tightening torque
Flywheel bolt : 130-140 Nm (1,300-1,400 kg.cm, 94-101 lb.ft)
Engine Mechanical System > Cylinder Block > Cylinder Block > Components and Components
Location
CYLINDER BLOCK(COMPONENTS)
Page 64 of 101
Engine Mechanical System > Cylinder Block > Cylinder Block > Repair procedures
INSPECTION
1. Visually check the cylinder block for scores, rust and corrosion.
Also check for cracks or any other defects. Correct or replace the block if defective.
2. Measure cylinder bore with a cylinder gauge at three levels in directions of A and B.
Level 1 : No.1 piston ring position with piston at TDC.
Level 2 : Center of cylinder
Level 3 : Bottom of cylinder
3. If cylinder bores show more the specified out-of-round or taper, or if the cylinder walls are badly scuffed or
scored, the cylinder block should be re-bored and honed and fitted with oversize pistons and rings.
Standard value
Cylinder bore : 85.00-85.03 mm (3.3465-3.3476 in.)
Out-of-roundness and taper of cylinder bore : Max. 0.01 mm (0.0004 in.)
Page 65 of 101
4. If cylinder top ridge is worn in stages, cut away with ridge reamer.
5. Oversize pistons are available in four sizes.
Piston service size and mark mm (in.)

0.25 (0.010) O.S : 0.25
6. To rebore the cylinder to oversize, keep the specified clearance between the oversize piston and the bore, and
make surethat all pistons used are of the same oversize. The standard measurement of the piston outside diameter
is taken at a level 2 mm (0.08 in.) above the bottom of the piston skirt and across the thrust faces.
Piston-to-cylinder wall clearance : 0.02-0.04 mm (0.0008-0.0012 in.)
7. Check for damage and cracks.

8. Check top surface for flatness. If excessive flatness is evident, grind to minimum limit or replace.
Standard value
Flatness of gasket surface : Max. 0.05 mm (0.0020 in.)
Cylinder block (New) height : 284 mm (11.18 in.)
Service limit
Flatness of gasket surface : 0.1 mm (0.0039 in.)
Overall height : -0.2 mm (-0.0079 in.)
The cylinder block gasket surface should be ground within -0.2 mm (-0.0079 in.) including the ground
surface of cylinder head gasket surface.
Boring Cylinder
1. Oversize pistons to be used should be determined on the base of the largest bore cylinder.
Size Identification mark
0.25mm(0.010 in.) O.S 0.25
0.50mm(0.020 in.) O.S 0.50
0.70mm(0.030 in.) O.S 0.75
1.00mm(0.039 in.) O.S 1.00
Size mark is stamped on top of piston.

2. Measure outside diameter of piston to be used.
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3. On the base of measured piston O.D., calculate boring finish dimension.
Boring finish dimension = Piston O.D + 0.02-0.04 mm (0.0008-0.0016 in.) (clearance between O.D and
cylinder)-0.02 mm (0.008 in.) (honing margin.)
4. Bore each of the cylinders to the calculated size.
To prevent distortion that may result from temperature rise during honing, bore cylinders, working from
No.2 to No.4 to No.1 to No.3.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check clearance between piston and cylinder.
When boring cylinders, finish all of four cylinders to the same oversize. Do not bore only one cylinder to an
oversize.
REASSEMBLY
Install the following parts by referring to the respective para-graphs
1. Crankshaft
2. Flywheel
3. Piston
4. Cylinder head
5. Timing belt train
6. Front case
REMOVAL
Remove the cylinder head, timing head, timing belt train, front case, flywheel, piston and crankshaft.
For further details, rrefer to the respective chapters.
Engine Mechanical System > Cylinder Block > Engine Mounts > Components and Components
Location
COMPONENTS
Page 67 of 101
Engine Mechanical System > Cylinder Block > Engine Mounts > Repair procedures
REMOVAL
Page 68 of 101
1. Attach an engine hoist to the engine hooks, and raise just enough so that there is no pressure on the insulators.
2. Engine Mounting
(1) Remove the engine mount insulator bolts.
(2) Remove the engine mount bracket from the engine.
3. Transaxle Mounting
(1) Remove the transaxle mount insulator bolts.
(2) Remove the transaxle mounting bracket from the transaxle.
4. Front Roll Stopper

Remove the front roll stopper bracket from the sub-frame.
Page 69 of 101
5. Rear Roll Stopper
(1) Remove the bolt from the rear roll stopper.
(2) Remove the rear roll stopper from the subframe.
INSPECTION ITEMS
Engine Mechanical System > Cooling System > Water pump > Components and Components Location
COMPONENT
Page 70 of 101
Engine Mechanical System > Cooling System > Water pump > Repair procedures
REMOVAL
1. Drain the coolant and disconnect the radiator outlet hose and Engine coolant by-pass hose from the engine
coolant pump.
2. Remove the drive belt and engine coolant pump pulley.
3. Remove the timing belt covers and the timing belt tensioner.
4. Remove the engine coolant pump mounting bolts and then remove the alternator brace.
Page 71 of 101
5. Remove the engine coolant pump assembly from the cylinder block.block.
INSTALLATION
1. Clean the gasket surfaces of the engine coolant pump body and the cylinder block.
2. Install the new O-ring onto the groove on the front end of the engine coolant pipe, then wet the O-ring with
engine coolant.
Do not apply oil or grease.
3. Install new Engine coolant pump gasket and Engine coolant pump assembly. Tighten the bolts to specified torque.
Tightening torque
Engine coolant pump bolt : 20-27 Nm (200-270 kg.cm, 14-20 lb.ft)
4. Install the timing belt tensioner and timing belt. Adjust the timing belt tension, and then install the timing belt
covers.
5. Install the engine coolant pump pulley and drive belt, and then adjust the belt tension.
6. Refill the coolant.
7. Run the engine and check for leak.
INSPECTION
1. Check the engine coolant pump for cracks, damage or wear, and replace the engine coolant pump assembly if
necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the engine coolant pump
assembly if necessary.
3. Check the seal unit for leaks, and replace the engine coolant pump assembly if necessary.
4. Check for engine coolant leakage. If the engine coolant leaks from hole "A"seal unit is defective. Replace engine
coolant pump assembly.
Engine Mechanical System > Cooling System > Thermostat > Components and Components Location
COMPONENTS
Page 72 of 101
Engine Mechanical System > Cooling System > Thermostat > Repair procedures
REMOVAL
1. Drain the coolant to the thermostat level or below.
2. Remove the Engine coolant outlet fitting and gasket
3. Remove the thermostat.
INSTALLATION
1. Check to ensure that the flange of the thermostat is correctly seated in the socket of the thermostat housing. If the
thermostat is installed in the wrong direction, the bottom of the thermostat will touch the rib inside the intake
manifold, making it impossible to seat flange in position.
2. Install a new gasket and Engine coolant outlet fitting.
Tightening torque
Engine coolant outlet fitting bolt : 10-15 Nm (100-150 kg.cm, 7-11 lb.ft)
3. Refill the coolant.
INSPECTION
1. Heat the thermostat as shown in the illustration.
2. Check that the valve operates properly.
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3. Check to determine the temperature at which the valve begins to open.
Valve opening temperature : 80.5-83.5°C (176.9-182.3°F)

Full opening temperature : 95°C (203°F)
Engine Mechanical System > Cooling System > Radiator > Components and Components Location
COMPONENTOR
Page 74 of 101
Engine Mechanical System > Cooling System > Radiator > Repair procedures
REMOVAL
Never open or disassemble any portion of the cooling system until the engine temperature has dropped to ambient
air temperature. Engine coolant escaping under heat and resulting pressure can cause severe burns and blindness.
1. Disconnect the ground cable from the battery terminal.
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2. Disconnect the fan motor connector.
3. Loosen the radiator drain plug to drain the coolant.
4. Disconnect the upper and lower hoses and overflow tube after making marks on the radiator hose and the hose
clamp
5. For vehicles with automatic transaxle, disconnect the oil cooler hoses from the automatic transaxle.
Cover or plug the hose and nipple part of the radiator so that dust, foreign materials, etc. do not enter after
the hose has been disconnected from the radiator.
6. Remove the radiator mounting bolt.
7. Remove the radiator together with the fan motor.

8. Remove the radiator fan motor, condenser fan motor from the radiator.
INSTALLATION
1. Fill the radiator and reservoir tank with clean coolant mixture.
2. Run the engine until the coolant has warmed up enough so that the thermostat valve opens, and then stop the
engine.
3. Remove the radiator cap and pour the coolant to the filler neck of the radiator. Fill the reservoir tank with the
coolant to the upper level.
4. Check that there is no leakage from the radiator, hoses or connections.
INSPECTION
1. Check for foreign material between radiator fins.
2. Check the radiator fins for damage and straighten if necessary.
3. Check the radiator for corrosion, damage, rust or scale.
4. Check the radiator hoses for cracks, damage or deterioration.
5. Check the reserve tank for damage.
6. Check the automatic transaxle oil cooler hoses for cracking, damage or deterioration.
Engine Mechanical System > Cooling System > Cooling Fan Motor Assembly > Components and
Components Location
COMPONENTS
Page 76 of 101
Engine Mechanical System > Cooling System > Cooling Fan Motor Assembly > Repair procedures
REMOVAL
1. Disconnect the ground cable from battery cable.
2. Disconnect the connectors from the fan motor and the harness from shroud.
3. For vehicles with automatic transaxle, remove the oil cooler hose from the shroud.
4. Remove the shroud mounting four bolts.
5. Remove the shroud with the fan motor.

6. Remove the fan mounting clip and detach the fan from fan motor.
7. Remove the three screws and detach the fan motor.
INSTALLATION
Page 77 of 101
1. Installation is the reverse order of removal procedures.
1. Make sure the cooling fan does not come into contact with the shroud when
installed.
2. After installation, make sure there is no unusual noise or vibration when fan is
rotated.
INSPECTION
Radiator Fan Motor and Condenser
1. Check that the radiator fan rotates when battery voltage is applied between the terminals (as shown table below).
2. Check that abnormal noises are not produced while the motor is turning
Terminal
Item MOTOR
1 2 3 4
SPEED
RADIATOR ― LOW
FAN ― MIDDLE
MOTOR ― ― HIGH
CONDENSER ― LOW
FAN ― MIDDLE
MOTOR ― ― HIGH
Cooling Fan Control System

ECM controls the cooling fan in 3 steps (LO/ MIDDLE/ HI) according to the vehicle speed, the air-conditioning
load and engine coolant temperature.
Page 78 of 101
ECM Control logic

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

1. Remove the radiator fan motor relay (High and Low) from the relay box in engine room.
2. Check the continuity of the terminals "86" and "85" with an ohmmeter.
Page 79 of 101
3. Apply DC12 V to the terminals "86" and ground the terminal "85".
4. Check the continuity between the terminals "87" and "30".
Engine Mechanical System > Cooling System > Engine Coolant Hose / Pipes > Components and
Components Location
COMPONENTS
Engine Mechanical System > Cooling System > Engine Coolant Hose / Pipes > Repair procedures
INSTALLATION
Fit O-ring in the groove provided at engine coolant inlet pipe end, wet the periphery of O-ing and insert engine
coolant inlet pipe.
1. Do not apply oils or greases to Engine coolant pipe O-ring.

2. Keep the Engine coolant pipe connections free of sand, dust, etc.
3. Insert Engine coolant pipe to its end bottoms.
4. While installing the engine coolant inlet pipe, always replace the O-ring with a new one.
INSPECTION
Check the engine coolant pipe and hose for cracks, damage, and restrictions. Replace if necessary.
Page 80 of 101
Engine Mechanical System > Lubrication System > Oil Pump > Components and Components Location
COMPONENTS
Engine Mechanical System > Lubrication System > Oil Pump > Repair procedures
REMOVAL
1. Remove the timing belt. Refer to "Timing Belt".
2. Remove all the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil screen and gasket.
5. Remove the relief plunger and gasket, and then take off the relief spring and relief valve from the oil filter bracket.
6. Remove the oil pressure switch.
7. Remove the oil filter bracket and gasket.

Page 81 of 101
8. Using the special tool, remove the plug cap from the oil pump portion of front case.
9. Remove the left side of cylinder block plug and insert a screw driver with an 8 mm (0.32 in.) diameter shaft into
plug hole. The screwdriver shaft must be inserted more than 60 mm (2.4 in.)
10. Remove the oil pump driven gear and left the counter balance shaft retaining bolt.
11. Remove the front case mounting bolts and remove the front case assembly and gasket. Remove the two counter
balance shafts from the cylinder block.
12. Remove the oil pump cover from the front case.
Page 82 of 101
13. Remove the oil pump gears from the front case.
INSTALLATION
1. Apply engine oil to the gear and align the two timing marks.
2. Using the special tool, Crankshaft Front Oil Seal Installer (09214-32000), install the crankshaft front oil seal into
the front case.
3. Set the special tool (09214-32100) on the front end of crankshaft and apply a thin coat of engine oil to the outer
circumference of the special tool to install the front case.
Page 83 of 101
4. Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than
those for tightening the filter bracket).
5. Install the front case assembly with a new gasket, and tighten the bolts to the specified torque.
Front case assembly
Tightening torque
All except : 20-27 Nm (200-270 kg.cm, 14-20 lb.ft)
6. Insert a screwdriver through plug hole in left side of cylinder block. After checking that the shaft is in position,
tighten.
7. Install a new O-ring to the groove of front case.

8. Using a special tool, install the plug case and tighten to the specified torque.
Page 84 of 101
9. Apply sealant into the groove of the pan flange as shown.
• Apply sealant approx. 4 mm (0.16 in.) in thickness.

• After application of sealant, do not exceed 15 minutes before installing the oil
pan.
10. Note the difference in bolt lengths at the location shown. Install the oil pan and tighten the bolts to the specified
torque.
Tightening torque
Oil pan bolt : 10-12 Nm (100-120 kg.cm, 7-9 lb.ft)
11. Using the special tool, install the oil pressure switch after applying sealant to the threaded area.
Sealant : Threebond 1104 or equivalent
Do not torque the oil pressure switch excessively.
Tightening torque
Oil pressure switch : 8-12 Nm (80-120 kg.cm, 6-8 lb.ft)
Page 85 of 101
INSPECTION
1. Assemble the oil pump gear to the front case and rotate it to ensure smooth rotation with no looseness.
2. Ensure that there is no ridge wear on the contact surface between the front case and gear surface of the oil pump
cover.
3. With the drive and driven gears installed into the front case, measure the tip clearance of the gears.
[Standard value]
Drive gear : 0.160-0.205 mm (0.0063-0.0081 in.)
Driven gear : 0.180-0.205 mm (0.0071-0.0081 in.)
[Limit]
Drive gear : 0.25 mm (0.0098 in.)
Driven gear : 0.25 mm (0.0098 in.)
4. Check the side clearance.

[Standard value]
Drive gear : 0.08-0.14 mm (0.0031-0.0055 in.)
Driven gear : 0.06-0.12 mm (0.0024-0.0047 in.)
[Limit]
Drive gear : 0.25 mm (0.0098 in.)
Driven gear : 0.25 mm (0.0098 in.)
Engine Mechanical System > Lubrication System > Front Case > Components and Components
Location
COPONENTS
Page 86 of 101
Engine Mechanical System > Lubrication System > Front Case > Repair procedures
REMOVAL
1. Remove the timing belt. Refer to "Timing Belt".
2. Remove all the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil screen and gasket
5. Remove the relief plunger and gasket, and then take off the relief spring and relief valve from the oil filter bracket.
6. Remove the oil pressure switch.
7. Remove the oil filter bracket and gasket.

Page 87 of 101
8. Using the special tool, remove the plug cap from the oil pump portion of front case.
9. Remove the left side of cylinder block plug and insert a screw driver with an 8 mm (0.32 in.) diameter shaft into
plug hole.
The screwdriver shaft must be inserted more than 60 mm (2.4 in.)
10. Remove the oil pump driven gear and left the counter balance shaft retaining bolt.
11. Remove the front case mounting bolts and remove the front case assembly and gasket.
Remove the two counter balance shafts from the cylinder block.
12. Remove the oil pump cover from the front case.
13. Remove the oil pump gears from the front case.
INSTALLATION
Page 88 of 101
1. Apply engine oil to the gear and align the two timing marks.
2. Using the special tool, Crankshaft Front Oil Seal Installer (09214-32000), install the crankshaft front oil seal into
the front case.
3. Set the special tool (09214-32100) on the front end of crankshaft and apply a thin coat of engine oil to the outer
circumference of the special tool to install the front case.
4. Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than
those for tightening the filter bracket).
5. Install the front case assembly with a new gasket, and tighten the bolts to the specified torque.
Front case assembly

Tightening torque
All except : 20-27 Nm (200-270 kg.cm, 14-20 lb.ft)
Page 89 of 101
6. Insert a screwdriver through plug hole in left side of cylinder block. After checking that the shaft is in position,
tighten.
7. Install a new O-ring to the groove of front case.

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

2. After application of sealant, do not exceed 15 minutes before installing the oil
pan.
10. Note the difference in bolt lengths at the location shown. Install the oil pan and tighten the bolts to the specified
torque.
Tightening torque
Oil pan bolt : 10-12 Nm (100-120 kg.cm, 7-9 lb.ft)
Page 90 of 101
11. Using the special tool, install the oil pressure switch after applying sealant to the threaded area.
Sealant : Threebond 1104 or equivalent
Do not torque the oil pressure switch excessively.
Tightening torque
Oil pressure switch : 8-12 Nm (80-120 kg.cm, 6-8 lb.ft)
INSpection
1. Check oil holes for clogging and clean if necessary.
2. Check the counter balance shaft front bearing section for wear, damage and seizure. If there is anything wrong
with the section, replace the front case.
3. Check the front case for crack and other damage.
Replace the cracked or damaged front case.
Counter Balance Shaft
1. Check journals for wear orseizure.
If excessive wear or seizure is evident, check the bearing carefully.
If necessary, replace the counter balance shaft bearing or both.
Oil Seal
1. Check the oil seal lip for wear and damage. Replace the oil seal if necessary.
2. Check the oil seal lip for deterioration. Replace the oil seal if necessary.
Oil Pressure Switch
1. If the "OIL PRESSURE" indicating lamp lights up when the ignition switch is "ON" and goes out when engine is
started andruns at idle, everything is in order. If "OIL PRESSURE" lamp does not light when ignition switch is
"ON" check switch, lamp and wiring.
Page 91 of 101
2. If there is current flow when ignition switch is "ON" and if there is no current flow when engine is running at idle,
the switch is good. If the switch is good, check the lamp and wiring.
Oil pressure switch operation pressure : 14.71-29.42 kPa (0.15-0.3 kg/cm² ,2.1-4.3 psi)
3. Using 24mm deep socket, tighten the switch to the specified torque.
Tightening torque
Oil pressure switch and sensor assembly : 8-12 N·m (80-120 kg-cm, 5.8-8.7 lb·ft)
Oil Pressure Sensor Assembly

1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed.
If there is continuity even when the fine wire is pushed, replace it.
3. Or, if there is no continuity when a 50 kPa (7 psi) vacuum is applied through the oil hole, the switch is operating
properly.
Check that air doesn't leak. If air leaks, the diaphragm is broken. Replace the switch.
Oil pump
1. Assemble the oil pump gear to the front case and rotate it to ensure smooth rotation it to ensure smooth rotation
with no looseness.
Page 92 of 101
2. Ensure that there is no rifge wear on the conact surface between the front case and gear of the oil pump cover.
3. With the drive and driven gears installed into the front case, measure the tip clearance of the gears.
[Stanard value]
Drive gear : 0.160-0.205mm(0.0063-0.0081 in.)
Driven gear : 0.180-0.205mm(0.0071-0.0081 in.)
[Limit]
Drive gear : 0.25mm(0.0098 in.)
Driven gear : 0.25mm(0.0098 in.)
4. Check the side clearance.
[Standard value]
Drive gear : 0.08-0.14mm(0.0031-0.0055 in.)
Driven gear : 0.06-0.012 mm(0.0024-0.0047 in.)
[Limit]
Drive gear : 0.25mm(0.0098 in.)
Driven gear : 0.25mm(0.0098 in.)
Engine Mechanical System > Intake And Exhaust System > Air Cleaner > Components and
Components Location
COMPONENTS
Page 93 of 101
Engine Mechanical System > Intake And Exhaust System > Air Cleaner > Repair procedures
REMOVAL
1. Remove the air intake hose and air duct connected to the air cleaner, and the resonator.
2. Remove the three bolts attaching the air cleaner mounting brackets.
3. Detach the air cleaner.
INSTALLATION
Install the air cleaner according to the reverse order of removal.
INSPECTION
Page 94 of 101
1. Check the air cleaner body, cover, or packing for distortion, corrosion or damage.
2. Check the air duct for damage.

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

5. Check the resonator for damage.
Engine Mechanical System > Intake And Exhaust System > Intake Manifold > Components and
Components Location
COMPONENTS
Page 95 of 101
Engine Mechanical System > Intake And Exhaust System > Intake Manifold > Repair procedures
REMOVAL
1. Disconnect the high pressure fuel hose connection after draining pressure in the fuel pipe line to prevent overflow
of fuel.
(Refer to "Fuel system")
Page 96 of 101
2. Remove the delivery pipe with the fuel injectors and pressure regulator.
Be careful not to drop the injectors when removing the delivert

pipe.
INSTALLATION
1. Make sure that the injector is not dropped, when installing the delivery pipe.
INSPECTION
1. Check for damage or cracking of any part.
2. Check for obstructions in the vacuum outlet port and the gas passage.
Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold > Components and
Components Location
COMPONENTS
Page 97 of 101
Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold > Repair procedures
INSPECTION
1. Check for damage or cracking of any part.
2. Exhaust manifold gasket
Check for flaking damage of the gasket.
Engine Mechanical System > Intake And Exhaust System > Muffler > Components and Components
Location
COMPONENTS
Page 98 of 101
Engine Mechanical System > Intake And Exhaust System > Muffler > Repair procedures
REMOVAL
Main Muffler
Before removing or inspecting the exhaust the exhaust system, ensure that the exhaust system is cool enough.
1. Disconnect the main muffler from the center exhaust pipe.
Page 99 of 101
2. Remove the rubber hangers and take out the main muffler.
INSTALLATION
1. Temporarily install the front exhaust pipe(Rear catalytic converter assembly), the center exhaust pipe, and the
main muffler, in order.
2. Install the rubber hangers so that they are identical (left and right) in length.
3. Tighten the parts securely, and then confirm that there is no interference with any body components.
INSPECTION
1. Check the mufflers and pipes for corrosion and damage.
2. Check the rubber hanger and hangers for deterioration and cracks.
Engine Mechanical System > Intake And Exhaust System > Front Exhsust Pipe > Repair procedures
REMOVAL
Center Exhaust Pipe
1. Disconnect the center exhaust pipe from the main miffler.
2. After disconnecting from the front exhaust pipe, remove the center exhaut pipe.
Front Exhaust Pipe(Including rear catalytic converter)

1. Remove the front exhaust pipe from the center exhaust pipe.
2. Remove the front exhaust pipe from the exhaust manifold(Including front converter).
Page 100 of 101
3. Remove the front exhaust pipe from the rubber hanger.
Engine Mechanical System > Troubleshooting > P0128

TROUBLESHOOTING
Engine coolant temperature circuit malfunction
P0128
Related items · Thermostat stuck opened
· After engine start-up, the elapsed time before feedback operation is initiated is
too long (engine coolant temperature sensor input is insufficient for closed loop
operation)
· Poor connections between ECTS and ECM
· Contaminated, deteriorated ECTS

Remove thermostat and check that Do all repairs associated with those codes
Yes
1 thermostat is stuck. before proceeding this procedure.
Is thermostat okay? No Go to step 2.
Problem is intermittent or was reapired and
Cpmmect SCAN TOOL to data link engine control module memory was not
connector or OBD-II check connector and Yes
turn ignition to ON. ECM and ECTS.
Is DTC P0115, P0116, or P0125 set?
No Go to step 3.
Start engine and allow engine to idle until
engine reaches operating temperature.
Do all repairs associated with those codes
Using SCAN TOOL and monitor ECT Yes
before proceeding this procedure.
signals.
3 · 2.3~2.9V (2.31~2.59 kΩ) @ 20°C
(68°F)
· 0.4~1.0V (0.31~0.33 kΩ) @ 80°C
(176°F) No Go to step 4.
Is signal within specifications?
Check ECTS for contamination, Clean ECTS with cleaner before installing. If
4 damaged or deteriorated, replace.
Is ECTS contaminated, deteriorated or
damaged? No Go to step 5.
Page 101 of 101
Thorughly check TPS for loose, poor Yes Go to step 6.
connection, bent, corrosion, contamination,
5
deterioration, or damage.
No Repair as necessary
Is TPS okay?
6
Page 1 of 136
OPTIMA(MS) > 2001 > G 2.4 DOHC > Fuel System
Fuel System > General Information > Special Service Tools

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

Quick connector
remover
0K3MS 131 001 Connection of fuel pressure gauge to delivery pipe for
Fuel pressure gauge measurement of fuel pressure (use with 0K3MS 131 001A)
adapter
Fuel System > General Information > Description and Operation

MULTIPORT FUEL INJECTION (MFI)
GENERAL INFORMATION
The Multiport Fuel Injection System consists of sensors which detect the engine conditions, the ENGINE
CONTROL MODULE (ECM) which controls the system based on signals from these sensors, and actuators which
operate under the control of the ECM. The ECM carries out activities such as fuel injection control, idle air control
and ignition timing control. In addition, the ECM is equipped with several diagnostic test modes which simplify the
troubleshooting when a problem develops.
FUEL INJECTION CONTROL
The injector drive times and injector timing are controlled so that the optimum air/fuel mixture is supplied to the
engine to correspond to the continually-changing engine operation conditions. A single injector is mounted at the
intake port of each cylinder. Fuel is sent under pressure from the fuel tank by the fuel pump, with the pressure being
regulated by the fuel pressure regulator. The fuel thus regulated is distributed to each of the injectors. Fuel injection is
normally carried out once for each cylinder for every two rotations of the crankshaft. The firing order is 1-3-4-2.
This is called multiport. The ECM provides a richer air/fuel mixture by carrying out "open-loop" control when the
engine is cold or operating under high load conditions in order to maintain engine performance. In addition, when the
engine is warm or operating under normal conditions, the ECM controls the air/fuel mixture by using the heated
oxygen sensor signal to carry out "closed-loop" control in order to obtain the theoretical air/fuel mixture ratio that
provides the maximum cleaning performance from the three way catalyst.
IDLE SPEED CONTROL
Page 2 of 136
The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle valve in
accordance with changes in idling conditions and engine load during idling. The ECM drives the idle speed control
(ISC) motor to keep the engine running at the pre-set idle target speed in accordance with the engine coolant
temperature and air conditioning load. In addition, when the air conditioning switch is turned off and on while the
engine is idling, the ISC motor operates to adjust the throttle valve bypass air amount in accordance with the engine
load conditions in order to avoid fluctuations in the engine speed.
IGNITION TIMING CONTROL
The ignition power transistor located in the ignition primary circuit turns ON and OFF to control the primary current
flow to the ignition coil. This controls the ignition timing in order to provide the optimum ignition timing with respect
to the engine operating conditions. The ignition timing is determined by the ECM from the engine speed, intake air
volume, engine coolant temperature and atmospheric pressure.
OTHER CONTROL FUNCTIONS
1. Fuel Pump Control : Turns the fuel pump relay ON so that current is supplied to the fuel pump while the engine is
cranking or running.
2. A/C Compressor Clutch Relay Control : Turns the compressor clutch of the A/C ON and OFF.
3. Fan Relay Control : The radiator fan and condenser fan speeds are controlled in response to the engine coolant
temperature and vehicle speed.
4. Evaporative Emission Purge Control.
DIAGNOSTIC TEST MODE
• When an abnormality is detected in one of the sensors or actuators related to emission control, the CHECK
ENGINE/MALFUNCTION INDICATOR LAMP illuminates as a warning to the driver.
• When an abnormality is detected in one of the sensors or actuators, a diagnostic trouble code corresponding to
the abnormality is output.
• The RAM data inside the ECM that is related to the sensors and actuators can be read by means of the scan
tool. In addition, the actuators can be controlled under certain circumstances.
HOW TO COPE WITH INTERMITTENT MALFUNCTIONS
Most intermittent malfunctions occur under certain conditions. If those conditions can be identified, the cause will be
easier to find.
TO COPE WITH INTERMITTENT MALFUNCTION;
1. Ask the customer about the malfunction. Ask what it feels like, what it sounds like, etc. Then ask about driving
conditions, weather, frequency of occurrence, and so on.
2. Determine the conditions from the customer's responses. Typically, almost all intermittent malfunctions occur from
conditions like vibration, temperature and/or moisture change, poor connections. From the customer's replies, it
should be reasoned which condition is influenced.
3. Use simulation test In the cases of vibration or poor connections, use the simulation tests below to attempt to
duplicate the customer's complaint. Determine the most likely circuit(s) and perform the simulation tests on the
connectors and parts of that circuit(s). Be sure to use the inspection procedures provided for diagnostic trouble
codes and trouble symptoms. For temperature and/or moisture conditions related intermittent malfunctions, using
common sense, try to change the conditions of the suspected circuit components, then use the simulation tests
below.
4. Verify the intermittent malfunction is eliminated. Repair the malfunctioning part and try to duplicate the
condition(s) again to verify the intermittent malfunction has been eliminated.
SIMULATION TESTS
For these simulation tests, shake, then gently bend, pull and twist the wiring of each of these examples to duplicate
the intermittent malfunction.
• Shake the connector up-and-down, and right-and-left.
• Shake the wiring harness up-and-down, and right-and-left.
• Vibrate the part or sensor.
A CAUTION FOR I/M TEST (2.5 V6 Vehicle with Traction Control System)
• To prevent the vehicle misfire, disconnect the connector of ABS.
Page 3 of 136
SERVICE POINTS IN INSPECTING A BLOWN FUSE
Remove the fuse and measure the resistance between the load side of the fuse and ground. Set the switches of all
circuits which are connected to this fuse to a condition of continuity. If the resistance is almost 0W at this time, there
is a short somewhere between these switches and the load. If the resistance is not 0W, there is no short at the
present time, but a momentary short has probably caused the fuse to blow.
The main causes of a short circuit are the following.
• Harness clamped by the vehicle body
• Damage to the outer casing of the harness due to wear or heat.
• Water getting into the connector or circuitry
• Human error (mistakenly shorting a circuit, etc.).
INSPECTING THE MFI SYSTEM
If the MFI system components (sensors, ECM, injector, etc.) fail, the interruption or failure to supply the proper
amount of fuel for various engine operating conditions will result. The following situations may be encountered.
1. Engine is hard to start or does not start at all.
2. Unstable idle
3. Poor driveability
If any of the above conditions is noted, first perform an inspection by self-diagnosis and subsequent basic engine
checks (ignition system malfunction, incorrect engine adjustment, etc.), and then inspect the MFI system
components.
ON-BOARD DIAGNOSTICS
• The recording condition of diagnostic trouble code. After the ECM first detects a malfunction, a diagnostic
trouble code is recorded when he engine is restarted and the same malfunction is re-detected. (Malfunction is
detected in driving cycle). However, for fuel system rich/lean misfiring, a diagnostic trouble code is recorded on
the first detection of the malfunction.
• The recording condition of diagnostic trouble code. After the ECM first detects a malfunction, a diagnostic
trouble code is recorded when he engine is restarted and the same malfunction is re-detected. (Malfunction is
detected in driving cycle). However, for fuel system rich/lean misfiring, a diagnostic trouble code is recorded on
the first detection of the malfunction.
- When driving conditions (engine speed, engine coolant temperature, etc.) are similar to those when the
malfunction was first recorded.
- When the ECM does not re-detect the malfunction for 80 driving cycles.
A "driving cycle" consists of the engine start, vehicle operation beyond the beginning of closed loop operation.
Malfunction Indicator Light (MIL)
An On Board Diagnostic lamp comes on to notify the driver that there is any problem on the vehicle.
However MIL will go off automatically after 3 subsequent sequential driving cycles not redetected same malfunction.
Immediately after the ignition switch turns on, the malfunction indicator light is lit for 5 seconds to indicate that the
malfunction indicator light operates normally.
Following Items will be Indicated by the MIL
• Catalyst
• Fuel system
• Air flow sensor (MAF sensor)
• Intake Air Temperature Sensor (IAT sensor)
• Engine Coolant Temperature Sensor (ECT sensor)
• Throttle Position Sensor (TPS)
• Upstream Oxygen Sensor
• Downstream Oxygen Sensor Heater
• Downstream Oxygen Sensor
Page 4 of 136
• Upstream Oxygen Sensor Heater
• Injector
• Misfire
• Crankshaft Position Sensor (CKP sensor)
• Camshaft Position Sensor (CMP sensor)
• Evaporative Emission Control System
• Vehicle Speed Sensor (VSS)
• Idle Speed Control
• ECM
• Manifold Absolute Pressure (MAP) Sensor (Except 2.5L V6 engine)
• EGR System (Except 2.5L V6 engine)
INSPECTING THE MALFUNCTION INDICATOR LAMP (MIL)
1. After turning on the ignition key, check that the light illuminates for 5 seconds without engine running.
2. If the light does not illuminate, check for an open circuit in harness, blown fuse and blown bulb.
SELF-DIAGNOSIS
The ECM monitors the input/output signals (some signals at all times and the others under specified conditions).
When the ECM detects an irregularity, it memorize the diagnostic trouble code, and outputs the signal to the self-
diagnosis output terminal. The diagnosis results can be read out Hi-Scan Tool. Diagnostic trouble code (DTC) will
remain in the ECM as long as battery power is maintained. The diagnostic trouble code will, however, be erased
when the battery terminal or the engine control module (ECM) connector is disconnected or erased by Generic
Scan Tool.
CHECKING THE PROCEDURES (SELF-DIAGNOSIS)
• When battery voltage is low, diagnostic trouble codes can not be read. Be sure to check the battery for voltage
and charging system before starting the test.
• Diagnosis memory is erased if the battery or the ECM connector is disconnected. Do not disconnect the
battery before the diagnostic trouble codes are completely read and recorded.
Inspection Procedure (Using Hi-Scan Tool)

1. Turn OFF the ignition switch.
2. Connect the scan tool to the data link connector on the lower crash pad.
3. Turn ON the ignition switch.
4. Use the Hi-Scan Tool to check the diagnostic trouble code.
5. Repair the faulty part from the diagnosis chart.
6. Erase the diagnostic trouble code.
7. Disconnect the Hi-Scan Tool.
OBD-II OVERVIEW
The goal of the On Board Diagnostics-II (OBD-II) regulation, which was mandated by the Environmental
Protection Agency (EPA), is to ensure proper emission system operation for the life of the vehicle by providing the
vehicle with an "on-board" diagnostic system which is capable of continuously monitoring the efficiency of the
emission control system. To achieve this goal, OBD-II diagnostics monitors emissions-related components and
systems for deterioration and identifies an emissions-related malfunction before the driver notices a problem with the
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vehicle. The Engine Control Module (ECM) monitors many different circuits in the fuel injection, ignition, emission
and engine systems. If the ECM senses a problem with a monitored circuit often enough to indicate an actual
problem, it stores a Diagnostic Trouble Code in the ECM memory. If the code applies to a non-emissions related
component or system and the problem is repaired or ceases to the exist, the ECM cancels the code after a
predetermined number of drive cycles. Certain criteria must be met before the ECM stores a DTC in memory. The
criteria may be a specific range of engine RPM, engine temperature, and/or input voltage to the ECM. Keep in mind
though that the ECM might not store a DTC for a monitored circuit even though a malfunction has occurred. This
may happen because one of the DTC criteria for the circuit has not been met. For example, lets SAY THE DTC
criteria requires the ECM to monitor the circuit only when the engine operates between 750 and 2000 RPM.
Suppose the sensors output circuit shorts to ground as a result of engine torque when the engine operates above
2400RPM (resulting in 0 volt input to the ECM). Since the condition happens at the engine speed above the
maximum threshold, in this case 2000 RPM, the ECM will not store a DTC.
As a functional test, the MIL (check engine) illuminates at key ON before engine cranking. Whenever the ECM sets
a DTC that affects vehicle emissions, it sends a signal to illuminate the MIL. There are some monitors that may take
consecutive trips, with a detected fault, before the MIL is illuminated. This is also known as "PENDING" codes.
Also, m the MIL flashes when the ECM detects an active engine misfire, then shuts off fuel to the affected cylinder.
OBD-II diagnostics supports not only the standard test mode of OBD-II (Mode 01~Mode 07) but also an
advanced test Mode (Mode 22: Supported PID-analog inputs and outputs, digital inputs and outputs). All of these
diagnostic test modes are supported using Hi-Scan Pro through the DLC.
The ECM executes the following key monitoring for OBD-II:
• Primary emission control system/components
• Heated oxygen sensors (includes heater)
• Catalyst
• Fuel system
• Evaporative emission system
• Misfire
• Comprehensive components (input and output)
HEATED OXYGEN SENSOR MONITORING (SYSTEM DESCRIPTION)
Effective control of exhaust emission is achieved by an oxygen "feedback system" to the ECM. This "feedback" is
accomplished with the HO2 Sensors. Once the HO2 Sensor reaches operating temperature, the sensor generates a
voltage signal to the ECM that is inversely proportional to the amount of oxygen in the exhaust. This voltage signal is
used by the ECM to calculate the fuel injector pulse width to maintain the ideal 14.7 to 1 Air Fuel (A/F) ratio. This is
the ideal mixture because at this ratio, the catalyst works best to remove hydrocarbons (HC), carbon monoxide
(CO) and nitrogen oxide (NOx) from the exhaust.
MONITORING PROCESS
To achieve the requirements of the HO2S Monitoring diagnosis, diagnostic tests have been designed to monitor the
following:
• Heater voltage and current.
• Period of front HO2S reaction
• Other parameter (Tv) to monitor sensor aging.
‍ Heater voltage and current
The voltage readings taken from the HO2 Sensor are very temperature sensitive and are not particularly accurate
below 300°C. For this reason, heating of the HO2 sensor is necessary to allow the engine controller to shift to
closed loop control as soon as possible. The heating element used to heat the HO2 Sensor must be tested to ensure
that it is heating the sensor properly.
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* Period of front HO2 reaction

The ECM is supplied with information regarding the oxygen content of the exhaust gases by the front HO2S. The
signal is used to compute the injection period. The front HO2S monitors the contaminated exhaust gases. This, in
time, causes aging of the device and a change in the signal.
To monitor the front HO2S responsiveness, the response period of the upstream oxygen sensor signal is compared
with a lower and upper threshold. This comparison is done in an applicable range of engine speed and load with the
engine at operating temperature. If the actual mean value of the period is outside of the lower and upper period
thresholds the diagnostic trouble code is set.
* Other parameter (Tv) to monitor sensor aging
The sensor aging is monitored by comparing the front and rear HO2S and also using the correction value (Tv) which
determines the mean value of the lean/rich shift necessary for optimal air/fuel ratio-control. With the help of this
information, the ECM can make allowance for aging of the front HO2S in its injection period calculations. When the
parameter-Tv is above or below the specific limits, the ECM will set the diagnosic trouble code HO2S Slow
Response by aging.
MIL illumination
If any fault relating to HO2S is detected, then the MIL is only truned ON if the same fault is again detected during a
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second drive cycle.
CATALYST MONITORING (SYSTEM DESCRIPTION)
To comply with clean air regulatings, vehicles are equipped with catalytic converters. These converters reduce the
emissions of hydrocarbons, oxides of nitrogen and carbon monoxide.
Normal vehicle operation or engine misfire can cause a catalyst to decay. A meltdown of the ceramic core can cause
a reduction of the exhaust passage resulting in an increase in vehicle performance and deteriorate engine
performance, driveablity and fuel economy.
The catalyst uses dual oxygen sensor to monitor the efficiency of the converter because as a catalyst deteriorates, its
oxygen storage capacity and its efficiency are both reduced. By monitoring the oxygen storage capacity of a catalyst,
its efficiency can be indirectly calculated. The upstream (front) HO2 Sensor is used to detect the amount of oxygen
in the exhaust gas before it enters the catalytic converter. A low voltage indicates a high oxgen content (lean air
mixture) A high voltage indicates a low content of oxygen (rich mixture).
When the front HO2 Sensor detects a lean condition, there is an abundance in the oxygen in the exhaust has. A
functioning converter would store this oxygen so it can use it for the oxidation of HC and CO. As the converter
absorbs the oxygen, there will be a lack of oxygen downstream of the converter. The output of the downstream
(rear) HO2 Sensor will indicate limited activity in this condition. As the converter loses the ability to store oxygen,
the condition can be detected from the operation of the rear HO2 Sensor. When the catalyst efficiency drops, no
chemical reaction takes place. This means the concentration of oxygen will be the same downstream (rear) as
upstream (front). The output voltage of the rear HO2 Sensor copies the voltage of the front HO2 Sensor. The only
difference is a time lag (monitored by the ECM) between the switching of the HO2 Sensors.
To monitor the system, the lean-to-rich switches of front to rear HO2 Sensors is counted. The ratio of rear switches
to front switches is used to determine whether the catalyst is operating properly. An effective catalyst will have fewer
rear switches than it has front switches, that is, a ratio closer to zero. For a totally ineffective catalyst, this ratio will
be one-to-one indicating that no oxidation occurs in the catalytic converter.
The system must be monitored so that when catalyst efficiency deteriorates and exhaust emissions increase to over
the legal limit, the MIL will illuminate.
FUEL SYSTEM MONITORING (SYSTEM DESCRIPTION)

The determination of how much fuel to deliver to the engine is the calculation of injector pulse width. Basic injection
duration (injector pulse width) is determined by :
• Engine load (MAF sensor)
• Engine Speed (SGT)
• Short fuel trim correction factor
• Long fuel trim correction factor
Fuel trim is monitored to meet the OBD-II requirements
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1. Short fuel trim (FT)
Short FT is a temporary correction to fuel delivery which changes with every cycle of the front Heated Oxygen
Sensor.
Under normal conditions, it fluctuates rapidly around its ideal value of 0% correction and is set to 0% during open
loop operation.
Short FT is a parameter of the OBD-II serial data stream and can be displayed by a scan tool. The normal range
of short FT is ±25%, but under normal operating conditions it rarely goes beyond ±10%. Short FT responds to
changes in front HO2S output. If basic injection duration results in a lean air/fuel ratio, Short FT responds with
positive corrections (+1% to +25%) to add fuel and enrich the mixture. If basic injection is too rich, Short FT
responds with negative corrections (-1% to -25%) to subtract fuel and lean the mixture.
2. Long fuel Trim
Long FT is a data parameter on the OBD-II data streams. It is a more permanent correction to fuel delivery
because it is part of the basic injection duration calculation. Long FT changes slowly, in response to short FT. It's
normal range is ±25%, positive values indicating rich correction and negative values indicating lean correction.
Unlike Short FT which affects injection duration calculation in closed loop. Because Long FT is stored in a non-
volatile RAM and is not erased when the ignition is swithed OFF, the fuel system is able to correct for variances
in engine and fuel conditions even during warm-up and wide open throttel conditions.
MONITORING PROCESS
The ECM monitors the averages of long term and short term fuel trim. If these fuel trim values reach and stay at their
maximum limits (±25%) for a defined period of time, a diagnostic trouble code is set.
MIL ILLUMINATION
When the fuel trim value exceeds the failure thresholds, when the MIL is only turned ON if the same fault is detected
during a second drive cycle.
EVAPORATIVE EMISSION CONTROLS (EVAPORATIVE CONTROL SYSTEM)
The evaporation control system prevents the emission of fuel tank vapor into the atmosphere. When fuel evaporates
in the fuel tank, the vapors pass through vent hoses or tubes to a charcoal filled evaporative canister. The canister
temporarily holds the vapors. The ECM allows intake manifold vacuum to draw vapors into the combustion
chambers during certain operating conditions.
Fuel tank
The fuel tank is located under the rear of the vehicle. The fuel pump, fuel level sending unit and fuel tank pressure
sensor are installed on the upper part of the fuel tank.
Fuel filler cap
A ratchet tightening device on the threaded fuel filler cap reduces the chances of incorrect installation, which would
prevent sealing fuel vapors. After the gasket on the fuel filler cap and the fill neck flange contact each other, the
ratchet produces a loud clicking noise indicating the seal has been set.
Evaporative emissions canister
The EVAP canister is filled with granules of an activated carbon mixture. Fuel vapors enter into the EVAP canister
are absorbed by the charcoal granules. Fuel tank pressure vents into the EVAP canister and are temporarily held in
the canister until they can be drawn into the intake manifold.
Canister close valve
The Canister Close Valve (CCV) closes off the air inlet to the Evaporative Emissions Canister for the Evaporative
Emissions System leak detection inspection function. The CCV also prevents fuel vapors from escaping from the
Evaporative Emissions Canister when the vehicle is not operating.
Purge solenoid valve
This valve is actuated by the purge control signal from the ECM and controls fuel vapor from the EVAP Canister to
the intake manifold.
Fuel tank pressure sensor
The Fuel Tank Pressure Sensor (FTPS) is an integral part of the monitoring system. The FTPS checks Purge
Solenoid Valve operation and leak detection in the Evaporative Emissions System by monitoring pressure and
vacuum levels in the fuel tank during and between Purge Solenoid Valve operating cycles.
EVAP SYSTEM MONITORING: LEAKAGE DETECTION (SYSTEM DESCRIPTION)
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The evaporative system is monitored by a pressure test. The canister close valve and fuel tank pressure sensor are
used to close the system and observe tank pressure respectively.
MONITORING CONDITIONS
The leak test is conducted when the vehicle is stopped during an idle condition.
MONITORING PROCESS
The canister close valve and the EVAP canister purge control valve are closed and an increase in fuel tank pressure
caused by fuel evaporation occurs (compensation gradient). Afterwards, the canister close valve and the purge
control valve are opened. The canister close valve will be shut if the purge control valve reached its final duty cycle.
1. Gross leak detection A gross leak is assumed if negative pressure is built-up below a certain threshold. In this
case, the EVAP canister purge control valve is closed and the canister close valve is opened. then, the diagnosis
is completed.
2. Small leak detection The EVAP canister purge control valve is closed as soon as the maximum vacuum level is
achieved. The rate of vacuum loss will be corrected by the above compensation gradient. A small leak is
assumed if this corrected rate of vacuum loss is above a certain threshold. Then, the canister close valve is
opened and the diagnosis is completed.
MIL ILLUMINATION
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If either a rough leak or a small leak is detected for two driving cycles, then a defective evaporative system is
assumed and the MIL is illuminated.
MISFIRE MONITORING (SYSTEM DESCRIPTION)
Misfire is monitored by evaluating fluctuations of the angular velocity of the crankshaft position sensor. The
crankshaft position sensor allows the ECM to monitor crankshaft speed variations during each cylinder power
stroke. When all cylinders of an engine are firing evenly, the crankshaft speeds up evenly with each power stroke.
During a misfire, crankshaft speed decreases in that cylinder. Kia OBD-II engines use a 60 minus 2 tooth crankshaft
position sensor to measure crankshaft speed and position. The ECM uses this information to determine if a misfire
occurs, which cylinder it is occurring in, and the degree of misfire. If a significant misfire is detected, a DTC is
stored. The MIL in the instrument panel will illuminate, informing the driver of a malfunction.
MONITORING CONDITIONS
The misfire monitoring begins as soon as 2.9 to 50 ignitions pass after engine start. It is disabled while the ECM
detects a sudden change of engine speed or load. The misfire monitoring covers the full range of engine operation.
MONITORING PROCESS
A new function for pre-filtering the sensor wheel segment duration has been introduced on the Optima in order to
expand the misfire monitoring range. The sensor wheel segment duration is pre-filtered by this function and then the
filtered value is used to calculate the engine roughness which is compared with the reference value to detect misfiring.
With this function, it is possible to eliminate the influence of the crankshaft-synchronous oscillations on the detection
of misfire. These oscillations can be caused by sensor wheel tolerance or crankshaft torsional vibration. The misfire
monitoring of this vehicle covers nearly the full range of engine operation in case of random or continuous misfire,
and for symmetrical misfire.
MIL ILLUMINATION
The MIL is illuminated when a misfire is detected which can cause the damage of catalyst or exhaust emission higher
than 1.5 times certification standard (I/M failure). The MIL flashes while a catalyst damaging misfire is being
detected.
COMPREHENSIVE COMPONENTS MONITORING
Any input or output components that can affect emissions or any input or output component used to monitor any
other moniotred component/system is monitored. The lack of circuit continuity and rationality, and out-of-range
values to ensure proper operation of the input devices, are monitored for proper response to ECM commands.
EGR SYSTEM MONITORING (EXCEPT 2.5L V6 ENGINE)
The EGR system is monitored by the measurement of manifold pressure variation by turning on EGR during
coasting. The manifold pressure is measured before and after EGR valve has been activated and the corresponding
pressure variation is compared with reference value to detect a EGR system malfunction.
Fuel System > General Information > Troubleshooting

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

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

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Engine will not start
Difficult to start (Engine turns over)

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Rough idle or engine stalls

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Engine hesitates or accelerates poorly

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Difficult to refuel/Overflowing or Spit-Back while refueling

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

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

TIGHTENING TORQUE
Item Nm Kg·cm lb·ft
Delivery pipe 10-13 100-130 7-9.5
installation bolt
Engine coolant 20-40 200-400 14-29
temperature
sensor
Heated oxygen 40-50 400-500 29-36
sensor
Heated oxygen 8-12 80-120 5.8-8.7
sensor connector
bracket bolt
High pressure 30-40 300-400 22-29
hose and fuel
main pipe
High pressure 25-35 250-350 18-25
hose and fuel
filter
High pressure 3-4 30-40 2.2-3
hose to delivery
pipe
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Fuel pump 2-3 20-30 1.4-2.2
assembly to fuel
tank
High pressure 30-40 300-400 22-29
hose at fuel tank
Throttle body to 15-22 150-220 11-12.7
surge tank
Fuel tank drain 15-25 150-250 11-18
plug
Fuel filter 9-14 90-140 6.5-10
mounting bolts
Accelerator arm 8-12 80-120 5.8-8.7
bracket bolts
ISC actuator 6-8 60-80 4.4-5.8
Fuel sender to 2-3 20-30 1.4-2.2
fuel tank
Throttle body Throttle position sensor Type Variable resistor
(TPS)
Resistance at 2.4 DOHC 3.5~6.5 kΩ
curb idle V6 1.6~2.4 kΩ
Output voltage 2.4 DOHC 300~900 mV

at curb idle V6 250~800 mV
Idle speed control (ISC) Type Double coil
actuator Opening 15.0~16.0 Ω
Resistance
Closing 17.0~18.2 Ω
Sensors Air flow sensor 2.4 DOHC HOT Film sensor (MAF)
Type
V6 HOT Film sensor (MAF)
Intake air temperature Thermistor type
Type 2.4 DOHC
(IAT) sensor (Built in MAF) 2.22~2.82 kΩ
at 20°C (68°F)
Resistance V6 Thermistor type
Engine coolant temperature Type Thermistor type
(ECT) sensor
2.31~2.59kΩ at 20at 20°C
Resistance (68°F)
0.30~0.34kΩ at 20°C (68°F)
Heated oxygen sensor 2.4 DOHC Zirconia type
Type
V6 Titania type
Vehicle speed sensor Type Hall effect type
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Camshaft position (CMP)
Type Hall effect sensor
sensor
Crankshaft position (CKP)
Type Hall effect sensor
sensor
Actuators Injector 2.4 DOHC Electromagnetic type, 4
Type, number
V6 Electromagnetic type, 6
Resistance 13.8~15.2Ω at 20°C (68°F)
Evaporative emission purge Type Duty cycle type
solenoid Resistance 20~32Ω
Fuel pressure Injector opening pressure 300±1.5 kPa (3.35±0.06
regulator kg/cm²)
Tank capacity 65 lit (17.1 US gal, 14.3 lmp.gal)
Fuel tank
Return system Equipped
Canister Volume/Nominal working capacity 3.0 liter/150g
SEALANT
Item Specified sealant
Engine coolant temperature LOCTITE 962T or equivalent
sensor
SERVICE STANDARDS
Item Standard valve
Basic ignition timing (2.4 DOHC) BTDC 5° ± 2° at curb idle
Actual ignition timing (V6) BTDC 12° ± 5° at curb idle
2.4 DOHC 800 ± 100
Curb idle speed (rpm)
2.5 V6 700 ± 100
Vacuum hose
330 ~ 350 (47-50) at curb idle
disconnection
Fuel pressure kPa (psi)
Vacuum hose
Approx. 270 (38) at curb idle
connection
Evap canister purge solenoid valve resistance 20-32Ω
Fuel System > Engine Control System > Schematic Diagrams

2.4L DOHC ENGINE ECM TERMINAL LAYOUT
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CONNECTOR<B-01>
CONNECTED
TERMINAL SIGNAL
TO
A1 Injector 1 Control Injector 1
A3 ― ―
A4 Idle Speed Control Opening Coil Control ISC
A5 ― ―
EGR Solenoid
A6 EGR Solenoid Valve Control
Valve
A7 ― ―
A8 Fuel Pump Relay Control Fuel Pump
A9 Evaporative Purge Solenoid Valve Control PSV
A10 Ignition Coil 1 (1 & 4) Control Ignition Coil 1
A11 ― ―
A12 Battery Voltage Battery
A13 Power Ground Ground
A16 ― ―
A17 Idle Speed Control Closing Coil Control ISC
A18 ― ―
A19 ― ―
A20 Cooling Fan Relay High Control Fan Relay High
A21 Cooling Fan Relay Low Control Fan Relay Low
A22 A/C Relay Control A/C Relay
A24 ― ―
A25 Battery Voltage Battery
A26 Power Ground Ground
CONNECTOR <B-02>
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TERMINAL SIGNAL CONNECTED TO
B1 - -
B2 - -
B3 - -
B4 Throttle Position Signal Input TPS
B5 - -
B6 MIL Control MIL
B7 Power Steering Switch Input Power Steering SW
B8 Control Realy Control Control Relay
B9 - -
B10 - -
B11 - -
B12 A/C Pressure Switch Signal Input A/C Pressure Switch
B13 - -
B14 - -
B15 A/C Pressure Switch Signal Input A/C Pressure Switc
B16 - -
CONNECTOR <B-03>
C1 - -
C2 Spark Timing Adjustment (+) Spark Timing Adjustment
C3 - -
C4 Rear HO2S Heater Control Rear HO2S
C5 Canister Close Valve Control CCV
C6 - -
C7 - -
C8 IG Failure Sensor Signal Input IG Failure Sensor
C9 - -
C10 Front HO2S Heater Control Front HO2S
C11 Fuel Tank Pressue Sensor Signal Input Tank Pressure Sensor
C12 Diagnosis K-Line Data Link Connector
CONNECTOR <B-04>
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D1 "ST" Signal Input Ignition Switch
D2 Intake Air Temperature Sensor LATS
D3 Map Sensor Signal Input Map Sensor
D4 Fuel Level Sensor Input Fuel Level Sensor
D5 Rear Ho2s Ground Rear Ho2s
D6 Front Ho2s Ground Front Ho2s
D7 Fuel Temperature Sensor Signal Input Fuel Temperature Sensor
D8 Knock Sensor Signal Input Knock Sensor
D9 Flash Eeprom Battery RCT
D10 Battery Back Up Control Relay
D11 Sensor Reference Voltage Sensors
D12 IG + Ignition Switch
D13 Engine Coolant Temperature Sensor Signal Input ECTS
D14 Throttle Position Sensor Signal Input TPS
D15 Mass Air Flow Sensor Signal Input MAFS
D16 Vehicle Speed Sensor Signal Input Vehicle Speed Sensor
D17 - -
D18 Campshaft Position Sensor Signal Input CMPS
D19 Crankshaft Position Sensor Signal Input CKPS
D20 - -
D21 - -
D22 Sensor Ground Ground
2.4L DOHE ENGINE TERMINAL LAYOUT (WITH TCM)
CONNECTOR B-01
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A3 Front Ho2s Heater Control (Bank 1) Front Ho2s (Bank 1)
A4 - -
A5 - -
A6 Egr Solenoid Valve Control Egr Solenoid Valve
A7 - -
A8 Alternator G Terminal Alternator
A10 - -
A13 - -
A14 Idle Control Opening Coil Control ISC
A15 - -
A16 - -
A17 Cooling Fan Relay High Control Fan Relay High
A18 Cooling Fan Relay Low Control Fan Relay Low
A19 - -
A20 Fuel Pump Relay Control Fuel Pump
A21 A/C Relay Control A/C Relay
A22 Mil Control MIL
A23 Spark Timing Adjustment (+) RCT
A25 - -
A26 Rear Ho2s Heater Control (Bank 1) Rear Ho2s (Bank 1)
A27 - -
A28 Idle Control Closing Coil Ground ISC
A29 - -
A30 Throttle Position Signal Output
A31 - -
A32 - -
A33 - -
A34 Evaporative Purge Solenoid Valve Control PSV
A35 Canister Purge Control Valve Control CCV
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CONNECTOR B-02
B1 Battery + Battery
B2 Ground -
B3 IG + Ignition Switch
B4 Engine Coolant Temperature Sensor Signal Input ECTS
B5 Crankshaft Position Sensor Signal Input CKPS
B6 Sensor Reference Voltage FTPS
B7 Battery + Battery
B8 Ground Ground
B9 Control Relay Control Control Relay
B10 AT Control Relay Control AT Control Relay
B11 Fuel Temperature Sensor Signal Input Fuel Temperature Sensor
B12 Power Steering Load Input Power Steering SW
B13 - -
B14 Alternator "FR" Terminal Alternator
B15 Mass Air Flow Sensor Signal Inpiut MAFS
B16 Camshaft Position Sensor Signal Input CMPS
B17 Sensor Ground Sensors
B18 Starter "S" Signal Input Starter
B19 - -
B20 Fuel Level Sensor Signal Input Fuel Leverl Sensor
B21 - -
B22 A/C Pressure Switch Signal Input A/C Pressure Switch
B23 - -
B24 Intake Air Temperature Sensor Signal Input IATS
B25 - -
B26 Battery Back Up -
CONNECTOR B-03
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C1 Front Ho2s Signal Input Front Ho2s
C2 - -
C3 Rear Ho2s Signal Input Rear Ho2s
C4 - -
C5 Auto Cruise Control Switch Auto Cruise Unit
C6 Ground Ground
C7 AT Control Relay Control AT Control Relay
C8 Throttle Position Sensor Signal Input TPS
C9
C10 Vehicle Speed Sensor Signal Input Vehicle Speed Sensor
C11 - -
C12 - -
C13 A/C Pressure Switch Signal Input A/C Pressure Switch
C14 - -
C15 Diagnosis Data Link K-Line Data Link Connector
C16 - -
C17 - -
C18 Power Ground Ground
C19 AT Solenoid Power AT Solenoid
C20 Knock Sensor Signal Input Knock Sensor
C21 Map Sensor Signal Input Map Sensor
C22 Fuel Tank Pressue Sensor Signal Input Tank Pressure Sensor
C23 - -
C24 - -
C25 - -
C26 - -
C27 Power Ground Ground
C28 IG + Ignition Switch
CONNECTOR B-04
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D1 Inhibitior Switch "P" Signal Input Inhibitior Switch
D2 Inhibitior Switch "D" Signal Input Inhibitior Switch
D3 Pulse Generator "A" Signal Input Pulse Generator "A"
D4 Pulse Generator "B" Signal Input Pulse Generator "B"
D5 AT 2nd Lamp Control Instrument Cluster
D6 AT 2nd Solenoid Control 2nd Solenoid
D7 DCC Solenoid Control DCC Solenoid
D8 Inhibitior Switch "R" Signal Input Inhibitior Switch
D9 Sports Mode Select Switch Input Sport Mode Select SW
D10 Sports Mode Down Switch Input Sport Mode Down SW
D11 - -
D12 - -
D13 Flash Eeprom Battery Rom Change Tool
D14 - -
D15 - -
D16 - -
D17 3rd Lamp Control Instrument Cluster
D18 2nd Lamp Control Instrument Cluster
D19 - -
D20 Up Solenoid Control Up Solenoid
D21 Inhibitor Switch "N" Signal Input Inhibitior Switch
D22 Sports Mode Up Switch Signal Input Sports Mode Up SW
D23 Stop Lamp Switch Signal Input Stop Lamp Switch
D24 Oil Temperature Sensor Signal Input Oil Temperature Sensor
D25 - -
D26 - -
D27 - -
D28 4th Lamp Control Instrument Cluster
D29 LR Solenoid Control LR Solenoid
D30 O/D Solenoid Control O/D Solenoid
Fuel System > Engine Control System > Flow Diagram

SYSTEM DIAGRAM FOR 2.4L DOHC
Page 32 of 136
Fuel System > Engine Control System > Intake Air Temperature Sensor (IATS) > Troubleshooting
MASS AIR FLOW (MAF) SENSOR & INTAKE AIR TEMPERATURE (IAT) SENSOR
This hot film type air flow sensor is composed of a hot film sensor, housing, metering duct (hybrid, sensor element).
Mass air flow rate is measured by detection of heat transfer from a hot film probe because the change of the mass
air flow rate causes change in the amount of heat being transferred from the hot film probe surface to the air flow.
The air flowsensor generates a pulse so it repeatedly opens and closes between the 5V voltage supplied from the
engine control module. This results in the change of the temperature of the hat film probe and in the change of
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resistance.
Circuit Diagram <2.4 DOHC>
Fuel System > Engine Control System > Engine Coolant Temperature Sensor (ECTS) >
Troubleshooting
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
• The engine coolant temperature sensor is installed in the engine coolant passage of the cylinder head, detects
engine coolant temperature and emits signals to the ECM. This part employs a thermistor which is sensitive to
changes in temperature. The electric resistance of a thermistor decreases in response to temperature rise. The
ECM judges engine coolant temperature by the sensor output voltage and provides optimum fuel enrichment
when the engine is cold.
Circuit Diagram
Page 34 of 136
SENSOR CHECKING
Using HI-SCAN
Check item Data display Check conditions Intake air Test specification
temperature
Engine coolant Sensor temperature Ignition switch : ON When -20°C (-4°F) -
temperature sensor or engine running
When 0°C (32°F) 4.05V
When 20°C (68°F) 3.44V
When 40°C (104°F) 2.72V
When 80°C (176°F) 1.25V
Page 35 of 136
Check item Data display Check conditions Intake air Test specification
temperature
Engine coolant Sensor temperature Ignition switch : ON When -20°C (-4°F) -
temperature sensor or engine running
When 0°C (32°F) 4.05V
When 20°C (68°F) 3.44V
When 40°C (104°F) 2.72V
When 80°C (176°F) 1.25V
Using multi-meter
1. Remove engine coolant temperature sensor from the intake manifold.
2. With temperature sensing portion of engine coolant temperature sensor immersed in hot engine coolant, check
resistance.
Temperature [°C (°F)] Resistance (KΩ)

20 (68) 2.31-2.59
80 (176) 0.31-0.34
3. If the resistance deviates from the standard value greatly, replace the sensor.
HARNESS INSPECTION
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DTC : Diagnosis Trouble Code

ECM : Engine Control Module
ECT : Engine Coolant Temperature
USING VOLTMETER
Check Item Coolant temperature 2.4 DOHC V6 DOHC
Engine coolant When 20°C 2.5~2.7V 3.6~3.8V

temperature sensor When 40°C 1.5~1.7V 2.7~3.0V
output voltage
When 80°C 0.5~0.7V 1.2~1.5V
TROUBLEHSOOTING HINTS
If the fast idle speed is not enough or the engine gives off dark smoke during the engine warm-up operation, the
engine coolant temperature sensor might be the cause.
Installation
1. Apply sealant LOCTITE 962T or equivalent to threaded portion.
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2. Install engine coolant temperature sensor and tighten it to specified torque.
Tightening torque
Engine coolant temperature sensor : 20-40 N·m (200-400 kg·cm, 14-29 lb-ft)
3. Securely connect teh harness connector
Fuel System > Engine Control System > Throttle Position Sensor (TPS) > Troubleshooting
THROTTLE POSITION (TP) SENSOR
• The TP Sensor is a variable resistor type that rotates with the throttle body throttle shaft to sense the throttle
valveangle. As the throttle shaft rotates, the output voltage of the TP Sensor changes. The ECM detects the
throttle valve opening based on voltage change.
Circuit Diagram
Page 38 of 136
SENSOR CHECKING
Using HI-SCAN
Check Item Data display Check conditions Throttle valve Test specification
Throttle position Sensor voltage Ignition switch : ON 300-900 mV (2.4
sensor At idle position DOHC)
250-800 mV (2.5 V6)
Increases with valve
Open slowly
opening
4.4~4.6 (2.4D)
Open widely
4.0~4.4 (2.7V6)
Using voltmeter
1. Disconnect the throttle position sensor connector.
2. Measure resistance between terminal 1 (sensor ground) and terminal 2 (sensor power) for 2.4 DOHC, between
terminal 1 (sensor ground) and terminal 2 (sensor power) for 2.5 V6.
Standard value
2.4 DOHC : 3.5-6.5 KΩ
V6 : 2.5 V6 1.6-2.4 KΩ
3. Connect a pointer type ohmmeter between terminal 1 (sensor ground) and terminal 3 (sensor output) for 2.4
DOHC and between terminal 2 (sensor ground) and terminal 3 (sensor output) for 2.5 V6.
4. Operate the throttle valve slowly from the idle position to the full open position and check that the resistance
changessmoothly in proportion with the throttle valve opening angle.
5. If the resistance is out of specification, or fails to change smoothly, replace the throttle position sensor.
Tightening torque
TP Sensor : 1.5-2.5 Nm (15-25 kg·cm, 1.1-1.8 lb·ft)
HARNESS INSPECTION
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TROUBLESHOOTING HINTS
The TPS signal is important in the control of the automatic transaxle. Shift shock and other trouble will occur if the
sensor is faulty.
Fuel System > Engine Control System > Throttle Position Sensor (TPS) > Repair procedures
THROTTLE POSITION SENSOR (TPS) ADJUSTMENT [2.4 DOHC]
1. Connect a HI-SCAN to the data link connector.
2. If a HI-SCAN is not used, connect a digital type voltmeter between connector 1 and 3.
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3. Turn the ignition switch to the ON position (do not start engine) and check that the TP Sensor output voltage is
as specified. If a HI-SCAN is used, read the voltage.
Standard value : 300-900 mV
4. If it is out of specification, loosen TP Sensor mounting screws and adjust by turning the TP Sensor.
• Turning the TP Sensor clockwise increases the output voltage.

• Tighten the screws securely after adjustment.
Fuel System > Engine Control System > Heated Oxygen Sensor (HO2S) > Troubleshooting
HEATED OXYGEN SENSOR (HO2S) [2.4 DOHC]
The heated oxygen sensor senses the oxygen concentration in exhaust gas, converts it into a voltage, which is sent to
the ECM. The oxygen sensor outputs about 1V when the air fuel ratio is richer than the theoretical ratio, and outputs
about 0V when the ratio is leaner (higher oxygen concentration in exhaust gas). The ECM controls the fuel injection
ratio based on this signal so that the air fuel ratio is maintained at the theoretical ratio. The oxygen sensor has a
heater element which ensures the sensor performance during all driving conditions.
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1. If the HO2S is defective, abnormally high emissions may occur.
2. If the HO2S check results were normal, but the sensor output voltage is out of specification, check for the
following items (related to air fuel ratio control system):
A. Faulty injector
B. Air leaks in the intake manifold
C. Faulty volume air flow sensor, intake air temperature sensor, barometric pressure sensor, engine coolant
temperature sensor.
USING GST
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Check
Check conditions Engine state Test specification
Item
Oxygen Engine: Warm-up (make the mixture lean by When suddenly 200mV or lower
sensor engine speed reduction, and rich by racing) deceleration from 4,000
rpm
When engine is suddenly
600-1,000 mV
raced
Engine: Warm-up (using the heated oxygen Idle rpm 400 mV or lower -
sensor signal, check the air/fuel mixture ratio, (oscilate)
and also check the condition of control by 600-1,000 mV
the ECU)
2,000 rpm
INSPECTION
• Before checking, warm up the engine until the engine coolant temperature reaches 80 to 95°C (176 to 205°F).
• Use an accurate digital voltmeter.
1. Disconnect the oxygen sensor connector, and measure the resistance between terminal 3 and terminal 4.
Temperature °C (°F) Resistance (Ω)

400 (752) 30 or more
2. Replace the oxygen sensor if there is malfunction.

3. Apply battery voltage directly between terminal 3 and terminal 4.
Take care when applying the voltage. Damage will result if the terminals are incorrect or are short
circuited.
4. Connect a digital-type volmeter between terminal 1 and terminal 2.
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5. While repeatedly racing the engine, measure the oxygen sensor output voltage.
Oxygen sensor output
Engine Resistance (Ω)
voltage
Race Min. 0.6V 30 or more
6. If there is a problem, there may be an oxygen sensor malfunction.
Tightening torque
Heated oxygen sensor : 40-50 Nm (400-500 kg·cm, 29-36 lb·ft)
HARNESS INSPECTION PROCEDURES
Fuel System > Engine Control System > Crankshaft Position Sensor (CKPS) > Troubleshooting
Page 44 of 136
CRANKSHAFT POSITION SENSOR
The crankshaft position sensor senses the crank angle (piston position) of each cylinder and converts it into a pulse
signal. Based on the input signal, the ECM computes the engine speed and controls the fuel injection timing and
ignition timing.
Circuit Diagram
Circuit Diagram
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1. If unexpected shocks are felt during driving or the engine stalls suddenly, shake the crankshaft position sensor
harness. If this causes the engine to stall, check for poor sensor connector contact.
2. If the tachometer reads 0 rpm when the engine is cranked, check for faulty crank angle sensor, broken timing belt
or ignition system problems.
3. If the engine can be run at idle even if the crank angle sensor reading is out of specification, check the following:
A. Faulty engine coolant temperature sensor
B. Faulty idle speed control motor
C. Poorly adjusted reference idle speed
USING GST
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Check Item Check conditions Check content Normal state
Crankshaft position sensor • Engine cranking Compare cranking speed Indicated speed agree
• Tachometer connected and multi-tester reading
(Check on and off
ignition coil by
tachometer)
Check Item Check conditions Coolant temperature Test specification

Crankshaft position • Engine : Running at When -20°C (-4°F) 1,500-1,700 rpm
sensor idle When 0°C (32°F) 1.350-1,550 rpm
• Idle position switch :
ON When 20°C (68°F) 1,200-1,400 rpm
When 40°C (104°F) 1,000-1,200 rpm
When 80°C (176°F) 650-850 rpm
HARNESS INSPECTION PROCEDURE
HARNESS INSPECTION PROCEDURE <V6>

Page 47 of 136
Fuel System > Engine Control System > Camshaft Position Sensor (CMPS) > Troubleshooting
CAMSHAFT POSITION SENSOR
The CMP sensor senses the camshaft position sensor on compression stroke of the No.1 and No.4 cylinders,
converts it in to a pulse signal, and inputs it to the ECM. The ECM then computes the fuel injection sequence, etc.
based on the input signal.
Circuit Diagram
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Circuit Diagram
Page 49 of 136
HARNESS INSPECTION PROCEDURE [DOHC 2.4]

Page 50 of 136
If the CMP Sensor does not operate correctly, correct sequential injection is not made so that the engine may stall
or run irregularly at idle or fail to accelerate normally.
HARNESS INSPECTION PROCEDURE [V6]
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If the camshaft position sensor does not operate correctly, correct sequential injection is not made so that the
enginemay stall or run irregularly at idle or fail to accelerate normally.
Fuel System > Engine Control System > Barometric Pressure (BARO) Sensor > Troubleshooting
MANIFOLE ABSOLUTE PRESSURE SENSOR (MAP) SENSOR
The manifold differential pressure (MAP) sensor converts intake manifold pressure into a voltage signal. The engine
control module (ECM) uses this signal to determine the condition of the exhaust gas recirculation (EGR).
Circuit Diagram (2.4 DOHC)
USING VOLTMETER
Page 52 of 136
Check item Data display Check conditions Engien state Test specification
MAP sensor Inlet manifold · Engine coolant Idel 0.8-2.4V
pressure temperature: 18°C
(65.4°F)
· Lamps, electric
cooling fan,
accessory units: All When the accel. Rise from 0.8-2.4V
OFF. Pedal is depressed
· Transaxle: Neutral subbenly at idle
(P range for vehicle
with A/T)
· Steering wheel:
Neutral
HARNESS INSPECTION PROCEDUE
TROUBLESHOOTING PROCEDURES MAP SENSOR
The MIL (Malfunction indicator Lamp) is ON or the DTC(Diagnostic Trouble Code) is displayed on the HI-SCAN
under the following conditions :
1. When the manifold pressure is 4.5V or more for 4 second.
2. When the manifold pressure is 0.2V or lower for 4 second.
SENSOR INSPECTION MAP SENSOR
1. Connect the voltmeter between 1 and 4 of MAP sensor connector.
Terminal 1 : MAP sensor ground

Terminal 4 : MAP sensor ouput
2. Measure the voltage of terminals
Engien state Test specification

Ignition SW.
4-5V
ON.
At idle 0.8 - 2.4V
3. If the voltage deviatef from the standard value, replace the MAP sensor assembly.
Fuel System > Engine Control System > Idle Speed Control Actuator (InodeA) > Troubleshooting
IDLE SPEED CONTROL ACTUATOR
The idle speed control actuator is the double coil type and has two coils. The two coils are driven by separate driver
stages in the ECM. Depending on the pulse duty factor, the equilibrium of the magnetic forces of the two coils will
result in different angles of the motor. In parallel to the throttle valve, a bypass hose line is arrange, where the
Page 53 of 136
idlespeed, actuator is inserted in.
Circuit Diagram <2.4DOHC/V6>
Page 54 of 136
The MIL is ON or the DTC is displayed on the HI-SCAN under the following conditions;
• When the primary voltage side in ECM is in short or open circuit.
• The ignition closed loop control in ECM is out of order.
• Open or short circuit is observed in idle air control system when ignition switch is turned on.
USING HI-SCAN
Check Item Check condition HI-SCAN Type
display
Idle speed Start the engine ISCA Activate
control actuator
‍ Actuator

Page 55 of 136
ACTUATOR INSPECTION
1. Disconnect the connector at the idle speed control actuator.
2. Measure the resistance between terminals.
Standard value
Terminal 1 and 2 : 17.0-18.2Ω [at 20°C (68°F)]
Terminal 2 and 3 : 15.0-16.0Ω [at 20°C (68°F)]
3. Connect the connector to the idle speed control actuator
Fuel System > Engine Control System > Components and Components Location
MFI COMPONENT INSPECTION
LOCATION OF MAI COMPONENTS
Page 56 of 136
Page 57 of 136
ECT Sensor Power Steering Oil Pressure Switch
Vehicle Speed Sensor Ignition Timing Adjustment Terminal
EVAP Solenoid Valve MAP, TPS, ISA, TR

Page 58 of 136
CMP Sensor CKP
Data Link Connector Heated Oxygen Sensor (HO2S)
Transaxle Range (TR) Switch Injectors
Knock
Fuel System > Engine Control System > Troubleshooting

DIAGNOSTIC TROUBLESHOOTING FLOW
Page 59 of 136
INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODE (FOR 2.4 DOHC)

DTC Diagnostic items Trouble area MIL
P0101 Mass or Volume Air Flow • Dirty air cleaner O
Circuit Range/Performance • Air leak in intake
Problem system
• Vacuum leak in intake
system
• Improper PCV valve
• Contaminated,
deteriorated or
damaged MAFS
Page 60 of 136
• Faulty mass air flow
sensor or throttle
position sensor
• Poor connections at
ECM, MAFS, or TPS
P0102 Mass or Volume Air Flow • Open or short to O
Circuit Low Input ground between MAFS
and ECM
• Open or short to
ground between MAFS
battery power and
engine main relay
• Faulty MAFS
P0103 Mass or Volume Air Flow • Short to battery O
Circuit High Input between MAFS signal
and ECM
• Faulty MAFS
P0112 Intake Air Temperature • Open or short to O
Circuit Low Input battery between IATS
signal and ECM
• Open between IATS
ground and ECM
• Faulty IATS
P0113 Intake Air Temperature • Short to ground O
Circuit High Input between IATS signal
and ECM
• Faulty IATS
P0115 Engine Coolant • Open or short to O
Temperature Circuit ground between ECTS
Malfunction and ECM
• Short to battery
between ECTS and
ECM
• Short between ECTS
wires
• Faulty ECTS
P0116 Engine Coolant • After engine start-up, O
Temperature Sensor the elapsed time before
Circuit Range/Performance feedback operation is
Problem initiated is too long
(engine coolant
temperature sensor
input is insufficient for
closed loop operation)
• Poor connections
between ECTS and
ECM
Page 61 of 136
• Misplaced, loose or
corroded terminals
• Foreign materials
fouled, contaminated,
deteriorated ECTS
• Faulty ECTS
• Faulty thermostat
P0125 Insufficient Coolant • After engine start-up, O
Temperature For Closed the elapsed time before
Loop Fuel Control feedback operation is
initiated is too long
(engine coolant
temperature sensor
input is insufficient for
closed loop operation)
between ECTS and
ECM
corroded terminals
• Foreign materials
fouled, contaminated,
deteriorated ECTS
• Faulty ECTS
• Faulty thermostat
P0128 Coolant thermostat stuck • Thermostat stuck O
opened
P0121 Throttle Position Sensor • Poor connections O
Circuit Range/Performance between TPS and ECM
Problem • Misplaced, loose or
corrodes terminals
• Contaminated,
deteriorated TPS
• Faulty TPS
P0122 Throttle Position Sensor • Open or short to O
Circuit Low Input ground between TPS
reference power and
ECM
• Short to ground
between TPS signal and
ECM
• Faulty TPS
P0123 Throttle Position Sensor • Open or short to O
Circuit High Input battery between TPS
signal and ECM
• Open between TPS
ground and ECM
Page 62 of 136
• Faulty TPS
P0132 HO2S Circuit Open (Bank • Open or short to O
1, Sensor 1) battery between front
HO2S and ECM
• Short to ground
between front HO2S
and ECM
• Short between front
HO2S wires
• Faulty front HO2S
between front HO2S
and ECM
• Misplaced, bent, loose
or corroded connector
terminals
P0133 HO2S Circuit Slow • Abnormal combustion O
Responsive (Bank 1, • Improper fuel pressure
Sensor 1) • Front and rear HO2S
connections reversed
• Faulty fuel delivery
system
• Leak in intake system
• Leak in exhaust system
P0134 HO2S Circuit No Activity • Open or short between O
Detected (Bank 1, Sensor HO2S signal terminal
1) and ECM
• Contaminated,
deteriorated or aged
HO2S
terminals
P0135 HO2S Heater Circuit • Open or short to O
Malfunction (Bank 1, battery between front
Sensor 1) HO2S heater and ECM
• Short to ground
between front HO2S
heater and ECM
ground between front
HO2S heater and main
relay
• Incorrect front HO2S
heater resistance
Page 63 of 136
heater
P0136 HO2S Circuit Open (Bank • Open or short to O
1, Sensor 2) chassis ground between
rear HO2S and ECM
between rear HO2S
and ECM
• Short between rear
HO2S wires
terminals
• Faulty rear HO2S
P0139 HO2S Circuit Slow • Abnormal combustion O
Responsive (Bank 1, • Improper fuel pressure
Sensor 2) • Front and rear HO2S
connections reversed
system
P0140 HO2S Circuit Short (Bank • Open or short to O
1, Sensor 2) chassis ground between
rear HO2S and ECM
between rear HO2S
and ECM
• Short between rear
HO2S wires
terminals
P0141 HO2S Heater Circuit • Open or short to O
Malfunction (Bank 1, battery between rear
Sensor 2) HO2S heater and ECM
• Short to ground
between rear HO2S
heater and ECM
ground between rear
HO2S heater and main
relay.
• Incorrect rear HO2S
heater resistance
Page 64 of 136
heater
P0171 Fuel System Too Lean • Faulty fuel delivery O
(Bank 1) system
• Clogged fuel injectors
• Faulty fuel injectors
• Faulty MAFS
• Faulty TPS
P0172 Fuel System Too Rich • Faulty ignition system O
• EVAP canister purge
valve malfunction
system
- Clogged fuel injectors
- Faulty fuel injectors
- Fuel pressure too high
- Fuel pressure
regulator failure
• Faulty MAFS
• Faulty TPS
P0201 Cylinder 1 Injector Circuit • Open or short to O
Malfunction ground between main
relay and injectors
ground between ECM
and injectors
• Faulty fuel injector
relay and injectors
ground between ECM
and injectors
relay and injectors
ground between ECM
and injectors
Page 65 of 136
relay and injectors
ground between ECM
and injectors
P0300 Random Misfire Detected • Vacuum leak in air O
intake system
P0301 Cylinder 1 Misfire • CKPS circuit O
Detected malfunction
• Ignition circuit
P0302 Cylinder 2 Misfire malfunction O
Detected • Faulty ignition coil or
plug wire
• Spark plug malfunction
P0303 Cylinder 3 Misfire O
Detected • Low compression due
to blown head gasket,
leaking valve or piston
P0304 Cylinder 4 Misfire ring O
Detected
• Low/high fuel pressure
due to faulty pressure
P0305 Cylinder 5 Misfire regulator, restricted fuel -
Detected lines, plugged fuel filter
or faulty fuel pump
P0306 Cylinder 6 Misfire • Fuel injector circuit -
Detected malfunction Faulty fuel
injector
P0320 Ignition Failure Sensor • Open or short to ▲
circuit Malfunction ground between ignition
failure sensor and ECM
ground between ignition
failure sensor and
ignition coil
• Open between ignition
failure sensor and
ground
• Faulty ignition failure
sensor
P0325 Knock Sensor Circuit • Open or short to ▲
Malfunction (Bank 1) ground between knock
sensor and ECM
• Source of high
P0330 Knock Sensor Circuit resistance between -
Malfunction (Bank 2) knock sensor and ECM
• Faulty knock sensor
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P0335 Crankshaft Position Sensor • Open or short to O
Circuit Malfunction ground between CKPS
and ECM
between CKPS and
ECM
• Short between CKPS
wires
• Out of allowable air gap
• Faulty Target wheel
tolerance
• Faulty CKPS
P0340 Camshaft Position Sensor • Open or short to O
Circuit Malfunction ground between CMPS
and ECM
between CMPS and
ECM
• Short between CMPS
wires
• Poor connection
between CMPS
connector & harness
connector
• Faulty CMPS
P0342 Camshaft Position Sensor • Open or short to -
Circuit Low Input ground between CMPS
signal and ECM
ground between CMPS
reference power and
ECM
• Faulty CMPS
P0343 Camshaft Position Sensor • Short to battery -
Circuit High Input between CMPS signal
and ECM
• Open between CMPS
ground and ECM
• Faulty CMPS
pP0350 Ignition Coil • Open or short between O
Primary/Secondary Circuit ignition coil and ECM
Malfunction • Open or short between
ignition coil and spark
plug
• Short between ignition
coil wires
• Faulty ignition coil
Page 67 of 136
• Poor connection at
ignition coil
• Faulty ignition system
P0401 EGR System Malfunction • Blocked and/or leakage O
vacuum tube between
EGR control valve and
intake manifold vacuum
port
• Blocked and/or leakage
tube between EGR
solenoid valve and
intake manifold port
corroded terminals at
MAPS, EGR solenoid
valve
• Leakage in EGR control
valve
• Poor connection
vacuum tubes
• Stuck closed EGR
control valve
• Stuck open EGR
control valve
P0403 EGR System Solenoid • Open between EGR O
Valve Circuit Malfunction solenoid valve and
ECM
between EGR solenoid
valve and ECM
• Short to between EGR
solenoid valve wires
• Faulty EGR solenoid
valve
P0421 Main catalyst efficiency • Catalytic converter O
deterioration (Bank1) deteriorated
P0441 EVAP Emission Control • PSV stuck opened O
System Purge Control
Valve stuck opened
P0442 EVAP Emission Control • Fuel filler cap loose or O
System Small Leak missing
(1mm/0.5mm) • Fuel filler cap o-ring
missing or damaged
• Faulty or damaged fuel
filler pipe
Page 68 of 136
• Leaking, disconnected
or plugged fuel vapor
lines
• Fuel in lines due to
faulty rollover valve, on-
board refueling vapor
recovery valve or stuck
P0455 EVAP Emission Control closed CCV O
System Large Leak • Canister close valve
clogged, stuck open or
closed
• Improperly installed
purge solenoid valve
• PSV stuck open or
closed
• Faulty fuel tank
pressure sensor
• Leaking canister or
catch tank
P0443 EVAP Emission Control • Open or short between O
System Purge Control main relay and purge
Valve Circuit Malfunction solenoid valve
• Open or short between
purge solenoid valve
and ECM
• Faulty purge solenoid
valve
P0446 EVAP Emission Control • Open or short to O
System Vent Circuit ground between main
Malfunction relay and CCV
ground between CCV
and ECM
between CCV and
ECM
• Faulty CCV
P0451 EVAP Emission Control • Poor connections O
System Pressure Sensor between FTPS and
Range/Performance ECM
Problem • Misplaced, loose, bent
or corroded terminals
• Contaminated,
deteriorated or
damaged FTPS
• Faulty FTPS
• Stuck closed CCV
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• Blocked vapor hose
between canister and
CCV
System Pressure Sensor ground between FTPS
Low Input reference power and
ECM
• Short to ground
between FTPS signal
and ECM
• Faulty FTPS
System Pressure Sensor battery between FTPS
High Input signal and ECM
• Open between FTPS
ground signal and FTPS
• Faulty FTPS
P0460 Fuel Level Sensor Circuit • Open or short to O
Malfunction battery between FLS
and ECM
• Short to ground
between FLS and ECM
between FLS and ECM
• Misplaced, loose, bent
or corroded terminals
• Faulty FLS or FLS
stuck
P0500 Vehicle Speed Sensor • Open or short to O
Circuit Malfunction battery between VSS
and ECM
• Short to ground
between VSS and
ECM
VSS wires
• Faulty VSS
P0506 Idle Control System RPM • Open or short between O
Lower Than Expected main relay and IACV
ECM and IACV
• Intake system is
plugged
• Carbon fouled throttle
plate
• Faulty IACV
Page 70 of 136
P0507 Idle Control System RPM • Short to ground O
Higher than Expected between IACV and
ECM
• Air leak in intake
system
• Improperly adjusted
accelerator cable
• Faulty IACV
• Faulty TPS
• Faulty PCV/PSV
P0560 System Voltage • Open or short to O
Malfunction ground between ECM
and battery
• Reverse battery cable
connection (+/- reverse)
• ECM internal faulty
• Faulty Alternator
P1100 Manifold absolute pressure • Open or short to O
sensor-EGR System ground between MAPS
Open/Short and ECM
• Open between MAPS
and ECM
• Open between MAPS
and ground
• Faulty MAPS
P1102 Manifold absolute pressure • Poor connections O
sensor-EGR Mode 3 between MAPS and
ECM
corroded terminals
• Foreign materials fouled
MAPS
P1103 Manifold absolute pressure • Stuck closed EGR O
sensor-EGR Mode 2 control valve
• Stuck closed EGR
control valve
• Stuck open EGR
control valve
• Faulty MAPS
P1330 Spark Timing Adjustment • Short to GND between O
ROM change tool and
ECM
P1521 Power Steering Switch • Open between power O
Malfunction steering switch and
ECM
Page 71 of 136
• Short to ground
between power steering
switch and ECM
• Faulty power steering
switch
FUEL INJECTOR [2.4 DOHC]

The injectors injector fuel according to a signal coming from the ECM. The amount of fuel injected by the injectors is
determined by the time which the solenoid valve is energized.
Circuit Diagram
HARNESS INSPESTION
Page 72 of 136
Troubleshooting Hints
1. If the engine is hard to start when hot, check for fuel pressure and injector leaks.
2. If the injector does not operate when the engine is cranked, then check the followings;
A. Faulty power supply circuit to the ECM, faulty ground circuit
B. Faulty control relay
C. Faulty crankshaft position (CKP) sensor, camshaft position (CMP) sensor
3. If there is any cylinder whose idle state remains unchanged when the fuel injection of injectors is cut one after
another during idling, check for the following items about such cylinder.
A. Injector and harness
B. Ignition plug and high tension cable
C. Compression pressure
4. If the injection system is ok but the injector drive time is out of specification, check for the following items.
A. Poor combustion in the cylinder (faulty ignition plug, ignition coil, compression pressure, etc.)
B. Loose EGR valve seating
EVAPORATIVE EMISSION CANISTER PURGE SOLENOID VALVE
Page 73 of 136
• The evaporative emission canister purge solenoid valve is a duty control type, which controls purge air from the
evaporative emission canister
Circuit Diagram
Page 74 of 136
USING HI-SCAN
Check item Check conditions HI-SCAN display Type
Evaporative emission IG. S/W ON PCSV Activate
canister purge solenoid (Do not start)
valve
Actuator test
HARNESS INSPECTION
Page 75 of 136
POWER STEERING PRESSURE (PSP) SWITCH [2.4 DOHC]

• The power steering oil pressure switch senses the power steering load into low/high voltage and inputs it to
ECM, which then controls the idle speed control motor based on this signal.
Circuit Diagram
Page 76 of 136
Using HI-SCAN
Check Item Data display Check conditions Steering wheel Normal indication
Power steering oil Switch state Engine : Idling Steering wheel OFF
pressure switch neutral position
(wheels straightahead
direction)
Steering wheel half ON
turn
HARNESS INSPECTION
EGR SOLENOID VALVE

The EGR solenoid valve is a duty control type solenoid valve, which controls EGR valve operating negative pressure
to the throttle body a port.
Page 77 of 136
TROUBLESHOOTING HINT
If the results of EGR solenoid valve on-vehicle and off-vehicle inspections are normal, but the diagnostic trouble
code for EGR system failure is displayed, check the EGR valve, vacuum hose and EGR passage for blocking.
USING GST
Check Item Drive content Check conditions Standard value
EGR Solenoid Valve Change solenoid valve Ignition switch : ON Operating sound is heard
from OFF to ON state when driven

Page 78 of 136
CANISTER CLOSE VALVE

• The canister close valve is an ON/OFF type which controls the inner pressure of fuel tank caused by fuel
evaporation. Itis used to close the evaporative system and to observe tank pressure respectively with the fuel
tank pressure sensor.
Circuit Diagram
Page 79 of 136
HARNESS INSPECTION
VALVE INSPECTION
Refer to EC GROUP - Emission Control System
Page 80 of 136
FUEL TANK PRESSURE SENSOR

• The fuel tank pressure sensor is a pressure sensitive variable resistor that measures the change of pressure in the
fueltank to monitor for leaks. It is used in the EVAP leak test monitoring with the canister close and purge
solenoid valves.
Circuit Diagram
Page 81 of 136

Page 82 of 136
SENSOR INSPECTION
Refer to EC GROUP - Emission Control System
Page 83 of 136
Fuel System > Engine Control System > Repair procedures

FUEL FILTER REPLACEMENT [2.4 DOHC]
1. Reduce the internal pressure of the fuel lines and hoses and perform the following operations.
A. Disconnect the fuel pump harness connector in the trunk room.
B. Start the engine and, after it stops, turn the ignition switch to OFF.
C. Disconnect the battery negative (-) terminal.
D. Connect the fuel pump harness connector.
2. Remove the two fitting nuts while holding the fuel filter nuts securely.
Page 84 of 136
3. Remove the fuel filter mounting bolts, and then remove the fuel filter from the fuel filter clamp.
Tightening torque :
Fuel filter fitting nut : 25-35 Nm (250-350 kg·cm, 18-25 lb·ft)
THROTTLE BODY CLEANING
Disconnect the intake air hose from the throttle body, and check the throttle valve surface for carbon deposits.
Spray cleaning solvent on the valve to remove carbon deposits.
1. Warm up the engine, then stop it.
2. Remove the intake air hose from the throttle body.
3. Plug the bypass passage inlet of the throttle body.
Make sure the solvent does not enter the by-pass

passage.
4. Spray cleaning solvent onto the valve through the throttle body intake port and let it soak for about 5 minutes.
5. Start the engine, race it several times and allow the engine to idle for 1 minute.
6. Repeat Steps 4 and 5.
7. Unplug the bypass passage inlet.
8. Attach the intake air hose.
9. Disconnect the battery ground cable for more than 10 seconds.
10. Adjust the SAS (Speed Adjusting Screw)

Page 85 of 136
FUEL PUMP OPERATION CHECK [2.4 DOHC]

2. Apply battery voltage to the fuel pump drive connector to check that the pump operates.
The fuel pump is in-tank type and its operating sound is hard to hear without removing the fuel tank
cap.
3. Pinch the hose to check that fuel pressure is felt.
EVAP Canister Purge Port Vacuum Check [2.4 DOHC]

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

Page 86 of 136
1. Reduce the internal pressure of the fuel pipes and hoses by the following procedures.
A. Open the trunk door and disconnect the fuel pump harness connector in the trunk room.
B. Start the engine and after it stalls, turn the ignition switch to the OFF position.
C. Disconnect the battery negative (-) terminal.
D. Connect the fuel pump harness connector.
2. Remove the bolt connecting the fuel line to the fuel delivery pipe.
Cover the hose connection with a shop towel to prevent splashing of fuel caused by fuel residual pressure
in the fuel line.
3. Using the fuel pressure gauge adapter, install the fuel-pressure gauge to the fuel pressure gauge adaptor. Tighten
the bolt to the specified torque.
Fuel pressure gauge to fuel delivery pipe : 25-35 Nm (250-350 kg·cm, 18-26 lb·ft)
4. Connect the battery's negative (-) terminal.

5. Apply battery voltage to the terminal for the pump drive and activate the fuel pump: then, with fuel pressure
applied, check that there is no fuel leakage from the pressure gauge or connection part.
6. Start and run the engine at curb idle speed.
Page 87 of 136
7. Disconnect the vacuum hose from the pressure regulator, and plug the hose end. Measure the fuel pressure at
idle.
, 46-49 psi)
8. Measure the fuel pressure when the vacuum hose is connected to the pressure regulator.
, 37 psi)
9. If the results of the measurements made in steps (7) and (8) are not within the standard value, use the table below
to determine the probable cause, and make the necessary repairs.
Condition Probable cause Remedy
• Clogged fuel filter
• Fuel leakage to the return side, • Replace fuel filter
caused by poor seating of the fuel • Replace fuel pressure regulator
Fuel pressure is too low pressure regulator
• Low discharge pressure of the fuel • Check the in-tank fuel hose or
pump replace the fuel pump
• Sticking fuel-pressure regulator
• Replace fuel pressure regulator
Fuel pressure is toot high • Clogged or bent fuel return hose or
• Repair or replace hose or pipe
pipe
There is no difference in • Clogging, or damaged vacuum hose
• Repair or replace the vacuum hose or
fuel pressure when the or the nipple
the nipple
vacuum hose is connected • Sticking or poor seating of the fuel
• Repair or replace hose or pipe
and when it is not. pressure regulator
Page 88 of 136
10. Stop the engine and check for a change in the fuel pressure gauge reading, which should hold for approximately
5 minutes.
If the gauge indication drops, observe the rate of drop. Determine and remove the causes according to the
following table.
Condition Probable cause Remedy
Fuel pressure drops slowly after
• Injector leakage • Replace injector
engine is stopped
Fuel pressure drops immediately • The check valve within the fuel
• Replace fuel pump
after engine is stopped pump is open
11. Reduce the pressure in the fuel line.

12. Disconnect the hose and the gauge.
Cover the hose connection with a shop towel to prevent splashing of fuel caused by fuel residual pressure
in the fuel line.
13. Replace the O-ring of the end of the hose.
14. Connect the fuel hose to the delivery pipe and tighten with the specified.
15. Check for fuel leakage.
Fuel System > Fuel Delivery System > Fuel Tank > Components and Components Location
COMPONENTS
Page 89 of 136
Fuel System > Fuel Delivery System > Fuel Tank > Repair procedures
REMOVAL
Page 90 of 136
1. To reduce the internal pressure of the fuel main pipes and hose, first start the engine and then disconnect the
electrical fuel pump connector in the rear seat side.
Be sure to reduce the fuel pressure before disconnecting the fuel main pipe and hose, otherwise fuel will
spill out, leading to the risk of fire or explosion.
2. Disconnect the battery cable from the negative terminal of the battery.
3. Remove the fuel tank cap.

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

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

Page 91 of 136
9. Remove the fuel vapor hose and the fuel tank.
INSTALLATION
1. Connect the leveling hose to the tank and approximately 40 mm (1.6 in.) at the filler neck.
2. When connecting the filler hose, connect the end with the shorter straight pipe to the tank side.
3. Confirm that the pad is fully bonded to the fuel tank. Install the fuel tank by tightening the self-locking nuts to
thetank bands until the rear end of the tank band contacts the body.
4. Connect the vapor hose and return hose. Attach the fuel hose to the line as shown in the illustration.
Page 92 of 136
5. To connect the high pressure hose to the fuel pump, temporarily tighten the flare nut by hand, and then tighten it to
the specified torque. Be careful that the fuel hose does not twist.
Tightening torque :
High pressure hose flare nut : 30-40 Nm (300-400 kg·cm, 22-29 lb·ft)
When tightening the flare nut, be careful not to bend or twist the line to prevent damage to the fuel pump
connection.
6. Connect the electrical fuel pump and fuel sender connector.
INSPECTION
1. Check the hoses and the pipes for cracks or damage.
2. Check the fuel tank cap for proper operation.
3. Check the fuel tank for deformation, corrosion or cracking.
4. Check the fuel tank inside for dirt or foreign material.
5. Check the in-tank fuel filter for damage or restriction.
6. Test the two-way valve for proper operation.
7. Using a vacuum hand pump, check the operation of the two-way valve.
Valve pump Guide lines for acceptance or
rejection
When connected to inlet side Negative pressure generated and vacuum
maintained
When connected to outlet side No negative pressure generated
Page 93 of 136
Fuel System > Fuel Delivery System > Injector > Repair procedures
INSPECTION
1. Measure the resistance of the injectors between the terminals using an ohmmeter.
Resistance : 13-16 Ω [at 20°C (68°F)]
2. If the resistance is not within specifications, replace the injector.
Fuel System > Fuel Delivery System > Accelerator Pedal and Cable > Components and Components
Location
COMPONENTS
Page 94 of 136
COMPONENTS
Page 95 of 136
Fuel System > Fuel Delivery System > Accelerator Pedal and Cable > Repair procedures
REMOVAL
1. Remove the bushing and inner cable of the accelerator arm side.
2. Pull the left side of the accelerator pedal toward you, and then remove the accelerator pedal from the accelerator
arm.
3. Loosen the bolts of the accelerator arm bracket and remove.
INSTALLATION
Page 96 of 136
1. When installing the return spring and accelerator arm, apply multi-purpose grease around each moving point of
the accelerator arm.
2. Apply sealant to the bolt mounting hole, and tighten the accelerator arm bracket.
Tightening torque : Accelerator arm bracket bolts : 8-12 Nm (80-120 kg·cm, 6-7 lb·ft)
3. Securely install the resin bushing of the accelerator cable on the end of the accelerator arm.
INSPECTION
1. Check the inner and outer cable for damage.
2. Check the cable for smooth movement.
3. Check the accelerator arm for deformation.
4. Check the return spring for deterioration.
5. Check the connection of the bushing to end metal fitting.
6. Check the accelerator proper operation.
It is essential that there is no binding or any interference with the operation of the throttle parts. A jammed
or stuck throttle can cause accidents, severe injury or death.
Fuel System > Fuel Delivery System > Fuel Line > Components and Components Location
COMPONENTS
Page 97 of 136
COMPONENTS
Page 98 of 136
COMPONENTS
Page 99 of 136
Fuel System > Fuel Delivery System > Fuel Line > Repair procedures
REMOVAL
1. Release residual pressure from the fuel line to prevent fuel spilling.
Cover the hose connection with rags to prevent splashing of fuel that could be caused by residual pressure
in the fuel line.
2. Remove the delivery pipe with the fuel injector and pressure regulator.
INSTALLATION
1. Install a new grommet and O-ring to the injector.
2. Apply a coating of solvent, spindle oil or gasoline to the injector O-ring.
3. While turning the injector to the left and right, install it on to the delivery pipe.
Page 100 of 136
4. Be sure the injector turns smoothly.
If injector does not turn smoothly, the O-ring may be jammed. Remove the injector and re-insert it into the
delivery pipe and re-check.
Installation
1. Install the fuel vapor hose and return hoses.
A. If the fuel line has a stepped section, connect the fuel hose to the line securely, as shown in the illustration.
B. If the fuel line does not have a stepped section, connect the fuel hose to the line securely.
INSPECTION
1. Check the hoses and pipes for cracking, bending, deformation or restrictions.
2. Check the EVAP Canister for restrictions.
3. Check the fuel filter for restrictions and damage.
Fuel System > Troubleshooting > P0101

TROUBLESHOOTING (FOR 2.4 DOHC)
Mass or volume air flow circuit range/performance problem
P0101
Related items · Dirty air cleaner
· Air leak in intake system
· Contaminated, deteriorated or damaged MAFS
· Poor connections at ECM, MAFS, or TPS
· Faulty MAFS or TPS
If any codes relating to MAFS or TPS are present, do all repairs

associated with them before this troubleshooting procedure.

connector or OBD-II check connector.
Page 101 of 136
Yes
Turn ignition to ON and monitor other before proceeding this procedure.
1
DTCs.
Is DTC P0102, P0103, P0121, P0122, or No Go to step 2.
P0123 set?
Using SCAN TOOL monitor MAFS Problem is intermittent or was repaired and
voltage signals. engine control module memory was not
Yes
2 · 1.4~1.6V @ idle cleared. Check terminal connections at
· 1.6~2.2V @ 3000rpm ECM and MAFS.
Is signal within specifications? No Go to step 3.
Thoroughly check MAFS for loose, poor
Yes Go to step 4.
connection, bent, corrosion, contamination,
3
deterioration, or damage.
No Clean or repair as necessary.
Is MAFS okay?
engine reaches operating temperature. Yes Go to step 5.
Using SCAN TOOL, monitor TP voltage
4 signals.
· 0.3~0.9V @ idle Do all repairs associated with TPS before
· 4.0~4.6V @ full open No
proceeding the next step.
Is signal with in specifications?
Turn ignition switch to OFF and disconnect
MAFS connector. Yes Go to step 6.
Turn ignition switch to ON and measure
voltage of MAFS power circuit between Open circuit or short circuit to chassis
5
MAFS harness connector and chassis ground between MAFS harness connector
ground. No
and ECM connector.
· Specification : approximately 5V Repair as necessary.
connector.
Measure resistance of MAFS signal circuit Yes Go to step 7.
between MAFS harness connector and
ECM harness connector.
6 Measure resistance of MAFS ground circuit
between MAFS harness connector and Open circuit between MAFS harness
ECM harness connector. No connector and ECM harness connector.
· Specification : below 1Ω Repair as necessary.
circuit?
ECM connector and MAFS connector is
still disconnected. Yes Go to step 8.
Turn ignition to ON.
Measure voltage of MAFS signal circuit
7
between MAFS harness connector and Short circuit to battery MAFS harness
ECM chassis ground. No connector and ECM harness connector.
· Specification : below 0.5V Repair as necessary.
Does voltage within specification?
Page 102 of 136
ECM connector and MAFS connector is Temporarily install a known good MAFS
still disconnected. Yes and check for proper operation.
Turn ignition to OFF. If problem is corrected, replace MAFS
Measure resistance between MAFS harness
connector and chassis ground at MAFS
signal circuit. MAFS harness connector and ECM harness
No
· Specification : infinite connector.
Check air cleaner for dirt, blockage, or Yes Go to step 11.
9 damage.
Is air cleaner okay? No Repair or replace as necessary.
Check entire air intake system for leaks or
blockages such as;
· Throttle body Temporarily install a known good MAFS
· PCV valve Yes and check for proper operation.
· Intake manifold If problem is corrected, replace MAFS
10
tank
injectors
· Seal between surge tank and PCV pipe No Repair or replace as necessary.
· Etc
Is entire air intake system okay?
11

TROUBLESHOOTING
Diagnostic trouble code No. P0102 Mass or volume air flow circuit low input
Diagnostic trouble code No. P0103 Mass or volume air flow circuit high input
Related items · Open between MAFS and engine main relay
· Open or short to chassis ground between
MAFS and ECM
· Short to battery between MAFS and ECM
· Faulty MAFS
Page 103 of 136
Turn ignition to ON and monitor MAFS Yes
voltage signals. ECM and MAFS.
· Specification : 1.4~1.6V @ idle
Is signal within specification? No Go to step 2.
MAFS connector. Yes Go to step 3.
Turn ignition switch to ON.
Measure voltage of MAFS reference 5V Open circuit or short circuit to chassis
2
circuit between MAFS harness connector ground between MAFS harness connector
and chassis ground. No
and ECM connector.
connector.
Measure resistance of MAFS signal circuit Yes Go to step 4.
between MAFS harness connector and
3 Measure resistance of MAFS ground circuit
between MAFS harness connector and Open circuit between MAFS harness
circuit?
ECM connector and MAFS connector is
still disconnected. Yes Go to step 5.
Measure voltage at MAFS signal circuit Short circuit to battery between MAFS
4
between MAFS harness connector and harness connector and ECM harness
chassis ground. No
connector.
· Specification : below 0.5V Repair as necessary.
Does voltage within specification?
ECM connector and MAFS connector is Temporarily install a known good MAFS
Turn ignition to OFF. If problem is corrected, replace MAFS
Measure resistance between MAFS harness
connector and chassis ground at MAFS Short circuit to chassis ground between
5 MAFS harness connector and ECM harness
signal circuit.
Measure resistance between MAFS signal connector.
No
circuit Short circuit between MAFS signal circuit
· Specification : infinite and ground circuit.
Does each resistance indicate open circuit? Repair as necessary.
6
Page 104 of 136
TROUBLESHOOTING
Intake air temperature circuit low input
No. P0112
Intake air temperature circuit high input
No. P0113
Related items · Open or short to chassis ground between IATS and main relay
· Open or short to chassis ground between IATS and ECM
· Short to battery between IATS and ECM
· Short between IATS wires
· Faulty IATS

1 Turn ignition to ON and monitor other
DTCs.
Is DTC P0102 or P0103 set? No Go to step 2.

engine reaches operating temperature. Problem is intermittent or was repaired and
Using SCAN TOOL and monitor IAT engine control module memory was not
Yes
voltage signals. cleared. Check terminal connections at
2 · 2.3~2.9V (2.22~2.82 kΩ) @ 20°C ECM and MAFS.
(68°F)
· 0.4~1.0V (0.29~0.36 kΩ) @ 80°C
Turn ignition to OFF and disconnect IATS
Yes Go to step 4.
connector.
Turn ignition to ON, measure voltage of
3 IATS battery power circuit between IATS Open circuit or short circuit to chassis
ground between IATS harness connector
· Specification : approximately B+ and ECM main relay.
Is voltage within specifications?
IATS connector and ECM connector.
Yes Go to step 4.
Measure resistance of IAT signal circuit
between IATS harness connector and ECM
harness connector.
4 Measure resistance of IAT ground circuit
between IATS harness connector and ECM Open circuit or short circuit to chassis
ground between IATS harness connector
harness connector. No
· Specifications : below 1Ω and ECM main relay.
circuit?
ECM connector and IATS connector is still
Page 105 of 136
ECM connector and IATS connector is still
disconnected. Yes Go to step 6.
Measure voltage at IATS signal circuit Short circuit to battery between IATS
5
between IATS harness connector and harness connector and ECM harness
chassis ground. No
connector.
Specifications : below 0.5V Repair as necessary.
Does vlotage within specification?
Ignition OFF, IATS connector and ECM Yes Go to step 7.
connector is still disconnected.
Measure resistance between IATS signal
circuit and IATS ground circuit. Short circuit between IATS signal circuit and
ground circuit.
6 Measure resistance between IATS harness
Short circuit to chassis ground between
connector and chassis ground at IATS signal No
IATS harness connector and ECM harness
circuit.
connector.
· Specification : infinite
Does resistance indicate open circuit?
7

TROUBLESHOOTING
No. P0115
Related items · Open or short to battery between ECTS and ECM
· Short to chassis ground between ECTS and ECM
· Short between ECTS wires
· Faulty ECTS

Using SCAN TOOL and monitor ECT engine control module memory was not
Yes
1 ECM and ECTS.
· 2.3~2.9V (2.31~2.59kΩ) @ 20°C (68°F)
· 0.4~1.0V (0.31~0.33kΩ) @ 80°C
Turn ignition to OFF and disconnect ECTS Yes Go to step 3.
voltage of ECTS reference power circuit
2 between ECTS harness connector and
ground between ECTS harness connector
chassis ground. No
and ECM harness connector.
· Specification : approximately 5V
Page 106 of 136
connector.
Measure resistance of ECTS ground circuit Yes Go to step 4.
between ECTS harness connector and ECM
harness connector.
3 Measure resistance of ECTS signal circuit
between ECTS harness connector and ECM Open circuit between ECTS harness
circuit?
Turn ignition to ON> Yes Go to step 5.
Measure voltage of ECTS signal circuit
between ECTS harness connector and Short circuit to battery between ECTS
chassis ground. No
· Specification : below 0.5V connector.
Ignition OFF, ECTS connector and ECM Temporarily install a known good ECTS and
connector is still disconnected. Yes check for proper operation.
Measure resistance between ECTS signal If problem is corrected, replace MAFS
circuit and ECTS ground circuit. Short circuit between ECTS signal circuit
5 Measure resistance between ECTS harness and ground circuit.
connector and chassis ground at ECTS Short to chassis ground between ECTS
signal circuit. No
harness connector and ECM harness
6

TROUBLESHOOTING
Engine coolant temperature circuit
Diagnostic trouble code No. P0116
range/performance problem
Insufficient coolant temperature for closed loop
Diagnostic trouble code No. P0125
fuel control
Related items · After engine start-up, the elapsed time before
feedback operation is initiated is too long (engine
coolant temperature sensor input is insufficient for closed
operation)
· Poor connections between ECTS and ECM
· Foreign materials fouled, contaminated, deteriorated
ECTS
· Faulty ECTS
· Faulty thermostat
Page 107 of 136
If any codes relating to ECTS are present, do all

repairs associated with them before this
troubleshooting procedure.

connector or OBD-II check connector Yes
DTCs.
No Go to step 2.
Is DTC P0115 set?
Using SCAN TOOL and monitor ECT engine control module memory was not
Yes
2 · 2.3~2.9V (2.31~2.59 kΩ) @ 20°C ECM and ECTS.
(68°F)
· 0.4~1.0V (0.31~0.33 kΩ) @ 80°C
Check ECTS for contaminaltion, Clean ECTS with cleaner before insalling. If
3 ECTS is damaged or deteriorated, replace.
Is ECTS contaminated, deteriorated or
damaged? No Go to step 4.
corroded connectors at ECM connector and Yes Go to step 5.
ECTS connector.
With ignition OFF, disconnect ECM
connector and ECTS connector.
4
Measure resistance of all two circuits
Open circuit between ECTS harness
between ECTS harness connector and
chassis ground No connector and ECM harness connector.
Does each indicate continuity circuit?
5

TROUBLESHOOTING
Page 108 of 136
No. P0121
Related items · Open or short to chassis ground between TPS and ECM
· Short to battery between TPS and ECM
· Misplaced, loose or corrodes terminals
· Contaminated, deteriorated TPS
· Faulty TPS

DTCs.
No Go to step 2.
Is DTC P0122, or P0123 set?
Problem is intermittent or was reapired and
engine reaches operating temperature. engine control module memory was not
Using SCAN TOOL, monitor TP voltage Yes
cleared. Check terminal connections at
2 signals.
ECM and ECTS.
· 0.3~0.9V @ idle
· 4.0~4.6V @ full open
No Go to step 3.
Ignition ON and engine OFF. engine control module memory was not
Yes
Using SCAN TOOL and monitor TP cleared. Check terminal connections at
3 voltage signals while slowly opening the ECM and TPS.
throttle. Temporarily install a known good TPS and
Does voltage signal increase? No check for proper operation. If problem is
corrected, replace TPS.
Turn ignition to OFF and disconnect TPS
Yes Go to step 5.
connector.
4 TPS reference voltage between TPS harness Open circuit or short circuit to chassis
ground between TPS harness connector and
connector and chassis ground No
ECM connector.
Temporarily install a known good TPS and
Yes check for proper operation.
Thorughly check TPS for loose, poor If problem is corrected, replace TPS
connection, bent, corrosion, contamination, Clean TPS with cleaner before installing. If
5
deterioration, or damage. damaged or deteriorated, temporarily install
Is TPS okay? No a known good TPS and check for proper
operation.
If problem is corrected, replace TPS.
6
Page 109 of 136

TROUBLESHOOTING
Diagnostic trouble code No. P0122 Throttle position sensor circuit low input
Diagnostic trouble code No. P0123 Throttle position sensor circuit high input
Related items · Open or short to chassis ground between TPS
and ECM
· Short to battery between TPS and ECM
· Short between TPS wires
· Faulty TPS

engine reaches operating temperature.
engine control module memory was not
Using SCAN TOOL, monitor TP voltage Yes
cleared. Check terminal connections at
1 signals. ECM and ECTS.
· 0.3~0.9V @ idle
· 4.0~4.6V @ full open
No Go to step 2.
Turn ignition to OFF and disconnect TPS
Yes Go to step 3.
connector.
2 TPS reference voltage between TPS harness
connector and chassis ground. ground between TPS harness connector and
No
ECM connector.

connector.
Measure resistance of TPS ground circuit Yes Go to step 4.
between TPS harness connector and ECM
harness connector.
3 Measure resistance of TPS signal circuit
between TPS harness connector and ECM Open circuit between TPS harness
circuit?
Yes Go to step 5.
Measure voltage of TPS signal circuit
between TPS harness connector and chassis
4 Short circuit to battery between TPS harness
ground.
No connector and ECM harness connector.
· Specification : below 0.5V
Ignition OFF, TPS connector and ECM Temporarily install a known good TPS and
connector is still disconnected. Yes check for proper operation.
Measure resistance between TPS signal If problem is corrected, replace MAFS
Page 110 of 136
circuit and ground circuit. Short circuit between TPS signal circuit and
5 Measure resistance between TPS harness ground circuit.
connector and chassis ground at TPS signal Short to chassis ground between TPS
circuit. No
6

TROUBLESHOOTING
HO2S circuit open (bank1, sensor1)
No. P0132
Related items · Open or short to battery between front HO2S and ECM
· Short to chassis ground between front HO2S and ECM
· Short between front HO2S wires
· Fauity front HO2S
· Poor connections between front HO2S and ECM
· Misplaced, bent, loose or corroded terminals

DTCs.
Are any other cods set? No Go to step 2.
Warm up engine to normal operating Problem is intermittent or was repaired and

temperature for more than 10 minutes. engine control module memory was not
Using SCAN TOOL, monitor HO2S signal Yes
wavefrom. ECM and HO2S.
Does the HO2S signal switch lean to rich or
rich to lean over 6 times for 10 seconds? No Go to step 3.
connector and HO2S connector.
Measure resistance of HO2S ground circuit Yes Go to step 4.
between HO2S harness connector and
3 Measure resistance of HO2S signal circuit
between HO2S harness connector and Open circuit between HO2S harness
circuit?
Measure voltage of HO2S signal circuit
Page 111 of 136
between HO2S harness connector and Short circuit to battery between HO2S
chassis ground. No
Ignition OFF, HO2S connector and ECM Yes Go to step 6.
Measure resistance between HO2S signal
circuit and ground circuit. Short circuit between HO2S signal circuit
5 Measure resistance between HO2S harness and ground circuit.
Short to chassis ground between HO2S
connector and chassis ground at HO2S No
signal circuit. harness connector and ECM harness
Clean HO2S with cleaner before installing. If

damaged or deteriorated, temporarily install
Yes a known good HO2S and check for proper
Thoroughly check HO2S for contamination, operation.
deterioration or damage. If problem is corrected, replace HO2S.
6
Is HO2S contaminated, deteriorated or Verify ECM and HO2S connectors are
damaged? secure. If connectors are okay, temporarily
No install a known good HO2S and check for
proper operation.
If problem is corrected, replace HO2S.
7

TROUBLESHOOTING
HO2S circuit slow responsive (bank1, sensor1)
P0133
Related items · Abnormal combustion
· Improper fuel pressure
· Front and rear HO2S connections reversed
· Fauity fuel delivery system
· Leak in intake system
· Leak in exhaust system
· Faulty front HO2S
If any misfire, purge solenoid valve, MAFS or HO2S heater codes are
present, do all repairs associated with those codes before proceeding this
Page 112 of 136
DTCs.
Are any other cods set? No Go to step 2.
Visually check for leak from exhaust system

Yes Repair intake system leaks as necessary.
(especially between TWC converter and
2
front exhaust pipe).
Are any leaks present? No Go to step 3.
Visually check for leak from intake system. Yes Repair exhaust system leaks as necessary.
3
Are any vacuum leaks present? No Go to step 4.
Start engine after installing fuel pressure Temporarily install a known good HO2S
gauge at service valve in fuel rail. Yes and check for proper operation. If problem
With engine running at operating is corrected, replace HO2S.
4 temperature, is fuel pressure within If measured pressure is too high : Go to
specification? step 5
Fuel pressure at idle : 46~49 psi No
If measured pressure is too low : Go to
(320~340kPa, 3.26~3.47 kg/cm²) step 6
Disconnect return line hose from fuel filter. Check for blockage in return line, clean or
Yes
5 Blow through line towards tank. replace as necessary.
Is return line restricted? No Repair pressure regulator
Yes Replace fuel delivery module.
Clamp a return line from fuel filter and check
6 if pressure rises. Check fuel filter at fuel pump. If it is OK,
Do fuel pressure rise? No measure fuel pump maximum pressure and
repair as necessary.
7

TROUBLESHOOTING
HO2S circuit no activity detected (bank1, sensor 1)
P0134
Related items · Open or short between front HO2S signal terminal and ECM
· Contaminated, deteriorated or aged front HO2S
· Misplaced, bent, loose or corroded connector terminals
If any misfire, purge solenoid valve or HO2S heater codes are present, do
all repairs associated with those codes before proceeding this
troubleshooting procedure
Page 113 of 136

1 Turn ignition to ON and monitor any other
DTC.

Yes
2 Using SCAN TOOL monitor HO2S signal. cleared. Check terminal connections at
Does the HO2S signal switch lean to rich or ECM and HO2S.
circuit?
chassis ground. No
Ignition OFF, HO2S connector and ECM
Yes Go to step 6.
Measure resistance between HO2S signal
Short circuit between HO2S signal circuit
circuit and ground circuit.
5 Measure rsistance between HO2S harness and ground circuit.
Short to chassis ground between HO2S
connector and chassis ground at HO2S No
signal circuit. harness connector and ECM harness
Does resistance indicate open circuit?
Thorughly check HO2S for contamination, operation.
6
damaged? secure. If OK, temporarily install a known
No good HO2S and check for proper
operation.
Page 114 of 136
If problem is corrected, replace HO2S
7
8

TROUBLESHOOTING
No. P0135
Related items · Open or short to battery between front HO2S heater and ECM
· Short to chassis ground between front HO2S heater and ECM
· Incorrect front HO2S heater resistance
· Faulty front HO2S heater

Visually inspect the HO2S circuit for Repair any concerns found in the visual
exposed wiring, contamination, corrosion Yes
inspection.
1 and proper installation.
Were any concems found during the visual
inspection? No Go to step 2.
Yes Go to step 3.
connector or OBD-II check connector. Problem is intermittent or was repaired and
2 engine control module memory was not
Turn ignition to ON and monitor DTCs. No
Is DTC P0135 also set? cleared. Check terminal connections at
ECM and HO2S
HO2S connector.
Yes Go to step 4.
Start engine and allow an engine to idle until
ECT reaches operating temperature.
Measure voltage of HO2S heater battery
3
voltage between HO2S heater battery
voltage between HO2S harness connector
No ground between main relay and HO2S
and chassis ground.
harness connector.
Is measured voltage within specification?
connector and HO2S connector. Yes Go to step 5.
Measure resistance of HO2S heater signal
circuit between HO2S harness connector Open circuit or short circuit to chassis
4
and ECM harness connector. ground between TPS harness connector and
· Specification : below 1Ω No
ECM connector.
Page 115 of 136
Does each resistance indicate continuity Repair as necessary.
circuit?
Measure resistance between HO2S heater Yes Go to stpe 6.
signal and battery power terminal. Temporarily install a known good HO2S
5
· 3.0~6.2 Ω at 20°C (68°F) No and check for proper operation.
Is measured resistance within specification? If problem is corrected, replace HO2S.
6

TROUBLESHOOTING
HO2S circuit open (bank1, sensor2)
No. P0136
Related items · Open or short to chassis ground between rear HO2S and ECM
· Short to battery between rear HO2S and ECM
· Short between rear HO2S wires
· Faulty rear HO2S

DTCs.
No Go to step 2.
Are any other codes set?
Does the HO2S signal switch lean to rich or
circuit?
Yes Go to step 6.
Measure voltage of HO2S signal circuit Short circuit between HO2S signal circuit
Page 116 of 136
between HO2S harness connector and and ground circuit.
4 Short to chassis ground between HO2S
chassis ground. No
· Specification : below 0.5V harness connector and ECM harness
Is voltage within specifications? connector.
Yes Go to step 6.
Ignition OFF, HO2S connector and ECM
connector is still disconnected. Short circuit between HO2S signal circuit
Measure resistance between HO2S signal and ground circuit.
circuit and ground circuit. No
· Specification : infinite harness connector and ECM harness
Does resistance indicate open circuit? connector.
Thoroughly Check HO2S for contamination, operation.
6
proper operation.
7

TROUBLESHOOTING
Diagnostic trouble code No. P0139 HO2S circuit slow responsive (bank1, sensor2)
Related items · Abnormal combustion
· Improper fuel pressure
· Front and rear HO2S connections reversed
· Faulty fuel delivery system
· Faulty rear HO2S
If any misfire, purge solenoid valve, MAFS or

HO2S heater codes are present, do all repairs
associated with those codes before proceeding this
troubleshooting guide.
Page 117 of 136
DTCs.

2
Visually check for leak from intake system. Yes Repair exhaust system liaks as necessary.
3
Are any vacuum leaks present? No Go to step 4.
Start engine after installing fuel pressure Temporarily install a known good HO2S
gauge at service valve in fuel rail. Yes and check for proper operation. If problem
With engine running at operating is corrected, replace HO2S.
4 temperature, is fuel pressure within If measured pressure is too high : Go to
specification? step 5
Fuel pressure at idle : 46~49 psi No
If measured pressure is too low : Go to
(320~340kPa, 3.26~2.47 kg/cm²) step 6
Disconnect ruturn line hose from fuel filter. Check fuel filter line, clean or replace as
Yes
5 Blow through line towards tank. necessary.
Is return line restricted? No Repair pressure regulator
Yes Replace fuel delivery module.
Clamp a return line from fuel filter and check
6 if pressure rises. Check fuel filter at fuel pump. If it is OK,
Do fuel pressure rise? No measure fuel pump maximum pressure and
repair as necessary.
7

TROUBLESHOOTING
HO2S circuit short (bank1, sensor2)
No. P0140
Related items · Open or short to chassis ground between rear HO2S and ECM
· Short to battery between rear HO2S and ECM
· Short between rear HO2S wires
· Faulty rear HO2S

Page 118 of 136
DTCs.
No Go to step 2.
Are any other codes set?
Does the HO2S signal switch to rich or rich
to lean over 6 times for 10 seconds? No Go to step 3.
circuit?
chassis ground. No
Ignition OFF, HO2S connector and ECM Yes Go to step 6.

connector is still disconnected. Short circuit between HO2S signal circuit
Measure resistance between HO2S harness and ground circuit.
5 connector and chassis ground at HO2S Short to chassis ground between HO2S
signal circuit. No
Thoroughly check HO2S for contamination, operation.
6
proper operation.
7

Page 119 of 136
TROUBLESHOOTING
Diagnostic trouble code No. P0141 HO2S heater circuit malfunction (bank1, sensor2)
Related items · Open or short to battery between rear HO2S heater
and ECM
· Short to Short to chassis ground between rear HO2S
heater and ECM
· Incorrect rear HO2S heater resistance
· Faulty rear HO2S heater

Visually inspect the HO2S circuit for
exposed wiring, contamination, corrosion Yes
1 and proper installation.
Were any concerns found during the visual
inspection? No Go to step 2.

Connect SCAN TOOL to data link engine control module memory was not
Turn ignition to ON and monitor DTCs. ECM and HO2S.
Is DTC P0141 also set?
No Go to step 3.
HO2S connector. Yes Go to step 4.
Start engine and allow an engine to idle until
ECT reaches operating temperature.
3 Measure voltage of HO2S heater battery
voltage between HO2S harness connector Open circuit between HO2S harness
and chassis ground. No connector and ECM harness connector.
· Specification : approximately B+ Repair as necessary.
connector and HO2S connector. Yes Go to step 5.
Measure resistance of HO2S heater signal
circuit between HO2S harness connector Short circuit to battery between HO2S
4
and ECM harness connector. harness connector and ECM harness
· Specification : below 1Ω No
connector.
circuit?
Yes Go to step 6.
Measure resistance between HO2S heater Short circuit between HO2S signal circuit
signal and battery power terminal. and ground circuit.
· 3.0~6.2Ω at 20°C (68°F) No
Is measured resistance within specification? harness connector and ECM harness
connector.
6
Page 120 of 136

TROUBLESHOOTING
Fuel system too lean (bank1)
P0171
Related items · Faulty fuel delivery system
· Clogged fuel injectors
· Faulty fuel injectors
· Faulty MAFS
· Faulty TPS
If any codes relating to injectors, HO2S, ECTS or MAFS are stored, do

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

Using SCAN TOOL, monitor short-term
and longterm on fuel trim data. Yes engine control module memory was not
· Short-term : -12.5~12.5 cleared.
2
· Long-term : -10~10
Is short-term and long-term within the
No Go to step 3.
specifications indicated?
Visually/physically inspect the following items
:
· Throttle body gasket
Yes Go to step 4.
tank
3
injectors
· Crankcase ventilation valve and/or system
No Repair or replace as necessary.
for leaks
· Contaminated fuel
Visually/physically inspect the following
items: Yes Go to step 5.
· Air cleaner element for being restricted.
4 · MAFS for proper installation and foreign
Page 121 of 136
objects
· Exhaust system for leaks No Repair or replace as necessary.
Check vacuum hoses for splits and proper
connections to engine dynamic chamber Yes Go to step 6.
5 (especially PSV, ISC hose, throttle body,
intake manifold, and brake booster). No Repair or replace as necessary.
Are connections OK?
With engine idling disconnect hose between EVAP canister purge valve or circuit failure.
EVAP valve and canister. Check for vacuum Yes Repair according to DTC P0443 repair
6 procedures.
at EVAP valve is vacuum available at purge
valve when EVAP valve is not operating? No Go to step 7.
Yes Go to step 8.
Low pressure :
Clamp return-line and check if pressure rises
:
After installing fuel pressure gauge to service - If pressure rises : replace pressure
port on fuel rail, connect DLC F/P and regulator
B(B+) with a jumper wire. - If pressure does not rise : check the
7 · Fuel pressure at idle : 46~49 psi strainer at the fuel pump.
(320~340kPa, 3.26~3.47 kg/cm²) No High pressure :
Is fuel line pressure correct with ignition Disconnect return-line from fuel filter side
switch ON? and blow through line towards tank.
- If line is clear : replace fuel delivery
module.
- If line is blocked : check for blockage in
return line and clear or replace as necessary.
If it is OK, check fuel.
Start engine and check for engine rpm
decrease when disconnecting each injector Yes Repair as necessary.
connector in sequence.
8 Measure the decreasing engine rpm of all 4
cylinders.
Is there any cylinder with no change in rpm No Go to step 9.
or only a small rpm change?
Remove spark plugs and inspect spark plug
tips. Check for engine mechanical failure. If it is
Yes
Check for abnormal color of spark plug tips OK, replace spark plugs.
9
compared to other cylinders.
Are any spark plugs with abormal color No Go to step 10.
compared to other cylinders?
Check for ECM input signal from MAFS, Yes Go to step 11.
10 HO2S, TPS and other input signals.
Are input signals within specification? No Replace all failed parts.
11
Page 122 of 136

TROUBLESHOOTING
Fuel system too rich (bank1)
P0172
Related items · Faulty ignition system
· EVAP canister purge valve malfunction
· Faulty fuel delivery system
- Clogged fuel injectors
- Faulty fuel injectors
- Fuel pressure too high
- Fuel pressure regulator failure
· Faulty MAFS
· Faulty TPS
If any injectors, front HO2S, ECTS, and MAFS codes are present, do all
repairs associated with those codes before proceeding this

Using SCAN TOOL, monitor short-term
and longterm on fuel trim data. Yes engine control module memory was not
· Short-term : -12.5~12.5
2 cleared.
· Long-term : -10~10
Is short-term and long-term within the
No Go to step 3.
specifications indicated?
:
Yes Go to step 4.
tank
3
injectors
No Repair or replace as necessary.
for leaks
· Contaminated fuel
Page 123 of 136
Visually/physically inspect the following
items: Yes Go to step 5.
· Air cleaner element for being restricted.
objects
· Exhaust system for leaks No Repair or replace as necessary.
Check vacuum hoses for splits and proper
connections to engine dynamic chamber Yes Go to step 6.
5 (especially PSV, ISC hose, throttle body,
intake manifold, and brake booster). No Repair or replace as necessary.
Are connections OK?
6 at EVAP valve procedures.
Is vacuum available at purge valve when
EVAP valve is not operating? No Go to step 7.
Yes Go to step 8.
Low pressure :
Clamp return-line and check if pressure rises
:
After installing fuel pressure gauge to service - If pressure rises : replace pressure
porton fuel rail, connect DLC F/P and regulator
B(B+) with a jumper wire. - If pressure does not rise : check the
7 · Fuel pressure at idle : 46~49 psi strainer at the fuel pump.
(320~340kPa, 3.26~3.47 kg/cm²) No High pressure :
Is fuel line pressure correct with ignition Disconnect return-line from fuel filter side
switch ON? and blow through line towards tank.
- If line is clear : replace fuel delivery
module.
- If line is blocked : check for blockage in
return line and clear or replace as necessary.
If it is OK, check fuel.
Start engine and check for engine rpm
decrease when disconnecting each injector Yes Repair as necessary.
connector in sequence.
8 Measure the decreasing engine rpm of all 6
cylinders.
Is there any cylinder with no change in rpm No Go to step 9.
or only a small rpm change?
Remove spark plugs and inspect spark plug
tips. Check for engine mechanical failure. If it is
Yes
Check for abnormal color of spark plug tips OK, replace spark plugs.
9
compared to other cylinders.
Are any spark plugs with abormal color No Go to step 10.
compared to other cylinders?
Page 124 of 136
Check for ECM input signal from MAFS, Yes Go to step 11.
10 HO2S, TPS and other input signals.
Are input signals within specification? No Replace all failed parts.
11

TROUBLESHOOTING
Diagnostic trouble
Cylinder 1 injector circuit malfunction
code No. P0201
Diagnostic trouble
code No. P0202
Diagnostic trouble
code No. P0203
Diagnostic trouble
code No. P0204
Related items · Open or short between main relay and injectors
· Open or short short between ECM and injectors
· Short to battery between ECM and injectors
· Faulty fuel injector

Turn ignition switch to OFF and disconnect Yes Go to step 2.
injector connector.
Measure resistance between injector
1 Temporarily install a known good injector
terminal 1 and terminal 2.
· 13~16Ω at20°C (68°F) No and check for proper operation.
If problem is corrected, replace HO2S.
Is measured resistance within specification?
injector connector. Yes Go to step 3.
With ignition ON and measure voltage of
2 battery voltage between injector harness Open circuit or short circuit to chassis
connector and chassis ground. No ground between main relay and injector
· Specification : approximately B+ harness connector Repair as necessary.
Disconnect ECM connector and injector
Yes Go to step 4.
connector.
Measure resistance between injector harness
3 Open circuit between injector harness
No connector and ECM harness connector.
· Specification : below 1Ω
Does resistance indicate continuity?
ECM connector and injector connector is Temporarily install a known good injector
Measure resistance between injector harness
Page 125 of 136
Measure resistance between injector harness If problem is corrected, replace HO2S.
4 connector and chassis ground at injector
signal circuit. Short circuit to chassis ground between
· Specification : infinite No injector terminal 2 and ECM.
Does resistance indicate open circuit. Repair as necessary.
5

TROUBLESHOOTING
Knock sensor circuit malfunction (bank 1)
No. P0325
Related items · Open or short to GND between knock sensor and ECM
· Source of high resistance between knock sensor and ECM
· Faulty knock sensor

Connect SCAN TOOL to data link connector Problem is intermittent or was repaired and engine
or OBD-II check connector. Yes control module memory was not cleared. Check
Turn ignition to ON and monitor KS voltage
1 terminal connections at ECM and KS.
signals.
· Specifications : 2.0~3.0V
Is signal with in specifications? No Go to step 2.
Start and run engine. Check any other DTCs. If any DTCs is present, do all
Using SCAN TOOL monitor KS voltage Yes repairs associated with those codes before proceeding
2 next step.
signals from idle to 3000rpm.
Does voltage signal increases? No Go to step 3.
Thoroughly check KS and ECM for loose, Yes Repair as necessary.
bent, corroded, contaminated, deteriorated or
3
damaged connectors.
No Go to step 4.
Turn ignition to OFF and disconnect KS
connector and ECM connector. Yes Go to step 5.
Measures resistance of KS signal circuit
between KS harness connector and ECM
harness connector.
4
Measure resistance of KS ground circuit
Open circuit bettery between KS harness connector
between KS harness connector and chassis
No and ECM harness connector.
ground.
Is each resistance within specification?
Measures voltage of KS signal circuit between
5 KS harness connector and chassis ground.
· Specifications : below 0.5V
Page 126 of 136
Measures voltage of KS signal circuit between
5 KS harness connector and chassis ground. Short circuit to battery KS harness connector and
· Specifications : below 0.5V No ECM harness connector.
Ignition OFF, KS connector and ECM Temporarily install a known good knock sensor and
connector is still disconnected. Yes check for proper operation. If problem is corrected,
Measures resistance between KS harness replace knock sensor.
connector and chassis ground at KS signal
6 circuit. Short circuit to chassis ground between KS harness
Measure resistance between KS signal circuit connector and ECM harness connector.
and ground circuit. No Short circuit between KS signal circuit and ground
· Specifications : infinite circuit.
Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with SCAN
7
TOOL connected and monitor for pending codes.

TROUBLESHOOTING
Crankshaft positions sensor circuit malfunction
No. P0335
Related items · Open or short to chassis ground between CKPS and ECM
· Short to battery between CKPS and ECM
· Short between CKPS wires
· Out of allowable air gap
· Faulty Target wheel tolerance
· Faulty CKPS

Thoroughly check CKPS and ECM for
loose, bent, corroded, contaminated,
1
deteriorated or damaged connectors.
No Go to step 2.
Turn ignition to OFF and disconnect CKPS
Yes Go to step 3.
connector.
2 CKPS power circuit between CKPS
ground between CKPS harness connector
and main relay.
connector. Yes go to step 4.
Measure resistance of CKPS signal circuit
between CKPS harness connector and
ECM harness connctor.
3 Measure resistance of CKPS ground circuit
Open circuit between CKPS harness
Page 127 of 136
chassis ground. connector and ECM harness connector
No
· Specifications : below 1Ω and/or chassis ground.
circuit?
Measure voltage of CKPS signal circuit
between CKPS harness connector and Short circuit to battery between CKPS
chassis ground. No
Temporarily install a known good CKPS
Turn ignition to OFF. Yes and check for proper operation. If problem
Measures resistance between CKPS is corrected, replace CKPS.
connector at CKPS signal circuit. Short circuit to chassis ground between KS
Measure resistance between CKPS signal
circuit and ground circuit. connector.
No
· Specifications : infinite Short circuit between CKPS signal circuit
Does resistance indicate open circuit? and ground circuit.
Return vehicle to original to original condition. Clear all diagnostic trouble codes. Verify by driving
6
vehicle with SCAN TOOL connected and monitor for pending codes.

TROUBLESHOOTING
Diagnostic trouble code No. P0340 Camshaft position sensor circuit malfunction
Related items · Open or short to chassis ground between CMPS and ECM
· Short to battery between CMPS and ECM
· Short between CMPS wires
· Faulty CMPS
Page 128 of 136
Thoroughly check CMPS and ECM for
loose, bent, corroded, contaminated,
1
deteriorated or damaged connectors.
No Go to step 2.
Turn ignition to OFF and disconnect CMPS
Yes Go to step 3.
connector.
2 CMPS power circuit between CMPS
harness connector and chassis ground. ground between CMPS harness connector
No
and main relay.
Measure resistance of CMPS signal circuit
between CMPS harness connector and
3 Measure resistance of CMPS ground circuit
between CMPS harness connector and Open circuit between CMPS harness
chassis ground. connector and ECM harness connector
No
and/or chassis ground.
circuit?
Measure voltage of CMPS signal circuit
between CMPS harness connector and Short circuit to power between CMPS
chassis ground. No
Turn ignition to OFF. Yes Go to step 6.
Measures resistance between CMPS
harness connector and ECM harness Short circuit to chassis ground between KS
connector at CMPS signal circuit. harness connector and ECM harness
5 connector.
Measure resistance between CMPS signal No
circuit and ground circuit and ground circuit. Short circuit between CMPS signal circuit
· Specifications : infinite and ground circuit.
Temporarily install a known good CMPS
Yes and check for proper operation. If problem
Turn ignition to OFF and disconnect CMPS is corrected, replace CMPS.
connector. Remove CMPS, install CMPS correctly,
6
Check for CMPS installation. and check CMPS for proper operation. If
Is CMPS installed properly? No not, temporarily install a known good CMPS
and check for proper operation.
If problem is corrected, replace CMPS.
7
Page 129 of 136

TROUBLESHOOTING
Fuel level sensor circuit malfunction
No. P0460
Related items · Open or short to battery between FLS and ECM
· Short to chassis ground between FLS and ECM
· Poor connections between FLS and ECM
· Misplaced, loose, bent or corroded terminals
· Faulty FLS or FLS stuck

Turn ignition to OFF and disconnect FLS
Turn ignition to ON
Measure voltage of FLS signal circuit
1
between FLS harness connector and chassis Open circuit or short circuit between FLS
ground. No harness connector and ECM connector.
Thoroughly check FLS and ECM for loose, Temporarily install a known good FLS and
bent, corroded, contaminated, deteriorated Yes check for proper operation.
2 If problem is corrected, replace FLS.
or damaged connectors.
Is connection okay? No Repair as necessary.
3

TROUBLESHOOTING
Vehicle speed sensor circuit malfunction
P0500
Related items · Open or short to battery between VSS and ECM
· Short to chassis ground between VSS and ECM
· Open or short between VSS wires
· Faulty VSS
If any codes relating to VSS(TCM) circuits are present, do all repairs

associated with those codes before proceeding with this troubleshooting
guide.
Page 130 of 136
Turn ignition to ON. Problem is intermittent or was repaired and
Using SCAN TOOL and monitor VSS engine control module memory was not
signal. Yes
· 5V at ignition ON ECM and VSS.
· 0~5V at driving
Is voltage within specification? No Go to step 2.
Turn ignition to OFF and disconnect VSS
2 between VSS harness terminal and chassis Open circuit or short circuit to chassis
ground. No ground between ECM harness connector
· Specification : approximately 5V and ECM connector.
Temporarily install a known good VSS and
Check VSS harness for open and/or short Yes check for proper operation. If problem is
3 circuit. corrected, replace VSS.
Is harness okay?
No Repair open or short circuit as necessary.
4

TROUBLESHOOTING
Idle control system rpm lower than expected
P0506
Related items · Open or short between main relay and IACV
· Open or short between ECM and IACV
· Intake system is plugged
· Carbon fouled throttle plate
· Faulty IACV
If any codes relating to TPS, MAFS, fuel injector or IACV present, do all
repairs associated with them before proceeding with this troubleshooting
guide

Are any other codes also set? No Go to step 2.
Page 131 of 136
Check accelerator cable free play Yes Go to step 3.
0.040~0.120 in (1.0~3.0mm) .
2
Is accelerator cable free play within
No Adjust cable.
specification.
3 signals.
· 4.0~4.6V @ full open No
Turn ignition to OFF and disconnect IACV Yes Go to step 5.
connector.
With ignition ON, measure voltage of IACV
4 battery voltage between IACV harness
ground between IACV harness connector
and main relay.
· Specifications : approximately B+
measure resistance of IACV opening coil
and closign coil.
5 Temporarily install a known good IACV and
· Opening coil : 17~18.2 Ω at 20°C (68°F)
· Closing coil : 15~16Ω at 20°C (68°F)
corrected replace IACV.
Is each resistance within specification?
Remove IACV from throttle body and
check for excessive carbon deposits and
sticking per following check.
Connect IACV battery terminal to 12V Thoroughly check for loose, bent or
power. One at a time, momentarily ground Yes corroded terminals at all connectors in
IACV opening coil signal terminal and circuit.
closing coil terminal while visually verifying
valve closes when the closing coil terminal is
grounded and valve opens when opening coil
signal terminal is grounded.
6
Repeat numerous times to ensure valve
reliability.
Is IACV moving freely and is not carbon
fouled?
Temporarily install a known good IACV and
While IACV is removed, inspect throttle
body for obstructions in idle circuit
ports. Repair or replace as necessary.

connector.
Measure resistance of IACV opening coil Yes Go to step 8.
signal circuit between IACV harness
Page 132 of 136
7 Measure resistance of IACV closing coil
signal circuit between IACV harness Open circuit between IACV harness
circuit?
ECM connector and IACV connector is still
Measure resistance between IACV harness
connector and chassis ground at IACV
opening coil circuit.
connector and chassis ground at IACV IACV harness connector and ECM harness
No
closing coil circuit. connector.
· Specifications : infinite Repair as necessary.
Does each resistance indicate open circuit?
Remove intake hose and inspect throttle
Yes Clean throttle body.
plate for excessive carbon deposits.
9
Is throttle plate being held open with
excessive carbon deposits? No Go to step 10.
Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehing vehicle
10
with SCAN TOOL connected and monitor for pending codes.

TROUBLESHOOTING
Idle control system rpm higher than expected
P05007
Related items · Short to ground between IACV and ECM
· Air leak in intake system
· Improperly adjusted acclerator cable
· Faulty IACV
· Faulty TPS
· Faulty PCV/PSV
If any codes relating to TPS, PSV, MAFS, fuel injector or IACV are
present, do all repairs associated with them before proceeding with this
troubleshooting guide

Are any other codes also set? No Go to step 2.
Page 133 of 136
Check accelerator cable free play Yes Go to step 3.
0.040~0.120 in(1.0~3.0 mm) .
2
Is accelerator cable free play within
No Adjust cable
specification?
3 signals.
· 4.0~4.6V @ fuell open No
Turn ignition to OFF and disconnect IACV Yes Go to step 5.
connector.
With ignition ON, measure voltage of IACV
4 battery voltage between IACV harness
ground between IACV harness connector
and main relay.
· Specifications : approximately B+
Measure resistance of IACV opening coil
and closing coil.
5 Temporarily install a known good IACV and
· Opening coil : 17~18.2 Ω at 20°C (68°F)
· Closing coil : 15~16 Ω at 20°C (68°F)
Is voltage within spcifications?
Remove IACV from throttle body and
check for excessive carbon deposits and
sticking per following check.
Connect IACV battery terminal to 12V Thoroughly check for loose, bent or
power. One at a time, momentarily ground Yes corroded terminals at all connectors in
IACV opening coil signal terminal and circuit.
closing coil terminal while visually verifying
valve closes when the closing coil terminal is
grounded and valve opens when gpening coil
signal terminal is grounded.
6
Repeat numerous times to ensure valve
reliability.
Is IACV moving freely and is not carbon
fouled?
Temporarily install a known good IACV and
corrected replacce IACV.
While IACV is removed, inspect throttle
body for obstructions in idle circuit
ports. Repair or replace as necessary.

connector.
Measure resistance of IACV opening coil Yes Go to step 7.
signal circuit between IACV harness
Page 134 of 136
7 Measure resistance of IACV closing coil
signal circuit between IACV harness Open circuit between IACV harness
circuit?
ECM connector and IACV connector is still
connector and chassis ground at IACV
opening coil circuit.
connector and chassis ground at IACV IACV harness connector and ECM harness
No
closing coil circuit connector.
· Specifications : infinite Repair as necessary.
Does each resistance indicate open circuit?
Check for any split, disconnected or
perforated vacuum hoses. Also, check PCV Yes Go to step 10.
valve for proper operation and purge
9
solenoid valve for proper installation and
operation. No Replace faulty vacuum hoses, PCV or PSV
Are vacuum hoses, PCV and PSV okay?
:
· Gasket between intake manifold and surge Yes Go to step 11.
tank
· Gasket between intake manifold and
10 cylinder head
injectors
· Seals between surge tank and PCV valves No Repair or replace as necessary.
for leaks
11 at EVAP valve. procedures.
Is vacuum available at purge valve when
EVAP valve is not operating? No Go to step 12.
Return vehicle to orignal condition. Clear all diagnostic trouble codes. Verify by driving vehicle with
12

Page 135 of 136
Code No.P0703 Stop lamp switch system Probable cause
If the stop lamp switch is on for 5 minutes or more while Malfunction of the stop lamp switch
driving, it is judged that there is a short circuit in the stop Malfunction of connector
light switch and diagnostic trouble code P0703 is output. Malfunction of the TCM

TROUBLESHOOTING
Manifold absolute pressure sensor (EGR system circuit malfunction)
P1100
Related items · Open or short to chassis ground between MAPS and ECM
· Open between MAPS and ECM
· Open between MAPS and chassis ground
· Faulty MAPS

Turn ignition to ON and monitor MAPS Yes
voltage signals. ECM and MAPS.
· Specification : 0.8~2.4V
Is signal within specification? No Go to step 2.
MAPS connector. Yes Go to step 3.
Turn ignition switch to ON.
Measure voltage of MAPS reference 5V Open circuit or short circuit to chassis
2
circuit between MAPS harness connector ground between MAPS harness connector
and chassis ground. No
and ECM connector.
Page 136 of 136
connector.
Measure resistance of MAPS signal circuit Yes Go to step 4.
between MAPS harness connector and
3 Measure resistance of MAPS ground circuit
between MAPS harness connector and Open circuit between MAPS harness
ECM harness connector. No connector and ECm harness connector.
circuit?
ECM connector and MAPS connector is
still disconnected.
Measure voltage at MAPS signal circuit
between MAPS harness connector and
4
Measure resistance of MAPS ground circuit Short circuit to battery between MAPS
between MAPS harness connector and harness connector and ECM harness
ECM harness connector No
connector.
circuit?
ECM connector and MAPS connector is Temporarily install a known good MAPS
Turn ignition to OFF. If problem is corrected, replace MAPS
Measure resistance between MAPS harness
connector and chassis ground at MAPS Short circuit to chassis ground between
5 MAPS harness connector and ECM harness
signal circuit.
Measure resistance between MAPS signal connector.
No
circuit and MAPS ground circuit. Short circuit between MAPS signal circuit
· Specification : infinite and ground circuit.
Does each resistance indicate open circuit? Repair as necessary.
6
Page 1 of 46
OPTIMA(MS) > 2001 > G 2.4 DOHC > Heating,Ventilation, Air Conditioning
Heating,Ventilation, Air Conditioning > General Information > Special Service Tools
Tool
Illustration Use
(Number and name)
09977-29000 Removal and installation of pressure

Pressure plate bolt remover plate
09455-34000
Removal of field coil
Heating,Ventilation, Air Conditioning > General Information > Troubleshooting

TROUBLESHOOTING
Before replacing or repairing air conditioning components, first determine if the malfunction is due to the refrigerant
charge, air flow or compressor. The following diagnostic charts have been developed as a quick reference for
determining the cause of the malfunction. If these charts do not satisfactorily describe the problem, refer to the
appropriate section for a more detailed explanation. After correcting the malfunction, check the complete system to
assure that performance is satisfactory.
MALFUNCTION CAUSES AND REMEDIES (Numbers Indicate checking/inspection order.)
Page 2 of 46
Page 3 of 46
Heating,Ventilation, Air Conditioning > General Information > Specifications

LUBRICANTS
Item Recommended lubricant Quantity
Heater control lever Mutipurpose grease As required
PAG (poly alkylene glycol) oil
Compressor oil 150cc
FD46XG or equivalent
Page 4 of 46
SPECIFICATION (R-134A)
Type Air-mix warm water type
Heater assembly
Heating capacity 4,400 Kcal/h (17,460 BTU/h)
Air conditioning Cooling capacity 4,200 Kcal/h (16,660 BTU/h)
Type/Model Swashplate, 5 Double Acting pistons
Bore x stroke ø29 mm x 25.7 mm
Compressor
No. of cylinders 10
Piston Displacement 170 cc/rev
Pulley Type ø125 (5K)
Voltage power
DC 12.8 ± 0.2/Max. 52W
consumption
Magnetic clutch
Torque 400 kg·cm Min.
Current draw 4.1 (A) Max. (12.8V, 20°C)
Coil resistance 3.24 (Ω) Max. (12.8V, 20°C)
OFF: 26 ± 2.0 kg/cm²
High pressure switch
ON: 32 ± 2.0 kg/cm²
Triple pressure OFF: 11.5 ± 1.2 kg/cm²

Medium pressure switch
switch ON: 15.5 ± 0.8 kg/cm²
OFF: 2.3 ± 0.25 kg/cm²
Low pressure switch
ON: 2.0 ± 0.2 kg/cm²
Electrical type (Thermistor)
Freezer prevention
OFF: below 0.5°C
Refrigerant and capacity R-134a, 1.49 ± 0.61b (670 ± 25g)
Heating,Ventilation, Air Conditioning > Air conditioning System > General Information
DISCHARGING THE REFRIGERATION SYSTEM
Federal regulations require that the discharging of R-134a refrigerant be performed by a licensed technician using
only an approved recovery and/or recycling system. Do not discharge R-134a refrigerant into the atmosphere.
When discharging the refrigerant system, always follow the recovery or recycling system equipment manufacturer's
instructions.
SAFETY PRECAUTIONS
1. The R-134a liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite.
When handling the refrigerant, be sure to wear gloves.
2. If the refrigerant splashes into your eyes, wash them with clean water immediately. It is standard practice to wear
goggles or glasses to protect your eyes, and gloves to protect your hands.
3. The R-134a container is a highly pressurized vessel. Never leave it in a hot place, and check that the storage
temperature is below 52°C (126°F).
4. A halide leak detector is often used to check the system for refrigerant leakage. Bear in mind that R-134a, upon
coming into contact with flame (this detector burns like propane to produce a small flame), produces phosgene, a
toxic gas.
Page 5 of 46
5. Use only recommended lubricant for R-134a A/C system and components. If lubricants other than recommended
one used, system failure may occur.
6. The PAG lubricant absorbs moisture from the atmosphere at a exceptionally fast rate and moisture can damage
the A/C system, therefore the following precautions must be observed:
A. When removing refrigerant components from a vehicle, immediately cap the components to prevent the entry
of moisture into A/C system.
B. When installing refrigerant components to a vehicle, do not remove the cap until just before connecting the
components.
C. Complete the connection of all refrigerant tubes and hoses without delay to prevent the A/C system from
entry of moisture.
D. Use the recommended lubricant from a sealed container only.
7. If accidental system discharge occurs, ventilate the work area before resuming service.
HOW TO INSTALL CONNECTING PARTSN (BOLT/NUT COUPLING TYPE)

1. Lubricate O-ring fittings with compressor oil for easy tightening and to prevent leaking of refrigerant gas.
2. Tighten the nut using two wrenches to avoid twisting the tube.
3. Tighten the O-ring fittings to the specified torque.
Page 6 of 46
FLANGE WITH GUIDE PIN TYPE

1. Check for missing or damaged the new O-ring. Replace the O-ring only with the specified one and lubricate the
new O-ring with compressor oil.
2. Hand tighten the nut or bolt by pushing the side pipe.
3. Tighten the nut or bolt.
INSTALLATION OF MANIFOLD GAUGE SET
When connecting the manifold gauge set test hoses, be sure to observe all safety precautions.
1. Close both hand valves of the manifold gauge fittings.
2. Install the charging hoses of the gauge set to the fittings. Connect the low-pressure hose to the low-pressure
service port, and the high-pressure hose to the high-pressure service port.
3. Tighten the hose nuts by hand.
Fitting for attaching the manifold gauge set are located on the compressor and the high pressure hose.
EVACUATING REFRIGERANT SYSTEM
It is necessary to evacuate the air conditioning system any time the system has been opened. Evacuation is
necessary torid the system of all air and moisture that may have been allowed to enter the unit. After installation of
a component, the system should be evacuated for approximately 15 minutes. A component in service that has been
opened for repair shouldbe evacuated for 30 minutes.
1. Engine should be off.
2. Connect a manifold gauge set to the compressor gauge fittings. Close both high and low pressure valves.
3. Make sure the refrigerant has been discharged from the system.
Page 7 of 46
4. Connect the center hose of the gauge set to the vacuum pump inlet.
5. Start the vacuum pump and then open the high and low manifold pressure valves.
6. After about ten minutes, check that the low pressure gauge reads more than 94.39 kPa (0.96 kg cm², 13.7 psi)
vacuum. If negative pressure can not be obtained, there is a leak in the system. In this case, repair the leak as
described in the following.
(1) Close both the manifold valves and stop the vacuum pump.
(2) Charge system with a can or refrigerant [about 0.4 kg (0.9 lb)]. Refer to Charging Refrigerant.
(3) Check for refrigerant leakage with a leak detector. Repair any leakage found. Refer to Checking Refrigerant
Leak.
(4) Discharge refrigerant again, and then evacuate the system. If no leaks are found, continue evacuating the
system.
7. Start the vacuum pump.
8. Open both manifold pressure valves to obtain 94.39 kPa (0.96 kg/cm², 13.7 psi) of vacuum.
9. After the low pressure manifold gauge indicates as close to 94.39 kPa (0.96 kg/cm², 13.7 psi) as possible,
continue evacuating for 15 minutes.
10. After evacuating for 15 minutes, close both manifold pressure valves and stop the vacuum pump. Disconnect the
hose from the vacuum pump. The system is now ready for charging.
HANDLING REFRIGERANT SERVICE TAP VALVE
1. Before connecting the valve to the refrigerant container, turn the handle fully counterclockwise.
2. Turn the disc counterclockwise until it reaches its highest position.
3. Connect the center hose to the valve fitting. Turn the disc fully clockwise by hand.
4. Turn the handle clockwise to make a hole in the sealed top.
5. Turn the handle fully counterclockwise to fill the center hose with air. Do not open the high and low-pressure
hand valves.
6. Loosen the center hose nut connected to the center fitting of the manifold gauge.
Page 8 of 46
7. Allow air to escape for a few seconds, and then tighten the nut.
CHARGING REFRIGERANT SYSTEM (VAPOR)
This step is to charge the system through the low pressure side with refrigerant in a vapor state. When the
refrigerantcontainer is placed right side up, refrigerant will enter the system as a vapor.
1. Install the refrigerant can tap valve as described in Handling the Refrigerant Service Tap Valve section.
2. Open the low pressure valve. Adjust the valve so that the low pressure gauge does not read over 412 kPa (4.2
kg/cm², 60 psi).
3. Put the refrigerant in a pan of warm water (maximum temperature 40°C or (104°F) to keep vapor pressure in the
container slightly higher than vapor pressure in the system.
Page 9 of 46
4. Run the engine at fast idle, and operate the air conditioning
Be sure to keep the container upright to prevent liquid refrigerant from being charged into the system
through the suction side, resulting in possible damage to the compressor.
5. Charge the system to the specified amount. Then close the low pressure valve.
Specified amount : 680±25g (1.49±0.6 lb)
When refrigerant charging speed is slow, immerse refrigerant can in water, heated to a temperature of about
40°C (104°F).
• Under any circumstances the refrigerant can must not be warmed in water heated to a temperature of
over 52°C (126°F).
• A blow torch or stove must never be used to warm up the can.
CHARGING REFRIGERANT SYSTEM (LIQUID)
This step is to charge an empty system through the high pressure side with refrigerant in a liquid state. When the
refrigerant container is held upside down, refrigerant will enter the system as a liquid.
Never run the engine when charging the system through the high pressure side. Do not open the low pressure valve
when the system is being charged with liquid refrigerant.
1. Close both high and low pressure valves completely after the system is evacuated.
2. Install the refrigerant can tap valve as described in "Handling Refrigerant Service Tap Valve" section.
Page 10 of 46
3. Open the high pressure valve fully, and keep the container upside down.
4. Charge the system to the specified amount by weighing the refrigerant with a scale. Overcharging will cause
discharge pressure (high side) to rise. Then, close the high pressure valve.
Specified amount : 680±25g (1.49±0.6 lb)
If the low pressure gauge does not show a reading, the system is restricted and must be repaired.
5. After the specified amount of refrigerant has been charged into system, close the manifold gauge valve.
6. Confirm that there are no leaks in the system by checking with a leak detector. Refer to Checking Refrigerant
Leak.
Conducting a performance test prior to removing the manifold gauge is good service opeation.
DISCHARGING THE SYSTEM

Use the refrigerant recovery unit to discharge refrigerant gas from the system.
Refer to the refrigerant recovery and recycling unit instruction manual for operation of the unit.
Heating,Ventilation, Air Conditioning > Air conditioning System > Components and Components
Location
COMPONENT LOCATION
Page 11 of 46
Heating,Ventilation, Air Conditioning > Air conditioning System > Troubleshooting

PERFORMANCE TEST DIAGNOSIS
The test gauge indicators shown in the following chapter are to be used as typical examples of common problem,
which you may need to diagnose.
GAUGE READINGS OTHER SYMPTOMS DIAGNOSIS CORRECTION
1. Leak test system.
Page 12 of 46
2. Discharge refrigerant
from system.
· Discharge air: slightly 3. Repair leaks as located.
cool. 4. Replace receiver-drier.
· Thermostatic switch (with The drier is porbably
Some air and moisture in
thermistor):Low side gauge saturated with moisture.
system.
doesn't fluctuate with 5. Evacuate the system for
switch "ON" and "OFF" at least 30 minutes.
cycle. 6. Charge system with
refrigerant.
7. Operate system and
check performance.
1. Discharge refrigerant.
· Discharge air: Becomes 2. Replace receiver-drier.
warm as low side cycles 3. Evacuate system with a
into vacuum. Excessive moisture in vacuum pump.
· Discharge air: Becomes system. 4. Recharge system to
warm all the time during hot proper capacity.
part of day. 5. Operate system and
check performance
1. Stop engine and turn air

conditioning "OFF".
2. Replace thermostatic
switch when installing new
· Compressor: Cycles on
thermostatic switch.
and off too fast.
Defective thermostatic Make sure that thermister
· Low side gauge: Not
switch. tube is installed in the same
enough range shown on
position and to the same
low side gauge.
depth in evaporator core as
old switch tube.
check.
1. Stop engine and turn air
conditioning "OFF".
2. Repair or replace the
· Compressor: low side
static switch with thermistor
pressure builds too high
Faulty thermostatic switch. (make sure that all wiring is
before compressor turns on
positioned so that no short
(cycle "ON" point too high)
circuiting can occurred).
check performance.
1. Check leake.
Page 13 of 46
3. Repair leaks.
4. Check compressor oil
level.
· Discharge air: Slightly System slightly low on
5. Evacuate system using a
cool. refrigerant.
vacuum pump.
6. Charge system with
refrigerant.
check performance.
1. Check leaks.
2. Leak test compressor
seal area very carefully.
4. Check compressor oil
· System very low on
level.
· Discharge air: Warm refrigerant.
5. Evaporate system using
· Possible leak in system.
a vacuum pump.
refrigerant.
check performance.
1. Discharge system.
2. Discharge pansion vavle
and remoove and inspect
screen.
· Discharge air: Slightly · Expansion valve stuck
3. Clean and replace
cool. closed.
screen and reconnect inlet
· Expansion valve: · Screen plugged.
line.
Sweating or frost build up. · Sensing bulb malfunction.
4. Evacuate system using a
vacuum pump.
refrigerant.
2. Remove and replace
receiver-drier, liquid pipes
· Discharge air: slightly or other defective
cool. components.
Restriction in high side of
· High side pipe: Cool and 3. Evacuate system using a
system.
also shows sweating or vacuum pump.
frost. 4. Charge system with
refrigerant.
check performance.
Page 14 of 46
1. Isolate compressor.
2. Remove compressor
cylinder head and inspect
compressor.
· Compressor: Noisy Compressor malfunction 3. Check compressor oil
level.
4. Replace receiver-drier.
5. Oprate system and
check performance.
1. Check for loose or worn
fan belt.
2. Inspect condenser for
clogged air passage.
3. Inspect condenser
· Discharge air: Warm. Malfunctioning condenser
mounting for proper
· High side pipe: Very hot overcharge.
radiator clearance.
4. Check for refrigerant
overcharge.
check performance.
1. Discharge refrigerant
from system.
2. Replace receiver-drier
which may be saturated
with moisture.
· Discharge air: Slightly Large amount of air and
3.Evacuate system using
cool. moisture
vacuum pump.
refrigerant.
check performance.
2. Replace expansion
valve, making sure all
contacts are clean and
· Discharge air: Warm. secure.
Expansion valve stuck
· Evaporator: Sweating or 3. Evacuate system using
open
frost. vacuum pump, then
recharge system with
refrigerant.
check performance.
DIAGNOSIS SYSTEM (OPERATION METHOD (SELF-DIAGNOSIS))

The F.A.T.C module self test feature will detect electrical malfunctions and provide error codes for system
components with suspected failures.
Page 15 of 46
DIAGNOSTIC TROUBLE CODE DESCRIPTION

1. A/C system is darned OFF during self diagnosis. The result of self diagnosis is displayed using 2 digits of the
temperature display.
2. Diagnostic trouble codes are displayed during self diagnosis. However, after diagnosis is complete, relevant data
is not stored in memory.
Page 16 of 46
3. Self diagnosis of photo sensor is performed using a light bulb over 60W placed within 40cm with sun load
applied.
Without sun load, photo sensor error code displays.

DTC CHART
If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below.
DTC
Detection item Trouble area
code
00 Normal · Incar sensor
· Harness or connector between incar sensor and A/C
11 Open INCAR Sensor circuit
control assembly
12 Shorted INCAR Sensor circuit · A/C control assembly
· Ambient sensor
13 Open Ambient sensor circuit
· Harness or connector between ambient sensor and
A/C control assembly.
14 Shorted Ambient sensor circuit
·A/C control assembly
· Evap. sensor
17 Open evap. sensor
· Harness or connector between evap. sensor and A/C
control assembly.
18 Shorted evap. sensor
· A/C control assembly
· Harness or connector between temp. door
19 Open or shorted temp. door potentiometer
potentiometer and A/C control assembly
· Temp. door potentiometer
· Harness or connector between temp. door actuator
20 Defective temp. door
and A/C control assembly
· A/C control assembly
FAILURE SAFE FUNCTION

NO. Item Description Fail-safe
Short/open circuit of IN CAR Once diagnosis is occurs, system is regarded
1 INCAR SENSOR
SENSOR as25°C constant
AMBIENT Short/open circuit of AMBIENT Once diagnosis is occurs, system is regarded
2
SENSOR SENSOR as20°C constant.
Short/open circuit of
EVAPORATOR Once diagnosis is occurs, system is regarded
3 EVAPORATOR TEMP.
TEMP. SENSOR as-2°C constant
SENSOR
• Temp.: 17°C↔24.5°C
TEMP DOOR Short/open circuit of TEMP. Temp. door→MAX COOL
4
POTENTIOMETER DOOR POTENTIOMETER • Temp.: 25°C→32°C
Temp. door→MAX HOT
SYMPTOM AND PROBABLE CAUSE

Page 17 of 46
Symptom Probable cause Recommendation
On ignition "ON", Damage on heater control panel. Replace the heater control panel.
A/C doesn't work
Open of short circuit harness wire. Repair harness wire.
Damage in the A/C control module. Replace the A/C control module.
On A/C "ON", the Damage on input circuit of in-car sensor. Check self-diagnosis and/or
inside temperature Damage on input circuit ambient sensor. replace damaged parts.
doesn't rise Damage on input circuit of photo sensor.
Damage on input circuit of temp. actuator potentiometer.
Damage on blend door actuator. Replace blend door actuator.
Sticking of blend door. Replace or repair blend door.
Open of short circuit between temp. actuator Repair or replace harness
potentiometer and A/C control module.
Damage on heater control panel. Replace heater control module.
Damage on A/C control module. Replace heater control module.
Damage of compressor relay in relay box. Replace the relay.
Refrigerant leak. Charge refrigerant or repair leaks
Blower motor doesn't Damage on Hi-blower relay. Replace
work Damage on blower motor.
Blown out thermo-fuse in power TR. Power TR.
Damage on Blower relay. Repair or replace circuit.
Short or open circuit blower relay or blower motor.
Short or open circuit between fuse in the engine relay &
fuse box and blower relay.
Short or open circuit between power TR and A/C
control module
Damage on heater control panel. Replace heater.
Damage on A/C control module. Replace A/C control module.
symptom and probable cause

Page 18 of 46
Symptom Probable cause Recommendation
Blower motor doesn't Damage on Hi-blower relay. Replace Hi-blower relay.
stop
Damage on power TR. Damage power TR.
Short or open circuit from Hi-blower relay to power TR Repair circuit
and A/C control module.
Damage on heater control panel. Replace
Damage in the A/C control module.
Air-mixing actuator in Damage on blend door actuator for air-mixing. Replace blend door actuator.
the blend door
Damage on linkage or damper between outside mode Repair linkage or damper.
actuator doesn't
and recycle mode.
work
Open or short circuit between blend door actuator and Replace circuit.
A/C control module.
Damage on heater control panel. Replace heater control panel.
Damage on A/C control module. Replace heater control panel.
Mode door actuator Damage on input circuit or In-car sensor. Replace in-car sensor.
doesn't work Damage on input circuit of ambient sensor. Replace ambient sensor.
Damage on mode door actuator. Replace mode door sensor.
Damage on mode door actuator linkage.
Open or short circuit between mode door actuator and Replace or repair circuit.
A/C control module.
Damage on heater control panel. Replace or repair heater control
panel.
On A/C switch "ON" Damage on condenser fan relay. Replace or repair condenser fan
condenser fan doesn't relay.
rotate.
Damage on condenser fan resistor. Replace or repair condenser fan
resistor.
Damage on condenser fan motor. Replace or repair condenser fan
motor.
On ignition S/W Damage on power TR circuit. Replace power TR.
"ON" or "OFF", the
temperature is set to
25°C
Heating,Ventilation, Air Conditioning > Air conditioning System > Drive belt > Repair procedures
DRIVE BELTS TENSION ADJUSTMENT
Page 19 of 46
1. Check that the belts are not damaged and fit properly into the pulley grooves.
1. When installing the V-ribbed belt, check that the V-ribs are properly aligned.
2. If noise or slippage is detected, check the belt for wear, damage, or breakage on the pulley contact
surface, and check the pulley for scoring. Also check for the proper belt deflection measurement.
2. Apply 100 N (22 lbs.) force to the belt back midway between the pulleys as shown in the illustration, measure
the amount of deflection with a tension gauge.
Standard value:
1. <For 2.4L I4 ENGINE>
Adjustment
Inspection
New Used
For air Deflection mm 11.7~15.3 8.8~11.0 12.5~14.3
conditioner (in.) (0.46~0.6) (0.35-0.43) (0.49-0.56)
compressor Tension (kg.f) 50 ± 10 75 ± 10 50 ± 5
2. <For 2.7L V6 ENGINE>

The drive belt tension is adjusted automatically by auto-tensioner.
The belt tension must be measured between the specified pulleys. When a new belt is installed, adjust the
tension to thecenter of the standard range indicated under "New." Let the engine idle for 5 minutes or
more, and check the standard value indicated under "Inspection." When adjusting a used belt or a newly
installed belt after 5 minutes or more of operation, refer to the standard value indicated under "Used."
Refer to the standard value indicated under "Inspection" for periodic inspections.
Adjustment
Page 20 of 46
1. <2.4L I4 ENGINE>
(1) Loosen the tension pulley fixing bolt A.
(2) Adjust the belt deflection with adjustment bolt B.
(3) Tighten the fixing bolt A.
(4) Re-check the belt deflection and re-adjust, if necessary.
Before re-checking, crank the engine one or more

revolutions.
2. <2.7L V6 ENGINE>
(1) If the mean indicator is positioned over the max. position, replace the drive belt.
(2) When replacing the drive belt, must position the mean indicator between min. position and max. position.
Type A tension gauge

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

1. When measuring, turn the reset button in the direction of the arrow to set the gauge needle to the RESET
position.
2. When the tension gauge is removed from the belt, the needle will still indicate the tension. Read the tension after
removing the gauge.
Page 21 of 46
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Components and
Components Location
DISASSEMBLY AND REASSEMBLY

Page 22 of 46
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Repair procedures
SERVICE POINT
If a new compressor is installed, first adjust the amount of oil according to the procedures described below, and
then install the compressor.
1. Measure the amount (X ) of oil inside the removed compressor.
Page 23 of 46
2. Drain the amount of oil calculated according to the following formula from the new compressor, and then install
the new compressor.
New compressor oil amount: 150 - X = Y
1. Y cm³ indicates the amount of oil in the refrigerant line, the condenser, the cooling unit, etc.
2. When replacing the following parts at the same time as the compressor, subtract the rated oil amount of
each part from Y and discharge this amount from the new compressor.
Compressor oil: FD46XG (PAG OIL)
Quantity:
Evaporator: 30 cm3(1.0 fl.oz.)
Condenser: 40 cm3(1.4 fl.oz.)
Suction hose: 10 cm3(.3 fl.oz.)
Receiver: 20 cm3(.6 fl.oz.)
REASSEMBLY SERVICE POINT

1. After reassembling the compressor assembly as the reverse of disassembly procedure given, check the clutch air
gap between the clutch hub and the pulley mating surface with a feeler gauge. The air gap should be as follows
Air gap : 0.35 ~ 0.65 mm (0.014 ~ 0.026 inch)
When reassembling the compressor assembly, clean the pulley bearing surface and coil press diameter of
the front head to remove any dirt or corrosion.
2. If the clutch air gap is not within the dimensions specified above, adjust the various thickness shims until the air
gap is between the specified limits.
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor oil > Repair procedures
COMPRESSOR OIL LEVEL CHECK
The oil used to lubricate the compressor circulates in the system while the compressor is operating. Whenever
replacingany component of the system or when a large amount of gas leakage occurs, add oil to maintain the original
total amount of oil.
Total amount of oil in the system : 150 cc (9.1 fl.oz)
HANDLING OF OIL
1. The oil should be free from moisture, dust, metal filings, etc.
2. Do not mix oils.
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3. The moisture content in the oil increases when exposed to the air for prolonged periods. After use, seal the
container immediately.
ADDING OIL FOR REPLACEMENT COMPONENT PARTS
When replacing the system's component parts, be sure to add the following amount of oil to the parts being
replaced.
Component parts to be Amount of oil cc
replaced (US fl oz, lmp fl oz)
Evaporator core 30 (0.96, 1.1)
Condenser 40 (1.3, 1.4)
Receive/Drier 20 (0.6, 0.7)
Compressor 50 (1.6, 1.8)
Hose 10 (0.3, 0.4)
HOSE AND PIPE CHECK

Check the heater and air conditioner hoses and lines for damage due to interference with adjoining parts. If damage
is major, replace the affected parts.
Carefully check the hoses and lines, especially those located close to moving parts or sharp panel edges.
COMPRESSOR NOISE
When investigating an air conditioning related noise, you must first know the conditions when the noise occurs.
These conditions are weather, vehicle speed, in gear or in neutral, engine temperature or any other special
conditions. Noises that develop during air conditioning operations can often be misleading. For example: what
sounds like a failed frontbearing or connecting rod may be caused by loose bolts, nuts, mounting brackets or a loose
clutch assembly. Check theaccessory drive belt tension (power steering, generator or air pump). Improper
accessory drive belt tension can cause a misleading noise when the compressor is engaged and little or no noise
when the compressor is disengaged. Drive belts are speedsensitive. That is, at different engine speeds and
depending upon belt tension, belts can develop unusual noises that are often mistaken for mechanical problems
inside the compressor.
Adjustment Procedures
1. Select a quiet area for testing. Duplicate conditions as much as possible.Switch the compressor on and off several
times to clearly identify the compressornoise.
To duplicate high ambient conditions (high head pressure),restrict air-flow through condenser. Install manifold
gage set to make suredischarge pressure does not exceed 2,070 kPa (300 psi).
2. Tighten all compressor mounting bolts, clutch mounting bolt, and compressordrive belt. Check to assure clutch
coil is tight (no rotation or wobble).
3. Check the refrigerant hoses for rubbing or interference that could causeabnormal noise.
4. Check the refrigerant amount. (Refer to "Charging the System.")
5. Recheck the compressor noise by the same procedure as given in step 1.
6. If noise still exists, loosen the compressor mounting bolts and re-tighten to the specified torque. Repeat step 1.
7. If noise continues, replace the compressor and repeat step 1.
Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser > Components and
Components Location
COMPONENTS
Page 25 of 46
Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser > Repair procedures
ON-VEHICLE INSPECTION (Condenser)
1. Check the condenser fins for blockages or damage. If the fins are clogged, clean then with compressed air. If the
fins are bent, straighten then with a screwdriver or a pair of pliers.
2. Check the condenser fittings for leakage. Repair or replace if necessary.
Condenser fan assembly
1. Check the condenser fan for blockage or damage.
2. Check the connection of the harness coupler.
3. Check that the fan motor runs when the battery voltage is applied.
Page 26 of 46
Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser fan & relay > Repair
procedures
INSPECTION OF CONDENSER FAN RELAY (BLOWER AND A C CONTROLS (MANUAL))
1. Check for continuity between the terminals. (After removing this relay using SST)
If continuity is not as specified, replay the relay
INSPECTION OF CONDENSER FAN RELAY (BLOWER AND A C CONTROLS (AUTO))

1. Check for continuity between terminals.
LOW
If continuity is not as specified, replace the relay.
HIGH

Page 27 of 46
Heating,Ventilation, Air Conditioning > Air conditioning System > Receiver/Drier > Repair procedures
ON-VEHICLE INSPECTION
1. Check the fusible plug and the fittings for leakage, using a leak detector.
2. Run the engine at fast idle with the air conditioning ON, and check both the inlet and outlet temperature. If
difference in temperatures between the inlet and outlet is large, replace the Receiver/Drier.
• Plug the all open fittings immediately to keep moisture out of the system.
• Do not remove the blind plugs until ready for connection.
• If the Receiver/Drier is replaced with a new unit, add 40cc of compressor oil to the compressor.
• Evacuate, charge and test refrigeration system.
Heating,Ventilation, Air Conditioning > Air conditioning System > A/C control relay > Repair
procedures
INSPECTION OF AIR CONDITIONING RELAY (BLOWER AND A C CONTROLS (MANUAL))
1. Check for continuity between the terminal. (After removing this relay using SST)
If continuity is not as specified, replay the relay
INSPECTION OF AIR CONDITIONING RELAY (BLOWER AND A C CONTROLS (AUTO))

Page 28 of 46
Heating,Ventilation, Air Conditioning > Air conditioning System > Triple pressure switch > Repair
procedures
TRIPLE PRESSURE SWITCH (DESCRIPTION)
• The triple pressure switch is a combination of the low pressure switch (for checking the quantity of refrigerant)
and the high pressure switch (for prevention of overheating) and medium pressure switch (for operating cooling
fan and condenser fan at high mode). It is installed in the receiver, and, when the pressure becomes
approximately 200 kPa (29 psi) or lower, the compressor stops, thus preventing the compressor from being
damaged by heat. When the pressure reaches 3,241 kPa (470 psi) or higher, the compressor stops, thus
preventing overheating. There is generally no necessity for inspection; if, however, an unusual condition, such as
non-operation of the compressor is encountered, check by following the procedures below.
1. Disconnect connector of the pressure switch.
2. Install the manifold gauge set.
3. Observe the gauge reading.
4. Check the continuity between the two terminals of the pressure switch shown in the figure. If defective, replace
the pressure switch.
Page 29 of 46
Heating,Ventilation, Air Conditioning > Air conditioning System > Thermistor > Repair procedures
1. Remove the glove box assembly.
2. Turn the blower and A/C switches ON.

4. With the thermostatic switch connector in coupled state, install a voltmeter between 2 and 3 (-) terminal and
check whether there is change in voltage between terminals according to the temperature of the evaporator
surface.
Thermostatic switch operating characteristics
Thermostatic switch Terminal voltage
Operating temp Remarks
operation (2 and 3)
1.5±1.0°C Compressor clutch should
OFF 0V
(34.7±1.5°F) be disengaged
4.3±1.0°C Compressor clutch should
ON 12V
(39.7±1.8°F) be engaged
Termostatic switch circuit
Thermistor
Operation
1. When the resistance (The temperature of the evaporator) in the thermistor increases:
→TR1"ON"→TR2"ON"→Thermostatic switch"ON"
2. When the esistance (the temperature of the evaporator) in the thermistor decreases:
→TR1"ON"→TR2"OFF"→Thermostatic switch"OFF"
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This check should be carried out on the back probes of the thermostatic switch when it is in coupled state.
5. If above condition is not satisfied, remove the evaporator unit and replace the thermostatic switch.
Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator temperature sensor >
Description and Operation
EVAPORATOR TEMPERATURE SENSOR
This sensor detects the temperature inside the cooling unit and sends the appropriate signals to the air conditioning
control assembly.
Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator temperature sensor >
Repair procedures
CHECKING
1. Remove evaporator.
2. Remove evaporator temperature sensor.
3. Remove evaporator between terminals 1 and 2 of evaporator temperature sensor connector at each temperature.
Resistance :
at 0°C : 11.1 ~ 11.6 kΩ
at 15°C : 5.8 ~ 6.1 kΩ
Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Description and
Operation
DESCRIPTION OF SENSORS (IN-CAR SENSOR)
The in-car sensor is located in A/C control assembly. The sensor contains a thermistor which measures the
temperature of the air inside the passenger compartment.
It perceives the passenger compartment temperature, changes the resistance value, and enters the corresponding
voltage into the automatic temperature control module.
Checking
Page 31 of 46
• Measure the resistance and the temperature.
25°C : 30 ± 0.36 kΩ
Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Description and
Operation
PHOTO SENSOR
1. The photo sensor located in the center of main crash pad assembly.
2. The photo sensor contains a photovoltaic (sensitive to sunlight) diode. The solar radiation received by its light
receiving portion, generated an electromotive force in proportion to the amount of radiation received which is
transferred to the automatic temperature control module so that the solar radiation compensation will be
performed.
Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Repair procedures
CHECKING
1. In bright place, measure amphare between pin 2 and battery (-) terminal.
2. In dark place, measure amphare between pin 2 and battery (-) terminal.
3. Check the amphare in the bright place is higher than in the dark.
The voltage is same as the amphare.
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Description and
Operation
AMBINENT TEMPERATURE SENSOR
Page 32 of 46
1. The ambient sensor is located in front of the condenser fan shroud.
2. The sensor contains a thermistor which measures the temperature of the outside aid.
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Repair procedures
CHECKING
1. Disconnect battery terminal (-).
2. Detach the harness of the ambient temperature sensor.
3. Measure the resistance as shown.
Resistance 20°C : 36.5 ± 2.3 kΩ
Heating,Ventilation, Air Conditioning > Air conditioning System > Air Conditioning Switch >
CONTROL PANEL ASSEMBLY
<ROTARY TYPE>
Page 33 of 46
TMNL
USE CIRCUIT
NO
1 EARTH
2 COMMON
BLOWER 3 MIDDLE HIGH
SW 4 LOW
5 MIDDLE LOW
6 HIGH
1 FLOOR
2 B L
3 VENT
4 FRE
5 S W (R DEFOG)
6 B (A C)
7 ILLUMI
8 IGN
MAIN
9 -
10 DEF
11 MIX
12 REC
13 R DEFOG IND
14 A C OUTPUT
15 ILLUMI-
16 GND
1 WARM
2 GND
Page 34 of 46
3 IGN
TEMP SW 4 SENSOR GND
5 F B
6 VCC
7 COOL
CONTROL MODULE
I NO USE TMNL NO CIRCUIT REMARK

1 RHEOSTAT ILL (-)
2 TAIL LAMP ILL (+)
3 B(+) BATTERY
4 POWER TR (B)
5 POWER TR (C)
6 -
7 HUMIDITY SNRINPUT
8 -
9 TEMP ACT'R (COOL)
10 INTAKE ACT'R (REC)
RR DER INDI. INPUT
11 HTD
(+)
12 IGN2
FATC 13 GND
A
COMPONENT
14 -
15 -
16 -
Page 35 of 46
17 A COUTPUT HIGHOUTPUT
18 HIGH SPEED RELAY LOWOUTPUT
19 PHOTO SENSOR (+)
20 PHOTO SENSOR GND
21 REAR DEFOG S W LOWOUTPUT
22 TEMP ACT'R (WARM)
23 INTAKE ACT'R (FREXH)
24 AQS SIGNALINPUT
25 IGN 2
26 GND
1 INCAR SENSORIN
2 A C SELECT SIGNAL HIGHOUTPUT
3 AMB. SNR INPUT
4 EVA. SNR INPUT
5 -
6 -
7 -
FATC 8 SENSOR REF. (+5V)

B
COMPONENT 9 INCAR SENSOR OUT
10 TEMP F B SIGNAL
11 VENT LOWOUTPUT
12 B L LOWOUTPUT
13 FLOOR LOWOUTPUT
14 MIX LOWOUTPUT
15 DEF LOWOUTPUT
16 SENSOR GND
WIRING DIAGRAM
Page 36 of 46
Heating,Ventilation, Air Conditioning > Air conditioning System > Air Conditioning Switch > Repair
procedures
CHECKING OF THE CONTROL PANEL ASSEMBLY
BLOWER SWITCH
Page 37 of 46
1. Check for continuity between terminals as shown below.
If continuity is not as specified, replace the control panel.
AIR CONDITIONING SWITCH

1. Check for continuity between terminals No. 21 and No.22.
MODE CONTROL SWITCH <Rotary and push button type only>
Mode switch Terminals
VENT 3 16
B/L 2 16
FLOOR 1 16
FLOOR/DEFROST 11 16
DEFROST 10 16
If continuity is not as specified, replace the control pannel.
FRESH/RECIRCE BUTTON
Mode switch Terminals
FRESH 4 16
RECIRCE 12 16
If continuity is not as specified, replace the control pannel.
Heating,Ventilation, Air Conditioning > Air conditioning System > Clutch Hub and Pulley > Repair
procedures
Page 38 of 46
DISASSEMBLY SERVICE POINTS
1. Remove the clutch hub retaining bolt with the aid of a spanner wrench.
2. Pull the clutch hub. If the hub can not be pulled from the compressor shaft, screw an 8 mm bolt into the shaft hole
of the clutch hub to force the hub from the shaft.
3. Remove the pulley retaining snap ring and then pull the pulley and bearing assembly from the compressor.
Heating,Ventilation, Air Conditioning > Air conditioning System > Clutch Field Coil > Repair
procedures
Disassembly
1. Remove the clutch hub and pulley following the procedure given.
2. Install shaft protector tool on the nose opening of the compressor.
3. Install the pulley on the compressor as shown in the illustration. Place the tip of the puller screw on the center
dimple of the shaft protector and the jaws of the puller around the back side of the field coil.
4. Tighten the forcing screw with a wrench to pull the coil loose from the compressor front head.
Heating,Ventilation, Air Conditioning > Air conditioning System > Repair procedures
CHECKING REFRIGERANT LEAKS
Conduct a leak test with an electronic leak detector whenever leakage or refrigerant is suspected and when
conducting service operations which are accompanied by disassembly or loosening or connection fittings.
ELECTRIC LEAK DETECTOR
The leak detector is a delicate device that detects small amounts of halogen.
Page 39 of 46
In order to use the device properly, read the manuals supplied by the manufacturer to perform the specified
maintenance and inspections.
If a gas leak is detected, proceed as follows:

1. Check the torque on the connection fitting and, if too loose, tighten to the proper torque. Check for gas leakage
with a leak detector.
2. If leakage continues even after the fitting has been retightened, discharge the refrigerant from the system,
disconnect the fittings, and check its seating face for damage. Always replace, even if the damage is slight.
3. Check compressor oil and add oil if required.
4. Charge the system and recheck for gas leaks. If no leaks are found, evacuate and charge the system.
PERFORMANCE TEST
1. Install the manifold gauge set.
2. Run the engine at 2,000 rpm and set the controls for maximum cooling and high blower speed.
3. Keep all windows and doors open.
4. Place a dry-bulb thermometer in the cool air outlet.
5. Place a psychrometer close to the inlet of the cooling unit.

6. Check that the reading on the high pressure gauge is 1,373-1,575 kPa (14-16 kg/cm², 199-228 psi). If the
reading is too high, pour water on the condenser. If the reading to too low, cover the front of the condenser.
1. Check that the reading on the dry-bulb thermometer at the air inlet at 25-35°C (77-95°F).
Page 40 of 46
2. Calculate the relative humidity from the psychrometric graph by comparing the wet-and dry-bulb reading of the
psychrometer at the air inlet.
3. Measure the dry-bulb temperature at the cool air outlet, and calculate the difference between the inlet dry-bulb
and outlet dry-bulb temperatures.
4. Check that the intersection of the relative humidity and temperature difference is between Block hard line. If the
intersection is within the block hard line, cooling performance is satisfactory.
Heating,Ventilation, Air Conditioning > Heater > Heater Unit > Components and Components Location
HEATER, BLOWER AND EVAPORATOR
COMPONENTS (HEATER UNIT)
Page 41 of 46
Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Description and
Operation
TEMP. ACTUATOR POTENTIOMETER
The electronic blend door actuator is located in the side of the evaporator case assembly on the driver's side. The
actuator controls the position of the temperature blend door based on a low current signal from the FATC module.
Internally an electronic circuit accepts the signal and positions the blend door with a small DC motor. Also included
is a blend door position potentiometer which provides feedback to the FATC module. The blend door actuator
operates based on input information of the temperature setting lever signal and the in-vehicle, ambient, engine
temperature sensor signal. The A/C control module actuates the DC motor according to these signals, also controls
the motor operation to adjust the air mixblend door opening.
Page 42 of 46
CHECKING
1. Connect voltmeter to pin 1 (+) and pin 6 (-).
2. Inspect that voltage changes up to air mixing door position pushing temperature S/W up and down. (COOL :
17°C, HOT : 32°C)
Cool means that the mix door is open to cool side. Of course, warm is opposite.
Heating,Ventilation, Air Conditioning > Blower > Blower Unit > Components and Components Location
COMPONENTS (EVAP. AND BLOWER UNIT)
Page 43 of 46
Heating,Ventilation, Air Conditioning > Blower > Blower Unit > Repair procedures
INSPECTION
1. Check the link mechanism for operation.
2. Check the heater core for restriction or water linkage.
3. Check the water valve for operation and clogging.
Page 44 of 46
Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Repair procedures
BLOWER AND A C CONTROLS (MANUAL)
INSPECTION OF BLOWER MOTOR
1. Connect the blower motor terminals directly to the battery and check that the blower motor operates smoothly.
2. Next, reverse the polarity and check that the blower motor operates smoothly in the reverse direction.
BLOWER AND A C CONTROLS (AUTO) (INSPECTION OF BLOWER MOTOR)

1. Auto A/C control module controls the blower motor speed by shifting the base voltage of power transistor.
FAN MOTOR MOLTAGE
OFF Below 0.1V
LOW 3.9±0.3V
MIDDLE LOW+3.5±0.4V
Hi when Hi-Blower doesn't run 10.5V
Hi when Hi-Blower runs B+
Heating,Ventilation, Air Conditioning > Blower > Blower Relay > Repair procedures
INSPECTION OF BLOWER RELAY (BLOWER AND A C CONTROLS (MANUAL))
Page 45 of 46
1. Check for continuity between the terminals. (After removing this relay using SST)
INSPECTION OF BLOWER RELAY AND HI-BLOWER RELAY (BLOWER AND A CONTROLS

(AUTO))
Heating,Ventilation, Air Conditioning > Blower > Power Transistor > Repair procedures
Power Transistor
1. Measure voltage between pin 1 and pin 2.
2. The voltage increases up to selecting blower motor speed button until Hi-blower relay works.
Heating,Ventilation, Air Conditioning > Blower > Blower Resistor > Repair procedures
INSPECTION OF BLOWER RESISTOR (BLOWER AND A C CONTROLS (MANUAL))
Page 46 of 46
1. Measure terminal-to-terminal resistance of the blower resistor. If measurd resistance is not within specification,
the blower resistor must be replaced. (After removing the resistor)
Page 1 of 23
OPTIMA(MS) > 2001 > G 2.4 DOHC > Manual Transaxle System
Manual Transaxle System > Manual Transaxle System > Manual Transaxle > Components and
Components Location
COMPONENTS
MANUAL TRANSAXLE DIAGRAM

Page 2 of 23
COMPONENTS (MANUAL TRANSAXLE ASSEMBLY)

Page 3 of 23
Manual Transaxle System > Manual Transaxle System > Manual Transaxle > Repair procedures
REMOVAL
1. Remove the battery (-) cable.
2. Remove the air duct.
3. Remove the air cleaner and air flow hose assembly.
4. Disconnect the backup light switch connector.
Page 4 of 23
5. Disconnect the clutch tube and clip.
6. Remove the clutch release cylinder (Refer to "CH" Group).

7. Remove the speedometer cable.
8. Remove the select cable and shift cable (Refer to "MT" Group).
9. Remove the starter motor mounting bolts. Remove the transaxle assembly upper connecting bolts.
10. Attach to the engine hooks using special tool (09200-38001).
11. Remove the transaxle mounting bracket and insulator.
12. Lift up the vehicle.
13. Remove the front tire.
14. Remove the drain plug and drain the transaxle gear oil.
15. Disconnect the tie rod end, lower arm ball joint and drive shaft. (Refer to "DS" Group).
16. Remove the gear box u-joint bolt and the return tube mounting bolts.
17. Remove the front muffler.
18. Remove the sub-frame mounting bolts and the sub-frame.
19. Remove the transaxle front and rear mounting bracket.
20. Remove the transaxle side mounting bolts.
Page 5 of 23
21. Remove the transaxle assembly supporting by a jack.
When supporting the transaxle assembly, make sure that the lifting force is applied to a wide area, not to a
small localizedarea.
1. Engine and transmission mounting insulators should be installed the specified them.
2. Mounting bracket installation procedures.
1) Engine mounting bracket.
2) T/M mounting bracket.
3) Rear roll stopper mounting bracket.
4) Front roll stopper mounting bracket.
3. Especially, when installing front roll stopper mounting bracket, be careful not to be crushed the
insulator, if being crushed, idle vibration is high.
INSTALLATION
DISASSEMBLY
1. Remove the T/M mounting bracket.
2. Remove the shift control cable bracket.
3. Remove the clutch release cylinder.

Page 6 of 23
4. Remove the backup lamp switch.
5. Remove the speedometer driven gear.
6. Remove the clutch release fork shaft and the release bearing sleeve.
7. Remove the reamer bolt.
8. Remove the poppet ball assembly.

9. Remove the side cover and the reverse idler gear assembly.
10. Remove the select lever, the shift lever and sealing cap.
Page 7 of 23
11. Remove the clutch housing from the transmission case with the snap ring extended.
12. Remove the interlock body and the control shaft.
13. Remove the shift rail.
14. Remove the fork shift (5th & Rev).
15. Remove the fork shift (3rd & 4th).
16. Remove the fork shift (1st & 2nd).

Page 8 of 23
17. Remove the bearing retainer.
18. Remove the output shaft assembly and the input shaft assembly.
19. Remove the differential assembly.
20. Remove the detent body cover and the roller bearing.
21. Remove the differential bearing outer spacer using special tool (09455-33200) and the drive shaft oil seal.
22. Remove the shift arm and the select arm from the transmission case.
REASSEMBLY
Page 9 of 23
1. Install the drive shaft oil seal using the special tool (09431-21200).
Insert the oil seal straightly.
2. Install the shift arm and the select arm in the transmission case.
3. Install the detent body cover and the roller bearing.
4. Install the differential assembly.
5. Install the output shaft assembly and the input shaft assembly.
6. Install the retainer bearing.

Page 10 of 23
7. Install the fork shift (1st & 2nd).
8. Install the fork shift (3rd & 4th).
9. Install the fork shift (5th & Rev).
10. Install the shift rail.
11. Install the interlock body and the control shaft.
12. Assemble the clutch housing and the transmission case with the snap ring extended.
Page 11 of 23
13. Install the select lever, the shift lever and the sealing cap.
14. Install the side cover and the reverse idler gear assembly.
15. Install the poppet ball assembly.
16. Install the reamer bolt.
17. Install the clutch release fork shaft and the release bearing sleeve.
18. Install the speedometer driven gear.
19. Install the backup lamp.

Page 12 of 23
20. Install the clutch release cylinder mounting bracket.
21. Install the shift control mounting bracket.

22. Install the mounting bracket.
Manual Transaxle System > Manual Transaxle System > Shift Lever > Components and Components
Location
COMPONENTS
Manual Transaxle System > Manual Transaxle System > Shift Lever > Repair procedures
Page 13 of 23
INSPECTION
1. Inspect the bushing for wear or damage.
2. Inspect the return spring for damage or deterioration.
REASSEMBLY
1. Apply multi-purpose grease to the sliding part of the bushings.
2. Reassembly is reverse of the disassembly.
Manual Transaxle System > Manual Transaxle System > Troubleshooting

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

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

Page 14 of 23
Manual Transaxle System > Manual Transaxle Gear System > Differential > Components and
Components Location
COMPONENTS
COMPONENTS
Page 15 of 23
Manual Transaxle System > Manual Transaxle Gear System > Differential > Repair procedures
DISASSEMBLY
1. Clamp the differential case in a vise.
2. Remove the differential drive retaining bolts and remove the differential drive gea from the case.
Page 16 of 23
3. Remove the taper bearing using the special tool (09433-21000).
Do not reuse the bearing removed from the shaft.
4. Drive out the lock pin from the hole A using a punch..
5. Drive out the pinion shaft.

6. Remove the pinion gears, washers, side gear and spacers.
REASSEMBLY
1. Install the spacer on the back of the side gear and then install the gear in the differential case.
1. When installing a new side gear, use a spacer of medium thickness [0.83-0.92 mm (0.33-0.036
in.)].
2. Do not reuse the lock pin.
3. The lock pin head must be sunk below the flange surface of the differential case.
2. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them
with the side gears by turning them.
3. Insert the pinion shaft.
Page 17 of 23
4. Measure the backlash between the side gears and pinions.
5. If the backlash is out of specification, disassemble and install the correct spacer, reassemble and remeasure.
Adjust the backlash of both side gears to the same specification.
6. Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.

2. The lock pin head must not protrude more than 3 mm (0.0118 in.) gear in the differential
case.
7. Install the tapered roller bearing on both sides of the differential case using the special tool (09455-21100).
When press-fitting the bearing, press on the inner race only.
8. Apply specified sealant to the entire threads of the bolts. Tighten to specifications using the sequence shown in the
illustration.
Specified sealant : BM stud locking No.2471
If a bolt is reused, remove the old sealant from the threads.

Page 18 of 23
DISASSEMBLY
1. Clamp the differential case in a vise.
2. Remove the differential drive retaining bolts and remove the differential drive gear from the case.
3. Remove the taper bearing using the special tool (09433-21000).
Do not reuse the bearing removed from the shaft.
4. Drive out the lock pin from the hole A using a punch.
5. Drive out the pinion shaft.
6. Remove the pinion gears, washers, side gear and spacers.
REASSEMBLY
1. Install the spacer on the back of the side gear and then install the gear in the differential case.
1. When installing a new side gear, use a spacer of medium thickness [0.93-1.00 mm (0.036-0.04
in.)].
3. The lock pin head must be sunk below the flange surface of the differential case.
2. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them
with the side gears by turning them.
Page 19 of 23
3. Insert the pinion shaft.
4. Measure the backlash between the side gears and pinions.
5. If the backlash is out of specification, disassemble and install the correct spacer, reassemble and remeasure.
Adjust the backlash of both side gears to the same specification.
6. Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.

2. The lock pin head must not protrude more than 3 mm (0.118 in.).
7. Install the tapered roller bearings on both sides of the differential case using the special tool (09455-21100).
When press-fitting the bearing, press on the inner race only.

Page 20 of 23
8. Apply specified sealant to the entire threads of the bolts. Tighten to specifications using the sequence shown in the
illustration.
Specified sealant : Three bond 1303
If a bolt is reused, remove the old sealant from the threads.
Manual Transaxle System > Manual Transaxle Gear System > Speedometer Driven Gear Assembly >
COMPONENTS
Manual Transaxle System > Manual Transaxle Gear System > Speedometer Driven Gear Assembly >
Repair procedures
ASSEMBLY
1. Apply gear oil sparingly to the speedometer driven gear shaft and insert the shaft.
2. Install the spring pin in such a way the slit does not face the gear shaft.
Page 21 of 23
Manual Transaxle System > Manual Transaxle Control System > Shift Fork > Components and
Components Location
SHIFT FORK AND CONTROL SHAFT ASSEMBLY
COMPONENTS
Manual Transaxle System > Manual Transaxle Control System > Manual Transaxle Shift Control >
COMPONENTS
Page 22 of 23
Manual Transaxle System > Manual Transaxle Control System > Manual Transaxle Shift Control >
Repair procedures
REMOVAL
1. Remove the console assembly (Refer to CONSOLE).
2. Remove the self locking pin and clips (shift lever side).
3. Remove the shift lever assembly.
4. Remove the retainer and bolts.
5. Remove the snap pin and clips (Transaxle side).
Page 23 of 23
6. Remove the shift cable and select cable.
INSPECTION
1. Check the select cable for proper operation and for damage.
2. Check the shift cable for proper operation and for damage.
3. Check the boot for damage.
4. Check each bushing for wear, abrasion, sticking, restricted movement or damage.
5. Check for a weak or damaged spring.
REASSEMBLY
1. Install the shift lever assembly.
2. Installation of shift lever and select cable.
Page 1 of 76
OPTIMA(MS) > 2001 > G 2.4 DOHC > Body (Interior and Exterior)
Body (Interior and Exterior) > General Information > Description and Operation
GENERAL
BUMPER
Front face damaged Accident Replace
Energy absorbing foam damagedor
Accident exposure Replace
deteriorated
Reinforcement damaged Accident Replace
Repair or
Brackets or stays damaged Accident
replace
Missing attaching hardware Accident Replace
SAFETY BELTS
Buckle release does not release
Faulty spring or dirt in mechanism Replace buckle assembly
reliably
Buckle release does not depress Jammed mechanism Replace buckle assembly
Buckle release button does not
Jammed mechanism Replace buckle assembly
return to normal position
Webbing is frayed Caught in door Replace retractor assembly
Stitching is loose Wear or accident Replace retractor assembly
Belt retracts part-way Faulty spring Replace retractor assembly
Belt does not extend completely Faulty mechanism Replace retractor assembly
Belt does not retract Wear or accident Replace retractor assembly
Belt does not extend Faulty mechanism Replace retractor assembly
Buckle assembly is loose Vibration or accident Tighten to specified torque
Retractor assembly is loose Vibration or accident Tighten to specified torque
Anchor assembly is loose Vibration or accident Tighten to specified torque
Isolate fault with continuity tester. If
Driver’s safety belt is fastened but
Cable harness, computer module, or test fails, repair or replace cable. If
reminder lamp and chime either do
indicator light test fails, repair or replace faulty
not actuate or fail to deactivate
component
Body (Interior and Exterior) > General Information > Specifications

Specifications
Tightening specifications
Item Description Tightening torque
Page 2 of 76
Bumper Front bumper back beam mounting nuts 14~20 lb-ft (19~28 N.m, 1.9~2.8 kg-
m)
Rear bumper mounting bolts 25~40 lb-ft (35~55 N.m, 3.5~5.5 kg-
m)
Doors Door checker bolts (Door side) 61~95 lb-in (7~11 N.m, 70~110 kg-
cm)
Door checker bolts (Body side) 12~16 lb-ft (17~22 N.m, 1.7~2.2 kg-
m)
Door hinge mounting bolts (Door side) 10~19 lb-ft (13~26 N.m, 1.3~2.6 kg-
m)
Door hinge mounting bolts (Body side) 25~30 lb-ft(35~42 N.m, 3.5~4.2 kg-
m)
Door lock assembly mounting screws 69~95 lb-in(8~11 N.m, 80~110 kg-
cm)
Door striker mounting screws 78~122 lb-in(9~14 N.m, 90~140 kg-
cm)
Door outside handle mounting bolts 61~95 lb-in(7~11 N.m, 70~110 kg-
cm)
Glass guide bolts/nuts 69~104 lb-in(8~12 N.m, 80~120 kg-
cm)
Glass mounting bolts 69~104 lb-in(8~12 N.m, 80~120 kg-
cm)
Regulator assembly mounting nuts 35~52 lb-in(4~6 N.m, 40~60 kg-cm)
Hood Hood hinge bolts/nut 16~20 lb-ft(22~27 N.m, 2.2~2.7 kg-
m)
Hood latch assembly bolt 61~95 lb-in(7~11 N.m, 70~110 kg-
cm)
Seats Front buckle assembly anchor bolt 36~43 lb-ft(50~60 N.m, 5.0~6.0 kg-
m)
Front seat mounting bolts 25~40 lb-ft(35~55 N.m, 3.5~5.5 kg-
m)
Front seat mounting nuts 17~26 lb-ft(24~36 N.m, 2.4~3.6 kg-
m)
Front seatback mounting bolts 36~43 lb-ft(50~60 N.m, 5.0~6.0 kg-
m)
Seat cushion mounting bolts 12~19 lb-ft(17~26 N.m, 1.7~2.6 kg-
m)
Rear seat back mounting bolts 12~19 lb-ft(17~26 N.m, 1.7~2.6 kg-
m)
Safety belts Front lap belt anchor mounting bolt 25~33 lb-ft(35~45 N.m, 3.5~4.5 kg-
m)
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Rear buckle assembly bracket mounting 29~40 lb-ft(40~55 N.m, 4.0~5.5 kg-
bolt m)
Rear lap belt anchor mounting bolt 29~40 lb-ft(40~55 N.m, 4.0~5.5 kg-
m)
Sunroof Glass panel mounting nuts 35~52 lb-in(4~6 N.m, 40~60 kg-cm)
61~95 lb-in(7~11 N.m, 70~110 kg-
Sunroof mounting bolts
cm)
Sunroof mounting nuts 35~52 lb-in(4~6 N.m, 40~60 kg-cm)
Trunk lid 61~95 lb-in(7~11 N.m, 70~110 kg-
Trunk lid hinge assembly bolt
cm)
61~95 lb-in(7~11 N.m, 70~110 kg-
Trunk lid latch assembly bolt
cm)
Item Description Specification
Rear window
Grid line center voltage 6V
defroster
Windshield wiper
Motor specification 12V DC
washer system
Body (Interior and Exterior) > Exterior > hood > Description and Operation
The vehicle hood is a front-opening type secured by a standard double-release latch. The hood release handle is
locatedbelow and to left of steering column. When the hood is opened, it pivots on two hinges and is held open by a
hood prop. The two hinges are secured to body with two bolts and to hood with two bolts on each hinge. The hood
alignment can be adjusted fore-and-aft and side-to-side by loosening hood bolts and moving the hood as necessary.
The hood latch can be adjusted in both axes to match position of the permanently attached striker.
Body (Interior and Exterior) > Exterior > hood > Components and Components Location
COMPONENTS
Page 4 of 76
Body (Interior and Exterior) > Exterior > hood > Repair procedures
REMOVAL
1. Raise hood and support with prop.
2. Support hood so it will not fall when hinges are removed.
Have an assistant help remove hood.
3. Remove hinges from hood by removing one nut and three bolts.
4. Remove prop from hood.
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5. Remove hood.
INSTALLATION
Have an assistant help install hood.

2. Tighten one nut and three hinge bolts to just over finger-tight.
3. Lower and lock hood.
4. Check fit and adjust as required in accordance with illustrated specifications.
Tighten latch and bolts to : 16~95 lb·ft (22~27 Nm, 2.2~2.7 kg·m)
5. Check alignment of locking mechanism and hood striker and align as required.
Tighten latch assembly bolts to : 61~95 lb·in (7~11 Nm, 70~110 kg·cm)
Body (Interior and Exterior) > Exterior > trunk lid > Description and Operation
Trunk lid attached to body by two hinges. Two hinges connected to each other by two damper stays and are
installed by bolts.
Two hinges connected by two damper stays provide an assist in raising trunk lid and fully supports it when it isopen.
A striker at center-top of body secures trunk lid in closed position.
Weatherstripping on trunk lid jamb flange prevents leakage between trunk and body. A latch is attached to center-
bottom of trunk lid. Trunk lid is fully adjustable.
Page 6 of 76
Body (Interior and Exterior) > Exterior > trunk lid > Components and Components Location
COMPONENTS
Body (Interior and Exterior) > Exterior > trunk lid > Repair procedures
REMOVAL
Have an assistant help remove trunk lid.

1. Unfasten upper and lower retaining clips from damper stay.
2. Remove damper stay from hinge assembly.
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3. Remove service hole cover from trunk and then remove electrical harness connector.
4. Support trunk lid so trunk lid will not fall when trunk lid installation bolts are removed.
5. Remove four trunk lid installation bolts and then remove trunk lid.
REMOVAL
Trunk Lid Lock Assembly
2. Open trunk lid.
3. Remove the trunk lid trim. Refer to "Trim" in this section.
4. Disconnect electrical harness connector.
5. Unfasten lock rod clip and fastener from keylock.
6. Remove one nut from keylock.
7. Disconnect actuator connector.
8. Remove two bolts from trunk lid lock assembly.
REMOVAL
Trunk Lid Moulding Assembly
2. Open trunk lid.
3. Remove three screws and thirteen fasteners from trunk lid trim.
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4. Remove back panel molding assembly.
(2) Remove one screw from outside of trunk lid.
(3) Remove thirteen nuts from trunk lid.
INSTALLATION
Have an assistant help install trunk lid.

2. Tighten four trunk lid installations bolts to just over finger-tight.
3. Lower and lock trunk lid.
4. Check fit and adjust the clearance on all sides before tightening bolts.
Tighten trunk lid hinge bolts to : 61~95 Ib-in (7~11 N.m, 70~110 kg-cm)
5. Check alignment of the locking mechanism and trunk lid striker and align as required.
Tighten striker bolts to : 61~95 Ib-in (7~11 N.m, 70~110 kg-cm)
INSTALLATION
Trunk Lid Lock Assembly
INSTALLATION
Trunk Lid Moulding Assembly
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1. Install back panel molding assembly.
(1) Install thirteen nuts on trunk lid.
(2) Install one screw on outside of trunk lid.
2. Install three screws and thirteen fasteners on trunk lid trim.
Body (Interior and Exterior) > Exterior > front door > Description and Operation
DESCRIPTION
Vehicle door is attached to vehicle body by two hinges and a door checker. Door checker limits amount of swing of
the vehicle door. A hollow rubber weatherstrip is installed on the door opening flange to prevents leaks between
vehicle door and inside of vehicle body. The door lock assembly is linked with outside and inside door handle.
The power window system is comprised of a window regulator assembly (on which glass is fastened), a front glass
guide (which guides movement of glass at front side) and a window power switch (switch for up and down
movement of glass, which is attached to armrest).
A plastic door screen covers door frame, protecting all components. The door striker may be adjusted for proper
operation and easy door closure.
Body (Interior and Exterior) > Exterior > front door > Components and Components Location
COMPONENTS
Page 10 of 76
Body (Interior and Exterior) > Exterior > front door > Repair procedures
REMOVAL
Front Door (On-Vehicle Service Procedure)
Page 11 of 76
2. Remove door garnish.
(1) Unfasten garnish.
3. Remove inside handle cover.
(1) Remove one screw.

(2) Unfasten inside handle cover.
(1) Remove one screw from pull handle bracket.
(2) Remove two screws from right side of door trim.

(3) Remove two screws and cover from left side of door trim.
(4) Remove two screws from bottom of door trim.
(5) Unfasten door trim.

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(3) Turn ignition "ON" and position window glass about halfway.
(4) Turn ignition "OFF".

Page 13 of 76

(1) Disconnect two remote control rods from outside door handle assembly.
(4) Remove one screw from rod cover of inside door handle.
11. Remove outside handle assembly.

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12. Remove two nuts from glass guide
13. Remove door speaker.

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

(2) Remove three bolts from outside rearview mirror assembly.
15. Remove wiring harness.

(1) Disconnect harness connectors from inner door frame.
(2) Pull out wiring harness from access hole.
16. Remove door checker installation bolt from body.
17. Remove door by removing bolts on both hinges.
REMOVAL
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Door Opening Weatherstrip
1. Remove front scuff plate, front side trim and A-pillar trim. Refer to "Trim" in this section.
2. Remove door opening weatherstrip from door opening flange.
INSTALLATION
Front Door (On-Vehicle Service Procedure)
1. Install door.
(1) Position door on vehicle properly.
(2) Install bolts on both hinges.
Tighten door hinge bolts to : 10~19 Ib-ft (13~26 N.m, 1.3~2.6 kg-m
2. Install dust weatherstrip.

3. Install one bolt on door checker pin assembly.
Tighten one bolt to : 12~16 Ib-ft (17~22 N.m, 1.7~2.2 kg-m
4. Install wiring harness.

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

(1) Position door speaker on door as originally positioned.
(2) Install four mounting screws.
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7. Install glass guide.
(2) Install two nuts.

(2) Install door lock cylinder on outside handle assembly .
Tighten mounting bolts to : 61~95 Ib-in (7~11 N.m, 70~110 kg-cm)

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

(5) Connect two remote control rods on outside handle.
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10. Install regulator assembly.
(1) Position regulator assembly through access hole.

Hold glass from both its inner and outer surfaces. While tilting it towards hinge side of door, place it on small

Page 18 of 76


(2) Place front door trim.
(3) Install two screws on bottom of door trim.
(4) Install two screws and cover on left side of door trim.
(5) Install two screws on right side of door trim.
(6) Install one screw on pull handle bracket.
17. Install inside handle cover.

(1) Fasten inside handle cover.
(2) Install one screw and cover.
18. Install door garnish.
INSTALLATION
Door Opening Weatherstrip
1. Position weatherstrip on door opening flange and press it in.
2. Start at one corner and work around entire edge of door opening.
3. Install front scuff plate, front side trim and A-pillar trim. Refer to "Trim" in this section.
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ADJUSTMENT
Door hinge and door lock striker
1. Check that door can be closed easily and properly. If door is loose, tighten door hinge installation bolts.
2. To adjust door-to-body offset, loosen door hinge installation bolts and make adjustment.
3. Check that door can be closed easily and properly. If there is a problem, loosen striker installation bolts and
adjust door by moving striker vertically and horizontally.
4. Adjust rear offset of door to body by moving door lock striker horizontally.
Body (Interior and Exterior) > Exterior > rear door > Components and Components Location
COMPONENTS
Page 20 of 76
Body (Interior and Exterior) > Exterior > rear door > Repair procedures
REMOVAL
Page 21 of 76
2. Remove inside door garnish.
(1) Remove screw cover and one screw.

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

(5) Disconnect power window switch connector.
(1) Disconnect two remote control rods from inside door handle.
Page 22 of 76

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

(3) Turn ignition "ON" and position window glass about halfway.
(4) Turn ignition "OFF".
(7) Remove door glass carefully. Hold glass from both its inner and outer surfaces. While tilting it toward hinge
side of door, pull it out from outside door frame.
Page 23 of 76

(1) Disconnect one remote control rod from outside door handle assembly.
12. Remove outside door handle assembly.

Page 24 of 76
13. Remove two bolts from glass guide
14. Remove wiring harness.

(1) Disconnect harness connectors from inner door frame.
(2) Pull out wiring harness from access hole.
15. Remove door checker installation bolt from body.
16. Remove door by removing bolts on both hinges.
INSTALLATION
1. Install door.
(1) Position door on vehicle properly.
(2) Install bolts on both hinges.
Tighten door hinge bolts to : 10~19 Ib-ft (13~26 N.m, 1.3~2.6 kg-m)
2. Install dust weatherstrip.

3. Install one bolt on door checker pin assembly.
Tighten one bolt to : 12~16 Ib-ft (17~22 N.m, 1.7~2.2 kg-m)
4. Install wiring harness.

(1) Position wiring harness in access hole.
(2) Fasten harness connectors onto door frame.
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5. Install glass guide.
(2) Install two bolts.

Tighten mounting nuts to : 61~95 Ib-in (7~11 N.m, 70~110 kg-cm)

Tighten nuts to : 69~95 Ib-in (8~11 N.m, 80~110 kg-cm)

(5) Connect one remote control rod on outside door handle assembly.
8. Install window regulator assembly.
(1) Position window regulator assembly through access hole.
Page 26 of 76
Hold glass from both its inner and outer surfaces. While tilting it towards hinge side of do or, place it on small

11. Install outside belt weatherstrip and door outside garnish.
(1) Fasten outside belt weatherstrip with door outside garnish.
(2) Install three screws on door outside garnish.

Page 27 of 76
14. Install inside door handle.


(2) Place door trim.
(4) Install one screw on right side of door trim.
(5) Install one screw on pull handle.

17. Install inside door garnish.
Body (Interior and Exterior) > Sun Roof > Components and Components Location
COMPONENTS
Page 28 of 76
Body (Interior and Exterior) > Sun Roof > Repair procedures
REMOVAL
1. Remove headliner.
Page 29 of 76
2. Remove glass panel. Refer to "Trim" in this section.
Tighten glass mounting nuts to : 35~52 lb-ft (4~6 N.m, 40~60 kg-cm)
3. Disconnect the drain hose
4. Remove the sunroof mounting bolts and nuts, and remove the sunroof assembly
Tighten sunroof mounting bolts to : 61~95 lb-ft (7~11 N.m, 70~110 kg-cm)
Tighten sunroof mounting nuts to : 35~52 lb-ft (4~6 N.m, 40~60 kg-cm)
When removing the sunroof assembly, carefully pull out the sunroof assembly to avoid damage to the other
parts
INSTALLATION
Installation is the reverse of removal.
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Check that the limit switches (LS1 and LS2) of the motor are at the fully colsed position.
Align the guide roller center and slider mating mark at the fully closed position.
check operating condition after installation

1. If the glass panel movement is difficult, check and adjust.
(1) Make sure the battery voltage is normal.
(2) Make sure that the sunroof sliding unit is free of foreign material.
(3) Make sure that, when the glass panel opens, the rear position of panel dose not interfere with the roof panel.
If the stopper is moved forward too far, it may cause malfunction or leaks. Make sure the gap between
the glass panel and roof panel is not more than 0.3 mm.
(4) Measure the driving force of the motor, and adjust it to 15~25 kg (33.1~55.7 lb) with the torque adjustment
nut on the motor.
(5) To measure, use the deep hole in the center of the lid lower panel.
(6) After adjustment, be sure to lock the nut with the pawl washer.
DISASSEMBLY
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1. Remove the drip rail.
2. Remove the stopper.
3. Remove the sunshade.
4. Remove the guide assembly.
5. Remove the deflector.

Page 32 of 76
6. Remove the motor assembly.
When removing the motor, the slider assembly should always be in the fully closed position. If there is a
discrepancy between the glass position and the motor ring fully closed position, the sunroof will not operate
correctly.
REASSEMBLY
Assembly is the reverse of disassembly.
ADJUSTMENT
1. Adjust the difference between the height of the glass panel and the roof panel.
Front side : -1~0 mm

Rear side : 0~1 mm
If the difference is not as specific, adjust the following procedure.

(1) Loosen the front screw and rear screw and adjust the height between the glass panel and roof panel.
(2) Loosen the glass panel mounting nuts and adjust the gap between the glass panel and roof panel.
Page 33 of 76
Body (Interior and Exterior) > Sun Roof > sun roof switch > Repair procedures
INSPECTION
1. Using an ohmmeter, check for continuity between terminals.
2. If the continuity is not as specified, replace the switch.
Body (Interior and Exterior) > Sun Roof > sun roof moter > Repair procedures
1. Remove the overhead console lamp.
2. Disconnect the motor connector from sun roof harness.
3. Apply DC 12V to the terminal 2 and ground the terminal 6.

4. Check that the motor turns.
Page 34 of 76
5. Reverse the connections and check that the motor turns in the opposite directions.
Body (Interior and Exterior) > Sun Roof > Sunroof Relay > Repair procedures
Body (Interior and Exterior) > Interior > crash pad > Description and Operation
Instrument panel
Instrument panel houses instrument cluster, center panel and a number of special switches and controls. Instrument
panel electrical system is discussed in Wiring Diagram Manual. Ducts installed in instrument panel are discussed in
this section.
Center panel
Center panel is a housing for ventilation control panel, radio, glove box, and with center panel trim serves as a base
Page 35 of 76
for cigarette lighter and ashtray. Center panel may remain in place when instrument panel is removed.
Interior lights control switch
Interior lights control allows adjustment of brightness of panel lights.
Radio and antenna cable
When a radio is installed in vehicle, user instructions are supplied. Radio is located in center panel. Antenna and
electrical connections are located at rear of unit. Antenna cable connects to radio. It is routed behind instrument
paneland connects to antenna. Radio receives signals through antenna cable from antenna. It is necessary to remove
radio when instrument panel is removed.
Ventilation control panel
Ventilation control panel provides control of heating and air conditioning and is mounted in center panel. There are
control cables from ventilation control panel that attach to heater assembly. Part of instrument panel must be
removed for access to where cables attach to heater or air conditioner units.
Body (Interior and Exterior) > Interior > crash pad > Components and Components Location
COMPONENT
Instrument Panel Assembly
Page 36 of 76
Ducts
Page 37 of 76
Body (Interior and Exterior) > Interior > crash pad > Repair procedures
REMOVAL
2. Remove drive airbag module. Refer to group RT, Restraints.
3. Remove steering wheel, turn signal assembly, and upper/lower column covers. Refer to Group ST, Steering
system.
4. Remove instrument cluster .
(1) Remove three screws from instrument cluster trim.
(2) Remove four mounting screws.
(3) Pull cluster from instrument panel.
(4) Disconnect two connectors.
(5) Remove instrument cluster.
Page 38 of 76
5. Remove console.
(1) Unfasten rear cover from console.
(2) Remove two mounting screws from front cover.

(4) Remove eight mounting screws from console.
6. Unfasten center panel cover and then disconnect electrical connector from rear of center panel trim.
7. Remove radio.
(1) Remove four screws from radio.
(2) Disconnect electrical connector and antenna cable from rear of radio.
8. Remove two mounting screws and then disconnect electrical connector from rear of lower LH cover.
9. Remove lower RH cover.

(1) Remove two grommet from glove box assembly.
(2) Remove two screws and one nut from top of lower RH cover.
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(3) Remove two bolts from bottom of lower RH cover.
10. Remove center panel.

(1) Remove five screws from center panel.
(2) Disconnect electrical connector from rear of center panel.
11. Remove instrument panel.

(1) Remove two bolts from left side of instrument panel.
(2) Remove two bolts from right side of instrument panel.
(3) Remove two bolts from center of instrument panel.
(4) Remove two mounting bolts from passenger airbag.
REMOVAL
Console
1. Unfasten rear cover from console.
2. Remove two mounting screws from front cover.
4. Remove eight mounting screws from console.
REMOVAL
Center Panel
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1. Remove console.
(1) Unfasten rear cover from console.
(2) Remove two mounting screws from front cover.

(4) Remove five mounting screws from console.
3. Remove radio.
(1) Remove four screws from radio.
(2) Disconnect electrical connector and antenna cable from rear of radio.
5. Remove lower RH cover.

(1) Remove two grommet from glove box assembly.
(2) Remove two screws and one nut from top of lower RH cover.
Page 41 of 76
(3) Remove two bolts from bottom of lower RH cover.
6. Remove center panel.

(1) Remove five screws from center panel.
(2) Disconnect electrical connector from rear of center panel.
REMOVAL
Lower LH Cover
REMOVAL
Lower RH Cover
1. Remove two grommet from grove box assembly.
2. Remove two screws and one nut from top of lower RH cover.
3. Remove two bolts from bottom of lower RH cover.
Page 42 of 76
REMOVAL
Ventilation Control Panel
2. Remove four mounting screws from rear of center panel trim.
3. Remove ventilation control panel.
REMOVAL
Glove Box
1. Remove two grommet from glove box assembly.
2. Remove three screws from bottom of glove box.

REMOVAL
Ducts
1. Remove mounting screws holding duct parts to instrument panel.
2. Remove LH side defroster duct.
3. Remove RH side defroster duct.
4. Remove center air duct.
5. Remove LH air duct grille.
6. Remove RH air duct grille.
REMOVAL
Floor-Mounted Ducts
1. Remove carpeting in area required for duct removal and installation.
2. Remove floor-mounted left, right, and center ducts.
3. Repair or replace section of floor-mounted ducts as necessary.
INSTALLATION
Page 43 of 76
1. Install instrument panel.
(1) Mount instrument panel into position.
Make sure steering column is mounted correctly through T-bar with electrical wire harness in position before
attempting to position instrument panel in place. If this is not done, column cannot be positioned correctly.
(2) Connect linking connectors between vehicle electrical wire harness and instrument panel.
Each connector is keyed so an electrical harness connector mates with correct instrument panel connector.
(3) Install two mounting bolts to passenger airbag.
(4) Install two mounting bolts on center of instrument panel.
(5) Install two mounting bolts on right side of instrument panel.
(6) Install two bolts on left side of instrument panel.
2. Install center panel.

(2) Install five screws on center panel.
3. Install lower RH cover.

(1) Install two bolts on bottom of lower RH cover.
(2) Install two screws and one nut on top of lower RH cover.
(3) Install two grommet on glove box assembly.

Page 44 of 76
4. Install two mounting screws and then connect electrical connector on rear of lower LH cover.
5. Install radio.
(1) Connect electrical connector and antenna cable on rear of radio.
(2) Install four screws on radio.
6. Connect electrical connector on rear of center panel trim and then fasten center panel cover.
7. Install console.
(1) Position console and install eight mounting screws.
(3) Install two mounting screws on front cover.
(4) Fasten rear cover to console.
8. Install instrument cluster.

(1) Position instrument cluster and connect electrical connector.
(2) Install four mounting screws.
(3) Install three screws to instrument cluster trim.
9. Install steering wheel, turn signal assembly and upper/lower column covers. Refer to group ST, Steering System.
10. Install driver air bag module. Refer to group RT, Restraints.
11. Install negative cable onto battery terminal.
INSTALLATION
Console
1. Position console and install eignt mounting screws.
3. Install two mounting screws on front cover.
4. Fasten rear cover to console.
INSTALLATION
Center Panel
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1. Install center panel.
(2) Install five screws on center panel.
2. Install lower RH cover.

(1) Install two bolts on bottom of lower RH cover.
(2) Install two screws and one nut on top of lower RH cover.
(3) Install two grommet on grove box assembly.
4. Install radio.
(1) Install four screws on radio.
(2) Connect electrical connector and antenna cable on rear of radio.
5. Fasten center panel cover and then connect electrical connector on rear of center panel trim.
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6. Install console.
(1) Position console and install five mounting screws.
(3) Install two mounting screws on front cover.
(4) Fasten rear cover to console.
INSTALLATION
Lower LH Cover
INSTALLATION
Lower RH Cover
1. Install two bolts on bottom of lower RH cover.
2. Install two screws and one nut on top of lower RH cover.
3. Install two grommet on grove box assembly.

INSTALLATION
Ventilation Control Panel
1. Position ventilation control panel.
2. Install four mounting screws from rear of center panel trim.
3. Install center panel trim.
(2) Install five screws on center panel trim.
INSTALLATION
Glove Box
1. Install two grommet on glove box assembly.
2. Install three screws on bottom of glove box.
INSTALLATION
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Ducts
1. Install RH air duct grille.
2. Install LH air duct grille.
3. Install center air duct.
4. Install RH side defroster duct.
5. Install LH side defroster duct.
6. Install mounting screws holding duct parts to instrument panel.
INSTALLATION
Floor-Mounted Ducts
1. Mount floor-mounted ducts into place on floor vehicle.
2. Install mounting screws.
3. Install carpeting in installation area.
Body (Interior and Exterior) > Interior > roof trim > Description and Operation
Description and Operation
Headliner is a cloth cushion that serves as a buffer between passengers and top of vehicle. It also covers thermal and
acoustic insulation in top of vehicle and wiring for dome light. Both headliner and insulation are replaceable.
Body (Interior and Exterior) > Interior > roof trim > Components and Components Location
COMPONENTS
Page 48 of 76
Body (Interior and Exterior) > Interior > roof trim > Repair procedures
REMOVAL
Headliner
1. Unscrew two mounting screws from sunvisors.
2. Remove sunvisors and sunvisors retaining clips.
3. Remove assist handle covers, unscrew mounting screws.
4. Remove three assist handles.
5. Gently remove lens assembly on interior and map light.

6. Remove light bulb.
7. Remove two mounting screws.
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8. Disconnect power connector and remove interior and map light.
9. Remove A,B and C-pillar trims. Refer to "Trim" in this section.

10. Remove seven fasteners.
11. Remove headliner.
INSTALLATION
Headliner
1. Reverse removal procedure.
Body (Interior and Exterior) > Interior > package trim > Repair procedures
REMOVAL
1. Remove high-mounted brake light assembly.
2. Remove five screws from left side of partition cover.
3. Repeat for right side.
4. Unfasten C-pillar trim.
5. Unfasten Package trim.
6. Remove Package trim.
INSTALLATION
1. Position Package trim.
2. Install five screws on right side partition cover.
3. Repeat for left side.
4. Install high-mounted brake light assembly.
Body (Interior and Exterior) > Interior > trunk trim > Repair procedures
Trunk End Trim
1. Remove two fasteners.
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2. Unfasten trunk end trim and remove trunk end trim.
INSTALLATION
Trunk End Trim
1. Position trunk end trim.
2. Install two fasteners to trunk end trim.
Body (Interior and Exterior) > Interior > interior trim > Description and Operation
Trim is a plastic molding and is used to cover interior of vehicle. It assists vehicle insulation by covering it in addition
to hiding vehicle metal frame. It also acts as a sound barrier.
It is used on all four doors of vehicle door opening scuff plate, A, B and C-pillars, front side, rear side and trunk end
trim. All door trim on vehicle includes pull handle. Each trim on front two doors provides a pocket for keeping
maps, etc.
Body (Interior and Exterior) > Interior > interior trim > Components and Components Location
COMPONENTS
Page 51 of 76
Body (Interior and Exterior) > Interior > interior trim > Repair procedures
REMOVAL
A-pillar Trim
1. Unfasten A-pillar trim with a trim removal tool.
2. Remove A-pillar trim.
REMOVAL
B-pillar Lower Trim
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1. Remove front and rear scuff plate.
2. Unfasten B-pillar lower trim with a trim removal tool.
3. Remove B-pillar lower trim.

REMOVAL
B-pillar Upper Trim
1. Remove front and rear scuff plate.
2. Unfasten B-pillar lower trim with a trim removal tool.
4. Remove two mounting screws from belt guide.
5. Remove upper anchor mounting bolt from safety belt.
6. Remove B-pillar upper trim with a trim removal tool.
REMOVAL
C-pillar Trim
1. Unfasten C-pillar trim.
2. Remove C-pillar trim.
REMOVAL
Front Door Trim
2. Remove door garnish.
(1) Unfasten garnish.
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(1) Remove one screw.

(1) Remove one screw on pull handle bracket.
(2) Remove two screws on right side of door trim.

(3) Remove two screws and cover on left side of door trim.
(4) Remove two screws on bottom of door trim.
(6) Remove front door trim by lifting front door trim up.
REMOVAL
Front Scuff Plate
1. Unfasten front scuff plate with trim removal tool.
2. Remove front scuff plate.
REMOVAL
Front Side Trim
1. Remove front scuff plate
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2. Remove one fastener from front side trim. Remove two screws from hood release handle(Left of front side trim
only)
3. Remove front side trim
REMOVAL
Rear Door Trim
2. Remove inside door garnish.
(1) Remove screw cover and one screw.

(1) Remove one screw on pull handle.
(2) Remove screw cover and two screws on left side of door trim.
(3) Remove one screw on right side of door trim.
(5) Disconnect power window switch connector.
REMOVAL
Rear Scuff Plate
1. Remove two fasteners from rear scuff plate.
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2. Unfasten rear scuff plate.
3. Remove rear scuff plate.
INSTALLATION
A-pillar Trim
1. Position A-pillar trim.
2. Press A-pillar trim into fasten clips.
INSTALLATION
B-pillar Lower Trim
1. Position B-pillar lower trim.
2. Press B-pillar lower trim into fasten clips.
3. Install front and rear scuff plate.
INSTALLATION
B-pillar Upper Trim
1. Position B-pillar upper trim.
2. Install upper anchor mounting bolt to safety belt.
Tighten mounting bracket bolt to : 25~33 Ib-ft (35~45 N.m, 3.5~4.5 kg-m)
3. Install two screws to belt guide.

4. Position B-pillar lower trim and press B-pillar lower trim.
5. Install front and rear scuff plate.
INSTALLATION
C-pillar Trim
1. Position C-pillar trim and press in.
INSTALLATION
Front Door Trim
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(2) Place front door trim.
(3) Install two screws on bottom of door trim.
(5) Install two screws on right side of door trim.
(6) Install one screw on pull handle bracket.

3. Install door garnish.
INSTALLATION
Front Scuff Plate
1. Position front scuff plate.
2. Press in front scuff plate into fasten clips.
INSTALLATION
Front Side Trim
1. Position front side trim.
2. Install one fastener to front side trim.
Install two screws to hood release handle(Left of front side trim only).
3. Install front scuff plate.
INSTALLATION
Rear Door Trim
(2) Place door trim.
(4) Install one screw on right side of door trim.
(5) Install one screw on pull handle.
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3. Install inside door garnish.

INSTALLATION
Rear Scuff Plate
1. Position rear scuff plate.
2. Press in rear scuff plate.
3. Install two fasteners to rear scuff plate.
Body (Interior and Exterior) > Bumper > front bumper > Description and Operation
DESCRIPTION AND OPERATING
Front and rear bumpers consist of three parts; bumper face, energy absorbing foam, and bumper reinforcement. The
bumperface is made of polypropylene and the absorption medium is styrofoam. Reinforcement is constructed of
polypropylene and reinforcing fiber with energy absorbing foam placed between bumper face and the reinforcement.
Body (Interior and Exterior) > Bumper > front bumper > Components and Components Location
COMPONENTS
Page 58 of 76
Body (Interior and Exterior) > Bumper > front bumper > Repair procedures
REMOVAL
1. Remove headlight and combination light assembly.
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2. Remove radiator grille guard.
3. Remove bumper face.

(1) Disconnect wire to fog light.
(2) Remove one fastener and two bolts from top of right side of bumper.
(3) Repeat for left side.
(4) Remove two screws from front side of bumper face.
(5) Remove one bolt from left side of bumper.

(6) Repeat for right side.
(7) Remove four fasteners from under cover.
4. Remove energy absorbent foam and reinforcement.

(1) Remove two nuts from left side of bumper back beam.
(2) Repeat for right side.
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REMOVAL, INSPECTION, REPLACEMENT
1. Remove fasteners from face and reinforcement while bumper is on work bench.
2. Remove reinforcement and inspect bumper face for damage. Replace as required.
3. Remove foam and inspect foam for damage or deterioration. Replace as required.
4. Inspect reinforcement for damage. Replace as required.
5. Install foam.
6. Install reinforcement.
7. Install fasteners that secure reinforcement to bumper face.
INSTALLATION
Install front bumper in reverse order of removal.
Tighten bumper mounting nuts to : 14~20 lb·ft (19~28 Nm, 1.9~2.8 kg·m)
INSPECTION
1. Inspect front bumper face for damage and check that front bumper is securely mounted.
2. Inspect front bumper for missing attaching hardware.
Body (Interior and Exterior) > Bumper > rear bumper > Components and Components Location
COMPONENTS
Page 61 of 76
Body (Interior and Exterior) > Bumper > rear bumper > Repair procedures
REMOVAL
1. Remove rear combination light assembly. Refer to BE Gr, Body Electrial System.
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2. Remove rear mud flap.
(1) Remove three bolts that secure left rear mud flap to mudguard.
(2) Repeat right side.
3. Remove trunk end trim and trunk side trim. Refer to "Trim" in this section.
4. Remove trunk side trim. Refer to "Trim" in this section.
5. Remove rear bumper assembly.
(1) Remove two bolts from left side of trunk.
(3) Remove one bolt from left side of bumper.
(5) Remove two bolts from top of left side of bumper.
(7) Remove two bolts from bottom of left side of rear bumper stay.
REMOVAL, INSPECTION, REPLACEMENT

1. Remove fasteners on face and reinforcement.
2. Inspect bumper face for damage. Replace as required.
3. Inspect energy absorbing foam for damage or deterioration. Replace as required.
4. Inspect reinforcement for damage. Replace as required.
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5. Install fasteners on face and reinforcement.
INSTALLATION
Tighten rear bumper mounting bolts to : 25~40 lb·ft (35~55 Nm, 3.5~5.5 kg·m)
INSPECTION
1. Inspect rear bumper face for damage and check that it is securely mounted.
2. Inspect rear bumper for missing attaching hardware.
Body (Interior and Exterior) > Seat & Power Seat > Components and Components Location
COMPONENETS
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Body (Interior and Exterior) > Seat & Power Seat > power seat moter > Repair procedures
INSPECTION
1. Disconnect the connectors for each motor.
2. When the battery connected directly to the motor terminals, check if the motors run smoothly.
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3. Reverse the connections and check that the motor reversely turns.
4. It there is an abnormality, replace the motors.
Body (Interior and Exterior) > Seat & Power Seat > powr seat control switch > Repair procedures
INSPECTION
1. Operate the power seat switch and check for continuity between terminals. If continuity is not as specified,
replace the switch.
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Slide motor limit switch

1. Disconnect the limit switch and operate the limit switch.
3. If there is an abnormality, replace the limit switch.
Height motor limit switch

The height motor limit switch builts in the height motor.
1. Check that the motor stop after about 1/2 turns counterclockwise.
2. Check that the motor stop after about 1/2 turns clockwise.
3. If operation is not as specified, replace the motor.
Body (Interior and Exterior) > Seat & Power Seat > front seat > Description and Operation
Front seat consists of a seat back and a cushion. Both items are replaceable or serviceable. Both seats can be
reclined or adjusted front-to-rear by two levers, adjusting lever and reclining lever. Head restraint can also be
adjusted or removed.
Seat adjuster lever is under right or left front corner of either front seat. Pulling on this lever unlocks seat, allowing it
to slide forward or backward on a track attached to vehicle floor. Track assembly and seat adjuster lock
arereplaceable items.
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Reclining lever arm is placed on door side of either seat. If this lever is pulled up and pressure is placed on seatback,
seatback will recline. If no pressure is applied, seat will spring forward past vertical driving position. If pressure is
applied to seatback, it will recline to vertical driving position and then lock. Reclining adjuster is a replaceable item.
Driver´s seat is also equipped with a lifter lever. This is controlled by a lever on left side of driver´s side seat cushion.
Lifter control lever is a replaceable item.
Body (Interior and Exterior) > Seat & Power Seat > front seat > Repair procedures
REMOVAL
Front Seat
1. Pull reclining lever and let seatback spring forward.
2. Pull seat adjuster and push seat all of the way back.
3. Remove two mounting bolts from front side of seat.
4. Move seat forward.
5. Remove mounting bolt and nut from rear side of seat.
6. Remove seat.
REMOVAL
Front Seatback
1. Remove seat from vehicle.
2. Remove back plate.
(1) Remove two clips from bottom of seat cushion.
(2) Pull out lower side of back plate.
(3) Remove back plate carefully, pulling down with hands.
3. Remove two mounting bolts from left side of seatback.

4. Repeat right side.
5. Remove seatback.
REMOVAL
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Front Seat Cushion
2. Remove four mounting bolts from bottom of seat assembly.
3. Remove seat cushion.
REMOVAL
Seat Side Cover
2. Remove four mounting bolts from bottom of seat assembly.
4. Remove seat adjust cover..

5. Remove four screws from side cover.
INSTALLATION
Front Seat
Reverse removal procedure.
Tighten bolts to : 25~40 Ib-ft (35~55 N.m, 3.5~5.5 kg-m)

Tighten nuts to : 17~26 Ib-ft (24~36 N.m, 2.4~3.6 kg-m)
INSTALLATION
Reverse removal procedures.
INSTALLATION
Front Seat Cushion
Tighten seat cushion mounting bolts to : 12~19 Ib-ft (17~26 N.m, 1.7~2.6 kg-m)
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INSTALLATION
Seat Side Cover
INSPECTION
1. Check that seat adjuster and reclining lever move smoothly.
2. Look under seat and visually check seat adjuster for wear or damage.
3. Apply grease to all exposed moving parts.
Body (Interior and Exterior) > Seat & Power Seat > rear seat > Description and Operation
The rear seat consists of two separate seatbacks, two separate side bolsters and a single cushion frame. Frame is
held in place by two mounted hinges.
Two side bolsters are attached to vehicle frame by bolt two seatbacks are attached toframe by mounted hinge
bushing and brackets.
In passenger carrying position, seatbacks are locked to vehicle frame by seatback strikers.
Body (Interior and Exterior) > Seat & Power Seat > rear seat > Repair procedures
REMOVAL
1. Remove two mounting bolts from rear side of cushion.
2. Push lock buttons as shown in figure to release cushion, and then pull seat cushion out.
3. Remove two mounting bolts from left side of seat hinge bracket.
4. Repeat right side.
5. Push lock button and fold seatback.

6. Remove four seatback mounting bolts from left ,right and center of hinge.
7. Remove one mounting bolts from left side bolster.
8. Remove one mounting bolts from right side bolster.
9. Remove left and right side bolster.
10. Remove left seatback.
11. Repeat for right side.
INSTALLATION
Reverse removal procedures.
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Tighten seat mounting bolts to : 12~19 Ib-ft (17~26 N.m, 1.7~2.6 kg-m)
Body (Interior and Exterior) > Seat Heater > Components and Components Location
COMPONENTS
Body (Interior and Exterior) > Seat Heater > Seat Heater switch > Repair procedures
INSPECTION
1. Inspect the switch continuity between terminals as below.
If the continuity is not as specified, replace the switch.

Page 71 of 76
Body (Interior and Exterior) > Seat Belt > front seat belt > Description and Operation
Safety belt system consists of five restraints. Outboard passengers (front and rear) have both shoulder and lap safety
belts. Inboard passenger (rear) has only a lap safety belt. Driver´s safety belt is equipped with a warning light on the
instrument panel and an audible chime to remind driver to fasten safety belt. Warning ceases after approximately 60
seconds. There are no warnings on other passengers´s belts. Retractors are securely mounted to body. Buckles are
also securely mounted to floor.
Body (Interior and Exterior) > Seat Belt > front seat belt > Components and Components Location
COMPONENTS
Body (Interior and Exterior) > Seat Belt > front seat belt > Repair procedures
REMOVAL
Page 72 of 76
Front Buckle Assembly
1. Remove screw cover near bottom of assembly.
2. Remove one bolt from mounting bracket.
REMOVAL
Front Lap/Shoulder Belt Assembly
1. Remove one bolt from mounting bracket and remove bracket.
2. Retract belt slowly as far as it will go.

3. Unsnap captive shoulder belt anchor bolt cover from bottom and lift up.
4. Remove one upper anchor bolt.
5. Remove retractor assembly.

(1) Remove B-pillar lower trim.
(2) Disconnect electrical connector from retractor assembly.
(3) Remove one sheet metal screw to remove retractor assembly.
6. Remove shoulder adjuster.

(1) Remove two sheet metal screws to remove belt guide.
(2) Unfasten B-pillar upper trim.
(3) Remove two mounting bolts from shoulder adjuster.
INSTALLATION
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Front Buckle Assembly
1. Install one bolt through mounting bracket.
Tighten mounting bolt to L 36~43 Ib-ft (50~60 N.m, 5.0~6.0 kg-m)
2. Install bolt cover.

INSTALLATION
Front Lap/Shoulder Belt Assembly
1. Install shoulder adjuster.
(1) Install two bolts to attach shoulder adjuster.
(2) Fasten B-pillar upper trim.
(3) Install two sheet metal screws to remove belt guide.
2. Install retractor assembly.

(1) Install one sheet metal screw to attach retractor assembly.
Exercise care to install belt so there are no twists in it. A twisted belt may be harmful to a passenger in
a serious accident. A twisted belt alters distribution of force resulting from sudden deceleration.
(2) Connect electrical connector to retractor assembly.

(3) Install B-pillar lower trim panel.
3. Install one upper anchor bolt.
Tighten anchor bolt to : 25~33 Ib-ft (35~45 N.m, 3.5~4.5 kg-m)

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4. Install one bolt through lap belt mounting bracket.
Tighten anchor bolt to : 25~33 Ib-ft (35~45 N.m, 3.5~4.5 kg-m)
INSPECTION
1. Inspect buckle assembly mounting to ensure that it is secure.
2. Inspect anchor assembly mounting to ensure that it is secure.
4. Inspect retractor assembly mounting to ensure that it is secure.
5. Install B-pillar lower trim.
6. Extend safety belt fully to ensure its motion is smooth and easy.
7. Retract safety belt fully to ensure its motion is smooth and easy.
8. Buckle safety belt. Pull firmly on each side of buckle to ensure that it is secure.
9. Press buckle release button to ensure that it releases correctly and returns to its original position. Do not
disassemble either buckle or retractor assemblies. They are not repairable.
10. Inspect safety belt reminder system with driver´s safety belt retracted. Turn ignition key to "ON" position. Safety
belt icon on warning and indicator panel will light up and a chime will be heard. Lighted icon and chime indicate
that driver´s safety belt is not buckled. Chime will not be heard after 5~6 seconds. Turn ignition key to "LOCK"
position. Safety belt icon and chime will extinguish. Turn key to "ON" position. Just as before, safety belt icon
will light up and chime will be heard. Buckle driver's safety belt. Safety belt icon and chime will extinguish. Turn
key to "LOCK" position and remove key.
If a safety belt is not functioning and cannot be immediately repaired, warn the customer not to use that seating
position. If the customer must use that seating position, encourage the customer to use a substitute vehicle until the
proper repairs can be made. If the customer refuses, refer the matter to the Service Manager.
Body (Interior and Exterior) > Seat Belt > rear seat belt > Repair procedures
REMOVAL
Rear Buckle Assembly
1. Pull safety belts to rear through seats.
2. Remove rear seat cushion.
3. Remove one bolt from rear buckle assembly mounting bracket.
REMOVAL
Rear Lap/Shoulder Belt Assembly
1. Remove rear seat cushion.
2. Remove side bolster.
(1) Fold rear seatback for the floor of body.
(2) Remove two mounting bolts from rear seat hinge.
(3) Remove one bolt from side bolster.
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3. Remove one bolt from lap belt mounting bracket.
4. Retract belt slowly as far as belt will go.

5. Remove C-pillar trim.
6. Remove package tray.
7. Remove one bolt and one sheet metal screw to attach retractor assembly.
INSTALLATION
Rear Buckle Assembly
1. Install mounting bolt through bracket.
Tighten mounting bolt to : 29~40 Ib-ft (40~55 N.m, 4.0~5.5 kg-m)
2. Feed buckle between seatback and cushion without any twists.

INSTALLATIN
Rear Lap/Shoulder Belt Assembly
1. Install retractor mounting bolt and sheet metal screw.
2. Install package tray.
3. Install C-pillar trim.
4. Install one bolt through lap belt mounting brakcet.
Tighten mounting bolt to : 29~40 Ib-ft (40~55 N.m, 4.0~5.5 kg-m)
5. Install side bolster.

6. Install rear seat cushion.
INSPECTION
1. Inspect three buckle assembly mountings to ensure that they are secure. (This is done from rear of vehicle.)
2. Inspect remaining belt´s mounting to ensure that it is secure. (This is done from rear of vehicle.)
3. Pull safety belts to rear between seatback and cushion.
5. Inspect outboard lap belt mountings to ensure that they are secure.
6. Disconnect fasteners of C-pillar trim from body and pull C-pillar trim down completely.
7. Fold rear seatback forward for front side of seat cushion.
8. Remove package tray.
9. Inspect retractor assembly mountings to ensure that they are secure.
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If a safety belt is not functioning and cannot be immediately repaired, warn the customer not to use that seating
position. If the customer must use that seating position, encourage the customer to use a substitute vehicle until the
proper repairs can be made. If the customer refuses, refer the matter to the Service Manager.
Page 1 of 45
OPTIMA(MS) > 2001 > G 2.4 DOHC > Restraint
Restraint > General Information > Special Service Tools

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

Dummy adapter
0957A-38000 Wiring harness checker of each

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

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

SRSCM(SRS CONTROL MODULE)
The supplement restraint system (SRS AIRBAG) is designed to supplement the seat belt to help reduce the risk or
severityof injury to the driver and passenger by activating and deploying the driver and passenger side airbag in
certain frontal or side collisions.
The SRSCM type equipped with this model is HAE-3. HAE-3 is applied for DAB + 2BPT, DAB + PAB + 2BPT,
DAB + PAB + 2BPT + 2FSAB.
The SRS (Airbag) consists of : a driver side airbag module located in the center of the steering wheel, which
contains the folded cushion and an inflator unit ; a passenger side airbag module located in the passenger side crash
pad containsthe folded cushion assembled with inflator unit ; Side airbag modules located in the driver and passenger
seat contain the folded cushion and an inflator unit. SRSCM located on the floor under the heater core which
monitors the system, an accelerometer which senses the vehicle deceleration, a spring interconnection (clock spring)
located within the steeringcolumn; system wiring and wiring connector; and a knee bolster located under the steering
Page 2 of 45
column. The impact sensing function of the SRSCM is carried out by electronic accelerometer that continuously
measure the vehicle's acceleration and delivers a corresponding signal through amplifying and filtering circuity to the
microprocessor. Deployment of the airbag is designed to occur in frontal or near-frontal or side impacts of moderate
of severe force. Only authorized service personnel should do work on or around the SRS components. Those
service personnel should read this manual carefully before doing any such work. Extreme care must be used when
servicing the SRS to avoid injury to the service personnel (by inadvertent deployment of the airbag) or the driver (by
render the SRS inoperative).
CUSTOMER CAUTIONS
Failure to carry out service operations in the correct sequence could cause the airbag system to unexpectedly deploy
during servicing, possibly leading to a serious injury. Further, if a mistake is made in servicing the airbag system, itis
possible that the airbag may fail to operate when required. Before performing servicing (including removal or
installation of parts, inspection or replacement), be sure to read the following items carefully.
1. Be sure to proceed airbag related service after approx. 30 seconds or longer from the time the ignition switch is
turnedto the LOCK position and the negative (-) terminal cable is disconnected from the battery. The airbag
system is equipped with a back-up power source to assure the deployment of airbag when the battery cable is
disconneted by an accident. The back-up power is available for approx. 150ms.
2. When the negative(-) terminal cable is disconnected from the battery, memory of the clock and audio systems will
be canceled. So before starting work, make a record of the contents memorized by the audio memory system.
When the work is finished, reset the audio system and adjust the clock.
3. Malfunction symptoms of the airbag system are difficult to confirm, so the diagnostic codes become the most
important source of information when troubleshooting.
4. When troubleshooting the airbag system, always inspect the diagnostic codes before disconnecting the battery.
5. Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.
6. Never attempt to disassemble and repair the airbag modules (DAB,PAB, SAB, BPT), clock spring and wiring in
order to reuse them.
7. If any component of SRS has been dropped, or if there are cracks, dents or other defects in the case, bracket or
connector, replace them with new ones.
8. After work on the airbag system is completed, perform the SRS SRI check. The airbag indicator lamp can be
interrupted byother curcuit fault in some cases. Therefore if the airbag indicator lamp goes on, be sure to erase
the DTC codes usingHi-scan just after repairing or replacing the troubled parts including fuse.
9. Especially in case of welding the body, never fail to disconnect the battery negative (-) terminal.
WARNING/CATTION LABELS
A number of caution labels relating to the SRS are found in the vehicle, as shown in the following illustration.
Followlabel instructions when servicing SRS. If labels are dirty of damaged, replace them with new ones.
Page 3 of 45
Page 4 of 45
A. DAB + PAB B. SUPPLEMENTAL RESTRAINT SYSTEM
CAUTION TO AVOID SERIOUS INJURY : (AIRBAG) INFORMATION
• For maximum safety protection in all types of The airbag is a supplemental restraint system (SRS).
crashes, you must always wear your safety belt. You must always wear the seat belts. The airbag system
• Do not install rearward-facing child seats in any front condition isnormal if "SRS" lamp in cluster flashes
passenger seat position. approximately 6 times after ignition key is turned on and
• Do not sit or lean unnecessarily close to the airbag. then goes out. If anyof the following conditions occur,
• Do not place any objects over the airbag or between the system must be serviced :
the airbag and yourself. 1. "SRS" lamp does not light when key is turned on.
• See the owner's manual for further information and 2. "SRS" lamp stays lit or flashes continuously.
explanation. 3. The airbag has inflated.
The airbag system must be inspected by an authorized
dealer ten years after vehicle manufacture date shown on
certification label located on left front door opening area.
C. CAUTION : AIRBAG ESPS UNIT D. CAUTION : SUPPLEMENTAL RESTRAINT
Detach connector before removing. Assemble strictly SYSTEM MODULE
according to manual instructions. To help avoid personal injury due to unwanted inflation
do not service or dispose of this unit without following
instructions in the service manual.
E. WARNING : F. CAUTION : SRS clock spring
Contents are poisonous and extremely flammable. Do This is not a repairable part. Do not disassemble or
not probe with electrical devices or otherwise tamper tamper. If defective replace entire unit per service
with in any way. Servicing of this unit to be performed manual instructions. To re-center rotate clockwise until
only by authorized personnel. tight. Then rotate in opposite direction approximately 3
turns and align. Failure to follow to instructions may
render SRS system inoperative risking serious driver
injury.
G. CAUTION : SRS H. WARNING
Before removal of steering gearbox, read service This car is equipped with a side airbag in each front seat.
manual, center front wheels and remove ignition key. • Do not use any accessory seat covers.
Failure to do so may damage SRS clock spring and • Use of other seat covers could reduce the effect of
render SRS system inoperative, risking serious driver the system.
injury. • Do not install any accessories on the side or near the
side airbag.
• Do not use excessive force on the side of the seat.
• For further information, see owner's manual.
I. ATTENTION
Do not open, remove or put into another vehicle. Risk of
malfunction and body injury.
ELECTRICAL SYSTEM
The SRS airbag system has sophisticate electrical and electronic components, therefore the airbag operating
components should be handled very carefully.
Page 5 of 45
1. SRSCM(Supplemental Restraint System Control Module)
SRSCM determines to deploy the airbag module by sensing the frontal and side impact sensed by the sensor built
in SRSCM.
A. DC/DC convertor : The power supply DC/DC converters include a step-up and step-down converter, which
provides the firingvoltage for two firing circuits and the internal operating voltage. If the internal operating
voltage falls below a defined threshold, a reset is executed.
B. Arming sensor/safing sensor : The arming/safing sensor built in the airbag firing circuit has the function of
arming theairbag circuit under all required deployment condition and maintaining the airbag firing circuits
unarmed under normal driving conditions. The safing sensor is a dual-contact electromechanical switch which
closes if it experiences a deceleration exceeding a specified threshold.
C. Back-up power : The SRSCM reserves the energy supply to provide deployment energy for a short second
when the vehicle voltage is low or if lost in a vehicle frontal crash.
D. Malfunction detection : The SRSCM continuously monitors the current SRS operation status while the ignition
key is turned on and detects the malfunction of the system. The malfunction can be displayed in the form of
diagnostic trouble code using Scan tool (Hi-scan).
E. MIL (Malfunction Indication Lamp) notification : If any fault is detected, the SRSCM sends signal to the
indicator lampon the cluster to warn the vehicle driver. The MIL indicator is the key to driver notification of
SRS faults. Verify lampand SRSCM operation by flashing 6 times when the ignition switch is first turned on.
F. Malfunction recording : Once a fault occurred in the system SRSCM records the fault in the memory in the
form of DTC and the DTC can only be erased with the scan tool.
G. Data link connector : The SRSCM memory stored data is accessed through the OBD-II Data Link
Connector (DLC) using a scantool. The DLC is located underneath the driver side crash pad.
H. After firing the airbags once, the SRSCM cannot be used again and must be replaced.
I. Crash output
The crash output is used to control an external device such as door control module in case of a crash event.
The crashoutput is specified as follows : The crash output is open-collector type switch logic output with
500mA of sine current and its output impedance is 100Ω. The crash output is switched to ground for 200ms
after the crash detected.
INFLATOR MODULE (DAB, PAB, SAB)
DAB (Driver airbag), PAB (Passenger airbag) module and SAB (Side Airbag) are comprised of inflator and
cushion. The initiator (A gas generator igniting device) is assembled in the inflator. When the vehicle is in a frontal or
side crash of sufficient force to close the sensor of SRSCM, current is developed through the deployment loop.
Current passing throughthe initiator ignites the material in the DAB and PAB module or SAB module and inflates the
airbag.
Page 6 of 45
1. When removing the airbag module or handling a new airbag module, it should be placed with the pad top surface
facing up.In this case, the twin-lock type connector lock lever should be in the lock state and care should be
taken to place it so the conector will not be damaged. Do not store a steering wheel pad on top of another one.
(Storing the pad with its metallic surface up may lead to a serious accident if the airbag should inflate for some
reason.)
2. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very
dangerous.)
3. Store the airbag module where the ambient temperature remains below 93°C (200°F), without high humidity and
away from electrical noise.
4. When using electric welding, disconnect the airbag connectors under the steering column near the MULTI-
FUNCTION SWITCH connector before starting work.
SRS HARNESS
The SRS harness is wrapped in a yellow split-wrap tube so that it can be easily identified from the other vehicle
harness. A shorting bar is included inside the wiring connectors of DAB, PAB SAB and BPT inflator side. The
shorting bar shorts the current flow DAB, PAB SAB and BPT module circuit when the connectors are
disconnected. The circuits to the inflator module are shorted in this way to help prevent unwanted deployment of the
airbag when servicing the airbag module.
SRSCM INDEPENDENT LAMP ACTIVATION
The SRS malfunction indicator lamp (MIL) is located on the cluster and provides information of SRS operating
conditions by the control signals from SRSCM.
There are certain fault conditions in which the SRSCM (SRS Control Module) cannot function and thus cannot
control the operation of the lamp. In these cases, the lamp is directly activated by appropriate circuitry that operates
independently of the SRSCM, as follow :
1. Loss of ignition voltage supply to the SRSCM : lamp turned on continuously.
2. Loss of internal operating voltage : lamp turned on continuously.
Page 7 of 45
3. SRSCM not connected : lamp turned on through shorting bar in wiring harness connector.
MIL OPERATIONG METHOD
CLOCK SPRING
1. The clock spring (coil spring) consists of two current carrying coils. It is attached between the steering column
and the steering wheel. It allows rotation of the steering wheel while maintaining continuous contact of the
deployment loop through the inflator module.
The steering wheel must be fitted correctly to the steering column with the clock spring at the neutral position,
otherwise cable disconnection and other troubles may result.
PPD (Passenger Presence Detection)

1. The passenger presence detection system detects the presence of passenger in the seat. The system is designed
primarilyto prevent replacement of airbag components that fire needlessly in an accident. The PPD system
consists of a weight sensor and an interface unit.
The threshold for PPD is ; occupied (15 kg), not occupied (0.6 kg) The sensor characteristics is defined :
RP ≤ 50 kΩ for W ≥ 15 kg
RP > 50 kΩ for W < 0.6 kg
(RP : Resistance of force sensing resistor)
(W : Mass of weight)
SATELLITE SENSOR (SIDE IMPACT SENSOR)

Page 8 of 45
1. The release system for the side airbag consists of a HEA-3 installed in the middle of the vehicle and two satellites
- one on the left-hand side and one on the right. Only the HEA-3 is capable of releasing the airbags or the seat-
belt pretensioners systems in the vehicle. In the dialog between the HEA-3 and the satellite, it is the HEA-3 which
makes the release decision. The HEA-3 is supported in connection with the side airbag function by the two
satellites, which act as intelligent acceleration sensors and as such back up the central airbag controller. Both the
satellites continuouslyreport the current system status on the left and right-hand sides of the vehicle to the HEA-3.
It monitors the acceleration sensor continuously. The test results are reported to the HEA-3 by means of periodic
status signals.
SYSTEM COMPONENT AND LAYOUT

Page 9 of 45
AIRBAG SYSTEM (SRS)
SRSCM CONNECTOR (SRE-HMC)

Page 10 of 45
Restraint > Supplemental Restraint System Control Module (SRnodeM) > Troubleshooting
TROUVLESHOOTING
DIAGNOSTIC TROUBLESHOOTING FLOW
Page 11 of 45
SPECIFICATION
Squibs
Items
DAB PAB SAB BPT
Resistance 2Ω ± 0.3Ω 2.2Ω ± 0.3Ω 2.15Ω ± 0.35Ω
0.36A for 10 200mA for
No-current 0.25A for 10sec 0.4A for 10 sec
sec 10sec
All-fire current 1.2A for 3msec 1.2a for 2msec 1.2A for 3mS 800mA for 2mS
Cyclic test
100mA continous 40mA continous
current
DIAGNOSIS WITH HI-SCAN

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

3. Perform the SRS diagnosis according to the vehicle model configuration.
Page 12 of 45
4. If a fault code is retrieved, then replace the component. Never attempt to repair the component.
5. If the Hi-scan finds that a component of the system is faulty, there is a possibility that the fault is not in the
components but in SRS wiring or connector.
INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODE
DTC No. Fault description
B1111 Battery voltage too high
B1112 Battery voltage too low
B1346 DAB, Resistance too high or open
B1347 DAB, Resistance too low or short
B1348 DAB, Short to GND
B1349 DAB, Short to Battery
B1352 PAB, Resistance too high or open
B1353 PAB, Resistance too low or short
B1354 PAB, Short to GND
B1355 PAB, Short to Battery
Driver side airbag, Resistance too
B1378
high or open
Driver side airbag, Resistance too
B1379
low or short
B1380 Driver side airbag, Short to GND
B1381 Driver side airbag, Short to Battery
Passenger side airbag, Resistance
B1382
too high or open
Passenger side airbag, Resistance
B1383
too low or short
Passenger side airbag, Short to
B1384
GND
Passenger side airbag, Short to
B1385
Battery
Driver seat belt pretensioner,
B1361
Resistance too high or open
Driver seat belt pretensioner,
B1362
Resistance too low or short
Driver seat belt pretensioner, Short
B1363
to GND
Driver seat belt pretensioner, Short
B1364
to Battery
Passenger seat belt pretensioner,
B1367
Resistance too high or open
B1368
Resistance too low or short
Page 13 of 45
B1369
Short to GND
B1370
Short to Battery
Satellite left side short to GND or
B1401
short
Satellite left side short to Battery or
B1402
open
B1400 Satellite left side defect
Satellite right side short to GND or
B1404
short
Satellite right side short to Battery
B1405
or open
B1403 Satellite right side defect
B1408 Satellite left communication error
B1410 Satellite right communication error
B1407 PPD communication error
B1406 PPD defect
B1661 ECU mismatching
Driver seat-belt buckle switch short
B1511
to Battery or open
Driver seat-belt buckle switch short
B1512
to GND or short
Passenger seat-belt buckle switch
B1513
short to Battery or open
Passenger seat-belt buckle switch
B1514
short to GND or short
B1650 Crash recorded front airbag
B1655 Crash recorded side airbag
B1657 Ignition recorded belt pretensioner
B2500 Warning lamp failure
B1620 Internal fault
Restraint > Airbag Module > Repair procedures

AIRBAG MODULE DISPOSAL
FIELD DEPLOYMENT PROCEDURES
When handling the deployed airbag, be careful not to let the by-product dust enter to eye and always wear gloves
to avoid direct contact the by-product material.
Page 14 of 45
AIRBAG MODURE DISPOSAL PROEDURES
Before either disposing of a vehicle equipped with an airbag, or prior to disposing of the airbag module, be sure to
first follow the procedures described below to deploy the airbag.
AIRBAG REMOTE DEPOLYMENT DEVICES
Tool, Number, Name Use
Deploymint tool (0957A-34100-A)
SRS DEPOLYMINT ADAPTER HARNESS
DAB : 0957A-38000
PAB : 0957A-34200
○Deploymint insede the vehicle (when wehicle eill not

longer be driven)
DISPOSAL PLAN
When the provblem occurs, thake disposal steps as follows.
Case Disposal plan
Abonormal problems in
Retrun to KMC
airbag module
Deploy the airban module in the ssscrapper yard with
Car scrapping DAB, PAB, SAB, BPT
SST
Crash (Deployed) Service station disposes the Airbag module
UNDEPLOYED AIRBAG MODULE DISPOSAL
1. If the vehicle is to be scrapped, junked, or otherwise disposed of, deploy the airbag inside the vehicle.
2. Since there is a loud noise when the airbag is deployed, avoid residential areas whenever possible. If anyone is
nearby, give warning of the impending noise.
3. Since a large amount of smoke is produced when the airbag is deployed, select a well-ventilated site.
Moreover, never attempt the test near a fire or smoke sensor.
DEPLOYMENT INSIDE THE VEHICLE(When vehicle will no longer be driven)
1. Open all windows and doors of the vehicle. Move the vehicle to an isolated spot.
Page 15 of 45
2. Disconnect the negative (-) and positive (+) battery cables from the battery terminals, and then remove the
battery from the vehicle.
Wait at least 30 seconds after disconnecting the battery cable before doing any further work.
3. Remove the center crash pad side cover.
4. Disconnect airbag SRSCM connector.
5. Connect deployment tool to the connector of each module.
6. At location as far away from the vehicle as possible, press the push button (removed from the vehicle) to deploy
the airbag.
1. Before deploying the airbag in this manner, first check to be sure that there is no one in or near the
vehicle. Wear safety glasses.
2. The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to allow
it to cool before attempting to handle it. Although not poisonous, do not inhale gas from airbag
deployment. See Deployed Airbag Module Disposal Procedures for post-deployment handling
instructions.
3. If the airbag fails to deploy when the procedures above are followed, do not go near the module.
Contact your local distributor.
DEPLOYMENT OUTSIDE VEHICLEF
1) Failure to follow all warnings, cautions, notices and procedures could result in personal injury or death.
2) Surface of a deployed airbag may contain small amounts of sodium hydroxide(NaOH). Prevent contact of
airbag module withliquids, combustibles, and flammable materials. Immediately wash hands and exposed skin
areas with mild soap and water. Flush eyes with water if exposed to by products. Failure to following these
instructions could result in chemical burns and personal injury.
3) A live(undeployed) airbag module may accidently deploy during handling. When carrying a live airbag module,
point trim cover away from your body to lessen chance of injury in case of accidental deployment. Never carry
module by its wiring or connectors.
4) Always place live airbag modules face up to lessen motion of module in case of accidental deployment. Keep
area clear of parts, tools, and debris.
5) Never place items on or above trim cover of a live airbag module. In case of accidental deployment, such items
may cause serious injury or death..
Page 16 of 45
6) Damaged airbag modules should be stored away from all acids, halogens, heavy metals, and metal salts.
Damaged units mayproduce hydrozoic acid if exposed to liquids. If an undeployed airbag module or inflator is
ruptured or tampered with, refer to particular module´s msds(material safety data sheet) for important
information concerning constituents of undeployed modules. Exposure to high concentrations of airbag
porpellant mixture can cause headaches, nausea, blurred vision, faintnesss, cyanosis, lowering of blood pressure
or tachycardia. Failure to comply with this warning can result in fire, noxious fumes, severe personal injury, or
death.
7) Air bag module components are very hot after deployment. Units should be deployed outdoors or in an open
area to prevent fires. Allow components at least twenty minutes to thoroughly cool. Cooling modules should be
continuously monitoredto ensure hot components do not create fires with spilled liquids or other debris. Failure
to allow unit to cool couldresult in burns, fires or personal injury.
8) Always wear rubber gloves and safety glasses when handling a deployed airbag module.
Storage, transportation, disposal and recycling of airbag module and components must be performed in
accordance with all applicable state and local regulations including, but not limited to, environmental protection,
occupational health and safety, and transportation.
Failure to follow the following procedures could result in personal in jury or death.
1. Remove battery.
2. Wait 30 seconds before proceeding.
3. Disconnect appropriate Airbag Module, and remove from vehicle.
4. Locate airbag in an area that will provide protection to personnel when it deploys. An example of a safe
deployment site is a stack of used tires, 6-8 high, with undeployed bag located inside column of tires.
5. Connect the Air Bag Deployment Tool (K95U-6000-BDY) to the Air Bag Module connector, and position the
deployment tool 20 feet away from the deployment site.
6. Connect the red lead to the positive terminal of the battery.
7. Connect the black lead to the negative battery terminal.
Do not place the airbag with the trim cover facing down, as the force of the deploying airbag could cause it
to ricochet and cause personal injury.
8. Verify that green POWER indicator on deployment tool is illuminated.
9. Depress and hold READY button (button number 1).
10. Verify that yellow READY indicator is flashing.
11. Depress and hold DEPLOY button (button number 2).
12. Verify that Air Bag module has deployed. If not, verify that red DEPLOY indicator is illuminated.
13. Release both READY and DEPLOY buttons.
Page 17 of 45
14. Verify that both READY and DEPLOY indicators are no longer illuminated.
15. If air bag successfully deployed, allow a minimum of twenty minutes for bag to cool before handling. Monitor
bag throughout cool-down period to ensure that hot components do not start a fire.
16. If air bag did not deploy, keep area around deployment site clear of personnel for a minimum of 30 minutes.
17. Disconnect the power leads from the battery.
18. Remove the air bag from the stack of tires carefully, wearing rubber gloves and eye/face protection to protect
yourself from possible chemical exposure.
19. Dispose of the complete air bag assembly. No part of the air bag may be reused. Place the air bag into a sturdy
plasticbag and seal securely. Dispose of the deployed air bag according to federal, state and local laws and
regulations including, but not limited to, EPA and OSHA regulations.
20. Install battery.

DEPLOYED AIRBAG MODULE DISPOSAL PROCEDURES
After deployment, the airbag module should be disposed of in the same manner as any other scrap parts, except that
the following points should be carefully noted during disposal.
1. The inflator will be quite hot immediately following deployment, so wait at least 30 minutes to allow it to cool
before attempting to handle it.
2. Do not put water or oil on the airbag after deployment.
3. There may be, adhered to the deployed airbag module, material that could irritate the eyes and/or skin, so wear
gloves and safety glasses when handling a deployed airbag module. IF DESPITE THESE PRECAUTIONS,
THE MATERIAL DOES GET INTO THE EYES OR ON THE SKIN, IMMEDIATELY RINSE THE
AFFECTED AREA WITH A LARGE AMOUNT OF CLEAN WATER. IF ANY IRRITATION
DEVELOPS, SEEK MEDICAL ATTEN-TION.
4. Tightly seal the airbag module in a strong vinyl bag for disposal.
5. Be sure to always wash your hands after completing this operation.
Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring > Components and
Components Location
COMPONENTS
Page 18 of 45
Restraint > Airbag Module > Driver Airbag (DAB) Module and Clock Spring > Repair procedures
REMOVAL
Page 19 of 45
1. Disconnect the negative battery cable and keep it secured away from the battery.
Wait at least 30 seconds after disconnecting the battery cable before doing any further work to prevent
inadvertent deployment of the airbags.
2. When disconnecting the clock spring connector from the airbag module, pull the locking device on the connector
outward and spread it open.
3. When disconnecting the connector of the clock spring from the airbag module, pull the airbag's lock toward the
outer side to spread it open.
• When disconnecting the airbag module-clock spring connector, take care not to apply excessive force
to it
• The removed airbag module should be stored in a clean, dry place with the pad cover face up.
4. Remove the steering wheel.
Do not hammer on the steering wheel. Doing so may damage the collapsible column mechanism, thus
reducing the protection to the driver in a frontal crash.
Page 20 of 45
INSPECTION
AIRBAN MODULE
If any improper parts are found during the following inspection, replace the airbag module with a new one.
Dispose the old module according to the specified procedure.
Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the specified
tester. If the circuit resistance is measured with a tester, accidental airbag deployment will result in serious personal
injury.
1. Check pad cover for dents, cracks or deformities.
2. Check the airbag module for denting, cracking or deformation.
3. Check hooks and connectors for damage, terminals for defor-mities, and harness for binds.
4. Check airbag inflator case for dents, cracks or deformities.
5. Install the airbag module to steering wheel to check fit or align with the wheel.
CLOCK SPRING
If, as a result of the following checks, even one abnormal point is discovered, replace the clock spring with a new
one.
1. Check connectors and yellow protective tube for damage, and terminals for deformities.
Restraint > Airbag Module > Passenger Airbag (PAB) Module > Repair procedures
REMOVAL
Page 21 of 45
1. Never attempt to disassemble or repair the airbag module.

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

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

CIRCUIT INSPECTION
B1111 Battery voltage
too high
DTC
B1112 Batteru voltage
too low
CIRCUIT DESCRIPTION
Since the source voltage can fluctrate, the SRS is equipped with a voltage-increase/voltage-decrease circuit
(DC/DC converter) in the SRSCM to adjust for any fluctuations in the sourcr voltage. When the battery voltage
fluctrates, the DC/ DC converter adjust the voltage to the SRS by either increasing or decreasing to maintain normal
system voltage. Lit up and the DTC is a B1111 or B1112 code, battery voltage too high or low is indicated.
Malfunction in this circuit is not recorded in the B1111 of B1112 code, battery voltage too high or low, and the
Page 22 of 45
voltage returns to normal, the SRS warning light automatically goes off.
INSPECTION PROCEDURE
Preparation
1) Disconnect negative (-) terminal cable
from the battery, and wait at least 30secids.
2) Remove the DAB module.
3) Disconnecto connectors of PAB left and
right side airbah, belt pretensioner and
1 satellite sensor. - -
4) Disconnect connector of SRSCM.
Store the DAB with the front surface

facing upward.
Check source voltage.

1) Connect negative (-) terminal cable to
battery.
2) Turn ignition switch ON. Check the harness between battery and
[CHECK] NG SRSCM, and check the battery and
Measure voltage between the battery supply charging system.
5 of SRS connector and body ground.
2 LIMIT : 10 - 16.5 V
OK Go to step
Check for DTCs. If a DTC is output,

perform troubleshooting for the DTC. If
NG
B1111 of B1112 is output, replace
3 Does SRS warning light goes off. SRSCM.
From the results of the above inspection. the
OK malfunctioning part can now be considered
normal.

B1346 DAB resistance
too high
DTC
B1347 DAB resistance
too low
CIRCUIT CESCRIPTION
Page 23 of 45
The DAB squi circuit consists of the SRSCM, clock spring and DAB. The squib is shat causes the airbag to deploy
shen airbag depolyment conditions are satisfied.
The above DTC's are recorded shen DAB resistance too high or low is detected in the DAB squib circuit.
DTC Detection Condition Troubler Area
· Too high or low resistane between DAB high (+)
· DAB squib
wiring harness and DAB low (-) wiring harness of squib
· Clock spring
· DAB malfunction
· Satellie sensor
· Clock spring malfunction
· Wire harness
· SRSCM malfunction
Preparation
1) Disconnect negative (-) terminal cable from the battery, and wait
at least 30secids.
3) Disconnect connectors of PAB left and rigt side airb, beot
1 pretensooner and satellite sensor. - -
Store the DAB with the front surface facing upward.
Check DAB resistance.

[PREPARATION]
Release airbag activation prevention mecganism on SRSCM side of
aifbag squib side.
NG Go to step "4".
Connect the dummy(0957A-38200) to clock spring side
connector.
[CHECK]
Measure the resistance between DAB high (+) and low(-).
2 1.7Ω < R < 2.3Ω
OK Go to step "3".
Check DAB squib

[PREPARATION]
1) Turn ignition switch to LOCK.
at least 30seconds.
3) Connect DAB connector. NG Replace DAB.
4)Connecto negative (-) terminal cable to the battery, and wait at
least 30seconds.
[CHECK]
Page 24 of 45
1) Turn ignition switch to ON, and wait at least 30 seconds.
2) Clear malfunction code stored in memory with Hi-scan.
3) Turn ignition switch to LOCK, and wait at least 30 seconds.
3 4) Turn ignition switch to ON, and wait at least 30 seconds.
5) Using Hi- scan, check DTC.
DTC is not output.
[HINT]
Codes other than these noes may be output at this time, but they
are not relevant to this check. From the result of the above
OK inspection, the malfunctioning part
can now be considered normal.
Check Clock spring.

[PREPARATION]
Disconnecto connector etween SRSCM clock sprin,g and connect
the dummy connector (0957A-38200) to colck spring side NG Replace clock spring.
connector.
[CHECK]
Measure the resistance between DAB high (+) and low(-).
4 1.7Ω < R < 2.3Ω
Repair or replace the harness

OK between SRSCM and clock
spring.

B1348 DAB Short ground
B1354 PAB Short to ground
B1380 Driver SAB Short to ground
B1363 Driver BPT Short to ground
B1369 Passenger BPT Short to ground
DTC
B1401 Satellite right side short to ground
B1512 Driver seat belt buckle switch to
groundor short
B1514 Passenger seat belt buckle switch to
ground or short
CIRCUIT CESCRIPTION
The squib circuit consists of the SRSCM, clock spring, DAB, PAB, SAB, BPT, BBS, and front satellite sensors, If
it causes the SRS to deploy when the SRS edpolymint conditions are satisfied.
Page 25 of 45
The above DTC's are recorded when a short to ground is detected in the squib circuit.
· DAB squib
· PAB squib
· Short circuit in squib wire · SAB squib
garness (to ground) · BPT squib
· Squib malfunction · BBS squib
· Clock spring malfunction · Satellie sensor
· SRSCM malfunction · Clock spring
· SRSCM
· Wire harness
Preparation
at least 30secids.
Check DAB squib circuit.

[CHECK]
For the connector (on the clock spring side ) between clock spring
and DAB, measure the resistance between DAB high and body NG Go to step "13".
ground.
Resistance : ∞
2
OK Go to step "8".
Check PAB squib circuit.

[CHECK]
For the connector (on the SRSCM side) between SRSCM and Repair or replace harness or
PAB, measure the resistance between PAB high and body ground. NG connector between SRSCM
Resistance : ∞ and PAB.
3
Page 26 of 45
3
OK Go to step"9".
Check SAB squib circuit.

[CHECK]
For the connector (on the STSCM side)between STSCM and SAB, Repair or replace harness
measure the resistance between SAB high and body ground. NG
between SRSCM and SAB.
Resistance :∞
4
OK Go to step "10".
Check BPT squib circuit.

[CHECK]
For the connector (on the SRSCM side) between STSCM and BPT, Repair or replace harness
measure the resistance between BPT high and body ground. NG
between SRSCM and BPT.
Resistance :∞
OK Go to step "11".
Check Satellite sensor circuit.

[CHECK]
For the connector (on the SRSCM side) between SRSCM and Repair or replace harness
Satellite sensor, measure the resistance between Satellite high and NG between SRSCM and Satellite
body ground. sensor.
Resistance : ∞
6
OK Go to step "12".
Check SRSCM.
[PREPARATION]
1) Connector to SRSCM.
2) Using a service wire, connect DAB high and DAB low on the
colck spring side of connector between clock spring and DAB.
Page 27 of 45
3) Using a service wire, connect PAB high and low on SRSCM side
of connector betwween SRSCM and PAB. NG Replace SRSCM.
4) Conncet SAB and BPT using the same method.
5) Connect negative (-) terminal cable to ttery, and wait at least 30
seconds.
[CHECK]
2) Clear malfunction code stord in memory with Hi-scan.
7 3) Turn ignition switch to LOCK, and wait at least 30 seconds.
5) Using Hi-scan, check DTC.
DTC is not output.
[HINT]
Codes other than these ones may be output at this time, but they are
From the result of the above
not relevant to this check..
inspection. the malfunction part
OK
can now be considerrde
normal.
Check DAB squib.

[PREARATION]
at least 30 seconds.
3) Connect DAB Connector. NG Replace DAB.
4) Connect negative (-) terminal cable to the battery, and wait at least
30 seconds.
[CHECK]
2) Clear malfunction doce stored in memory with Hi-scan.
3) Turn ignition swithc to LOCK. and wait a least 30seconds.
DTC is not output.
[HINT]
Codes other than thse ones may be output at this time, But they are
not relevant to this check. From the result of the above
inspection, the malfunction part
OK
can now be considered
mormal.
Check PAB squib.

Page 28 of 45
[PREPARATION]
2) Disconnect negative (-) terminal cablefrom the battery, and wait at
least 30 seconds.
3) Conncet PAB connector. NG Replace PAB.
4) Connect negative (-) terminal cable to the battery, and wtit at least
30 seconds.
[CHECK]
1) Turn igniton switch to O, and wait at least 30 seconds.
2) Clear malmunction code stored in memory with Hi-scan.
3) Turn ingition switch to LOCK, and wait at least 30 seconds.
DTC is not output.
[HINT]
OK inspection, the malfunction part
can now be considerde normal.
Check SAB squib.

[PREPARATION]
1) Turn igniton switch to LOCK.
3) Connect SAB conncetor. NG Replace SAB.
4) Connect negative (-) terminal cable from the battery, and wait at
least 30 seconds.
[CHECK]
10 4) Turn ignition switch ot ON, and wait at least 30 seconds.
5) Using HI-scan, check DTC.
DTC is not output.
[HINT]
no relevant to this check. From the result of the above
Chcek BPT squib.

Page 29 of 45
[PREPARATION]
2) Disconncet negative (-) terminal cable from the battery, and wait
3) Connect BPT connector. NG Replace BPT.
least 30 seconds.
[CHECK]
1) Turn ignition switch to ON, anad wait at least 30 seconds.
2) Clear malfunction code stored in memory with HI-scan.
DTC is not output.
[HINT]
Codes other than these ones may be output at this time, but they are From the result of the above
not relevant to this check inspection. the malunuction part
OK
can now be considerde
mormal.
Check Satellite sensor.

[PREPARATION]
1) Turn ignition swtich to LOCK,
3) Connecto Satellite sensor connector. NG Replace Satellite sensor.
4) Connecto negative (-) terminal cable from the battery, and wait at
least 30 seconds.
[CHECK]
12 4) Turn ignition switch to ON, and wait at least 30 secones.
5)Using Hi-scan, check DTC.
DTC is not out put.
[HINT]
Codes other thatn these ones may be output at this time but they are
Check clock spring circuit.

Page 30 of 45
[PREPARATION]
Disconnect connector between SRSCM and clock spring.
NG Replace clock spring.
[CHECK]
Measure resistance between DAB hign on clock spring side of
connector between clock spring and DAB and body ground.
Resistance : ∞
13
Repair or replace harness or

OK connector between SRSCM
and clock spring.

CIRCUIT INSPECTION
B1349 DAB Short battery
B1355 PAB Short to battery
B1381 Driver SAB Short to battery
B1364 Driver BPT Short to battery
B1370 Passenger BPT Short to battery
DTC
B1402 Satellite left side short to battery
B1511 Driver seat belt buckle switch short
to battery
B1513 Passenger seat belt buckle switch
short to battery
CIRCUIT CESCRIPTION
The squib circuit consists of the SRSCM, clock spring, DAB, PAB, SAB, BPT, BBS, and satellite sensor. If it
cause the SRS to deploy shen the SRS deploymint conditions are satisfied. The aboe DTC's are recorded when a B
short is detected inthe suib circuit.
· DAB squib
· Short circuit in squib wire
· PAB squib
harness (to ground)
· SAB squib
· Squib malfunction
· BPT squib
· Clock spring malfunction
· Satellie sensor
· Wire harness
Preparation
at least 30secids.
Page 31 of 45
Check DAB squib circuit.

[CHECK]
For the connector (on the clock spring side ) between clock spring
and DAB, measure the resistance between DAB high and body NG Go to step "13".
ground.
Voltage : 0V
OK Go to step "8".
Check PAB squib circuit.

[CHECK]
For the connector (on the SRSCM side) between SRSCM and
PAB, measure the resistance between PAB high and body ground.
NG connector between SRSCM
Voltage : 0V
and PAB.
OK Go to step"9".
Check SAB squib circuit.

[CHECK]
For the connector (on the SRSCM side)between SRSCM and
SAB, measure the resistance between SAB high and body ground. Repair or replace harness
NG
Voltage : 0V between SRSCM and SAB.
4
Page 32 of 45
OK Go to step "10".
Check BPT squib circuit.

[CHECK]
For the connector between SRSCM and BPT, measure the voltage
between BPT high and body ground. Repair or replace harness
NG
Voltage : 0V between SRSCM and BPT.
OK Go to step "11".
Check Satellite sensor circuit.

[CHECK]
For the connector between SRSCM and Satellite sensor, measure
Repair or replace harness
the resistance between Satellite high and body ground.
NG between SRSCM and Satellite
Voltage : 0V
sensor.
OK Go to step "12".
Check SRSCM.
[PREPARATION]
1) Connector to SRSCM.
2) Using a service wire, connect DAB high and DAB low on the
colck spring side of connector between clock spring and DAB.
3) Using a service wire, connect PAB high and low on SRSCM side
of connector betwween SRSCM and PAB.
4) Using a service wire, connect SAB high and low on SRSCM side NG Replace SRSCM.
connector between SRSCM and SAB.
5) Using a service wire, connect BPT high and low on SRSCM side
connector between SRSCM and BPT.
6) Using a servic wire, connect satellite high and low on SRSCM
Page 33 of 45
side connector bdtween SRSCM and satellite sensor.
7) Connect negative (-) terminal cable to battery, and wait a least 30
seconds.
[CHECK]
7
2) Clear malfunction code stord in memory with Hi-scan.
DTC is not output.
[HINT] From the result of the above
Codes other than these ones may be output at this time, but they are OK inspection. the malfunction part
not relevant to this check.. can now be considered normal.
Check DAB squib.

[PREARATION]
3) Connect DAB Connector.
4) Connect negative (-) terminal cable to the battery, and wait at NG Replace DAB.
least 30 seconds.
[CHECK]
3) Turn ignition switch to LOCK, and wait a least 30seconds.
8 5) Using Hi-scan, check DTC.
DTC is not output.
[HINT]
Codes other than thse ones may be output at this time, But they are
not relevant to this check.
Check PAB squib.

[PREPARATION]
Page 34 of 45
2) Disconnect negative (-) terminal cablefrom the battery, and wait at
least 30 seconds.
3) Conncet PAB connector.
4) Connect negative (-) terminal cable to the battery, and wait at NG Replace PAB.
least 30 seconds.
[CHECK]
1) Turn igniton switch to On, and wait at least 30 seconds.
2) Clear malmunction code stored in memory with Hi-scan.
3) Turn ingition switch to LOCK, and wait at least 30 seconds.
9 5) Using Hi- scan, check DTC.
DTC is not output.
[HINT]
not relevant to this check.
Check SAB squib.

[PREPARATION]
1) Turn igniton switch to LOCK.
3) Connect SAB conncetor.
4) Connect negative (-) terminal cable from the battery, and wait at NG Replace SAB.
least 30 seconds.
[CHECK]
10 5) Using HI-scan, check DTC.
DTC is not output.
[HINT]
no relevant to this check.
Page 35 of 45
Chcek BPT squib.

[PREPARATION]
2) Disconncet negative (-) terminal cable from the battery, and wait
3) Connect BPT connector.
4) Connect negative (-) terminal cable from the battery, and wait at NG Replace BPT.
least 30 seconds.
[CHECK]
11 5) Using Hi-scan, check DTC.
DTC is not output.
[HINT]
not relevant to this check
OK inspection. the malunuction part
can now be considerde mormal.
Check Satellite sensor.

[PREPARATION]
1) Turn ignition swtich to LOCK.
3) Connect Satellite sensor connector. NG Replace Satellite sensor.
least 30 seconds.
[CHECK]
12 4) Turn ignition switch to ON, and wait at least 30 secones.
5)Using Hi-scan, check DTC.
Page 36 of 45
DTC is not output.
[HINT]
Codes other than these ones may be output at this time but they are
Check clock spring circuit.

[PREPARATION]
Disconnect connector between SRSCM and clock spring.
NG Replace clock spring.
[CHECK]
Measure resistance between DAB hign on clock spring side of
connector between clock spring and DAB and body ground.
Voltage : 0V
13

OK connector between SRSCM
and clock spring.

B1352 PAB resistance
too high
DTC
B1353 PAB resistance
too low
CIRCUIT CESCRIPTION
The PAB squib circuit consists of the SRSCM and PAB. The squib is shat causes the airbag to deploy when airbag
depoly conditions are satisfied.
The above DTC's are recorded shen PAB resistance too high or low is detected in the PAB squib circuit.
· Too high or low resistane between PAB high (+)
· PAB squib
wiring harness and PAB low (-) wiring harness of squib
· SRSCM
· PAB malfunction
· Wire harness
Preparation
Page 37 of 45
3) Disconnect connectors of PAB left and
rigt side airb, beot pretensooner and satellite
1 sensor. - -

facing upward.
Check PAB resistance.

[PREPARATION]
Release airbag activation prevention
vechanism aon SRCM side of airbag squib
side. NG Go to step "4".
Connect the dummy connector (0957A-
38200) to PAB connector of the SRSCM
connector side.
[CHECK]
2 Measure the resistance between PAB
high(+) and PAB low (-).
17Ω < R < 2.3Ω
Repair or replace the harness between

OK
SRSCM and PAB.
Check PAB squib

[PREPARATION]
from the battery, and wait at least
30seconds.
3) Connect DAB connector.
4)Connect negative (-) terminal cable to the NG Replace DAB.
battery, and wait at least 30seconds.
[CHECK]
1) Turn ignition switch to ON, and wait at
least 30 seconds.
2) Clear malfunction code stored in memory
with Hi-scan.
3) Turn ignition switch to LOCK, and wait
3 at least 30 seconds.
least 30 seconds.
DTC is not output.
Page 38 of 45
[HINT]
Codes other than these noes may be output
From the result of the above inspection, the
at this time, but they are not relevant to this
check.
normal.

B1378 DSAB Resistance
too high
B1397 DSAB Resistance
too low
DTC
B1382 PSAB Resistance
too high
B1383 PSAB Resistance
too low
CIRCUIT DESCRIPTION
The SAB squib circuit consists of the SRSCM and SAB. The squib is shat causes the airbag to deploy when airbag
deploy conditions are satisfied.
The above DTC's are recorded when SAB resistance too high or low is detected in the SAB squib circuit.
· Too high or low resistane between SAB high (+)
· SAB squib
wiring harness and SAB low (-) wiring harness of squib
· SRSCM
· SAB malfunction
· Wire harness
Preparation
1 sensor. - -

facing upward.
Page 39 of 45
Check SAB resistance.
[PREPARATION]
Release airbag activation prevention
vechanism aon SRCM side of airbag squib
side. Repair or replace harness between SRSCM
NG
Connect the dummy connector (0957A- and SAB.
38200) to PAB connector of the SRSCM
connector side.
[CHECK]
2 Measure the resistance between SAB
high(+) and SAB low (-).
1.9Ω < R < 2.5Ω
OK Go to step 3
Check SAB squib

[PREPARATION]
30seconds.
3) Connect SAB connector.
4)Connect negative (-) terminal cable to the NG Replace SAB.
[CHECK]
least 30 seconds.
with Hi-scan.
least 30 seconds.
DTC is not output.
[HINT]
check.
normal.
Page 40 of 45

B1408 Satellite left
DTC
communication error
B1410 Satellite right
communication error
CIRCUIT DESCRIPTION
The release system for the airbag consists of the SRSCM and two satelliter-one on the left-hand side and noe on the
right. The above DTC's are recoreded when the defect or communication error ofr sate llite is detected in the sate
lited circuit.
WIRING DIAGRAM
Preparation
1 sensor. - -
Page 41 of 45

facing upward.
Check Satellite circuit (Communication

error).
[PREPARATION]
Check continuity between SRSCM Replace harness between SRSCM and
NG
connector and satellite connector as high (+) Satellite sensor.
and , low(-) and low(-).
OK : Continuity
2
OK Go to step 3
Check Satellite sensor (Defect).

[PREPARATION]
30seconds.
4)Connect negative (-) terminal cable to the NG Replace Satellite sensor.
[CHECK]
least 30 seconds.
with Hi-scan.
least 30 seconds.
DTC is not output.
[HINT]
check.
normal.
Page 42 of 45

B1408 Satellite left
DTC
communication error
B1410 Satellite right
communication error
CIRCUIT DESCRIPTION
The release system for the airbag consists of the SRSCM and two satelliter-one on the left-hand side and noe on the
right. The above DTC's are recoreded when the defect or communication error ofr sate llite is detected in the sate
lited circuit.
WIRING DIAGRAM
Preparation
1 sensor. - -
Page 43 of 45

facing upward.
Check Satellite circuit (Communication

error).
[PREPARATION]
Check continuity between SRSCM Replace harness between SRSCM and
NG
connector and satellite connector as high (+) Satellite sensor.
and , low(-) and low(-).
OK : Continuity
2
OK Go to step 3
Check Satellite sensor (Defect).

[PREPARATION]
30seconds.
4)Connect negative (-) terminal cable to the NG Replace Satellite sensor.
[CHECK]
least 30 seconds.
with Hi-scan.
least 30 seconds.
DTC is not output.
[HINT]
check.
normal.
Page 44 of 45

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

B2500 Warning lamp
DTC
failure
CIRCUIT DESCRIPTION
The SRS warning lamp is located on the cluster. When the airbag system is normal, the Service Reminder Indicator
(SRI) or SRS Warning Lamp flashes for approximately 6 Seconds agter the ignition switch in struned ON< and ten
turns offaruovaticatlly.If there is a malfunction in the airbag system, the SRE lights up to inform the driver of the
abnormaliyt, The SRSCM measrues the voltage at the airbag SRI outpit pin, both when the p,ap is no and shen the
pamp is off, to detect whether the commanded state natches the actral atate.
Page 45 of 45
Check the fuse.
1) Remove the fuse NO. 11 and 14 from the
1 junction block. - -
2) Inspect the condition of fuse.
3) Replace if necessary.
Check SRS warning lamp circuit
[PERPARATION]
1) Connect negative (-) terminal cable to the
battery. Check SRS warning light bulb/repair SRS
2) Turn ignition swtich to ON. NG
warning light circuit.
[CHECK]
1) Measure voltage of harness side
connector of SRSCM.
2
Voltage : 10-16.5 V
OK Go to step 3.
[CHECK]
check SRS SRI (Service Reminder
If no fault is found in wiring or connector,
Indicator). NG
replace the SRSCM.
OK : SRS SRI ON

OK malfuunctioning part can now be considered
normal.
Page 1 of 44
OPTIMA(MS) > 2001 > G 2.4 DOHC > Steering System
Steering System > General Information > Special Service Tools

SPECIAL SERVECE TOOLS
Tool (Number and Name) Illustration Use
09222-21100
Installation of the pinion gear bearing
09222-32100
Installation of the oil pump oil seal
09431-11000
Installation of the pinion gear oil seal
Front oil seal installer
09432-21601
Installation of the pinion gear bearing
Bearing installer
09571-21400 1)Removal of pinion gear bearing

Drift 2)Removal of pinion bearing outer race
Removal and installation of the oil seal

09555-21000
(use with 09573-33001, 09573-
Bar
21200, 09573-21000)
09565-11100 Measurement of the main shaft pre-

Pre-load socket load
09565-21000 Removal and installation of pinion gear

Pinion bearing remover and installer bearing
09565-31300 Removal. installation and adjustmint of

Yoke plug torque wrench socket wteering gear yoke plug
0K670-321-019
Separation of the tie rod end ball joint
Ball joint remover
Page 2 of 44
09572-21000/0K201 323 AA1 Measurement of the oil pressure (use

Oil pressure gauge with 09572-33100, 09572-21200)
09572-22000
Measurement of the oil pressure (use
Oil pressure gauge adapter V6,
with 09572-21000, 09572-22100)
DOHC ENG.
09572-22100
Measurement of the oil pressure (use
Oil pressure gauge adapter V6,
with 09572-21000, 09572-22000)
DOHC ENG.
Installation of the ack up washer and

09573-21000
oil seal (use with 09573-33000,
Oil searl installer guide
09573-33100, 09555-21000)
Installation of the back up washer and

09573-33000
oil sea (use with 09573-21000,
Oil seal installer
09573-33100, 09555-21000)
Removal and installation of the oil seal

09573-33100
(use with 09573-21000, 09573-
Oil seal guide
33000, 09555-21000)
Steering System > General Information > Troubleshooting

TROUBLESHOOTING
Steering wheel return Incorrect tire pressure Adjust the tire pressure
malfunction
Steering operation is "hard" Incorrect tire pressure Adjust the tire pressure
Loose belt Adjust the belt tension
Damaged belt Replace the belt
Low fluid level Refill fluid
Air in fluid line Bleed the system
Steering wheel pulls to one side Twisted hose Correct the hose routing or replace the
hoses
Incorrect mounting of the steering gear Retighten
box on the crossmember
Fluid leakage Check the fluid leakage and retighten or
replace
Page 3 of 44
Incorrect wheel alignment (especially Adjust the wheel alignment
caster)
Malfunction of gear box Check and replace the gear box if
necessary
Malfunction of oil pump Check the oil pump pressure and repair
oil pump
Excessive steering wheel play Adjust the steering wheel play
Insufficient tire inflation pressure Adjust the tire pressure
Unevenly worn or deformed tire Rotate the wheel or replace the tire
Dragging brake Adjust
Deteriorated or broken front spring Replace
Deformed knuckle arm Replace
Poor wheel alignment Adjust the wheel alignment
Damaged wheel bearing Replace
Deformed or loose lower arm Retighten or replace
Loose linkage joints Retighten
Malfunction of ball joints (Too small Replace
ball joint starting torque)
Deteriorated or broken lower arm Replace
bushing
Incorrect installation or internal damage Correct or replace
in gear
Malfunction of shock absorber Replace
Steering wheel vibrates Insufficient tire inflation pressure Adjust the tire pressure
Unevenly worn or deformed tire(s) Rotate the wheels or replace the tire(s)
Loose hub nut Retighten
Excessive runout, or unbalance of tire Adjust the wheel balance or replace
and wheel
Poor wheel alignment Adjust the wheel alignment
Damaged wheel bearing Replace
Deformed or loose lower arm Retighten or replace
Deformed linkage Repair or replace
Loose linkage joints Retighten
Malfunction of ball joints (Too small Replace
ball joint starting torque)
Malfunction of front suspension Check and adjust; replace the parts if
necessary
Incorrect installation or internal damage Correct or replace
in gear box
Page 4 of 44
Malfunctioning of shock absorber Replace
Road shock is felt in steering Insufficient steering wheel play Adjust the steering wheel play
wheel
Insufficient tire inflation pressure Adjust the tire pressure
Unevenly worn or deformed tire(s) Rotate the wheels or replace the tire(s)
Malfunction of shock absorber Replace
Poor recovery of steering wheel Insufficient tire inflation pressure Adjust the tire pressure
to straight ahead position Stuck or damaged ball joint Replace
Improper wheel alignment angles Adjust the wheel alignment
Rattling noise Loose installation of oil pump or gear Retighten the oil pump and gear box
box
Steering linkage looseness or play Retighten or replace the steering linkage
Loose oil pump pulley nut Retighten the oil pump pulley nut
Interference around column or between Correct or replace the pressure hose
pressure hose and other parts and the parts around the column
Abnormal noise inside the gear box and Replace the gear box or oil pump
oil pump
Strident noise Air sucked into oil pump Check the oil level and hose clips;
bleed the system or replace the oil
pump
Seizure inside oil pump Replace the oil pump
Squealing noise 1) Loose belt Adjust the belt tension
Seizure inside oil pump Replace the oil pump
Hissing noise Air sucked into oil pump Check the oil level and hose clips;
bleed the system
Damage to the gear box port section Replace the gear box
Malfunction of return hose Replace the hose
Whistling noise Malfunction of gear box port section Replace the gear box
Droning noise Loose mounting bolt on oil pump or oil Retighten the pump bracket and pump
pump bracket installing bolt
Poor condition of oil pump body 2) Replace the oil pump
Squeaking noise 2) Malfunction of steering stopper contact Check and adjust the steering stopper
Interference of wheel with vehicle body Adjust the steering angle
Interference of steering shaft and joint Reposition the interfering parts
assembly with other parts
Malfunction of gear box Replace the gear box
Shuddering vibration 3) Air suction Bleed the system
Malfunction of gear box Replace the gear box
Page 5 of 44
Oil leakage from hose Improperly tightened flare nut Check, repair or replace
connection Incorrectly inserted hose
Improperly clamped hose
Oil leakage from hose assembly Damaged or clogged hose Replace
Hose connector malfunction
Oil leakage from oil reservoir Leaking reservoir Replace
Overflow Bleed the system or adjust the oil level
Oil leakage from oil pump Malfunction of oil pump housing Replace the oil pump
Malfunction of O-ring and/or oil seal Replace the O-ring and oil seal
Oil leakage from gear box Malfunction of gear box housing Replace the gear box
(including leakage from air hole)
Malfunction of O-ring and/or oil seal Replace the O-ring and oil seal
Steering System > General Information > Specifications

SPECIFICATIONS
Collapsible, crossjoint with
Shaft and joint type
tilt column
Steering gear type Rack and pinion
Rack stroke 150 ± 1 mm
Oil pump type Vane type
9.6 cm³/rev. Max. (0.59
Displacement
in³/rev. Max)
SERVICE STANDARD
Steering sheel free play 0-30 mm (0-1.1 in.)
Inner wheel 40.63° ±2°
Steering angle
Outer wheel 32.37°
Tie rod end ball joint staring torque 0.5-2.5Nm (5-25 kg·cm, 0.36-1.78 lb·ft)
Stationary steering effort 3.0 kg Max.
Belt deflection [under 98 N(10kg, 22lbs) 8.8-11.0 mm (New one)
force] 11.7-15.3 mm(Refular inspection)
Oil pump relief pressure 75-82 kg/cm²(6.1-6.6 MPa, 882-953 psi)
TIGHTENING TORQUE
Page 6 of 44
Nm kg·cm lb·ft
Airbag module mounting bolt 8-11 80-110 6-8
Steering column to column member
13-18 130-180 8-13
mounting(upper)
Steering column
Steering column to cloumn member
and shaft 13-18 130-180 8-13
mounting(lower)
Steering wheel lock nut 40-50 400-500 30-36
Joint assembly 15-20 150-200 10-15
Pressure hose to gear box 12-18 120-180 8.8-13
Return tube to gear box 12-18 120-180 8.8-13
Steering gear
Tie rod to rack (MANDO) 80-100 800-1000 59-74
box
Tie rod end lock nut 50-55 500-550 37-41
Rack support plug lock nut(MANDO) 50-70 500-700 36-51
Pinion and valve assembly to self locking nut
50-70 500-700 36-51
(MANDO)
Steering gear End plug 50-70 500-700 36-51

box Feed tubes 12-18 120-180 8.8-13
Tie rod end to knuckle 24-34 240-340 17-24
Mounting bracket to crossmember 60-80 600-800 43-58
Pressure hose to oil pump 55-65 550-650 41-47
Oil pump mounting bolt 39-60 390-600 30-43
Heat protector mounting bolt 45-55 450-550 33-40
Oil pump Oil pump bracket mounting bolt 39-60 390-600 30-43
pump cover to pump body 21-29 210-290 14.9-20.6
Suction connector to pump body 13.6-18.4 136-184 9.7-13.1
Flow control valve connector to pump body 70-80 700-800 51-58
Oil reservoir bracket mounting bolt 4-6 40-60 3-4.4
Cooler tube clamp mounting bolt(MANDO) 4-6 40-60 3-4.4
Steering hoses
Trbe clip and tube bracket 4-6 40-60 3-4.4
and oil reservoir
pressure gose bracket mounting bolt 4-6 40-60 3-4.4
Hose clamp 4-6 40-60 3-4.4
LUBRICANTS
Page 7 of 44
Items Quantity
Multipurpose grease SAE J310a, NLGI
Steering column bearing
No.2 As required
Steering gear box rack. pinion gear
Multipurpose grease SAE J310a, NLGI As required
part
No.2 As required
Bellows
Silicone grease As required
Oil pump
Power steering fluid(PSF-3) 1.0 lit (0.88 qts.)
Power steering fluid
Power steering fluid(PSF-3)
Steering System > Hydraulic Power Steering System > Troubleshooting

SERVICE ADJUSTMENT PROCEDURE
CHECKING STEERING WHEEL FREE PLAY
1. Start the engine with the steering wheel in the straight ahead position. Apply a force of 5 N (1.1 lb) to the steering
wheel in the peripheral direction.
2. Measure the play at the circumference of the steering wheel.
Steering wheel free play [Standard value] : 30 mm (1.1 in.)
3. If the play exceeds the standard value, inspect the contact of the steering shaft and tie rod ball joints.
CHECKIN STEERING ANGLE
1. Place the front wheel on a turning radius gauge and measure the steering angle.
Wheel angle [Standard value]

Inside wheel : 40.63° ± 2°
Outside wheel : 32.37°
2. If the measured value is not within the standard value. Adjust the linkage.
CHECKING STEERING WHEEL RETURN
Check the steering wheel return and confirm the following points :
1. The force required to turn the steering wheel and the wheel return should be the same for left and right for both
moderate turns and sharp turns.
Page 8 of 44
2. When the steering wheel is turned 90° and held for a couple of seconds while the vehicle is being driven at 20-30
kph (12-19 mph), the steering wheel should return at least 70° from the neutral position when it is released.
If the steering wheel is turned very quickly, the steering wheel operation may be momentarily difficult. This
is not a malfunction.
CHECKING TIE ROD END BALL JOINT STARTING TORQUE
1. Disconnect tie rod and knuckle.
2. Shake the ball joint stud several times.
3. Mount two nuts on the ball joint, and then measure the ball joint starting torque.
Standard value : 0.5-2.5 Nm (5-25 kg·cm, 0.36-1.78 lb·ft)
4. If the starting torque exceeds the upper limit of standard value, replace the tie rod end.
5. Even if the starting torque is below the lower limit of the standard value, the ball joint may be reused unless it has
drag and excessive play.
CHECKING POWER STEERING FLUID LEVEL
1. Position the vehicle on a level surface.
2. Start the engine. With the vehicle kept stationary, turn the steering wheel several times continuously to raise the
fluid temperature from 50-60°C (122-140°F).
3. With the engine at idle, turn the steering wheel fully clockwise and counterclockwise several times.
4. Make sure that there is no foaming or cloudiness in the reservoir fluid.
Page 9 of 44
5. Stop the engine and check for any difference in fluid level between a stopped and a running engine.
1. If the fluid level varies 5 mm (0.2 in.) or more, bleed the system again.
1. If the fluid level suddenly rises after stopping the engine, it shows that bleeding is not
satisfactory.
2. Incomplete bleeding will produce a chattering sound decreasing durability of the pump, etc.
REPLACING POWER STEERING FLUID

1. Jack up the front wheels and support with rigid racks.
2. Disconnect the return hose from the oil reservoir and install a plug on the oil reservoir.
3. Connect a vinyl hose to the disconnected return hose, and drain the oil into a container.
4. Disconnect the high-tension cable at the ignition coil side. While operating the starter motor intermittently, turn the
steering wheel all the way to the left and then to the right several times to drain the fluid.
5. Connect the return hoses securely, and then fill the oil reservoir with the specified fluid.
6. Bleed system.
Power steering fluid (PSF-3)type :

Total quantity : Approx. 1.0 liter
AIR BLEEDING
1. Disconnect the high tension cable, and while operating the starting motor intermittently (for 15-20 seconds), turn
the steering wheel all the way to the left and to the right five or six times.
1. During air bleeding, replenish the fluid supply so that the level never falls below the lower position of the
filter.
2. If air bleeding is done while the vehicle is idling, the air will be broken up and absorbed into the fluid; be
sure to do the bleeding only while cranking.
2. Connect the high tension cable, and then start the engine (idling).
3. Turn the steering wheel to the left and then to the right until there are no air bubbles in the oil reservoir.
Do not hold the steering wheel turned all the way to either side for longer than ten seconds.
4. Confirm that the fluid is not milky, and that the level is up to the specified position on the level gauge.
Page 10 of 44
5. Confirm that there is little change in the surface of the fluid when the steering wheel is turned left and right.
1. If the surface of the fluid changes considerably, air bleeding should be done again.
2. If the fluid level rises suddenly when the engine is stopped, it indicates that there is still air in the system.
3. If there is air in the system, a jingling noise may be heard from the pump and the control valve may also
produce unusual noises. Air in the system will shorten the useful life of the pump and other parts.
CHECKING POWER STEERING BELT TENSION

1. Press the V-belt applying a pressure of 98 N (10 kg, 22 lb) at the specified point, and measure the deflection to
confirm that it is within the standard value range.
V-belt deflection [Standard value]

Rdgular inspection : 11.7-15.3 mm (0.46-0.60 in.)
New one : 8.8-11.0 mm (0.35-0.43 in.)
2. To adjust the belt tension, auto tensioner does automatically adjust to obtain the standard value (V6 ENG).
3. To adjust the belt tension, loosen the tensioner adjusting bolt, and then retighten the bolts. (I4 ENG.)
OIL PUMP PRESSURE TEST

1. Disconnect the pressure hose from the oil pump, and then connect the special tool between the oil pump and
pressure hose as illustrated.
Page 11 of 44
2. Bleed the air. Start the engine and turn the steering wheel several times so that the fluid temperature rises to
approximately 50°C (122°F) operating temperature.
3. Set the engine speed to 1,000 rpm.
4. Fully close and then fully open the shut-off valve of the special tool and measure the fluid pressure to confirm that
it is within the standard value range.
Oil pump pressure [Standard value]

Gauge hose valve closed : 80 kg/cm² (0038 psi )or less
Be sure not to keep the shut-off valve on the pressure gauge closed for longer than ten seconds.
5. Remove the special tools and then tighten the pressure hose to the specified torque.
Tightening torque : 55-65Nm (50-650 kg·cm)
Steering System > Hydraulic Power Steering System > Power Steering Gear Box > Components and
Components Location
COMPONENTS
Page 12 of 44
COMPONENTS
Page 13 of 44
Steering System > Hydraulic Power Steering System > Power Steering Gear Box > Repair procedures
REMOVAL
1. Drain the power steering fluid.
Page 14 of 44
2. Remove the joint assembly connecting bolt.
3. Using the special tool (0K670-321-019), disconnect the tie rod end from the knuckle arm.
4. Disconnect the front muffler temporarily.
5. Remove the connecting bolts of front of front and rear roll stopper.
6. Remove mounting bolts(6EA) of crossmember complete assembly.
7. Disconnect the pressure hose and the return tube.

Page 15 of 44
8. Remove the steering gear box mounting brackets and remove the steering gear box assembly together with
mounting rubber.
Move the rack completely to the right and then remove the gear box to the left from the crossmember.
When removing the gear box, pull it out carefully and slowly to avoid damaging the boots.
9. Remove the stabilizer bar.
REMOVAL
1. Loosen the tapping screws and lift up the horn pad and remove it.
2. Remove the lock nut and the washer.
Before doing these procedures, see the SRS section (RT Group) for further information (SRS equipped
vehicle only).
3. Remove the steering wheel useing the special tool. (09561-11001)
Do not hammer on the steering wheel to remove it; doing so may damage the collapsible
mechanism.
4. Remove the steering column lower and upper shrouds.
Page 16 of 44
5. Remove the lower cover.
6. Disconnect the connectors and remove the multifunction switch.
7. Remove the bolts securing the coupling and universal joint.

Pull out the coupling and universal joint from the gear box.
8. Remove the dust cover mounting bolts.

9. Remove the steering column mounting bolts (4 bolts).
10. Remove the steering column and shaft together with the universal joint and dust cover.
INSTALLATION
1. When installing the mounting rubber, align the projection of the mounting rubber with the indentation in the
crossmember to install the gear box.
2. Confirm that there is no oil leak.
3. Confirm that the steering wheel rotates smoothly when it is turned.
4. Adjust the toe-in.
Page 17 of 44
5. Install the parts by reference to torque specifications.
INSTALLATION
1. Before installation, apply multipurpose grease to the groove on the inside of the bearing and mating surfaces of
the boot and cover assembly.
2. Connect the steering lower shaft and joint assembly.
When installing, secure the U-joint to the gear box first, then to the steering column
shaft.
3. Install the dust cover with column shaft assembly.
4. Install the steering column assembly to the column member assembly (4 bolts).
5. Install the multi function switch and connect the connectors.
6. Install the lower cover and upper and lower shroud.
7. Install the steering wheel.
When installing, do not use a hammer as the collapsible column shaft could be
damaged.
DISASSEMBLY
Page 18 of 44
1. Remove the tie rod end from the tie rod.
2. Remove the dust cover from the ball joint.
3. Remove the bellows band.
4. Remove the bellows clip.

5. Pull the bellows out toward the tie rod.
Check for rust on the rack when the bellows are

replaced.
6. Remove the feed tubes from the gear housing.
7. While moving the rack slowly, drain the fluid from the gear housing.
8. Unstake the tab washer which fixes the tie rod and rack with a chisel.
Page 19 of 44
9. Remove the tie rod from the rack.
Remove the tie rod from the rack, taking care not to twist the
rack.
10. Remove the rack support plug lock nut.
11. Using the special tool (09565-31300), remove the rack support plug.
12. Remove the rack support spring, rack support and bushing from the gear box.
13. Remove the end plug self-locking nut.

14. Detach the dust seal.
15. Remove the snap ring with a snap ring plier.
Page 20 of 44
16. Remove the pinion and valve assembly together with the oil seal (upper) using a soft hammer.
17. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the gear housing.
18. When the end of the circlip comes out from the notched hole of the housing rack cylinder, turn the rack stopper
counterclockwise and remove the circlip.
Do not damage the rack.

19. Remove the rack stopper, rack bushing and rack from the gear housing by moving it toward the piston side.
When the rack gas ben removed, be sure to replace the housing side oil seal with a new one.
20. Remove the O-ring from the rack bushing.
Page 21 of 44
21. Remove the oil seal from the rack bushing.
22. Drive out the ball bearing using special tool (09517-21400) and hammer.
Do not damage the pinion valve cylinder inside of the gear housing.
23. Drive out the needle bearing and oil seal.
24. Use the special tools (09555-21000, 09573-33100) to remove the back washer and oil seal from the gear
housing.
Do not damage the rack cylinder inside of the gear housing.
DISASSEMBLY
1. Remove the coupling and universal joint from the steering column and shaft assembly.
Page 22 of 44
2. If it is necessary to remove the steering and ignition lock assembly, use a hack saw to cut the torsion bolt at the
key holder assembly side.
INSPECTION
1. Rack
(1) Rack tooth face damage or wear

(2) Oil seal contact surface damage
(3) Bending or twistion
(4) Oil seal ring damage or wear
(5) Oil seal damage or wear
2. Pnion valve
(1) Pinion gear tooth face damage or wear

(2) Oil seal contact surface damage
(3) Seal ring damage or wear
(4) Oil damage or wear
3. Bearing
(1) Sezure or abnormal noise during bearing rotation
(2) Escessive poay
(3) missing nedle bearing rollers
4. Others
(1) Damage of the gear housing cylinder bore
(2) Boot damage, cracking or ageing
INSPECTION
1. Check the steering shaft for damage, play and round movement.
Page 23 of 44
2. Check the joints for excessive play, damage or rough movement.
3. Check the tilt bracket for cracks or damage.
4. Check the cover or boot for damage
5. Check that the steering lock mechanism operates properly. If necessary, replace.
ASSEMBLY
1. Apply the specified fluid to the entire surface of the oil seal and gear housing.
Recommended fluid : Power steering fluide (PSF-3)
2. Using the special tools (09555-21000, 09573-21000, 09573-33000, 09573-33100), install the backup washer
and oil seal to the specified position in the gear housing.
3. Apply the specified grease to the entire surface of the needle bearing.
Recommended trease : Multipurpose grease SAE H310a, NLGI No.2
4. Install the needle bearing in the gear housing using special tool (09222-21100).
5. Set the scribed side of the oil seal (inner) in the special tool (09431-11000) and install in the gear housing.
1. Note the direction of the oil seal.

2. Use a new oil seal.
6. Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recinnebdead fkyud : Power steering fluid (PSF-3)
7. Install the oil seal on the rack bushing.

Page 24 of 44
8. Apply the specified fluid to the entire surface of the O-ring and install to the rack bushing using the special tool
(09431-11000).
9. Apply the specified grease to the rack teeth and wrap with vinyl tape.
Recommended trease : Multipurpose grease SAE J310a, NLGI grade 2 EP
Do not plug the vent hole in the rack with grease. All cautions must clearly state the possible harmful result
or risk. What would happen if the vent hole was plugged with grease?
10. Insert the rack into the gear housing.
Install the rack bushing and rack stopper.
11. Push in the rack stopper until the circlip groove of the rack stopper is aligned with the notched hole of the rack
housing and then install the circlip while turning the rack stopper.
The circlip end should not be vilsble through the notched hole of the rack housing.
Page 25 of 44
12. Apply the specified fluid and grease to the pinion valve assembly and install to the gear housing assembly.
Recommened fluid : Power steering fluid (PSF-3)

Recommended grease : Mutipurpose grease SAE J310A, NLGI Grade 2 EP
13. Install the ball bearing using special tool (09222-21100).

14. Install the pinion and valve assembly to the valve housing.
15. Install the oil seal using the special tool (09432-21601).
16. Install the snap ring with snap ring plier.
17. With the pinion turned all the way clockwise, thghten the self-locking nut.
Always replace the self-locking nut with a new one.
18. Apply semi-drying sealant to the threaded section of the end plug and tighten to the specified torque.
Tightening torque : 50-70Nm(500-700 kg·cm, 36-51 lb·ft)
19. Stake the end plug at two points on its circumference with a punch.
Page 26 of 44
20. Install the tab washer and then the tie rod and peen the tab washer end at two points to the tie rod.
1. Align the tab washer pawls with the rack grooves.

2. Use a new tab washer.
21. Install the bushing, rack support, rack support spring and rack support cover in the order shown. Apply thread
sealant to the threaded section of the rack support cover before installation.
22. With the rack placed at the center position, attach the rack support plug to the gear housing. Tighten the rack
supportplug within the range of 20-25 Nm (200-250 kg·cm, 14.5-18 lb·ft), using the special tool. Loosen the
rack support plug for approximately 10° and adjust torque to the standard value.
Total pinion torque[Standard value] : 0.6-1.3 Nm (6-13kg·cm, 0.4-0.9 lb·ft)
23. After adjusting, lock rack support plug with lock nut.
When it cannot be adjusted within the specified return angle, check rack support plug components or
replace.
24. Tighten the feed tube to the specified torque and install the mount rubber using adhesive.
Page 27 of 44
25. Apply the specified grease to the bellows fitting position (fitting groove) of the tie rod.
Recommended grease : Multipurpose grease SAE J3120a, NLGI gread 2 EP
26. Install the new attaching band to the bellows.
Whenever the bellows are installed, a new band must be

used.
27. Install the bellows in, taking care not to twist it.
28. Fill the dust cover inner side and lip with the specified multipurpose grease, and fix the dust cover in position
with the clip ring attached in the groove of the tie rod end.
Recommended grease : Multipurpose rease SAE J310a, NLGI grade 2 EP
29. Install the tie rods so that the length of the left and right tie rods will be equal to the standard value.
Tie rod free length [Standafd value] : 47.2mm(1.86 in.)
ASSEMBLY
Page 28 of 44
1. When installing the steering & ignition lock and steering lock bracket to the column tube, temporarily install the
steering lock in alignment with the column boss.
2. After checking that the lock works properly, tighten the special bolts unitl the head twists off.
The steering lock bracket and bolts must be replaced with new ones when the steering lock is
installed.
3. Cover the inside lip of the inner cover with grease and pull the outside of the cover onto the joint.
4. Fill the inside of the bearing with multipurpose grease.

5. Install the bearings to the shaft on the joint assembly.
Steering System > Hydraulic Power Steering System > Power Steering Hoses > Components and
Components Location
COMPONENTS
Page 29 of 44
Steering System > Hydraulic Power Steering System > Power Steering Hoses > Repair procedures
REMOVAL
1. Drain the power steering fluid.
2. Disconnect the return hose and the suction hose from the oil reservoir.
3. Remove the flare nut of pressure hose.
4. Remove the return tube and rubber hose together with the flare nut and O-ring.
5. Remove the cooler tube.
Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Components and
Components Location
COMPONENTS
Page 30 of 44
Be sure to cover te Generator with a protector when servicing the oil pump.
Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Repair procedures
REMOVAL
Page 31 of 44
1. Remove the pressure hose from the oil pump.
When assembling, use a new O-ring.

2. Disconnect the suction hose from the suction connector and drain the fluid into a container.
When removing the suction hose, cover the generator with vinyl not to be damaged by the oil
inflowing.
3. Remove the V-belt. (V6 ENG.)
4. Loosen the tensioner adjusting bolt to remove the V-belt (I4 ENG).
5. Remove the oil pump mounting bolts and disconnect the pressure switch connector.
1. Install the oil pump to the oil pump bracket.

2. Install the suction hose.
3. Install the ribbed V-belt and adjust the belt tension.
Page 32 of 44
4. Connect the pressure hose to the oil pump, and the suction hose to the oil reservoir.
Install the hoses so that they are not twisted and they do not come in contact with any other
parts.
5. Replenish the reservoir.
Recommended fluid : Power steering fluid (PSF-3)

7. Check the oil pump pressure.
8. Install parts by reference to the torque specification.
DISASSEMBLY
1. Remove the suction pipe and the O-ring from the oil pump.
2. Remove the rear cover with the gasket.

3. Remove the cam ring.
4. Remove the rotor and vanes.
5. Remove the front side plate.
6. Remove the inner and outer O-ring.

7. Remove the spring.
When assembling, use a new gasket and O-

ring.
8. Remove the pulley nut and the spring washer.
Page 33 of 44
9. Pull off the pulley and the woodruff key.
10. Remove the snap ring using the snap ring pliers.
11. Drive out the pulley shaft and bearing.
If necessary, use a plastic hammer.
12. Remove the oil seal from the oil pump body.
When assembling, use a new oil seal.

13. Remove the connector from the oil pump body, and then remove the flow control valve and flow control spring.
14. Remove the O-ring from the connector.
Do not disassemble the flow control

valve.
15. Remove the oil pump switch.
16. Take out the spring and the spool.
17. Remove the O-ring from the oil pump switch.
INSPECTION
1. Clean all disassembled parts with a suitable cleaning solvent.
Page 34 of 44
2. If any inside parts of the oil pump have been damaged, replace the pump as an assembly.
3. If the pulley is cracked or deformed, replace it.
4. If oil leaks around the pulley shaft oil seal, replace the oil seal.
5. If the serrations of the pulley or pulley shaft are deformed or worn, replace them.
ASSCMBLY
1. Install the oil pump switch.
2. Install the flow control valve spring, valve and connector in the pump body.
Apply a thin coat of Power steering fluid type to all aparts including the oil seal and O-
ring.
3. Using special tool (09222-32100), install the oil seal into the pump body.
4. Gently insert the shaft assembly and install the snap ring.
5. Install the pump pulley with woodruff key in place.
6. Install the spring and the inner and outer O-rings.

7. Install the front side plate.
8. Insert the pins into the pin grooves of the front housing, then install the cam ring, paying attention to its direction.
9. Install the rotor with its punch marked side facing towards the front side plate.
Page 35 of 44
10. Install the vane plates with the round end facing outward.
11. Install the gasket and rear cover.

12. Tighten the suction connector.
Steering System > Electronic Power Steering System > Description and Operation
GENERAL
The electronic power steering (EPS) system uses the same components at that of conventional power steering
system. In addition, it has a solenoid valve on power steering gear box, and a control unit underneath the audio of
the center facia.To control the oil flow of steering gear box, a solenoid is provided and it functions by the current
from control module which receives signal from VSS (Vehicle Speed Sensor).
EPS performs the conventional power steering function in case a fail has occurred in the system.
EPS electronically controls the current to the solenoid of by-pass valve by input sensor's signal to control the
hydraulic amount in cylinder chamber thereby varying the steering effort versus the hydraulic pressure according to
vehicle speed.
ELECTRONIC POSER STEERING CONTROL MODULE(Electronic power module)
The EPSCM is installed underneath the audio inside the center facia.
Page 36 of 44
EPS SLENOID(Solenoid valve)

A solenoid valve is provided in the gear box to control the flow of power steering oil. The solenoid valve is
composed of a releasing spring, a piston and a plunger. The input current is varying from 0A to 1A according to the
vehicle speed and is controlled by EPS control module. When the ignition switch is turned on, current is sent to the
solenoid valve topush up the plunger and accordingly the piston contacting the plunger is pushed up while
overcoming the spring force. As the vehicle speed increasing the current flow to the solenoid decreased pulling down
the piston bottom by the releasing spring force. When the piston is pushed up, it closes the oil passing hole, therefore
the power steering oilpressure is delivered into the cylinder without any interruption. But when the hole is opened as
the piston is pulling down, some of the oil coming from the rotary valve is drained into reservoir via the hole inside
the rotary valve.
Page 37 of 44
When it is necessary to remove the EPS gear box, be sure to disconnect the connector to avoid damage.
EPS GEAR BOX(OPERATION)
LEFT TURN (CONTERCLOCKWISE)
The power steering oil pump generates the oil pressure and the oil enters into the rotary valve. And the torsion bar
istwisted by the force between the steering wheel rotation and the resistance of the tire to the ground. At a high
speed ofvehicle, the oil passing the rotary valve comes into the solenoid valve through the lower hole and goes out
through theupper hole flowing the connecting space of piston. At this time the piston is back away due to the spring
force overcoming the solenoid plunger. The oil flows through the space between the piston and side wall. And then
the oil flows againinto the rotary valve and finally drained to reservoir through the drain hole between the rotary valve
and the torsion bar. Therefore the oil pump pressure does not affect to the steering effort.
Page 38 of 44
As the vehicle speed decreasing the hole of piston connecting the left chamber and right chamber is gradually closed
asthe oil pressure produced by oil pump is delivered to the left chamber. Therefore, the steering effort is reduced.
RIGHT TURN(CLOCKWISE)
The operation procedure of right turn is the reverse sequence of left turn.
Page 39 of 44
Steering System > Electronic Power Steering System > Troubleshooting

TROUBLESHOOTING (E.P.S)
Page 40 of 44
Trouble symptom Trouble area Inspection item
Steering wheel movement is heavy (When Steering gear Solenoid valve continuity
ignition key is turned to ON, no current flows and linkage
By-pass valve
through the solenoid)
Harness of Blown fuse
fuse Remove the control unit connector and check the
continuity in the solenoid harness (between terminal
No. 1 and No. 2)
Control Turn the ignition key momentarily to ACC or
module LOCK
Check for continuity in each harness and for
abnormalities in the control module power circuit
While driving at medium or high speed, Control Use a tester to check the stationary steering effort
steering remains light module
Check the solenoid current in relation to changes in
vehicle speed
Steering gear Solenoid by-pass valve operation
and linkages
Trouble Symptom 1
Trouble Symotom 2
Page 41 of 44
Page 42 of 44
Steering System > Electronic Power Steering System > Repair procedures
The removal and installation procedure is the same as that of conventional power steering system except the
solenoid valve components and EPS control module. Refer to the following figures.
Page 43 of 44
Steering System > Troubleshooting > P1521

TROUBLESHOOTING
Power steering switch malfunction
P1521
Related items · Open between power steering switch and ECM
· Short to chassis ground between power steering switch and ECM
· Faulty power steering switch
Page 44 of 44
Check power steering switch for poor
terminal contacts due to bent, damaged, or
Turn ignition to OFF and disconnect power misplaced terminal at power steering switch.
steering switch. If OK, temporally install a known good
Turn ignition to ON. Yes
power steering switch and check power
Measure voltage of power steering switch steering switch for proper operation. If
1
between power steering switch harness problem is corrected, replace power steering
connector and chassis ground. switch.
· Specifications : approximately 10~15V
Is voltage within specifications? Open circuit or short circuit to chassis
No ground between power steering switch
connector and ECM.
Return vehicle to original condition. Clear all diagnostic trouble. Verify by driving vehicle with SCAN
2
TOOL connected and monitor for pending codes.
Page 1 of 37
OPTIMA(MS) > 2001 > G 2.4 DOHC > Suspension System
Suspension System > General Information > Special Service Tools

SPECIAL TOOLS
Tool(Number and name) Illustration Use
09216-21600 Removal and installation o trailing arm

Mount brshing remover and installer bushin
arbor (use with 09552-38100)
Removal and installation of rear center

09453-33000B
arm bushin
Snap ring installer
(use with 09552-38200)
09455-21000/0K011 430 017

Removal of the front lower arm all joint
09529-21000
measurement of the wheel alignment
Wheel alignment gauge attachment
Measurement of the front lower arm

0953-11600
ball joint startin torque.
Preload socket
(use with torque wrench)
Removal and installation of the shock

09545-21100
absorer mountin bush
Ball joint dust cover remover
(use with 09551-31000)
0K670-321-019
Removal of rear center arm ball joint
Ball joint remover
Removal and installation of the shock

09551-31000
bsorber mounting vush
Upper arm bushing remover /installer
(use 09545-21100)
09552-38000
Assis arm bushing remover and
Page 2 of 37
09552-38000
Removal and installation of the assist
Assis arm bushing remover and
arm bushing
installer
09552-38100 Removal and installation of teh rear

Rear trailing arm bushin remover and trailing arm bushing
installer (use with 09216-21600)
09552-38200
Remval and installation of the rear
Rear center arm bushin remover and
center arm bushing
installer
09624-34000
Removal and installation of the lower
Trailing arm bushing remover and
arm bush(G)
installer
0K2A1 341 AA1A

Compression of coil spring
Coil spring compressor
Suspension System > General Information > Troubleshooting

TROUBLESHOOTING
Hard steering Improper front wheel alignment Correct
Excessive turning resistance of lower Replace
arm ball joint
Flat tire Repair
No power assist Repair or replace
Poor return of steering wheel to Improper front wheel alignment Correct
center
Poor riding Improper front wheel alignment Correct
Malfunctioning shock absorber Repair or replace
Broken or worn stabilizer Replace
Broken or worn coil spring Replace
Worn lower arm bushing Replace
Improper tire inflation pressure Correct
Page 3 of 37
Abnormal tire wear Improper front wheel alignment Correct
Malfunctioning shock absorber Replace
Wandering Improper front wheel alignment Correct
Poor turning resistance of lower arm Repair
ball joint
Loose or worn lower arm bushing Retighten or replace
Vehicle pulls to one side Improper front wheel alignment Correct
arm ball joint
Bent lower arm Replace
Steering wheel shimmy Improper front wheel alignment Correct
arm ball joint
Broken or worn stabilizer Replace
Worn lower arm bushing Replace
Bottoming Broken or worn coil spring Replace
Abnormal sound Loose installation parts Replace
Damaged or worn wheel bearings Replace
Faulty shock absorber Replace damaged parts
Defective tire Replace
Poor ride control Excessive tire pressure Adjust pressure
Faulty shock absorber Replace
Loose wheel nuts Tighten to specified torque
Sagging or broken coil spring Replace
Vehicle body tilts to one side Defective tire Replace
Worn bushing Replace
Deformation of torsional axle and Replace
arm assembly
Worn bushings Replace
Sagging or broken coil spring Replace
Page 4 of 37
WHEEL AND TIRE DIAGNOSIS
BOTH SIDES OF ONE SIDE OF
CENTER OF TREAD WORN CHUNKING OF TIRE
TREAD WORN WORN
TOTALLY UN
FLAT SPOT FEATHERING BAD PLUGGING UNEVEN TIRE WEAR
TIRE
Suspension System > General Information > Specifications

SPECIFICATIONS
Front suspension system(Double wishbone with stabilizer bar type)
Page 5 of 37
Type Gas pressuirzde type
Stroke(mm(in)) 125.5(4.94)
Shock absorber
Damping Expansion(N(kg)) 1160 ± 170 (116 ± 17)
force at
0.3m/s Compression(N(kg)) 680 ± 130 (68 ± 13)
Wheel type Steel Aluminum
Wheel size 6.0J × 15 6J × 15
Wheel and Tire
Tire size P205/60 R 15 P205/60 R 15
Tire inflation pressure (kPa(psi)) 210(30) 210(30)
Wheel size 4T × 15
Temporary spare
Tire size T125/70 D 15
tire
Tire inflation pressure (kPa(psi)) 414 kPa (60psi)
Rear suspension system(Multi link type)
SERVICE STANDARD
Standard value
Front 0 ± 2 mm (at the center of tire tread)
Toe-in
Rear 2 ± 2 mm (at the center of tire tread)
0° ± 30'(Max. difference between LH and RH :
0°30')-for general suspension
Front
8' ± 30' (Max. difference beween LH and RH :
0°30')-For high suspension
Camber
-30' ± 30' (Max. difference between LH and RH :
0°30')-For general suspension
Rear
38' ± 30' (Max. difference between LH and RH :
0°30')-For high suspension
3°15' ± 1° (Max.difference between LH and RH :
Caster Front
0°30')
King pin angle Front 8°29'
Wheel runout [Steel wheel] [Aluminum wheel]
Page 6 of 37
0.6(0.024) : Average of
Radial mm(in.) 0.3(0.012)
LH &U RH
Axial mm(in.) 1.0(0.039) 0.3(0.012)
TIGHTENING TORQUE
Nm Kg·cm lb·ft
Wheel nut 90-110 900-1100 67-81
Front upper arm ball joint self-
35-45 350-450 26-33
locking nut
Front upper arm shaft nut 55-65 550-650 40-48
Front upper arm mounting nut 80-100 800-1000 59-73
Lower arm ball joint self-locking
75-90 750-900 55-66
nut
Lower arm ball joint to knuckle
100-120 1000-1200 74-88
mounting bolt
Lower arm to connector nut 100-120 1000-1200 74-88
Lower arm bushing (A) to sub-
100-120 1000-1200 74-88
frame mounting bolt
Lower arm bushing (G) to sub-
120-140 1200-1400 88-103
frame mounting bolt
Fork to lower arm connector nut 100-120 1000-1200 74-88
Fork to strut mounting bolt 60-80 600-800 44-59
Strut upper mounting nut 40-50 400-500 30-36
Strut mounting self-locking nut 20-25 200-250 15-18
Stabilizer link mounting self-
35-45 350-450 26-33
locking nut
Stabilizer bar bracket to sub-
30-45 300-450 22-33
frame bolt
Stabilizer bar bracket to
35-45 350-450 26-33
crossmember bolt
Shock absorber upper mounting
40-50 400-500 30-36
nut
Shock absorber lower mounting
80-90 800-900 59-66
bolt
Shock absorber mounting self-
20-25 200-250 15-18
locking nut
Rear upper arm to carrier nut 100-120 1000-1200 74-88
Rear upper arm bracket to body
40-50 400-500 30-36
mounting bolt
Page 7 of 37
Rear upper arm to bracket nut 50-60 500-600 37-44
Assist arm to carrier nut 100-120 1000-1200 74-88
Assist arm to crossmember nut 80-100 800-1000 59-73
Center arm to carrier nut 60-72 600-720 44-53
Center arm to crossmember nut 100-120 1000-1200 74-88
Trailing arm to body nut 140-160 1400-1600 103-118
Trailing arm to carrier nut 100-120 1000-1200 74-88
Crossmember to body mounting
100-120 1000-1200 74-88
bolt
Tie rod end lock nut 50-55 500-550 37-40
LUBRICANTS
Item Recommended Quantity
lubricant
Front upper arm ball joint Sunlight MB-2 or As required
equivalent
Stabilizer link (front and Sunlight MB2 or As required
rear) equivalent
Rear upper arm pillow ball Polylub 801K As required
Suspension System > Front Suspension System > Front Strut Assembly > Components and
Components Location
components
Page 8 of 37
Suspension System > Front Suspension System > Front Strut Assembly > Repair procedures
REMOVAL
2. Detach the brake hose from the fork.
Page 9 of 37
3. Remove the bolt from the shock absorber bushing.
4. Remove the bolt then remove the fork from the shock absorber.
5. Remove the strut upper mounting 3 nuts and top mounting ring.
6. While pushing the axle assembly upward remove the strut assembly.
INSTALLATION
1. Place the fork bracket of the strut toward the inside of the vehicle, then install the strut assembly to the wheel
house.
2. Install the fork to the strut assembly.
3. Install the brake hose.

4. Install the wheel and tire.
DISASSEMBLY
Page 10 of 37
1. Using the special tool, spring compressor, compress the coil spring.
Do not use an impact wrench.
2. Remove the self-locking nut.

3. Remove the special tool, bracket, spring pad and coil spring.
INSPECTION
1. Check the rubber parts for damage or deterioration.
2. Check the spring for deformation, deterioration or damage.
3. Check the shock absorber for abnormal resistance or unusual sounds.
When discarding the gas pressurized shock absorber, follow the disposa.
precedure.
REASSEMBLY
Page 11 of 37
1. Install the special tool, spring compressor, on the coil spring and compress the spring.
After spring is fully compressed, install it on the shock absorber assembly.
1. Do not use and impact wrench.

2. Coil spring installation chart to load classification.
LH spring ↔ RH spring
White ↔ White
Yellow ↔Yellow
Red ↔ Red
2. Install the dust cover, upper spring pad, bushing (B), bracket, bushing (A) in that order and hand tighten the new
self-locking nut.
3. Position the upper and lower ends of the coil spring in the upper spring pad and lower spring seat groove.
4. Place the bracket to align the bracket bolt with the projection of the fork bracket in a straight line.
5. Loosen the special tool.
Page 12 of 37
6. While holding the piston rod, tighten the new self-locking nut to the specified torque.
Tightening torque Nm (kg·cm, lb·ft)
Pison rod to bracket nut 20-25(200-250, 15-18)
DISPOSAL
1. Fully extend the shock absorber rod.
2. Drill a hole to remove gas from the cylinder.
The gas coming out is harmless, but be careful of chips that may fly up when
drilling.
Suspension System > Front Suspension System > Front Lower Arm > Components and Components
Location
components
Page 13 of 37
Suspension System > Front Suspension System > Front Lower Arm > Repair procedures
REMOVAL
2. Loosen the ball joint nut but do not remove it
Page 14 of 37
3. Using the special tool, disconnect the lower arm ball joint from the lower arm connector.
4. Remove the ball joint assembly.
5. Remove the bolt, fork to lower arm connector.
6. Remove the stabilizer link from the lower arm.
7. Remove the 2 bolts from the lower arm bushing (A).
8. Remove the bolt from the lower arm bushing (G).
9. Remove the steering gear box (see steering system).

Page 15 of 37
10. Remove the stabilizer bar.
INSTALLATION
1. Install the stabilizer link so that the distance (A) is at the standard value.
Standard value (A) : 3~5 mm(0.0118-0.197 in.)
DISASSEMBLY
1. Remove the connector from the lower arm.
2. Using the special tool, remove the shock absorber mounting bushing.
3. Using the special tool, remove the lower arm bushing (G).
INSPECTION
1. Check the bushing for wear and deterioration.
2. Check the lower arm for bending or breakage.
3. Check the ball joint dust cover for cracks.
4. Check all bolts.
Page 16 of 37
5. Check the lower arm ball joint for rotating torque.
(1) If a crack is noted in the dust cover, replace the ball joint assembly.
(2) Shake the ball joint stud several times.
(3) Measure the ball joint rotating torque.
Standard value : 0.2~1.0Nm, (2~10 kg·cm, 1.77~8.5 lb·in)
(4) If the rotating torque is below the lower limit of standard value, replace the ball joint assembly.
(5) Even if the rotating torque exceeds the upper limit of standard value, it may be reused unless it is 1.5 Nm (15
kg·cm, 13.3 lb·in.) or more.
6. Check the stabilizer link ball joint rotating torque.
(1) If there is a crack in the dust cover, replace it and add grease.
(2) Shake the stabilizer link ball joint stud several times.
(3) Mount the self-locking nut on the ball joint, and then measure the ball joint rotating torque.
Standard value : 1.7-3.2 Nm (17-32kg·cm, 15-27 lb·in.)
(4) If the rotating torque exceeds the upper limit of standard value, replace the stabilizer link.
(5) Even if the rotating torque is below the lower limit of the standard value, the ball joint may be reused unless it
has drag and excessive play.
INSTECTION
1. Using the special tool, press-fit the shock absorber mounting bushing.
Page 17 of 37
2. Position the lower arm bushing (G) at the angle indicated in the illustration.
3. Using the special tool, press-fit the lower arm bushing (G).
4. Install the connector to the lower arm assembly.
Suspension System > Front Suspension System > Front Upper Arm > Components and Components
Location
COMPONENTS
Page 18 of 37
Suspension System > Front Suspension System > Front Upper Arm > Repair procedures
REMOVAL
2. Loosen the ball joint nut but do not remove it.
Page 19 of 37
3. Using the special tool, disconnect the upper arm ball joint from the knuckle.
4. Remove the 2 nuts from the wheel house panel then remove the upper arm assembly.
5. Remove the upper arm shaft.
INSPECTION
1. Check the bushing for wear and deterioration.
2. Check the upper arm for bending or breakage.
3. Check the ball joint for rotating torque.
Standare value : 0.5~1.5 Nm (5~15 kg·cm, 4.43~13.27 in.)
(4) If the rotating torque exceeds the upper limit of standard value, replace the upper arm assembly.
(5) Even if the rotating toque is below the lower limit of the standard value, the ball joint may be reused unless it
Page 20 of 37
Suspension System > Front Suspension System > Front Sub Frame > Repair procedures
Replacement
1. Raise the hood.
2. Remove the battery (C).
3. Remove the air cleaner (D).
4. Remove the 2 main wiring harness mounting nuts (E) then make the wiring harness loose.
5. Remove the rear roll stopper mounting bolt (F).
6. The portion where the rear roll stopper mounting bolts had been installed (G).
Page 21 of 37
7. Lift the vehicle off the ground.
8. Remove the 2 right under covers (I).
9. Remove the front exhaust pipe (J).
10. Remove the front roll stopper mounting bolt (K).
11. Remove the 2 steering gearbox mounting bolts (L) from the left side.
Page 22 of 37
12. Remove the steering gearbox mounting bolts (M) from the right side.
13. Remove the power steering hose mounting bolt (N) from the top of the steering gear box.
The bolt can be invisible to the naked eye from under the vehicle.
14. Remove the power steering hose mounting bolts (O) between the steering pump and the steering gearbox.
15. Remove the sub frame brackets and mounting bolt (P).
Page 23 of 37
16. Support the sub frame with a jack (Q).
17. Remove the ball joint mounting bolt (R).

18. Remove the bolts (S) from the lower end of the strut assembly.
19. Remove the sub frame center mounting nut (T).
20. Detach the sub frame (U) from the steering gearbox and then remove the sub frame.

22. Refil the power steering fluid and bleed the air.
Page 24 of 37
Suspension System > Rear Suspension System > Rear Shock Absorber > Components and
Components Location
components
Suspension System > Rear Suspension System > Rear Shock Absorber > Repair procedures
REMOVAL
Page 25 of 37
1. Remove the wheel and tire
2. Remove the shock absorber mounting bracket bolts.
3. Remove the upper arm and rear carrier mounting bolt.
4. Remove the shock absorber mounting bracket.
INSTALLATION
1. When installing the rear shock absorber, be sure to clear the connection surface.
2. Tighten the components below to the specified torque as follows.
Items Torque N·m(kgf·cm,lb·ft)
Shock absorber lower mouning bolt. 80-90(800-900, 59-66)
Rear upper arm to rear carrier mounitng. 100-1200(1000-1200, 74-88)
Rear shock absorber mounting bracket ot
40-50(400-500, 30-36)
body mounint bolt.
Rear upper arm to rear shock absorber
60-78(600-780, 44-58)
mounting bracket.
DISASSEMBLY
Page 26 of 37
1. Using the special tool, spring compressor, compress the coil spring.
Do not use an impact wrench.

2. While holding the piston rod, remove the self locking nut.
3. Remove the shock absorber mounting bracket, dust cover and spring upper pad.
4. Remove the special tool, bushing, bracket, spring pad, dust cover and coil spring.
INSPECTION
1. Check the rubber parts for damage or deterioration.
2. Check the spring for deformation, deterioration or damage.
3. Check the shock absorber for abnormal resistance or unusual sounds.
when discarding gas pressurized shock absorber, follow the disposal

procedure.
DISPOSAL
1. Fully extend the shock absorber rod.
Page 27 of 37
2. Drill a hole to remove gas from the cylinder.
The gas coming out is harmless, but be careful of chips that may fly up when
drilling.
REASSEMBLY
1. Install the special tool, spring compressor, on the coil spring and compress the spring.
After spring is fully compressed, install it on the shock bsorber.
1. Do not sue an impact wrench.

2. Coil spring installation chart to load classification.
LH spring ↔ RH spring
White ↔ White
Yellow ↔ Yellow
Red ↔ Red
Page 28 of 37
2. Install the dust cover, bushing (B), upper spring pad, bracket, bushing (A) and washer in this order and tighten
the new selflocking nut temporarily.
3. Position the upper and lower ends of the coil spring inthe upper spring pad and lower spring seat groove.
1. Install so that the upper spring pad is fit in the shock absorber mounting bracket correctly.
2. Install so that the spring urethane tube is located down.
4. With the position of the bracket assembly is as shown in the illustration, tighten the new self-locking nut.

6. Tighten the new self-locking nut to the specified torque.
Suspension System > Rear Suspension System > Rear Suspension Arm > Components and
Components Location
COMPONENTS
Page 29 of 37
Suspension System > Rear Suspension System > Upper Arm, Lower Arm And Assist Link > Repair
procedures
Rear Upper Arm Assembly
1. Raise the rear of the vehicle and support it with safety stands.
2. Loosen the installation bolts.
3. Inspect for damage, deformation or cracking of the upper arm.
4. Inspect for wearing or deterioration of the upper arm bushing.

5. Remove and replace if damaged, deformed or cracked; replace bushing if worn or deteriorated. Refer to "On-
Vehicle Service" in this section.
Rear Lower Arm Assembly
1. Raise the rear of the vehicle and support it with safety stands.
2. Loosen the installation bolts.
Page 30 of 37
3. Inspect for damage, deformation or cracking of the lower arm.
4. Inspect for wearing or deterioration of the lower arm bushing.

5. Remove and replace if damaged, deformed or cracked; replace bushing if worn or deteriorated. Refer to "On-
Vehicle Servicd" in this section.
INSPECTION
1. Inspect the lower arm for bends, cracks and/or other damage.
2. Inspect the lower arm bushings for wear and/or deterioration.
3. Replace if damaged, deformed or cracked: replace bushings if worn or deteriorated. Refer to “Bushing
Replacement” in the following procedure.
REAR UPPER ARM REPLACEMENT

1. Remove the rear upper arm assembly.
2. Using the special tool, remove the pillow ball.
3. Set the pillow ball so that identification color is visible on the outside of the upper arm.
4. Press fit the pillow ball to the upper arm.

5. Install the upper arm assembly.
REAR ASSIST ARM REPLACEMENT

Page 31 of 37
1. Remove the assist arm assembly.
2. Using the special tool. replace the bushing.
3. When press fitting, apply a soap solution to the bushing and inside the assist arm.
4. Install he assist arm assembly.
REAR CENTER ARM REPLACEMENT
1. Loosen the ball joint nut but do not remove it.
2. Using the special tool, disconnect the ball joint from the rear axle carrier.
3. Remove the center arm mounting bolt.

4. Remove the center arm assembly.
5. Using the special tool, replace the bushing.
Suspension System > Rear Suspension System > Trailing Arm > Repair procedures
TRAILING ARM REPLACEMENT
1. Remove the rear side bolt.
Page 32 of 37
2. Remove the front side trailing arm nut.
3. Remove the trailing arm assembly.
4. Using the special tool, removal and press fit the bushing.
5. When press fitting, apply a soap solution to the outside surface of the bushing to aid in assembly. Position it as
shown in the illustration.
6. Install the trailing arm.
Suspension System > Rear Suspension System > Rear Stabilizer Bar > Repair procedures
REAR STABLIZER LINK REPLACEMENT
1. Remove the stabilizer link assembly.
Page 33 of 37
2. Check the stabilizer link ball joint rotating torque.
Standard value : 1.7-3.2 Nm(17-32kg·cm, 15-27 lb·ft)
(4) If the rotating torque exceeds the upper limit of standard value, replace the stabilizer link.
(5) Even if the rotating torque is below the lower limit of the standard value, the ball joint may be reused unless it
Suspension System > Tires/Wheels > Tire > Repair procedures

TIRE WEAR
1. Measure the tread depth of the tires.
Tread depth of tire [Limit] : 1.6 mm(0.06 in.)
2. If the remaining tread depth is less than the limit, relpace the tire.
When the tread depth of the tires is reduced to 1.6mm (0.06 in.) or less, the wear indicators will
appear.
Suspension System > Tires/Wheels > Wheel > Repair procedures

WHEEL RUNOUT
1. Jack up the vehicle and support it with jack stands.
2. Measure wheel runout with a dial indicator as illustated.
Page 34 of 37
3. Replace the wheel of wheel runout exceeds the limit
Wheel runout [Limit]
Radial 0.6 mm (0.028 in.) :
Steel wheel (Average of LH &RH)
Axial 1.0 mm (0.039 in.)
Radial 0.3 mm (0.012 in.)
Aluminum type wheel
Axoa; 0.3 mm (0.012 in.)
TIGHTENING WHEEL NUT

1. Tightening torque.
Specified torque : 90-110 Nm (900-1100 kg·cm. 66-81 lb·ft)
When using an impact gun, ensure to use the correct tightening torque.
2. Tighten all wheel nuts in the such order as shown in the illustration.
Suspension System > Tires/Wheels > Repair procedures

FRONT WHEEL ALIGNMENT
When using a wheel alignment tester to inspect front wheel alignment, always position the car on a level surface and
thefront Wheels in the straight ahead position. Prior to inspection make sure that the front suspension and steering
system are in normal operating condition and that wheels and tires are free of deflection and tires are inflated to
specification.
Page 35 of 37
1. Toe-in
Toe-in (B-A or angle α+β) is adjusted by turning the tie rod turnbuckles. Toe in on the left front wheel can be
reduced by turning the tie rod toward the rear of the car. Toe change is achieved by turning the tie for the right
and left wheels simultaneously the same amount as follows :
Toe-in (B-A) : -2 mm~ +2 mm

Toe-in (α+β) : -10'48''~ +10'48''
Description Toechange
No.of turn of tie rod 1/2 Approx. 4.8 mm (57'40'')
(same amount for right and left) 1 Approx. 9.6 mm (1°55'20'')
• Toe-in adjustment should be made by turning the right and left tie rods the same amount.
• When adjusting toe-in, loosen the outer bellows clip to prevent twisting the bellows.
• After the adjustment, firmly tighten the tie rod end lock nuts and reinstall the bellows clip.
Tightening torque
Tie rod end lock nuts tigtening torque : 50-55 Nm(500-550 kg·cm, 37-40 lb·ft)
2. Camber
The steering knuckle which is integral with the strut assembly is preadjusted to the specified camber at the factory
and requires no adjustment.
Camber : (0° ± 30' For general suspension) (8' ± 30' For high suspension)
Page 36 of 37
3. Caster
Caster is pre-set at the factory and can not be adjusted. If caster is not within standard value, replace the bent or
damaged parts.
1. The front suspension assembly must be free of worn, loose or damaged parts prior to measuring front
wheel alignment.
2. Measure wheel alignment by using the special tool (09529-21000).
3. Camber and caster are pre-set at the factory and cannot be adjusted.
4. If camber and caster are not within specifications, replace bent or damaged parts.
REAR WHEEL ALIGNMENT INSPECTION

1. Toe-in
Standard value : 2 ± 2 mm
The assist arm mounting bolt (crossmember side) should be turned an equal amount on both sides when
adjusting.
Inside direction of the vehicle : toe-in

Outside direction of the vehicle : toe-out
The scale has gradations of approximaterly 2.4 mm (14').

Page 37 of 37
2. camber
Standard value : (-30' ± 30' For general suspension), (38' ± 30' For high suspension)
1. The rear suspension assembly must be free of worn, loose or damaged parts prior to measuring rear
wheel alignment.
2. Camber is pre-set at the factory and cannot be adjusted.
3. If camber is not within the specifications, replace bent or damaged parts.

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Page 1 of 21

OPTIMA(MS) > 2001 > G 2.4 DOHC > General Information

General Information > General Information > General Information

VEHICLE IDENTIFICATION NUMBER

ENGINE IDENTIFICATION NUMBER

3. Cleaning parts for reuse

RUBBER PARTS AND TUBING

BODY DIMENSION MEASUREMENT

CHECKING CABLES AND WIRES

2. Check terminals and wires for corrosion by battery electrolyte, etc.

SERVICING THE ELECTRICAL SYSTEM

PRECAUTIONS FOR A CATALYTIC CONVERTER

STANDARD PARTS TIGHTENING TORQUE TABLE

Bolt nominal diameter Pitch Torque Nm (kg.cm, lb.ft)

M5 0.8 3-4 (30-40, 2.2-2.9) 5-6 (50-60, 3.6-4.3)

5. Pull the dipstick out in order to check the oil level.

REPLACEMENT OF THE ENGINE OIL FILTER

REPLACEMENT OF THE ENGINE OIL FILTER

3. Remove the air cleaner filter.

• Standard value ( For V6 ENGINE)

REPLACEMENT OXYGEN SENSOR

TRANSAXLE OIL (Replace)

Transaxle oil total capacity :

INSPECT STEERING LINKAGE

Maximum steering wheel freeplay : 30 mm (1.181 in.)

2. Check steering linkage for looseness and damage as follows.

INSPECT BRAKE LINE

FRONT DISC BRAKE PADS

Thickness of pad lining "A" [Limit] : 2.0 mm (0.079 in.)

REAR DRUM BRAKE LININGS AND (REAR WHEEL CYLINDERS)

Thickness of lining "B" [Limit] : 0.8 mm (0.032 in.)

CHECKING THE BRAKE FLUID LEVEL

CHANGING BRAKE FLUID

Brake fluid : DOT 3 or equivalent

CHECKING OF THE TIRE INFLATION PRESSUE

09452-21401/0K011 171 002 Installation of oil pump

09453-33100 Measurement of the low and reverse brake

09431-39000 Installation of differential oil seal

09432-33800 1. Removal of transfer driven gear taper

09433-21000 1. Removal of transafer driven gear taper

09500-11000 Installation of differential bearing outer race

09455-33200 Installation of differential ball bearing and

09455-21000/0K011 430 017 Removal of ball bearing and transfer drive

09455-21100 1. Intallation of ball bearing and transfer

09532-11500 Installation of differential bearing outer race

09453-21000 • Removal and installation of low-reverse

09432-21701 Installation of output shaft outer race

09452-33100 Removal of the oil pump

09452-21200 Installation of the oil pump oil seal

09200-38001 Removal and installation of transaxle

09456-39100 Measurement of low-reverse brake and

SPECIAL SERVICE TOOLS

Installation of input and output shaft bearing

09432-33200 Removal of input shaft's gear and ball

09432-33400 Installation of input shaft bearing outer race

09455-32200/0K011 190 008

09517-21400 Separation of T/M housing from T/M

09532-11000 Removal and installation of differential

Installation of output shaft and differential

09200-38001(J28467-B) Removal and installation of transaxle

Automatic Transaxle System > General Information > Troubleshooting

Automatic Transaxle System > General Information > Specifications

Operating Element and Their Functions